ENERGY CONSERVATION IN PNEUMATIC SYSTEMS Solutions That Save Do we - - PowerPoint PPT Presentation

SLIDE 1

ENERGY CONSERVATION IN PNEUMATIC SYSTEMS Solutions That Save

SLIDE 2

Do we recognize the cost of air?

SLIDE 3

Typical Plant Power Consumption (kW)

Should you focus on compressed air savings?

Idle Mode

SLIDE 4

Discussion Topics

• 1. Plant Case Study – The Ripple Effect
• Every change, good or bad, results in other changes
• 2. General Overview of Energy Conservation
• 1. Air Quality
• 2. Air Leaks
• 3. Non-Productive Use of Air
• 4. Design Improvements
• 5. Idle Mode Demand
• 6. Over-Pressurization

SLIDE 5

Plant Case Study Here’s what can happen when complacency sets in

SLIDE 6

Plant Case Study At Start Up

65 psi 30 CFM 65 psi 30 CFM 65 psi 30 CFM 65 psi 30 CFM Total Case Packer Demand = 600 SCFM Additional Plant Usage = 200 SCFM 2 Compressors running 100 HP @ 90 psi

SLIDE 7

Plant Case Study Six Years Later

90 psi 80 CFM 100 psi 90 CFM 105 psi 100 CFM 109 psi 105 CFM Total Case Packer Demand = 1,875 SCFM Additional Plant Demand = 1,350 SCFM 9 Compressors running 100 HP @ 115 psi

SLIDE 8

What happened?

• The artificial over pressurization of CP #1 and CP

#2 starves CP3 thru CP20.

• Other operators responded to the pressure loss

by elevating their own pressure, which results in excessive flow on each machine.

• This leads to a plant wide pressure elevation

which in turn elevates the flow on every unregulated user including leaks.

SLIDE 9

What was the catalyst for all this?

Poor Air Quality due to lack of proper filtration

• Food grade oil was used in compressors:
• Oil easily migrated downstream (incorrect mainline filtration)
• Oil reacts poorly to heat - both in total life and in varnishing
• Direct-operated valves stick due to limited shifting force
• Internally piloted valves required higher pilot pressures
• Heat build up in valves contributed to failure (leaking & sticking).
• Poor filtration/valve selection for the environmental conditions.
• Plant addressed the symptom, not the problem.

SLIDE 10

Financial Ramifications

• Case Packers Costs – 1875 SCFM @ $0.056 / kWh
• Annual total $174,606
• Additional Plant Demand – 1350 SCFM
• Annual total $125,716
• Total annual cost to the plant $300,322
• Initial annual cost to the plant $78,419
• Additional cost to the plant $221,903

419 , 78 $ 95 . 057 . $ 8760 746 200 = × × × = . Cost Annual

Efficiency Motor kWh per Cost Operation

• f

Hours . BHP Cost Annual × × × = 746

SLIDE 11

Additional Ramifications

Lost production due to pressure swings Additional breakdown calls for compressed air issues Elevated compressor maintenance costs Water and oil carryover issues High scrap rate relative to other plants Increased capital budget Significant infrastructure upgrade required Cost of compressed air was ~4 times original value

SLIDE 12

How did we fix this?

• Address filtration issues in compressor room to minimize oil carryover
• Added backup filtration at point-of-use
• Used metal bowls which will not deteriorate from compressor oil
• Added service indicators
• Added tamper resistant regulators so that pressure would not be elevated
• Replaced direct-acting valves with indirect-acting valves
• Indirect-acting valves are less prone to sticking & generate less heat
• Fringe benefit:
• Indirect-acting valves lower power consumption from 9 watts to 1 watt
• Controlled pressure at point-of-use so that pressure could be restored to 90 PSI
• Took un-needed compressors offline, and rotated them into service periodically

SLIDE 13

Where do we go from here?

Energy Conservation Overview

SLIDE 14

• Energy efficiency is often overlooked on pneumatic systems.
• The pneumatic products applied have a far reaching effect
• n energy efficiency.
• OEM pneumatic product selection is often based on price.
• Very little consideration is given to energy consumption,

compressed air quality, environmental conditions or sustainability.

• When evaluating your compressed air system for energy

inefficiency, the first and least expensive place to start is with your pneumatic point-of-use systems.

