Free Air Delivered. By: Power Supply Industries, Inc. Presented by Curt Hertel & Scott Bertelsmeyer Material by Jim Timmersman 08/10/2016

Transcription

1 Free Air Delivered By: Power Supply Industries, Inc. Presented by Curt Hertel & Scott Bertelsmeyer Material by Jim Timmersman 08/10/2016

2 COMPRESSED AIR 10% of all industrial electricity in the U.S./90,000,000,000 kwh Roughly 16% of U.S. industrial motor system energy use 50% of industrial plant air systems harbor opportunities for large energy savings with relatively low project costs Only 10% of industrial users reported that they kept track of the energy cost of their compressed air systems

3 DON T BELIEVE IT!

4 Contrary to popular opinion-

5 COMPRESSED AIR Called industry s fourth utility Used extensively in industry Consumes $4.5 billion in electricity annually Savings of 20-50% in your facility are very possible!

6 COMPRESSOR AIR COSTS IN PERSPECTIVE Compressed Air is probably the most inefficient source of energy in your plant 1 hp air motor = 5-7 hp of electrical power $1,164 vs. $194

7 TYPICAL COMPONENTS OF DEMAND Inappropriate Uses 15-20% Leaks 20-25% Artificial Demand 10-15% Production 50%

8 OPTIMIZE YOUR COMPRESSED AIR SYSTEM An optimized system ensures that efficient and effective compressed air is available for the lowest possible cost with minimal environmental consequences Have your production and management teams implemented a plan to enhance your compressed air system?

9 OPTIMIZE YOUR COMPRESSED AIR SYSTEM Ameren Illinois Energy Efficiency Program options for your Compressed Air System: Retro commissioning program to optimize your compressed air system Leak Survey & Repair program (for all systems; no horsepower requirement) Custom Application 9

10 Ameren Illinois Energy Efficiency RCX COMPRESSED AIR STUDY CAN BE PROFITABLE FOR YOU..

11 Ameren Illinois Energy Efficiency program will pay 80% of the cost of the study including flow pressure & power measurement pay for the comprehensive study with all leaks and waste documented in your facility fund the repair of the leaks and low cost energy savings at $.02 per kwh 11

12 Ameren Illinois Energy Efficiency program will fund up to 50% of the cost of any custom project identified during the course of the study at $.06 per kwh with a potential 15% bonus if the custom project is submitted within 6 months of survey reduced to 5% if submitted within 12 months. fund studies for larger systems of 300HP total horsepower fund Leak Survey and Repair for systems under 300HP 12

13 COMPRESSED AIR MUST BE TREATED AS A SYSTEM

14 SYSTEMS APPROACH & DYNAMICS The focus is shifted away from individual components to total system performance With compressed air systems, Dynamic Efficiency (matching supply with demand over time) are especially important Using controls, storage, and demand management to design a system that meets peak requirements but also operates efficiently at part loads is key to a high performance compressed air system

15 WHAT IS THE SUPPLY SIDE? Consists of components prior to and including the primary receiver and the pressure/flow controller if present Sales Focus

16 SUPPLY SIDE LOW COST CHECK LIST Supply cool clean air for compression Reduce air lost during water removal Manage compressor operation Operate dryers with dew point demand Fix leaks / open drains you can hear

17 SUPPLY SIDE LOW COST CHECK LIST Optimize compressor set points Verify compressor performance/power/flow Check delta P on clean up equipment Check for proper pipe sizing remove restrictions Compressor room ventilation/ recovery 17

18 THE MANAGED SYSTEM 80 PSIG Flow Pressure Controller w/ Dry Storage 40 PSIG 55 PSIG 60 PSIG 75 PSIG Refrigerated Air Dryer -Stable System Pressure -Reduced Energy Consumption -Better Quality Control -Fewer Complaints -Improved Productivity -Air System Cruise Control Varied Set Points

19 COMPRESSOR MANAGEMENT

20 PRECISE PRESSURE CONTROL

21 COMPRESSED AIR STORAGE

22 How dedicated storage was used to shield the system from a high flow using application Needle valve for metered rate of recovery Check valve Filter/Regulator gallon typical At the mineral processing facility, storage was added to protect the entire system from this intermittent application which caused header pressure fluctuations when it actuated.

23 How dedicated storage was used to shield the system from a high flow using application Needle valve for metered rate of recovery Check valve Filter/Regulator gallon typical Upon actuation, the mass required is provided by the receiver. The needle valve is adjusted to control the rate of recovery of the receiver pressure which creates a more constant and lower rate of flow to the system. It is important that the recovery time in the receiver is equal to or greater than the actuation time. The receiver pressure need only recover before the next actuation. This way the use volume can be spread over the entire cycle time.

24 WHAT IS THE DEMAND SIDE? Includes all the components after the primary receiver or pressure/flow controller if present Compressor salesman's nightmare

25 DEMAND SIDE LOW COST CHECK LIST Check piping Delta P static vs dynamic Locate all Air blow off applications Product Drying with compressed air Creating Vacuum with compressed air Fix leaks you can hear Product/Process Cooling Check your dust collection for savings

26 DEMAND SIDE LOW COST CHECK LIST Process cooling covert to blowers Sparging convert to blowers / mixers Personnel cooling convert to fans Air Mixers convert to electric mixers Disconnect abandoned equipment Install auto air disconnect on idle equipment

27 COMMON LEAK LOCATIONS Pipe joints Couplings, Hoses, & Fittings Drains FRL s

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30 Wide gap air knives are mounted in an arrangement that pushes water or debris to the side edge of the product.

31 Nozzle arrays provide better low pressure blow-off performance when more than 4 from product.

32 ELIMINATE INAPPROPRIATE USES Potentially Inappropriate Uses Clean-up, Drying, Process cooling Sparging Aspirating, Atomizing Padding Vacuum generator Personnel cooling Open-tube, compressed air-operated vortex coolers without thermostats Air motor-driven mixer Air-operated diaphragm pumps Idle equipment* Abandoned equipment** Suggested Alternatives/Actions Low-pressure blowers, electric fans, brooms, nozzles Low-pressure blowers and mixers Low-pressure blowers Low to medium-pressure blowers Dedicated vacuum pump or central vacuum system Electric fans Air-to-air heat exchanger or air conditioner, add thermostats to vortex cooler Electric motor-driven mixer Proper regulator and speed control; electric pump Put an air-stop valve at the compressed air inlet Disconnect air supply to equipment *Equipment that is temporarily not in use during the production cycle. **Equipment that is no longer in use either due to a process change or malfunction.

33 SUMMARY Compressed Air is a frequently overlooked source of cost savings and production benefits Compressed Air System management starts with a demand side review followed by a supply side review Compressed air audits/ studies are essential to baseline your compressed air system Compressed Air Systems can and must be controlled

34 SUMMARY The efficiency of a compressed air system can be maintained with basic management tools By developing a plan, you can work towards increasing your compressed air dynamic efficiency Free Air/Capacity is the primary benefit to you for using the Ameren Compressed Air Program 34

35 Energy Advisors 1. Chad Whitehead Steve Smith Rod Rhoads Mark Steinmetz John Strode Fred Joshu Larry Erwin Ameren Illinois EA territory map 35

36 Resources A complete list of approved Retro-commissioning Service Providers: compressed-air-rsp-list.pdf Website: ActOnEnergy.com/Business Phone: ActOnEnergyBusiness@Ameren.com

37 Power Supply Industries Curt Hertel Scott Bertelsmeyer Jim Timmersman (314)

38 Questions?

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