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Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A.

Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A. Three-Day Compressed Air Energy Saving A ssessment. U.S.-Brazil Industrial Energy Efficiency Workshop Rio de Janeiro , Brazil August 8-11, 2011. Overview of 3-Day Assessment. Before Visit

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Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A.

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  1. Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A. Three-Day Compressed Air Energy Saving Assessment U.S.-Brazil Industrial Energy Efficiency Workshop Rio de Janeiro, Brazil August 8-11, 2011

  2. Overview of 3-Day Assessment • Before Visit • Send data loggers to plant • Ask plant to install Air Master+ software • Day 1 • Brief plant management • Inspect compressed air plant and major end-uses of compressed air • Down-load and analyze pressure and current data • Day 2 • Show “Energy Efficient Compressed Air” slide show to production and maintenance personnel. • Gather additional data to quantify savings • Enter data into Air Master+ to quantify savings • Day 3 • Teach staff how to use Air Master+ • Closing meeting with management to discuss results.

  3. Plant Inspection Plant Inspection

  4. Compressed Air Plant

  5. Compressor Types and Sizes

  6. Compressor Controls

  7. Pressure in Compressed Air Plant

  8. Compress Indoor or Outdoor Air

  9. Compressed Air Dryer

  10. Compressed Air Storage

  11. Condensate Drains

  12. Compressed Air Piping

  13. Pressure at End Uses

  14. End Uses

  15. Power and Pressure Data Power and Pressure Data

  16. Load/unload and Modulation Control

  17. Two Compressors Properly Staged

  18. Size Dryer for DP< 5 psi Low Flow: DP = 1 psi High Flow: DP = 6 psi

  19. Nights and Weekend Operation

  20. Compressed Air Storage

  21. Production and Maintenance Briefing Production and Maintenance Briefing

  22. Install Nozzles on Air Tubes

  23. Install Solenoid Valves on Part Movers

  24. Use Blowers Instead of Compressed Air

  25. Use Electric Pumps Instead of Air Pumps

  26. Activate Bag House Air Pulses with Pressure Drop

  27. Identify and Fix Leaks

  28. Add Storage to Decrease Cycling

  29. Use Sequencer to Stage Multiple Compressors

  30. D.O.E. Air Master+ Software • AIRMaster+ provides a systematic approach for assessing the supply-side performance of compressed air systems. • AIRMaster+ evaluates the energy savings potential of any or all of the following eight energy efficiency actions: • Reduce air leaks • Improve end-use efficiency • Reduce system air pressure • Use unloading controls • Adjust cascading set points • Use automatic sequencer • Reduce run time • Add primary receiver volume • http://www1.eere.energy.gov/industry/bestpractices/

  31. Short Concise Report

  32. Thank you!

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