Cost saving in compressed air systems

Compressed air system too often lack of transparency in terms of performance, costs and efficiency. Roughly 60,000 plants are in use in Germany. Although compressed air is the most expensive energy form, industrial corporations consume up to 40 % more of it than really necessary. Many plants are not adapted to the actual requirements or are in need of repair. Saving energy is key to reduction of green house gases and a healthy future. Besides it comes with huge saving in costs making the production more competitive in the global business world. The costs of compressed air can be split into the investment of equipment (compressor, dryer, etc.), the cost of maintenance and the cost of energy. Energy contributes the most to the overall costs and provides the biggest opportunity for savings. Leak repairs alone could save about 200 million in electricity and avoid about 1.7 million tons of carbon dioxide emissions every year. (Source: Fraunhofer Institute, Karlsruhe).
Cost distribution in compressed air systems:
Maintenance Equipment Electricity

Step 1: Measurement with DS 300-P

The very first step before any actions, if necessary, can be initiated is to get a full picture of the state of the the existing compressed air system. This is done by measuring and recording the essential parameters in the system, which are: current consumption of compressors, pressure profile, air delivery of compressors. Recording these values over one week answers following questions:
Flow

Clamp sensor

What is the total air consumption?

Compressor Dryer Pressure

How much electricity is used? Are the compressors running at optimum load conditions? What is the efficiency of the compressor? When are peak and low level consumptions? What is the pressure profile?
m /h
3

MPa

How much does the compressed air cost ? What is the potential cost saving for leakage

Typical data recording at a compressed air system

Features DS 300-P
Easy installation of sensors: Flow senor is inserted into the pipe through a 1/2 ball valve Amps sensor is clamped on one of the compressor life supplies Pressure sensor is clicked onto a fast connector Available measurement values: Total consumption in m3 Pressure dew point in Ctd Line pressure in MPa (bar) Current consumption in A Temperature in C Data recorder with 1,000,000 values Mains supply with short term battery operations

Data recorder DS 300-P

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Cost saving in compressed air systems

Flow Clamp sensor Compressor Dryer

Clamp sensor

Clamp sensor

Easy sensor connection through Quick-Disconnectors or through ball valves

DS 300-P6 can record up to 4 amps channels plus flow and dew point. In bigger systems where more than 4 amp channels are required, a number of DS 300-P can be used, and the recorded measurement data utilized in a single analyzes.

Clamp sensor

Step 2: Analyzes with Compressed Air Analyzer

m3 /h

After recording the data on the site, DS 300-P will be taken back to office for analyzes. The data is transferred to the appropriate PC and evaluated by the compressed air analyzer (CAA),which is especially designed to evaluate compressed air systems and allow the user to easily generate the required reports for the customer.

Memory read out and configuration of DS 300-P through PC and USB port

Compressed Air Analyzer 2.7.2

File Setting Tool View Help Compressed Air Analyzer Record Period: 23.10.09 18:12 to 30.10.09 18:15

Available types of analyzes

6.75 95.40 90.80 86.20 81.60 77.00 72.40 67.80 63.20 6.50 6.25 6.00 5.75

190000.0 180000.0 170000.0 160000.0 150000.0 140000.0 130000.0 120000.0

285.00 270.00 255.00 240.00 225.00 210.00 195.00 180.00

Pressure

5.50 5.25 5.00 4.75 4.50

1. Flow analyzes Cost calculation is based on a flow measurement. 2. Compressor analyzes Cost calculation is based on amps measurement of compressor.In this analyzes the flow values are calculated based on the compressor specs. 3.System analyzes This is a combination of 1 and 2.

