Permanent Monitoring is Key for Maximizing Efficiency … · 5/4/2011 1 Permanent Monitoring is Key for Maximizing Efficiency of Compressed Air Systems ‘If you cannot measure it

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Permanent Monitoring is Key for Maximizing Efficiency of Compressed Air Systems

‘If you cannot measure it you cannot improve it’™

Introduction

Cynthia KuiperSales and Marketing Director, VP Instrumentscynthia@vpinstruments [email protected]

www.vpinstruments.com

Background:

•Industrial Design Engineer

•2006 to current: VPInstruments


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Introduction

Hank van OrmerPresident, Air Power [email protected]@ pwww.airpowerusainc.com

Background (19xx? to current):

•Audited 900+ plants

•Managed installations at 500+ plants

•Led product development and/or technical sales at IR, CompAir, Kellogg, Worthington


•Helped start DOE’s Compressed Air Challenge (CAC)

•Written 100+ books, articles, or workbooks on compressed air

•Started Air Power USA in 1987 as independent, brand-neutral consultants

Content

• Introduction: VPInstruments and Air Power USA

• Compressed air costs p

•Value of permanent monitoring

•Types of flow meters

•Lessons learned in using flow meters

•Getting utilities to help pay for monitoring systems


•Getting utilities to help pay for monitoring systems

•Putting it all together

•Takaways

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Introduction

VPInstruments

Development, production and supply of measuring and energy management systems for compressed airy p

Insights into consumption and savings of compressed air and industrial gases

Reliable, user-friendly, and turnkey solutions.

Flow meters: Sensors

Displays: Read out locally ortie to internet

Software Insights/Reports


Introduction

VPInstruments

Based in the Netherlands

International distribution networkDistributors in Europe, Asia, North and South America, Oceania, Africa

90% Export60% Export within Europe

2010: 20% growth


2011: 30% expected growth

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Introduction

Air Power USA

Working with VPInstruments to:•Test and refine VP productsTest and refine VP products

•Identify U.S. market needs for measurement systems

One of the country’s largest and most experienced consulting firms focused on compressed air systems

Independent, not involved in the sale of compressor equipment

Active throughout North America in all types of air systems


Active throughout North America in all types of air systems

70% of business is performance-based – i.e. fees tied directly to actual savings

$10M+ in rebates and services obtained for customers

Compressed air costs


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Controlling energy costs is key to managing compressed air costs


Example: 24/7hr system

kW hPAnnual Annual Electricity


kW hPkWh

yCosts (8¢ / kWh)

75 ~100 657,000 $ 50K

250 ~335 2,190,000 $ 175K

750 ~1000 6,570,000 $ 500K


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Example: 24/7hr system

kW hPAnnual Electricity Annual Savings


kW hPy

Costs (8¢ / kWh)g

(@ 35%)

75 ~100 $ 50K $ 17K

250 ~335 $ 175K $ 60K

750 ~1000 $ 500K $ 175K


Value of Permanent Monitoring


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1. Track air system efficiency in order to maintain savings levels (“savings persistence”)

2. Understand the impact of new production equipment and production levels on air supply system needs (e.g. new compressor sizing)

3. Help identify energy projects and document savings to collect utility rebates


Value of Permanent Monitoring:#1 Savings Persistence

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Consumption with permanent monitoring

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Value of Permanent Monitoring#1 Savings Persistence

• Flow meters: detect changes in air demands or air leak levels and give instantaneous feedback on repairsand give instantaneous feedback on repairs

• Leak detectors: identify and quantify specific leaks, so you can repair


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A lower pressure direct result in savings

14.5 psi (1 bar) < pressure saves 7% of electricity costs

Avoid: - big pressure drops over e.g. dryers and filters- under sizing of piping- turbulence by proper layout of the piping system- compensating leakage by generating more compressed air


New filter: $100~500Costs pressure drop: 7 psi 3% energy

($3,000 on electricity bill of $100,000)

Value of Permanent Monitoring#2 Understanding Changes in Air Demand

• New departments/machines

• Shut down of departments/machines do not forget to close compressed air installation or use of automatic shut of valves

• Crisis/seasonal less production


• Growth increase of compressed air consumption

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Value of Permanent Monitoring#3 Identify and document energy savings

Examples:

• Leak management system → Compressed air consumption down

→ Turn off compressor

→ Pressure increases→ More new/other leakages


• New compressor controls or control system→Different sequencing of compressors for energy savings


1. Track air system efficiency in order to maintain savings levels (“savings persistence”)

2 Understand the impact of new production equipment and2. Understand the impact of new production equipment and production levels on air supply system needs (e.g. compressor projects and capacity)

3. Help identify energy projects and document savings to collect utility rebates

4 T bl h t d di i t bl d


4. Troubleshoot and diagnose air system problems and bottlenecks

5. Allocate compressed air system costs at the department level

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Types of Flow Meters

The key parameters to measure in a permanent monitoring system are:• Compressor input power (kW not amps)Compressor input power (kW, not amps)• Air flow• Pressure (compressor room and critical points-of-use)

Historically, the air flow measurements are the most difficult and erratic.

