Identifying Energy Waste in your Plant/Facility Webinar with Fluke

800.828.1470 Transcat.com
Energy
Measurement
Principles
Helping identify and
quantify energy
waste
Energy Measurement Principles 1

Seminar Presenter
2
• Curt Geeting, Fluke Corporation
• Sales Application Manager –Northeast U.S.
• Curt.geeting@fluke.com
• Level 1 Thermographer
• Level 1 Vibration Specialist
• 38 Years in the Test Equipment Market
• 22 Years with Fluke Corporation
• Customer application support and product training is primary focus
in the Industrial, Commercial, Utility, Municipal and Field Service markets
• Fundamental expertise is in Electrical, Electronic, Mechanical, Process and Thermal
applications.
.

Things to think about during this Fluke
Energy Webinar
• How much is your Electric bill per month on average?
• Do you pay any penalty charges from your Utility provider
...such as a Demand or Power Factor penalty ?
• Since you did a lighting upgrade how much has this
Electric bill decreased by dollars and / or by percent ?
• How much is your Natural Gas or Oil Bill per month ?
• Does that change much during the year ?

–The Electrical System in any facility is the backbone to the
operation of all that functions within it.
– There are key issues involved in operating properly and
safely:
•A properly functioning ground system
•Correctly installed system components and loads
•All segments of the system operating within operational parameters
•Periodic confirmation that the system stays within safe operating
conditions
•Verification of changes in the system including additions or
modifications
ELECTRICAL SYSTEM HEALTH

Warm up: What is energy?
• Energy is measured in Joule (j).
– The energy of one Joule in one second = one Watt (W).
• We use energy to produce work.
– When we do, a part of the original energy is transformed
into thermal energy.
– We call that energy loss and the amount of that loss
defines the efficiency of a process.
• Ideal electric motor efficiency is 80-90%.
– That means 80-90% of the electrical energy is
transformed into work and 10-20% into heat.
– If a motor gets warmer than it should, efficiency
decreases and energy is wasted
Measureable energy formats:
• Heat
• Electrical
• Pressure (steam, air, water)
• Mechanical force (rotating/centrifugal)

How is energy waste manifested?
Electrical
• Power
consumption
• Power distortion
• Overheating
Mechanical
• Excessive
vibration, friction
• Overheating
• Excessive sound
Input vs. output
• Pressure drop
• Conditioned air
• Compressed air
• Temperature drop
• Steam
• Conditioned air

How can energy waste be
quantified?
• Measurements on energy usage and indicators
• Electrical
– kWh
– Harmonics
– Unbalance
– Power Factor
– Peak demand
• Vibration
• PSI
• Heat
• Delta-T

Savings
$$$ Biggest Opportunities
$$ Medium Opportunities
$ Smaller long-term Opportunities
Biggest savings opportunities
Electric Utility,
IT/Computers
HVAC,
Motors & Drives
Lighting,
Compressed
Air, Steam
Systems
Building
Envelope

Building Infrastructure
Three-phase electrical
distribution (Mains)
Ventilation,
heating, cooling Building envelope Lighting
Electrical subsystem
Utility billing
Electrical
distribution
infrastructure
Focus on three building systems
Production process systems
Mechanical loads Flow: Air compression, steam

How utilities measure energy
consumption
Understand what to measure.
Energy consumption is
the accumulation of power
over time expressed in
kilo watt hours (kWh)
Utility energy consumption
charges are broken into
•Active (or true) power (kW)
delivered by the utility
•Variances due to Power Factor
•Variances due to market demand

What is electrical energy?
Power, kW
Rate at which ac energy is expended. Watts measure the
energy required to do actual work, such a running a motor.
Demand, kVA
Total voltage and current required from the utility,
regardless of its efficiency or whether it does actual work.
Power factor, PF
When a circuit operates at 100% efficiency, demand =
power. When power is less than demand, the difference,
kW/kVA, is power factor. PF below .95 is inefficient.
Harmonics and unbalance
Other causes of inefficient power usage
To measure power the way the utility bills for it,
a power measurement accounting for volts, amps, watts, and PF is necessary.
To increase efficiency, harmonics and unbalance should be also be assessed.

