Index

............................................................................................................................................

1 Compressed air area ..................................................................................................

1.1 Executive summary ..........................................................................................

1.2 State of the art ...................................................................................................

1.2.1 Compressed air production centre ................................................................

1.2.2 Compressed air network ...............................................................................

1.3 Compressors measurement ...............................................................................

1.3.1 Compressor GA1408 n°1 .............................................................................

1.3.2 Compressor GA1408 n°2 .............................................................................

1.3.3 Compressor ZR200 ......................................................................................

1.3.4 Compressor ZR315 n°1 ................................................................................

1.3.5 Compressor ZR315 n°2 ................................................................................

1.3.6 Compressor ZR315 n°3 ................................................................................

1.3.7 Compressor ZR315 n°4 ................................................................................

1.3.8 Air leak evaluation .......................................................................................

1.4 Energy consumption of the area .......................................................................

1.5 Economic analysis ............................................................................................

1.5.1 Compressor driven by inverter .....................................................................

1.5.2 Compressors maintenance ............................................................................

1.5.3 Leaks prevention ..........................................................................................

1.5.4 System pressure ............................................................................................

1.5.5 Compressor cooling system .........................................................................

1.6 Conclusions ......................................................................................................

Compressed air area
 1.1 Executive summary

In this report, results regarding compressed air system have been reported together with
energy saving proposal definition.

Some investigations have been conducted in order to measure the electric consumptions
of the compressors and the amount of compressed air lost through lacks in the network.

Evaluation of installation of compressor equipped with inverter, evaluation of cost of air

production and cost of lacks through the network have been also reported, together with cost of
compressor cooling water.
 1.2 State of the art

1.2.1 Compressed air production centre

Compressed air production centre is equipped by 4 compressors Atlas Copco ZR315, 1
compressor Atlas Copco ZR200 and 3 compressors Atlas Copco GA1408. Compressors type
ZR315 and ZR200 have been recently installed. All compressed air produced by compressors
passes through 3 dryers Atlas Copco ZD2000, also recently installed. The air produced is sent to
the plant.

At the moment, the system used to control the compressed air production is semi-
automatic and allows only an on-off regulation of the all compressors. It detects the pressure
inside the manifold and maintains it inside a preset range (6,8÷7,2 bar). Normally, production
centre knows the air demand of the plant and turns on the compressors necessary to satisfy it. The
regulation is done by an on-off control of one compressor, while the remaining compressors are
kept in operation at full load. The on-off controlled compressor is normally an Atlas Copco
GA1408 type. In this configuration the manifold pressure is not constant, but varies within the
range 6,8÷7,2 bar, based on the air required by the industrial plant and on the air production.
Figure 0-1 shows the lay out of the production centre and it can be noted that the air produced by
compressor flows through the dryers and feeds the network.

Figure 0-1: Lay out of compressed air production centre

1.2.2 Compressed air network
Compressed air is sent to the factory through 5 main pipelines (5 inches diameter). These
pipelines are separated from each other and supply different areas of the factory:

1. Injection molding area;

2. Assembly lines;
3. Drum line, maintenance area, cutting centre and modeling area;
4. Varnishing area and plate presses;
5. Packaging area.

Pipelines are connected to the same manifold and receive air at the same pressure.
Moreover pipelines are not equipped by flow meter, so the amount of air sent to each line is not
known.

Figure 0-2 shows the lay out of the compressed air network.
Figure 0-2: Lay out of the compressed air network
 1.3 Compressors measurement

The compressors energy consumptions have been measured in order to evaluate the total
consumption of the area, the specific consumption of each compressor, the specific cost of a cube
meter of air and the cost of air losses along the network.

Compressors are not equipped with flow meter and an air production at full load (as
reported in the compressor catalogue) has been considered in the following measurements.

Free air delivered at 7,5 bar:

GA1408 20 m3/min

ZR200 36,4 m3/min

ZR315 51,3 m3/min

The capacity of a compressor is defined as the full rated volume of compressed air flowed
and delivered under conditions of total temperature, total pressure and composition prevailing at
the compressor inlet. It can be considered that the values presented above are the flows of air sent
to the network when the compressors work. When they are in idle, the air sent to the network is
equal to zero even if the electric consumption is not null. While a compressor is in idle, electric
motor spins freely and the compressor (the screw) is off.