But flow measurement is essential especially if air leak


But flow measurement is essential, especially if air leak management programs are involved.

Types of Flow Meters

Basic types of flowmeters commonly used to measure gases:

Positive Displacement: Correlate flow volume to measured pressure drop of separate flo s at specific temperat re and press re orificedrop of separate flows at specific temperature and pressure -- orifice plate, piston, valve, variable area, etc.

Pressure Differential to Velocity: Calculate velocity by interpreting flow disturbance and separately or integrally measured temperature and pressure – with pipe i.d.

Thermal Mass Flow: Use cooling rate of air compared to i.d. of pipe to id tif l it d fl i f


identify velocity and mass flow in scfm.

Ultrasound Clamp On: Ultrasonic signals from outside the pipe resonate through the flowing fluid and determine velocity and pipe i.d. to calculate mass flow. Depends on relatively dense fluid to deliver proper reading.

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Positive Displacement Meters

•Read accurately in center of ranges; less accurately at lower and upper end

•Must use temperature and pressureMust use temperature and pressure compensation

•Create pipeline pressure loss

•Non-insertion type -- difficult to service

•Need clean dry air

Piston Variable Area

Vane Variable Area


Orifice Plate

V-Cone

Pressure Differential to Velocity

•Still only read accurately in center part of operating range to create legible disturbance

•Limited by maximum air velocity ratingLimited by maximum air velocity rating

•Uses flow disturbance and measured temperature and pressure to calculate velocity

•Very sensitive to upset

•Requires clean dry air

Vortex Shedder


Annubar

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Thermal Mass Flow Meter•Reads velocity and mass flow directly by measuring controlled cooling capabilities

•Needs no correction or recalibration for temperature or pressure changes to

Heated Wire Insert

temperature or pressure changes to reasonable results

•Answers very readable

•Limited by velocity rating

•Reads accurately over total operating range



Ultrasonic Clamp-On

•Very successful with liquids

•More limited with air/gas

•Larger the pipe the lower the maximum velocity; down to less than 2,000 ft/min (30 ft/sec)

•Relatively expensive and cumbersome

•Non-invasive



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Lessons Learned in Flow Measurement

Seem Simple?

•Just put in meter and read the answer!

•The flow meter always gives you an answer!

•Sometimes it is right!


Lessons Learned in Flow Measurement#1 – Read the Directions

FLOWMETER INSTALLATION GUIDELINES FOR INSERTION TYPE FLOW METER

Follow proper installation guidelines for all flowmeters

The flow must be undisturbed

1” – 1 ¼” Full Port ball valve

Weld‐o‐letShort nipple


undisturbed10 pipe diameters of straight pipe, no valves, turns, takeoffs, etc.

20 pipe diameters of straight pipe, no valves, turns, takeoffs, etc.

Example: 3” pipe = 90” of straight pipe, 30” downstream of meter and 60” upstream of meter. This can be on a vertical or a horizontal pipe. Air should be clean and dry.

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Lessons Learned in Flow Measurement#2 - Compressed Air Velocity Exceeds Meter Rating

•Air velocity limit: 25,000 fpmy p•Pipe: 1.25 inch diameter•Maximum Flow Capability: 260 scfm•Maximum Flow Reading: 259.68 scfm•Clue: Flat flow line; making pressure


Lessons Learned in Flow Measurement#2 - Compressed Air Velocity Exceeds Meter Rating

Add 2” spool pieces / same meter

•Maximum flow capability: 582.5 scfmMaximum flow capability: 582.5 scfm•Measured actual flow: 390 scfm•Actual total 36 units – 14,040 scfm•Magnitude of error – 4,692 scfm (33%)


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Lessons Learned in Flow Measurement#3 - Contamination

•Oil carryover insulates the heated

i i h twire causing poor heat transfer and low readings.•Oil, water and particulates in positive displacement and pressure differential driven velocity flow meters foul the critical

Effect of oil coating a thermal mass flow

meter


meters foul the critical air flow parts and control geometry to create significant upsets

Lessons Learned in Flow Measurement#3 – Contamination


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Lessons Learned in Flow Measurement#3 – Contamination

Water incursion causes high reading in thermal mass flow meter•Water incursion causes high reading in thermal mass flow meter

•Condensed water vapor in the air lines has the opposite effect of oil in thermal mass flow meters causing higher readings.

•Pressure remains constant; flow continues to creep up (6-7%) due to observed water incursion. The magnitude of the distortion is dependent on operating and liquid load conditions.