Energy Conservation Overview

SLIDE 15

Areas of Energy Conservation

Areas of Focus

• 1. Air Quality
• 2. Air Leaks
• 3. Non-Productive Use of Air
• 4. Idle Mode Demand
• 5. Over-Pressurization

SLIDE 16

Air Quality

SLIDE 17

Air Quality Sustainability Considerations

• Dew point and Particulate Contamination

levels are managed by:

• Mainline Filter
• Point of Use Filter
• Dryer

SLIDE 18

Leaks

SLIDE 19

Cost of Air Leaks & Potential Savings

DISCHARGE THROUGH AN ORIFICE

DIAMETER OF ORIFICE, INCHES

1/16 1/8 1/4 1/2 3/4 1 INCH PRESSURE DISCHARGE IN CUBIC FEET OF AIR PER MINUTE 70 PSI 4.79 19.2 76.7 307 690 1227 Annual Cost To Operate $590 $2,269 $9,062 $36,281 $81,545 $145,009 100 PSI 6.49 26 104 415 934 1661 Annual Cost To Operate $765 $3,072 $12,290 $49,045 $110,382 $196,300

125 PSI 7.90 31.6 126 506 1138 2023 Annual Cost of Leak $931 $3,734 $14,890 $59,800 $134,491 $239,082

SLIDE 20

Leaks

• 95% of leaks occur at a pneumatic product other than the

mainline plumbing.

• The most commonly failed components are:
• Fittings and tubing
• Air prep units i.e. filter, regulator, lubricator (FRL)
• Cylinders or actuators

SLIDE 21

Why are they leaking? Fittings and Tubing

• 1. Faulty installation – Accounting for

70% of failures tested during our audits.

• 2. Poor quality – Tubing or fitting

failure not caused by installation or the environment.

• 3. Misapplication – Fittings or tubing

exposed to wash down or other environments they were not manufactured to handle.

Fittings and Tubing

SLIDE 22

Air Prep Units (FRL’s)

• 1. Age and general wear – Most

leaking components showed failures indicative of general wear which accounted for approximately 45% of failures.

• 2. Internal exposure to water,

Polyolester and Diester oils or rust – These leaks tend to be the largest, accounting for approximately 45% of failures.

• 3. External damage, operator or

mechanical force – Accounting for 10% of failures.

Why are they leaking? Air Prep Units

SLIDE 23

Cylinders

• 1. Internal exposure to water,

Polyolester and Diester oils or rust – Accounting for approximately 55% of failures.

• 2. Age and general wear – Most

leaking components showed failures indicative of general wear which accounted for approximately 25% of failures.

• 3. Misapplication – Accounting for

approximately 20% of failures.

Why are they leaking? Cylinders

SLIDE 24

Leaks Case Study

Leaks by Percent of CFM

29% 20% 13% 13% 8% 6% 5% 6% Fitting FRL Valve Blowgun Cylinder Coupling Hose Other

SLIDE 25

Leaks Detection

What a lot of work!

Flow Meters Parabolic Dish and Ultrasonic Leak Detector

Flow Meters tell us that leaks have developed. Now we need to know where they are!

SLIDE 26

Compressed Air Audit

Tool of Choice – Ultrasonic Leak Detector

• Expensive
• Pack In, Pack Out…Hassle

Auditing

• Expensive, but…
• Leak repair savings usually recover cost
• Time-consuming
• Auditor examines plant-wide system
• Conducted once or twice yearly
• Customer pays every time
• Report can be overwhelming

Leaks Conventional Detection

SLIDE 27

Leaks Automatic Leak Detection System Goals

• Decrease detection cost
• Fewer man hours
• Lower skill requirement
• Lower cost equipment
• Increased detection frequency
• Minimizes leak impact
• Rapidly pinpoint leaks
• Accurate leakage value

(as low as .07 SCFM)

SLIDE 28

Leaks ALDS Concept - Implementation Hardware

• Flow Meter and Diverter

Valve

• Installed in machine’s

main air supply line Software

• Written in the machine’s

PLC

• Runs leak detection sub-

routine

SLIDE 29

Leaks ALDS Advantages

SLIDE 30

Non-Productive Use of Air

SLIDE 31

Non-Productive Use of Air Air Blow Common Applications

Drying Contaminate removal Part transfer Open blow Air-blow has the potential to be the most wasteful end- use- application of compressed air.

SLIDE 32

Non-Productive Use of Air Air Blow Improvement Reduce pressure loss and air consumption while maintaining work surface impact.

100 PSI With Nozzle Without Nozzle 100 PSI 60 PSI 100 PSI 20 PSI High-efficiency nozzle Pressure Loss is minimal Pressure loss is great

SLIDE 33

Non-Productive Use of Air Air Blow Solutions

Nozzle Diameter mm Pressure before nozzle PSIG Distance Impact Pressure PSIG Air Flow Rate SCFM Current 4 3 4" 0.25 4 Improved 2 13 4" 0.25 2 Improved 1 30 4" 0.25 1

SLIDE 34

Non-Productive Use of Air Air Blow High Pressure Solutions

A great amount of money can be saved on blow-off applications by using high efficiency nozzles, regulation and effective tube to nozzle ratios, while maintaining the same impact work pressures required for the job.

