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
Why Customers Should Care About Compressed Air? • 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 Energy Conservation Staff Care About Compressed Air? • 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
A Word of Warning
Compressed air is…. NOT FREE! Often referred to as the 4 th utility • • 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”
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? 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 8
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, or VFD • Regenerative Air Dryers • Dewpoint dependent switching • Assorted purge methods • Heated purge • Blower purge • Vacuum purge • Low pressure drop filters • Maintenance • Zero air loss drain valves
Solutions – Distribution Systems • A closed loop system is recommended • Large consistent pipe diameter • Avoid too many elbows, tees, etc. Keep it simple! • Drops should come off the top of the main header to prevent any condensate from entering the process. • Account for any critical application and high-volume/intermittent applications by installing satellite air receivers and metered recovery
Solutions – Pressure Reduction • Reducing pressure also reduces the amount of energy lost by leaks • Regulate the “system” and points of use • Lockable? • Pressure is often raised to appease a specific process or machine • Booster?
Solutions – Inappropriate End Uses • Address points of use for volume, pressure, and quality • Challenge point of use requirements and appropriateness or inappropriateness of applications • Investigate and address high volume, intermittent applications (metered recovery?)
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!
My Contact Information 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
Questions?
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