Energy logging: Why and where
9/5
8/5
7/5
6/5
5/5
4/5
3/5
Total
(
kW)
160
140
120
100
80
60
40
Where:
1. Log power at main and
secondary panels and
major loads
2. Record kW, kWh, and
power factor
3. Identify any peak
usage times (below)
4. Determine if usage can
be adjusted and how
else to reduce cost
Total
kW
Why: You need to map where your consumption is going
• Compare against utility meter/bills
• Evaluate peak demand and any power factor charges

Loads: Lighting, computers etc.
Main Service
Entrance
Load #1 50 kVA
Load #2
100 kVA
Motor #1
Sub-
panel
#1.1
Sub-
panel
#1.2
480 V
panel
Measure
for waste
Motor #2
Starter
Disconnect
Disconnect
Transformer
Measure
for waste
Measure
for waste
Measure
for waste Disconnect
Capacitor
Electrical subsystem waste
points

Unit Measurements Objective
Main switchgear KW, PF, unbalance,
harmonics
Compare usage to bill,
evaluate level of waste
Switchgear/Capacitor
bank
PF Verify efficiency of PF
mediation
Switchgear/Alt energy
source
KW, inverter efficiency,
temperature
Verify power contributed
and inverter efficiency
277/480 Panel or load KW, PF, unbalance,
harmonics, temperature
Evaluate level of waste and
ROI for mitigation or
changes to loads or
schedules
Measurements to determine
electrical waste

Typical reasons for
electrical hotspots:
• Unbalanced loads
• Harmonics (3rd harmonic
current in Neutral)
• Overloaded systems/excessive current
• Loose or corroded connections
increased resistance in the circuit
(typically one side of a component heats
up)
• Insulation failure
• Component failure
• Wiring mistakes
• Underspecified components
(like fuses, would heat up on both sides
of the fuse)
Thermal inspections that
identify waste

Overloaded
circuit fuse
hot on both
ends
Loose
connection,
fuse hot on
one end only
Thermography helped distinguish
between loose connection and
overloaded circuit
Thermal inspections that
identify waste

Fluke Thermal Imagers
• Enhanced problem detection and analysis with IR- Fusion
Technology – only from Fluke
– Combines the power of infrared images with visible light
images on the same display
• Optimized for field use in harsh work environments
– Withstand a 6.5 foot drop
– IP 54 rated for dust and water
• Delivers clear, crisp images to find problems fast
– Multiple measurement capabilities
– Easy to use with simple navigation through menu driven
selections
– IR-OptiFlex focus system and manual focus
• Smartview Software
– Easy, high-performance analysis and reporting
• TiS20+ - TiS75+ Performance Series: Lightest, rugged, easy to use thermal imagers
• Ti401 Pro & Ti480 Pro Professional Series: Proven, Practical, Performance
• TiX501 & TiX580 Expert Series: Expert Series for demanding applications

Main Service
Entrance
Load #1 50 kVA
Load #2
100 kVA
Motor #1
Sub-
panel
#1.1
Sub-
panel
#1.2
480 V
panel
Detect
waste
Motor #2
Starter
Disconnect
Disconnect
Transformer
Detect
waste
Detect
waste
Detect
waste
Disconnect
Capacitor
Unit Measurements Objective
Main switchgear KW, PF, unbalance,
harmonics
Compare usage to bill,
evaluate level of waste
Switchgear/Capacitor
bank
PF Verify efficiency of PF
mediation
Switchgear/Alt energy
source
KW, inverter efficiency,
temperature
Verify power contributed
and inverter efficiency
277/480 Panel or load KW, PF, unbalance,
harmonics, temperature
Evaluate level of waste
and ROI for mitigation or
changes to loads or
schedules
Follow up with electrical
measurements

Fluke Connect Wireless
Measurement Tools

Measurement Tools

Measuring Power , Energy and Wasted Energy Cost Directly
• Use a power quality analyzer connected to the drive input.
• First measure at the load, then, if needed, work back to the service entrance.
Three Phase Power
Measurement Tools
Fluke Exclusive Energy Cost Calculator-Built Into Energy Loggers!

