Getting Started: Your 90-Day Plan for Compressed Air Optimization
Ready to optimize your compressed air system? At Emergent Energy Solutions, we've refined a proven 90-day implementation methodology that takes facilities from initial assessment to fully operational sequenced system with utility rebates secured. This plan is based on our experience with dozens of successful implementations across manufacturing, food and beverage, automotive, pharmaceutical, and other industrial sectors.
Phase 1: Assessment and Baseline (Days 1–15)
Week 1: Information Gathering and System Inventory
Day 1–2: Compressor Room Inventory Document every piece of equipment in the compressor room: - All compressors: make, model, serial number, HP, rated capacity (CFM), age, control type (load/unload, modulating, VFD) - Air treatment equipment: dryers (type, capacity), filters (type, size), separators - Receivers: sizes and locations - Cooling systems: air-cooled or water-cooled, cooling water source - Piping: sizes, materials, layout (sketch the main distribution)
Day 2–3: Documentation Collection Gather existing records: - 12 months of electricity bills for the facility (or preferably sub-metered compressor data) - Maintenance records for the past 2–3 years - Compressor run-hour meter readings - Any previous compressed air audits or assessments - Process information (shifts, production schedules, seasonal variations)
Day 3–5: Stakeholder Interviews Talk to the people who know the system: - Maintenance technicians: known issues, frequent repairs, pressure complaints - Production supervisors: air quality concerns, pressure-sensitive applications, demand peaks - Plant engineer: system history, planned changes, capital budget process - Energy manager: utility programs, sustainability goals, reporting requirements
Week 2: Baseline Data Collection
Day 6: Install Monitoring Equipment Emergent Energy Solutions installs our cloud-connected monitoring platform: - Power meters on each compressor (kW, kWh, amps) - Pressure transducers at compressor discharge, after treatment, and at critical point of use - Flow meters on main header (and critical branches if appropriate) - Temperature sensors on compressor discharges
All data feeds continuously to our cloud platform, updating every 60 seconds.
Day 7–15: Data Collection Period Allow at least 7–10 days of monitoring to capture full operating patterns: - All production shifts (day, evening, night if applicable) - Weekday production and weekend/shutdown periods - Any known demand peaks or unusual events
Key measurements to extract: - Average and peak demand (CFM) by shift and day of week - System pressure profile (header and point of use) - Individual compressor loading percentages and run hours - Current specific power (kW/100 CFM) - Non-production air consumption (leak load) - Pressure drops across treatment equipment and piping
Phase 2: Analysis and Planning (Days 16–30)
Week 3: Data Analysis and Opportunity Identification
Day 16–18: Performance Analysis Using the baseline data, Emergent Energy Solutions' engineering team conducts a comprehensive analysis:
- Calculate current system efficiency (specific power, cost per 1,000 SCF)
- Compare to DOE and Compressed Air Challenge® benchmarks
- Quantify waste from unloaded running, modulation, and over-pressurization
- Assess VFD integration opportunities (existing or new)
- Identify pressure reduction potential
- Measure and cost the leak load
Day 19–20: Modeling and Scenario Analysis Using AIRMaster+ and our proprietary analytics: - Model the optimal sequencing strategy for your compressor fleet - Evaluate VFD sizing and placement options - Calculate savings for pressure optimization scenarios - Estimate leak repair savings based on measured leak load - Develop combined savings projections
Week 4: Project Planning and Specification
Day 21–25: Develop Detailed Project Scope Based on the analysis: - Specify sequencer requirements (number of compressors, communication protocols, features) - Define sensor locations and quantities - Identify any ancillary improvements (storage, piping, treatment) - Prepare detailed cost estimate - Develop implementation schedule
Day 26–28: ROI Analysis and Business Case Prepare the financial justification: - Current cost vs. projected cost with optimization - Capital cost breakdown with and without rebates - Simple payback, NPV, and IRR calculations - Risk assessment (what could reduce savings below projection?) - Comparison to alternative investment opportunities
Day 29–30: Preliminary Vendor Engagement - Contact qualified sequencer suppliers for pricing - Get quotes for any ancillary equipment - Identify installation contractors with compressed air experience
Phase 3: Funding and Approvals (Days 31–60)
Weeks 5–6: Utility Rebate Application
Day 31–35: Program Research and Pre-Application Emergent Energy Solutions handles this process: - Identify all available utility, state, and federal incentives - Prepare pre-application with engineering analysis and savings calculations - Submit to utility energy efficiency program - Follow up with program staff to expedite review
