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2010 Energy Expo Hosted by National Grid NYSERDA

Tom Taranto. 2010 Energy Expo Hosted by National Grid NYSERDA. Reducing Compressed Air Energy Cost Using a Systems Approach. Energy. Product. Eliminate Irrecoverable Pressure Loss. Power House / Compressor Room. Manufacturing Plant / Production Floor. Producers of Compressed Air.

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2010 Energy Expo Hosted by National Grid NYSERDA

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  1. Tom Taranto 2010 Energy ExpoHosted by National GridNYSERDA Reducing Compressed Air Energy Cost Using a Systems Approach

  2. Energy Product Eliminate Irrecoverable Pressure Loss Power House / Compressor Room Manufacturing Plant / Production Floor Producers of Compressed Air Consumers of Compressed Air Consume Less Compressed Air Produce Compressed Air More Efficiently Supply Compressors Filters / Dryers Piping Primary Storage Transmission Pipelines Filters / Dryers Secondary Storage Total Energy Reduction Demand Machines / Process Point of Use Piping Filters / Dryers Storage Tanks Systems Approachplant efficiency: energy >> product

  3. Systems Approachcost of ownership • Equipment cost and maintenance cost represent only a small part of the total cost of operating a compressed air system. • Electrical cost usually exceeds 75% of the total operating expense. Source: Compressed Air Challenge®

  4. Systems Approachenergy flow 5% Motor and Drive Efficiency 80% Heat of Compression 5% to 10% Waste: Irrecoverable Pressure Loss Leakage Artificial Demand Inappropriate Use Energy Input 100 kW 10% to 5% Productive use

  5. Systems Approachdemand side energy reduction 5% Excessive Pressure 10% Inappropriate Use 50 % Productive Demand 15% Artificial Demand 20% Leakage Loss

  6. Systems Approach • Reduce Air Demand • Reduce System Pressure • Improve Compressor Control Reduce Air Demand Improve Compressor Control Reduce Compressor Discharge Pressure

  7. Reducing Compressed Air Energy CostUsing a Systems Approach Compressed Air Efficiency Services

  8. Assessment of the Market for Compressed Air Efficiency Services

  9. Assessment of the Market for Compressed Air Efficiency Services • Office of Industrial Technologies (2001) • Office of Energy Efficiency and Renewable Energy - U.S. Dept. of Energy • Oak Ridge National Labs Motor Market Assessment by XENERGY (1998) • Pacific Gas & Electric “Compressed Air Market Transformation Program” (1999)

  10. Key Findings • Awareness and concern for energy efficiency is low. • Principal objective is consistent reliable air supply. • Serious problems reported. • 35% had shutdowns in past 12 months • 21% were shutdown for 2 or more days

  11. Reported Air SystemProblems

  12. Summary • 71% Consistent, Reliable Performance - primary objective. • Only 17% “mentioned” efficiency. • 35% Have had serious problems this yr. Apply the Systems Approach

  13. Reducing Compressed Air Energy CostUsing a Systems Approach Identify Opportunities

  14. Reducing Compressed Air Operating CostIdentify Opportunities • Compressed air – primary functions • Power • As an energy source to perform work • Process • Air becomes part of a process • Control • To stop, start or regulate the operation of a machine

  15. Identify Opportunitieshighest priority • Reliability of the Production Process • Deliver Energy to Production • Stakeholder’s needs • Reliable production – no production outages • Maintain product quality – minimum scrap and rework • Little energy concern if production is affected

  16. Identify Opportunitiessustainable energy savings • Comprehensive solutions • Improve critical production end use applications • Eliminate irrecoverable pressure loss • Provide compressed air energy storage • Optimize compressor control • Solutions must be long term and reliable • If production is interrupted the energy efficient solution will be abandoned in favor of the previous more energy intensive operation. • Improving Performance Reducing Energy

  17. Reducing Compressed Air Energy CostUsing a Systems Approach Improve Performance Fix Leaks Reduce System Pressure

  18. Improve Performancepoint of use pressure profile • Test Machine Flow Dynamic Demand • What’s Wrong With This Picture?

  19. Improve Performancepoint of use pressure profile • Validate Perceived High Pressure • Pressure Gauges – Mechanical Damping

  20. Improve Performancepoint of use pressure profile

  21. Improve Performancepoint of use pressure profile • Diagnostic DataARPAC Wrapper

  22. Improve Performancepoint of use pressure profile • Diagnostic Data - ARPAC Wrapper

  23. Improve Performanceeliminate artificial demand • 15% Artificial Demand • Applying  Pressure (PSIG) to an Orifice will Increase  Flow Rate (SCFM)

  24. Improve Performancereduce leakage • 20% Leakage Loss • Establish Leak Repair Priority • Leak Repair is Most Effective if Pressure is Controlled