Analyzer installed in each electrical station have been used to collect the energy
consumption along a month. The analysis of this data allows to know how many hours the
compressors work and also the total energy consumption of the compressed air area.
1.3.1 Compressor GA1408 n°1
Maximum air flow at 7,5 bar: 20 m3/min

Motor power: 135 kW

Water cooling consumption 1,9 l/s

Figure 0-3: Power profile of compressor GA1408 n°1

Table 0-1: Results of analysis of compressor GA1408 n°1

Average energy consumption 100 kWh/h
Average air delivered 13,36 m3/min
Maximum power 133 kW
Minimum power 30,3 kW
1.3.2 Compressor GA1408 n°2
Maximum air flow at 7,5 bar: 20 m3/min

Motor power: 135 kW

Water cooling consumption 1,9 l/s

Figure 0-4: Power profile of compressor GA1408 n°2

Table 0-2: Results of analysis of compressor GA1408 n°2

Average energy consumption 81,07 kWh/h
Average air delivered 6,00 m3/min
Maximum power 157 kW
Minimum power 41,3 kW
1.3.3 Compressor ZR200
Maximum air flow at 7,5 bar: 36,4 m3/min

Motor power: 200 kW

Water cooling consumption 3 l/s

Figure 0-5: Power profile of compressor ZR200

Table 0-3: Results of analysis of compressor ZR200

Average energy consumption 150,76 kWh/h
Average air delivered 23,23 m3/min
Maximum power 219 kW
Minimum power 39 kW
1.3.4 Compressor ZR315 n°1
Maximum air flow at 7,5 bar: 51,3 m3/min

Motor power: 315 kW

Water cooling consumption 4,4 l/s

Figure 0-6: Power profile of compressor ZR315 n°1

Table 0-4: Results of analysis of compressor ZR315 n°1

Average energy consumption 318,47 kWh/h
Average air delivered 51,3 m3/min
Maximum power 320,9 kW
Minimum power 316,8 kW
1.3.5 Compressor ZR315 n°2
Maximum air flow at 7,5 bar: 51,3 m3/min

Motor power: 315 kW

Water cooling consumption 4,4 l/s

Figure 0-7: Power profile of compressor ZR315 n°2

Table 0-5: Results of analysis of compressor ZR315 n°2

Average energy consumption 316,1 kWh/h
Average air delivered 51,3 m3/min
Maximum power 319,1 kW
Minimum power 314,0 kW
1.3.6 Compressor ZR315 n°3
Maximum air flow at 7,5 bar: 51,3 m3/min

Motor power: 315 kW

Water cooling consumption 4,4 l/s

Figure 0-8: Power profile of compressor ZR315 n°3

Table 0-6: Results of analysis of compressor ZR315 n°3

Average energy consumption 285,3 kWh/h
Average air delivered 51,3 m3/min
Maximum power 286,6 kW
Minimum power 283,4 kW
1.3.7 Compressor ZR315 n°4
Maximum air flow at 7,5 bar: 51,3 m3/min

Motor power: 315 kW

Water cooling consumption 4,4 l/s

Figure 0-9: Power profile of compressor ZR315 n°4

Table 0-7: Results of analysis of compressor ZR315 n°4

Average energy consumption 289,6 kWh/h
Average air delivered 51,3 m3/min
Maximum power 292,0 kW
Minimum power 288,0 kW
1.3.8 Air leak evaluation
The compressed air is sent to the factory plant through five main pipelines, separated from
each other. During a day off some analysis have been performed in order to evaluate the amount
of air leaks in each of the 5 area supplied by the 5 pipelines.

The measurements of air leaks have been done by subtracting the amount of air required
by Rosa (that was always constant) from the compressed air produced by the compressors within
a certain range of time. Rosa is an external supplier of Electrolux sits inside the Porcia plant and
it uses the compressed air produced by the compressed air centre. The results of the evaluation
gives exactly the air wasted through leaks in the network, as all machines fed by compressed air
were turned off. Air leaks, in general, occur at joints, flange connections, elbows, reducing bushes,
sudden expansions, valve systems, filters, hoses, check valves, relief valves, extensions, and at
equipment connected to the compressed air lines.

