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Compressed Air Best Practice Tool
Compressed Air Best Practice Tool
An energy service demand for a specific level of work or activity to be performed. However, an Energy Service is more than simply 'Compressed Air'. To identify the Energy Service, ask yourself: - What do I want to do with the compressed air? - What requires the compressed air? - What is the fundamental piece of work that I want compressed air to do?
An example of a compressed air related Energy Service might be: to produce a vacuum to pick up a product from one belt an another. 2 Then, for each Energy Service, ask yourself: - Do I really need (paid-for) energy to deliver this energy service? - Is there another way of delivering the output that requires using less or no energy? - Can I use a less energy intensive alternative? - What is the minimum specification required? - Can I reduce (increase) pressures, temperatures, run times, flowrates, currents etc. to reduce the energy required?
3 Start at the point of energy service demand and work back upstream through the energy distribution and conversion system( consistent with the energy efficiency hierarchy.
4 Is the technology that is currently satisfying each energy service demand appropriate? Or can it be eliminated or replaced b effective alternative? 5 Can the system be designed better?
6 Identify the most efficient / optimum operational control parameters for the most effective technology to satisfy each service Can cycle times be adjusted?
7 Are there opportunities to distribute the energy more efficiently, e.g. insulation, improved structural integrity (elimination of lea etc.?
8 Is there scope for technical or operational modifications to the energy conversion systems (compressors, boilers, chillers etc. the consumption of energy resources (natural gas, gasoil, electricity, wood chips etc.)? 9 Finally, are there O&M or housekeeping actions that can be taken to reduce the consumption of energy resources?
10 The following Onion diagram illustrates this approach and also identifies some best practice energy savings measures at di 'layers'. Simple energy saving calculation sheets for each of these measures are included in this spreadsheet.
Housekeeping
What do I want to do with the compressed air? What requires the compressed air? What is the fundamental piece of work that I want compressed air to do?
Repair Leaks
Control Systems
Plant Design
Do I really need energy to deliver this energy service? Is there another way of delivering the output that requires using less or no energy? Can I use a less energy intensive alternative? What is the minimum specification required? VSD Control
Process Technology
Multiple-stage Com
Energy Service
Energy Efficient Mo
Reduce pressure
11 SEAI operates an accelerated capital allowance (ACA) scheme, which is a tax incentive for companies to purchase energy e equipment. It allows companies to write off 100% of the purchase value of specified energy efficient equipment in the year of To see which equipment qualifies for ACA and to find out more go to www.seai.ie/aca or click on the graphic below. There is technical information available on the qualifying equipment. There is also an ACA worksheet in this spreadsheet.
centre of the Onion (see diagram below) by identifying the relevant Energy Service. An energy service demand is the need c level of work or activity to be performed. However, an Energy Service is more than simply 'Compressed Air'.
he Energy Service, ask yourself: I want to do with the compressed air? quires the compressed air? he fundamental piece of work that I want compressed air to do?
e of a compressed air related Energy Service might be: to produce a vacuum to pick up a product from one belt and drop it on
ach Energy Service, ask yourself: ly need (paid-for) energy to deliver this energy service? another way of delivering the output that requires using less or no energy? e a less energy intensive alternative? the minimum specification required? duce (increase) pressures, temperatures, run times, flowrates, currents etc. to reduce the energy required?
point of energy service demand and work back upstream through the energy distribution and conversion system(s) this is with the energy efficiency hierarchy.
nology that is currently satisfying each energy service demand appropriate? Or can it be eliminated or replaced by a more ernative?
most efficient / optimum operational control parameters for the most effective technology to satisfy each service demand. mes be adjusted?
pportunities to distribute the energy more efficiently, e.g. insulation, improved structural integrity (elimination of leaks), isolation
pe for technical or operational modifications to the energy conversion systems (compressors, boilers, chillers etc.) to reduce ption of energy resources (natural gas, gasoil, electricity, wood chips etc.)?
there O&M or housekeeping actions that can be taken to reduce the consumption of energy resources?
ng Onion diagram illustrates this approach and also identifies some best practice energy savings measures at different mple energy saving calculation sheets for each of these measures are included in this spreadsheet.
Housekeeping
Repair Leaks
Control Systems
Variable Inlet Volume
Plant Design
VSD Control
Process Technology
Multiple-stage Compressor
ss energy intensive
inimum specification
Energy Service
Reduce pressure
tes an accelerated capital allowance (ACA) scheme, which is a tax incentive for companies to purchase energy efficient It allows companies to write off 100% of the purchase value of specified energy efficient equipment in the year of purchase. ch equipment qualifies for ACA and to find out more go to www.seai.ie/aca or click on the graphic below. There is also useful formation available on the qualifying equipment. There is also an ACA worksheet in this spreadsheet.
982,800 [kWh/y] = (Annual Energy Consumption [kWh]) x (% Savings [%]) [/kWh] [/y] Insert from Energy Bills Analysis Tool = (Annual Energy Savings [kWh/y]) x (Average Electricity Price [/kWh])
Payback: Depends on the number of problems in the system & additional controls required (if any); could be < 1 year.
Source: SEAI Energy Agreements Programme 2007 Compressed Air Technical Guide
[kWh/y] = (Air Leakage Rate [l/s]) x 700 [kWh/(l/s)] [/kWh] [/y] Insert from Energy Bills Analysis Tool = (Approximate Energy Wasted [kWh/y]) x (Average Electricity Price [/kWh])
Payback: Due to the large savings associated with a regular Leak Detection Programme, the potential savings associated with this opportunity to save energy often results in payback periods of less than 1 year.
