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General Inputs
Number of Compressors Utilization Factor
Horse Power N Value
Efficiency 91.5 % Current Operating Pressure
Load Factor 0.84 Maximum Rated Pressure
Operating Hours hrs Atmosphere Pressure
Cost of Electricity $/kWh Demand Cost
Current Energy Consumption - kWh
Air Compressor Optimization
Additional Resources
• The US DOE Energy Management Portal: https://save-energy-now.org
• The US DOE Compressed Air site: http://www1.eere.energy.gov/industry/bestpractices/compressed_air.html
• The US DOE Compressed Air Tip Sheets:
http://www1.eere.energy.gov/industry/bestpractices/tip_sheets_compressed_air.html
• The Compressed Air Challenge: http://www.compressedairchallenge.org/
Acknowledgement
This tool was created by the West Virginia University Industrial Assessment Center. For more information about the WVU
Industrial Assessment Center, visit their website www2.cemr.wvu.edu/~wwwiac/.
Like all electro-mechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak efficiency and
minimize unscheduled downtime. Inadequate maintenance can increase energy consumption via lower compression efficiency, air
leakage, or pressure variability. It also can lead to high operating temperatures, poor moisture control, excessive contamination, and
unsafe working environments. Most issues are minor and can be corrected with simple adjustments, cleaning, part replacement, or
elimination of adverse conditions.
This tool calculates the energy savings associated with making minor changes to your air compressor system. Each tab calculates the
energy savings associated with one of the following changes:
Air Compressor Optimization Calculator
• Use outside air for air compressor intake
• Reduce compressor air pressure
• Repair compressed air leaks
• Use synthetic lubricant in compressors
• Recover waste heat from air compressor and use it to heat the plant in the winter
• Use vortex nozzle for cleaning
Enter the data specific to your compressor in the section labeled Compressor Data. These inputs are shared by the six tabs below this
section. Each tab requires additional inputs specific to the changes listed above. The cumulative savings for implementing all the changes
is calculated at the bottom of the tool.
1.25
psig
psig
14.7 psig
$/kWh-mo
Air Compressor Optimization
• The US DOE Energy Management Portal: https://save-energy-now.org
• The US DOE Compressed Air site: http://www1.eere.energy.gov/industry/bestpractices/compressed_air.html
• The US DOE Compressed Air Tip Sheets:
http://www1.eere.energy.gov/industry/bestpractices/tip_sheets_compressed_air.html
• The Compressed Air Challenge: http://www.compressedairchallenge.org/
This tool was created by the West Virginia University Industrial Assessment Center. For more information about the WVU
Industrial Assessment Center, visit their website www2.cemr.wvu.edu/~wwwiac/.
Like all electro-mechanical equipment, industrial compressed air systems require periodic maintenance to operate at peak efficiency and
minimize unscheduled downtime. Inadequate maintenance can increase energy consumption via lower compression efficiency, air
leakage, or pressure variability. It also can lead to high operating temperatures, poor moisture control, excessive contamination, and
unsafe working environments. Most issues are minor and can be corrected with simple adjustments, cleaning, part replacement, or
elimination of adverse conditions.
This tool calculates the energy savings associated with making minor changes to your air compressor system. Each tab calculates the
energy savings associated with one of the following changes:
Air Compressor Optimization Calculator
• Use outside air for air compressor intake
• Reduce compressor air pressure
• Repair compressed air leaks
• Use synthetic lubricant in compressors
• Recover waste heat from air compressor and use it to heat the plant in the winter
• Use vortex nozzle for cleaning
Enter the data specific to your compressor in the section labeled Compressor Data. These inputs are shared by the six tabs below this
section. Each tab requires additional inputs specific to the changes listed above. The cumulative savings for implementing all the changes
is calculated at the bottom of the tool.
