Compressed Air

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Compressed Air Energy efficiency gains with
master controls and continuous monitoring DTE
EDS Conference May 5th 2009
Presenter Jan Hoetzel, Business Manager SIGA
Green Technologies
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• SIGA Green Technologies is a B2B partner to small
  and mid-sized entrepreneurial businesses with
  focus on energy efficiency, energy conservation
  and the environment.
• We facilitate access to new markets,
  predominantly North America and Germany.

Visit our Airleader booth in the Exhibit Hall
booth 504
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• Our Vision
• Eliminate the equivalent of a 500 MW coal power
  plant trough energy efficiency projects by 2020

Our Mission Significantly reduce energy
consumption by providing BEST-IN-CLASS green
products and services while improving the bottom
line of our clients and help them achieve their
environmental goals
Our Motto Promote Energy Efficiency
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Compress your air cost
Compress your air cost
With an intelligent Master Control and Monitoring
System
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Energy cost represents the single biggest EXPENSE
in a compressed air system
With energy cost on the rise, monitoring and
master control for compressed air systems become
a crucial necessity
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Compressed air the 4th utility
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What do you know about your compressor station
today?
Energy

• How many compressors?
• What size HP?
• How controlled?
• -modulation or
• -load unload

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Compressor Controls HPCFM
Variable Drive
100 80 60 40 20 0
100 80 60 40 20 0
KW 93 75 56 37 19 0
Multiple Load / Unload
100 80 60 40 20 0
100 80 60 40 20 0
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What do you know about your compressor station
today?
Energy

• How many compressors?
• What size HP?
• How controlled?
• -modulation or
• -load unload
• System pressure (Pmin / Pmax)?

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Cascading Pressure Control
PSI 105
101
96
92
88
84
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Cost of high Air Pressure

• A 10 PSI Reduction of System Pressure results in
• Energy reduction by 5 (Less load energy at
  the compressor motor)
• Air Demand reduction by 10
• (Less loading times)

145
169
130
148
115
?
130
100
114
85
100
System Pressure (PSI)
Energy Cost
Source S. Kupp Energieargentur Mittelfranken
E.V.
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What do you know about your compressor station
today?
Energy

• How many compressors?
• What size HP?
• How controlled?
• -modulation or
• -load unload
• System pressure (Pmin / Pmax)?
• Air demand min/max average?
• Energy use and or energy cost? (day, week,
  month)

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Unknown
Whats critical about compressed air?
?
How much air do we need?
How many kWh do we use ?
Benchmark How are we doing compared to other
compressed air systems in the industry?
What do we pay a day, a week, a month, a year?
What are the saving potentials?
or more?
30
20
10
5
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Compressor Management
We know how many kWh we use every day
Master Control Monitoring System
We are in charge of our system.
We have total control.
or more?
30
10
5
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Master Control not a sequencer!
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Monitoring
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AIRppraisal

• Captured information during test period
• Energy use in kWh
• Compressed Air use in CF (Cubic Foot)
• System Net pressure in PSI
• Load / Unload
• Start/Stops, Load Cycles
• Calculate
• Key Performance Indicator
• Energy cost for compressed Air per unit
• Evaluate potentials

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Pre AIRppraisal
Noload Energy
Load Energy
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Pre AIRppraisal
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Pre AIRppraisal
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Savings Calculation or alternative Test Data
Simulation
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Approval to implement Master Control and
Monitoring system
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Post AIRppraisal
Noload Energy
Load Energy
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Post AIRppraisal
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Post AIRppraisal
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Monitoring with System Software
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Load / Unload Cycles Motor Starts
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Project Summary
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A Recent Master Control Installation
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Payback less than 7 month
Cost per Year
Key Performance Index
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Payback in month
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Continuous Improvements
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KPI Key Performance Indicator
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System Benefits not quantified in

• Less start and stops
• Less load / unload cycle
• Less service hours and service cost
• Monitoring of KPI Key Performance Factor
• Early indication of malfunction E-mail/Text
  message/Visual
• Temperature
• Humidity
• Net Pressure
• Air Dryer
• Condensate Drains
• Leaks
• Managing compressed air system
• Behavior change

Case Study B
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Summary

• Energy is the main cost driver of compressed air
  systems
• Smart compressed air system sizing builds the
  base for cost effectiveness
• Demand driven master control is key for best
  energy efficiency results
• Monitoring the tool to manage systems and drive
  KPI and behavior change

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Installation Schematic
Optional
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VPN Access to AIRLEADER
AIRLEADER Panel
AIRLEADER Maintenance Schedule
AIRLEADER Compressor, Demand and Pressure Profile
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Reference Customers
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• Yes, we can help you
• save energy and improve efficiency and drive
  behavior changes.
• Visit us at Booth 504

Thank you Your SIGA Green Technologies Team