COMPRESSED AIR SOLUTIONS

ENERGY SAVINGS
IN
COMPRESSED AIR SYSTEM

LIFE LONG LEARNING

PROGRAMME
 COMPRESSED AIR SOLUTIONS

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AirMetrix System Assessment Software

AirMetrix system assessment software is designed to provide a systematic approach to
improving a compressed air system. It provides a single source for system assessment
tools and common engineering applications that will help customers manage and
achieve the greatest return on their compressed air system investments.

K TURBO BLOWERS System Assessment Create Quote Sullair Tools

& Open Project Open Quote Customer Info

COMPRESSORS

SCREW COMPRESSOR
SUPPLY SIDE
CONTROLS

DEMAND SIDE

ALWAYS AIR ALWAYS THERE

CONTROLS
What does your
Compressed Air
Cost???

3
Energy Cost

500 SCFM Compressor i.e.

Water 120HP / 90kW Motor
running 24 hrs X 365 days
with 70% Load consumes ~
6,00,000 kWh annually
Electricity
at rate of Rs. 4/kWh,
Air
Costs Rs. 24,00,000/year

Which is 4 times the cost of

Compressor itself !! 4
 Compressed Air Utilisation In
A Conventional System

Artificial Demand, 20%

System Losses, 20%

Poor Practices, 10%

Production, 50%

5
 What’s the definition of Artificial Demand?

When an air application is supplied higher pressure than it needs, it will

consume more air than it should. The additional air consumption is artificial
demand.

6
Supply Side Management for
Energy Saving & Intelligent
Control of Air Compressors

7
Inherent Drawbacks -- Pressure
140 400

Utilising a number of individual pressure 120 Power

350

Power (kW)
switches forces the system to produce

Flow (l/s)
100
compressed air at a pressure above that 300
required. 80 Flow
60 250

40 200
4 5 6 7 8 9 10 11
100 Pressure (bar)

95
Compressor House Pressure
90

85

80

75

70

65

60
16:20
16:32
16:43
16:54
17:05
17:17
17:28
10:09
10:20
10:32
10:43
10:54
11:05
11:17
11:28
11:39
11:50
12:02
12:13
12:24
12:35
12:47
12:58
13:09
13:20
13:32
13:43
13:54
14:05
14:17
14:28
14:39
14:50
15:02
15:13
15:24
15:35
15:47
15:58
16:09

8
 60
65
70
75
80
85
90
10:09

10:20

10:32

10:43

10:54

11:05

11:17

11:28

Pressure Trending before EnergAir

11:39

11:50

12:02

12:13

12:24

12:35

12:47

12:58

13:09

13:20

Pressure Trending with EnergAir

13:32

13:43

13:54

14:05

14:17

14:28

14:39

14:50

15:02

15:13

15:24

15:35
Control with Godrej Metacentre

15:47

15:58

16:09

16:20
Single Pressure Band

16:32

16:43

16:54

17:05

17:17

17:28
10
 PRESSURE OPTIMISATION
With EnergAir SX

Single Pressure Band Control

with Enercon SX

7.0
1
2
3
4
5

Without EnergAir SX
! CAP

6.5

EnerconS5
!

Kg/cm2
Conventional Cascade 6.0
+0.5% +0.5% +0.5% +0.5% +0.5%
7.0 5.5
1 Optimised System Pressure
6.5 2
Kg/cm 2
3
Air Demand 100%
6.0 4
System Pressure 5
5.5

Air Demand 100%

11
Operation Modes

12
4. Maximum Efficiency Mode HIGH

Selects the most efficient combination of

compressors to satisfy demand

AIR DEMAND
A IR D EM A ND

LOW

13
 Demand Side
Control Systems

14
Every Industry Has The Problem Of

psi

100

95

90

85 PROBLEMS WITH FLUCTUATING AIR PRESSURE

Ø Higher Energy Consumption.
Ø Variable product quality.
80 Ø Interruptions in production schedules.
Ø Inconsistent equipment performance

