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 ers 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.
- 6. AIRMaster+ Modules Eleven (11) Modules ers energy&resource solutions © 2003 Energy and Resource Solutions, Inc.
- 7. Company Module Information: Address, Contact ers energy&resource solutions © 2003 Energy and Resource Solutions, Inc.
- 8. Utility Module Information: Utility Information and Rate Schedules ers energy&resource solutions © 2003 Energy and Resource Solutions, Inc.
- 9. Facility Module Information: Facility Address and Applicable Rate Schedules ers energy&resource solutions © 2003 Energy and Resource Solutions, Inc.
- 10. System Module Information: Receiver Volume, Daytypes and End Use Database ers energy&resource solutions © 2003 Energy and Resource Solutions, Inc.
- 11. Compressor Module Information: Compressor Details ers energy&resource solutions © 2003 Energy and Resource Solutions, Inc.
- 12. Profile Module Information: Input Data for Modeling 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.
- 25. Questions?? ers energy&resource solutions © 2003 Energy and Resource Solutions, Inc.