Managing the utility bill
• Kilowatt hours (energy consumed)
• Peak demand
• Power factor
Utilities usually bill for:

Energy consumption (kWh)
kWh is an accumulation of
the true power (kW) delivered
by the utility

• 25
Peak Demand Charges
and Penalties
• Peak Demand determines how big the
“electricity pipe” must be
• Peak demand is the highest of consecutively-
measured, 15-minute average kW readings
(technique may vary by supplier)
• The Fluke 435, 1730 and 1736 can average
kW over these intervals and report the highest

Power factor penalties
• Many utilities charge for every percentage point over limit (< 0.97).
Some charge based on the VARs you use. Check your utility rate plan.
• How does your utility measure power factor or VARs?
Are they looking at peak intervals or averages? DPF or total PF?
• Identify loads causing lagging reactive power and work with engineers to develop
a correction strategy
Example Calculation
• Assume the utility adds 1% demand charge for each 0.01 below PF 0.97
• Assume your PF averages 0.86/month and your demand charge is $7000
(0.97-0.86) * 100 % = 11 % (11 % x $7000) x 12 months
= $9,240 avoidable annual cost
Since reactive power requires system capacity, but performs
no work, utilities and plants try to keep net kVARs low

PQ Troubleshooting: Power Factor
Power Factor Correction
Capacitors are installed to supply VARs locally, relieving upstream system
of the burden. Cap sizing requires PF and kW measurement.

• 28
Three Phase Power Meters:
Power Factor

120°
120°
120°
A
B
B
Unbalance is a measurement of the
degree of inequality between phase
voltages.
Voltage unbalance causes stress on
3-phase loads, leading to inefficient
consumption and eventual device failure.
What is voltage unbalance?

Why care about harmonics
waste?
Power quality analyzers display a
spectrum graph of harmonic components
present in a system, but the graph on its
own does not quantify the amount of
energy wasted by harmonics.
Harmonics cause:
• Unusable power, drawn from utility
but not converted to actual work
• High current to flow in neutral
conductors
• Motors and transformers to run
hot, decreasing efficiency and
shortening lifespan
• Reduced transformer efficiency —
or, a larger unit is required to
accommodate harmonics

The Fluke Energy Loss Calculator
Identify, quantify and monetize comprehensive energy losses,
including harmonics, unbalance, power factor and cabling
Useful kilowatts (power)
available
Reactive (unusable) power
Power associated to
unbalance
Power associated to
harmonics
Total cost of wasted
kilowatt hours per year
Neutral current
Cable length and diameter are
factored in to the wastes above
Exclusive to Fluke-Patented Algorithm

The costs of poor power quality can be significant
• Lost production: Each time production is interrupted, your business
loses profit on product that is not manufactured and sold.
• Damaged product: Interruptions can damage a partially complete
product, causing the material to be re-run or scrapped.
• Energy cost: Electric utilities may charge penalties on poor power factor
or high peak demands.
• Maintenance: Premature equipment failures can tie up available
resources and incur cost, involving restoring production, diagnosing and
correcting the problem, clean up and repair.
• Environmental and safety costs: In some cases loss of power can
cause environmental damage or compromise life safety.
• Market impact: The costs of losing repeat sales, product recalls and
negative public relations can be significant, though hard to quantify.
Costs of poor power quality

Fluke Power Quality Troubleshooting
Seminars
1. Branch circuit and service panel
3. Feeder loads
2. Distribution
Transformer

Energy measurement tools:
• Fluke 376 FC & 1587 FC
• Fluke 1736 / 1738 Power
Quality Analyzers
• Fluke 1746 / 1748 Watertight
Power Quality Loggers
• Fluke 435-II Power Analyzer
• Fluke 438-II Motor Efficiency
Analyzer
• Fluke 810 & 805 Vibration
Testers

Utility billing
Electrical
distribution
infrastructure
Ventilation,
Building infrastructure
sub-system

Building infrastructure:
Lighting
Electrical
distribution
Transformer Disconnect Light control
Point of use
Log power
consumption
Appropriate
Illumination?
Are automatic
controls in place?

