Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A.
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Transcript of Kelly Kissock Director: University of Dayton Industrial Assessment Center Dayton, Ohio U.S.A.
Program Name or Ancillary Text eere.energy.gov
Three-Day Compressed Air Energy Saving Assessment
Kelly KissockDirector: University of DaytonIndustrial Assessment CenterDayton, Ohio U.S.A.
U.S.-Brazil Industrial Energy Efficiency WorkshopRio de Janeiro, Brazil August 8-11, 2011
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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.
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Plant Inspection
Plant Inspection
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Compressed Air Plant
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Compressor Types and Sizes
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Compressor Controls
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Pressure in Compressed Air Plant
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Compress Indoor or Outdoor Air
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Compressed Air Dryer
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Compressed Air Storage
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Condensate Drains
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Compressed Air Piping
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Pressure at End Uses
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End Uses
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Power and Pressure Data
Power and Pressure Data
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Load/unload and Modulation Control
180-hp Rotary Screw Air Compressor - Load/Unload Control
0
50
100
150
200
250
14:40:00 14:42:00 14:44:00 14:46:00 14:48:00 14:50:00 14:52:00 14:54:00 14:56:00 14:58:00 15:00:00
Cur
rent
Dra
w (A
mps
)
150-hp Rotary-Screw Air Compressor - Inlet Modulation Control
0 20 40 60 80
100 120 140 160 180 200
13:40:00 13:45:00 13:50:00 13:55:00 14:00:00 14:05:00 14:10:00 14:15:00 14:20:00
Current Draw (Amps)
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Two Compressors Properly Staged
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Size Dryer for DP< 5 psi
Low Flow: DP = 1 psi High Flow: DP = 6 psi
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Nights and Weekend Operation
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Compressed Air Storage
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Production and Maintenance Briefing
Production and Maintenance Briefing
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Install Nozzles on Air Tubes
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Install Solenoid Valves on Part Movers
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Use Blowers Instead of Compressed Air
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Use Electric Pumps Instead of Air Pumps
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Activate Bag House Air Pulses with Pressure Drop
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Identify and Fix Leaks
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Add Storage to Decrease Cycling
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Use Sequencer to Stage Multiple Compressors
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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 volume
• http://www1.eere.energy.gov/industry/bestpractices/
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Short Concise Report
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Thank you!