  25. Reduce Pressure optimize the pressure profile • Demand side target pressure – lowest optimum pressure to support manufacturing • Eliminate artificial demand • Reduce compressor power 1% per 2 psig • Identify perceived high pressure demand – they prevent system pressure from being reduced. • Validate the need for high pressure • Check for piping restrictions • Determine the present operating pressure (at the point of use)

  26. Reduce Pressure optimize the pressure profile • If the need for high pressure is valid – do not let a small percentage of air demand cause the entire system to operate at high pressure. • Consider other ways to serve the high pressure need • Consider air amplifiers or booster compressors • Consider a separate dedicated compressed air system

  27. Reducing Compressed Air Energy CostUsing a Systems Approach Inappropriate Use of Compressed Air 19

  28. Inappropriate Useof compressed air • Compressed Air is Expensive and Inefficient • $250 to $500 per Million Cubic Feet (MMCF) • 80% to 85% of energy is waste heat • 1 hp air motor requires 7 to 8 Hp at compressor • 8 hp / 100 cfm – low pressure blower • 23 hp / 100 cfm – 100 psig compressor • Alternate sources are frequently 1/3 the energy cost of compressed air • Review Applications and Consider Alternative Energy Sources 19

  29. Inappropriate Useof compressed air • Abandoned & Malfunctioning Equipment 20

  30. Inappropriate Useof compressed air • Air Powered Vacuum – 25 hp 21

  31. Compressed Air Powered Cabinet Coolers 3300 watts input > 500 watts Cooling Refrigerated Cabinet Cooler 750 watts input > 500 watts Cooling Compressed Air Cabinet Cooler Refrigerated Cabinet Cooler Inappropriate Useof compressed air 22

  32. Inappropriate Useof compressed air • Idle Machine w/ Blowing Tubes Wasting Air 23

  33. Inappropriate Useof compressed air • Air Operated Reciprocating Pump 24

  34. Inappropriate Useof compressed air • Chip Blowing w/ Compressed Air 25

  35. Inappropriate Useof compressed air • Air Motors Driving Ink Pumps 26

  36. AIR NOZZLE Inappropriate Useof compressed air • Compressed Air Blowing Tube 27

  37. VACUUM CUPS VACUUM GENERATOR Inappropriate Useof compressed air • Air Powered Vacuum Generator 28

  38. Inappropriate Useof compressed air • KEY Points – Inappropriate Air Use • Compressed air is expensive and due waste heat at the compressor, an inefficient power source. • Using high pressure 100 psig air (23 Hp/100 cfm) for low pressure 8 psig requirements (8 Hp/100 cfm) is inefficient. • Review applications to investigate a more direct conversion of energy supply (electricity) to the application requirements. • Abandoned and malfunctioning equipment should be eliminated or repaired. • Air powered vacuums should be replaced with electric models if possible. 28

  39. Inappropriate Useof compressed air • KEY Points – Inappropriate Air Use • Air powered cabinet coolers use 70% to 80% more energy than small refrigeration units. • Idle equipment should have compressed air automatically shut off whenever possible. • Air operated piston pumps should be replaced with electric pumps if possible. • Chip blowing applications can often use low pressure blowers and delivery devices. 29

  40. Reducing Compressed Air Energy CostUsing a Systems Approach Monitor & Maintain System Efficiency

  41. Monitor & Maintain System Efficiencymanagement information • Cost of compressed air is derived from reliably measured performance data. • Energy performance and cost are reported to management. • Compressed air demand of production operations is documented through airflow measurement and recording. • The consistent, reliable, supply of compressed air is achieved. Performance measurement information shows corrective measures to optimize performance. • Unscheduled downtime is minimized or eliminated. 40

  42. Monitor & Maintain System Efficiencymanagement information • Compressed Air Flow Measurement 34

  43. Monitor & Maintain System Efficiencymanagement information 36

  44. Reducing Compressed Air Energy CostUsing a Systems Approach Summary: 2010 Energy Expo Hosted by: National Grid & NYSERDA

  45. Reduce Compressed AirOperating Cost • Using a Systems Approach • Improve Performance – Consistent Reliable Air Supply • Fix Leaks and Eliminate Waste • Reduce System Pressure and Eliminate Artificial Demand • Eliminate Inappropriate Use

  46. Reduce Compressed AirOperating Cost • Using a Systems Approach • Target Pressure – Lowest Optimum Pressure • Improve Generation Efficiency – with Efficient Trim Compressors • Operate Multiple Compressors – Efficient Control Automation • Monitor & Maintain System Efficiency – Management Reports

  47. Questions Reducing Compressed Air Energy CostUsing a Systems Approach 2010 Energy Expo Hosted by: National Grid & NYSERDA

  48. Questions Reducing Compressed Air Energy CostUsing a Systems Approach 2010 Energy Expo Hosted by: National Grid & NYSERDA Thank You !

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