INTRODUCTION

Company incorporated in 2002 Collaboration with Fouress Co. LLC. USA Patented Technology (US Patent No. 6860103) More than 100 energy audits done Six major projects implemented Six more under implementation Some are repeat orders. Atleast 12 planned for this year.

Energy Saving Potential in Compressors

U.S.A. energy consumption on compressors in 2002-100 billion Kwhs 20% energy saving @ 0.35$ per Kwh - $0.7 billion. Assuming India consumes only 8% of US Consumption Energy consumption on compressors in India 8 billions Kwhs 20% saving @ Rs.4.50 per kwh = Rs.7.2 billion =Rs.720 crores

Importance of Energy saving Potential in compressors

100 H P compressor Rs.6 To 8 lakh. Annual running cost 300 days @Rs.4.50 per unit = Rs.25 lakh. 25% saving Rs.6.25 lakh Equal to cost of the compressor itself! Energy cost of running a compressor is quite significant!

Who is running your compressed air system? Our compressed air system is running itself ---------------and we are chasing it! -Tom Taranto-

Energy Loss in compressed air system

Energy loss in compressors Waste of compressed air in use Losses in driers, pipelines, etc Losses due to improper point of use applications

Energy Loss in Compressors

Unloading costs money A compressor consumes energy while unloading! Reciprocating compressor 15% to 20% Screw compressor 25% to 40%

Waste of Compressed air in use!

Artificial Demand costs money! Difference between air flow at optimum operating pressure and actual pressure applied to the system is artificial demand Reduced pressure will consume less air quantity through the same pipe line Every two PSI reduction in pressure saves 1% energy!

Why Artificial Demand?

To Compensate for Response Time Compressors are Reactive To Overcome Imaginary Pipeline Losses To Overcome Equipment Resistance
Air System - Average Vs Installed

Installed - volume 1700 SCFM @ 115 PSIG

1700

115

1000

Average - volume 1000 SCFM @ 80 PSIG

80

Losses Due to Improper Use!

Air abuse costs money! How much does it cost to clean? A airline at 100 PSI in use for 2 hours a day Costs Rs.45,000/- per annum One can do it with a blower at 10% of the cost! Air abuse all includes other Unregulated demands.

Driers may add to Losses!

There may be Pressure loss across drier if not maintained properly! Under capacity Driers may add to the problem of Condensate Drains. Selection of proper type/ capacity drier is another challenge!

Dryer - 500 SCFM - operating 10-60 % Capacity Pressure Loss Across Dryer - Data Taken on 04/06/2004

130
Before Dryer

127 124 121 118

PSIG

115
Pressure Loss at Minimum Flow = 2.5 PSIG (@ 50 SCFM)

112 109 106 103 100

10 0 :1 10 0 :2 10 0 :3 10 1 :4 10 1 :5 11 2 :0 11 2 :1 11 2 :2 11 3 :3 11 3 :4 11 4 :5 12 4 :0 12 4 :1 12 5 :2 12 5 :3 12 6 :4 12 6 :5 13 6 :0 13 7 :1 7
TIME
After Dryer Pressure Loss at Maximum Flow = 11.2 PSIG (@ 300SCFM)

10

:0

Pipe Lines may add to your woes!

There is always Pressure drop as the air passes thro the pipe line. Longer the distance travelled, Larger the pressure drop! Smaller the Pipe Dia., Larger the Pressure Drop!

Pressure drop in pipe line

Pressure 100 PSI Pipe Dia 1/8 1 /4 3 /8 1 /2 Pressure drop in PSI 1.31 0.285 0.064 0.020

For a flow of 2 CFT per minute and a distance of 100 ft

Leaks 15%

Poor Practices 10%

Artificial Demand 25% Production 50%

Traditional

Vs

Optimair
Plant productivity is Number one Priority ! Plant Air Demand must always be Supplied! Supply must Balance Demand - Over supply and Under supply are Unacceptable ! Pressure must be Consistent Low pressure and High pressure are equally Unacceptable!

Plant production is Number one Priority ! Plant Air Demand must always be met ! Over Supply is Acceptable Under Supply is Not ! Minimum Pressure must be maintained Higher Pressure is acceptable !

System can be optimized a) By optimizing the operating pressure. b) By reducing the No. of unloaded hours. c) By controlling the unregulated demand. d) By eliminating deficiencies in the System.

What Does Optimair Do?

Data logging of the System for 48 to 72 Hrs. Detailed Study of the System Components, their functions and inefficiencies, if any. Detailed Study of the Point of use applications and their pressure requirements. Present Health condition of the Compressors. Optimum Pressure and CFM requirments of the System Present and Future.