Instantaneous flow

4.25

Pressure (bar)

Consumption (m3 )

110000.0 100000.0 90000.0 80000.0 70000.0 60000.0 50000.0 40000.0 30000.0 20000.0 10000.0 0.0

Flow (m 3 /min)

4.00 165.00 150.00 135.00 120.00 3.75 3.50 3.25 3.00

Velocity (m /s)

58.60 54.00 49.40 44.80 40.20 35.60 31.00 26.40 21.80 17.20 12.60 8.00

Total consumption
105.00 90.00 75.00 60.00 45.00 30.00 15.00 0.00 18:00 18:30 19:00 23.10.2009 Fri

2.75 2.50 2.25 2.00 1.75 1.50 1.25 1.00

Instantaneous velocity

0.75 0.50 0.25

19:30 20:00

20:30 21:00 21:30

22:00 22:30 23:00

23:30 00:00

00:30 01:00

01:30 02:00 02:30 03:00 03:30 04:00

0.50 04:30 05:00 05:30 06:00

Total consumption
Pressure

Instantaneous velocity

Instantaneous flow

Graphical analyzes of air consumption and pressure profile

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Cost saving in compressed air systems

Compressor settings
Measurement channels
Select current channel: Assign flow channel: Type of compressor:

Compressor 3
None Load/Unload

Copy to:

Compressor 1
1: 2: 3: VF Setting

Description Compressor 1 Compressor 2 Compressor 3

Status OK OK OK

Select

Step 3: Report generated with CAA

Comprehensive reports can be generated to document the measurement. Available are: Cover page with company address, logo. General comments Graphic reports of flow rates, pressure and/or any other recorded values on a daily or weekly basis

Compressor description: Air delivery Full load: Unload: Stop: 20

Compressor 3
Unit m3/min > > < Load/Unload Threshold(A) 184.4 101.4 10.1

Threshold setting

Supply voltage:

400.0

cos Setting

Cost Settings
6 Energy costs per kWh: 0.10 To 21 21 0.15 To 6 (O'Clock) Euros

Statistics report with energy consumption, load/unload cycles and costs.

Statistics Report
Previous 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 Next

OK

Cancel

Statistics for the selected time period : 30.07.2009 11:00:00 to 04.08.2009 13:00:00

Compressor 1 Load/Unload Atlas copco 132 Valid record time Load analyzes Full load time (hours[%]) Unload time (hours) Stop time (hours) number of starts number of load/unload cycles Energy Full load energy (kwh) Un load energy (kwh) Stop energy (kwh) Total energy consumption (kwh) Specific power (kwh/m3) Costs Full load costs (Euros) Unload costs (Euros) Stop costs (Euros) Total costs (Euros) Costs per m3 (Euros) Air delivery Average flow (m3/min) Max flow (m3/min) Total air delivery (m3) Leakage Average leakage (m3/h) Total leakage (m3 ) Leakage costs (Euros) CO2 Emission CO2 Emission (kg) Cumulated for 8400 h Load anaylzes Full load time (hours[%]) Unload time (hours) Stop time (hours) Number of starts Number of load/unload cycles Energy Full load energy (kwh) Unload energy (kwh) Stop energy (kwh) Total energy consumption (kwh) Costs Full load costs (Euros) Unload costs (Euros) Stop costs (Euros) Total costs (Euros) Air delivery 0.0 h 0.0 h (0%) 0.0 h (0%) 0.0 h (0%) 0 0

Compressor 2 Load/Unload Atlas copco 132 0.0 h 0.0 h (0%) 0.0 h (0%) 0.0 h (0%) 0 0

Compressor 3 Load/Unload Atlas copco 132 120.6 h 18.4 h (15%) 4.9 h (4%) 97.3 h (81%) 16 376 2340.0 2108.7 217.0 14.2 2340.0 0 .1

Sum Of All

Compressor settings can be entered in order to calculate the energy costs and to determine the load/unload intervals. Up to 12 measurement channels (amp channel) are available.

