COMPREHENSIVE COMPRESSED AIR

ASSESSMENTS: THE 5-STEP PROCESS

NEIL MEHLTRETTER, ENGINEERING MANAGER

KAESER COMPRESSORS INC.
TOPICS
• Why do an air audit?
• 5 Basic Steps to an Audit
• What you should achieve?
COMMON COMPONENTS OF WASTE IN INDUSTRIAL PLANTS

Downtime Scrap

Rework Energy
COMPRESSED AIR IN CONTEXT
• Air Quality and Air Treatment in Compressed Air Systems

Compressed air is
used in more than
70% of all
manufacturing
activities.
50% OF ALL COMPRESSED AIR GENERATED IS WASTED
76% OF A COMPRESSOR’S LIFE CYCLE COSTS IS ELECTRICITY
AIR ASSESSMENTS

• Do you have enough compressed air?

• Do you have the right operating
pressure?
• Do you have the correct air quality?
• Is your system reliable?
• Is your system efficient?
WHY DO A COMPRESSED AIR AUDIT?

Detailed demand profile Actual power consumption

Determine
optimal system Identify leaks and
Baseline existing system
non-productive losses
WHAT TO LOOK FOR IN AN AIR AUDITOR
• Someone you can trust
• Sufficient experience
• Understands your needs and goals
• Gets out of the compressor room
• Identifies problems and solutions
• May not include new compressors
• Focuses on optimization
STEPS TO A COMPREHENSIVE AIR ASSESSMENTS
• Conduct a site survey
1

• Measure and quantify kW / 100 cfm

2

• Understand the system dynamics

3

• Implement a recommendation to improve kW / 100 cfm

4

• Verify performance of kW / 100 cfm

5
STEP 1: CONDUCT A SITE SURVEY
• What do you spy?
• What’s important?
• Take notes
• Take pictures
• Take measurements
• Ask multiple people
STEP 1: CONDUCT A SITE SURVEY
• Where to install measurement equipment?
• Compressor room
• Points of use
• What types of equipment to install?
• Pressure
• Flow
• Power
• Other?
STEP 1: CONDUCT A SITE SURVEY
• Why get outside the compressor room(s)?
87 psig
• Pressure profile
59 psig
• High demand events
• Point of use air quality
• Solving plant problems involves the plant
not just the compressor room

89 psig 99 psig

Max. 102 psig

CASE STUDY: SITE SURVEY
Compressor Room #1
• (1) Compressor #1, 60 hp, water-cooled screw
compressor with modulation control - Rated 267 cfm
at 125 psig
• (1) 240-gallon storage receiver prior to air treatment
• Refrigerated air dryer with one pre-filter and two
afterfilters
CASE STUDY: SITE SURVEY
Compressor Room #2
• (1) Compressor #2, 50 hp, air-cooled screw
compressor with modulation control - rated 215
cfm at 125 psig
• (1) Compressor #3, 75 hp, air-cooled screw
compressor with modulation control - rated at 350
cfm at 125 psig
Note: offline during testing period
• (1) Refrigerated air dryer with pre-filter and
afterfilters
• (1) 240-gallon storage receiver after air treatment
STEP 2: MEASURE AND QUANTIFY KW / 100 CFM
• Key Performance Index (KPI) – specific power
• Power
• Flow
• Pressure
• Target 21 kW / 100 cfm or under
• Nights, weekends, holidays
CASE STUDY: MEASUREMENT & QUANTIFY
• Compressor 1
• Flow meter downstream of dryer
• Pressure after dryer
• Power into unit
• Compressor 2
• Flow via proportional valve
• Pressure after dryer
• Power into unit
• Quantify
• Existing KPI: 32.14 kW/ 100 cfm
STEP 3: UNDERSTAND THE SYSTEM DYNAMICS
• What is causing plant issues?
• Pressure variability
• Compressor reliability
• Piping size
• High intermittent demand events
• Inefficient uses of compressed air
• Compressors fighting each other
• … 2” Main Header

2” Distribution
CASE STUDY: THE SYSTEM’S DYNAMICS
• Units fighting each other
• Pressure drop varies
• Can one unit operate the plant?
CASE STUDY: THE SYSTEM’S DYNAMICS
• One unit unable to meet demand
• Low overall system pressure
• Pressure drop between sides
• Back flow
• Leakage
CASE STUDY: CALCULATING SPECIFIC POWER KPI
Description Compressor 1 (60 hp) Compressor 2 (50 hp)
Annual Flow (cf/year) 55,112,752 72,914,530
Annual Energy Consumption 347,282 kWh/yr 338,523 kWh/yr
Energy Cost 0.065 $/kWh
Annual Energy Costs $22,573/yr $22,004/yr
Specific Power KPI 37.81 kW/100 cfm 27.86 kW/100 cfm

