MAXIMIZE your Compressor System Incentives through the Save ON Energy Program

Transcription

1 MAXIMIZE your Compressor System Incentives through the Save ON Energy Program Shannon de Souza, CEM Compressed Air Efficiency Specialist O M E Shannon@boge.ca Compressors air Us Inc Timberlea Blvd. Mississauga, ON L4W 2S2

2 Objectives For Today s Session By the end of this session you will be able to make Intelligent Compressed Air Decisions armed with a firm knowledge of how to: Identify components of a typical compressed air system Calculate a first cut estimate of your current annual compressed air costs Differentiate between compressed air supply and demand and how they are audited Utilize innovative products and services to optimize your compressed air system Attain rapid payback period on your Energy Saving Projects using the Save ON Energy Audit Funding and Retrofit Programs

3 Introduction What is Compressed Air and how is it used? Compressed Air is a means to produce and store energy that can be used anywhere it is transported as mechanical energy. Discharged by a compressor and then distributed to plant equipment through a piping network Converted back into mechanical energy for use in equipment Compressed Air is an afterthought unless workers complain about inadequate air pressure Easiest solution is to increase the pressure from the supply system 75% of it s users have no concept of how to optimize their compressed air system

4 Compressed Air Costs Compressed Air Costs Money! The power conversion efficiency of compressed air is just under 10%. 7-8kW You will require 7-8kW of input energy at your compressor system, 1 kw to realize 1kW of power at your plant. Most end users in a factory think compressed air is free. THEY COULDN T BE MORE WRONG!

5 Energy Consumers in the Supply System Where does the money go? Air Intake Air Compressor (modulation control) After Cooler Wet Control Receiver Particulate Filter Air Dryer After Filter Air Distribution Pipes to Plant Timer Drain Timer Drain Timer Drain Timer Drain Timer Drain Supply Demand

6 Compressed Air Supply Components Air Compressor The role of your compressor Reciprocating Compressor Centrifugal MOST Compressor COMMON CONTROL Rotary LOGIC Screw Compressor (oil free and oil less) Modulation Control Load/Unload Control Variable Speed Drive Control Compressed Air. The heart of any manufacturing facility

7 Compressed Air Supply Components Moisture Separator More than 60% of all condensate found in the compressor system accumulates in the moisture separator The Moisture Separator is installed downstream of the compressor and upstream of any filtration and air treatment. Units with filter elements and incorrectly sized separators can increase power consumption of the compressor. Responsible for removal of bulk water from the airstream

8 Compressed Air Supply Components Dryers Refrigerated Air Dryers (PDP of 38F) Refrigerated air dryers consume electricity when their refrigeration compressor is running Desiccant Dryers (PDP to -100F) Desiccant Dryers use up to 15% of their rated CFM capacity This increases the consumption of the compressors Dryers lower the temperature at which water will condense out of the compressed air stream [Pressure Dew Point]

9 Compressed Air Supply Components Filtration and ISO Air Treatment Standards Removal of particulate and oil content to ISO Standards Rated for dry/wet pressure drop When filters are undersized or plugged this causes excessive pressure drop Increases power consumption of the compressor Air Treatment to various ISO Air Quality Standards remove particles and oil content from the compressed air stream

10 Compressed Air Supply Components Receiver Tank A reservoir of compressed air storage for plant use Storage of compressed air allows the compressor to rest occasionally. Wet Tank Dry Tank

11 Compressed Air Supply Components Drains Float Drains Electric Timer Drains Electric timer drains are an artificial demand on the system

12 Energy Consumers in the Demand System Where does the money go? Plant production equipment Air Intake Air Compressor (modulation control) After Cooler Wet Control Receiver Particulate Filter Point of use Filtration Air Dryer Plant tools After Filter Air Distribution Pipes to Plant Other compressed air users Timer Drain Timer Drain Timer Drain Timer Drain Improper uses of compressed air Supply Demand

13 Compressed Air Demand Components Piping Network Improper piping size Octopus configuration and deadheads Leaks Proper piping based on velocity Transports compressed air from the supply system to the equipment in the facility

14 Compressed Air Demand Components Point of Use filtration and Drains Filters air at the point of use Many times is redundant if filters are already present in the supply system Multiple drains throughout the plant can quickly become a significant artificial demand on the system Filtration at the point of use (machinery)

15 Compressed Air Demand Components Improper uses of compressed air Cooling Vacuum Low Pressure Applications Debris Removal You're throwing your money away!

