Workshop Q. Compressed Air System Performance, Reliability & Energy Efficiency. Tuesday, February 19, :15 p.m. to 4:30 p.m.

Transcription

1 Workshop Q Compressed Air System Performance, Reliability & Energy Efficiency Tuesday, February 19, :15 p.m. to 4:30 p.m.

2 Biographical Information Steve Briscoe, Vice President, Energy Management Group Industrial Air Centers for Ohio, Indiana & Kentucky 2840 Fisher Road, Suite E, Columbus, OH Steve Briscoe is currently the Vice-President of the Energy Management Group for Industrial Air Centers for Ohio, Indiana and Kentucky. Steve has been in the industrial compressed air field for 23 years and has performed compressed air audits for facilities across the US for the past 18 years. Steve has been a Qualified US Department of Energy AIRMaster+ Specialist since 2004 and he leads a team of auditors which provide product neutral evaluations of compressed air and vacuum systems in all facilities nationwide. He also leads a team of System Specialists across a three-state area to help develop, install, and service energy efficient solutions. Steve currently sits as the President of a not for profit organization, "The Compressed Air Challenge" (CAC), which is focused on the education and training of end users on improving efficiency of compressed air systems. Steve has presented at the Annual Ohio Energy Conference in the past, he holds regular training workshops for engineering, end users and contractors, as well as presenting at the Kentucky Association of Manufacturer s Energy Conference.

3 Steps to Assess Compressed Air Systems How to Assess Your Compressed Air System - The Steps to Success February 19, 2019 Steve Briscoe Vice President IAC Energy Management Group

4 Agenda How to assess your compressed air system Baseline of the current status What instrumentation is required, where should it be placed Expectation of results Demand side opportunities Reduction of demand Leak Studies System Management and Continuous Monitoring

5 How do you assess your system? A full assessment of your compressed air system should include comments on the complete system -- installation, performance, maintenance, and even the ventilation. What key components should you consider gathering data from? No brainers: Each air compressor. Power (kw not Amps) Pressure (at the discharge of the compressor) Evaluate the controls Efficiency System demand CFM

6 How do you assess your system? The often missed: Each air dryer, refrigerated and/or desiccant. Dewpoint Power Desiccant dryers flow downstream versus what is produced Cooling water temperatures / ambient conditions ( F / %RH) Filter/dryer/supply-side piping pressure drop. Is the dryer still sized appropriately? Pressure differential compared at peak loads Demand side piping pressure drop. Who are the first to complain when pressure drops? Pressure fluctuation for the entire network Forgotten filtration throughout the facility? Treasure hunt for leaks!

7 How do you assess your system? k W k W k W T R H P P D P A D P A A D P D e w P

8 How do you assess your system? P P F P P P P D e w BAG HOUSE P D e w

9 Who should perform the assessment? Assessor should be qualified and experienced! Look for credentials over only looking at independent Most of the time those involved with compressed air have the most experience Service team to support mechanical issues Avoid Free, fastest way to a new compressor quote Some Qualifications (all exam based): US Department of Energy AIRMaster+ Specialist NEW in 2019: ANSI Accredited Compressed Air System Professional FUTURE in 2020: ANSI Accredited Compressed Air System Assessor

10 What do you need to prepare? Be clear with the expectations of this audit Small Facility 1 to 100 HP Pick 2-3 Opportunities for exploration Medium Facility 100 to 1000 HP Pick 4-5 Opportunities for exploration Large Facility over 1000 HP Explore all opportunities Gather production data. Can you assign costs to a product line? To each shift? To product throughput?

