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Improving Compressed Air System Performance. a Sourcebook For U.S. DEPARTMENT OF Energy Efficiency & ENERGY Renewable Energy ADVANCED MANUFACTURING OFFICE Improving Compressed Air System Performance A Sourcebook for Industry Third Edition IMPROVING COMPRESSED AIR SYSTEM PERFORMANCE: A SOURCEBOOK FOR INDUSTRY U.S. Department of Energy Energy Efficiency and Renewable Energy Bringing you a prosperous future where energy is clean, abundant, reliable, and affordable ACKNOWLEDGEMENTS Improving Compressed Air System Performance: A Sourcebook for Industry is a cooperative effort of the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) Advanced Manufacturing Office and the Compressed Air Challenge®. EERE originally undertook this project as part of a series of sourcebook publications on industrial systems. Other topics in this series include: pump systems; fan systems; motors; process heating; and steam systems. As work on the first edition progressed, the Compressed Air Challenge® was formed, bringing together the extraordinary combined talents of compressed air system auditors, trade associations, equipment manufacturers and distributors, utilities, and government agencies in a collaborative effort to improve the performance of industrial compressed air systems. The two programs joined forces in preparing the second and this third edition. For more information about EERE and the Compressed Air Challenge®, see Section 3: Where to Find Help. The Compressed Air Challenge®, EERE’s Advanced Manufacturing Office, Lawrence Berkeley National Laboratory, and Resource Dynamics Corporation wish to thank the staff at the many organizations who so generously assisted in the collection of data for this sourcebook. The contributions of the following participants are appreciated: Ron Marshall, Manitoba Hydro William Scales, Scales Industrial Technologies, Inc. Gary Shafer, Shafer Consulting Services, Inc. Paul Shaw, Scales Industrial Technologies, Inc. Paul Sheaffer, Lawrence Berkeley National Lab Rick Stasyshan, Compressed Air and Gas Institute H.P. Van Ormer, Air Power USA The review and comment from the following participants is also appreciated: Niff Ambrosino, Scales Industrial Technologies, Inc.; Joseph Ghislain, Ford Motor Company; Thomas Hyde, Alcoa, Inc.; Tracey Kohler, Compressed Air Challenge; Doug Peace, Shaw Industries Group, Inc.; David Prator, Atlas Copco; Tom Osborn, Bonneville Power Administration; Bill Orthwein, U.S. Department of Energy, Dean Smith, Air Science Engineering, Inc.; Dusty Smith, Pneu-Logic Corp.; Jody Sutter, Ingersoll Rand; Tony Yanessa, Tennessee Valley Authority; Jeff Yarnall, Rogers Machinery Co. Finally, a special thanks to William Scales for his extraordinary assistance in developing this third edition and previous editions. Prepared for: Compressed Air Challenge and the United States Department of Energy Prepared by: Lawrence Berkeley National Laboratory Berkeley, CA Resource Dynamics Corporation McLean, VA IMPROVING COMPRESSED AIR SYSTEM PERFORMANCE: A SOURCEBOOK FOR INDUSTRY CONTENTS QUICK START GUIDE SECTION 1. INTRODUCTION TO INDUSTRIAL COMPRESSED AIR SYSTEMS SECTION 2. PERFORMANCE IMPROVEMENT OPPORTUNITY ROADMAP FACT SHEET 1: ANALYZING COMPRESSED AIR NEEDS ..................................................................................................................... 20 FACT SHEET 2: POTENTIALLY INAPPROPRIATE USES OF COMPRESSED AIR ..................................................................................... 24 FACT SHEET 3: COMPRESSED AIR SYSTEM LEAKS ............................................................................................................................. 28 FACT SHEET 4: PRESSURE DROP AND CONTROLLING SYSTEM PRESSURE ......................................................................................... 31 FACT SHEET 5: COMPRESSED AIR SYSTEM CONTROLS ..................................................................................................................... 34 FACT SHEET 6: COMPRESSED AIR STORAGE ..................................................................................................................................... 43 FACT SHEET 7: PROVEN OPPORTUNITIES AT THE COMPONENT LEVEL ............................................................................................. 45 FACT SHEET 8: MAINTENANCE OF COMPRESSED AIR SYSTEMS FOR PEAK PERFORMANCE .............................................................. 51 FACT SHEET 9: HEAT RECOVERY AND COMPRESSED AIR SYSTEMS ................................................................................................... 58 FACT SHEET 10: BASELINING COMPRESSED AIR SYSTEMS ................................................................................................................ 60 FACT SHEET 11: DETERMINING YOUR COMPRESSED AIR SYSTEM ANALYSIS NEEDS ........................................................................ 62 FACT SHEET 12: COMPRESSED AIR SYSTEM ECONOMICS AND SELLING PROJECTS TO MANAGEMENT ............................................. 65 SECTION 3. WHERE TO FIND HELP ADVANCED MANUFACTURING OFFICE ............................................................................................................................................ 70 THE COMPRESSED AIR CHALLENGE .................................................................................................................................................. 71 DIRECTORY OF CONTACTS ............................................................................................................................................................... 73 RESOURCES AND TOOLS .................................................................................................................................................................. 74 BOOKS AND REPORTS ................................................................................................................................................................................ 74 EDUCATIONAL BROCHURES ......................................................................................................................................................................... 77 ONLINE RESOURCES .................................................................................................................................................................................. 78 DOE TIP SHEETS ...................................................................................................................................................................................... 79 DOE CASE STUDIES .................................................................................................................................................................................. 79 PERIODICALS ............................................................................................................................................................................................ 79 SOFTWARE .............................................................................................................................................................................................. 79 VIDEOS ................................................................................................................................................................................................... 80 WORKSHOPS AND TRAINING COURSES .......................................................................................................................................................... 80 APPENDIX A: GLOSSARY OF BASIC COMPRESSED AIR SYSTEM TERMINOLOGY ................................................................................ 83 APPENDIX B: PACKAGED COMPRESSOR EFFICIENCY RATINGS ......................................................................................................... 89 APPENDIX C: CAGI COMPRESSOR AND DRYER DATA SHEETS ........................................................................................................... 91 ROTARY COMPRESSOR ............................................................................................................................................................................... 92 REFRIGERANT DRYERS ............................................................................................................................................................................... 93 ROTARY VARIABLE FREQUENCY DRIVE COMPRESSOR ....................................................................................................................................... 94 CENTRIFUGAL COMPRESSORS ...................................................................................................................................................................... 95 IMPROVING COMPRESSED AIR SYSTEM PERFORMANCE: A SOURCEBOOK FOR INDUSTRY APPENDIX D: THE COMPRESSED AIR SYSTEM MARKETPLACE .......................................................................................................... 96 MARKET SIZE AND ENERGY CONSUMPTION ................................................................................................................................................... 96 COMPRESSED AIR SYSTEM MARKETPLACE ..................................................................................................................................................... 96 THE MARKET FOR COMPRESSED AIR SYSTEM EFFICIENCY SERVICES .................................................................................................................
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