IAC ENERGY WORKSHOP June 23, 2006

Douglas A. Hopper

AIR COMPRESSORS
AIR COMPRESSOR
IMPROVEMENTS
By Douglas A. Hopper
and Michael Kostrzewa
June 23, 2006
Save Energy Now Workshop
June 23, 2006

Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

Types of Air Compressors

Rotary Screw (most common)

Reciprocating (looks like an engine, pistons)

Oil lubricant (or not)

Most economical
Oil lubricant (or not)
Low duty cycle (<50%)

Centrifugal (high hp)

June 23, 2006

Impeller driven
No lubricant
Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

System Components
Air compressor: Motor, Air End, Coolant
Control Panel: monitoring, set points
Lubricant/Air Separator (oil contaminant)
Dryer (desiccant or refrigerant)
Air storage (receiver, piping, and end use)
Filters and pressure regulators
End use equipment (specifications)

June 23, 2006

Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

Features of Air Systems

80 to 85% of energy is output as heat
Higher hp motor is more efficient

Tend to be oversized for plant expansion

Roughly 4 cfm per hp rating

Air storage may be limiting

Short cycling of compressor

Leaks at major fittings or equipment

Employees think it is free air

June 23, 2006

Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

Typical System at a Plant

50 to 200 hp units; 24/5 or 24/7 hours
Primary unit and a backup unit
100 psig at the compressor
Air storage receiver (150 to 1,500 gal)
Lead/lag or modulating controls
One dryer (desiccant or refrigerant)
Vent to outside air (excess heat, inlet air)
20 to 30% hp lost to air leaks

June 23, 2006

Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS
Plant System
Operation:
Power Used

PLANT 550 COMPRESSOR LOADS

Thursday, June 3, 2004 - Monday, June 14, 2004

45

15-MINUTE LOAD, kW

Douglas A. Hopper

40
35
30
25
20
15
10
5

6/14/04
11:45 AM

6/13/04
11:45 AM

6/12/04
11:45 AM

6/11/04
11:45 AM

6/10/04
11:45 AM

6/9/04
11:45 AM

6/8/04
11:45 AM

6/7/04
11:45 AM

6/6/04
11:45 AM

6/5/04
11:45 AM

6/4/04
11:45 AM

0
6/3/04
11:45 AM

Operate with
Production
Possibly shut off
at night

TIME (hr:min)

CSU IAC PLANT 537 AIR PRESSURE at Amada Pulsar 1212XL

Thurday, August 21, 2003 - Thursday, September 4, 2003
140
120

Laser Air Pressure, psig

100
80
60
40
20
0
8/21 8/22 8/23 8/24 8/25 8/26 8/27 8/28 8/29 8/30 8/31
TIME (hr:min)

June 23, 2006

Photo by: Douglas A. Hopper

9/1

9/2

9/3

9/4

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

Pressure Variation

Pressure, psig

120

IAC 531: Cooper Turbocompressor 250 hp Air Compressor

June 18 - 19, 2003

110

100

90
16:00 18:00 20:00 22:00

0:00

2:00

4:00

6:00

8:00

10:00 12:00 14:00 16:00

TIME (hr:min)

June 23, 2006

Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

Control Strategies: Systems Approach

Match supply with demand

Individual compressor controls

June 23, 2006

Avoid short-cycling or blowing off excess

Start/stop
Load/unload (not deliver air in unload)
Modulating match delivery to demand
Restrict inlet flow or vary controls
Variable frequency drive (VFD)
Reduce speed with low demand
From: Compressed Air Tip Sheet #7
Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

Control Strategies: Systems Approach

Multiple compressor controls

Pressure/flow controllers

June 23, 2006

Lead/lag: one compressor is primary

One fully loaded, others as trim
System master controller: coordinates all units
Monitor with trending data
Separate supply from demand side
Requires storage
Deliver air at lowest stable pressure
From: Compressed Air Tip Sheet #7
Photo by: Douglas A. Hopper

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

10

Seven Step Action Plan

Basic Block Diagram
Measure baseline; calculate use and costs
Control strategy aided by specialist
Determine energy, pressures, and leak load
Schedule preventative maintenance (PM)
Fix inappropriate uses; adjust controls
Evaluate performance, inform management

June 23, 2006

Photo by: Douglas A. Hopper

10

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

11

Top Recommendations
Repair Air Leaks
Shut Off Compressors When Not Needed
Install a Smaller Compressor
Use Waste Heat in Another Area
Use Outside Air for Inlet Air
Lower Pressure Set Points
Reduce Inappropriate Uses of Air
Install a VFD with Control System

June 23, 2006

Photo by: Douglas A. Hopper

11

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

12

Cost of Air Leaks vs. Hole Size

COST OF ENERGY LOST TO AIR LEAKS
$8,000

Energy and Demand Costs, per yr

$7,000

$6,000
$5,000

$4,000
$3,000
$2,000

$1,000
$0
0

1/32

1/16

3/32

1/8

5/32

3/16

7/32

1/4

Leak Diameter, inches

June 23, 2006

Photo by: Douglas A. Hopper

12

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

13

Uses and Inappropriate Uses

Pneumatic controls

Electronic alternatives: microcontrollers

Equipment actuators
Electric or hydraulics
Blowers: lower pressure

Cooling cabinets or equipment

Blowers/fans use lower power

Blow off equipment vs. brushes

June 23, 2006

Photo by: Douglas A. Hopper

13

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

14

Uses and Inappropriate Uses

Fluid agitation

Vacuum creation

Blowers usually as effective

Use an actual vacuum system

Pneumatic tools: grinders, drills, wrenches

Electric usually as effective, but heavier
Hazardous environment may use air vs. electric

