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compressed air system audits / compressed air management


Industrial Compressed Air Systems can be one of the most inefficient systems in the typical Industrial Plant- 50% of the energy used to compress air can be wasted through leakage, misapplications, artificial demand, improper compressor control or inefficient equipment. By conducting a compressed air system audit and implementing a 24/7/365 Compressed Air Management solution, an industrial plant can save 20-50% of its compressed air operating expense. Continuous monitoring and fault condition analytics ensure the system remains in the performance envelope and provides early warning, predictive actionable intelligence of developing machine problems.

​​(2) 200 HP Oil Flooded Rotary Screw

One operating 24/7 / and one backup for high usage periods
8760 operating hours per year (maintain pressure entire week)
$ .08 / KWH average energy cost
Typical operating KW [160KW-180KW]
​System Energy cost $118,320​


​​TYPICAL SYSTEM IMPLEMENTATION EXAMPLE 

(Based on an actual manufacturer installation)

  • Industrial SCADA System
  • Modbus Communication
  • Monitor Energy, Flow, Pressure, Temperature
  • Thermal Imaging & Vibration Inputs Optional
  • Collects and Pushes Data to the Sparks Cloud
  • ViewMaster Allows Web Based Access to Data 24/7
  • Remote Air Compressor Monitoring 
  • Data Analytics Alert User to​ System Anomalies

Data Collection System

COMPRESSED AIR  AS A UTILITY

Financial Structure


  • 3 year contract monthly payment
  • $500 monthly equipment/ sensors/ KW meters + $ .50/ HP monitored load
  • Example: $500 (hardware and setup) + $200 (software monitoring) = $700 monthly payment for 3 years
  • After 3 years $200/month
  • Documented Energy Savings of $2,000 /month​ (Basic leak management and application control)
  • ​Positive cash flow years 1-3  $1,300/month $15,600 annually
  • Positive cash flow years 4+  $1,800 /month $21,600 annually​
NIST Case Study

solution


  • ReMaster Data Collection equipment is installed to establish a baseline 
  • System data is analyzed to determine inefficiencies and areas for optimization
  • Propose energy efficiency projects and upgrades.
  • Implement, manage and finance custom projects
  • Continue to verify system performance by tracking real time data. 
  • System alarms and alerts can be sent by email or text
  • ​Measurement and verification for utility rebate projects