Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air...

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California Statewide Utility Codes and Standards Program Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011

Transcript of Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air...

Page 1: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

California Statewide Utility Codes and Standards Program

Compressed Air SystemsCEC Pre-Rulemaking Workshop

Energy Solutions

April 27, 2011

Page 2: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 2

April 27, 2011

Air Compressors

Scope of Proposal

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

● Mandatory requirements for compressed air systems over 25hp in new construction and major renovations.

Page 3: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 3

April 27, 2011

Air Compressors

Proposed Code LanguageSECTION 127 – MANDATORY REQUIREMENTS FOR COMPRESSED AIR SYSTEMSA compressed air system with a total system power of 25 horsepower (hp) or larger

shall meet the requirements of this section. This section applies to construction projects for which an application for a building permit or renewal of an existing permit is filed (or is required by law to be filed), and where the total combined horsepower of the compressors is increased.

(a) Controls Requirements. Compressed air systems with more than one compressor must operate with a controller that is able to choose the most energy efficient combination of compressors within the system based on the current air demand as measured by a sensor.

EXCEPTION to Section 127(a): Compressed air systems with a total system horsepower of 100 hp or less.

(b) Trim Compressor Requirements. Compressed air systems shall include at least one compressor capable of maintaining 22 kW or less of input per 100 acfm of output throughout the usable trim load of the system.

EXCEPTION to Section 127(b): Compressed air systems in existing facilities.

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 4: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 4

April 27, 2011

Pump24%

Fan14%

MaterialHandling

12%

MaterialProcess

23%

Other4%

CompressedAir16%

Refrigeration7%

Air Compressors

Why Compressed Air?● 16 % of U.S. industrial

motor systems energy in● 10% of total industrial

energy use● ~90,000 GWh annual

consumption● With cost-effective

measures, savings can be upwards of 17% or more (~15,000 GWh)● Measures with <3yr payback● Source: Assessment of the

Market for Compressed Air Efficiency Services, EERE 2001

Motor System Energy Use per Application

(source: Motor Systems Opportunities Market Assessment, 2002 EERE)

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 5: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 5

April 27, 2011

Many Possible Energy Efficiency Measures

● Require minimum compressor efficiency● Reduce leaks to a maximum threshold● Limit max pressure● Max pressure drop● Only condition enough air for the specific

applications● Primary receiver requirements● Secondary receiver requirements● Site compressors near loads● Remove or close off unused lines● Size compressors appropriately● Increase piping and accessory sizes● Use smooth bore piping● Eliminate unnecessary bends in piping● Compressor room ventilation● Cool intakes● Install adequate dryers● Replaced compressed air with direct

acting units● Common head on all compressors● Controls based on common head● Filter requirements

● Cool compressor air intake with heat exchanger

● Recover waste heat● Ban inappropriate uses● Condensate trap standards● Commissioning requirements● Require cycling refrigerated dryers● Max pressure drop in last 10 ft. before

the end use● Ban unregulated end uses● Require submitting a system diagram● Require generation and submitting a

system pressure profile● Require reporting about the system● Require data logging● Controls requirements● Regulate total system efficiency● Require pressure-flow controllers● Require VFD for trim● Require a maintenance plan

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 6: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 6

April 27, 2011

Air Compressors

Code Proposals

● Requirements for a full-range efficient trim compressor as the designated trim compressor on all compressed air systems● Based on VSD specifications

● Allows for flexibility in technology

● Requirements for Smart System Controls on multi-compressor systems● Minimum requirements

● Able to make decisions based on current demand

● Various manufacturers and compressor types

Focusing on:New Construction and Major RenovationsPermanent installationsCost-effective system size threshold

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 7: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 7

April 27, 2011

● 4 Baselines● Different total size

● 2 different load profiles● Matched to compressor

makeup

● Slight change

● Load profiles normalized to compressor system capacity

● Auto shutdown timers

● Baselines made with feedback from stakeholders

● Model each baseline in AirMaster+● Worked with certified

AirMaster+ Instructor

● Apply Smart Controls manually

● Compare energy use to determine annual savings

Baselines Modeling Plan

Air Compressors

Methodology: Energy Savings (Smart Controls)

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 8: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 8

April 27, 2011

● Load/UnloadLubricant-Injected Rotary Screwwith 2 gal/cfm● Based on feedback from

stakeholders

● Modeling both VSDs and baseline with 2 gal/cfm

● Model each baseline with excel formulas● Technical information from

AirMaster+

● Compare energy use per hour

Baselines Modeling Plan

Air Compressors

Methodology: Energy Savings (VSDs)

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 9: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 9

April 27, 2011

● Includes● Control Unit

● Interfaces with Compressors

● Sensors

● Installation Labor

● Based on estimates from 3 manufacturers for the modeled baseline systems.

● Costs are based on values from manufacturers.

● Includes a trendline for parametric analysis

Smart Controls VSDs

Air Compressors

Methodology: Incremental Costs

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 10: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 10

April 27, 2011

Air Compressors

Methodology: Incremental CostsManufacturer Estimated Costs to Add Smart Controls

$0

$2,000

$4,000

$6,000

$8,000

$10,000

$12,000

$14,000

$16,000

0.5 1 1.5 2 2.5 3 3.5 4 4.5Baseline Systems

Incr

emen

tal C

ost

Baseline 1 Baseline 2 Baseline 3 Baseline 4

*Other more expensive controllers exist on the market, but they include additional functionality beyond our requirements.