Air Temperatures
Current Discharge Pressure psig
Proposed Discharge Pressure psig
Implementation Details
Labor Hours for Pressure Adjustment
Labor Rate $/hr
Savings
Annual Energy Savings - kWh
Demand Savings - kW
Annual Energy Cost Savings $ -
Annual Demand Cost Savings $ -
Total Annual Cost Savings $ -
CO2 Savings - Lbs
Implementation Cost
Total Cost of Implementation $ -
Current Energy Consumption - kWh
Reduce Air Pressure
Air Temperatures
Current Average Intake Temperature ⁰F
Average Outdoor Temperature 51 ⁰F
Implementation Details
Total Feet of Duct ft
Number of Elbows
Cost of Duct $/ft
Cost of 1 Elbow $
Labor Hours hrs
Labor Rate $/hr
Savings
Annual Energy Savings - kWh
Demand Savings - kW
Annual Energy Cost Savings $ -
Annual Demand Cost Savings $ -
Total Annual Cost Savings $ -
CO2 Savings - Lbs
Implementation Cost
Total Cost of Implementation $ -
Current Energy Consumption - kWh
Outside Air
Implementation Details
Cost Difference per Gallon $
Gallons Required gallons
Savings
Annual Energy Savings - kWh
Demand Savings - kW
Annual Energy Cost Savings $ -
Annual Demand Cost Savings $ -
Total Annual Cost Savings $ -
CO2 Savings - Lbs
Implementation Cost
Total Cost of Implementation $ -
Current Energy Consumption - kWh
Synthetic Lubricants
Waste Heat
Cost of Fuel $/MMBtu
Number of Months Plant Required Space Heating
Savings
Annual Energy Savings - kWh
Annual Energy Savings - MMBtu
Total Annual Cost Savings $ -
CO2 Savings - Lbs
Current Energy Consumption - kWh
Waste Heat
Vortex Nozzle
Number of Vortex Nozzles
Compressed Air Usage Factor
SCFM from Nozzle
Operating Period of Nozzle min/day
Usage Factor of Nozzle
Implementation Details
Cost per Nozzle $
Labor Time per Nozzle hrs
Labor Rate $/hr
Savings
Annual Energy Savings - kWh
Demand Savings - kW
Annual Energy Cost Savings $ -
Annual Demand Cost Savings $ -
Total Annual Cost Savings $ -
CO2 Savings - Lbs
Implementation Cost
Total Cost of Implementation $ -
Current Energy Consumption - kWh
Vortex Nozzle
Air Temperatures
Line Pressure at the Leak psig
Average Line Temperature ⁰F
Current Average Intake Temperature ⁰F
Number of Air Leaks
Average Size (Diameter) in
Implementation Details
Total Feet of Duct ft
Number of Leaks per year
Cost to Fix a Leak $
Labor Hours to Fix a Leak hrs
Labor Rate $/hr
Savings
Annual Energy Savings - kWh
Demand Savings - kW
Annual Energy Cost Savings $ -
Annual Demand Cost Savings $ -
Total Annual Cost Savings $ -
CO2 Savings - Lbs
Implementation Cost
Total Cost of Implementation $ -
Current Energy Consumption 0 kWh
Air Leaks
1 Enter the general inputs on the first tab. All fields must be filled in.
2
3 Results will appear in the grey section of each tab.
KeyUtilization Factors
Load Factors
Efficiency
Maximum Rated Pressure
Current Operating Pressure
Atmospheric Pressure
Enter input values into the 6 tabs (Outside Air, Reduce Air Pressure, Synthetic Lubricants, Waste
Heat, Vortex Nozzles, and Air Leaks). All of the tabs do not need to be filled in.
Instructions for using the Air Compressor Tool
N Value
Enter the general inputs on the first tab. All fields must be filled in.
Results will appear in the grey section of each tab.
KeyThe maximum demand of a system divided by its rated capacity.
The average power divided by the peak power over a period of time.
Enter the efficiency of your system as a decimal value between 0 and
1.
The maximum pressure at which the manufacturer determines it is
safe to operate the nozzle.
The pressure the compressed air system is currently operating at.
If unknown, use the default value of 14.7 psig.
Enter input values into the 6 tabs (Outside Air, Reduce Air Pressure, Synthetic Lubricants, Waste
Heat, Vortex Nozzles, and Air Leaks). All of the tabs do not need to be filled in.
Instructions for using the Air Compressor Tool
Compression factor based on type of compressor and polytropic
efficiency. Use the following list to determine the N-value for your
system.
· N = 1.25 for screw compressors with polytropic efficiency of 80%
· N = 1 for reciprocating compressor with single stage
· N = 2 for reciprocating compressor with double stage