In some facilities, lighting costs can account for as
much as 20% of a building’s energy cost.
• The opportunity is to reduce that percentage, by
quantifying existing consumption and lighting
requirements compared to upgrades.
• The risk is in replacing resistive incandescent lighting
loads with reactive high-e lighting loads.
Standard practice is to inspect the building’s lighting
system, replace fixtures and/or bulbs with high-
efficiency models, and sometimes to install timers
and other controls.
1. Measure and adjust foot-candle illumination levels to
industry recommendations
2. Evaluate ballast and breaker contact temperatures
3. Look for hotspots and compare values with baselines
4. Evaluate upgrades to higher efficiency technologies
for lights and signs
Amprobe LM-120
Light Meter
Lighting

System components Measurements
Lighting electrical panel Log Voltage and current over time,
mapped to energy bill
Area illumination level Lux, footcandles, square footage
Operations schedule and controls Identify hours of peak usage, seasonal
lighting requirements, and current
occupant usage patterns
Lamp audit Number and type of lamps, from
incandescent to fluorescent to High-e
Lighting controls Manual inspection of existing system
controls, from any master building-level
lighting controls to individual dimmers and
on/off switches
Lighting measurements

Methodology: Replace lighting with higher efficiency models and install
occupancy sensors and timers to automate shutdown.
GLENDORA
ORANGE
$66,395 -51%
$18,635 -48%
ELECTRICITY COST KWH REDUCTION
Total Savings - $156,568 Investment - $127,125
SAVINGS
MATERIAL
COST SCE REBATE ROI EPAct 2005
GLENDORA (79,099)
$ 87,620
$ (37,535)
$ 0.75 TBD
ORANGE (21,447)
$ 39,505
$ (18,487)
$ 0.99 TBD
Bldg 1
Bldg 2
Bldg 1
Bldg 2
Case study: Lighting controls

Ventilation
Registers
HVAC
Air supply
VFD
pump
Electric
distribution
Leakage
Air return
Windows,
doors,
walls, roof
Temperature
& air flow
% outside air,
filter inspection
Log power
consumption
Temperature
& vibration

Temp &
Humidity
Outside
Air Levels
Airflow
Electrical
Demand
Recalibrate thermostats
Implement setbacks
Optimize Ventilation
Constant/Variable
Volume
Variable Speed Drives
Proper right-sized fans
1. Add variable speed
drives to big loads:
reduce energy by
nearly 50%!
2. Optimize, upgrade
or retrofit HVAC
system: New
systems use
30-60% less
electricity!
3. Right-size fans:
60% of building
fans are oversized!
Ventilation savings opportunities

Unit Measurements
Air supply CO2 , % outside air, Air Flow
Power supply panel Voltage, current, kW, power factor
Fans, air handlers and motors Temperature, vibration, current, voltage
Ductwork (distribution) Temperature, pressure: air leaks
Registers Temperature, Air Flow
Thermostats and sensors Comparative Temperature
Building envelope
(Walls, roof, doors, windows)
Air Leakage, Comparative Temperature
Differences, Temperature Differential
Ventilation & envelope
measurements

Quantify electrical cost of
ventilation
1. Profile your HVAC system
2. Log energy consumption at the power
supply as well as large loads, so that you
can quantify specific costs and savings
3. Assess presence of waste energy (power
factor, harmonics, unbalance)
4. Check for peak demand charges and
identify biggest rate schedule/time-of-use
issues, both weekly and seasonally
5. Thermally inspect all electrical and
electro-mechanical equipment

Fluke 810
Vibration
Tester
Measure differential
and static pressure,
velocity and airflow
to identify clogged air
filters and evaluate
efficiency of air
handlers and
compressors
Fluke Ti401 Pro
Thermal Imager:
Detect insulation
leaks and spot
check sensors
Fluke ii900
Sonic Industrial
Imager
Collect all variables
necessary to assess
and optimize outside
air conditioning and
ventilation
effectiveness
Fluke 1738/EUS
Power Logger
Log energy supply to
large loads within the
HVAC system before
and after optimization
to quantify savings
Tools to identify and quantify
waste

