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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(s
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 d
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 dif
'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 Comp
Energy
Service
Reduce pressure
11 SEAI operates an accelerated capital allowance (ACA) scheme, which is a tax incentive for companies to purchase energy ef
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'.
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
point of energy service demand and work back upstream through the energy distribution and conversion system(s) this is
ith the energy efficiency hierarchy.
ology that is currently satisfying each energy service demand appropriate? Or can it be eliminated or replaced by a more
ernative?
em be designed better?
most efficient / optimum operational control parameters for the most effective technology to satisfy each service demand.
mes be adjusted?
portunities 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.)?
here O&M or housekeeping actions that can be taken to reduce the consumption of energy resources?
g 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.
t to do with the
ir?
the compressed
ndamental piece of
nt compressed air to
d energy to deliver
vice?
er way of delivering
requires using less
ss energy intensive
nimum specification
Housekeeping
Repair Leaks
Control Systems
Variable Inlet Volume
Plant Design
VSD Control
Process
Technology
Multiple-stage Compressor
Energy
Service
Reduce pressure
es an accelerated capital allowance (ACA) scheme, which is a tax incentive for companies to purchase energy efficient
t allows companies to write off 100% of the purchase value of specified energy efficient equipment in the year of purchase.
h 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
ormation available on the qualifying equipment. There is also an ACA worksheet in this spreadsheet.
Compressed Air
- Reduce System Pressure
If pressure is set higher than needed then energy is being wasted. The discharge pressure set point range should be
set to the minimum level needed for process air requirements.
Example
Your Data
Unit
Comment
Sum of all compressor, cooling fan and dryer motor ratings
Motor Power :
150.00
[kW]
Motor Efficiency :
90%
[%]
% Full Load :
65%
[%]
8,400
[h/y]
Pressure Reduction :
1.00
[bar]
Annual Energy
:
Consumption
910,000
% Savings :
6.5%
59,150
0.140
8,281
#DIV/0! [kWh/y]
0.0%
[%]
= (Motor Power [kW]) / (Motor Efficiency [%]) x (% Full Load [%]) x (Operation
Hours [h])
= (Pressure Reduction [bar]) x (6 - 7% saving per bar)
[/y]
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
Compressed Air
- Energy Wasted from Leaks
Leaks are an unfortunate but regular feature in compressed air distribution networks. Typically, the energy
requirements served by a compressed air system are intermittent in nature; however leaks are constant and potentially
significant. The monetary cost of leaks can be quite startling, and surprising. In order to move forward with any leak
reduction programme, it is important to benchmark the current leakage rate. The extent to which a compressed air
system is leaking can be easily determined during non-production hours through assessment of Monitoring & Targeting
(M&T) data (if present) or through manual pressure indicator readings in the distribution network with some quick
calculations.
A first cut estimate of the percentage of air leaked in a system can be calculated using the following method.
Method : During a period where there is no demand for the compressed air allow the compressor to build up the
system pressure until it reaches the shutoff point. Then, for a given period of time (e.g 30 minutes), record the time the
compressor runs for and the time that it is shut off. The percentage of air that is leaking from the system can be
estimated using the following formula.
% of Air Leaking = (Time in Operation x 100 ) / ( Time in Operation + Time not in Operation )
The above formula can be modified to calculate the rate of air leakage, giving:
Rate of air leakage [l/s] = (Rated F.A.D of Compressor [l/s] x Time On Load [sec]) / (Time on Load [sec] x Time
off Load [sec])
Example
Your Data
200
Unit
Comment
[l/s]
Rated Free Air Delivery rate of the compressor (200 l/s typical for a 75kW
Compressor)
Time on Load
[min]
10
[min]
% Air Leaks :
23%
#DIV/0!
[%]
= (Time on Load [min] x 100) / (Time On Load [min] + Time Off Load [min])
46
#DIV/0!
[l/s]
Approximate Energy
:
Wasted
32,308
#DIV/0!
0.140
Approximate Energy
:
Cost of Leakage
4,523.08
#DIV/0!
[/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.
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
Compressed Air
- Savings from Reducing Leaks
Leaks are an unfortunate but regular feature in compressed air distribution networks. Typically, the energy
requirements served by a compressed air system are intermittent in nature; however leaks are constant and
potentially significant. The monetary cost of leaks can be quite startling, and surprising.
Example
Your Data
Comment
Unit
Motor Power :
111.90
[kW]
Motor Efficiency :
92%
[%]
Motor efficiency for compressor that can be Switched Off (default = 92%).
70%
[%]
6,000
[h/y]
510,848
#DIV/0! [kWh/y]
0.140
[/kWh]
71,519
#DIV/0!
[/y]
= (Motor Power of Compressor that is turned Off [kW]) / (Motor Efficiency [%])
x (Average Part Load of Compressor [%]) x (Annual Operating Hours [h])
Insert from Energy Bills Analysis Tool
= (Annual Energy Savings [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.
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.