Leakage can occur at any point in a compressed air system, but the most common culprits include piping joints, drains, relief valves, drain valves, flexible hose pipes, filter and lubricator units, pressure regulators, condensate traps and thread sealants. The best means of locating compressed air leaks is an ultrasonic acoustic detector capable of identifying the high frequency noise synonymous with compressed air leaks. When this technology is not available, simpler methods such as applying soapy water to the distribution network and waiting for bubbles to form is just as A leak reduction program will involve identification (tagging), tracking, repairing, The most valuable tool in combating leakage in the system are personnel who should be brought onboard and actively engaged in the programme. Plant personnel will often become actively engaged in a leak reduction programme. Knowing that a reduction in leaks will lead to a more comfortable working environment will often result in more active involvement from personnel. The goal of any programme is to make individual departments responsible for usage. Accordingly, flow to these departments should be monitored to ensure that area ownership is taken. Facilities utilising significant volumes of compressed air should aggressively engage in a Leak Detection Programme and carry out a biannual compressed air leakage survey. Finally, it is important to bear in mind that one of the most effective means of reducing compressed air leakage is to reduce the distribution pressure. Fixing the leaks is often as simple as tightening connections or applying sealant at strategic points. However leaks will be found that require the replacement of faulty components. In all instances, select the highest quality fittings, disconnects, hoses, tubes, etc. and install them as appropriate with high quality thread sealant. A 10% reduction in leakage, which is a modest target for leakage in any system, would often be gained as a result of carrying out an intensive leak reduction programme. Source: SEAI Energy Agreements Programme 2007 Compressed Air Technical Guide
Average Part Load : Condition Annual Operation Hours : Saved (Off) Annual Energy Savings :
70%
[%]
6,000
[h/y]
Payback: Due to the large savings associated with a regular Leak Detection Programme, the potential savings associated with this opportunity to save energy often results in payback periods of less than 1 year.
The most valuable tool in combating leakage in the system are personnel who should be brought onboard and actively engaged in the programme. Plant personnel will often become actively engaged in a leak reduction programme. Knowing that a reduction in leaks will lead to a more comfortable working environment will often result in more active involvement from personnel. The goal of any programme is to make individual departments responsible for usage. Accordingly, flow to these departments should be monitored to ensure that area ownership is taken. Facilities utilising significant volumes of compressed air should aggressively engage in a Leak Detection Programme and carry out a bi-annual compressed air leakage survey. Finally, it is important to bear in mind that one of the most effective means of reducing compressed air leakage is to reduce the distribution pressure. Fixing the leaks is often as simple as tightening connections or applying sealant at strategic points. However leaks will be found that require the replacement of faulty components. In all instances, select the highest quality fittings, disconnects, hoses, tubes, etc. and install them as appropriate with high quality thread sealant. A 10% reduction in leakage, which is a modest target for leakage in any system, would often be gained as a result of carrying out an intensive leak reduction programme.
= (Motor Power [kW]) x (% Full Load [%]) x (Operation Hours [h]) x #DIV/0! [kWh/y] ((1/Compressor Motor Efficiency [%]) - (1/(Compressor Motor Efficiency [%] + 1.5%))) [/kWh] #DIV/0! [] Insert from Energy Bills Analysis Tool = (Annual Energy Savings) x (Average Electricity Price [/kWh])
Payback: Base loaded machines that operate close to full load for more hours annually will show quicker returns on the investment in the high efficiency motor than trim machines that operate fewer hours annually.
Payback: The premium paid for equal power, two-stage machines will be 30 to 40%. However, the two-stage machine will have more capacity (l/s) than the same power, single-stage machine. Therefore sometimes a smaller power two-stage machine can be used instead of the larger power single-stage machine for the same job, resulting in an effective cost premium of less than 30%.
#DIV/0! [kWh/y] = (Average Power Saving [kW]) x (Annual Operating Hours [h/y]) [/kWh] [/y] Insert from Energy Bills Analysis Tool = (Annual Energy Savings [kWh/y]) x (Average Electricity Price [/kWh])
Payback:
#DIV/0! [kWh/y] = (Average Power Saving [kW]) x (Annual Operating Hours [h/y]) [/kWh] [/y] Insert from Energy Bills Analysis Tool = (Annual Energy Savings [kWh/y]) x (Average Electricity Price [/kWh])
Payback:
12.5%
12.5%
[%] Standard capital allowance allows firms to write off 1/8 of capital cost against tax each year (for 8 years) Accelerated capital allowance allows firms to write off ALL of capital cost against tax in first year = (Actual Year 1 Net Cashflow without ACA) - (Actual Year 1 Net Cashflow with ACA) The Discount Rate used by your business Present Value (PV) to your business of the Standard Capital Allowances, i.e. no ACA Present Value (PV) to your business of the Accelerated Capital Allowances, i.e. with ACA
0 0 0
[] [] [] [%]
0 0
[] []
1.1 1.2
Release for Energy MAP Day 2 Limited cell protection Addition of "What does this Sheet Do?" Addition of ACA link Addition of sheets: ACA, Leaks - Energy Wasted Final - for publication Final - updated links and logos to reflect SEAI rebranding
5/19/2008 5/22/2008
1.3
12/18/2008
2.0 3.0
6/9/2009 10/5/2010
ol Version History
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