09:20 09:40 10:00 10:20 10:40 11:00 11:20 11:40 12:00 12:20

Hours, 10/12/99 - 10/12/99

 Air In Air Out

On Load On Load

PSIG
Without IFC

PSIG
Air Air

16
 Air In Air Out

On Load Unload

IFC Online

Air In Air Out

17
 Reduces Load Period of the Compressor –
TM Gives Energy Savings

90

Online Data Logging Pressure Graph at Compressor House of an Industry

psi

85

80

75

Compressor Load-Unload before Installation of ControlAiR System

70
Compressor Load-Unload after Installation of ControlAiR System

time
65

18
 ControlAiR Intelligent Flow
Control (IFC) System

Solution
C.I.I.
Innovative
Energy Saving
Product
Award

2008

19
20
 Case Study-1

TATA POWER,MUMBAI

21
 TATA POWER CO. MUMBAI 500 MW

ENERGY CONSERVATION IN
POWER PLANT AUXILIARIES

22
 Station TATA THERMAL POWER PLANT
Air Line joining Unit.5 & Unit 6 Station air lines

Line joining Unit 5 and

Unit 6 Instru.air lines

E F

Main Bypass valve.

E F
Main Bypass valve

Dryer

Instru. network
Dryer
Dryer

Dryer
Station air

Station
Dryer

air
Dryer

10 m3 10 m3 10 m3 10 m3 10 m3
10 m3

Instru. network

215 HP 215 HP 215 HP 215 HP 215 HP 215 HP 205 HP 205 HP 205 HP 205 HP

Air Compressors
23
 TATA THERMAL POWER PLANT

Executive Summary for Unit 5

• Present average daily energy consumption 9,331 kWh/day

• Daily Energy Saving projected (@9%) 864 kWh

• Annual Energy cost saving Rs. 6,30,580

(365 days@ Rs. 2 per kWH)

• Constant pressure throughout the header within 1 psig

24
 Case Study -2

RELIANCE THERMAL POWER PLANT

25
 Modified Layout of Compressed Air Network at Reliance Energy
Ø4”
I.A. Boiler & TG SIDE 2
Ø4” Ø4”
S.A. Boiler & TG SIDE 4
I.A. OFF SITE 3
Ø4” Ø6”
S.A. OFF SITE 1

Ø3” Ø6”
Ø6” Ø4”
Ø3”

Ø4” Ø2” Ø2”

Ø6”

Ø4” Dryer Dryer

Ø3” Ø3” 5m3
Ø6”
GE 30 Ø6”

7.5m3 7.5m3 7.5m3 7.5m3

IFC - SA Ø6” Ø6” Ø6” Ø6” Ø6”

IR Q = 1235 scfm IR Q = 1235 scfm

P = 250kW P = 250kW Ø6”
V = 3,300V V = 3,300V

IR Q = 1235 scfm IR Q = 1235 scfm IR Q = 1235 scfm

P = 250kW P = 250kW P = 250kW
V = 3,300V V = 3,300V V = 3,300V

IA = Instrument Air
SA = Station Air

Running Stand by
Receiver Dryer Valve open Valve Close
Compressor Compressor

26
 RELIANCE ENERGY - THERMAL POWER PLANT

Benefits of energy saving &

constant air pressure

•Daily Energy Consumption : 10,694 kWh

•Daily Energy Savings : 749 kWh (@ 7%)

