Compressed Air Systems. Wasting Energy Since The Start Of The - - PowerPoint PPT Presentation

Compressed Air Systems….

Wasting Energy Since The Start Of The Industrial Revolution!

Jeff Scott, CEM, CMVP – Key Accounts & Outreach Manager

ENWIN Utilities Ltd., Windsor, Ontario, Canada 2018 Energy Summit (May 30-31, 2018) Disclaimer: All Slides created by ENWIN Utilities Ltd.

About the Speaker

• Responsible for key accounts and industrial

customer outreach in ENWIN Utilities (Windsor) territory

• Is a Certified Energy Manager (CEM) and

Certified Measurement & Verification Professional (CMVP)

• Over 20 years experience in the compressed air

& gas industry

• Utility costs rising and they want to reduce costs
• Need to replace old compressor or expand existing

system

• Need to fix air system and don’t know where to start
• Production is suffering due to downtime, or inadequate
• pressure. Compressed air can secretly wreak havoc on

production in many ways.

Why Customers Should Care About Compressed Air?

• Can represent one of the largest energy consumers in some

industrial facilities

• Can represent one of your greatest energy reduction
• pportunities
• Most compressed air systems are misunderstood and poorly

utilized

• Customers will often consider them a priority project once the

costs are understood

Why Energy Conservation Staff Care About Compressed Air?

A Word of Warning

Compressed air is….

• Often referred to as the 4th utility

NOT FREE!

• One of the most inefficient forms
• f energy in an industrial facility
• One of the most poorly utilized

and misunderstood systems

• Often “out of sight and out of

mind”

A Lifetime of Compressed Air Costs

1 Shift 2 Shifts 3 Shifts 2,800 Hours 5,600 Hours 8,400 Hours 50 HP $10,444.00 $20,888.00 $31,332.00 (37 KW) 104,440 KWh's 208,880 KWh's 313,320 KWh's 100 HP $20,888.00 $41,776.00 $62,664.00 (75 KW) 208,880 KWh's 417,760 KWh's 626,640 KWh's 500 HP $104,440.00 $208,880.00 $313,320.00 (373 KW) 1,044,400 KWh's 2,088,800 KWh's 3,133,200 KWh's 1,000 HP $208,880.00 $417,760.00 $626,640.00 (746 KW) 2,088,800 KWh's 4,177,600 KWh's 6,266,400 KWh's 2,500 HP $522,200.00 $1,044,400.00 $1,566,600.00 (1,865 KW) 5,222,000 KWh's 10,444,000 KWh's 15,666,000 KWh's

Assuming 7 days/week, 50 weeks/year, and $.10/KWh

Where Do You Start With Compressed Air?

8

• Two distinct systems:
• Supply Side which includes

compressors, storage, air quality equipment, and controls

• Demand Side which

includes distribution system, secondary storage, and end-use equipment

Solutions - Supply Side

• Right sizing
• Controls
• Sequencing multiple

compressors

Solutions - Supply Side

• Increased system storage
• Reducing system pressure
• Preventative maintenance
• Heat recovery

Solutions - Supply Side

Other Compressor Room Items:

• Refrigerated Air Dryers
• Thermal mass, cycling,
• r VFD
• Regenerative Air Dryers
• Low pressure drop filters
• Maintenance
• Zero air loss drain valves
• Dewpoint dependent

switching

• Assorted purge methods
• Heated purge
• Blower purge
• Vacuum purge

Solutions – Distribution Systems

• A closed loop system is recommended
• Large consistent pipe diameter
• Avoid too many elbows, tees, etc. Keep it simple!
• Account for any critical application and high-volume/intermittent

applications by installing satellite air receivers and metered recovery

• Drops should come off the top of the main

header to prevent any condensate from entering the process.

Solutions – Pressure Reduction

• Reducing pressure also reduces

the amount of energy lost by leaks

• Pressure is often raised to appease

a specific process or machine

• Booster?
• Regulate the “system” and points of

use

• Lockable?

Solutions – Inappropriate End Uses

• Address points of use for

volume, pressure, and quality

• Investigate and address high

volume, intermittent applications (metered recovery?)

• Challenge point of use

requirements and appropriateness

• r inappropriateness of

applications

Solutions – Inappropriate End Uses

Solutions – Leak Repairs

• Typical system has 15 – 25% air leakage
• Normally a simple payback of less than 6

months

• Not caring about leaks could lead to

increasing compressor system capacity

Solutions – Leak Repairs

• Leak management MUST be an ongoing

process

• Leak tag and awareness program
• Try a weekend leak audit
• Duct tape is NOT an

acceptable solution

Action Items

• Basic block diagram
• Supply and Demand

sides

• Baseline and calculate energy

use and costs

• Implement control strategy
• Baseline, determine leak load

and recalculate

• Identify and fix leaks
• Reduce pressure

Action Items

• Correct inappropriate uses
• Check preventive maintenance items

and other opportunities to reduce costs and improve performance

• Review distribution system and identify

high volume demands

• Dedicated/metered storage
• Re-measure, and optimize controls
• Implement continuous improvement

program

Available Resources

• Compressed Air Challenge
• Training sessions (Fundamentals & Advanced)
• Eligible for IESO Training incentive program
• Online resources
• Compressed Air & Gas Institute (CAGI)
• Compressed Air Best Practices E-Magazine
• Your Compressed Air Service Provider
• Your Electricity Service Provider!
• WE WANT TO HELP!

Jeff Scott, CEM, CMVP Key Accounts & Outreach Manager – Industrial ENWIN Utilities Ltd. Tel: (519) 255-2888 Ext: 726 Email: jscott@enwin.com www.ENWIN.COM

My Contact Information

Questions?