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•Understanding the Context•Need for EnCon•Saving Potential
Contents
Energy Efficiency Summit 20102
• Designing Energy Efficient Compressed Air System
•Supply•Distribution•Demand
Understanding the Context
• What is “Compressed Air System”?• Why ENCON in Compressed Air System ?• Where do I Save Cost in “Compressed Air System”?
Energy Efficiency Summit 20103
• Where do I Save Cost in “Compressed Air System”?
• As Fourth Utility has one of the widest industry usage .
• By far the most Energy Intensive
Understanding the ContextWhy ENCON in Compressed Air System ?
Energy Efficiency Summit 20105
• By far the most Energy Intensive
• Scope of Energy Conservation spans right from point of generation to point of use.
Compressed air energy
16%
Heat of
Ratio: 8:1
Understanding the ContextWhy ENCON in Compressed Air System ?
Energy Efficiency Summit 20106
Heat of compression
84%
Compressed Air – Energy Utilization
Leaks5%
End users9%
Pressure drop2%
Heat of compression
84%
• CAPEX• Cost of energy to operate the driver• Space cost• Installation cost• Routine maintenance cost
Understanding the ContextWhere do I Save Cost in Compressed Air System ?
Energy Efficiency Summit 20107
• Routine maintenance cost• Repair cost• Overhaul cost• Supervisory cost
•Understanding the Context•Need for EnCon•Saving Potential
Contents
Energy Efficiency Summit 20108
• Designing Energy Efficient Compressed Air System
•Supply•Distribution•Demand
• Supply– Compressor– System
Controls– Air Dryer– Aftercoolers
Designing Energy Efficient “CAS”• Distribution
– Air piping– Filters– Lubricators
Energy Efficiency Summit 20109
– Aftercoolers– Air Filters– Primary
Storage– Flow controls
All elements of Compressed Air System provide opportunity for energy savings
•Demand–Pneumatic tools–Mechanical drive–Blowers–Vacuum generators–Etc . . .
Ten Questions You Should Ask Before Purchasing Air
Energy Efficiency Summit 201010
Ask Before Purchasing Air Compressor
1. Do I Need a Compressor ?
2. Can I Not eliminate the usage of Compressed Air?
3. What Air Quality Do I Need ?
4. Where will compressor be located?
5. How much pressure (PSI) is needed?
Designing Energy Efficient “CAS”Supply Side
Energy Efficiency Summit 201011
4. How much air flow (CFM) is needed?
5. What horsepower is required?
6. What type and size tank is needed?
7. What are the electrical requirement?
8. What Compressor Features Are Needed?
9. Do I Need a dryer?
• Pressure• Capacity• Horsepower
Remember The Three Main Parameters?
Three Parameters Are Directly Related
Air Basics
Designing Energy Efficient “CAS”Supply Side
Energy Efficiency Summit 201012
• Horsepower
• Capacity Or Flow Determines How Much Work Is Done.
• Pressure Determines How Fast The Work Is Done.• Horsepower Is The Energy Input Required To Get
The Work Done.
Horsepower = Pressure x Flow x Constant
Three Main Parameters As A Formula
Air Basics
Energy Efficiency Summit 201013
The Three Are Directly Related
Horsepower = Pressure x Flow x Constant
The Three Main Parameters As A Formula
Air Basics
Energy Efficiency Summit 201014
The Three Are Directly Related
Horsepower = Pressure x Flow x Constant
The Three Main Parameters As A FormulaThe Three Main Parameters As A Formula
Air Basics
Energy Efficiency Summit 201015
The Three Are Directly Related
“ Think, Learn, Apply”
Horsepower = Pressure x Flow x Constant
The Three Main Parameters As A Formula
Air Basics
Energy Efficiency Summit 201016
The Three Are Directly Related
Can you Increase Horsepower Of An Electric Motor??
“ Think, Learn, Apply”
Horsepower = Pressure x Flow x Constant
The Three Main Parameters As A Formula
Air Basics
Energy Efficiency Summit 201017
The Three Are Directly Related
Or
Horsepower = Pressure x Flow x Constant
“ Think, Learn, Apply”
• Centrifugal Air compressors with Heat recovery units. (Capacity >1500 cfm)
• Two stage Rotary screw compressors. (Capacity < 1500 cfm)
• Single Stage rotary screw compressors with integrated VFD (5 to 50 hp), Refrigerated Dryer & Air receiver
Designing Energy Efficient “CAS”Supply Side – Selection of Compressor - Guidelines
Energy Efficiency Summit 201018
• Screw Compressors with Hybrid Permanent Magnet motors (50hp to 350 hp)
• Skid packaged Reciprocating Air compressors for Oil free Air (50 to 1000 cfm)
• Properly sized air receivers & Air Treatment Components (Variable capacity ref dryer & Heat of compression dryers)
A Paper mfg manufacturing company
• Replacement of old & inefficient multiple reciprocating compressors with
one Centrifugal air compressor
• 4 # 1000CFM Base Load & 1 # 1000CFM trimming reciprocating air
compressors.
• Power consumption - 700kW for 3500CFM@100PSIG
• Investment - Rs.75Lacs.
Case Study
Energy Efficiency Summit 201019
• Centrifugal air compressor - 560kW for 3500CFM
• Energy Savings – 140 kW
• Payback period less than 2 years.