June 23, 2006

Photo by: Douglas A. Hopper

14

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

15

Preventative Maintenance
Periodic changes of filters/lubricants
Monitor pressure/power
Operate/test backup systems
Maintain dryer, separator, and storage
Check condensate drain traps
Repair air leaks; keep records
Manufacturer representative checkup

From: Best Practices for Compressed Air Systems

June 23, 2006

Photo by: Douglas A. Hopper

15

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

16

AIRMaster+ Software
Objective performance assessment
Model supply side and electrical demands
Efficient and systematic approach
Impact of potential changes

Control strategy
Adding air storage
Compressor replacement

from: Best Practices for Compressed Air Systems

June 23, 2006

Photo by: Douglas A. Hopper

16

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

17

Summary
Universal need for compressed air
Major use of energy at most plants
20 to 30% hp lost to air leaks
Preventative maintenance needed
Uses and appropriate uses
Control strategies influence efficiency

June 23, 2006

Photo by: Douglas A. Hopper

17

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

18

Questions?
Benefits of storage?
Air compressor energy efficiency?
Oil and condensate removal methods?

Discussion

June 23, 2006

Photo by: Douglas A. Hopper

18

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

19

DOE Air Compressor Performance Tools

Sourcebook available to help

designers & operators improve
air compressor system
performance through better
compressor selection and
improved operation &
maintenance practices.

AIRMaster+ available on Save

Energy Now CD
June 23, 2006

Photo by: Douglas A. Hopper

19

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

June 23, 2006

Photo by: Douglas A. Hopper

Douglas A. Hopper

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IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

21

Interval data (30 seconds) for System (Trim, Baseload, System) and Periods (Baseline)
4/ 20/ 2006 12:45:44 PM to 4/ 26/ 2006 7:39:04 AM

amps

psi

300

130

120

110

200

100

90

100hp amp (amps)

150hp amp (amps)
Pressure (psi)

80

100

70

60

50

June 23, 2006

Photo by: Douglas A. Hopper

26
W
ed

25
Tu
e

24
M
on

23
Su
n

Sa
t2
2

Fr
i2
1

40

21

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

June 23, 2006

Photo by: Douglas A. Hopper

Douglas A. Hopper

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22

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

23

Partial Hourly Results Production Days

150 hp Base Load
Calc Power, kW
Calc Airflow, acfm
Calc %Capacity
Cascade #
100 hp Trim
Calc Power, kW
Calc Airflow, acfm
Calc %Capacity
Cascade #
Total Power, kW
Total Airflow, acfm
% System Capacity

June 23, 2006

120.8
664
100
1

122.3
664
100
1

119.3
664
100
1

119.6
664
100
1

0.8
4
0.9
2

0.1
0
0.1
2

0.1
0
0.1
2

0.1
0
0.1
2

121.6
668
60.2

122.3
664
59.9

119.3
664
59.9

119.6
664
59.9

Photo by: Douglas A. Hopper

23

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

24

Partial Hourly Results Non-Production Days

150 hp Base Load
Calc Power, kW
Calc Airflow, acfm
Calc %Capacity
Cascade #
100 hp Trim
Calc Power, kW
Calc Airflow, acfm
Calc %Capacity
Cascade #
Total Power, kW
Total Airflow, acfm
% System Capacity

June 23, 2006

0
0
0
0

0
0
0
0

0
0
0
0

0
0
0
0

74.1
377
84.7
1

74.3
379
85
1

74.6
380
85.3
1

74.8
381
85.5
1

74.1
377
34

74.3
379
34.1

74.6
380
34.2

74.8
381
34.4

Photo by: Douglas A. Hopper

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IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

25

Annual Results
Total
Motor
Operating Average Average
Load
Hours
Airflow Airflow
Factor
Daytype
per yr
acfm
% System % Rated
Production
7,488
658
59.3%
58.3%
Non-Production
1,272
375
33.8%
36.0%
System Totals

June 23, 2006

8,760

516

46.6%

Photo by: Douglas A. Hopper

47.1%

Annual Annual
Energy Energy
Consmpt'n
Cost
kWh/yr per year
892,781 $30,765
93,633 $3,227
986,414 $33,992

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IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

26

AIRMaster+ Features
Builds a model of compressed air system
Use the model for what-if scenarios
Helpful calculators to estimate:

SCFM to ACFM
Air storage capacity
Elevation correction
Cycle time

June 23, 2006

Photo by: Douglas A. Hopper

26

IAC ENERGY WORKSHOP June 23, 2006

AIR COMPRESSORS

Douglas A. Hopper

27

AIRMaster+ Limitations
Fair amount of data required
Uses hourly performance data

Doesnt tell full story of compressor operation

or compressed air system performance

Doesnt make user a compressor expert!

June 23, 2006

GIGO means WYSIWYG

Photo by: Douglas A. Hopper

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