Main Headquarters: 120 Water Street, Suite 350, North Andover, MA 01845 With offices in: NY, ME, TX, CA, OR

www.ers-inc.com

COMPRESSED AIR LOAD

REDUCTION APPROACHES AND

INNOVATIONS

presented byMark D’AntonioENERGY & RESOURCE SOLUTIONS, INC.

Air System Overview Compressor Plant Plant Auxiliaries Air Receivers Distribution System End Uses and Loads

Air System Overview

Source: DOE Compressed Air Challenge

Demand Side End-Uses Normal Appropriate Uses Air Leaks Artificial Demand due to Excessive Pressure Inappropriate Uses

Appropriate Uses Pneumatically Actuated Equipment Pneumatic Hand tools Instrument and Control Air Medical Applications Process Air

Air Leaks Monitoring

Ultrasonic Leak Detection

Typical Leaks

 Leak Repair Procedures

Tag # Room Location (psi) CFM Description/Comments00-834 Machine Dept. Air drop 2" nipple 105 2.5 Reducer to iron nipple00-835 Tool Room Sharp milling machine air gun 105 3.8 Quick connect at air gun00-836 Tool Room Sharp milling machine regulator 105 1.3 Brass coupling-outlet of regulator00-837 Wax Dept Assembly line- hose to air gun 65 1.6 Leak in air hose (taped up at leak)00-838 Wax Dept Assembly line regulator 45 1.1 Regulator at 10' height, undetermined fitting00-839 Wax Dept Solubles area air gun 45 1.6 Brass coupling into air gun 45 elbow00-840 Wax Dept Wax press #009 87 2.1 Brass nipple to hose connector at regulator00-862 Wax Dept Wax press #010 95 2.3 T connectors underneath unit, several00-863 Wax Dept Wax press #006 105 5.0 Back of press-brass nipple into elbow00-864 Wax Dept 208 Tank #3 35 1.3 Oil lubricator at regulator undetermined00-865 Wax Dept Wax Press #004 105 2.5 Ball valve L into solenoid underneath machine00-866 Wax Dept Wax Press #003 105 3.8 Brass coupling into solenoid below machine

Air Leak Savings Analysis

ERS Ultrasonic Leak Detection Survey

Results Summary

Facility: ____________ Corp.Survey Date: April 1, 2001

Leak Repair Cost Summary Annual Demand and Energy SavingsNumber of leaks detected and tagged: 176 Peak AnnualEstimated CFM attributed to repairable leaks: 450.2 kW kWh

Total Existing Usage: 538.9 3,052,863Estimated Leak Repair Cost (at $100 per tagged leak): $17,600 Total Proposed Usage: 423.5 2,399,874

Additional Materials Required: $0 Annual Savings: 115.4 652,989contingency 0% $0

Total Leak Repair Cost: $17,600 Cost Savings SummaryDemand Energy

Economic Summary kW saved: 115.4 kWh Saved per Year: 652,989Total Electrical Cost Savings: $53,429 Rate: $6.72 On-Peak Rate ($/kWh): $0.0707EEM Measure Life (Years): 3 Off-Peak Rate ($/kWh): $0.0658Simple Payback (Years): 0.3 Total Electrical Cost Savings: $53,429

Improving Efficiency of Appropriate Uses

Pressure Reduction Volumetric Flow Control Demand Flow Control

Reduce Artificial Demand : Pressure Reduction

Reduce Artificial Demand Pressure Reduction

• Point of Use Regulation• Central Regulation

Volumetric Flow Control Nozzles Air Knives Air Amplifiers

Demand Flow Control Interlocked Solenoid Valves Flow Controllers

Solutions for Inappropriate Uses

Open Blowing - Blowers Sparging/Agitation - Blowers Aspirating - Blowers Personnel Cooling - Fans Air Powered Diaphragm Pumps - Electric Powered Pumps Induced Vacuum Systems - Vacuum Pump Cabinet Cooling - Blowers/Heat Pipe Condensate Drains - Airless Float-Activated Drains

Solutions for Inappropriate Uses

Case Study - Automotive Sealing Systems Compressor Plant

Full Line

Size Load Average Percent Loading Average CFM Pressure

Manufacturer Type (HP) CFM 1st Shift 2nd Shift 3rd Shift 1st Shift 2nd Shift 3rd Shift (psi)

Sullair Rotary Screw, Single-Stage, Modulating 150 616 90% 90% 90% 554.4 554.4 554.4 105

Worthington Rotary Screw, Single-Stage, Modulating 150 600 44% 44% 44% 271.0 271.0 271.0 105

Worthington Rotary Screw, Single-Stage, Modulating 150 600 18% 18% 18% 110.9 110.9 110.9 105

Gardner Denver Rotary Screw, Single-Stage, Modulating 150 625 92% 78% 78% 566.7 480.5 480.5 105

Gardner Denver Rotary Screw, Single-Stage, Modulating 150 625 57% 57% 57% 351.1 351.1 351.1 105

