Compressed Air Repair Implementation

Kevin Whitehead Sr. Technician

TVA (retired)

Kenley Allen Sr. Utility Analyst

Yates Services at Nissan-Decherd

Calculating the Financial Opportunity of Fixing Leaks

July 17, 2013 – Industrial Energy Efficiency Summit

Presenter Background

• Personal Info

–Retired after 30+ years working in TVA’s

energy conservation programs

–Certified Energy Manager (CEM)

–Certified Level 2 infrared thermography

–Certified Level 2 airborne ultrasound

detection

The 4 Major Utilities in an Industry

•Electricity

•Natural Gas

•Water

•Compressed Air

I Always Thought That…

Compressed Air is FREE !

Reality

NOT !!!

Issues with Compressed Air

• Not Enough

• Not Enough Pressure

• Contaminates in the Lines

• Misuse of Compressed Air

• Wrong Compressor(s) for the Job

• Leaks

LEAKS

• Can Be 25%-55% of an Industries’

Cost to Generate Compressed Air

• Fixing Leaks Can Justify Turning Off

Compressors

Things to Know When Preforming a Leak Survey

A-How many compressors are in operation?

B-What kind of compressor(s) are at the facility? (rotary, centrifugal,

reciprocating)

C-Is the name-plate data and operating specification readily available?

D-What are the loading/unloading characteristics of the system?

E-What are the hours of operation of the facility/compressor system?

F-What is the cost of electricity? (energy charge & demand charge)

G-If multiple compressors are used, are they located together or apart?

H-If there are multiple compressors, are there multiple piping systems?

I-What is/are the delivery pressure(s) to the equipment?

J-How many and what kind of dryers are there?

K-How many and what size are the storage tanks?

Plant Layout

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Searching For Leaks

Tagging the Leak

Oh Boy!!

YOU’VE FOUND A LEAK!

IS IT WORTH REPAIRING?

Old Fashion Way of Calculating Cost

Another way to calculate cost is

by using the following formula:

(cfm)($/kWh)(.207)(hours of

operation per year)

Spreadsheet Method COMPANY NAME 0 Leak Total => 835 438,744 54,843$ 1,513,667 8,846$

Type

Leak # Column # Equip. # Leak Description H F R Other

Pressure

(PSI)

Sensitivity

Level

Flow Rate

(CFM)

Annual

Vol. (kcf)

Annual

Savings ($)

Energy

(kWh/yr.)

Repair

Date

Sensitivity

Level

Repaired

Savings ($)

1 3.4 1,769 221$ 6,103 ####### 221$

2 3.4 1,769 221$ 6,103 -$

3 3.4 1,769 221$ 6,103 -$

4 3.4 1,769 221$ 6,103 -$

5 3.4 1,769 221$ 6,103 -$

6 3.4 1,769 221$ 6,103 ####### 221$

7 3.4 1,769 221$ 6,103 ####### 221$

8 3.4 1,769 221$ 6,103 -$

9 3.4 1,769 221$ 6,103 -$

10 3.4 1,769 221$ 6,103 -$

11 3.4 1,769 221$ 6,103 -$

12 3.4 1,769 221$ 6,103 -$

13 3.4 1,769 221$ 6,103 -$

14 3.4 1,769 221$ 6,103 -$

15 3.4 1,769 221$ 6,103 -$

16 3.4 1,769 221$ 6,103 -$

17 3.4 1,769 221$ 6,103 -$

18 3.4 1,769 221$ 6,103 -$

19 3.4 1,769 221$ 6,103 -$

Video

A New Approach!

Making Air Leaks Visual

Non Production Base-Lining

Air Leak Pressure Gauge

Two variables must be known to estimate the CFM of

compressed air leakage.

1) Pressure within the line near the leak while leaking in

conjunction with…

2) the decibel reading through proper use of the Ultrasonic

leak detector.

When there were no existing pressure gauges installed

near the leak a technician would have to estimate (guess)

the flow pressure.

In-Line Pressure Gauge

Using the in-line air gauge

tool helps increase the

accuracy of calculating

CFM of leaking air

If the line air pressure is unknown, insert the gauge, take a flow

pressure reading before making the repair…

Then again after making the repair for a static pressure reading.

In-Line Pressure Gauge Example

EXAMPLE: If the Ultrasonic gun indicated 99dB

and an estimation of 50# flow pressure would

equal 9.6 CFM of leakage.

Using the gauge indicates an actual flow

pressure of 75# then leak is actually 10.0

CFM (a 4% improvement in CFM estimation

accuracy)

• Quantify the Loss: First analysis of Kevin’s

random Audit

Decherd Air Compressor Run Time History

7 ALL Compressor’s

kWh From Air Leak Repairs