Step 4: Actions
Based on the analyzes a couple of measures should be taken to optimize the compressed air system. These will vary from system to system, but typically include following options:

0.0 0.0 0.0 0.0 0

0.0 0.0 0.0 0.0 0

2108.7 217.0 14.2 2340.0 0.1

0 0 0 0 0

0 0 0 0 0

210 21 1 234 0.0106

210 21 1 234 0.0106

0 0 0

0 0 0

3.05 20 22073

3.05 20 22073

0 0 0

0 0 0

0 0 0

0.0 0 0

1286

1286

0 0 0 0 0

0 0 0 0 0

1281 h 342 h 6777 h 1114 26188

0 0 0 0

0 0 0 0

146868 15115 991 162975

146868 15115 991 162975

0 0 0 0

0 0 0 0

14686 1511 117 16315

14686 1511 117 16315

Leak detection with LD 300

Check for leaks in the compressed air system and fix them. They are usually to be found at joints and connection points, and fix them. (50 holes smaller than 1 mm can cost 11,000 Euro per year) According to the load/unload analyzes and pressure profile the compressor control and setup has to be optimized. By the use of modern compressor management systems the unload times can be minimized. (during unload the compressor consumes ~30% of the full load energy, but delivers no air) Reduce pressure if possible (reducing the line pressure by 100 kPa saves 8% energy) Reduce inlet temperature (10 degree drop in inlet temperature can save 3 % energy) Optimize the piping system, avoiding unnecessary pressure drops

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Specification DS 300-P
Number of inputs DS 300-P2 2 digital inputs DS 300-P4 2 digital inputs 2 analogue inputs DS 300-P6 2 digital inputs 4 analogue inputs Digital input: Dew point sensor FA 410 Flow sensor VA 400 Analogue input: Pressure sensor Clamp-on Amp sensor 0-20, 4-20 mA 0-1V, 0-10V Pt100/Pt1000 USB 100-240 VAC, 50-60 Hz, Internal rechargeable battery (5 hours operation) Accuracy 1) Dew point: Flow: Pressure: Amps: Typical 2 Ctd 3 % of reading 0.5 % F.S 5% < 25A. 2 % >100 A 1 % > 250 A 0.01 mA 0.01 V 0.5 C 0.5 C -80 ... +20 Ctd See sensor specs. 0 ... 4.0 MPa,gage 0 ... 500 A -200 ... 600 C -200 ... 600 C

Connectable sensors

0-20 mA: 0-10 V: Pt100: Pt1000: Measuring range Dew point: Flow: Pressure: Amps: Pt100: Pt1000: 0 ... 50 C -20 ... 70 C 2400 g

Interface Power supply

Memory Operating temperature Transport temperature Weight Dimensions

1,000,000 values

265 x 220 x 150 mm

Order no.
0500 3101 0500 3225 0500 3226 0695 0083 0695 0122 0699 0419 0694 1886 0694 0356 0554 0500 0604 0100 0553 0103 0553 0110 0554 6005 0599 2010 0554 6003 0554 6004 0599 7010

Description
DS 300-P2, 2 channel data recorder, including USB cable, mains cord. DS 300-P4, 4 channel data recorder, including USB cable, mains cord. DS 300-P6, 6 channel data recorder, including USB cable, mains cord. Flow sensor VA 400, standard range, 5 m cable Flow sensor VA 400, max range, 5 m cable Dew point sensor FA 410, -80 ... +20 Ctd, DS 300 portable, including 5 m cable, measuring chamber. Pressure sensor, 0 - 1.6 MPa Pressure sensor, 0 - 4.0 MPa Clamp-on amp sensor 0-1000 A Pt100 probe type A, 160 x 6 mm, 5m cable Extension cable DS 300-P, ODU connection male-female, 5 m Cable 5m, 5 pole, with ODU connector, for DS 300-P, open wires Probe case Compressed Air Analyzer CAA Compressed fitting 6mm,G ", PTFE ring, pressure rating: 0.6 MPa Compressed fitting 6mm, G ", metal ring, pressure rating:1.6 MPa CS Soft single license (please contact us for multi-user licenses)

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