Compressed Air
- High Efficiency Motor
Compressors usually do not come with high efficiency motors as standard; however, they are often offered as
options. If the compressor will have long annual run hours, then a high efficiency motor may be more economical.
Example
Your Data
Comment
Unit
Compressor motor rating
Motor Power :
111.90
[kW]
Motor Efficiency :
92%
[%]
% Full Load :
65%
[%]
8,760
[h/y]
11,111
0.140
1,555
[]
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.
Compressed Air
- Multiple-stage Compressor
Normally buyers may select between a single-stage and a two-stage machine when purchasing an air compressor.
In most cases, multiple-stage compression results in more efficient operation. Multiple-stage means that the final
discharge pressure is generated over several steps. Efficiency is significantly increased as a result of the cooling of
air between stages, thereby reducing the volume and work required to compress the air. In the case of reciprocating
compressors, each stage usually requires a separate cylinder, and in rotary screw compressors, each requires a
separate rotor disc; in either case the air is passed though the stages in succession.
Example
Your Data
Comment
Unit
Compressor motor rating
Motor Power :
111.90
[kW]
Motor Efficiency :
92%
[%]
% Full Load :
65%
[%]
8,760
[h/y]
13%
[%]
% Savings over
Single- stage:
Annual Energy Savings :
90,033
#DIV/0! [kWh/y]
0.140
[/kWh]
12,605
#DIV/0!
[]
= (Motor Power [kW]) / (Motor Efficiency [%]) x (% Full Load [%]) x (Operation
Hours [h]) x (% Savings over Single-stage)
Insert from Energy Bills Analysis Tool
= (Annual Energy Savings) x (Average Electricity Price [/kWh])
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%.
Compressed Air
- VSD for Part Load Control
Traditionally, a number of compressors provide the base load at a facility with one compressor providing top up. A
standard compressor operating in this top up mode cannot ramp up and down to track transient demands; airflow is
typically controlled by a valve that modulates between open and closed positions. Unfortunately, this method results
in a higher discharge pressure, lower part load efficiencies, and increased overall power consumption. Accordingly, a
strong economic case can often be made for installation of Variable Speed Drive (VSD) motor for the compressor at
facilitates displaying inherently variant demand profiles for the top up compressor.
Example
Your Data
Comment
Unit
Compressor motor rating
Motor Power :
150.00
[kW]
Motor Efficiency :
92%
[%]
VSD Efficiency :
96%
[%]
75%
[%]
6,000
[h/y]
27.39
[kW]
= (Motor Power [kW]) / (Motor Efficiency [%]) x 70% x (100% - Average Part
Load Condition [%]) x VSD Efficiency [%]
164,348
0.140
23,009
#DIV/0!
#DIV/0! [kWh/y] = (Average Power Saving [kW]) x (Annual Operating Hours [h/y])
[/kWh]
#DIV/0!
[/y]
Payback:
Compressed Air
- Variable Inlet Volume for Part Load Control
Traditionally, a number of compressors provide the base load at a facility with one compressor providing top up. A
standard compressor operating in this top up mode cannot ramp up and down to track transient demands; airflow is
typically controlled by a valve that modulates between open and closed positions. This control scheme is applied to
rotary screw compressors, but is an inefficient means for controlling compressor output for displacement
compressors. Most manufacturers offer options in the larger compressors (>75 kW) that have more efficient part
load characteristics. In one model, which is the variable inlet volume model, the length of the compression chamber is
effectively decreased by the use of internal valves, allowing the compressor to reduce airflow quite efficiently down to
about 50% of rated full flow capacity.
Example
Your Data
Comment
Unit
Compressor motor rating
Motor Power :
150.00
[kW]
Motor Efficiency :
92%
[%]
75%
[%]
6,000
[h/y]
18.34
[kW]
= (Motor Power [kW]) / (Motor Efficiency [%]) x 45% x (100% - Average Part
Load Condition [%])
110,054
0.140
15,408
#DIV/0!
#DIV/0! [kWh/y] = (Average Power Saving [kW]) x (Annual Operating Hours [h/y])
[/kWh]
#DIV/0!
Payback:
[/y]
Example
Your Data
Comment
Unit
100,000
12.5%
12.5%
[%]
98,438
[]
Standard capital allowance allows firms to write off 1/8 of capital cost against
tax each year (for 8 years)
87,500
[]
Accelerated capital allowance allows firms to write off ALL of capital cost
against tax in first year
10,938
[]
= (Actual Year 1 Net Cashflow without ACA) - (Actual Year 1 Net Cashflow
with ACA)
Discount Rate :
9.0%
[%]
[]
PV of standard Capital
Allowance
9,426
[]
Present Value (PV) to your business of the Standard Capital Allowances, i.e.
no ACA
PV of Accelerated
Capital Allowance
12,500
[]
Description of Modification(s)
Date
1.0
5/19/2008
1.1
5/19/2008
1.2
5/22/2008
1.3
12/18/2008
2.0
6/9/2009
3.0
10/5/2010
ol Version History
Additional Comments