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Compressed Air System Background

DOE began compressed air system-focused activities at its Roundtable on Market Transformation Strategies in April 1995. During the roundtable, a wide range of stakeholders participated in one of three breakout groups, one of which was Air Compressor Systems. The group discussed possible actions to accelerate the

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transformation of the compressed air system market, reviewed key market deficiencies, and identified leading actions that could be taken to move the process forward. Participants concluded that the DOE should emphasize the benefits of efficient systems, such as increased productivity and reduced downtime, rather than energy efficiency, since end users generally make system changes because it makes economic sense, not because it will improve energy efficiency.

The group identified the following actions to bring about transformation of the market for energy-efficient compressed air systems.

• Develop Compressed Air and Gas Institute (CAGI) test procedure fact sheet and standardized reporting of performance data.

• Improve the consistency and availability of plant energy audits.

• Prepare a directory of market stakeholders. • Develop a directory of services and information • Prepare in-plant air distribution guidelines and

checklists.

• Publish case studies of cost savings and performance improvements.

• Initiate customer awareness program to provide questions and talking points for use when purchasing equipment.

• Develop standardized purchasing specification boilerplate.

DOE has worked in collaboration with others to implement these ideas in three areas.

Collaboration with the Compressed Air Collaboration with the Compressed Air and Gas Institute

and Gas Institute

CAGI formed an Energy Awareness Committee and became an Allied Partner. Related projects being developed by CAGI include:

• Standard performance reporting forms (data sheets) that allow consumers to compare products more easily (see Appendix B)

• A consumer fact sheet explaining compressor testing methods and the importance of standard reporting forms • An Internet-accessible database containing information

from the standard performance data sheets, and participation in CAC.

Improving Compressed Air System Performance Improving Compressed Air System Performance Sourcebook (1st Edition)

Sourcebook (1st Edition)

This document updates this effort.

Organization of and Participation in the New Organization of and Participation in the New Compressed Air Challenge

Compressed Air Challenge®®

This is a national effort involving all relevant stakeholders aimed at improving the performance of compressed air systems. This initiative is described in detail in the next subsection.

Further information on BestPractices is available from: Industrial Technologies Clearinghouse

P.O. Box 43171 Olympia, WA 98504-3171 Phone: (800) 862-2086 Fax: (206) 586-8303 www.eere.energy.gov/industry/bestpractices www.eere.energy.gov/industry/bestpractices

The Compressed Air Challenge

The Compressed Air Challenge

A national collaborative, the CAC was formed in October of 1997 to assemble state-of-the-art information on compressed air system design, performance, and assessment procedures. This collaborative is delivering compressed air system best practices information to the plant floor, creating a consistent national market message that supports the application of these best practices, providing a technically sound and professionally delivered training program for plant operating personnel, and will, through a certification program, recognize plant personnel’s skills in operating compressed air systems. Participants include: large industrial users of compressed air, manufacturers and distributors of compressed air equipment and their associations, facility engineers and their associations, compressed air system consultants, state research and development agencies, energy efficiency organizations, and utilities. The goals of the CAC are to:

• Increase the reliability and quality of industrial production processes

• Reduce plant operating costs

• Expand the market for high quality compressed air services

• Save energy: a 10 percent improvement over current usage, resulting in annual savings of approximately 3 billion kilowatt-hours of electricity nationwide.

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The purpose of the CAC is to initiate a national collaborative that develops materials, a training curriculum, a certification program, and other information that can be used by the project sponsors in cooperation with others to:

• Raise awareness of the importance of efficient, effective plant air systems

• Train industrial plant operating personnel on best practices for plant air systems

• Expand the market for expert plant air assessment services

• Help build the local market infrastructure to deliver these services.

The CAC has developed two training workshops that are being taught across the United States.

•• FundFundamenamentals of Cotals of Comprempressed Aissed Air Syster Systems,ms, (Level 1), is a 1-day introductory course designed to teach facility engineers, operators and maintenance staff how to achieve 15 to 25 percent cost savings through more effective production and use of compressed air. •• AdvanAdvanced Manced Managemenagement of Cot of Compressempressed Air Sd Air Systemsystems,,

(Level 2), is an intensive 2-day training that provides in-depth technical information on troubleshooting and making improvements to industrial compressed air systems.

See the Resources and Toolssection for more information on these workshops.

The CAC has developed two documents: Guidelines for Selecting a Compressed Air System Service Provider (see Appendix E) and Best Practices for Compressed Air Systems. These are described in the Resources and Toolssection.

The Best Practices for Compressed Air Systemsmanual was developed to provide the tools needed to reduce the operating costs associated with the use of compressed air and improve the reliability of the entire system. This manual addresses the improvement opportunities from the air entering the compressor inlet filter to the end uses, including hoses, quick couplers, air tools, cylinders and other devices.

The CAC created the Best Practices for Compressed Air Systems manual to provide “how to” information to implement recommendations, which will achieve peak performance and reliability of the system at the lowest operating cost. Following these recommendations will:

• Reduce energy and repair costs • Improve system reliability • Increase productivity

• Reduce unscheduled down time.

The manual begins with the considerations for analyzing existing systems or designing new ones, and continues through the compressor supply to the auxiliary equipment and distribution system to the end uses. Determine how to use measurements to audit his own system, calculate the cost of compressed air, and even how to interpret utility electric bills. Best practice recommendations for selection, installation, maintenance, and operation of all the equipment and components within the compressed air system are in bold font and easily selected from each section.