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Energy Efficiency in Compressed Air
Solutions At A Glance
` 60,000
` 50,000
` 40,000
` 30,000
` 20,000
` 10,000 6,80,000
13,61,000
27,22,000
54,43,000
` 01 2 3 4
Higher returns w
ith bigger insta
llations
CompressedAir
Compression
AtmosphericAir
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.
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
Typical compressed Air Consumption
Leak 25%
Production 65%
Artificial Demand 15%
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
2) Inefficient generation
3) Inefficient distribution
4) Malpractices
5) Insufficient storage
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
Present Savings
hidden Savingsby Proper Monitoring, Metering and Controlling ofCompressed Air
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
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.
Analyse
Overview study
Audit & data collection
Helping Implement
Recommend
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.
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
PSI100
80
Before MAC
After MAC
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
Total estimated savings
(All prices in table- in Rs. Lakhs))
Total system KW
%saving 75 150 300 600
18% 6.80 13.61 27.22
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
More efficient sequencing 10% 3.78 7.56 15.12 30.24
54.43
Investment
InstallationMaintenance
Energy consumption
System without SequenceAIR System with SequenceAIR
Investment
InstallationMaintenance
Savings
Energy consumption
SequenceAIR
The SequenceAIR offers intelligent
compressor control, to efficiently
and economica l ly manage
compressed air systems. It pro-
a c t i v e l y a n d d y n a m i c a l l y
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
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
Some Facts
The following graph shows the annual power loss
against leakages and over-pressurisation for different
compressor power consumption:
0.2
200
400
600
800
1000
1200
0.3 0.4 0.5 0.6 0.7 0.8 0.9
70 KW
90 KW
100 KW
120 KW
150 KW
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
FAD meter
FAD meter input to Count Air
To PC/Laptop ( through LAN)(For Viewing)
Input to CountAir from Aimons
AIR COMPRESSOR
AIR COMPRESSOR
AIR COMPRESSOR
User areas Aimons
To User Department Dry Air Receiver
1
2
n
Count Air
PO
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
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Forbes Marshall Pvt. Ltd.A-34/35, MIDC, Industrial Estate, ‘H’ Block, Pimpri, Pune - 411 018. India.Tel.: 91(0)20 - 27442020Fax: 91(0)20 - 27442040 E-mail: [email protected]
Domestic:Ahmedabad, Alibag, Bangalore, Bhopal / Indore, Chandigarh, Chennai, Coimbatore, Delhi, Hyderabad, Jamshedpur, Kolkata, Mumbai, Nagpur, Navi Mumbai, Surat, Trichy, Vadodara, Visakhapatanam
International Operations: [email protected], Bolivia, Canada, Chile, Columbia, Egypt, Indonesia, Kenya, Malaysia, Nepal, Peru, Singapore, Sri Lanka, Thailand, U.A.E., USA, Venezuela
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.
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.
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%