High-Efficiency Blow Gun The ratio of effective area and pressure

SLIDE 35

Non-Productive Use of Air Air-Blow Solutions

Momentary positive pressure Appropriate tubing size Auto shut off when not in use Venturi style nozzles Reduce to the lowest effective pressure

SLIDE 36

Non-Productive Use of Air Design Alternatives

• Primary Considerations

– Cylinder Sizing – Double Acting vs. Single Acting – Regenerative Circuits – Tubing length: Filling tube with no benefit – Pressure Control

SLIDE 37 Pneum neumat atic Model

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Syst System chara racteri rist stics Part number Model Fitting 1 Cylinder Solenoid valve Manifold Silencer Speed controller R Piping R Shock absorber NCGT[]A32-400[] SY3240[]-[][][][]-01N TU0604[]-[] KQ2L06-U01 KQ2L06-U01 KQ2L06-U01 AN103-N01 AS2200-N01-[] AS2200-N01-[] Stroke: Total length (R): Supply pressure: Full stroke time: Ambient temperature: Moving direction: Total length (L): Speed controller position (R): Speed controller position (L): Load mass: Friction factor: Application/Load rate: Mounting angle: Resistance force: Input nput val alues ues 400 mm 1.00 s Push (L) 0.5 MPa 20 degC 9.0 ft 9.0 ft On cylinder 0 m On cylinder 0 m 55.0 lb N 0 deg Transfer Sliding friction Full stroke time: Start up time: 90% Force time: Mean velocity:

• Max. velocity:

Stroke end velocity:

• Max. acceleration:
• Max. pressure:

Air consumption/cycle: Required air flow: 0.81 s 0.06 s 1.02 s 496 mm/s 782 mm/s 782 mm/s 3.8 m/s2 0.50 MPa 3.933 dm3(ANR) 156.3 dm3/min(ANR) TU0604[]-[] 1 1 1 1 2 1 2 1 1 Absorption energy: Allowable energy: 0.91 J 7.77 J Out of the allowable range Judgment result: Out of the allowable range: Review the operating conditions and the load conditions. Or use shock absorber. Condensation probability is very small 0 % Condensation probability: Cus ushi hion

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Non-Productive Use of Air Design Alternatives - Cylinders

Pneum neumat atic Model

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Syst System chara racteri rist stics Part number Model Fitting 1 Cylinder Solenoid valve Manifold Silencer Speed controller R Piping R Shock absorber NCGB[]A50-400[] SY7240[]-[][][][]-02N TU0604[]-[] KQ2L06-U02 KQ2L06-U02 KQ2L06-U02 AN202-N02 AS2200-N02-[] AS2200-N02-[] Stroke: Total length (R): Supply pressure: Full stroke time: Ambient temperature: Moving direction: Total length (L): Speed controller position (R): Speed controller position (L): Load mass: Friction factor: Application/Load rate: Mounting angle: Resistance force: Input nput val alues ues 400 mm 1.00 s Push (L) 0.5 MPa 20 degC 9.0 ft 9.0 ft On cylinder 0 m On cylinder 0 m 55.0 lb N 0 deg Transfer Sliding friction Full stroke time: Start up time: 90% Force time: Mean velocity:

• Max. velocity:

Stroke end velocity:

• Max. acceleration:
• Max. pressure:

Air consumption/cycle: Required air flow: 1.00 s 0.07 s 1.36 s 401 mm/s 538 mm/s 538 mm/s 10.1 m/s2 0.50 MPa 9.015 dm3(ANR) 293.5 dm3/min(ANR) TU0604[]-[] 1 1 1 1 2 1 2 1 1 Absorption energy: Allowable energy: 3.40 J 3.82 J Out of the allowable range Judgment result: Out of the allowable range: Review the operating conditions and the load conditions. Or use shock absorber. Condensation probability is very small 0 % Condensation probability: Cus ushi hion

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nput Val alue ue Condens

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ent: 0.7 0.3 Quan. Quan. Quan. Fitting 2 Opening: 100 % Opening: 100 % Silencer opening: Quick exh. valve opening: Selection method: Optimal size priority Speed controller L Piping L Quick exhaust valve

55 lbs. / Sliding 16” / 1 second

2” bore ~10 SCFM 1-1/4”” bore ~5 SCFM

SLIDE 38

Non-Productive Use of Air Design Alternatives - Cylinders

Consider Single-Acting over Double Acting

• Ways to save:
• Gravity Down?
• Single Acting Cylinder?
• Regenerative Circuits

40% Savings

SLIDE 39

load Tank Pressure regulator for low-pressure setting Supply / Exhaust valve

Energy Saving Lifter

75% Savings Design Alternatives

SLIDE 40

Non-Productive Use of Air Design Alternatives - Tubing

Tubing Length

• Consider that air used to fill the tubing on the way

to the actuator does no work!

