Pressure rise or drop

100%
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Load curv

speed
80% sp
Compressor Optimization:

60% sp

eed
eed
Static
Increasing Reliability and Efficiency
Inlet flow

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Compressor Optimization: Increasing Reliability and Efficiency
Today’s Speakers

Aaron Hand Mark Pipher Sam Deptula Matthew Wells

Moderator Vice President / General Engineer General Manager
Executive Editor Manager B2Q Associates Automation Software
Automation World FacilityConneX GE Digital
Compressor Optimization: Increasing
Reliability and Efficiency
Matt Wells – General Manager
Automation Software – GE Digital

Imagination at work
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Why is it important?

Compressed Air Systems:

•  Are located in 70% of manufacturing plants
•  Consume over 90 Billion kWh per year in the US*
•  Cost over $1.5 Billion dollars per year to operate in the US*
•  Consume 8% of net electricity use in manufacturing facilities,
across all industries**

*Dept of Energy
**E Source

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 Why is it important?

0.5%
Every 1 PSI of excess operating
pressure increases air compressor
1PSI power consumption by about 0.5%.

Source: quincycompressor.com

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Decision Support for Operations

Efficient HMI* Information Anywhere, Anytime

Identify
On-Demand
Problems &
Support
Causes
DECISION
SUPPORT
Prevent Intelligent
Mistakes Warnings

Integrated Work Processes

Operational Analytics
*HMI: Human Machine Interface

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 Powered  By  

Why  Op'mize…    
Your  Compressed  Air  System
What  is  your  Equipment  Saying?  

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How  do  you  use  your  Compressed  Air  System?  
 
•  Produc.on  
•  Product  Quality  
•  Lab  Environments  
•  Support  Systems  
 
What  Does  It  Cost  You?  
 
How  do  you  Measure  its  Use  (Demand  PSI,  DownBme,  …)?  
 

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Why  Do  You  Care  …
q  Reliability  in  ProducBon  
q  UpBme  
q  Avoidance  of  Repair  Costs  
 
q  Energy  Costs  
q  COMPRESSED  AIR  SYSTEMS  IS  ONE  
OF  THE  LEADING  CONTRIBUTORS  TO  
YOUR  ENERGY  BILL!  
Break/Fix  –  Never  Ending  

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A  Typical  Approach  to  Maintain  Op'miza'on  Will  Not  
Persist!

Equipment  Tune-­‐up  and  

Periodic  Maintenance  

Performance  
ReducBon    
and  Energy  DriX  

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A  Con'nuous  Approach  to  Protect  Your  Investment!

Savings  DriX  Avoided  

Performing single or
periodic Equipment
Optimization only.

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Using  Visibility  and  Advanced  Analy'cs  to…  
Deliver  Double  the  Savings!

Performing single or
periodic Equipment
Optimization only.

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The  Path  to  Sustained  30%!  
30%  Reliability  
•  Monitoring   30%  Savings  

•  DetecBon  
•  OpBmizaBon  
•  UBlity  IncenBves  

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Case  Study:    Global  Home  
Products  Manufacturer  
THE  NEXT  GENERATION  OF  COMPRESSED  AIR  DETECTION

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Global  Home  Products  Manufacturer
Industrial  Compressed  Air  Reliability  and  Energy  Savings!  

Manufacturing Environment
•  Central Compressed Air
System
•  Ten (10) Compressed Air Units
•  Several Millions in Electricity
•  Energy Authority Funded Study
•  Complete Leak Audit

ConBnuous  Monitoring     UBlity  IncenBves   Complete  System  Study  

Global  Home  Products  Manufacturer
Industrial  Compressed  Air  Reliability  and  Energy  Savings!  

•  Control Points Monitoring – 500 Points
•  Potential Cost Improvements – 35%
•  Optimization Adjustments
•  Reduce Downtime And Rental Exposure

Optimization
Scheduling
Blowoff

Staging

Compressed Air Complex Staging , Blow 35% More Efficiency

Supply and Demand Offs, and Scheduling How much is that WORTH?
Algorithms
Con'nuous  Monitoring  and  Detec'on
ü   Real  Time  and  Con.nuous  Detec.on  of  Devia.on  and  Change  
ü   Advanced  Analy.cs  across  Schedule  Op.miza.on,  Short  Cycling,  and  Blow  Off  Balancing  
ü Instant  Detec.on  through  Mobile  Visualiza.on  Views  
ü   Deeper  Analysis  

Within  one  week,  opBmizaBon  detecBon  close  to  $135,000!  

