Energy Efficiency in Compressed Air Solutions At A Glance COMPRESS YOUR AIR COSTS Compressed air finds widespread and varied usage in the manufacturing industry and is considered the fourth utility. Due to its nature, compressed air is considered to be a free utility. On the contrary, according to a US Department of Energy study, generating compressed air consumes an average of 10% of electricity in any plant. For industries like automobiles and cement, it may be as high as 30%. Inefficient generation and leakages further add to the generation cost. Compressed Air Atmospheric Air Compression ` 60,000 54,43,000 ` 50,000 ons llati sta ` 40,000 ` 30,000 her rns ig hb wit in ger retu 27,22,000 Hig ` 20,000 ` 10,000 13,61,000 6,80,000 ` 0 1 2 3 4 Important Facts • You may be spending upto Rs 31 lakhs per annum on operating your 90KW compressor • 30% of your electricity cost may be through compressed air • Cost of off-load running a 90KW compressor for 4 hours daily is Rs 1.3 lakhs per annum • Leakages contribute to upto 40% of your compressed air costs, costing upto Rs 15 lakhs per annum. • A single1/8” leak at 6.5 bar drains out Rs 1.5 lakhs per annum. • Over pressurization by even 0.5 bar costs you Rs 1lakh per annum • Compressed Air is costlier than Steam What are your losses? Sources of losses in a compressed air network can be of a varied nature. They can range from the obvious to the hidden, from the large to the very small. Putting together all these can harm your system in significant ways 1) Leakages Typical compressed Air Consumption 2) Inefficient generation 3) Inefficient distribution 4) Malpractices 5) Insufficient storage Leak 25% Production 65% Artificial Demand 15% Factors affecting the efficiency of compressed air systems • Inefficient compressors • Over pressurisation • Unbalanced compressed air requirement • Insufficient storage • Compressed air malpractices • Piping issues and angle connections • Moisture traps, filters etc malfunctions How can you save? Achieving energy efficiency and cost savings on compressed air networks takes patience, expert guidance and meticulous planning. Compressed air as a utility, is often disregarded, and becomes a large source of losses. To address this issue one has to look beyond the just the obvious sources – leakages and compressor inefficiency – and closely look at other avenues: 1. Reduce over-pressurisation 2. Balance your air requirement 3. Eliminate improper usage 4. Add to insufficient storage 5. Correct piping issues The steps taken towards energy savings by most companies, while being effective, only scratch the surface of the overall savings potential. In order to achieve greater efficiency and to tap hidden potential, one must delve deeper and go in for more thorough measures. Forbes Marshall’s Air Efficiency Solutions help in identifying the necessary measures to achieve industry best practices. You cannot save, unless you measure Present Savings hidden Savings by Proper Monitoring, Metering and Controlling of Compressed Air Solutions at a glance Air Audits - The air audit helps you identify various losses in compressed air networks and recommends solutions which help in reducing the compressed air costs. MAC - Master Air Control (MAC) is a demand side load controller which helps reduce energy costs by eliminating artificial demand and ensures a steady delivery. SequenceAIR - SequenceAIR is an intelligent compressor sequencing controller which delivers an efficient and economical compressed air system. CountAIR - CountAIR is a comprehensive monitoring solution for compressed air networks. It keeps track of compressed air from generation to consumption and aids in running the compressed air network in balance. FAD Meter - The FAD meter with online pressure and temperature compensation is an ideal and highly accurate solution for monitoring compressor efficiency. AirMon - AirMon is an innovative cost-effective flowmeter for monitoring of compressed air on plant lines. Compressed Air Audits We offer a comprehensive bundle of services that help optimisation of compressed air networks. Our offerings go beyond just leak detection, the Forbes Marshall air audit will help you identify and define your system problems, whether they are in demand, distribution or supply and recommend solutions, allowing you to meet your return on investment goal. Overview study Audit & data collection Recommend Analyse Helping Implement Objectives of the Air Audit • Reduce operating cost • Improve productivity • Improve quality • Minimise or eliminate future capital costs Scope of the Air Audit • Compressor performance testing • Analysis of compressed air demand and supply • Air leak detection • Piping and pressure drop measurement. • Audits of pressure drops, malpractices and mal-functioning of the equipment. Beyond Audits Forbes Marshall does not just conduct an audit and submit the report; we support and work with our customers till they have realised the saving potential identified through the air audit. Depending on the need we provide solutions for areas such as: • Demand and supply side load balancing • Compressor sequencing • Anti-surge control • Compressor network monitoring Master Air Control (MAC) The Master Air Control (MAC) is an energy saving control system, which actively helps you control the balance across the demand and supply sides. The Master Air Control helps reduce energy spent on compressed air by eliminating artificial demand from the compressed air network. As usage fluctuates in the plant, it creates peaks and troughs in the compressed air demand. Peaks in demand are handled by MAC, rather than being directed towards the compressors. This allows compressors to run longer on a no-load condition, and as a result, compressor load cycles are reduced. This decrease in compressor load cycles is directly proportional to the decrease in energy consumed by the compressors. Features • Highly responsive to fine changes in demand • Accurate pressure control • Fail safe operation • History and trending feature • 7” touch screen HMI Benefits • Separates compressors from demand side peaks and lows, thus prevents compressor cycling to minimal • Consistent air pressure delivery to demand side • Enhanced useful air storage capacity • Accommodates any make of compressor • Demand reduction tends to reduce leakages in plant Before MAC PSI 100 80 After MAC SequenceAIR The SequenceAIR offers intelligent compressor control, to efficiently and economically manage compressed air systems. It proactively and dynamically determines the compressors to use for the required system load and keeps the system operating in a narrow band. It can also be set up to automatically change the compressor sequence basis, a settable order, day and time Total system KW % saving More efficient sequencing 10% 75 3.78 150 7.56 300 15.12 600 30.24 Tighter pressure band 5% 1.89 3.78 7.56 15.12 Reduced unregulated demand/leaks 3% 1.13 2.27 4.54 9.07 Total estimated savings 18% 6.80 13.61 27.22 54.43 (All prices in table- in Rs. Lakhs)) Features • Touch screen HMI display • Target pressure setting • Pressure sensor calibration • History and trending display • Full range diagnostics • Web based control features • System response tuning Benefits • SequenceAir connects to any type of compressor, it is expandable upto 12 compressors • Match compressed air supply to compressed air demand dynamically • Preventive maintenance scheduling, thereby avoidance of costly breakdowns • Minimise final system pressure fluctuation, improving plant production System without SequenceAIR System with SequenceAIR Savings Installation Maintenance Investment Maintenance Energy consumption Installation Investment Energy consumption Some Facts The following graph shows the annual power loss against leakages and over-pressurisation for different compressor power consumption: 1200 1000 70 KW 800 90 KW 600 100 KW 400 120 KW 200 150 KW 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 CountAIR CountAir provides information on • Real-time specific compressor and machine data • Deviations of any machine or area from its trend line and rated consumption • An overall plant demand overview • All necessary information to save and control • Unaccounted losses in the system • Presence of leakages in distribution lines What does the CountAIR offer? • Historical trends of each area/unit with graphs • Benchmarks for the system • Alarms when demand spikes in any area • Real time, user selectable alarms • Intelligent or user-defined benchmarks for generation and consumption • Real-time compressor efficiency monitoring • Linking with existing DCS or SCADA User areas To PC/Laptop ( through LAN) (For Viewing) Count Air Input to Count Air from Aimons FAD meter input to Count Air n AIR COMPRESSOR 2 AIR COMPRESSOR 1 AIR COMPRESSOR PO FAD meter Dry Air Receiver To User Department Aimons AirMon Cost effective flow metering for compressed air AirMon is an innovative cost-effective solution for monitoring of compressed air on plant distribution lines. With online pressure and temperature compensation, it is the only practical solution for measuring compressed air consumption. It is not only cost effective, but also highly accurate and easy to install. Benefits • Specialised solution for utility metering of compressed air • High accuracy • Cost effective solution • Maintenance-free sensor design • AirMon is a 2-wire transmitter specifically designed to measure compressed air on distribution lines FAD Meter The only way to know how much air your process is actually getting is with effective air flow metering. With our FAD meter, downstream of your compressor, you will know at every moment exactly how much air is reaching your process. Plus, its proprietary software automatically compensates for your plant's relative humidity (RH) levels and rated shaft RPM, ensuring 100% reading accuracy. Benefits • 2-wire device with integrated pressure (optional) and temperature compensation • Wear-resistant as it is a fully welded stainless steel vortex shedding Structure • High corrosion, pressure and temperature resistance • Optimum process reliability. • Maintenance-free sensor design • It has an accuracy of +/- 1% of measured value Benefits of metering compressed air • Know your losses vs leakages • Avoid periodical overhauls • Reduce downtime through preventive maintenance • Avoid over pressurisation. • Annual power loss vs over pressure% Compress Your Air Costs With Us The avenues for energy savings are not limited to the those mentioned above. The potential areas for energy efficiency and energy savings are endless and deserve a thorough exploration. With our expertise in Control & Instrumentation and domain knowledge of Compressed Air, we can help you realise maximum optimisation of your compressed air network. Forbes Marshall Pvt. Ltd. A-34/35, MIDC, Industrial Estate, ‘H’ Block, Pimpri, Pune - 411 018. India. Tel.: 91(0)20 - 27442020 Fax: 91(0)20 - 27442040 E-mail: firstname.lastname@example.org Domestic: Ahmedabad, Alibag, Bangalore, Bhopal / Indore, Chandigarh, Chennai, Coimbatore, Delhi, Hyderabad, Jamshedpur, Kolkata, Mumbai, Nagpur, Navi Mumbai, Surat, Trichy, Vadodara, Visakhapatanam International Operations: email@example.com Bangladesh, Bolivia, Canada, Chile, Columbia, Egypt, Indonesia, Kenya, Malaysia, Nepal, Peru, Singapore, Sri Lanka, Thailand, U.A.E., USA, Venezuela Doc#CIG0214/242/V1.R0 Why Meter Compressed Air? Monitoring your network from generation to consumption is the first step to achieving energy savings and an optimal compressed air network. Most utility managers are now looking at various ways to control rising energy costs. However, due to lack of information, most compressed air networks tend to be mismatched – the generation often outstrips the demand, and most utility managers provide air to processes based on an approximate or intuitive guess about the requirements.
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