Technology for Energy Saving in Compressed Air System

Copyright © 2021 Alpha Winac Engineering & Services Sdn Bhd . All rights reserved.Copyright © 2021 Alpha Winac Engineering & Services Sdn Bhd . All rights reserved.

Technology for Energy Saving in

Compressed Air System


“Energy Saving ” Technology for Compressed Air System

1. Variable Speed Drive (VSD) Compressor– How true is the claim of Energy Saving “up to 35%” ? – What is the right expectation on Saving quantum ?

2. High Speed Turbo Compressor– What is this Technology ?– Its’ value proposition

3. Master Controller for Multiple Compressors– How & When to deploy ?– OEM or 3rd Party solution

4. Pressure Flow Controller (PFC)– How it work & its Energy Saving Quantum potential ?– PFC vs VSD

5. Acoustics Imaging Leak Detector– Advantage and usage


1. Variable Speed Drive (VSD) Compressor

Origin of claim - “35% energy Saving”

• A study done by well-known brand in collaboration with Laborelec Research Center, Belgium back in 1996.

• 3 different demand profile were analyzed and the “energy saving” achieved with VSD compressor (strangely, it was a 50kW VSD compressor)

38% saving 29% saving 14% savingAchieved

Saving

64% saving 28% saving 8% savingApplication

Weightage

Calculated average about 35% !

5 days + fluctuation Erratic Constant


What is the right expectation of Saving Quantum ?

Important Factors affecting the “saving” quantum

1. Fluctuation Level of Air Demand

– VSD Compressor achieve saving with elimination of

“unload” power consumption of typical Fixed speed

compressor

– Constant demand pattern will not provide much energy

saving opportunity

2. VSD for Partial Load or Top Load purpose

– A full load VSD will consume higher power, comparing

to a fixed speed compressor

3. Do not operate VSD near to “minimum speed” level

– Efficiency degradation at minimum speed is very high,

especially for 75kW or smaller compressor.

5% to 15% Energy

Saving are commonly

achieved.

Anything higher, is

possible but only on

special conditions


2. Emergence of “High Speed Turbo” Compressor

Centrifugal Magnetic Technology

“VSD” High Speed Turbo Compressor

All photos are extracted from Tamturbo.com. The presenter do not own any copyright of the photos and purely use it for technical sharing purpose


The Value Proposition of “VSD High Speed Turbo”

1. Reliability on Long Term Performance

2. Ability to operate efficiently as VSD within

“targeted flow windows”

3. Amazing saving on Maintenance Cost

“VSD Turbo”

“VSD Turbo”

All photos are extracted from Tamturbo.com. The presenter do not own any copyright of the photos and purely use it for technical sharing purpose


3. Master Controller for Multiple Compressors

Problem of typical compressor room

• Multiple units of compressors of different sizes, ages and efficiency

• Manually turn on more units when air demand increases during the day, and vice versa

• Two or more units are operating at Partial load condition (less efficient range)

Ideal way

✓ Run the most efficient base load units first,

✓ Only have one unit operating at partial load,

preferably also the more efficient unit

✓ Automatically start up another standby unit

when air demand increase (pressure drop)

✓ Automatically switch off extra compressor

when not needed


What a Master Controller can do

2. Timer Logic to match Production

Pattern

▪ Operating different combination of

compressors (different numbers) at fixed

schedule

▪ Weekday or Weekend

▪ Day Shift or Night Shift

1. Energy Optimization

▪ Matching Air Demand by operating the

most efficient combination of multiple

compressors

3. Monitoring of Efficiency

▪ Continuously monitoring compressor

efficiency and give early warning for

maintenance intervention.


OEM or 3rd Party System ?

OEM (Original Equipment maker)

• Mainly designed for own brand in mind

• Able to interact with compressor’s

algorithms for best operation mode

• Able to collect and log machine

parameters for monitoring and analysis

• Unable to do much with others’

compressor brand

3rd Party System

• Designed with Compressed Air System

performance in mind, and lesser on

compressors’ internal algorithms

• Uses standard communication protocol to

send basic signal (start, stop) to different

brands of compressors

• Operate with additional system data from

measuring devices (flow, pressure,

power) to develop best operating mode


4. Pressure Flow Controller

Production usage50%

Artificial Demand

25%

Air Leakages

15%

Air Misuse10%

Up to 25% of Generated Air can be

lost through Artificial Demand

(Supplying air at higher pressure

than what is actually required)


Pressure Flow Controller (PFC)

Operation Concept of PFC

• PID control of Targeted Outlet Pressure to Stabilize Fluctuation in

Air Usage

• Outlet Pressure can be achieved with Precision within 1 to 2%


Pressure Flow Controller (PFC)

For PFC, every 2psi reduction contribute 1% energy saving of

total compressed air system.

Saving from VSD compressor is only on the VSD compressor

itself !

Flow Demand Reduction

• Elimination of Artificial Demand

• Reduced Air LeakageARTIFICIAL DEMAND


PFC vs VSD

Multiple PFC can maximize saving on

Artificial Demand at different

production floors & pressure needs

Compressed Air System with VSD only

can provide one single target pressure,

regardless of different pressure level

required at different locations.


5. Acoustics Imaging Leak Detector

Leaks in compressed air, gas, steam and vacuum

are very costly

– Energy used in generation is wasted not doing

work.

– Extra Energy to run another unit to compensate

the leak (loss)

Production usage50%

Artificial Demand

25%

Air Leakages

15%

Air Misuse10%


Technology of Acoustic Imaging

“See the Sound” through an Imaging Technology

Create an image of the scene based on the sound at the site and

overlaid on the visible image.

Other background noise is filtered out


A great tool for Energy Saving

• Visual imaging enable and accurate detection

• Can be used to detect leak at high risk (hot or

hazardous) or inaccessible locations.

Copyright © 2021 Alpha Winac Engineering & Services Sdn Bhd . All rights reserved.

For further enquiries on

Compressed Air Optimization, Energy Audit, Energy Efficiency Improvement projects, feel free to contact.

Phun L.M. (Director)

Tel : +6012-3158895

Mohd Hanif (Registered Electrical Energy Manager)

Tel : +6019-2800338

Alpha Winac Engineering & Services Sdn Bhd

www.alphawinac.com.my

THANK YOU

http://www.alphawinac.com.my/

Technology for Energy Saving in Compressed Air System

Documents

Transcript of Technology for Energy Saving in Compressed Air System