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Slide 2: Many Thanks to the US Department of Energy & the Compressed Air Challenge
This course was produced using material from the US Department of Energy’s “Improving Compressed Air
System Performance”. The source book is free and available for download from the Compressed Air
Challenge website: www.compressedairchallenge.org.
Slide 3: Welcome
For best viewing results, we recommend that you maximize your browser window now. The screen controls
allow you to navigate through the eLearning experience. Using your browser controls may disrupt the
normal play of the course. Click ATTACHMENTS to download important supplemental information for this
course. Click the Notes tab to read a transcript of the narration.
Slide 4: Objectives
At the completion of this course, you will be able to:
Manage a seven-step action plan to improve the efficiency of your system to save money
Recognize the cost of leaks and benefits of a maintenance program to save energy
List inappropriate uses of compressed air and alternative methods to do the tasks
Slide 5: Introduction
Compressed air is commonly referred to as the fourth utility. Utilities play a major role in the modern world –
without them, today’s technologically advanced society could not function. While compressed air systems
are widespread, they can also be extremely inefficient. Compressed air systems typically consume more
energy and cost more to operate than anything else in industrial environments. All of that can change by
utilizing an action plan that will help reduce inefficiencies, thereby saving valuable assets.
In this class, we will explore a seven step action plan designed to improve the efficiency of any compressed
air system.
If you have the required skills in house you can implement this plan with your compressed air team.
Otherwise you may benefit from outside support from an expert.
A block diagram is a simple drawing that identifies all the components in the system. This ensures that you
know what all the components are, and can ensure they are adequately covered by preventative
maintenance plans, and replacement provisions as necessary. It also identifies all the points of use which
allows you to analyze the appropriate use of the expensive compressed air.
Here is a simple block diagram for a dual-compressor system, with filter, dryer, receiver, distribution system,
and end uses.
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Compressed Air VI Seven Steps to Better Efficiency
This diagram is for a more complicated facility with 11 compressors, after-coolers, dryers, filters, final filters,
distribution piping and service to large plant loads regulated at the machines.
To do this
Measure your baseline (kW, pressure profile, demand profile, and leak load) and calculate energy use and
costs.
Document operating schedules
Document control methods
Measure or estimate power (demand and energy) for each major piece of supply-side equipment
Determine system performance
Calculate the cost of air
A system pressure profile looks like this. Two transmission and distribution piping pressure-drop lines are
shown; a high-loss drop is shown in red line color, and a good system with low pressure-drop is shown with
a green line.
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Compressed Air VI Seven Steps to Better Efficiency
Document:
The operating range of your compressors
The normal expected pressure drop of dryers
Filters as measured on-site, and
The system pressure profiles as distributed to end-users.
Inspect for any opportunities to reduce air pressure supplied to the plant by the air compressors.
Remember the high financial penalty for higher than needed pressure.
Note this diagram is a snapshot of a certain point in time. To get a more complete picture data loggers
should be used to capture the effect of intermittent loads and changing behaviors. Be sure to measure and
document pressure drop in distribution lines and determine if pipe size is adequate.
Pressure drop is a term used to characterize the reduction in air pressure from the compressor discharge to
the actual point-of-use. Pressure drop occurs as the compressed air travels through the treatment and
distribution system.
A properly designed system should have a pressure loss of much less than 10% of the compressor’s
discharge pressure, measured from the receiver tank output to the transmission system. The longer and
smaller the diameter the pipe is, the higher the friction loss. In general this means that total pressure drop
should not exceed 1 bar or 15 psi across all compressed air system components, including piping.
Pressure drops caused by corrosion and the system components themselves are important issues. Excess
pressure drop due to inadequate pipe sizing, choked filter elements, improperly sized couplings and hoses
represent energy wastage.
Inlet to compressor compared to atmospheric air pressure - to find the pressure drop across the inlet air
filter;
Differential across the air/lubricant separator, if there is one;
Across each stage of the compressor;
Across the aftercooler;
Treatment equipment such as dryers and filters; and
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Various points in the distribution system.
