Ultrasound World VI (2010)

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1 Ultrasound World VI (2010) Mass flow meters and leak detectors: an essential combination establish energy savings in compressed air systems If you cannot measure it, you cannot improve it

2 Introduction Cynthia Kuiper Background: Industrial Design Engineer Master: Design for Interaction 2006: Start at VPInstruments 2010: Sales and Marketing Director

3 Content - Introduction VPInstruments - Compressed air systems and energy losses - Leak detectors and mass flow meters - Systematic approach: air audits - Savings examples - Mass flow meters - Conclusion

4 Introduction VPInstruments Development, Production and Supply of energy management systems for compressed air installations. Insight in compressed air consumption and savings. (technical gasses) Reliability, user friendliness and complete solutions. Flow meters: sensors Displays: read out locally Software Insights/ Reports

5 Introduction VPInstruments Based in the Netherlands International distribution network Distributors in Europe, Asia, North and South America, Oceania, Africa 80% Export 60% Export in Europe 2009: 30% growth: now is the time for energy savings! 2009: 10 year existence

6 An efficient compressed air installation An efficient installation is constructed around the purpose of use Based on usage, the capacity and necessary quality can be determined.

7 Compressed air installations in reality Only 50% of the generated compressed air is used usefully!

system -Use of wrong hoses and connections -Incorrect dimensioning of

8 Leakage management There is always leakage in a compressed air system. -Worn out piping -Obsolete maintenance -Obsolete/absence of condensate drain system -Use of wrong hoses and connections -Incorrect dimensioning of systems Experience +/ % leakage of compressor capacity in a standard installations.

9 Leakage management Hole of 1/5 inch costs +/ USD/yr of energy. (7barg in 24/24h system) Leakage can be reduced to 5-10%. Don t let your profit be blown away!

10 Repairing leaks: most efficient energy savings measure Adjustable speed drives Radgen, P., Blaustein, E., Compressed Air Systems in the European Union, 2001, Stuttgart

11 Compressed air installations in reality Energy savings: Leakage repair Instruments needed: Leak detectors: allocate Flow meters: detect and feedback Why the combination?

12 Leak detector: advantages Leak detector is only tool to actually locate a leak in your factory.

13 Leak detector: disadvantages Leak detector is necessary in a factory, but - No indication of total leakage level, only per leak. - Time (labour) consuming, walk through entire factory. - No objective, direct feedback on overall results.

Divide by average consumption: obtain leakage in %.

14 Mass flow meter: advantages Detect leakage level of entire plant and divisions. Measure leakage in downtime of the plant. Divide by average consumption: obtain leakage in %. Reveal additional compressed air savings potential. Flow Pressure Temperature Data logger

15 Mass flow meter: disadvantages Mass flow meter, gives overall insight, but - No detection of actual leak locations: so no possibility to pinpoint and repair them. - In continuous production plant without stops in production: not so easy to see the % leakage in the total flow consumption

16 Mass flow meter combined with leak detector The winning team: Leak detectors need mass flow meters Mass flow meters need leak detectors Essential combination! Distributors VPInstruments use both.

17 Air audits Energy savings starts with air audit. Factory implements an energy savings management program. Use of both leak detectors and mass flow meters.

A systematic approach starts with measuring A systematic approach on how to improve your compressed air usage: Implementation Improvements

18 A systematic approach starts with measuring A systematic approach on how to improve your compressed air usage: Implementation Improvements Goal: Continuous improvement of energy efficiency Data Consumption Leakage measurement Power consumption Other relevant data Data analysis

19 Systematic approach: air audit General audit structure: 1. Gather general data 2. Flow measurement (before) + Leak detection Get complete picture of the air demand Perform overall leakage measurement in the downtime (while compressors are still running) 3. Repair of major leaks, action plan for minor leaks 4. Flow measurement (after) see the improvement, keep track Work consistently, to create comparable results!

20 Systematic approach: air audit 1. Gather general data : Compressor types (P&ID if available ) Running hours Load / Unload hours (if applicable) Total installed compressor power Specific energy Total installed air treatment equipment (cooler, dryer) power Electricity price per kwh Air quality requirements

21 Systematic approach: air audit 1. Gather general data : Total power * running hours = annual costs Total power / total air consumption (projected) = cost per CF

22 Systematic approach: air audit 1. Gathering data: Specific energy example: Specific energy Efficiency improvement potential Compressor type: Screw, specific energy = 17 kw/(cfm*100) (6 kw/m3/min) Output = 600 SCFM Power = 125 kw Specific energy is 125/ kw/(cfm*100) (7,3 kw/m3/min) Potential improvement: 18% Efficiency = output / input Electrical power Output Air flow

23 Systematic approach: air audit 1. Gathering data : Load/Unload example Unload hours are a waste of energy. Total unload hours/total load hours = potential % savings Load/Unload hours: load unload v olast Reek s unload hours 7000 running hours 2200/7000 ~ 17% time

24 Systematic approach: air audit 1. Gathering data : Load/Unload example Unload up to 30% of nominal power Example: Compressor: 250kW nominal power 0,3 * 250 kw = 75kW unload power Price per kw ~ 0.1 USD Costs unload = Price per kw * unload hours * kw of unload 0,1 USD * 2200hrs/yr * 75 kw = 16,500 USD per year v olast Reek s unload hours 7000 running hours 2200/7000 ~ 17% time