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 11: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 11

April 27, 2011

Air Compressors

Methodology: Incremental Costs

VSD Incremental Costs(Compared to Rotary Screw Compressor)

y = -0.3779x2 + 151.07x + 815.61R2 = 0.9758

$0

$2,000

$4,000

$6,000

$8,000

$10,000

$12,000

$14,000

$16,000

$18,000

0 20 40 60 80 100 120 140 160 180 200HP

Inc.

Cos

ts

Original Discounted Trendline

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 12: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 12

April 27, 2011

Air CompressorsLCC Analysis and Results (Smart Controls)

● Smart Controls are cost effective

● Incremental costs have been averaged

● LCC not dependent on system size

Baseline Incremental Costs

Energy Cost Savings (TDV$) LCC Savings

1 $6,173 $18,812 $12,639

2 $6,173 $8,395 $2,222

3 $6,173 $12,026 $5,836

4 $10,159 $48,832 $38,673

50 hp RS75 hp RS

50 hp RS150 hp RS

150 hp RS300 hp RS

200 hp RS300 hp RS500 hp C_

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 13: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 13

April 27, 2011

Air Compressors

LCC Analysis and Results (VSDs)

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 14: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 14

April 27, 2011

Air Compressors

Renovation/Retrofit

● Smart Controls:● Mandatory for renovations/retrofits if the total combined

horsepower of the compressors in the system is increased.

● VSDs:● Not mandatory for renovations/retrofits.

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 15: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 15

April 27, 2011

Air Compressors

Proposed Code LanguageSECTION 127 – MANDATORY REQUIREMENTS FOR COMPRESSED AIR SYSTEMSA compressed air system with a total system power of 25 horsepower (hp) or larger

shall meet the requirements of this section. This section applies to construction projects for which an application for a building permit or renewal of an existing permit is filed (or is required by law to be filed), and where the total combined horsepower of the compressors is increased.

(a) Controls Requirements. Compressed air systems with more than one compressor must operate with a controller that is able to choose the most energy efficient combination of compressors within the system based on the current air demand as measured by a sensor.

EXCEPTION to Section 127(a): Compressed air systems with a total system horsepower of 100 hp or less.

(b) Trim Compressor Requirements. Compressed air systems shall include at least one compressor capable of maintaining 22 kW or less of input per 100 acfm of output throughout the usable trim load of the system.

EXCEPTION to Section 127(b): Compressed air systems in existing facilities.

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 16: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 16

April 27, 2011

Air Compressors

Part Load Performance Metrics

● Industry standard metrics for evaluating trim compressor part load performance?

● Current approach: For some continuous range X% of the compressor’s total range, the compressor can deliver air at pressure using less than some efficiency performance value P kW/cfm at all points within the range.

● Possible trim compressor requirements:● X is 70% of the range● P is 22 kW/cfm (for 100 psi discharge, other pressure levels

would require other P values)● Other sources of VSD part load performance data

beyond CAGI datasheets that should be included?

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 17: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 17

April 27, 2011

Air Compressors

Enforcement / Acceptance Testing

● Analysis assumes set-up process● Is there a standard output from this set up process?

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 18: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 18

QUESTIONS & COMMENTS

April 27, 2011

Russell Torres

[email protected] x269

Ransom Byers

[email protected] x214

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 19: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 19

April 27, 2011

Air Compressors

Appendices

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 20: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 20

April 27, 2011

Air Compressors

Methodology: Incremental Costs

Receiver Tanks: This is cost, not incremental cost

Receiver Tank Prices(NOT Incremental Costs)

y = 287.31x0.3828

R2 = 0.5311

$0

$1,000

$2,000

$3,000

$4,000

$5,000

$6,000

0 100 200 300 400 500 600Gallons

Cost

s

Carbon Steel Price Power (Carbon Steel Price)

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 21: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 21

April 27, 2011

Air Compressors

Methodology: Incremental CostsReceiver Tank Prices

(NOT Incremental Costs)

y = 287.31x0.3828

R2 = 0.5311

$0

$1,000

$2,000

$3,000

$4,000

$5,000

$6,000

0 100 200 300 400 500 600Gallons

Cost

s

Carbon Steel Price Power (Carbon Steel Price)

Inc Cost!

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 22: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 22

April 27, 2011

Air Compressors

LCC Analysis and Results (VSDs)

Increased Storage LCC Savings(from 2 to 3 gal/cfm)

($50,000)

$0

$50,000

$100,000

$150,000

$200,000

$250,000

$300,000

$350,000

0 25 50 75 100 125 150 175 200 225

Trim Compressor HP

LCC

Sav

ings

Trim Compressor Operating in 0%-100% Range

Trim Compressor Operating in 75%-100% Range

Trim Compressor Operating in 80%-90% Range

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes

Page 23: Compressed Air Systems CEC Pre-Rulemaking · PDF file27.04.2011 · Compressed Air Systems CEC Pre-Rulemaking Workshop Energy Solutions April 27, 2011 . ... Compressed air systems

CALIFORNIA STATEWIDE UTILITIES CODES AND STANDARDS PROGRAM 23

April 27, 2011

Air Compressors

LCC Analysis and Results (VSDs)

Increased Storage LCC Savings(from 2 to 3 gal/cfm)

$0

$5,000

$10,000

$15,000

$20,000

$25,000

0 25 50 75 100 125 150 175 200 225

Trim Compressor HP

LCC

Sav

ings

Trim Compressor Operating in 0%-100% Range

Trim Compressor Operating in 75%-100% Range

Trim Compressor Operating in 80%-90% Range

Scale adjusted for detail

CA Utilities 2013 Title 24 Stakeholder Meeting for Proposed Code Changes