• The conductance of tubing decreases

dramatically with an increase in length

– Shorten tubing as much as feasible – Beware that larger diameter = larger volume – Size tubing for flow required – don’t guess!

SLIDE 41

Non-Productive Use of Air Design Alternatives - Tubing

Right Sizing Tubing Diameter – Example 4 cylinder case erector 3/8" Tubing 1/4" Tubing Operating Pressure 50 50 Bore (inch) 3 3 Stroke (inch) 3.41 3.41 # of cylinders 4 4 Tubing Length (inch) 96 96 Tubing I.D. (inch) 0.25 0.16 # of elbow fittings 2 2 Rate: Cycle Time (sec) 1.5 1.5 CFM Required 25 21 Annual Cost of Operation $ 4,979 $ 4,120 ANNUAL SAVINGS $ 625

The savings is a reduction of 4.14CFM or 17.3%.

Of course, if you had used a cylinder with integrated valve, the savings would have been $855

SLIDE 42

Non-Productive Use of Air Design Alternatives - Pressure

• Extend and retract strokes frequently do not require

the same operating pressure. A reduction in pressure on the non-working side of the cylinder will lead to significant energy savings.

SLIDE 43

Idle-Mode Savings

SLIDE 44

Idle Mode Demand

• Examples

–Machines need to shut off when not in use –Isolate during breaks, maintenance, etc. –Machines typically do not operate 100%

SLIDE 45

Idle Mode Demand

• Idle Mode demand is defined as:
• Equipment using air (leaks, air-blow, vacuum, etc.) while

an operator stops production equipment from running during a product change over, preventative maintenance

• r scheduled breaks.
• Idle Mode demand during idling can be a significant draw on a

compressed air system.

SLIDE 46

Intermittent Demand Macro Case Study

Idle flow 5,420 CFM Annual cost $145,541

Paint 6/27/06 12:00 - 7:00 AM

2000 3000 4000 5000 6000 7000 8000 9000 10000 0:00 1:00 2:00 3:00 4:00 5:00 6:00 7:00 90 91 92 93 94 95 96 97 98 99 100 CFM PSI

Waste

SLIDE 47

1 2 3 4 5 6 7 8

Leaks 22.60 CFM Air supply + leak ... 60 CFM

Snack Chip Line

Intermittent Demand Micro Case Study

SLIDE 48

1 2 3 4 5 6 7 8

Leaks 22.60 CFM

Air supply + leak 60 CFM

Shut Off Valve D E Shut Off Valve

Auto Drains Auto Drains

Proposed Solution

Intermittent Demand Micro Case Study

SLIDE 49

Intermittent Demand The Cost of the Case Study

• The current leak load is 22.60 CFM.
• Cost is $4,102 for leaks per line
• $4102 * 8 lines = $32,816 per year
• Savings by turning air off on weekends:
• $10,830 per year.

SLIDE 50

Intermittent Demand Solutions

When you require a moment of positive pressure When product is present Auto shut off used in conjunction with equipment power or photo eye. Soft-Start / Quick Exhaust Valves

SLIDE 51

Over - Pressurization

SLIDE 52

Over-Pressurization Examples

Equipment operators rarely understand the relationship between flow and pressure. What leads to excessive pressurization of pneumatic systems?

• Misdiagnosis of equipment malfunction
• Flow rate increases force a “droop” in downstream pressure
• Mismanaged point-of-use filtration

In each case, equipment

• perators respond by increasing

the pressure at the regulator.

Generally, a 2 PSI increase adds about 1% more to energy costs.

SLIDE 53

Excessive Pressure Case Study

Over Pressurization 100 psi vs. 80 psi

40 50 60 70 80 90 100 110 120 0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 Time (Minutes) psi 40 50 60 70 80 90 100 110 120 CFM

Pressure (psi) Flow (CFM)

Pres s ure (ps i) 100 80 Flow (CFM) 71.40 57.10 Annual Cos t $13,069 $10,047 Statis tics

SLIDE 54

Excessive Pressure Solutions

Use gauges with visual pressure range display

SLIDE 55

Excessive Pressure Solutions Continued

Precision Style Regulator Locking Regulator

Regulators with locking adjustment knob or a pressure lock out device prevent costly over-pressurization Manage pressure with precision regulators

Tamper Resistant Regulators Tamper Proof Regulators Restricted Regulators

E/P Control

SLIDE 56

Wrap up!

• Savings start in the design phase, however…
• For existing systems:
• Evaluate your system from point-of-use backward
• Reduce consumption
• Enjoy the quick return on investment!

SLIDE 57

If you have any questions or require additional information, please do not hesitate to contact SMC!

Thank you!