© 2008 Data Power Services, LLC By: Tom Taranto 2010 Energy Expo Hosted by National Grid NYSERDA Reducing Compressed Air Energy Cost Using a Systems Approach Tom Taranto

© 2008 Data Power Services, LLC By: Tom Taranto Systems Approach plant efficiency: energy >> product Supply Compressors Filters / Dryers Piping Primary Storage Transmission Pipelines Filters / Dryers Secondary Storage Demand Machines / Process Point of Use Piping Filters / Dryers Storage Tanks Energy Product Power House / Compressor Room Manufacturing Plant / Production Floor Producers of Compressed Air Consumers of Compressed Air Produce Compressed Air More Efficiently Consume Less Compressed Air Total Energy Reduction Eliminate Irrecoverable Pressure Loss

© 2008 Data Power Services, LLC By: Tom Taranto Systems Approach cost of ownership Equipment cost and maintenance cost represent only a small part of the total cost of operating a compressed air system. Electrical cost usually exceeds 75% of the total operating expense. Source: Compressed Air Challenge®

© 2008 Data Power Services, LLC By: Tom Taranto Systems Approach energy flow Energy Input 100 kW 5% Motor and Drive Efficiency 80% Heat of Compression 5% to 10% Waste: Irrecoverable Pressure Loss Leakage Artificial Demand Inappropriate Use 10% to 5% Productive use

© 2008 Data Power Services, LLC By: Tom Taranto Systems Approach demand side energy reduction 50 % Productive Demand 5% Excessive Pressure 10% Inappropriate Use 15% Artificial Demand 20% Leakage Loss

© 2008 Data Power Services, LLC By: Tom Taranto Reduce Air Demand Improve Compressor Control Systems Approach Reduce Air Demand Reduce System Pressure Improve Compressor Control

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach Compressed Air Efficiency Services

© 2008 Data Power Services, LLC By: Tom Taranto Assessment of the Market for Compressed Air Efficiency Services

© 2008 Data Power Services, LLC By: Tom Taranto Assessment of the Market for Compressed Air Efficiency Services Office of Industrial Technologies (2001) Office of Energy Efficiency and Renewable Energy - U.S. Dept. of Energy Oak Ridge National Labs Motor Market Assessment by XENERGY (1998) Pacific Gas & Electric “Compressed Air Market Transformation Program” (1999)

© 2008 Data Power Services, LLC By: Tom Taranto Key Findings Awareness and concern for energy efficiency is low. Principal objective is consistent reliable air supply. Serious problems reported.  35% had shutdowns in past 12 months  21% were shutdown for 2 or more days

© 2008 Data Power Services, LLC By: Tom Taranto Reported Air System Problems

© 2008 Data Power Services, LLC By: Tom Taranto Summary 71% Consistent, Reliable Performance - primary objective. Only 17% “mentioned” efficiency. 35% Have had serious problems this yr. Apply the Systems Approach

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach Identify Opportunities

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Operating Cost Identify Opportunities Compressed air – primary functions  Power As an energy source to perform work  Process Air becomes part of a process  Control To stop, start or regulate the operation of a machine

© 2008 Data Power Services, LLC By: Tom Taranto Identify Opportunities highest priority Reliability of the Production Process  Deliver Energy to Production Stakeholder’s needs  Reliable production – no production outages  Maintain product quality – minimum scrap and rework Little energy concern if production is affected

© 2008 Data Power Services, LLC By: Tom Taranto Identify Opportunities sustainable energy savings Comprehensive solutions  Improve critical production end use applications  Eliminate irrecoverable pressure loss  Provide compressed air energy storage  Optimize compressor control Solutions must be long term and reliable  If production is interrupted the energy efficient solution will be abandoned in favor of the previous more energy intensive operation. Improving Performance Reducing Energy

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach Improve Performance Fix Leaks Reduce System Pressure

© 2008 Data Power Services, LLC By: Tom Taranto Improve Performance point of use pressure profile Test Machine Flow Dynamic Demand  What’s Wrong With This Picture?

© 2008 Data Power Services, LLC By: Tom Taranto Improve Performance point of use pressure profile Validate Perceived High Pressure  Pressure Gauges – Mechanical Damping

© 2008 Data Power Services, LLC By: Tom Taranto Improve Performance point of use pressure profile

© 2008 Data Power Services, LLC By: Tom Taranto Improve Performance point of use pressure profile Diagnostic Data ARPAC Wrapper

© 2008 Data Power Services, LLC By: Tom Taranto Improve Performance point of use pressure profile Diagnostic Data - ARPAC Wrapper

© 2008 Data Power Services, LLC By: Tom Taranto Improve Performance eliminate artificial demand 15% Artificial Demand  Applying  Pressure (PSIG) to an Orifice will Increase  Flow Rate (SCFM)