Day 36–42: Utility Review and Pre-Approval - Respond to any utility engineering questions - Provide additional data or analysis if requested - Receive pre-approval letter with committed incentive amount
Weeks 7–8: Internal Approval
Day 43–50: Management Presentation Present the business case to decision-makers: - Lead with financial impact: payback period and annual savings - Include utility pre-approval letter as commitment confirmation - Reference DOE/CAC industry benchmarks for credibility - Show before/after performance data from monitoring - Address questions about production impact (minimal to none)
Day 51–56: Capital Approval Process Navigate your organization's approval process: - Submit capital expenditure request with supporting documentation - Work with finance to structure the investment (some clients finance with lease agreements to keep the project off the capital budget) - Obtain final approval to proceed
Day 57–60: Purchase Orders and Scheduling - Issue purchase orders for sequencer and ancillary equipment - Schedule installation during planned downtime - Coordinate with electrical contractor for power and communication wiring - Order any long-lead items
Phase 4: Implementation (Days 61–90)
Weeks 9–10: Preparation and Installation
Day 61–65: Infrastructure Preparation - Install communication wiring between sequencer location and each compressor - Install electrical feeds for sequencer and sensors - Mount pressure transducers and flow meters if not already installed - Install or relocate receivers for optimal control storage
Day 66–72: Sequencer Installation and Configuration - Mount sequencer in compressor room (or adjacent electrical room) - Connect all communication links to compressors - Connect all sensors (pressure, flow, temperature, power) - Configure sequencer programming: - Compressor assignments (base, swing, trim, backup) - Staging thresholds and dead bands - VFD speed limits and control mode - Run-hour equalization parameters - Alarm setpoints and escalation - BMS communication (if applicable)
Week 11: Commissioning and Optimization
Day 73–78: System Commissioning - Verify all communication links (sequencer to compressors) - Test each staging scenario manually - Verify pressure control under various demand conditions - Test alarm and safety functions - Fine-tune timing and pressure parameters
Day 79–82: Performance Optimization - Monitor system under actual production conditions - Adjust staging thresholds based on observed demand patterns - Optimize VFD trim response for minimum specific power - Verify pressure control band meets target (±2 PSI) - Confirm energy savings match projections
Week 12–13: Verification and Close-Out
Day 83–86: Training Emergent Energy Solutions conducts training for: - All operating shifts (what to expect, what to look for, when to call for help) - Maintenance personnel (routine checks, alarm response, basic troubleshooting) - Engineering staff (platform navigation, report interpretation, optimization techniques)
Day 87–90: Verification and Documentation - Document post-installation performance metrics - Compare to baseline: energy consumption, specific power, pressure control - Prepare utility rebate final application with verified savings data - Submit all documentation for rebate payment - Schedule 90-day performance review
Beyond Day 90: Continuous Improvement
The 90-day plan delivers immediate, measurable results. But the real value compounds over time:
Ongoing monitoring through Emergent Energy's cloud platform identifies additional optimization opportunities as production patterns evolve, equipment ages, and new technology becomes available.
Quarterly reviews ensure the sequencer remains optimally configured as conditions change.
Leak management program uses sequencer data to track and reduce leak loads systematically.
Demand-side improvements are identified and implemented using flow and consumption data from the monitoring platform.
Future rebate opportunities are captured as additional efficiency measures are identified and implemented, with each subsequent application supported by the growing body of monitoring data.
Getting Started Today
The first step is the easiest: contact Emergent Energy Solutions for a complimentary initial consultation. We'll discuss your facility, your compressed air system, and your goals. If a detailed assessment is warranted, we can have monitoring equipment installed within a week and baseline data flowing within days.
Emergent Energy Solutions, LLC 831 Lincoln Ave, Unit D-10, West Chester, PA 19380 Phone: 215-645-7141 Email: sales@emergentenergy.us Web: www.emergentenergy.us
COSTARS | AEE Member | Niagara 4 Tridium Certified | Goldman Sachs 10KSB Alumni
We look forward to partnering with you on your compressed air optimization journey.