Air Demand Analysis

2016 Kaeser Compressors, Inc., USA (V1.0)

Air Demand Analysis (ADA) and Kaeser Energy Saving System (KESS) analysis

performed by Palmetto Compressors, Inc. and prepared by Kaeser Compressors, Inc.

**********– January 2016

2016 Kaeser Compressors, Inc., USA (V1.0) 2

As recorded during initial site survey.

System Sketch

Motor Signal

Load Signal

Pressure Transducer

kW Meter

SSR EP100

SSR EP100

ZHA1000 Dryer

250 gallon tank


The above calculations were based on the measured data from the testing period. The energy cost was based on the sample week between Saturday 1/9/2016 and Friday 1/15/2016 and extrapolated over 364 days per year at $0.08/kWh.

Existing System Data Summary

Total Energy Consumption (kWh/yr)Maximum kW Draw (kW)Average kW Draw (kW)Specific Power (kW/100 CFM)Total Energy Cost ($/YR)Total Flow (CF/YR)Available Capacity (CFM)Peak Flows: Excluding Startup (CFM)Duration of Peak Flow (Minutes)Average Flow (CFM)Minimum Flow (CFM)

Wet Pressure

Dry Pressure

Maximum Pressure (PSIG) 111 110Minimum Pressure (PSIG) 77 76Average Pressure (PSIG) 102 101

Pressure

$62,644223,251,081

783,05015690

21.04

Energy

Flow

868761

3426251

DATA SUMMARY


Averaged over 5 minutes. This chart highlights the cumulative flow throughout the test as measured via the load signals of the Ingersoll Rand SSR EP100 compressors.

Compressor System Capacity868 cfm-fad at 125 psig

Cumulative Flow Profile – Summary


Averaged over 5 minutes. This chart highlights the cumulative flow throughout the test as measured via the load signal of the Ingersoll Rand SSR EP100 compressor.

Compressor Capacity434 cfm-fad at 125 psig

Cumulative Flow Profile – Ingersoll Rand SSR EP100 Unit 1


Averaged over 5 minutes. This chart highlights the cumulative flow throughout the test as measured via the load signal of the Ingersoll Rand SSR EP100 compressor.

Compressor Capacity434 cfm-fad at 125 psig

Cumulative Flow Profile – Ingersoll Rand SSR EP100 Unit 2


Cumulative Pressure Profile – Wet Pressure

Averaged over 5 minutes.


Cumulative Pressure Profile – Dry Pressure



Cumulative kW Profile – Ingersoll Rand SSR EP100 Unit 1



Cumulative kW Profile – Ingersoll Rand SSR EP100 Unit 2



KESS Energy Cost Comparisons – As Measured

The above calculations were based on the measured data from the testing period. The energy cost was based on the sample week between Saturday 1/9/2016 and Friday 1/15/2016 and extrapolated over 364 days per year at $0.08/kWh.

Note: If demands change from the recorded flow profile, the proposed solutions may no longer be feasible for plant operations and savings potential may differ.

Energy Cost ($/kWh) $0.080Interval of Calculation 5 Minutes

Total Energy Cost ($/yr) $62,644 $51,939 $60,422 $60,327

Total Energy Consumption (kWh/yr) 783,050 649,232 755,280 754,088

Maximum Power Consumption (kW) 156.5 127.7 125.1 137.4

Specific Power (kW / 100 CFM) 21.04 17.45 20.30 20.27

Existing SystemProposal 1: SFC 132 + Storage

Proposal 2: DSD 200 +

Storage

Proposal 3: (2) CSD 100S +

Storage

Annual Energy Cost Savings ($/yr) - $10,705 $2,222 $2,317

Annual Energy Consumption Savings (kWh/yr) - 133,818 27,770 28,962

Power Consumption Reduction (kW) - 28.8 31.4 19.0

Savings Potential

Totals

Existing SystemProposal 1: SFC 132 + Storage

Proposal 2: DSD 200 +

Storage

Proposal 3: (2) CSD 100S +

Storage


Daily Charts


Daily Charts

Averaged over 5 minutes. The Ingersoll Rand 100hp compressors are rated for 434 cfm at 125 psig, typical operation only requires one unit to run and the second unit to trim. These compressors are set to run in Load/Unload control. Therefore, the load signals are scaled for flow as these units will provide their rated flow at rated pressure.