The energy consumption of the compressor ZR315 n°4 has been evaluated in 6 cases,
when different users were fed. The cases were:

1. Rosa;
2. Rosa, injection molding area;
3. Rosa, assembly area;
4. Rosa, drum line, maintenance area, cutting centre and modeling area;
5. Rosa, varnishing area and plate presses area;
6. Rosa, packaging area.
Figure 0-10: Energy consumption of compressor n°4 – Case 1

Figure 0-11: Energy consumption of compressor n°4 – Case 2

Figure 0-12: Energy consumption of compressor n°4 – Case 3

Figure 0-13: Energy consumption of compressor n°4 – Case 4

Figure 0-14: Energy consumption of compressor n°4 – Case 5

Figure 0-15: Energy consumption of compressor n°4 – Case 6

 Air losses summary:

Table 0-8: Summary of air losses

Area Air consumption due
to leaks [m3/min]
Injection molding 11,67
Assembly area 13,13
Drum line, maintenance area, cutting centre and modeling area 12,52
Varnishing and plate presses 12,34
Packaging area 3,18

Table 0-8 shows the amount of waste compressed air in different areas when the line are
fed, but the factory is not in operation. The area that works well enough is the packaging one, in
fact it presents the lowest air losses. Other areas have a lot of dissipations, especially in the
connection close to the users. Other dissipations have been detected in valves, filters and so on.
 1.4 Energy consumption of the area

Thanks to the four analyzers installed in the compressed air area, it was possible to
evaluate the total energy consumption of the area and also to understand how many hours a day
compressors work. With this data it was then calculated the specific cost of compressed air
necessary to evaluate the energy and the economic savings obtainable thanks to the improvements
proposed. Data were collected during 4 weeks, between the end of August and the beginning of
September, when factory worked regularly 5 days a week, on 2 shifts.

The four TA analyzers were connected with four electrical stations which feed all
compressors of the area:

- Station 10: ZR315 n°3, 4, dryer n°3

- Station 27: GA1408 n°1, 2, 3, ZR200
- Station 31-1: ZR315 n°1
- Station 31-2: ZR315 n°2, dryers n°1, 2

Figure 0-16: Energy consumption, week 34

Figure 0-17: Energy consumption, week 35

Figure 0-18: Energy consumption, week 36

 Figure 0-19: Energy consumption, week 36

Figures presented above show that energy consumption is quite constant during working
days, while it diminishes on Saturday and it is almost zero on Sunday, except for few Sundays
when Rosa works. In Figure 0-19 it can be noted that there is a lower consumption on Wednesday.
The reason is that it was a day off.

With the data collected it is possible to consider a typical week as a reference. In this way,
detection of not motivated inefficiencies will be easier.

The analysis (on an average of 49 weeks per year) shows:

Hours per week Hours per Average power

year [kW]
ZR315 at full load 178 8.722 300
ZR 200 at full load 47 2.303 220
GA1408 at full load 143 7.007 140
GA 1408 at partial load 150 7.350 100

Average energy consumption per week: 94,8 MWh

Total yearly net energy consumption of compressed air area: 4.841 MWh/y
Total yearly cost of compressed air area: 510 k€/y

Figure 0-20: Energy consumption in a typical week

 1.5 Economic analysis

The results introduced in the previous paragraphs have been used to evaluate the cost of
compressed air produced in the area.

Cost of compressed air during a typical working day (2 compressors ZR315 at full load,
2 GA1408 at full load and 1 at partial load) (71% of the total time) 0,0110 €/m3

Cost of compressed air during a typical working night (2 GA1408 at full load and 1 at
partial load) (29% of the total time) 0,0138 €/m3

Average cost of compressed air: 0,0118 €/m3

1.5.1 Compressor driven by inverter

At the moment the regulation of the compressed air system is made by an on-off control
of one compressor GA1408. There are 3 compressors GA1408 installed inside the area. During
data collection have been measured only 2 compressors GA1408 (number 1 and 2) and it is
resulted that compressor number 1 absorbs 15% less than compressor number 2 at full load.

It has been evaluated the profitability of the installation of an inverter in one of the
compressor GA1408 (20 m3/min). Assuming that the same compressor would be equipped with
a drive, the free air delivered that can be regulated would be the 75% of the nominal flow (15
m3/min).

