Program Name or Ancillary Texteere.energy.gov Three-Day Compressed Air Energy Saving Assessment Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A. U.S.-Brazil Industrial Energy Efficiency Workshop Rio de Janeiro, Brazil August 8-11, 2011 2 | Industrial Energy Efficiencyeere.energy.gov Overview of 3-Day Assessment Before Visit Send data loggers to plant Ask plant to install Air Master+ software Day 1 Brief plant management Inspect compressed air plant and major end-uses of compressed air Down-load and analyze pressure and current data Day 2 Show Energy Efficient Compressed Air slide show to production and maintenance personnel. Gather additional data to quantify savings Enter data into Air Master+ to quantify savings Day 3 Teach staff how to use Air Master+ Closing meeting with management to discuss results. 3 | Industrial Energy Efficiencyeere.energy.gov Plant Inspection 4 | Industrial Energy Efficiencyeere.energy.gov Compressed Air Plant 5 | Industrial Energy Efficiencyeere.energy.gov Compressor Types and Sizes 6 | Industrial Energy Efficiencyeere.energy.gov Compressor Controls 7 | Industrial Energy Efficiencyeere.energy.gov Pressure in Compressed Air Plant 8 | Industrial Energy Efficiencyeere.energy.gov Compress Indoor or Outdoor Air 9 | Industrial Energy Efficiencyeere.energy.gov Compressed Air Dryer 10 | Industrial Energy Efficiencyeere.energy.gov Compressed Air Storage 11 | Industrial Energy Efficiencyeere.energy.gov Condensate Drains 12 | Industrial Energy Efficiencyeere.energy.gov Compressed Air Piping 13 | Industrial Energy Efficiencyeere.energy.gov Pressure at End Uses 14 | Industrial Energy Efficiencyeere.energy.gov End Uses 15 | Industrial Energy Efficiencyeere.energy.gov Power and Pressure Data 16 | Industrial Energy Efficiencyeere.energy.gov Load/unload and Modulation Control 17 | Industrial Energy Efficiencyeere.energy.gov Two Compressors Properly Staged 18 | Industrial Energy Efficiencyeere.energy.gov Size Dryer for DP< 5 psi Low Flow: P = 1 psi High Flow: P = 6 psi 19 | Industrial Energy Efficiencyeere.energy.gov Nights and Weekend Operation 20 | Industrial Energy Efficiencyeere.energy.gov Compressed Air Storage 21 | Industrial Energy Efficiencyeere.energy.gov Production and Maintenance Briefing 22 | Industrial Energy Efficiencyeere.energy.gov Install Nozzles on Air Tubes 23 | Industrial Energy Efficiencyeere.energy.gov Install Solenoid Valves on Part Movers 24 | Industrial Energy Efficiencyeere.energy.gov Use Blowers Instead of Compressed Air 25 | Industrial Energy Efficiencyeere.energy.gov Use Electric Pumps Instead of Air Pumps 26 | Industrial Energy Efficiencyeere.energy.gov Activate Bag House Air Pulses with Pressure Drop 27 | Industrial Energy Efficiencyeere.energy.gov Identify and Fix Leaks 28 | Industrial Energy Efficiencyeere.energy.gov Add Storage to Decrease Cycling 29 | Industrial Energy Efficiencyeere.energy.gov Use Sequencer to Stage Multiple Compressors 30 | Industrial Energy Efficiencyeere.energy.gov D.O.E. Air Master+ Software AIRMaster+ provides a systematic approach for assessing the supply- side performance of compressed air systems. AIRMaster+ evaluates the energy savings potential of any or all of the following eight energy efficiency actions: Reduce air leaks Improve end-use efficiency Reduce system air pressure Use unloading controls Adjust cascading set points Use automatic sequencer Reduce run time Add primary receiver volumey/bestpractices/http://www1.eere.energy.gov/industr y/bestpractices/ 31 | Industrial Energy Efficiencyeere.energy.gov Short Concise Report 32 | Industrial Energy Efficiencyeere.energy.gov Thank you!