The left hand side shows the supply side drop across the compressors, and secondly the dryers and filters
The right hand side shows the measurements taken at various points in the distribution system.
Enter the pressure measurements on the chart for reference as shown. In this example, the system was
not near full load and has excessive pressure drop that can benefit from improvement.
One cause of unacceptable pressure drops is old distribution piping that was originally designed for another
process that is now too small for current processes. It’s not unusual to find this in older plants where
packaging or other air intensive processes have been added.
The type of control specified for a given system is largely determined by the type of compressor being used
and the facility's demand profile. If a system has a single compressor with a very steady demand, a simple
control system may be appropriate. On the other hand, a complex system with multiple compressors,
varying demand, and many types of end-uses will require a more sophisticated strategy. In any case, give
careful consideration to compressor and system control selection because they can be the most important
factors affecting system performance and efficiency.
In previous classes we discussed Start-stop, Load/Unload, Modulation, multi-step, and variable speed drive
compressors. In addition to these methods of capacity control, single-master and multi-master controls are
used to manage larger systems. Master control systems carefully stage on and off compressors as needed
for minimum energy consumption and offer the advantage of more precise low air pressure supplied to the
site for reliable production.
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Compressed Air VI Seven Steps to Better Efficiency
Doing this helps bring the system in line and to establish savings related to improper control settings.
Following these steps will uncover energy waste and needs for repairs out in the system.
Flow meters are valuable in larger systems to measure total flow profiles and to determine normal
consumption and waste. Flow should be measured:
During various shifts to discover variations in end use caused by equipment or operating personnel
As energy saving measures are implemented to monitor, verify savings, and sustain savings over time
For leaks during non-production periods track waste that can be eliminated with off-shift maintenance
Preventative maintenance items can be implemented quickly for immediate savings and improved system
reliability. Implement maintenance at prescribed intervals for compressors, dryers, filters, traps, control
valves, and meters.
Be sure to:
Inspect hoses, traps, fittings and valves for obvious maintenance problems or leaks. Look for
excessive pressure drop, high pressure dewpoint levels from dryers, and other issues leading to
energy waste.
Inspect end uses and find failed components or systems such as bag filter houses that use electric
solenoids. These can sometimes fail open undetected and vent a large amount of compressed air.
Know costs, re-measure, and adjust controls.
In addition to wasting energy, leaks also contribute to other operating losses. Leaks cause a drop in system
pressure, which can make air tools function less efficiently, adversely affecting production. In addition, by
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Compressed Air VI Seven Steps to Better Efficiency
forcing the equipment to run longer, leaks shorten the life of almost all system equipment (including the
compressor package itself). Increased running time can also lead to additional maintenance requirements
and increased unscheduled downtime. Finally, leaks can lead to adding unnecessary compressor capacity.
We can reduce the waste due to leaks by minimizing the system pressure. All unregulated end uses will
use more air when pressure increases, so keeping the system pressure as low as possible saves money.
Common leak locations include pipe joints, drains, couplings, hoses and fittings and filters, regulators and
lubricators. However leaks can occur anywhere in the compressed air system and at any time. Abandoned
air lines can have leaks even when there is no equipment connected, so it’s a good idea to valve off
abandoned lines. Be suspicious of more fragile components such as regulators, solenoids, and control
valves. Also inspect pipe fittings and joints, especially those high and out of reach, and sometimes out of
sight.
Maintenance personnel should inspect compressed air lines weekly. Periodically a leak survey should be
carried out using an ultrasonic leak detector. A quick, non technical method is to walk through the plant
when noisy equipment is not running and listening for the characteristic hissing sound of a leak.
SI Units Example -
Look at the two tables which relate to the flow and cost of air leaks of different sizes at different pressures.
Let’s imagine that you are paying €0.10 per kWh and the efficiency of your compressor is 10.5 kW per 100
CMH.
What would you lose from a leak measuring 1mm in diameter at a pressure of 6.0 bar g?
