Welcome Compressed Air Supply & Demand Side Control Systems

Transcription

1 Welcome Compressed Air Supply & Demand Side Control Systems Energy Efficient Screw Compressors 3 & 4 September 2010, Chennai

2 Total Compressors Air Solutions TURNKEY CONTRACTS SYSTEM DESIGN COMP AIR AUDITS & TOOLS CENTRIFUGAL / TURBO COMPRESSORS SYSTEM CONTROLS ENERGY EFFICIENT COMPRESSORS

3 Compressed Air System Audits Pressure & Flow Trending of Compressed Air System: Air Compressor Air Treatment Equipment (Filters & dryers) Air Line Headers Capacity effectiveness of Air Compressors Flow Modelling of Air Compressors

4 Compressed Air System Audits Compressor Utilisation Individual & Total Compressors energy consumption Productive & Non-productive energy consumption Energy Efficiency Quantification of Plant air leakage Recommendations for Energy Savings / Air Compressors / Accessories. Recommendations for air system performance

5 PSIG Variations Compressed Air Pressure Real Time Data :05 12:15 13:37 14:36 15:58 Time

6 Pressure Graphs: With VFD Compressor

7 Response Time of Compressors with VFD or Load /Un load capacity control to meet sudden air demand? Comp. Receiver Treatment Receiver Air Network

8 INTELLIGENT FLOW CONTROL SYSTEMS More than 1000 Energy Saving installed 100 million units (kwh) of Energy Saving eac h year

9 Response Time of Compressors ControlAir IFC System on-line to meet sudden air demand? Comp. Receiver Treatment Receiver IFC Air Network

10 Pressure Graphs: With Godrej Control System Constant at Plant header

11

12 5 Fixed Cascade : a series of individual pressure switches set at different levels. Selection Cascade : a series of individual pressure switches + selector switches to base or trim load compressors. Pressure Switches : Repeatability not precise Variation in 4 100% Air Demand Traditional Air Compressors Control 3 P band System Pressure Conventional Cascade 3 Air Demand %

13 Metacentre SX & XC: Controls up to 12 & 24 Compressors Solution

14 Supply Side Control System Compressors Local- Zone 1 PT1 Control Pressure for Metacenter can be: Avg. of PT1, PT2, PT3 ix Box XPM 485 Metacenter XC Highest of PT1, PT2, PT3 Lowest of PT1, PT2, PT3 PT3 PT2 EX Box EX Box Compressors Remote-Zone 3 Compressors Remote - Zone

15 Case Study CEMENT INDUSTRY Air Quality Improvement & Demand Side Control Systems

16 Cement Industry: Power Plant Service Air

17 Cement Industry: Power Plant Service Air

18 Service Air: Result of installation of ControlAir IFC & Dryer Before Godrej IFC & Air Dryer Energy Consumed = 7,506 kwh/day Main Header Pressure Variances = +/- 15 psig After Godrej IFC & Air Dryer Energy Consumed = 5,276 kwh/day Main Header Pressure Variances = +/- 0.6 psig Benefits Daily Energy Savings = 2,229 kwh/day Actual Energy Savings = 30% Plant Service Air is maintained at constant pressure of 60 Psig (4.23 Kg/cm2) with a variation of +/- 0.6 psig

19 Cement Industry: Power Plant Instrument Air

20 Cement Industry: Power Plant Instrument Air

21 Instrument Air: Result of installation of ControlAir IFC & Dryer Before Godrej IFC & Air Dryer Energy Consumed = 4,694 kwh/day Main Header Pressure Variances = +/- 6 psig After Godrej IFC & Air Dryer Energy Consumed = 2,700 kwh/day Main Header Pressure Variances = +/- 0.2 psig Benefits Daily Energy Savings = 1,995 kwh/day Actual Energy Savings = 42% One Air Compressor of Capacity : 550 CFM is stopped. Plant Instrument Air is maintained at constant pressure of 87 Psig (6.1 kg/cm2) with a variation of +/- 0.2 psig

22 Case Study AUTOMOBILE INDUSTRY Supply Side & Demand Side Control Systems

23 VEHICLE QUALITY AREA VEHICLE QUALITY AREA STORAGE AREA PAINT SHOP No. 4 PAINT SHOP No. 3 WELDING SHOP FRAME ASSEMBLY PAINT SHOP No. 1 PAINT SHOP No. 2 PARTS INSPECTION ROOM MATERIAL STORAGE AREA FRAME ASSEMBLY FUEL TANK ASSEMBLY ENGINE ASSEMBLY WELDING SHOP MACHINE SHOP MACHINE SHOP PRESS SHOP FINISHING AREA ( PRESS SHOP) ENGINE ASSEMBLY STC 1 1/2 1 1/2 HPDC 1 1/2 3m 3 1 LPDC GDC 8 6m 3 6m / / /2 Atlas Copco Cap:132Kw,1000scfm (4 Nos.) Atlas Copco Cap: 160Kw, 1000 scfm (4 Nos.) COMPRESSOR HOUSE MOTORCYCLE PLANT SCOOTER PLANT 1 1/2 Atlas Copco Cap:160Kw 6m 3 Upstream ControlAiR System IN 6m 3 3m 3 OUT Compressed Air Network

24 Automobile Company Pressure Charts: Inlet & Outlet of ControlAiR System 100 ControlAiR Inlet ControlAiR Outlet Hours, 05/11/06-05/11/

