ENERGY CONSERVATION
COMPRESSED AIR ENERGY COST
25-35% of the load energy is consumed during idle run without producing any air.
Computing Energy Costs
Annual Electricity Cost (simple formula)
bhp x 0.746 x hours x cost
motor efficiency
Example:
200 hp compressor, 95% efficient motor, 4160 hours per year and $ 0.10/kWh electricity cost
200 x 0.746 x 4160 x .10 /
0.95 = $ 65,334 per year
It’s the power cost stupid
You have a gas meter(s) a water meter(s) a electrical meter(s) why, so you can monitor your usage of those utilities. Compressed Air is also a utility yet you have no meter, why? How can you manage something when you don’t know how much you’re using!!!
Find Out Your Energy Costs
COMPRESSED AIR AUDITS
Our approach and philosophy in the pursuit of energy savings has always been to start with the simple less costly solutions. First get your system into balance then evaluate other technologies that are available to see which ones make sense for you. Reach for the low hanging fruit first.
Unless you have the luxury of a management mandate and or utility company's unlimited funds to reduce your compressed air energy profile, high tech solutions are seldom the best first choice.
In keeping with our philosophy we offer different levels of compressed air energy evaluation tailored to your circumstances and needs not ours.
Overview of Levels of Analysis of compressed air System we offer.
- System “Review”: (1 to 2 days)
- Meeting with facility personnel to indentify issues, problems and area of concerns.
- Gather compressor model numbers method of control location within the facility.
- Hours of operation cost of energy (demand, peak and off-peak)
- Current Discharge pressure minimum required system pressure.
- Data log compressors and pressures to get a baseline on demand system dynamics.
- Write a report of finding
- System “Assessment”: (2 to 3 days)
- All the above components of a System “Review”
- Walk-through and Evaluation of “demand side” issues such as:
- Inappropriate applications with high volume users
- Areas sensitive to low pressure
- Leaks.
- Write a report of findings
- System Audit: (3 to 7 days)
- All the above listed in System Review and System Assessment
- Data Log compressors
- Monitor pressure and, if possible, airflow throughout the system while analyzing the dynamics of the complete system
- Detailed compressor control set-points
- List all drying & filtering equipment size type location.
- Dryer load factors inlet and outlet pressure, total pressure drop and fluctuations.
- List Receivers --- Size, location dry or wet primary or secondary-pressures
- Condensate Drains --- List all, type, location bypasses yes or no. Can they be easily checked to ensure they are working?
- Distribution system
- Piping layout size & type, looped or branched
- Quantify Air consuming equipment. (Note Pressure & Flow Requirements)
- Identify the energy reduction opportunities and system improvement benefits.
- Submit comprehensive written report of findings and recommendation
Beware of Free Audits (Why They Are Not “Free”):
- A Compressor Salesperson offers you a free audit.
- Audit report comes back with significant energy saving potential with the use of variable speed technology.
- The Salesperson recommends that you purchase a variable speed compressor.
What they are not telling you is that this “free audit” is a sales tool for compressor manufactures and their distribution to promote VSD compressors by stating exaggerated payback with theoretical energy savings. That is how they get paid for free audits.
VSD is one of many technologies that, when properly applied, can lower your compressed air energy profile; however, it is not a magic bullet. In fact, in some cases, a VSD will actually increase your energy cost.
Remember “Reach for the low hanging fruit first.”
It is one of the oldest expressions but it still holds true. “You get what you pay for!” |