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A leak of that size would leak 3.89 cubic meters per hour and would cost around €360 per year
A leak twice the diameter, 2 mm, would leak 4 times as much, 15.58 CMH. That would be €1,430 per year
A leak of 5 mm would be over 4 times again, 97.4 CMH, at a cost of nearly €8,960 per year
US Units Example -
Look at the two tables which relate to the flow and cost of air leaks of different sizes at different pressures.
Let’s imagine that you are paying $0.10 per kWh, and the efficiency of your compressor is 18 kW per 100
cfm.
What would you lose from a leak measuring 1/32 inch in diameter at a pressure of 90 psi?
A leak of that size would leak 1.48 cubic feet per minute and would cost around $230 per year
A leak twice the diameter, 1/16 inch would leak 4 times as much, 5.92 CFM. That would be $930 per year
A leak of 1/8 inch would be over 4 times again, 23.7 CFM, at a cost of nearly $3,740 per year
If you have not already done so, you can download charts showing the losses from leaks of various sizes
and various pressures. Click the ATTACHMENTS link.
Note that surveyors typically will not attempt to measure leaks to this degree of accuracy. It’s more
important to identify the larger ones and fix them, than to estimate them all individually.
In summary leak detection and repairs in compressed air systems are essential to efficient operation.
As mentioned before, this should be less than 10% in a well-maintained system. It can be as high as 20 to
30% in a poorly maintained system.
1. The volume of the distribution system must be estimated, by adding the volume of the mains, piping, and
any secondary receivers.
2. Once the delivery network is at full pressure, the compressor is turned off. The delivery valve between
the compressor and the receiver is closed.
3. The pressure gauge is monitored to determine the time (t) in seconds for the pressure to decay by
exactly 1 bar or 15 psi.
4. The leakage rate can be calculated using this formula.
The result will be in cubic metres per second, or litres per second, or cubic feet per second depending on
what units are used for the volume. Note that, at lower system pressures, this method will return less
accurate results.
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The leakage is given in cubic feet per minute
V is the system volume
p1 and p2 are the pressure measurements
T is the time in minutes for p1 to fall to p2.
14.7 is atmospheric pressure.
1.25 is an adjustment to correct the leakage to normal system pressure, allowing for reduced leakage as
the system pressure falls.
A small leak of 1.5 CMH or 1 CFM cannot be felt and cannot be heard with just your ear.
A large leak of 150 CMH or 100 CFM will be painfully loud if you are standing close to it.
Surveyors may use an approximate classification of small, medium and large to assign flow values to leaks
they have detected and estimate the costs.
A simple maintenance and repair program can save this site over $21,000 with repair costs that typically
pay back in a few months rather than years.
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Nozzles can greatly increase the force of a compressed air stream, developing more thrust with less
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Compressed Air VI Seven Steps to Better Efficiency
compressed air.
Despite using less high-pressure compressed air, nozzles actually increase the amount of delivered air flow
because they are designed to draw in and accelerate ambient air. Some manufacturers claim that well-
designed nozzles can increase overall delivered air flow by a factor of 25 while using less compressed air
than a simple tube.
Many nozzles are adjustable, allowing the user to optimize the amount of air used for a particular
application.
Nozzles, because of the vents in their sides, are more difficult to obstruct than simple cut-off tubes. This
can improve worker safety.
Sparging is aerating, agitating, oxygenating or percolating liquid with compressed air. Low pressure
blowers and mixers can be used instead – and may actually have better results.
Aspirating is using compressed air to induce another gas to flow. Atomizing is using compressed air to
disperse a liquid, with an aerosol effect. Low pressure blowers may be used instead.
Padding is using compressed air to transport liquids and light solids, for example when unloading a tank.
Low or medium pressure blowers may be used instead.
