Compressed Air Energy Efficiency

A. Bhatia, B.E.

Course Outline

Most manufacturing facilities use compressed air for at least some functions. For many plants, energy for compressed air systems can account for up to 35% of the total electrical power billing of a facility.  Over 15% of total motor energy in the industrial sector goes to producing compressed air, yet compressed air systems are inherently inefficient, producing only one unit of useful work for every 5 units of energy input. It is obvious that the electrical costs of your particular installation need to be fully understood.

This 6 -hour course explains how the optimum selection, control and maintenance of compressed air plant can improve plant energy efficiency and reduce operating costs. 

This course includes a multiple-choice quiz at the end, which is designed to enhance the understanding of the course materials.

Learning Objective

At the conclusion of this course, the reader will:

• Understand various types of compressors; their applications, advantages and limitations;
• Understand various types of system controls; their pros and cons;
• Understand how the control systems are matched to the needs of the users;
• Understand the key components of compressed air system and learn how each component functions;
• Describes the air storage, air drying, piping, filtration and air cleaning methods;
• Understand the limits of dew point suppression in refrigerant and desiccant dryers;
• Understand the different types of filters and how coalescing filters benefit in removal of lubricant and moisture;
• Understand the difference between SCFM, ICFM, ACFM and FAD;
• Understand the pros and cons of centralized v/s de-centralized systems;
• Understand how to quantify and select appropriate compressor for base and trim demand;
• Understand what features to specify and what information to seek when making a compressed air proposal;
• Understand the compressed air system assessment procedure and energy audit methodology;
• Understand the common losses in compressed air systems and the ways to conserve energy;
• Understand the impact on energy when delivering compressed air at higher pressures, taking high temperature intake air and inappropriate leakages;
• Understand the routine maintenance schedule for air compressors;
• Learn a generic checklist for energy efficiency in compressed air system;
• Understand the engineering formulae and technical relationship between compressor motor power-draw and process variables; and
• Learn by example the method for evaluating compressed air costs.
  

Intended Audience

This course is applicable to mechanical engineers, energy auditors, facility managers, operation and maintenance personal and others in the design and renovation of facilities.

Benefit to Attendees

It will help you determine the current limitations of your existing system and guide you through the process towards finding the best solution, including:

• Improving the existing system
• Designing a new system
  
  

Course Introduction

Compressed air is widely used for industrial machinery, cooling, hand tools, materials handling, extrusion processes, paint spraying and blow moulding as well as generic processes such as vacuum production and manipulation processes and control applications. Because many industrial compressed air systems operate at only a fraction of their potential efficiency, there are excellent opportunities for energy savings.
The course describes how to select appropriate compressed air equipment and how to conserve energy in compressed air operation. Discussion will be in five modules which cover:

SECTION #1               Compressor Types and Controls: Describes various types of compressors commonly used and how the control systems are matched to the needs of the users.
SECTION #2               Compressed Air Systems Auxiliary Components: Provides an overview of the key components of compressed air system and what each component does.
SECTION #3               Choosing the Right Compressor Package: Compares various options on the technical parameters and energy efficient features.
SECTION #4               Compressed Air System Assessments: Provides an overview of the energy audit methodology.
SECTION #5               Energy Efficiency Measures: Provides an overview of the common losses in compressed air systems and the ways to conserve energy.

 

Course Content

This course is in the following PDF document:

Compressed Air Energy Efficiency

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Course Summary

Compressed air is often referred to as the “fourth utility” in industrial facilities—after electricity, natural gas, and water. In terms of electrical power usage and direct electrical power costs, the air compressor installation is probably the highest and most inefficient in terms of energy usage. This course proposes the following action plan in order to improve efficiency in compressed air systems:

• Analyze the compressed air needs
• Avoid inappropriate use of compressed air
• Reduce air system leaks
• Analyze operating data and working regime of the production system
• Check for opportunities at the component level
• Check for opportunities at the system control level
• When an optimization is implemented, continue to monitor the performance
• Continue to monitor and optimize the system

Energy efficiency measures can achieve significant energy savings, as high as 50 percent in some cases. Because of expensive operating costs, improving the energy efficiency of compressed air systems often payback investment in short time.

Quiz

Once you finish studying the above course content, you need to take a quiz to obtain the PDH credits.

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DISCLAIMER: The materials contained in the online course are not intended as a representation or warranty on the part of PDH Center or any other person/organization named herein. The materials are for general information only. They are not a substitute for competent professional advice. Application of this information to a specific project should be reviewed by a registered architect and/or professional engineer/surveyor. Anyone making use of the information set forth herein does so at their own risk and assumes any and all resulting liability arising therefrom.

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