•Daily Cost Savings (@ Rs. 3.50/kWh) : Rs. 2,620/-

•Annual Savings (365 days) : Rs 9.56 Lacs

27
 Our Approach

Enquiry Field Data Sheet Data Analysis

Data Logging
MONEY BACK
GUARANTEE

Proposal
28
ENERGY EFFICIENT
Turbo Blowers
Certified as High Energy Efficiency Equipment by
Korea Energy Management Corporation
Turbo Blowers from K Turbo Inc.,
South Korea
 Core Components & Salient Features
• Permanent Magnet Motor: a) Power required only to rotate &
not for magnetizing of rotor; b) Can be started & stopped any
number of times; c) High Efficiency even at part load
• No Gear Box: No transmission loss due to direct drive & no
lubrication required.
• Variable Speed Drive for achieving high speed, smooth starts
(reduced starting current) & energy efficient capacity control as part
of the Blower package.
• No Lubrication Air-Foil Bearing for high speed operation (used
in Jet engines)
• Oil Free air
• Low Noise: 80 dB against 100 dB of PD blowers
• Entire range is air-cooled & no need of water for cooling.
 APPLICATIONS OF K TURBO BLOWERS

• Air (gas) conveying of powder (Cement factory, Chemical

factory, Food & Beverage factory, Power station etc.)

• Aeration for water treatment (municipal sewage disposal

plant, water treatment systems in factories etc.)

• Agriculture and food processing (drying, processing,

conveying etc.)

• Biotechnology (Oil free air supply)

Comparison with PD blowers
 HMI with touch screen

•Touch Screen Display

•On-line Flow Trend

•On-line Pressure Trend

•On-line Performance Curve

•On-line Pressure, Flow,

Temperature, Power,
Speed readings

•Thousands of installations
in Japan, Korea, USA,
Europe, Indonesia
COMPRESSED AIR SOLUTIONS

GODREJ SULLAIR
SCREW
COMPRESSOR
ALWAYS AIR ALWAYS THERE
 COMPRESSED AIR SOLUTIONS

The reliable Sullair air end

Longer average bearing life,

designed for up to 100,000
hours of service

UNMATCHED

RELIABILT
ALWAYS AIR ALWAYS THERE
 COMPRESSED AIR SOLUTIONS

VARIABLE CAPACITY
CONTROL

SAVING
10 – 15 % ENERGY SAVINGS
REDUCED PRESSURE FLUCTUATIONS

ALWAYS AIR ALWAYS THERE

COMPRESSED AIR SOLUTIONS

ALWAYS AIR ALWAYS THERE

COMPRESSED AIR SOLUTIONS

ALWAYS AIR ALWAYS THERE

COMPRESSED AIR SOLUTIONS

Variable Capacity Air-End

Featuring Spiral Valve Technology

ALWAYS AIR ALWAYS THERE

COMPRESSED AIR SOLUTIONS
Duration 1:08

Single-click box to start/stop movie.

Double-click box to restart
SPIRAL VALVE
Hit white area key to go back

ALWAYS AIR ALWAYS THERE

 COMPRESSED AIR SOLUTIONS
110
100
90

% OF BHP USED
80
70
60
50
40
30
Theoretical Load/No Load
20
Actual Load/No Load 0 10 20 30 40 50 60 70 80 90 100
Modulation % OF FULL LOAD CAPACITY

Sullair Spiral Valve

Spiral Valve cuts energy costs dramatically

An outstanding feature of the compressors is Sullair’s unique capacity control system, which
consists of a spiral valve and an inlet butterfly valve. This system delivers greatly improved part-
load performance, especially when compared with compressors having suction throttling or
load/no load controls. The power savings is independent of receiver size.

ALWAYS AIR ALWAYS THERE

CASE STUDY

ALWAYS AIR ALWAYS THERE

GUARANTEED
BENEFITS

ALWAYS AIR ALWAYS THERE

TEN YEAR WARRANTY ON THE AIR END

NO FLUID CHANGE FOR TEN YEARS

FIVE YEARS WARRANTY ON THE AIR END

FLUID LIFE OF 8000 HRS

MULTI STAGE SEPERATION WITH 1 PPM OIL

CARRY OVER

8000 HRS SEPERATOR LIFE

ALWAYS AIR ALWAYS THERE

 Thank you

ALWAYS AIR
ALWAYS THERE

Mr Shawn Vincent Lonen - shawn@godrej.com

Mr Shashank Hemant Kale – skale@godrej.com

Contact- 022 – 67962257 - 59