AEP Ohio Compressed Air Expo

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1 AEP Ohio Compressed Air Expo September 19, 2012 Hank van Ormer John Skelton Air Power USA airpowerusainc.com 1

2 Topic: Hands on Examples to Reduce Air System Costs (Demo Exhibit) Company: Air Power USA Columbus OH with offices on east & west coasts Group of 20 technical consultants and support staff Independent and brand neutral we do not sell equipment 1,200 systems audited and 800 air projects implemented Experience in all types of industries addressing both demand side and supply side issues 2

3 3

4 Compressor Electric Cost = Input HP x.746 x Hrs x Electric Rate / Motor Efficiency 100 psig, 4.0 cfm/input hp, 0.06 kwh, 8000 hours/yr 1 cfm = $100/Year in Electric Cost 4

5 Why Care About Air? 14 R s #1 Leaks #2 Pressure: Points of Use #3 Pressure: Source #4 Pressure: Fluctuations #5 Partly Loaded Units Compressors #6 Potentially Inappropriate Uses of Air #7 Pressure Drop #8 Dryer Sizing and Type #9 Condensate Drains #10 Preventative Maintenance #11 System Benchmarking #12 Usage Pattern Charting #13 Heat Recovery #14 Full Economic Evaluation #15 Retrocommissioning (O&M) 5

6 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) 6 R#15 Retro-commissioning (O&M activities)

7 Plant Air 3 3 Areas of high turbulent driven back pressure Gallon Receiver 3 3 Zeks 1100 scfm Mist Eliminator 3 Quincy QSI HP Atlas Copco GA 55W 75 HP Atlas Copco GA 55W 75 HP /25/2007 2:00 10/24/ :54 10/24/ :57 Kilowatts 10/25/2007 4:03 10/25/2007 6:06 10/25/2007 8:09 10/25/ :12 10/25/ :15 10/25/ :18 10/25/ :21 10/25/ Bottling plant BEFORE psig ON ON ON/OFF Zeks 1000 scfm Non-Cycling D 105 psig Rental Tie In 50% Flow 80% Power 7

8 Bottling Plant 3 copper Short radius 90 copper T with opposing air flows creates a dead head. 8

9 Bottling plant AFTER o o o Eliminate crossing Tee s and Dead Head Replace copper pipe with properly sized low pressure loss extruded aluminum Add a large storage to allow 2 step controlled Atlas Copco to not short cycle. 80% Flow 85% Power 4 4 o o o 4 Lowered discharge pressure 20 psig Run (1) one single unit on weekends Nothing else on, run only Quincy 100% time during production Zeks 1000 scfm Non-Cycling Dryer Removal and Installation 3 Men 14 Hours psig 3000 Gallon Receiver psig Gallon Receiver Quincy QSI HP Atlas Copco GA 55W 75 HP Atlas Copco GA 55W 75 HP ON OFF OFF Rental Tie-in with aftercooler 9

10 10 10

11 BOTTLING PLANT ECONOMICS PROJECT COSTS $99,068 REBATE $41,000 NET PROJECT COSTS $58,068 TOTAL SAVINGS $116,500 SIMPLE PAYBACK 6 months 11

12 Performance at Part Load With the exception of the new magnetic bearing driven centrifugal almost all air compressors are less power efficient at part load compared to full load. The type of compressor and type of local capacity controls determines the actual performance. The actual performance can be further enhanced with an effective central air management system. Well applied this can match optimum supply of air to the actual floor demand Many are not well applied 12

13 Compressor Use Profile Current System Actual Elec Demand Actual Air Flow Compressor Manufacturer/Model % of Full Actual % of Full Actual kw kw Flow scfm All Shifts: Operating at 110 psig discharge pressure for 8,760 hours Machine Shop Compressor Room Quincy 200-hp 27% % 0 Quincy 200-hp 83% % 418 Quincy 200-hp 93% % 691 Quincy 200-hp 92% % 644 Quincy 200-hp 92% % 644 Quincy 200-hp 13% 24 0% 0 Casting Compressor Room Quincy 300-hp 97% % Quincy 300-hp 77% % 313 Quincy 300-hp 86% % 586 Quincy 200-hp 92% % 664 Quincy 150-hp 73% % 68 PreMelt Quincy 200-hp 91% % 636 TOTAL (Actual): Cost per year $883, kw 5,892 scfm 13