Lessons Learned in Flow MeasurementSummary

All meters require clean dry air for accuracy and repeatability•All meters require clean dry air for accuracy and repeatability

•Often a severe limitation – cannot measure flow until after the dryer, filter units

•Centrifugal compressors are the most difficult to accurately estimate flow without a fluid meter. Multiple units to a single header can be a real issue.


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There is a New Technology on the Way

Measure with accuracy and repeatability in saturated and dirty air

Insertion ∆P (pressure differential) meter with the pressure differential sensing of a controlled flow in a secure, filtered encased head sending the signal to the microprocessor in the upper housing


Special insertion encased filtered senor head. Controls flow to generate proper signal to internal microprocessor

Does it Work? You Bet!

This meter, dd d hadded to the standard alignment available,

accurately and repeatability data can be

used to implement


implement effective

monitoring and control

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Getting Rebates from Utilities


Getting Help from Utilities

•Financial incentives for energy projects and even for engineering studies are nearly everywhere and growing more common

•Don’t rely on what the utility websites tell you – they are often out-of-y y y ydate or incomplete

•Air Power provides a rebate processing service for plants that typically obtains 50% more than what plants get on their own

•This service is offered on a performance fee basis in the form of a % of what the plant actually gets.

•Just contact us with your project information and we will provide a one-minute summary of what we might be able to collect for your project


minute summary of what we might be able to collect for your project –(740) 862-4112

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Getting Help from Utilities

•The newest trend in utility assistance centers on “savings persistence” –i.e., helping plants sustain the efficiency and savings associated with air system improvements.

•Guess what – this is how plants can get an average of 50% or more of the cost of their monitoring system and meters reimbursed by selected utilities

•Call us if you have plants in California, Illinois, Missouri, or Oregon and we will check to see if we can get you signed up: (740) 862-4112


A systematic approach starts with measuring

Putting it All Together

Continuousimprovement

ofenergy

Goal:

FlowPressure

Temperature

DataImprovements

Implementation


Data analysis

energyefficiency

TemperaturePower consumptionOther relevant data

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Measure :

• Power consumption of the compressors (kW, not

Putting it All Together

amps)

• Compressor output (flow, pressure)

• Pressure drops

• Dew point

• Consumption measurement for individual


departments and at key points of use.

Monitoring systems make compressed air savings easy and rewarding

VPVision monitoring system


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Monitoring systems make compressed air savings easy and rewarding





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Example at KIKKOMAN


VPVision Kikkoman

Producer of soy sauceMarket leader

Since 1917Japanese factory

Kikkoman Foods Europe B.V., HollandSince 1997Annual production: 13 million liter


Annual production: 13 million liter

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VPVision Kikkoman

2004: ‘Energy Saving Committee’Goal: reduce compressed air consumption per liter of produced soy sauceproduced soy sauce.

• Change compressors: more capacity + more efficient• 2 identical compressors: redundancy • Leakage detection introduction energy saving

components• Intelliflow pressure controller


Results:

Efficient system with built-in redundancy

VPVision Kikkoman

Efficient system with built in redundancy

Pressure: 109 84 psi

Energy savings: 32%


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Compressor house overview

Main header

VPVision Kikkoman

1

2

3

4

75 kw

Intelliflow

Main header


5

6

7

8

75 kwWet air buffer

Dry air buffer

VPVision Kikkoman

2010: Implementation VPVision

To keep a continuous eye on:To keep a continuous eye on: • Actual consumption• See leakage in downtime• See any unwanted air consumption

Making compressed air savings and insight: • Quicker• Easier


• Easier • Less time consuming

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VPVision Kikkoman


First results:

Last week discovered leak of 70 SCFM

VPVision Kikkoman

Last week discovered leak of 70 SCFM

Leak was caused by pulse jet bag filter on roof

Normally: rooftop not regularly visited

VPVision problem noticed immediately


After repair: consumption back to 4 SCFM

Annual savings: $ 20,000

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Mr. Gerrit Renting (Kikkoman):

“VPVision is really a powerful tool for us to keep our

VPVision Kikkoman

VPVision is really a powerful tool for us to keep our compressed air consumption at the lowest possible level.

It helps us to prevent leakage and to decide when we need to change or expand our compressed air supply.”


Takeaways

1. Compressed air systems represent the best target for quick energy savings

2. Permanent monitoring is key to identifying and sustaining savings

3. VPInstruments offers the key components needed for financial directors and maintenance managers:• Flow meters for contaminated lines• VPVision: Integrated monitoring system


VPVision: Integrated monitoring system

4. Utilities can help pay for projects and CA, IL, MO and OR are targets for monitoring system funding

Documents

Permanent Monitoring is Key for Maximizing Efficiency … · 5/4/2011 1 Permanent Monitoring is Key for Maximizing Efficiency of Compressed Air Systems ‘If you cannot measure it