A simulation with and without inverter has been performed. In Figure 0-21 it can be seen
that a compressor with inverter needs as much power as one without inverter at full load and about
20% less at 25% of the load. So that, the energy saving due to the installation of the inverter is
strongly affected by the variation of the demand during the whole year. The evaluation of the
amount of energy and money savings due to the installation of drives has been performed
assuming that a compressor that regulates the air compressed systems works 7.350 hours per year
at 65% of load level.
 Figure 0-21: Simulation of GA1408 working at partial load with and without inverter

Table 0-9: Analysis of inverter installation

Average flow 13,36 m3/min
Power consumption at full load 133 kW
Power consumption at partial load 100 kW (-24%)
Power consumption at partial load with inverter 84,91 kW (-35%)
Energy yearly saving 136,9 MWh
Money early saving 14,4 k€

When the inverter is installed in almost one compressor, the pressure of the manifold will
be constant as well as the pressure of other compressors. This means that the reduction of energy
consumption can be achieved also by the compressors that work always at full load and it can be
estimated equal to 29 MWh and 3 k€ per year.

Total energy saving is: 164,3 MWh

Total money saving per year is: 17,4 k€

Investment cost: 80÷100 k€

1.5.2 Compressors maintenance
Over the investment lifetime of a compressor, the operating energy represents its greatest
cost. Nevertheless the maintenance in the compressor air area is very important because even if it
does not exceed the 6% of the total cost (as reported in literature), it allows to save energy and to
increase the reliability of the area.

Table 0-10 shows that compressors of the same kind need different amount of energy to
produce the same amount of air at the same conditions. This situation can be solved by planning
maintenance interventions in compressors that show performance losses.

Table 0-10: Summary of compressor power consumptions

Compressor Theoretical power Real power [kW] @ 7 Percentage
[kW] @ 7,5 bar bar
GA1408 n°1 135 133 Reference
GA1408 n°2 135 157 +18,04%

ZR315 n°1 315 318,5 +11,63%

ZR315 n°2 315 316,1 +10,79%
ZR315 n°3 315 285,3 Reference
ZR315 n°4 315 289,6 +1,51%

At the moment the compressors work alternatively and assuming that they can work better
after maintenance, the total energy that can be saved is reported below:

Hours per week Hours per Average power

year [kW]
ZR315 at full load 178 8.722 285
ZR 200 at full load 47 2.303 220
GA1408 at full load 143 7.007 135
GA 1408 at partial load 150 7.350 100

Average energy consumption per week: 91,6 MWh

Total yearly net energy consumption of compressed air area: 4.637 MWh/y

Total yearly cost of compressed air area: 490 k€/y

Annual saving is equal to 20 k€

Investment cost cannot be evaluated and investigation with the compressors supplier
(Atlas Group) need to be done.
1.5.3 Leaks prevention
In the Electrolux Porcia Plant, leaks are a significant source of wasted energy and
normally, during working day, 38% of a compressor’s output is wasted. In addition leaks can, by
being source of wasted energy, make air tolls less efficient and adversely affect production,
shorten the life of equipments, lead to additional maintenance requirements and increase
unscheduled downtime. To prevent performance losses, the plant asks to the air compressed centre
to increase the line pressure, and this produces further losses, and increases energy and
maintenance cost of compressed air area.

The cost of compressed-air leaks is the cost of the energy required to compress the volume
of lost air, from the atmospheric pressure to the line pressure.

This cost has been evaluated in Table 0-11, assuming 19 hours a day, 5 days per week,
and 49 weeks per year.

Table 0-11: Leaks costs

Area Consumption Cost Annual Annual cost
[m3/min] [€/min] hours [k€]
Injection molding 11,67 0,14 4.655 37,8
Assembly area 13,13 0,15 4.655 42,5
Drum line, etc. 12,52 0,15 4.655 40,5
Varnishing 12,34 0,14 4.655 39,9
Packaging 3,18 0,04 4.655 10,3

Total 52,84 171,2

Estimated cost of leaks is 171,2 k€/year (33,5%)

During air leaks measurements have been identified some air leaks that generally occur
at joints, flange connections, elbows, reducing bushes, sudden expansions, valve systems, filters,
hoses, check valves, relief valves, extensions, and at the equipment connected to the compressed-
air lines.