1,854 1,768 1,768

kW kWh

Facility Compressed Air Usage: 538.9 3,052,863

Case Study Compressor Performance

110 PSI motorcapacity CFM % HP BHP eff. KW KW/CFM

100% 616 110% 165 0.945 130.25 0.21190% 554 100% 150 0.942 119.19 0.21580% 493 91% 136 0.938 108.04 0.21970% 431 81% 121 0.935 96.82 0.22560% 370 71% 107 0.932 85.52 0.23150% 308 62% 92 0.928 74.13 0.24140% 246 52% 78 0.925 62.66 0.25430% 185 42% 63 0.922 51.11 0.27720% 123 32% 49 0.918 39.48 0.32010% 62 23% 34 0.915 27.76 0.4510% 0 13% 0 0.000 0.00 0.000

150 HP Rotary Screw - single stage, inlet modulation, air-cooled, premium efficiency motor

Case Study Air Leak Resolution

Total Cost

$

Energy Savings

kWh

Demand Savings

kW

Annual Savings

$

$14,960 652,989 115.4 $53,429

Simple Payback (years): 0.3

ERS performed a compressed air survey using ultrasonic leak detection equipment and tagged one hundred seventy six (176) compressed air leaks throughout the facility. The majority of these leaks were located at connection points of fittings, filters, lubricators, regulators, control valves, and hand blow-off guns.

Most of the leaks were easily repaired. Leaks at threaded connections were repaired by simply backing off the fitting, applying thread sealant, and reassembling. Where parts had failed, such as hoses and filter bowls, new replacement parts were installed.

We estimate the diversity of compressor loading and, utilizing a performance curve for the size and type of compressor involved, predict energy losses due to the leaks observed.

Case Study Efficient Air Nozzles

Total Cost

$

Energy Savings

kWh

Demand Savings

kW

Annual Savings

$

$5,180 79,698 10.3 $5,482

Simple Payback (years): 0.9

Blow-off and part positioning on selected equipment is achieved with a steady stream of high velocity compressed air. The compressed air is delivered through copper tubing focused on the desired locations. These machines currently use 1/16” copper tubing to deliver air streams at 95-100 psi for part positioning and feeding. At 100 psi, such an orifice will deliver just under 6.5 CFM.

Installation of efficient air nozzles was recommended to meet the process requirements but with significantly reduced compressed air consumption. An efficient air nozzle at similar pressure will consume only 4.5 CFM of compressed air. These nozzles are designed to significantly reduce compressed air consumption, thereby reducing compressor runtime.

Case Study Install Air Solenoid Valves

Total Cost

$

Energy Savings

kWh

Demand Savings

kW

Annual Savings

$

$3,650 121,499 na $8,357

Simple Payback (years): 0.4

There is a wide array of distributed equipment in the facility that requires compressed air. During non-producing periods, some of this point-of-use equipment continues to consume air and waste energy. Air loss at the equipment during non-producing times can be curtailed by controlling the supply to the equipment.

Compressed air supply should be controlled by installing solenoid valves that are electrically interlocked with machine operation.With such an installation, compressed air can be supplied to the equipment only when it is required for operation, eliminating waste during machine downtimes.

Case Study Flow Controller/Reduce Pressure

Total Cost

$

Energy Savings

kWh

Demand Savings

kW

Annual Savings

$

$40,600 72,724 60.6 $9,850

Simple Payback (years): 4.1

The existing compressed air system pressure setpoint of 105 psi is currently required to meet the facility demand. This pressure setting is necessary to account for pressure band fluctuations typical to compressed air systems with large demand, inadequate storage and no precise flow controlling equipment. Pressure swings of 10 psi are common. Subsequently, system pressures are set artificially high to ensure demand requirements at the point of use equipment.

Installing a flow controller and storage capacity will solve this problem and save energy. Flow controllers with sophisticated sensing and flow response capabilities allow for delivery of pressures within a two psi band. This narrow band allows demand side delivery pressures to be reduced considerably, lowering overall compressed air consumption and reducing compressor run times.

Case Study Install Sequencing Control

Total Cost

$

Energy Savings

kWh

Demand Savings

kW

Annual Savings

$

$43,405 657,842 na $45,246

Simple Payback (years): 1.0

The facility’s compressor plant is composed of multiple rotary screw compressors operating continuously in modulation mode. Each compressor operates on local controls; no central sequencing controls exist. Installing a master sequencing control system to network the compressors together will allow for dynamic optimization of the system as a function of demand. Networking multiple compressors with a microprocessor based sequencing controller facilitates system optimization by minimizing compressor horsepower to meet the load.

The controller dynamically monitors system demand and continually adjusts the compressors’ operating sequence. The controller will select horsepower in a programmable manner to best match available compressor capacity, minimizing compressor part-load operation and maximizing system efficiency. By establishing a base/trim profile, all compressors on line are operated fully loaded before the next compressor is brought online in the system.

Case Study Install Blowers for Blow-Off Operations

Total Cost

$

Energy Savings

kWh

Demand Savings

kW

Annual Savings

$

$79,278 683,940 220.9 $64,846

Simple Payback (years): 1.2

On several extrusion lines, compressed air is currently used for blow-off drying as the product exits the cooling tanks. Additionally, blow-off is used as the product exits flocking stations to remove excess flock. The same function can be provided at a much lower operating cost with centrifugal blower systems.

Installation of three centralized blower and air knife/nozzle systems to supply blow-off air to the extrusion lines will result in lower operating costs. Blower systems that deliver high volumes of lower pressure air directed with air knife and nozzle systems are effective and economical compared to compressed air.

Conclusions Optimize Appropriate End-Uses Eliminate Inappropriate End-Uses Reduce Artificial Demand Pressure and Pressure Drop Reduction