Benefits Achieved:• High efficiency, highly reliable, auto control, low maintenance prone
compressors
Centrifugal Compressor
Energy Efficiency Summit 201020
The most Cost-effective SolutionMajor IR CENTAC Customer in Pulp & Paper Industries• Hyundai Motors India Limited• Ford India• Maruti• CPCL,MRPL,GGSR,BPCL• ITC Limited, HNPL,HPCL,BILT and more
Centac with Heat Recovery Unit
Energy Efficiency Summit 201021
Save upto 40% of the power consumption using Heat recovered thru the water (intercooler & after cooler)
Two stage screw compressors
⇒ Air is compressed in two stages, which allows “More Flow/ Unit Power”
⇒ Optimization of power usage–ability to upgrade existing systems by replacing with 2-
2 Stage Energy Savings
Energy Efficiency Summit 201022
systems by replacing with 2-stage and getting more flow (increased value)
⇒ This increases the overall compression efficiency up to 15% of the total full load power consumption.
• VFD provides the ability to exactly match the compressors’ output to the capacity required by a plant air system.
Screw Compressors with Integrated VFD
� Provides constant system pressure +/- 2psi� Significant energy savings.� Precise pressure control.
Energy Efficiency Summit 201023
� Prolonged life of the compressor.
Hybrid Permanent Magnet motors for Rotary Screw Com pressors
Cylindrical Roller Bearing
Triple Lip Shaft Seal
Duplex Tapered Roller Bearing
Direct drive – Motor stator mounted on primary rotor shaft
Energy Efficiency Summit 201024
Airend Discharge Connects directly to Separator Tank
Triple Lip Shaft SealAspirated, Scavenged
Bearing Coolant Dam
95% efficiency, .96 power factor
Hybrid Permanent Magnet Motors
Induction MotorInduction Motor HPM MotorHPM Motor
Energy Efficiency Summit 201025
PDP = Class 1 or 2
Compressed Air Quality ISO 8573.1
QualityClass
1 -100.0 -702 -40.0 -403 -4.0 -20
WaterPressure Dewpoint (°F / °C)
Designing Energy Efficient “CAS”Supply Side – Selection of Dryer - Guidelines
Energy Efficiency Summit 201026
PDP = Class 1,2 or 3
PDP = Class 4, 5 or 6
3 -4.0 -204 37.4 35 44.6 76 50.0 10
Common findings with un-managed systems:
o More compressors are running than required
–Higher energy
–Higher maintenance
–Lower reliability, less standby capacity
Why System Control?
System Automation
Energy Efficiency Summit 201027
–Lower reliability, less standby capacity
o System pressure is much higher than required
–Higher energy
–Higher maintenance
–Lower quality and repeatability
As much as 20%-60% of the energy used to operate typical compressed air
systems…is wasted!
Control Objective
• Manage Compressors
• Base load & trim
• Single point pressure control
• Stabilize Pressure
System Automation
Energy Efficiency Summit 201028
• Stabilize Pressure
• Prioritize Sequences
• Operate only as needed
Fully Loaded and Standby Compressors
Control Philosophy:
Base Load- Trim Load…
System Automation
Energy Efficiency Summit 201029
Variable Speed Trim Compressors
• Pipe System-the compressed air distribution system that carries the air from compressor discharge to the point of use (tools or equipment).
Designing Energy Efficient “CAS”Distribution System
Energy Efficiency Summit 201030
• 2 basic types– Loop– Grid
Loop Systems
• Loop systems – Compressor/s located centrally– Air to point of use from two directions– Pressure droop is cut in HALF
� How….think of it as doubling the pipe size
•
Energy Efficiency Summit 201031
• What’s good about them– Good pressure distribution– Good flow distribution– Great for high usage/production facilities– Easy to expand/add drops later (and more cost
effective)
Grid Systems
• Grid Systems– Simply a main trunk line with several branches serving
points of use/drops.– Compressor/s located at one end of trunk line– Not as efficient as the loop/unit loop systems
Energy Efficiency Summit 201032
• What’s good about them– Might be cheaper to install than a loop/unit loop system– Simple & intuitive
Materials
• Typical materials– Stainless Steel
� Clean, expensive– Aluminum
� No scale rust, cost– Black iron
� Cheap, high labor
• Connection types– Thread– Flange– Compression– Crimp– Sweat (solder),
Energy Efficiency Summit 201033
� Cheap, high labor – Galvanized
� Cheap, dirty– Copper
� Little scale, cost– Brass (fittings)
� Tough, expensive
– Sweat (solder), – Twist lock– Press fit
• For every 2 psi increase in pressure approximately 1% more power is
required.
• Compressors capacity to horsepower or specific powe r ratio is
approximately 4 to 5 cfm-fad per hp .
• The typical oil consumption for rotary screw compre ssors per 100 cfm-
fad at a rated 4 ppm is approximately 1/2 gallon for every 2000 hours of
Rule of Thumb
Energy Efficiency Summit 201034
fad at a rated 4 ppm is approximately 1/2 gallon for every 2000 hours of
operation .
• On a typical 75 deg F day with 75% RH a compressor can introduce 18
gallons of water in the form of condensate/vapor for every 100 cfm-fad .
• Every 20 deg F rise in operating temperature cuts lubricant life by 50%.
• Every 20 deg F reduction of air temperature cuts the moisture cont ent by
50%.
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