The cost of compressed-air leaks increases exponentially as the diameter of the leak
increases. Leaks should be repaired as soon as it is practical, and may easily be located through
their hissing when other plant operations are idle. In some situations, it may be necessary to wait
for a scheduled plant shutdown. Temporary repairs can often be made by placing a clamp over
the leak. The best way to detect leaks is to use an ultrasonic acoustic detector, which can recognize
the high frequency hissing sounds associated with the air leaks. Ultrasonic leak detection
equipment is an essential component to successful leak abatement programs. This equipment
facilitates the identification of even the smallest leak regardless of the baseline ambient noise
level in an industrial plant. Figure 0-22 shows and ultrasonic leak detector.

Figure 0-22: Ultrasonic leak detector

Total elimination of air leaks is impractical, but 40% leakage rate is considered
acceptable.

This elimination would save: 68,5 k€

Investment cost can be estimated equal to 30 k€

1.5.4 System pressure

The pressure that the assembly line requires is 6 bar and the manifold pressure is on an
average of 7 bar. The pressure measured near the assembly line is 6,2 bar, so that the pressure
drop occurs in the main pipelines, from air centre to the line. All other areas require air at a lower
pressure than assembly area.

Table 0-12: Manifold pressure VS saving money

Manifold pressure Saved Annual money % Saved Annual money
[k€]
7,0 Reference 0
6,8 -1,21% 6,50
6,6 -2,47% 13,23
6,4 -3,74% 20,04
6,2 -5,06% 27,07
6,0 -6,42% 34,35
 If the total line pressure could be lowered to 6 bar, after more evaluations, the total annual
saving would be of 34 k€

Investment depends on the improvements required to lower pressure drop in the line. If
there is an interest in this direction, more analysis can be done and cost of improvement will be
evaluated.

1.5.5 Compressor cooling system

The compressor need to be intercooled, in order to improve the compression efficiency.
At the moment the compressors are cooled through ground water, supplied by water pumps, at
about 10°C. After a settling period in a big tank where dirt settles and water temperature
diminishes, the water is wasted . Current cooling cost may be charged to the water pumps only
because at the moment the water is withdrawn from the ground at no cost.

Average energy for moving water inside the plant is 0,4 kWh/m3 (2009 values) (0,042
€/m3).

Table 0-13 shows the annual energy and cost of compressor cooling systems.

Table 0-13: Cooling systems evaluation

Type Water flow Average Annual Annual Annual cost
[l/s] power water energy [k€]
[kWh/h] amount [MWh]
[m3]
ZR315 4,4 6,34 143.795 57,5 6,0
ZR200 3,0 4,32 26.163 10,5 1,1
GA1408 1,9 2,74 107.576 44,8 4,7
Total 277.535 111,0 11,6

Other configurations of the cooling systems have been evaluated:

 Compression chiller;
 Trigeneration systems.

But they results not profitable at current conditions.

When the cost of water withdrawn from the ground is greater than 0,3 €/m3 a new cooling
systems with compression chillers will become profitable.
 1.6 Conclusions

Analysis carried out in compressed air area allowed to identify some wastes and to
propose new solutions in order to save money thanks to energy savings. The analysis carried out
have been reported in paragraphs number 1.3 and 1.4, while the proposals have been introduced
in paragraph number 1.5.

Current costs:

Annual cost [k€/year] Percentage of total cost

Compressors ZR 315 274 52,9%
Compressor ZR 200 53 10,2%
Compressors GA1408 180 34,7%
Water pumps 12 2,2%
Total annual cost 520 100%

Savings:

Description Investment Annual saving Pay back % of total

[k€] (year) cost
Compressor with 90 k€ 17,4 5,2 3,34%
inverter
Compressors - 20 - 3,84%
maintenance
Leak prevention 30 k€ 68,5 0,4 13,17%
System pressure 18 €/m 34,4 - 6,61%
Total annual saving - 140 - 26,92%

Summary shows that suggested improvements can allow achievement of 27%

total annual cost reduction, equal to 140 k€. Investment cost have to be evaluated by
asking a specific quotation to supplier.

Compressed air area represents the 19,6% of the total electricity consumption of
the factory (related to year 2009) and so these improvements can reduce the electric bill
by about 5%.