Existing System Annual Energy Cost $44,577/yr

Existing System Specific Power 32.14 kW/100 cfm
STEP 4: IMPLEMENT A RECOMMENDATION TO
IMPROVE KW / 100 CFM
• Typical system improvements
• Replace compressors
• Add VFD compressor(s)
• Add fixed speed compressor(s)
• Add storage
• Add flow controller
STEP 4: IMPLEMENT A RECOMMENDATION TO
IMPROVE KW / 100 CFM
• Fix leaks!
• Augment piping, if necessary
• …
STEP 4: IMPLEMENT A RECOMMENDATION TO
IMPROVE KW / 100 CFM
• Fix leaks!
• Augment piping, if necessary
• Address system controls
• Address system operating pressure
• …
STEP 4: IMPLEMENT A RECOMMENDATION TO
IMPROVE KW / 100 CFM
• Fix leaks!
• Augment piping, if necessary
• Address system controls
• Address system operating pressure
• Hours of operation
• ...
STEP 4: IMPLEMENT A RECOMMENDATION TO
IMPROVE KW / 100 CFM Dilute Phase
Conveying
• Fix leaks!
• Augment piping, if necessary
• Address system controls
• Address system operating pressure Open Blowing Personal Cooling

• Hours of operation
• Inefficient uses of compressed air
• …

Vacuum Venturi Diaphragm pumps

STEP 4: IMPLEMENT A RECOMMENDATION TO
IMPROVE KW / 100 CFM
• Fix leaks!
• Augment piping, if necessary
• Address system controls
• Address system operating pressure
• Hours of operation
• Inefficient uses of compressed air
• Storage
• Notice no equipment replacement yet?
CASE STUDY: RECOMMENDATIONS IMPLEMENTED
• Reconfigured the piping to eliminate pressure losses and air leaks

New 3” aluminium piping

CASE STUDY: RECOMMENDATIONS IMPLEMENTED
• Reconfigured the piping to eliminate pressure losses and air leaks
• Removed Compressor #3
• Retained Compressors #1 and #2 for back-up
CASE STUDY: RECOMMENDATIONS IMPLEMENTED
• Reconfigured the piping to eliminate pressure losses and air leaks
• Removed Compressor #3
• Retained Compressors #1 and #2 for back-up
• Increased storage with a 1040 gallon dry tank
CASE STUDY: RECOMMENDATIONS IMPLEMENTED
• Reconfigured the piping to eliminate pressure losses and
air leaks
• Removed Compressor #3
• Retained Compressors #1 and #2 for back-up
• Increased storage with a 1040 gallon dry tank
• Installed a 55 kW VFD, air-cooled, rotary screw air
compressor
STEP 5: VERIFY PERFORMANCE OF KW / 100 CFM
• Key Performance Index (KPI) – specific power
• Power
• Flow
• Pressure
• Target 21 kW / 100 cfm or under
• Nights, weekends, holidays
• Take pictures
HOW TO VERIFY SYSTEM PERFORMANCE
• Stable pressure
• Minimal pressure drop
• VFD within 40%-85% of range
• Off nights and weekends
CASE STUDY
Description Proposal Estimate Verification
Annual Flow (cf/year) 128,010,406 130,600,442
Original System: Energy Consumption 685,792 kWh/yr -/-
New System: Energy Consumption 395,942 kWh/yr (est.) 404,822 kWh/yr
Annual Energy Savings 289,850 kWh/yr (est.) 294,846 kWh/yr
Energy Cost 0.065 $/kWh 0.065 $/kWh
Original System: Energy Cost $44,577/yr -/-
New System: Proposed Energy Cost $25,736/yr (est.) $26,313/yr
Annual Energy Savings $18,840/yr (est.) $19,165/yr
Original System: Specific Power KPI 32.14 kW/100 cfm -/-
Specific Power KPI 18.56 kW/100 cfm (est.) 18.60 kW/100 cfm
NOW WHAT?
• Continuous monitoring
• Status messages: alarm and warning
• Heartbeat
• Key performance index
• Leaks?
• Through individual controllers
or master controller
IN CONCLUSION
• Conduct a site survey
• Know your system 1
• Involve all parties within plant
• Measure and quantify kW / 100 cfm
• Include a compressed air system expert 2
• Collect data
• Understand the system dynamics
• Evaluate data 3
• Implement improvements
• Verify performance • Implement a recommendation to improve kW / 100 cfm
4
• Continuously monitor
• Verify performance of kW / 100 cfm
5
ADDITIONAL BENEFITS TO AN AIR DEMAND ASSESSMENT

 Reduce energy costs; increase productivity

 Identifying and eliminating inefficiencies
 Lower maintenance costs
 Minimize downtime
 Qualify for utility rebate programs
 Reduce production scrap/waste
 Reduce production equipment maintenance costs
 Reduce your carbon footprint
THANK YOU! Additional Resources
o us.kaeser.com/whitepapers: white papers on
leaks, audits, controls, and more
o us.kaeser.com/fixleaks: air leak audit and
detection program
o us.kaeser.com/ada: Air Demand Analysis—air
audits
o us.kaeser.com/resources: more resources
including a Compressed Air Engineering
Handbook
o www.kaesertalksshop.com: technical blog
o www.compressedairchallenge.org: Compressed
Air Challenge