25 Systematic approach: air audit 2. Flow measurements and leak detection VPFlowScope: - Min. 1 week measurement: overall usage profile - Get overview of total air demand - Get overview of leakage level: main header and possibly per department Ultra probe: - Detect leaks - Cost breakdown per leak Compressor dryer filter Machine 1 Machine 2

26 Systematic approach: air audit 1+2 Combine general data and audit results - Specific energy % efficiency improvement - Unload hours/ load hours: % potential savings on control system - Total leakage % * annual electricity costs = total savings potential on leakage - Air treatment: Higher air quality results in higher energy consumption. E.g. entire company running on instrumentation air, while wet air was ok. - Pressure losses on Dryers and filters : 7% per bar / 14.5 psi

27 Systematic approach: air audit 3. Repair of leaks, (& shutdown of unused lines) - Prioritise: Ranking of leaks - Investment vs. savings 4. Flow measurement (after) - Show improvement of leak repairs and other measures - Keep track of leakage level - Permanent monitoring to optimise resources vs results

28 Example 1: Mineral water company 1. Gather general data: Compressor type : Turbo Running hours : 7500 Total installed power : 962 kw 1290 HP [E] Specific energy : not known Price per kwh : 0.10 Euro 0.13 USD Estimation costs/cf : 0.02 USD Total power * running hours * price per kwh = annual costs 962 * 7500 * 0.13 = 937,500 US Dollar/yr

29 Example 1: Mineral water company Audit performed by: 2. Flow results: 5927 SCFM General air usage 1765 SCFM Leakage

30 Example 1: Mineral water company 2. Flow results: - Leakage: ~30% (1765 SCFM / 5927 SCFM) - Potential savings on leakage costs: 274,000 USD/yr Annual cost for leakage can be calculated by: Leak % = Leakage (CFM)/ average consumption (CFM) Savings potential = Leakage % * total annual costs

31 Example 1: Mineral water company 3. Leak detectors were used to find leakage Leaks were ranked and major leaks were repaired almost 50% of total leakage were repaired. 4. Resulting flow measurements 1059 SCFM Leakage

32 Example 1: Mineral water company Results: Savings: 706 SCFM (~ 200 HP compressor) 137,000 USD/yr Implementation of energy management system: Purchasing of 7 mass flow meters and 2 leak detectors

33 Example 2: Automotive company 1. Gather general data Compressor type : Turbo Load / unload : no Total power : 4500 kw hp [E] Specific energy : 0.12 kwh/m kwh/cfm*100 (0.2038kWh/CFM) Running hours : 7000 Electricity costs : 0.10 Euro/kWh 0.13 USD/kWh

34 Example 2: Automotive company 2. Flow results: flow results of one department 885 SCFM

35 Example 2: Automotive company 2. Flow results Total leakage: 885 SCFM Potential savings: [leakage] * [total operating hours] * [efficiency (specific energy)] * [price] 885 SCFM * 7000 hr * kwh/cfm * 0.13 USD/kWh = 163,800 USD/yr Company implemented leakage management system

36 A systematic approach starts with measuring A systematic approach on how to improve your compressed air usage: Implementation Goal: Air audits start and ends with flow measurements Improvements Continuous improvement of energy efficiency Leak detection important part! Data Consumption Leakage measurement Power consumption Other relevant data Data analysis

37 Extra savings tips With flow meters: more accurate location of leakage: - Flow meter: main pipe line: total leakage - Measure per division: narrow down area for leak detection Packaging $30,000 / yr Repair shop $5,000 / yr Assembly line $25,000 / yr Paint shop $15,000 / yr Metal workshop $2,500/ yr Press 1 Press 2

38 Consumption Extra tips With flow meters: possibility to establish a permanent management system: when to search with leak detector for leaks. Permanent monitoring: keep leakage level at minimum Check flow every 2 weeks: establish if leak detection is necessary Air Audit Consumption at permanent monitoring Optimization Time

Advantages: - Cost effective solution for flow measurements.

39 Mass Flow meters Start of each air audit: Flow measurement. Insight in compressed air usage and leakage levels. Advantages: - Cost effective solution for flow measurements. - Output comparable directly with output compressor. - Versatile usage: one insertion probe for various pipe diameters, flow-, pressure- and temperature ranges. - Additional data besides leakage level:

40 Mass flow meters: usage Compressor dryer filter Compressor Performance check: Specs: 3000 SCFM VPFlowScope: 2000 SCFM Maintenance required Machine 1 Machine 2

41 Mass flow meters: usage Compressor dryer filter Machine consumption Monitoring: Specs: 60 SCFM Actual: 75 SCFM Cause: wrong use >> Training of machine operator Machine 1 Machine 2

42 Mass flow meters: usage Compressor dryer filter Leakage management: Average: 763 SCFM Week-end: 270 SCFM Cause: leaking flange gasket Leakage repairs Machine 1 Machine 2

43 Mass flow meters: usage Compressor Compressor dryer filter dryer filter Control system optimisation

44 Mass flow meters: usage Compressor dryer filter Total air consumption + Cost allocation Estimation Machine 1 Machine 2

45 Mass flow meters vs. Ultrasonic equipment Mass flow meters provide: - Overview of compressed air usage - Detect measures for improvement. - Indication for where savings are possible. - Indication for how much the total savings potential can be Ultrasonic equipment provide: - Allocate leakage - Help in localising other problems: like e.g. bearing check.

46 Conclusion: Perfect team! Mass flow meters combined with Ultrasonic leak detectors form the perfect team for a continuous leakage management program around the factory. Video VPFlowScope instruction video on: YouTube.com:

47 If you can not measure it, you can not improve it

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