Cooling/Chiller
Building infrastructure: Cooling
Water Supply
Electrical
distribution
Motor/ pump Condenser/
compressor
AHU
Log power
consumption
Temperature
& vibration
Pressure &
temperature
Cooling
tower

Log power
consumption and
check for
harmonics and
unbalance Thermally scan for
differences in
temperature that can
indicate harmonics or
unbalance
Use vibration testing to check for
friction inefficiencies in mechanical
operation: imbalance, looseness,
misalignment and worn bearings
Thermally scan motor, shaft,
coupling and bearings for
overheating indicating
alignment, wear, cooling or
insulation problems
Use a Fluke 700G
Pressure Gauge or
Fluke Pressure like a
719 Pro to measure
pressure differential
Cooling waste: Chillers,
cold water

Case study: Chiller operational
savings
• Thermal imaging
• Power consumption
• Maintenance
• Operational changes
Current Operation Proposed Cost Savings
Power (252.1 KW) $287,114 $258,403 $28,711
Water (20,000 gpd) $4,500 $4,500 $0
Cleaning, salt $4716 $1462 $3254
Corrosion Inhibitor $3,000 $6,000 ($3,000)
Shutdown 102 1HP pump $854 $0 $854
Total $29819

Heating/Boiler
Process subsystem: Steam Heat
Measurement points per unit:
Insulation, pipe/lines, valves, traps,
seals
Water
Log
Gas
Boiler
Electric
VFD pump
Radiator
Steam trap
Condensation
return

Why should I care?
According to the U.S. Department of Energy,
more than 45% of all the fuel burned by U.S.
manufacturers is consumed to generate steam.
Savings opportunities?
Steam system improvements can save 11% in
fuel costs at a typical industrial facility.
Efficiency depends on:
• Equipment efficiency
• Amount of distribution
standby losses incurred
• Removal of condensate
Inspection points:
• Equipment
• Standby losses
• Duct leakage
• Envelope air leakage
• Envelope conductive
losses
Boiler/Steam system inspection

Unit Measurements
Boiler Temperature, Current, Voltage, water flow
Power supply panel Voltage, current, kW, power factor
VFD or controller Current, voltage
Pumps and drive motors Temperature and/or temperature
differential, current, voltage, water flow
Pipes (distribution), steam traps Temperature and/or temperature
differential
Helper pumps Temperature, Current, Voltage, water flow
Faucets Temperature
Production equipment Temperature of water, steam or liquid;
pressure
Boiler/steam system
measurements

Case study: Steam waste
Inspection
discoveries:
• 6 failed traps
• Replacement
cost per trap:
$500
• Savings per
trap: $3,200
Total savings:
$16,200

http://www1.eere.energy.gov/consumer/tips/air_leaks.html
Savings opportunity:
Reduced HVAC costs!
Primary locations of unintentional
heat transfer (loss or gain):
• Roof defects and moisture damage
• Pipes and ducts
• Door and window frames
• Switches and sockets
• Cracks in structural joints
• Faulty or insufficient wall insulation
Building infrastructure: Envelope

Thermal imagers can identify areas in the building envelope that are
allowing unintentional heat transfer, including loss of conditioned air.
Identifying waste in the
building envelope

Utility billing
Electrical
distribution
infrastructure
Ventilation,
Production processes
subsystem

Energy logging: Why and where
Where:
1. Log power at main and secondary
panels and major loads
2. Record kW, kWh, and power factor
3. Identify any peak
usage times (below)
4. Determine if usage can be adjusted and
how else to reduce cost
Why: You need to map where your
consumption is going
• Compare against utility meter/bills
• Evaluate peak demand and any power
factor charges

Main Service
Entrance
Load #1 50 kVA
Load #2
100 kVA
Motor #1
Sub-
panel
#1.1
Sub-
panel
#1.2
480 V
panel
Measure
for waste
Motor #2
Starter
Disconnect
Disconnect
Transformer
Measure
for waste
Measure
for waste
Measure
for waste Disconnect
Capacitor
Electrical subsystem waste
points