16 What s the first step? 1 st step How do I take the first step towards optimizing my compressed air system?

17 Calculating Compressor Operating Costs A First Cut Estimate All calculations are based on $0.10/kWh These calculations are intended to give the user a rough estimate of the annual costs to run their compressed air system For an accurate total cost consumption data should be captured with power meters during an air audit 3 Shift Operation 2 Shift Operation 1 Shift Operation $690/hp $460/hp $230/hp Quantify the potential $$ your plant currently spends on compressed air to determine if efficiency upgrades should be a priority

18 How The Save ON Energy Program Can Help Your Business Why should we do an Audit? You suspect your system is inefficient Planning to retrofit your compressors Yearly energy saving targets to reach "If we have data, let's look at data. If all we have are opinions, let's go with mine." -Jim Barksdale

19 Types of Audits Supply Audit Audit of the equipment inside the compressor room only Can be done with or without a flowmeter Data gathering ends at the dry receiver Artificial demand and leakage is not measured =VSD

20 Types of Audits Supply and Demand Audit Supply F Demand

21 How The Save ON Energy Program Can Help Your Business Save ON Energy Audit Funding Program Subsidize 50% of the cost of a compressed air audit up to $5, for detailed analysis of non-capital incentives program Get a quote from your auditor Submit signed Pre Energy Audit Application/Participant Agreement Secure written approval from LDC Issue PO to your auditor Review results with your auditor and pay for your audit Submit Post Project Submission to LDC with copy of the audit report, energy auditor invoices and proof of payment LDC will cut check for approved audit funding incentive The saveonenergy Audit Funding Program allows you to discover what the opportunities are in your plant without committing to purchasing retrofit equipment

22 How The Save ON Energy Program Can Help Your Business MOU Complete Air Audit YOU WILL NEVER STAND OUT IF YOU TRY TO LOOK LIKE EVERYONE ELSE INNOVATION IS NOT IMITATION Designed for customers with large opportunity for energy savings who are having difficulty getting internal approval for audit Includes signed Memorandum of Understanding (MOU) that client will use Compressors air Us as their preferred supplier for any RETROFIT recommendations from the audit CRU will provide at no cost a complete plant supply and demand audit including report and presentation Great way to kickstart an energy savings project without going to management for funds without proof of a significant opportunity Innovation not Imitation. There are some things you can't learn from the competition!

23 Modern Technology to Increase your System s Efficiency Effective Technology Compressed air industry has gravitated towards energy efficiency Zero Loss Air Drains Energy Efficient Dryer Technology Oil Mist Eliminators Intelligent Master Controllers Oil Converters Increasing Tank Storage Flow Controllers Heat Recovery and DUOTHERM You know you can save money. Here's some ways to do it!

24 Modern Technology to Increase your System s Efficiency Zero Loss Drains THE MOST EFFICIENT WAY TO DISPOSE OF CONDENSATE FROM THE SYSTEM Water is removed without any air loss! AIR LOSS Payback on Zero Loss Drains is almost INSTANTANEOUS!