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Compressed  Air  Study  and  Leak  Audit
 
ü   Complete  Leak  Audit  
ü   Funded  U.lity  Incen.ve  Study  for  Compressed  Air  Op.miza.on  
ü   Insights  on  Efficiency  of  Compressed  Air  Types  in  the  Manufacturing  Environment  
ü   Compressed  Air  System  Energy  Conserva.on  Measures  Iden.fied  
ü   Master  Maintenance  and  Energy  Plan  with  Priori.zed  Next  Steps  
 

IdenBfied  PotenBal  Savings  of  Over  $1,000,000  Year  over  Year  

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Deep  Detec'on  Scenarios
THE  NEXT  GENERATION  OF  COMPRESSED  AIR  DETECTION

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Plant  Wide,  At  the  Compressor,  and  Inside  …  
 
Compressed  Air  ConBnuous  Monitoring  and  DetecBon

Compressed  Air  System  Checks  

 
•  Motor  condi.ons  and  control  
•  Compressor  modula.on  
•  Equipment  staging  op.miza.on  
•  Blow-­‐off  monitoring  
•  Pressure  control  
•  Capacity  issues  
•  Compressor  cooling  systems  
•  Dryer  maintenance  and  control  
•  Compressed  air  and  inlet  filtra.on  
•  Water  and  oil  separators  
•  Heat  recovery  
•  Pressure  and  flow  controllers  
•  Distribu.on  losses  
•  Leakage  

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Let’s  Go  Deeper  …  
ü  Does  your  plant  have  an  integrated  compressor  
control    system  and  is  it  properly  configured?    

ü  Are  your  compressors  modulaBng  and  staging  

for  opBmal  efficiency  and  control  precision?  

ü  Are  pressure  and  other  set-­‐points  matched  to  

the  needs  of  end-­‐devices  and  machinery?  

ü  Have  you  implemented  a  program  to  

idenBfy  and  correct  leaks  on  a  regular  basis?  

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Air  Compressor  AnalyBcs  
 
Staging  OpBmizaBon  Opportunity

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Staging  
Op'miza'on
Many  compressed  air  plants  
are  manually  operated  with   Compressor  staging  analysis:  
local  controls.  Those  plants   Inefficient  staging  of  
compressors  in  plant  
that  do  feature  automated  
sequencers  or  integrated  
control  systems  can  o_en  be  
improperly  configured  to  
achieve  op.mal  efficiency.    
Use  analy.cs  to  recommend  
staging  improvements  and  
determine  the  poten.al  cost   Compressor  staging  analysis:  
More  compressors  running  
savings  opportunity  in  real-­‐ than  needed  to  meet  the  load  
.me.  

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Op'miza'on  
Across  Plant  
Compressors
Analy.cs  so_ware  can  not  
only  look  at  the  subsystems  
of  a  single  compressor,  but  
also  across  compressors  in  
the  plant  to  iden.fy  staging  
and  scheduling  
opportuni.es.  

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See  the  Cause  
and  the  Effect
Improved  insights  with  root  
cause  analysis  and  
recommended  ac.ons.  
Tools  designed  to  help  you  
understand  current  and  
projected  equipment  
opera.on.  

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Air  Compressor  AnalyBcs  
 
Short  Cycling

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Short  Cycling
An  issue  that  can  impact  both  
energy  use  and  compressor  life  is  
short  cycling  
Some.mes  an  air  compressor  will  
load  and  unload  in  short  bursts  that  
can  go  on  for  days,  weeks,  or  
months  before  the  condi.ons  is  
no.ced.  
Can  prevent  complete  blowdown  and  
reduces  the  life  of  the  equipment  

AnalyBcs  soXware  can  detect  

across  your  fleet  of  
Compressed  Air  System  -­‐    Short  
Cycling  CondiBon.  

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Analy'cs  
Performance  
Dashboard
Iden.fy  and  detail  over  .me  
and  provide  informa.on  
including:  
•  Finding  
•  Severity  
•  Dura.on  
•  Probable  Causes  
•  Interval  Occurrences  Over  
Time  
•  Energy  &  Cost  Opportunity  
Savings  

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 Year  over  Year  Savings  with  CorrecBve  AcBons  Up  to  30%  

Your  ROI  Goals  

ü  IdenBfied  UBlity  Savings  
Capital  UBlity  IncenBves   15-­‐30%   Equipment  OpBmizaBon  
ü  PreventaBve  Maintenance  
ü  Reliable  Comfort  
ü  Six  (6)  Month  Payback*   10-­‐15%   Controller  Updates  

Maintenance  and  OperaBons  Efficiency  

Total  Investment  with  CorrecBve  AcBons*  

Control/Scheduler  Updates  
FCX  Investment  

*Based  on  Correc.ve  Ac.on  and  Culture  

3  Months      6  Months      12  Months          24  Months          36  Months  

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Compressor Optimization: Increasing Reliability and Efficiency
Questions

Aaron Hand Mark Pipher Sam Deptula Matthew Wells

Moderator Vice President / Engineer General Manager
Executive Editor General Manager B2Q Associates Automation Software
Automation World FacilityConneX GE Digital

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