Identifying cost-saving
energy options
1. Compare operating schedule
to against utility rate
schedule
2. Change operations to take
advantage of:
• Lower cost energy times of
day
• Times when machinery can be
turned off
• Sensors and controls that
could enable systems to be
turned off when not needed
3. Set up infrastructure
equipment start up/shut
down schedules for occupied
vs. unoccupied modes
2009 Usage Pattern
50.00
60.00
70.00
80.00
90.00
100.00
110.00
0
0
:
0
0
0
1
:
0
0
0
2
:
0
0
0
3
:
0
0
0
4
:
0
0
0
5
:
0
0
0
6
:
0
0
0
7
:
0
0
0
8
:
0
0
0
9
:
0
0
1
0
:
0
0
1
1
:
0
0
1
2
:
0
0
1
3
:
0
0
1
4
:
0
0
1
5
:
0
0
1
6
:
0
0
1
7
:
0
0
1
8
:
0
0
1
9
:
0
0
2
0
:
0
0
2
1
:
0
0
2
2
:
0
0
2
3
:
0
0
kWh
Weds 7th Jan
Thurs 5th Feb
Sun 25th Jan
Weds 10th Jun
Sun 17th May
Fri 31st Jul
Sat 25th Jul
Sat 20th Jun
Sample energy log
4. For start up, stage equipment with large
electrical power consumption at least 15
minutes apart to avoid peak demand charges
5. Install VFDs for large motors and replace
existing bad motor with a high efficiency
motors

Case Study – Furnaces operating at
peak demand
12h
10h
8h
6h
4h
2h
0h
22h
20h
18h
16h
Total
(
kW)
150
100
50
0
First hour – 130kW peak
Potential $1950 month
penalty
Active Pow er Avg
16/6 12h
16/6 6h
16/6 0h
15/6 18h
Total
(
kW)
40
30
20
10
0
17 hours – 34kW peak
Potential $510 month
penalty
Goal:
• Optimize demand and energy
consumption vs. utility rate schedule
Measurement method:
• Log over a full operational cycle to
obtain the complete demand profile
• Know the utility rate schedule /
understand how the utility bills
• Develop load management plan to
prevent large loads from peaking
during the most expensive utility rate
hours

PQ
Electro-mechanical loads
Insulation resistance
And Unbalance
Temp and Vibration
Temp

Causes of mechanical overheating
• Bad cooling due to reduced airflow
• Bearing problems lubrication,
wear, tolerance
• Bad alignment
• Electrical
5 point thermal inspection
1. Windings and general heat pattern
2. Termination box / junction box
opened up, all electrical components*
3. Couplings / shaft / drive belts
4. Bearings, where not blocked by
cowling covers or fans
(Drive-end and non drive-end)
5. Convection cooling fan, if present
* with appropriate electrical safety
Motor Overheating Cost
Increase over
Maximum
Temperature Rating
Insulation Life
Reduced by
+10°C (18°F) -50%
+20°C (36°F) -75%
+30°C (54°F) -88%
Temperature measurement

Fluke Thermal Imagers
• Enhanced problem detection and analysis with IR- Fusion
Technology – only from Fluke
– Combines the power of infrared images with visible light
images on the same display
• Optimized for field use in harsh work environments
– Withstand a 6.5 foot drop
– IP 54 rated for dust and water
• Delivers clear, crisp images to find problems fast
– Multiple measurement capabilities
– Easy to use with simple navigation through menu driven
selections
– IR-OptiFlex focus system and manual focus
• Smartview Software
– Easy, high-performance analysis and reporting
• TiS10-TiS65 Performance Series: Lightest, rugged, easy to use thermal imagers
• Ti400 Professional Series: Proven, Practical, Performance
• TiX500, TiX600 Expert Series: Expert Series for demanding applications

Electro-mechanical friction waste
Friction-based inefficiencies in electro-mechanical equipment = energy waste
• Alignment: In motor drivetrains, it is how well centerline of two coupled shafts coincide
• Bearings: Operating at reduced efficiency
• Imbalance: Occurs when center of mass is not on center “heavy spot”
• Looseness: Excessive clearance between parts or mountings that need tightening

