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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 Michigan energy Efficiency Conference & Exhibition (May 8, 2018)
Disclaimer: All Slides created by ENWIN Utilities Ltd.
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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
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Objectives
• Attendees will learn about…
• The supply and demand side of
a compressed air system
• Proven opportunities for energy
savings
• How to evaluate your
compressed air system
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• 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?
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• Can represent one of the largest energy consumers in some
industrial facilities
• Can represent one of your greatest energy reduction
opportunities
• 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?
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Compressed air is….
• Often referred to as the 4th utility
NOT FREE!
• One of the most inefficient forms of energy in an industrial facility
• One of the most poorly utilized and misunderstood systems
• Often “out of sight and out of mind”
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A Lifetime of Compressed Air
Costs
1 Shift 2 Shift 3 Shift
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
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Where Do You Start With Compressed Air?
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• Two distinct systems:
o Supply Side which includes
compressors, storage, air
quality equipment, and
controls
o Demand Side which
includes distribution
system, secondary storage,
and end-use equipment
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Supply Side Opportunities
• Compressor Specific
• Compressor controls
• Variable speed/displacement controls
• Compressor rightsizing
• Sequencing multiple compressors
• System storage
• Reducing system pressure
• Preventative maintenance
• Heat recovery
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Solutions - Supply Side
• Right sizing
• Controls
• Sequencing multiple
compressors
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Solutions - Supply Side
• Increased system storage
• Reducing system pressure
• Preventative maintenance
• Heat recovery
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Solutions - Supply Side
Other Compressor Room Items:
• Refrigerated Air Dryers
• Thermal mass, cycling, or VFD
• Regenerative Air Dryers
• Low pressure drop filters
• Maintenance
• Zero airloss drain valves
• Dewpoint dependent switching
• Assorted purge methods • Heated purge
• Blower purge
• Vaccuum purge
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Demand Side Opportunities
• Distribution system
• Pressure reduction
• Inappropriate End Uses
• Leaks
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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.
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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?
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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
or inappropriateness of
applications
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Solutions – Inappropriate End
Uses
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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
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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
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Case Study:
Oversized Compressor With Poor
Control Method
• 100 Horsepower compressor operating 24/7
• Modulation controls
• Undersized primary storage
• Significant reduction in staff and production
• Customer locked in at $.14/kWh
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Case Studies – Fixing Leaks
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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
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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
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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!
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Jeff Scott, CEM, CMVP
Key Accounts & Outreach Manager – Industrial
ENWIN Utilities Ltd.
Tel: (519) 255-2888 Ext: 726
Email: [email protected]
www.ENWIN.COM
My Contact Information