11 What do you need to prepare? Collect the following: Your Power costs Water costs (if water cooled) Heating fuel costs Discuss the compressed air supply with Production. Downtime or quality problems? Growth plans? Bottle-necks? Understand the problems within your existing system. Review maintenance records and costs Are there maintenance recommendations that have not been acted upon The more information you provide the better the assessment can be

12 Opportunities: 1. Energy Usage

13 Opportunities: 1. Energy Usage 2. Efficiency

14 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability - Longevity

15 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality

16 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives

17 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives 6. Savings

18 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives 6. Savings 7. Future changes to air demands

19 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives 6. Savings 7. Future changes to air demands 8. Redundancy

20 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives 6. Savings 7. Future changes to air demands 8. Redundancy 9. Ease of Maintenance

21 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives 6. Savings 7. Future changes to air demands 8. Redundancy 9. Ease of Maintenance 10.Rate of Return

22 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives 6. Savings 7. Future changes to air demands 8. Redundancy 9. Ease of Maintenance 10.Rate of Return 11. What other Projects besides Compressed Air should I look at?

23 Opportunities: 1. Energy Usage 2. Efficiency 3. Reliability 4. Air Quality 5. Utility Incentives 6. Savings 7. Future changes to air demands 8. Redundancy 9. Ease of Maintenance 10.Rate of Return 11. What other Projects besides Compressed Air should I look at? 12. Leak Load

24 How we might select opportunities Why shouldn t ALL opportunities be selected? What is most important to you? What will drive the biggest benefit? Budget status, is there capital? An assessor can help you choose based on a walkthrough

25 How else we might select opportunities Are there other benefits to this measure? Heat reclamation? Production benefits? Space benefits? An easily implementable project Consult your end-users. Maybe a project for them will raise awareness. What are their concerns? Make sure you report the Actions, Costs, and Total Effects and Benefits to the appropriate management to gain buy-in for future projects. Beware of political restrictions Did your manager install that piece of equipment that is no longer viable and you want to remove? Tricky ground.

26 How else we might select opportunities Talk to Production Managers Can you find out downtime and scrap expense, leading causes Perceived or actual compressed air problems What s in it for them? Talk to Maintenance Managers Find out what is really going on Talk to Finance Financing options Corporate Incentives Talk to your Utilities Incentive programs / custom or prescriptive Requirements to qualify

27 Resources What are you looking for when someone comes to your plant? CAC Guidelines published in 2002 ASME EA Standard published in

28 What should you expect from an assessment

29 Supply Side Supply Side Source: Compressed Air Challenge

30 Supply Side Total Cost of Ownership Energy cost can be up to 88% of a 10 year cost of ownership Typical 100 HP example Equipment 5% ($35,000) Maintenance (Service Provider) 7% ($50,000) Electricity 88% ($600,000) Based on $0.08/kWh, 24/7 Operation

31 Demand Side Demand Side Source: Compressed Air Challenge

32 Demand Side Why Demand Side? On average, 50% of Compressed Air is wasted! Artificial Demand 15% ($9,000) Poor Practices 10% ($6,000) Air Leaks 25% ($15,000) Production 50% ($30,000) Based on $0.08/kWh, 24/7 Operation

33 Comprehensive Compressed Air Audit Supply Side on: Reliability of equipment Produce air in the most efficient means possible based on actual demand VSD Applications Sequencing Properly sized filtration and dehydration Adequate Storage Reduce inefficiencies in the compressor room Demand Side focuses on: Reduction of compressed air usage Inappropriate uses Pressure reduction Leaks Distribution issues

34 Baseline Your System (Assessment) What should be included in this assessment: 1. Power on all compressors (kw, not amps) This will give you a starting point Identify current demand Provide current energy costs Not designed to provide a solution 2. Pressure at discharge of compressors 3. Pressure at discharge of compressor room 4. Pressure in the plant in one or two critical areas See range of pressures seen Pressure loss across cleanup equipment and distribution

35 Block diagram 100 HP 450 CFM 100 HP 450 CFM 50 HP 225 CFM 400 GALLON 200 CFM 200 CFM Identifies Potential Issues 500 CFM 500 CFM 200 CFM 450 CFM 450 CFM 500 CFM 500 CFM 600 GALLON

36 Air Leak Audit Performed via Ultrasonic Leak Detection Very effective in the hands of an experienced user Identify Leaks Tag based on severity Put a program in place to repair