Compressed Air Systems Management

System Auditing & Performance Management

Average system pressure = 84 PSIG

PSIG

Artificial demand

New average system pressure = 70 PSIG

Reduction in artificial demand = 14 PSIG Operational savings = 21 %

Time
32

Base Load With Minimum # of Machines

To Maximize Percentage of the Total Demand at Full Load Efficiency

Trim with the Trim Station

To Remaining Percentage of the Total Demand In Load/No Load Mode

One or more Receiver(s) One or more Flow Controller(s) One PLC Based control system.(MCSC) A set of Compressor Interfaces Installation and Commissioning by Optimair Production Down Time None Energy savings up to 40% SIMPLE ROI - 8 months to 16 months

115 PSIG

C5
D5

Multiple Compressor System

Figure 2

125 PSIG

C6
D6
90-100 PSIG

Main Distribution Header Main Distribution Header

120 PSIG

C7 Main Distribution Header

D7

90-100 PSIG

C4
105 PSIG

D4

Main Distribution Header

90-100 PSIG

Main Distribution Header

90-100 PSIG

C3
110 PSIG

D3

C2
115 PSIG

D2
115 PSIG

Main Distribution Header

90-100 PSIG

C1
D1
90-100 PSIG

90-100 PSIG

C5
95 PSIG

D5

Multiple Compressor System Optimair Solution

C6
95 PSIG

D6

90 PSIG

Main Distribution Header

C7
95 PSIG

D7

Main Distribution Header

C4
95 PSIG

D4

C3
95 PSIG

Main Distribution Header

D3
90 PSIG

Main Distribution Header

90 PSIG

Flow Controller Main Distribution Header

D1

C1
95 PSIG

90 PSIG

90 PSIG

C2
120 PSIG

D2

90 PSIG

Main Distribution Header

115 PSIG

New Receiver

Storage Receiver 12000 Litres Flow Controller One PLC Based MCSC. Energy 15 %

R Electronic Controller

Constant Pressure Reduction in No. of compressors in operation. Saving in labour. Improvement in quality of out put which improves productivity.

No of Compressors in Operation reduced from 5 to 3. Two compressors removed. Average CFM Generated reduced from 820 to 600. Power consumption reduced from 3700 KWh. to 2400 KWh per day. Saving of 1300 units per day. Investment Rs.1.60 Millions Pay Back period- 10 months.

TSFpress ure

98

96

94

92

90

88

86

84

20:00

20:10

20:20

20:30

20:40

20:50

21:00

21:10

21:20

21:30

21:40

21:50

22:00

Hour s, 09/16/02 - 09/16/02

415 TSF Pr.

80

79

78

77

76

75

74 73

72

71 18 19 20 21 Hours , 0 4/1 5/03 - 04 /15 / 03 22 23

No of Compressors in Operation reduced from 4 to 3. Average CFM Generated reduced from 990 to 900 Power consumption reduced from 4700 KWh. to 4000 KWh. per day. Saving of 700 units per day. Investment Rs.1.50 Millions Pay Back period- 18 months.

S c re w p re s s u re

96

94

92

90

88

86

15

16

17

18

19

20

21

22

23

00

01

02

03

04

05

06

07

H o u r s , 1 0 /2 2 /0 2 - 1 0 /2 3 /0 2

H e a d e r P re s s u r

85 84 83 82 81 80 79 78 77 76 75 74 73 72 18 19 20 21 22 23 00 01 02 03 04 05 06 07

H o u r s , 1 1 / 1 8 /0 3 - 1 1 / 1 9 / 0 3

Optimair System Advantages

Only one trim compressor operates at a higher pressure to create extra storage. 7 to 10% more energy saving than other systems. Smaller receiver capacity (one third as compared to other systems.) Single system for all locations. Less number of flow controllers only one in many cases. No downtime for installation

Major installations/orders received

HLL Pondicherry TVS Motors Hosur Pricol I Coimbatore Ucal Chennai Ashok Leyland Hosur MRF Chennai TVS Motors Mysore Pricol III Coimbatore Premier Mills Hosur HAL - Bangalore

Total Compressor Automation

A Case Study.

Integration & Control of Compressors of all 3 Plants Integration of Intermediate Controller (IC1) Integration of VFD of one compressor if required at a later date Monitoring / alarm annunciation of compressor parameters Control & Monitoring of compressors auxiliaries Generation & User Pressure logging at 10 different locations Monitoring & control of main valves of Plant I, II & Plant III (RMB)

Energy optimization using MCSC Time based sequencing of compressors & Priority based sequencing of compressors PC based operator interface for on-line monitoring, control, data logging, trending & history of alarms, report generation (SCADA) SCADA will have user security levels with passwords for monitoring & control Preventive maintenance schedules for various sub systems based on running hours PC based Monitoring Stations at multiple locations ( Max. 4 ) Ethernet communication using existing fiber optic cable between SCADA PC & monitoring Station PCs Provision to changeover to old controls in case of failure