25 Without ControlAiR: Energy Consumed = 16,22 4 kwh/day Plant Header Pressure Vari ances = +/- 5 psig Automobile Company Demand Side Control Systems installed With ControlAiR: Energy Consumed = 14,7 58 kwh/day Plant Header Pressure Va riances = +/- 0.5 psig Energy Savings achieved = 1466 kwh/day Guaranteed Savings = 5% Actual Energy Savings ~ 9%

26 VEHICLE QUALITY AREA VEHICLE QUALITY AREA STORAGE AREA PAINT SHOP No. 4 PAINT SHOP No. 3 WELDING SHOP FRAME ASSEMBLY PAINT SHOP No. 1 PAINT SHOP No. 2 PARTS INSPECTION ROOM MATERIAL STORAGE AREA FRAME ASSEMBLY FUEL TANK ASSEMBLY ENGINE ASSEMBLY WELDING SHOP MACHINE SHOP MACHINE SHOP PRESS SHOP FINISHING AREA ( PRESS SHOP) ENGINE ASSEMBLY STC 1 1/2 1 1/2 HPDC 1 1/2 3m 3 1 LPDC GDC 8 6m 3 6m / / /2 Atlas Copco Cap:132Kw,1000scfm (4 Nos.) Atlas Copco Cap: 160Kw, 1000 scfm (4 Nos.) COMPRESSOR HOUSE MOTORCYCLE PLANT SCOOTER PLANT 1 1/2 Atlas Copco Cap:160Kw 6m 3 Upstream ControlAiR System IN 6m 3 3m 3 OUT Compressed Air Network

27 Without EnergAiR: Energy Consumed = 16,666 kwh/day Automobile Company Supply Side Control System installed Comp Header Pressure Variances = +/- 5 psig With EnergAiR: Energy Consumed = 15,666 kwh/day Comp Header Pressure Variances = +/- 1.5 psig Energy Savings achieved = 1,000 kwh/day Guaranteed Savings = 3% Actual Energy Savings ~ 6%

28 To Paint Shop ControlAiR System Model: GE-10(A) Capacity: 500 cfm OUT IN Air from Scooter Plant Compressor House Main Header To Paint Shop OUT IN PAINT SHOP No. 1 ControlAiR (IFC) System Model: GE-10(A) Capacity: 500 cfm Shop-wise IFCs PAINT SHOP No. 2 Air from Motorcycle Plant Compressor House (Main Header) IN OUT Air from Scooter Plant Compressor House Main Header IN OUT ControlAiR (IFC) System Model: GE-10(A) Capacity: 500 cfm WELDING SHOP (SC) OUT IN Air from Scooter Plant Compressor House Main Header PAINT SHOP No. 4 OUT IN PAINT SHOP No. 3 ControlAiR System Model: GE-10(A) Capacity: 500 cfm HPDC 1 ½ WELDING SHOP (MC) Air from Scooter Plant Compressor House Main Header 3m 3 IN OUT ControlAiR (IFC) System Model: GE-10(A) Capacity: 500 cfm Air from Motorcycle Plant Compressor House (Main Header)

29 Benefits with Localised ControlAir IFC Example of Artificial Demand Reduction in one of the Shops Before Local IFC System: Air Flow Consumed = cfm Paint Shop Pressure Variances = +/- 2 psig After Local IFC System: Air Flow Consumed = cfm Paint Shop Pressure Variances = +/- 0.5 psig Air Flow Savings = 83 cfm Actual Flow Savings = 39%

30 Energy Efficient Screw Compressors

31 SCREW AIR COMPRESSORS 5 Year Warranty! 10 Year Warranty!!

32 After the initial payback period, power savings continue to add up, day after day, year after year. SPIRAL VALVE Compressed air volume is varied by rotating the spiral valve, which opens and closes by-pass ports in the stator, and returns air to suction rather than compressing it. By matching compressor displacement with output need, this energy-saving system uses up to 17% less power

33

34 Spiral control cuts energy costs dramatically 110 Theoretical Load/No Load Actual Load/No Load Modulation Sullair Spiral Valve % OF BHP USED % OF FULL LOAD CAPACITY Spiral Valve cuts energy costs dramatically An outstanding feature of the compressors is Sullair s unique capacity control system, which consists of a spiral valve and an inlet butterfly valve. This system delivers greatly improved part-load performance, especially when compared with compressors having suction throttling or load/no load controls. The power savings is independent of receiver size

35 Case Study Sullair Tandem Screw Compressor with VCC Before After Old Reciprocating Air Compressor For 2200 cfm compressed air requirement, two reciprocating compressors having total motor capacity of 400 kw were run. Energy per Annum = Lacs kwh Replaced by Tandem Screw Compr:- Energy efficient Sullair Tandem Screw Compressor of 2200 cfm with Spiral Valve control technology installed. Energy per Annum = lacs kwh Energy Cost = Rs Lacs/Yr Energy Cost = Rs Lacs/Yr Energy Cost Saving per Compressor = Rs. 25 Lacs/Yr

36 -36- Thank You! Godrej & Boyce Mfg Co Ltd Compressed Air Solutions, Godrej Electrical & Electronics Pirojshanagar, Vikhroli, Mumbai India Tel.: to 2255 Fax: / s: kcp@godrej.com; jayraj@godrej.com; roshe@godrej.com; EnergAir Metacentre Air Compressors Air Treatment ControlAir IFC