14 Compressor Use Profile Modified System Actual Elec Demand Actual Air Flow Compressor Manufacturer/Model % of Full Actual % of Full Actual kw kw Flow scfm All Shifts: Operating at 110 psig discharge pressure for 8,760 hours Machine Shop Compressor Room Quincy 200-hp Quincy 200-hp Quincy 200-hp Quincy 200-hp Quincy 200-hp OFF Quincy 200-hp 99% % 891 Casting Compressor Room Quincy 300-hp 100% % 1,364 Quincy 300-hp 100% % 1,364 Quincy 300-hp 100% % 1,364 Quincy 200-hp 100% % 909 Quincy 150-hp OFF PreMelt Quincy 200-hp OFF TOTAL (Actual): Cost per year $553, kw 5,892 scfm 14 Savings of $329,590 per year and kw

15 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) 15 R#15 Retro-commissioning (O&M activities)

16 Types of Venturi Vacuum Generators Single-Stage Multi-Stage Co-Axial 16 Courtesy of piab.com

17 Venturi Vacuum Generators Shut Shut off off air air supply supply not not the UPPLY vacuum the vacuum supply Solenoid or Manual Ball Valve M Compressed Air 17

18 Venturi Vacuum Generators Auto Shut Off Typical venturi vacuum generators on palletizer Auto shut off venturi generator 18

19 Venturi Vacuum Generators: Multi stage Co axial often more efficient than Single stage Inlet Pressure Single Stage Compressed Air Vacuum Inlet Pressure Co axial Compressed Air Vacuum Generate similar vacuum at lower pressure and lower flow

20 Larger Cups at Lower Vacuum Better holding forces while using less energy = less compressed air 20

21 Decentralize Vacuum System Use smaller point of use vacuum systems / Auto shut off Venturi vacuum generator with auto start/stop. On time =.72 minutes per hour Centralized $11,200 per yr / 112 cfm Decentralized AS&S $1,079 per yr / cfm 21

22 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) 22 R#15 Retro-commissioning (O&M activities)

23 Compressed Air Linear Actuators (Air Cylinders) Lowest Effective Pressure, Power and Return Stroke 23

24 High Pressure Low Pressure Possible New Technology 3/2 Valve X-Block High Pressure Low Pressure POWER STROKE 3/2 Valve X-Block RETURN STROKE 24

25 Two return air exhaust compressed air storage Two X-Block return stroke air controllers BEFORE 25 cylinders 7.82 cycles/min 105 psig 22 cfm AFTER Standard 2-way Control valve 7.82 cycles/min 95 psig 5.94 cfm 25

26 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) 26 R#15 Retro-commissioning (O&M activities)

27 32 cfm 80 psig Venturi Amplifiers or Flow Inducers ¼ Tube 12 Inches Long 80 cfm - $3,200 year 80 cfm 26 cfm 80 psig ¼ Tube with Air Dispersion Nozzle 95 cfm - $2,600 year 95 cfm 10 cfm 80 psig ¼ Tube with Venturi Nozzle 250 cfm - $994 year cfm

28 Typical Open Blow Application 1/4 Tube Open Blow uses 25 cfm: Add Fixed ¼ air amplifier: 9 cfm Energy Cost (Uncontrolled): $2,500 /yr Energy Cost w/ Nozzle: $900 /yr Energy Savings: $1,600 /yr Cost of Nozzle: $17 28

29 Steel Plant Rolling Mill Open Blow Energy Savings: $7,000 /yr Nozzle Cost: $110 29

30 Blow Off Air ¼ tube blows continuously to clear parts from press 32 cfm 30

31 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) R#15 Retro-commissioning (O&M activities) 31

32 CONTROL CABINET COOLING Do you actually need cabinet cooling? 32

33 Heat Pipe Cabinet Cooling Air-cooled will not cool below ambient; Water-cooled will 33

34 VORTEX TUBE REFRIGERATION CABINET COOLER Compressed air temperature Drop 60 to 90 o F Compressed Air 90 psig 70 o F Hot Air from Vortex Tube 230 o F Cabinet Air Exhaust Cold Air -10 o F 34

35 THERMOSTATIC AUTOMATIC SHUT OFF 110 Volt Normally Closed 2 way solenoid Air Supply Air Filter Cabinet Wall Ducting 8 long Thermostat Vortex tube cools quickly Unlimited starts & stops; just shut off / turn on Muffler 35

