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Airmasterpresentation
- 1. Application of AIRMaster+ in Real
Industrial Facilities
presented by
Satyen Moray
ERS
ACEEE Summer Study on Energy Efficiency in Industry
August 2003
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 2. Overview
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 3. Why is Compressed Air Important?
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 4. Steps in Compressed Air Assessment
Initial Interview
Facility Walk Through
Installation of Data Loggers
Data collection
(On Site)
Detailed Investigation of Opportunities
Analytical Assessment
Report Generation
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energy&resource solutions
Off Site
© 2003
Energy and Resource Solutions, Inc.
- 5. AIRMaster+ Background and Capabilities
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 13. Energy Efficiency Measures Module
Analysis of Various Measures
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 14. Other Modules
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 15. Integration of AIRMaster+ in an
Assessment
Print Data Input
Forms Module
Initial Interview
Facility Walk Through
Company,
Utility and
Facility Modules
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 16. Integration of AIRMaster+ in an
Assessment
Print Data Input
Forms Module
Data Logging
Final Site Visit
ers
Profile and
Compressor Modules
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 17. Integration of AIRMaster+ in an
Assessment
Print Data Input Forms Module
and other Modules
Efficiency Measures Module
Analysis
• 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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 18. Strengths of AIRMaster+
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 19. Suggestions for Improvement of
AIRMaster+
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 daytypes
Does not have the ability to investigate flow controllers
Compressor curves are generic
Software algorithms are not described in the manuals
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 20. Case Study – Allegheny Rodney Metals
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 21. Case Study – Allegheny Rodney Metals
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 22. Case Study – Allegheny Rodney Metals
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
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
- 23. Allegheny Rodney Metals – Savings Summary
Energy Efficiency Measure
EEM -1 Reduce Compressor Pressure Setpoints
EEM -2 Install Efficient Compressed Air Nozzles
EEM -3 Install Solenoid Valves on Furnaces and M illing M /Cs
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 M easure
ers
energy&resource solutions
Energy
S avings
(kWh)
64,970
130,936
26,817
20,846
46,453
248,247
739,918
Demand
Reduction
(kW)
7.4
14.9
0.0
3.7
5.5
30.3
84.6
Installed
Cost
$
$0
$260
$500
$1,500
$1,725
$8,444
$78,129
© 2003
Annual
Cost
S avings
$5,894
$11,879
$2,226
$1,977
$4,307
$22,633
$73,208
S imple
Payback
(Years)
0.0
0.0
0.2
0.8
0.4
0.4
1.1
Energy and Resource Solutions, Inc.
- 24. Conclusion
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.
ers
energy&resource solutions
© 2003
Energy and Resource Solutions, Inc.