Dense-phase transport is used to move solids in a batch format. The batch is typically weighed in a
transport vessel, padded with compressed air, forced into a transport line and then moved with a boost of
compressed air at the beginning of the transport pipe. Once a plug of the material is moving the material
may be fluidized with booster nozzles along the path. The material is usually transported to a holding
vessel that dispenses it as needed. This uses control air for the equipment, pad air, transport air and the
booster fluidizers. The peak energy to support this process can be reduced if metered storage is used, and
if a blower can be used for the transport air.
Personnel cooling is an abuse of the compressed air system when operators direct the flow onto
themselves for ventilation. It is not only an extremely expensive cooling method, but is dangerous because
it can fire particles into the skin. An electric fan can deliver much the same cooling effect for 1% to 4% of
the power.
Open hand-held blowguns or lances must conform to occupational health and safety standards.
Unregulated hand held blowing is a violation of most codes. The proper gun and nozzle must be chosen,
and should have a spring-operated throttle so that is shuts off automatically if dropped.
Cabinet cooling can be found in hot environments where heat-sensitive equipment is located, such as
motor control centers, programmable controllers, relay panels and computer cabinets. Thermoelectric
coolers or air conditioners can do the job more efficiently, using much less energy but make sure to
examine and account for maintenance costs when considering air conditioners.
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Any end use which does not have a fitted pressure regulator will use full system pressure, and potentially
waste air.
Idle or abandoned equipment may be located at the end of a considerable length of distribution piping,
which is prone to leaks and influences the pressure profile of the system.
Air flow to unused equipment should be stopped, preferably as far back in the distribution system as
possible without affecting operating equipment.
Idle equipment is equipment that is temporarily not in use during the production cycle.
For idle equipment an air-stop valve at the compressed air inlet may be the most convenient solution, since
it may be necessary to bring the equipment back into service at short notice.
At 7 bar or 100 psig discharge pressure, most air compressors deliver 6.6 to 8.4 CMH per kW or 4-5 CFM
per horsepower.
Every 0.14 bar or 2 psig of pressure changes the power draw of a compressor by 1%.
Efficiency is affected by about 1% for every 5.5°C or 10°F change in inlet air temperature. Warmer
temperature decreases and colder temperature increases efficiency.
Compressors convert 80% to 90% of their incoming energy to heat. 50% to 90% of this can be recovered
and used for thermal energy.
A 37 kW or 50 hp compressor rejects about 30 kW or 100,000 Btu per hour. It is possible to regain a
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significant amount of this in the form of heat recovery, perhaps 24kW or 80,000 Btu per hour.
The power cost for a 1 kW compressor for three shifts, seven days a week (8,760 hours) at €.10/kWh
equals approximately €877 per year. Similarly 1 horsepower on a similar schedule costs approximately
$750 per year.
The control air receiver located after the compressor should be sized for about 2.2 liters per CMH of
compressor capacity or 1 gallon capacity per CFM.
To ensure an effective demand side control management system, the storage air receiver should be sized
for about 4.4 liters per CMH to 8.8 liters per CMH or 2-4 gallon capacity per CFM of compressor capacity.
Total pressure drop should not exceed 1 bar or 15 psi across all compressed air system components,
including piping.
Take time to do the energy efficiency process right away. Include manufacturing and other stakeholders in
the assessment process so they understand why you are trying to save energy and costs. This chart
depicts tool output capability compared to tool pressure. Your best results are sustained with a team
approach and careful implementation that doesn’t have unwelcome impacts on production.
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Compressed Air VI Seven Steps to Better Efficiency
Leaks can be extremely expensive and should be detected and fixed regularly as part of a maintenance
program.
Compressed air can be inappropriately used for applications such as open blowing, mixing, aspirating,
vacuum generation, personnel cooling and others. Often there are cheaper alternatives or easy
modifications including mixers, blowers, nozzles, and even simple brushes and brooms.
Seven steps to bring your compressed air system under control are:
1. Develop a block diagram
2. Measure your baseline
3. Implement appropriate control
4. Re-measure
5. Maintenance walk-through
6. Identify and fix leaks
7. Re-evaluate and continuously improve
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