25 Modern Technology to Increase your System s Efficiency Energy Efficient Dryer Technology Cycling and Thermal Mass Refrigerated Air Dryers Low pressure drop design Purge Economizer Controls Make the decision to purchase energy efficient options for dryers

26 Modern Technology to Increase your System s Efficiency Oil Mist Eliminators Standard Filtration Quality Ultra Low Pressure Drop Replacement Life of years (standard filters must be changed every 6-12 months) Typically provide a savings of up to 6 PSIG in reduced pressure drop OME s can significantly reduce pressure drop and they can meet most ISO Air Quality Requirements

27 Modern Technology to Increase your System s Efficiency Intelligent Master Controllers Key component of multiple compressor installations Reduces pressure band and intelligently selects compressors to run for optimum system efficiency New models offer touchscreen and ipad apps through the Apple Store Installed Compressor Power (hp) First Cut Estimate of Annual Electrical Costs 100 $69, $86, $103, $138,000 Pressure Reduction (psi) Annual Savings Opportunity with BOGE AIRtelligence Master Controller 4,120 hrs 8,760 hrs 10 $4,685 $9, $9,432 $18, $5,856 $11, $11,790 $23, $7,028 $14, $14,148 $28, $9,370 $18, $18,865 $37,674 Intelligent Master Controllers are a must for multiple compressor installations

28 Modern Technology to Increase your System s Efficiency Oil Converters Highly efficient alternative to multiple levels of filtration to attain oil free air Provides Class 0 oil free air with extremely low pressure drop Alternative to purchasing oil free compressors New innovative product for Class 0 oil free air.

29 Modern Technology to Increase your System s Efficiency Increasing Tank Storage Size tanks based on 4-10 gallons per CFM Easy way to stabilize plant pressure in conjunction with a flow controller Adequate storage may allow compressor to shut off intermittently, conserving energy A properly sized tank will always be beneficial to your air compressors

30 Modern Technology to Increase your System s Efficiency Flow Controllers Works in conjunction with large storage tanks Allows compressed air to be stored at a higher pressure while delivering consistent, lower pressure air to the demand system. Significantly reduces energy wastage Reduces leak rate on the demand side of the system Flow controllers are beneficial in all compressor applications with a large tank including VSD Installations

31 Modern Technology to Increase your System s Efficiency Heat Recovery and DUOTHERM 94% of energy used in compression is converted to heat Through the use of a heat exchanger like BOGE DUOTHERM, process water can be pre-heated, reducing the boiler load. If that heat can be reused, efficiencies of over 90% can be achieved Indoor space heating can be realized through ducting Heat Recovery Projects have a payback of 6 months or less

32 How The Save ON Energy Program Can Help Your Business Save ON Energy Retrofit Custom Track Funding Program Available incentive of $800/kW or $0.10/kWh for custom projects HOW TO GET STARTED: Register for online account Submit all required documentation Can be for a planned or unplanned equipment replacement LDC will review application and only after approval is issued can you issue purchase orders to your suppliers Once project is installed any additional information and project invoices should be submitted online Your LDC will assess demand or energy consumption savings and issue incentive payment accordingly

33 How The Save ON Energy Program Can Help Your Business Case Study ARLA FOODS Baseline Data Baseline Energy Consumption was 734,977 kwh Client and Cheese Manufacturing Plant COMPRESSORS INCLUDED: 100HP modulation 30HP load/unload 40HP load/unload System had insufficient compressed air storage System had excessive filtration for the air quality required With The saveonenergy Program Arla will see phenomenal savings

34 How The Save ON Energy Program Can Help Your Business ARLA FOODS- Retrofit Energy Efficient Case Data Verified Energy Efficient Case Consumption is 218,225 kwh BOGE SLF 75HP VSD Compressor Cycling LP Refrigerated Air Dryer Oil Mist Eliminator All drains replaced with zero-loss units Large storage tank with epoxy internal coating for corrosion protection Total Project Cost - $91, Actual Participant Incentive Paid was $45, on 457,600 kwh's of first year energy savings capped at 50% of total project cost BOGE DUOTHERM system included in compressor for supplementary application for additional incentives from gas distribution company You can easily be saving your company money

35 Thank You For Giving Us An Opportunity To Earn Your Trust Shannon de Souza, CEM Compressed Air Efficiency Specialist O E Shannon@boge.ca Compressors air Us Inc Timberlea Blvd. Mississauga, ON L4W 2S2