Load Signals

Pressure Signals

kW Signals


Daily Charts


Unit at full load and pressure drops


Daily Charts



Daily Charts


Peak demand


Daily Charts



Daily Charts


End of ADA test


Miscellaneous Charts


Miscellaneous Charts – Typical Peak Operation

Averaged over 20 seconds.


Miscellaneous Charts – Sample Day

Averaged over 20 seconds.


Existing Receiver Tank Storage

The existing receiver tank storage is capable of providing 45.6 cfm of air for 30 seconds based on the 10 psi differential as measured. It is recommended by the Compressed Air Challenge (CAC) to have 30 seconds of the largest cycling base load compressor’s capacity available from storage. Since the existing compressor is rated for 434 cfm, the storage volume is marginally undersized.

The calculations above are based on the formula: C = [V (P1 - P2)] / (T Pa)

V = storage capacity in FT3, C = air flow in cfm (peak demand flow), Pa = absolute atmospheric pressure, P1 = initial receiver pressure (normal unload setting), P2 = final receiver pressure (normal load setting)

CFM FLOW TANK SIZEPSIA Ambient 14.7 Enter Data 14.7 Enter Data

PSIG 2 110 Enter Data 110 Enter DataPSIG 1 100 Enter Data 100 Enter DataPSIA 2 124.7 124.7PSIA 1 114.7 114.7

Pressure Differential 10 10

Receiver Size-Gallons 250 Enter Data 2386.19 Answer

Receiver Size-CF 33.50 319.75CF Storage at PSIG 2 250.68 2392.69CF Storage at PSIG 1 227.89 2175.17

Useable Storage 22.8 217.5

Cycle time in minutes 0.50 Enter Data 0.50 Enter Data30.0 Seconds 30.0 Seconds

CFM Flow 45.6 Answer 434 Enter Data


TANK SIZEPSIA Ambient 14.7 Enter Data

PSIG 2 110 Enter DataPSIG 1 100 Enter DataPSIA 2 124.7PSIA 1 114.7

Pressure Differential 10

Receiver Size-Gallons 2292.72 Answer

Receiver Size-CF 307.22CF Storage at PSIG 2 2298.96CF Storage at PSIG 1 2089.97

Useable Storage 209.0

Cycle time in minutes 0.50 Enter Data30.0 Seconds

CFM Flow 417 Enter Data

TANK SIZEPSIA Ambient 14.7 Enter Data

PSIG 2 110 Enter DataPSIG 1 100 Enter DataPSIA 2 124.7PSIA 1 114.7

Pressure Differential 10

Receiver Size-Gallons 4739.40 Answer

Receiver Size-CF 635.08CF Storage at PSIG 2 4752.29CF Storage at PSIG 1 4320.27

Useable Storage 432.0

Cycle time in minutes 0.50 Enter Data30.0 Seconds

CFM Flow 862 Enter Data

Recommended Receiver Tank Storage

For the DSD 200 unit, the recommended receiver tank storage would be capable of providing 862 cfm from provided cfm of air for 30 seconds based on the 10 psi differential as measured. It is recommended by the Compressed Air Challenge (CAC) to have 30 seconds of the largest cycling base load compressor’s capacity available from storage. Therefore, it is recommended to integrate an additional 5,000 gallons of receiver tank storage volume (or larger) downstream of air treatment equipment but prior to the distribution piping network based on largest compressor’s full flow capacity and control method (load/no load). It is recommended to install an additional 2,200 gallons of dry storage with the CSD 100S and SFC 132 compressors.

The calculations above are based on the formula: C = [V (P1 - P2)] / (T Pa)

V = storage capacity in FT3, C = air flow in cfm (peak demand flow), Pa = absolute atmospheric pressure, P1 = initial receiver pressure (normal unload setting), P2 = final receiver pressure (normal load setting)

SFC 132 DSD 200 (2) CSD 100S

* It is recommended to integrate an additional 2,200 gallons of dry storage to this system with the SFC 110.

Air Demand Analysis

Engineering

Transcript of Air Demand Analysis