Compressed AirCompressed AirManaging the Costs

National Grid

Upstate Energy Efficiency Conference

April 2011

Why Compressed Air?

• Compressors account for 10% of all electricity used in U.S.

• 1 million Compressors sold in the US/ year• 80% of the energy is consumed by those 25 hp

and larger (less than 1% of the population)

– 2015 predictions are 1.9 Trillion kWH/year

– 20% efficiency gain saves 392 billion kWH/yr or $19.6 Billion dollars potential annual savings

Why Compressed Air?

• Only 9% of end users identified controlling energy costs as the primary objective in compressed air system maintenance and management.

• Only 17% mentioned efficiency at all as a management objective.

• 71% of end users report adequate air supply is their primary objective in system management

• 35% of end users reported unscheduled shut downs in the past 12 months

• 75% of operators report having no efficiency training

Energy (Power) Efficiency

KW Compressor KW

10 1:

Air is FREE until you mess with it !!!!

Total Life Cycle Costs

Costs Over 10 Years

Equipment

Maintenance

Electricity

12%

12%

76%

Life Cycle Costs

BHP kW $ / kW Hours kWh Annual Power 10 Year Elec First Cost 10 Year Maint Total 10 Year

165 129.5684 0.05$ 8760 1,135,019 56,750.97$ 567,509.68$ 68,101.16$ 68,101.16$ 703,712.01$ 80.6% 9.7% 9.7%

165 129.5684 0.10$ 8760 1,135,019 113,501.94$ 1,135,019.37$ 68,101.16$ 68,101.16$ 1,271,221.69$ 89.3% 5.4% 5.4%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0%

1 2 3

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%60.0%

70.0%

80.0%

90.0%

1 2 3

(First cost = comp $ + 30% for install / Maintenance = parts & 1 air end replacement)

Apply the Resource Wisely

Excessive Pressure 10%

Leaks 20%

Production 60%

Inappropriate Uses 10%

Perception

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

Reality

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

CFAir

100 #

Measure

0.0

200.0

400.0

600.0

800.0

1000.0

1200.0

1400.0

1600.0

1/27

/200

5 0:

00

1/27

/200

5 0:

12

1/27

/200

5 0:

24

1/27

/200

5 0:

37

1/27

/200

5 0:

49

1/27

/200

5 1:

02

1/27

/200

5 1:

14

1/27

/200

5 1:

26

1/27

/200

5 1:

39

1/27

/200

5 1:

51

1/27

/200

5 2:

04

1/27

/200

5 2:

16

1/27

/200

5 2:

28

1/27

/200

5 2:

41

1/27

/200

5 2:

53

1/27

/200

5 3:

06

1/27

/200

5 3:

18

1/27

/200

5 3:

30

1/27

/200

5 3:

43

1/27

/200

5 3:

55

1/27

/200

5 4:

08

1/27

/200

5 4:

20

1/27

/200

5 4:

32

1/27

/200

5 4:

45

1/27

/200

5 4:

57

1/27

/200

5 5:

10

1/27

/200

5 5:

22

1/27

/200

5 5:

34

1/27

/200

5 5:

47

1/27

/200

5 5:

59

1/27

/200

5 6:

12

1/27

/200

5 6:

24

1/27

/200

5 6:

36

1/27

/200

5 6:

49

1/27

/200

5 7:

01

1/27

/200

5 7:

14

1/27

/200

5 7:

26

1/27

/200

5 7:

38

1/27

/200

5 7:

51

1/27

/200

5 8:

03

1/27

/200

5 8:

16

1/27

/200

5 8:

28

1/27

/200

5 8:

40

Series1 Series2

- Dec 6 - Flow

0.0

500.0

1000.0

1500.0

2000.0

2500.0

12/6

/200

6 14

:40

12/6

/200

6 14

:55

12/6

/200

6 15

:10

12/6

/200

6 15

:25

12/6

/200

6 15

:40

12/6

/200

6 15

:56

12/6

/200

6 16

:11

12/6

/200

6 16

:26

12/6

/200

6 16

:41

12/6

/200

6 16

:56

12/6

/200

6 17

:12

12/6

/200

6 17

:27

12/6

/200

6 17

:42

12/6

/200

6 17

:57

12/6

/200

6 18

:12

12/6

/200

6 18

:28

12/6

/200

6 18

:43

12/6

/200

6 18

:58

12/6

/200

6 19

:13

12/6

/200

6 19

:28

12/6

/200

6 19

:44

12/6

/200

6 19

:59

12/6

/200

6 20

:14

12/6

/200

6 20

:29

12/6

/200

6 20

:44

12/6

/200

6 21

:00

12/6

/200

6 21

:15

12/6

/200

6 21

:30

12/6

/200

6 21

:45

12/6

/200

6 22

:00

12/6

/200

6 22

:16

12/6

/200

6 22

:31

12/6

/200

6 22

:46

12/6

/200

6 23

:01

12/6

/200

6 23

:16

12/6

/200

6 23

:32

12/6

/200

6 23

:47

Manage the Relationship

PSIG

(Pressure)

CFM

(Flow)

KW

(Power)

Time

Managing the Relationship

TIME

FlowPressurePowerTIME

Manage Asset SelectionPOWER VS FLOW VARIOUS CONTROL METHODS

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

450.00

500.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

0.00

20.00

40.00

60.00

80.00

100.00

120.00

ACFM FLOW

BHP @ I/M

BHP @ V/D

BHP @ L/NL

Manage System Configuration

Comp100 hp125 hp

Comp150 hp125 hp

Comp150 hp125 hp

RSD1500

ESP-1000Control

4”

4”

4”

3”3”3”

4”

Monitor

Power and Temp plots indicate all is well with this compressor

Solutions

• Understand the process needs• VFD when appropriate• Control options (VFD, L-NL, Variable Displacement)

• System Configuration• Simple sequencing• Control automation and system management• Design to process requirements