1. Compressed Air Managing the Costs National Grid Upstate Energy Efficiency Conference April 2011

2. Why Compressed Air? Compressors account for 10% of all electricity used in U.S. 1 million Compressors sold in the US/ year 80% of the energy is consumed by those 25 hp and larger (less than 1% of the population) –2015 predictions are 1.9 Trillion kWH/year –20% efficiency gain saves 392 billion kWH/yr or $19.6 Billion dollars potential annual savings

3. Why Compressed Air? Only 9% of end users identified controlling energy costs as the primary objective in compressed air system maintenance and management. Only 17% mentioned efficiency at all as a management objective. 71% of end users report adequate air supply is their primary objective in system management 35% of end users reported unscheduled shut downs in the past 12 months 75% of operators report having no efficiency training

4. Energy (Power) Efficiency KW Compressor KW 101 : Air is FREE until you mess with it !!!!

5. Total Life Cycle Costs

6. Life Cycle Costs (First cost = comp $ + 30% for install / Maintenance = parts & 1 air end replacement)

7. Apply the Resource Wisely Excessive Pressure 10% Leaks 20% Production 60% Inappropriate Uses 10%

8. Perception CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 #

9. Reality CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 # CF Air 100 #

10. Measure

11. Manage the Relationship Flow Pressure Power TIME

12. Manage Asset Selection

13. Manage System Configuration Comp 100 hp 125 hp Comp 150 hp 125 hp Comp 150 hp 125 hp RSD 1500 ESP-1000 Control 4” 3” 4”

14. Monitor Power and Temp plots indicate all is well with this compressor

15. Solutions Understand the process needs VFD when appropriate Control options ( VFD, L-NL, Variable Displacement) System Configuration Simple sequencing Control automation and system management Design to process requirements