37 Cost of Leaks At $0.10 / kwh cost of electricity: A $ 200 / year leak cannot be felt or heard A $ 800 / year leak can be felt, but not heard A $1,400 / year leak can be felt and heard Source: Compressed Air Challenge

38 Demand Side Study LEAK STUDY FIND LEAKS Inappropriate uses of compressed air: Cabinet Cooling Personal cooling Equipment isolation when not in use Air motors 8 HP Compressor = 1 HP work Poor Practices Open blow-offs without engineered nozzles Low pressure applications Vacuum generation Aeration Open Valves for drains Image courtesy of Reliable Plant ompressed-air-energy-carbon

39 Information Unit Manufacturer Model Compressor Information Nominal HP Air Compressor Ratings Motor Eff. Pressure (psig) Flow (ACFM) Package Power (kw) Specific Energy (kw/100cfm) Fan HP Stages Type Capacity Control AC1 Sullair V200S-200H LS VSD AC2 Sullair VCC200S-150H LS VCC AC3 Kaeser CDS LS L/UL AC4 Kaeser CDS LS L/UL Compressor Types: LS=Lubricated Screw, OFLS=Oil Free Lubricated Screw, DAR=Double Acting Recip Control Types: MOD=Inlet Modulation, VCC= Variable Capacity Control, VSD= Variable Speed Drive, L/UL=Load Unload Dryer Information Air Dryer Ratings Unit Manufacturer Model Dryer Type Capacity (scfm) Pressure (psig) Control Type Total (kw) Cooling Method AD1 ICP IDHPE-1500 Heated Desiccant 1, DDS 16.0 N/A AD2 ICP IDHPE-1500 Heated Desiccant 1, DDS 16.0 N/A Control Types: Fixed=Fixed Time Cycle, DDS=Dew Point Dependent Switching,

40 Performance Equipment Performance Air Compressor Performance Summary Compressor Hours Avg Kw % Power (kw) Avg Flow (scfm) % Flow (scfm) Specifiic Energy (kw/100cfm) Avg Wet Pressure (psig) Annual Cost AC1 6, % % $59,624 AC2 8, % % $74,826 AC % % $1,758 AC % % $1,240 Total Compressor Energy Costs Total Dryer Energy Costs Total Annual Energy Costs $137,447 $15,240 $152,687 System Performance System Performance Summary System Avg System Power System Avg System Flow % Specific Energy Avg Dry Hours Power (kw) % (kw) Flow (scfm) (scfm) (kw/100cfm) Pressure (psig) 8, % 1,097 50%

41 Overall Flow Graph

42 Overall Flow Histogram AVG scfm % OF TIME CUMULATIVE % OF TIME % 6.2% % 20.2% % 26.4% % 30.1% % 38.1% 1, % 39.6% 1, % 44.4% 1, % 67.2% 1, % 91.0% 1, % 100.0%

43 Details of Events Found

44 Pressure Graphs

45 Pressure Histograms AVG psig % OF TIME CUMULATIVE % OF TIME % 0.1% % 0.3% % 1.3% % 2.3% % 2.7% % 3.5% % 13.0% % 69.3% % 87.1% % 100.0%

46 Recommendations Recommendations should be listed individually and not as one ROI Equipment / Controls improvements Plant piping distribution Lowering Plant Pressure Alternatives for compressed air usage (Blowers, electric motors) Etc.

47 Where to Start Compressed air reduction projects Low cost opportunities Projects which can utilize incentives Reduction of pressure drops (1% power for every 2 psi) Best ROI Solutions Reduce usage as much as possible, then re-log for supply side evaluation Heat Recovery

48 Compressed Air VS. Electric The overall efficiency of a typical compressed air system can be as low as percent Annual energy costs for a 1 hp air motor versus a 1 hp electric motor, 5 day per week, 2 shift operation, $0.10/kWh $ 2,330 (compressed air) $ 390 (electric)

49 Shortcuts

50 Repairs

51 But I do Have a Looped System??

52 Resource Material Best Practices of Compressed Air Systems $ Through Amazon.com Second edition released 2009

53 Thank You for Your Time and Attention Do you have Questions?