36 THERMOELECTRIC REFRIGERATION CABINET COOLERS Peltier Cooling Average cooling o F Works in a totally sealed cabinet 36

37 Refrigerated Heat Pipe (Air or Water) Air Water 1,500 Btu/hr = 1.5 kw 1,500 Btu/hr =.035 kw.140 kw 6,000 Btu/hr = 2.0 kw 6,000 Btu/hr =.140 kw.035 kw 8,000 Btu/hr = 2.3 kw 8,000 Btu/hr =.140 kw.035 kw 12,000 Btu/hr = 3.5 kw 12,000 Btu/hr =.280 kw.105 kw Thermoelectric Max Nominal 400 Btu/hr Rating 100 Watts 70 Watts 800 Btu/hr Rating 200 Watts 150 Watts 1,500 Btu/hr Rating 400 Watts 280 Watts (20) 6,000 Btu/hr Refrigerated 40 kw $21,000/yr (20) 6,000 Btu/hr Heat Pipe 2.8 kw $ 1,475/yr 37

38 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) R#15 Retro-commissioning (O&M activities) 38

39 Pulse Jet Baghouse 39

40 Cleaning Pulse 40

41 Compressed Air Delivery and Supply May Create an Ineffective Pulse * Use proper line size to handle rate of flow without high pressure loss * Use of storage to supply air without pulling down feed to receiver/collector * Monitor inlet pressure and drop at pulse * Monitor flow 41

42 Typical Compressed Air Use One, 10 row Dust Collector Valve Size Standard Pulse with Demand Control Continuous 356 pulse/hour $ / Year Avg. scfm $ / Year Avg. scfm 3/4 $1, $3, /8 $2, $6, /2 $3, $10, $4, $14,

43 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) 43 R#15 Retro-commissioning (O&M activities)

44 Optimizing Air operated Double Diaphragm Pumps Control Pressure Control Cycles Automatic Shut-off Controls Covert to Electric Install Electronic Stroke Optimizers 44

45 Air-operated Diaphragm Pump Compared to Electric 2 Diaphragm Pump / Water/ 40 foot head 75 gallons per minute 75 psig inlet pressure 70 cfm $7,000 per year Electric Pump 3 Horse Power $780 per year 45

46 Electronic Optimized Stroke Control, Pneumatic operated or 24V AirVantage Pneumatic Potential Compressed Air Savings $3,000 to $6,000 / year Cost $1,000 to $1,200 MizAir 24v Electric Drive 46

47 Electronic Stroke Optimizer At the same input pressure, the compressed air usage fell 36% to 50% The stroke rate falls to optimum rate The product capacity per stroke increased Product flow per unit of energy increased from 50 to 100% efficiency Run quieter low exhaust 47

48 Air Power USA Presentation Outline R#5 -- Partly Loaded Units Re-piping R#6 Potentially Inappropriate Uses of Air Vacuum generators Air cylinders Open blows Cabinet coolers Dust collectors Air-operated diaphragm pumps (AODD) R#15 Retro-commissioning (O&M activities) 48

49 14 R s #1 Leaks #2 Pressure: Points of Use #3 Pressure: Source #4 Pressure: Fluctuations #5 Partly Loaded Units 5 15% 0 2% 0 2% 0 2% 0 10% #6 Inappropriate Uses of Air #7 Pressure Drop #8 Dryer Sizing and Type #9 Condensate Drains #10 Preventative Maintenance 5 10% 0 2% 0 2% 0 1% #11 System Benchmarking #12 Usage Pattern Charting #13 Heat Recovery #14 Full Economic Evaluation #15 Retrocommissioning (O&M) 0 5% 49

50 Did You Know? 30% of all compressor controls or control systems are not operating properly 40% of all air system dryers are installed improperly, plugged, bypassed, or otherwise not performing their intended purpose 50% of all air systems are not piped correctly 60% of all plants could reduce their air demand by 1/4 if they eliminated the air use or switched to an alternative energy source Amazingly, 30% of all brand new or reconstructed air systems are engineered incorrectly 50

51 Thank you for this opportunity to present Come visit our hands-on exhibit (740) airpowerusainc.com Hank van Ormer John Skelton Air Power USA Inc 51

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