Case study: Cost of mechanical
unbalance
Company:
Steel recycling industry - Germany
Application:
Belt-driven fan for process cooling, 24/7
Test:
Fluke 810 detected a moderate unbalance as
well as misalignment and bearing wear
Fix:
Re-balancing
Energy savings
• 350 kW Motor running at 80% of
nominal power.
• Measured power: ~280 kW
• After balancing, reduced power
consumption by 3%
• 8.4 kW saving x 8760 = 73,584 kWh
• At 0.11 Euro / kWh, annual savings:
73584 x 0.11 = 8,094 Euro

Detecting waste with vibration
testing
Capabilities of the Fluke 810
Vibration Tester
• On-board diagnosis and location of mechanical faults:
– Bearings, looseness, misalignment, unbalance and
other (nonstandard faults)
• Fault severity scale
– Slight, Moderate, Serious, and Extreme
• Prioritized repair recommendations
• Diagnostic details include
– cited peaks and vibration spectra
• Data export for more detailed Analysis
• Data storage and tracking with VIEWER Software
1 2 3

Primary waste sources:
Over production due to inefficient
distribution (leaks) and usage
Common inefficiencies:
• Leaks, blockages, failures
• Sensor misalignment
• Consumption patterns
Primary sources of leaks:
• Leaks in hoses, connections, tools, etc.
• Mechanical failure of valves, cylinders, etc.
• Condensate collection systems and pressure
regulators
• Drainage and purge points
Process subsystems:
Compressed air
Panel
Compressor
Pipes and
Valves
Pneumatic
tools
Log Pressure
output
Leaks Pressure drop

Energy flow in a compressor
100% Electrical
Energy
Energy in the form of
compressed air: 5%
Energy lost to cooling: 75%
Other energy losses (noise, radiation, friction, etc.): 20%
Compressed air inefficiencies
• Only 5% of the total energy consumed by compressors is converted into
compressed air. The remaining 95% is transformed into mechanical, heat, noise
loss, etc.
– Between 20 to 30% of a compressor’s output is often lost via air leaks
• In factories with pneumatics, compressed air = 10% of the total energy bill.
• Electrical bills can be reduced by 20%-40% by detecting and sealing air leaks

How to quantify waste
1. Log energy consumption at full load
over a full production cycle - quantify
total cost an identify unnecessary
operational hours
2. Determine demand requirements
3. Check pressure differential at
compressor vs. demand
4. Use an ultrasonic tester to scan
for air leaks
Savings Goal
1. Determine the lowest possible pressure
level required to operate equipment.
2. Eliminate excessive pressure drop
across filter banks or other components
which will cause higher than normal
energy consumption.
Quantifying compressed air waste

Before and After Leak Inspection
Genie, case study
• #4 compressor idle
• 25.7% Recovered Capacity
• $48,754 savings
• 90HP compressor #4 working
full-time (red)
• Air working at max capacity at
peak times
Power/Energy
Log Compressor #1 Compressor #2 Compressor #3 Compressor #4 TOTAL
Week
Before 7,954 kWh 2,849 kWh 8,502 kWh 13,818 kWh 33,124 kWh
Week
After 10,913 kWh 5,513 kWh 6,779 kWh 1,418 kWh 24,623 kWh
= 2,959 kWh 2,664 kWh (1,772) kWh (12,400) kWh (8,501) kWh
0
100
200
300
400
Active Power over 7-day (kW)
Compressor #1
Compressor #2
Compressor #3
0
100
200
300
400
Active Power over 7-day (kW)
Compressor #1
Compressor #2
Compressor #3
Compressor #4
4 AIR COMPRESSORS: (2) 75 HP + (2) 90 HP
BEFORE
:
AFTER:
Case Study
Case study:
Compressed air savings

Energy measurement tools:
• Fluke 1738 Power Quality
Analyzer
• Fluke 1748 Watertight Power
Quality Logger
• Fluke 438-II Motor Efficiency
Analyzer
• Fluke Ti401 Pro Thermal Imager
• Fluke 810 & 805 Vibration
Testers
• Fluke ii900 Sonic Imager

Questions?
Email Christina Spearman
christina.spearman@transcat.com
For related product information,
go to:
www.transcat.com/brand/fluke-store

Energy
Measurement
Principles
Identifying and
quantifying
energy waste
Thank you!

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