1. Main Headquarters: 120 Water Street, Suite 350, North Andover, MA 01845 With offices in: NY, ME, TX, CA, OR www.ers-inc.com
APPLICATION OF AIRMASTER+ IN
REAL INDUSTRIAL FACILITIES
presented by
Satyen Moray
ENERGY & RESOURCE SOLUTIONS
ACEEE Summer Study on Energy
Efficiency in Industry

2.  Why is Compressed Air Important?
 Steps in a Compressed Air Assessment
 AIRMaster+ Background and
Capabilities
 AIRMaster+ Modules
 Integration of AIRMaster+ in an
Assessment
 Case Study
 Conclusions
OVERVIEW
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3. Compressed Air Systems:
 Consume over 90 Billion kWh per year
 Cost over $1.5 Billion dollars per year to operate
 Consume 10% of all electricity in US
 Constitute 16% of industrial motor systems
 Are located in 70% of the manufacturing plants
 Represent the “fourth utility” in an industrial facility
 Have low system efficiencies (10%-15%)
 Savings can range from 15% to 60% of existing
compressed air energy usage in most cases
WHY IS COMPRESSED AIR IMPORTANT?
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4.  Initial Interview
 Facility Walk Through
 Installation of Data Loggers
 Detailed Investigation of Opportunities
 Analytical Assessment
 Report Generation
STEPS IN COMPRESSED AIR ASSESSMENT
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Off Site
Data collection
(On Site)

5.  Funded by the Department of Energy
 Provided by the Best Practices Initiative of the Office of
Industrial Technologies (OIT)
 Stand alone windows based software
 Analysis of multiple facilities and compressors can be
conducted
 Extensive database of generic compressors
 Simulates existing and proposed case energy use
 Uses hourly flow or power data
 Individual and Interactive measure analysis capability
 Life cycle cost analysis can be performed
AIRMASTER+ BACKGROUND AND
CAPABILITIES
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6.  Eleven (11) Modules
AIRMASTER+ MODULES
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7.  Information: Address, Contact
COMPANY MODULE
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8.  Information: Utility Information and Rate Schedules
UTILITY MODULE
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9.  Information: Facility Address and Applicable Rate Schedules
FACILITY MODULE
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10.  Information: Receiver Volume, Daytypes and End Use Database
SYSTEM MODULE
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11.  Information: Compressor Details
COMPRESSOR MODULE
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12.  Information: Input Data for Modeling
PROFILE MODULE
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13.  Analysis of Various Measures
ENERGY EFFICIENCY MEASURES
MODULE
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14.  Maintenance Module
• Provides central location for keeping a
maintenance log
 Catalog Module
• Keeps a database of compressors that can
be used for future use
 Life Cycle Cost Module
• Useful life cycle analysis tool
 Print Data Input Forms Module
• Provides printable data collection forms for
different phases of an assessment
OTHER MODULES
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15. INTEGRATION OF AIRMASTER+ IN AN ASSESSMENT
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 Initial Interview
 Facility Walk Through
Print Data Input
Forms Module
Company,
Utility and
Facility Modules

16. INTEGRATION OF AIRMASTER+ IN AN ASSESSMENT
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 Data Logging
 Final Site Visit
Profile and
Compressor Modules
Print Data Input
Forms Module

17. INTEGRATION OF AIRMASTER+ IN AN ASSESSMENT
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 Analysi
s
Print Data Input Forms Module
and other Modules
Efficiency Measures Module
• Reduce Air Leaks
• Improve End Use Efficiency
• Reduce System Air Pressure
• Use Unloading Controls
• Adjust Cascading Set Points
• Use Automatic Sequencer
• Reduce Run Time
• Add Primary Receiver Volume

18.  Provides standardized analysis software that is user
friendly
 Excellent database of compressors with performance
curves
 Facilitates management of multiple compressors and
facilities
 Provides ability to run comparative scenarios
 Easily facilitates interactive analysis of various
measures
 Results available in easy to print reports
 Offers handy calculators for receiver capacity, cycle
times, and SCFM to ACFM calculation
STRENGTHS OF AIRMASTER+
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19.  Static analytical tool
 Does not provide performance curves for VFD compressors
 Does not analyze compressed air treatment opportunities
 Complicated rate structures are hard to input
 Loadings for the proposed case scenarios are shifted without
user prompts
 There is no control over distribution of leak load over day-types
 Does not have the ability to investigate flow controllers
 Compressor curves are generic
 Software algorithms are not described in the manuals
SUGGESTIONS FOR IMPROVEMENT OF
AIRMASTER+
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20. Manufacturer of Custom Thin Film Metals
Funded by NSTAR Electric
 Existing Compressor Plant
• One 125 HP and two 100 HP rotary screw variable
displacement compressors
• 7 days per week operation
• Pressure based compressor controls
• 1,000 CFM refrigerated dryer
• Receiver capacity: 1200 gallons
 Application: Pneumatic actuations, particulate blow
offs
CASE STUDY – ALLEGHENY RODNEY
METALS
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21. CASE STUDY – ALLEGHENY RODNEY METALS
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 Data Collection Process
• Initial site interview and walk through
• Measures are identified
• Power monitoring using HOBO 4-channel loggers
• Final walk through to characterize end uses and collect loggers
Analysis Process
• Entering data in AIRMaster+
• View results and verify accuracy
• Assess identified measures

22.  Measures
• EEM-1 Reduce Compressor Pressure Set Points
• EEM-2 Install Efficient Compressed Air Nozzles
• EEM-3 Install Solenoid Valves on all Furnaces and
Milling Machines
• EEM-4 Replace Pneumatically Driven Pumps
• EEM-5 Repair Tagged Compressed Air Leaks
• EEM-6 Install Blower Air-Wipe Systems
• EEM-7 Compressed Air System Optimization
Measure
CASE STUDY – ALLEGHENY RODNEY METALS
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23. ALLEGHENY RODNEY METALS – SAVINGS SUMMARY
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Energy Demand Installed Annual Simple
Savings Reduction Cost Cost Payback
Energy Efficiency Measure (kWh) (kW) $ Savings (Years)
EEM-1 Reduce Compressor Pressure Setpoints 64,970 7.4 $0 $5,894 0.0
EEM-2 Install Efficient Compressed Air Nozzles 130,936 14.9 $260 $11,879 0.0
EEM-3 Install Solenoid Valves on Furnaces and Milling M/Cs 26,817 0.0 $500 $2,226 0.2
EEM-4 Replace Pneumatically Driven Pumps 20,846 3.7 $1,500 $1,977 0.8
EEM-5 Repair Tagged Compressed Air Leaks 46,453 5.5 $1,725 $4,307 0.4
EEM-6 Install Blower Air-Wipe Systems 248,247 30.3 $8,444 $22,633 0.4
EEM-7 Compressed Air System Optimization Measure 739,918 84.6 $78,129 $73,208 1.1

24.  Useful and efficient tool
 Contains extensive database of compressor performance
 User friendly
 Easy interactive analysis of measures based on hourly profiles
for different day-types.
 Could not be used in special instances of end use analyses
 Augmentation to the software is recommended to include
specific end-use analyses options (nozzles, blower alternatives,
etc.) as well as for dryers and VFD compressors.
 Additionally, analysis methodology and supporting algorithm
documentation should be made available.
 Overall, we believe AIRMaster+ is a powerful tool that provides
a standardized methodology for compressed air analysis.
CONCLUSION
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