Compressed Air Managing the Costs National Grid Upstate Energy Efficiency Conference April 2011.
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Transcript of Compressed Air Managing the Costs National Grid Upstate Energy Efficiency Conference April 2011.
Compressed AirCompressed AirManaging the Costs
National Grid
Upstate Energy Efficiency Conference
April 2011
Why Compressed Air?
• Compressors account for 10% of all electricity used in U.S.
• 1 million Compressors sold in the US/ year• 80% of the energy is consumed by those 25 hp
and larger (less than 1% of the population)
– 2015 predictions are 1.9 Trillion kWH/year
– 20% efficiency gain saves 392 billion kWH/yr or $19.6 Billion dollars potential annual savings
Why Compressed Air?
• Only 9% of end users identified controlling energy costs as the primary objective in compressed air system maintenance and management.
• Only 17% mentioned efficiency at all as a management objective.
• 71% of end users report adequate air supply is their primary objective in system management
• 35% of end users reported unscheduled shut downs in the past 12 months
• 75% of operators report having no efficiency training
Energy (Power) Efficiency
KW Compressor KW
10 1:
Air is FREE until you mess with it !!!!
Total Life Cycle Costs
Costs Over 10 Years
Equipment
Maintenance
Electricity
12%
12%
76%
Life Cycle Costs
BHP kW $ / kW Hours kWh Annual Power 10 Year Elec First Cost 10 Year Maint Total 10 Year
165 129.5684 0.05$ 8760 1,135,019 56,750.97$ 567,509.68$ 68,101.16$ 68,101.16$ 703,712.01$ 80.6% 9.7% 9.7%
165 129.5684 0.10$ 8760 1,135,019 113,501.94$ 1,135,019.37$ 68,101.16$ 68,101.16$ 1,271,221.69$ 89.3% 5.4% 5.4%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
1 2 3
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%60.0%
70.0%
80.0%
90.0%
1 2 3
(First cost = comp $ + 30% for install / Maintenance = parts & 1 air end replacement)
Apply the Resource Wisely
Excessive Pressure 10%
Leaks 20%
Production 60%
Inappropriate Uses 10%
Perception
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
Reality
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
CFAir
100 #
Measure
0.0
200.0
400.0
600.0
800.0
1000.0
1200.0
1400.0
1600.0
1/27
/200
5 0:
00
1/27
/200
5 0:
12
1/27
/200
5 0:
24
1/27
/200
5 0:
37
1/27
/200
5 0:
49
1/27
/200
5 1:
02
1/27
/200
5 1:
14
1/27
/200
5 1:
26
1/27
/200
5 1:
39
1/27
/200
5 1:
51
1/27
/200
5 2:
04
1/27
/200
5 2:
16
1/27
/200
5 2:
28
1/27
/200
5 2:
41
1/27
/200
5 2:
53
1/27
/200
5 3:
06
1/27
/200
5 3:
18
1/27
/200
5 3:
30
1/27
/200
5 3:
43
1/27
/200
5 3:
55
1/27
/200
5 4:
08
1/27
/200
5 4:
20
1/27
/200
5 4:
32
1/27
/200
5 4:
45
1/27
/200
5 4:
57
1/27
/200
5 5:
10
1/27
/200
5 5:
22
1/27
/200
5 5:
34
1/27
/200
5 5:
47
1/27
/200
5 5:
59
1/27
/200
5 6:
12
1/27
/200
5 6:
24
1/27
/200
5 6:
36
1/27
/200
5 6:
49
1/27
/200
5 7:
01
1/27
/200
5 7:
14
1/27
/200
5 7:
26
1/27
/200
5 7:
38
1/27
/200
5 7:
51
1/27
/200
5 8:
03
1/27
/200
5 8:
16
1/27
/200
5 8:
28
1/27
/200
5 8:
40
Series1 Series2
- Dec 6 - Flow
0.0
500.0
1000.0
1500.0
2000.0
2500.0
12/6
/200
6 14
:40
12/6
/200
6 14
:55
12/6
/200
6 15
:10
12/6
/200
6 15
:25
12/6
/200
6 15
:40
12/6
/200
6 15
:56
12/6
/200
6 16
:11
12/6
/200
6 16
:26
12/6
/200
6 16
:41
12/6
/200
6 16
:56
12/6
/200
6 17
:12
12/6
/200
6 17
:27
12/6
/200
6 17
:42
12/6
/200
6 17
:57
12/6
/200
6 18
:12
12/6
/200
6 18
:28
12/6
/200
6 18
:43
12/6
/200
6 18
:58
12/6
/200
6 19
:13
12/6
/200
6 19
:28
12/6
/200
6 19
:44
12/6
/200
6 19
:59
12/6
/200
6 20
:14
12/6
/200
6 20
:29
12/6
/200
6 20
:44
12/6
/200
6 21
:00
12/6
/200
6 21
:15
12/6
/200
6 21
:30
12/6
/200
6 21
:45
12/6
/200
6 22
:00
12/6
/200
6 22
:16
12/6
/200
6 22
:31
12/6
/200
6 22
:46
12/6
/200
6 23
:01
12/6
/200
6 23
:16
12/6
/200
6 23
:32
12/6
/200
6 23
:47
Manage the Relationship
PSIG
(Pressure)
CFM
(Flow)
KW
(Power)
Time
Managing the Relationship
TIME
FlowPressurePowerTIME
Manage Asset SelectionPOWER VS FLOW VARIOUS CONTROL METHODS
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
450.00
500.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
0.00
20.00
40.00
60.00
80.00
100.00
120.00
ACFM FLOW
BHP @ I/M
BHP @ V/D
BHP @ L/NL
Manage System Configuration
Comp100 hp125 hp
Comp150 hp125 hp
Comp150 hp125 hp
RSD1500
ESP-1000Control
4”
4”
4”
3”3”3”
4”
Monitor
Power and Temp plots indicate all is well with this compressor
Solutions
• Understand the process needs• VFD when appropriate• Control options (VFD, L-NL, Variable Displacement)
• System Configuration• Simple sequencing• Control automation and system management• Design to process requirements