© 2008 Data Power Services, LLC By: Tom Taranto Improve Performance reduce leakage 20% Leakage Loss  Establish Leak Repair Priority  Leak Repair is Most Effective if Pressure is Controlled

© 2008 Data Power Services, LLC By: Tom Taranto Reduce Pressure optimize the pressure profile Demand side target pressure – lowest optimum pressure to support manufacturing  Eliminate artificial demand  Reduce compressor power 1% per 2 psig Identify perceived high pressure demand – they prevent system pressure from being reduced.  Validate the need for high pressure  Check for piping restrictions  Determine the present operating pressure (at the point of use)

© 2008 Data Power Services, LLC By: Tom Taranto Reduce Pressure optimize the pressure profile If the need for high pressure is valid – do not let a small percentage of air demand cause the entire system to operate at high pressure.  Consider other ways to serve the high pressure need  Consider air amplifiers or booster compressors  Consider a separate dedicated compressed air system

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach Inappropriate Use of Compressed Air 19

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Compressed Air is Expensive and Inefficient  $250 to $500 per Million Cubic Feet (MMCF)  80% to 85% of energy is waste heat  1 hp air motor requires 7 to 8 Hp at compressor  8 hp / 100 cfm – low pressure blower  23 hp / 100 cfm – 100 psig compressor  Alternate sources are frequently 1/3 the energy cost of compressed air Review Applications and Consider Alternative Energy Sources 19

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Abandoned & Malfunctioning Equipment 20

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Air Powered Vacuum – 25 hp 21

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Compressed Air Powered Cabinet Coolers  3300 watts input > 500 watts Cooling Refrigerated Cabinet Cooler  750 watts input > 500 watts Cooling Compressed Air Cabinet Cooler Refrigerated Cabinet Cooler 22

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Idle Machine w/ Blowing Tubes Wasting Air 23

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Air Operated Reciprocating Pump 24

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Chip Blowing w/ Compressed Air 25

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Air Motors Driving Ink Pumps 26

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Compressed Air Blowing Tube AIR NOZZLE 27

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air Air Powered Vacuum Generator VACUUM GENERATOR VACUUM CUPS 28

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air KEY Points – Inappropriate Air Use  Compressed air is expensive and due waste heat at the compressor, an inefficient power source.  Using high pressure 100 psig air (23 Hp/100 cfm) for low pressure 8 psig requirements (8 Hp/100 cfm) is inefficient.  Review applications to investigate a more direct conversion of energy supply (electricity) to the application requirements.  Abandoned and malfunctioning equipment should be eliminated or repaired.  Air powered vacuums should be replaced with electric models if possible. 28

© 2008 Data Power Services, LLC By: Tom Taranto Inappropriate Use of compressed air KEY Points – Inappropriate Air Use  Air powered cabinet coolers use 70% to 80% more energy than small refrigeration units.  Idle equipment should have compressed air automatically shut off whenever possible.  Air operated piston pumps should be replaced with electric pumps if possible.  Chip blowing applications can often use low pressure blowers and delivery devices. 29

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach Monitor & Maintain System Efficiency

© 2008 Data Power Services, LLC By: Tom Taranto Monitor & Maintain System Efficiency management information  Cost of compressed air is derived from reliably measured performance data.  Energy performance and cost are reported to management.  Compressed air demand of production operations is documented through airflow measurement and recording.  The consistent, reliable, supply of compressed air is achieved. Performance measurement information shows corrective measures to optimize performance.  Unscheduled downtime is minimized or eliminated. 40

© 2008 Data Power Services, LLC By: Tom Taranto Monitor & Maintain System Efficiency management information Compressed Air Flow Measurement 34

© 2008 Data Power Services, LLC By: Tom Taranto Monitor & Maintain System Efficiency management information 36

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach Summary: 2010 Energy Expo Hosted by: National Grid & NYSERDA

© 2008 Data Power Services, LLC By: Tom Taranto Reduce Compressed Air Operating Cost Using a Systems Approach  Improve Performance – Consistent Reliable Air Supply  Fix Leaks and Eliminate Waste  Reduce System Pressure and Eliminate Artificial Demand  Eliminate Inappropriate Use

© 2008 Data Power Services, LLC By: Tom Taranto Reduce Compressed Air Operating Cost Using a Systems Approach  Target Pressure – Lowest Optimum Pressure  Improve Generation Efficiency – with Efficient Trim Compressors  Operate Multiple Compressors – Efficient Control Automation  Monitor & Maintain System Efficiency – Management Reports

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach 2010 Energy Expo Hosted by: National Grid & NYSERDA

© 2008 Data Power Services, LLC By: Tom Taranto Reducing Compressed Air Energy Cost Using a Systems Approach 2010 Energy Expo Hosted by: National Grid & NYSERDA