Main Headquarters: 120 Water Street, Suite 350, North Andover, MA 01845 With offices in: NY, ME, TX, CA, OR

www.ers-inc.com

APPLICATION OF AIRMASTER+ IN REAL INDUSTRIAL FACILITIES

presented bySatyen MorayENERGY & RESOURCE SOLUTIONS

ACEEE Summer Study on Energy Efficiency in Industry

04/12/2023

Why is Compressed Air Important? Steps in a Compressed Air

Assessment AIRMaster+ Background and

Capabilities AIRMaster+ Modules Integration of AIRMaster+ in an

Assessment Case Study Conclusions

OVERVIEW

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Compressed Air Systems: Consume over 90 Billion kWh per year Cost over $1.5 Billion dollars per year to

operate Consume 10% of all electricity in US Constitute 16% of industrial motor systems Are located in 70% of the manufacturing

plants Represent the “fourth utility” in an industrial

facility Have low system efficiencies (10%-15%) Savings can range from 15% to 60% of

existing compressed air energy usage in most cases

WHY IS COMPRESSED AIR IMPORTANT?

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Initial Interview Facility Walk Through Installation of Data Loggers Detailed Investigation of Opportunities Analytical Assessment Report Generation

STEPS IN COMPRESSED AIR ASSESSMENT

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Off Site

Data collection(On Site)

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Funded by the Department of Energy Provided by the Best Practices Initiative of the Office of

Industrial Technologies (OIT) Stand alone windows based software Analysis of multiple facilities and compressors can be

conducted Extensive database of generic compressors Simulates existing and proposed case energy use Uses hourly flow or power data Individual and Interactive measure analysis capability Life cycle cost analysis can be performed

AIRMASTER+ BACKGROUND AND CAPABILITIES

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Eleven (11) Modules

AIRMASTER+ MODULES

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Information: Address, Contact

COMPANY MODULE

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Information: Utility Information and Rate Schedules

UTILITY MODULE

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Information: Facility Address and Applicable Rate Schedules

FACILITY MODULE

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Information: Receiver Volume, Daytypes and End Use Database

SYSTEM MODULE

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Information: Compressor Details

COMPRESSOR MODULE

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Information: Input Data for Modeling

PROFILE MODULE

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Analysis of Various Measures

ENERGY EFFICIENCY MEASURES MODULE

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Maintenance Module

• Provides central location for keeping a maintenance log

Catalog Module

• Keeps a database of compressors that can be used for future use

Life Cycle Cost Module

• Useful life cycle analysis tool Print Data Input Forms Module

• Provides printable data collection forms for different phases of an assessment

OTHER MODULES

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INTEGRATION OF AIRMASTER+ IN AN ASSESSMENT

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Initial Interview Facility Walk

Through

Print Data Input Forms Module

Company,

Utility and

Facility Modules

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INTEGRATION OF AIRMASTER+ IN AN ASSESSMENT

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Data Logging Final Site

Visit

Profile and

Compressor Modules

Print Data Input Forms Module

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INTEGRATION OF AIRMASTER+ IN AN ASSESSMENT

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Analysis

Print Data Input Forms Module

and other Modules

Efficiency Measures Module• Reduce Air Leaks

• Improve End Use Efficiency

• Reduce System Air Pressure

• Use Unloading Controls

• Adjust Cascading Set Points

• Use Automatic Sequencer

• Reduce Run Time

• Add Primary Receiver Volume

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Provides standardized analysis software that is user friendly

Excellent database of compressors with performance curves

Facilitates management of multiple compressors and facilities

Provides ability to run comparative scenarios Easily facilitates interactive analysis of

various measures Results available in easy to print reports Offers handy calculators for receiver capacity,

cycle times, and SCFM to ACFM calculation

STRENGTHS OF AIRMASTER+

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Static analytical tool Does not provide performance curves for VFD

compressors Does not analyze compressed air treatment

opportunities Complicated rate structures are hard to input Loadings for the proposed case scenarios are shifted

without user prompts There is no control over distribution of leak load over

day-types Does not have the ability to investigate flow controllers Compressor curves are generic Software algorithms are not described in the manuals

SUGGESTIONS FOR IMPROVEMENT OF AIRMASTER+

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Manufacturer of Custom Thin Film MetalsFunded by NSTAR Electric

Existing Compressor Plant• One 125 HP and two 100 HP rotary screw

variable displacement compressors• 7 days per week operation• Pressure based compressor controls• 1,000 CFM refrigerated dryer• Receiver capacity: 1200 gallons

Application: Pneumatic actuations, particulate blow offs

CASE STUDY – ALLEGHENY RODNEY METALS

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CASE STUDY – ALLEGHENY RODNEY METALS

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Data Collection Process• Initial site interview and walk through• Measures are identified• Power monitoring using HOBO 4-channel loggers• Final walk through to characterize end uses and collect

loggers

Analysis Process• Entering data in AIRMaster+

• View results and verify accuracy• Assess identified measures

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Measures• EEM-1 Reduce Compressor Pressure Set

Points • EEM-2 Install Efficient Compressed Air

Nozzles • EEM-3 Install Solenoid Valves on all Furnaces

and Milling Machines • EEM-4 Replace Pneumatically Driven Pumps• EEM-5 Repair Tagged Compressed Air Leaks • EEM-6 Install Blower Air-Wipe Systems • EEM-7 Compressed Air System Optimization

Measure

CASE STUDY – ALLEGHENY RODNEY METALS

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ALLEGHENY RODNEY METALS – SAVINGS SUMMARY

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Energy Demand Installed Annual Simple

Savings Reduction Cost Cost Payback

Energy Efficiency Measure (kWh) (kW) $ Savings (Years)

EEM-1 Reduce Compressor Pressure Setpoints 64,970 7.4 $0 $5,894 0.0

EEM-2 Install Efficient Compressed Air Nozzles 130,936 14.9 $260 $11,879 0.0

EEM-3 Install Solenoid Valves on Furnaces and Milling M/Cs 26,817 0.0 $500 $2,226 0.2

EEM-4 Replace Pneumatically Driven Pumps 20,846 3.7 $1,500 $1,977 0.8

EEM-5 Repair Tagged Compressed Air Leaks 46,453 5.5 $1,725 $4,307 0.4

EEM-6 Install Blower Air-Wipe Systems 248,247 30.3 $8,444 $22,633 0.4

EEM-7 Compressed Air System Optimization Measure 739,918 84.6 $78,129 $73,208 1.1

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Useful and efficient tool Contains extensive database of compressor

performance User friendly Easy interactive analysis of measures based on hourly

profiles for different day-types. Could not be used in special instances of end use

analyses Augmentation to the software is recommended to

include specific end-use analyses options (nozzles, blower alternatives, etc.) as well as for dryers and VFD compressors.

Additionally, analysis methodology and supporting algorithm documentation should be made available.

Overall, we believe AIRMaster+ is a powerful tool that provides a standardized methodology for compressed air analysis.

CONCLUSION

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