C837 For-Data-Collectors QRG
Uploaded by
Muhammad UmairC837 For-Data-Collectors QRG
Uploaded by
Muhammad UmairCSA C837-16 Monitoring and Energy
Performance Measurements of Compressed
Air Systems – for data collectors
Topics in the Course
• CSA C837-16 and related standards
• Measurement of Energy Performance
• Data Collection and Testing of EnPIs and EnBs, Levels of Measurement
• Mandatory & Optional EnPIs
• Compressed Air System Parameter Measurements
• Reporting
Excerpts from Each Topic
The content below are samples from each of the topics in this course.
Topic 1- CSA C837 and Related Standards
CSA C837-16
CSA C837 specifies which information is to be gathered and how system parameters like power,
energy, flow, pressure, and production output are measured to calculate energy performance
indicators. The goal is to ensure energy performance is calculated using transparent, uniform,
validated, repeatable, and consistent methods of measurement. CSA C837 provides guidance in the
methodologies for establishing energy performance indicators and creating energy baselines to be
used as part of an overall energy management system.
Other standards
ISO 50001 - provides a framework of the requirements that help organizations develop a policy for
more efficient use of energy. The general idea is to follow a Plan-Do-Check-Act cycle.
ISO 50006:2014 - helps users establish, use and maintain energy performance indicators and energy
baselines as part of the process of measuring and tracking energy performance.
ISO 11011:2013 - sets requirements for conducting and reporting the results of a comprehensive
compressed air system assessment.
What CSA 837 means to you?
• Energy management systems and the EnPIs within are only as valuable as the action they
inspire. If nothing is done with the data, then the whole process is a waste of time.
• EnPIs are a form of communication; they should be succinct, clear and relevant.
• Ensure the measurement work you are doing is in accordance with the full requirements of the
data user.
© 2020 Canadian Standards Association 1
Topic 2- Measurement of Energy Performance
Energy Performance Baselines and Measurement Periods
Energy Performance Indicators (EnPIs)
• Used to quantify the energy performance of the compressed air system within a specific
measurement boundary, and to compare against the baseline period to determine if the newly
measured performance is above or below an organizations desired target value.
Energy performance baseline (EnBs)
• Measurable reference used to compare values over time. Useful in quantifying changes in
energy performance.
Measurement period
• Typically selected as a reference. Must be long enough to capture all normal conditions in the
system.
Measurement Boundary
• The subset of components of the compressed air system that are significant energy user (SEU)
that are deemed relevant to measure to establish EnPIs.
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Measurement Process
1. Determine boundaries
2. Determine SEUs energy inputs/outputs
3. Determine measurement techniques (EnPI process)
4. Determine measurement period (EnB process)
5. Normalize
6. Evaluate
7. Report
8. Repeat
Static Factors
A static factor is a condition or a variable that impacts energy performance but does not routinely
change. If any static factors change between the baseline period and any subsequent measurement
period, it may cause difficulty in properly comparing the data. In these cases, the data user will be faced
with a choice of adjusting the baseline period to compensate for the changes or normalizing the data
from the most recent measurement period so that they can be compared with the baseline. To adjust
this data the user needs complete information about the plant conditions.
Normalization
Normalization might be required if the facility changed:
• Hours of operation
• Production throughput
• Raw material quality
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• Product type
• Process type
• Production volumes / quantity
• Number of production lines
• Air compressor type or operating mode
Since the data user is often blind to these changes, make sure to fully document them. It is the
responsibility of the data user to do the normalization, but the data collector is responsible for collecting
all the supporting information to enable this normalization to take place.
Determining the baseline and reporting period
The required duration is up to the data user, who needs to communicate it to you before measurement
takes place. The baseline period should represent all typical operating modes of the compressed air
system, spanning at least one full facility production cycle from maximum to minimum energy use. The
minimum baseline period duration for compressed air measurement specified in CSA C837 is one
week.
Topic 3- Data collection and Testing of EnPls and EnBs Levels of
Measurement
Gathering Data
Indirect measurement - determining the value of a measured parameter using a sufficiently
comprehensive group of related parameters to quantify the desired parameter.
Data collection frequency - the frequency of data sampling is an important consideration. The data user
will need to advise you of their required data collection frequency.
Data quality - the highest quality of measurement instruments should be chosen within the
measurement budget.
Levels of Measurement
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Make sure you are aware what measurement level is required by the data user:
Level 1 Level 2 Level 3
• Low cost • Moderate cost • High cost
• Low accuracy • More detailed energy • Very accurate, consistent
• Rough estimate of system performance information, results
efficiency for further longer period, higher • Large compressed air
investigation sample rate systems of high intensity
• Small compressed air • SEUs or larger systems
systems representing small
percentage of total facility
electrical demand
Topic 4- Mandatory and Optional EnPls
Mandatory EnPls
SSP- System Specific Power kW/100 cfm
TEC – Total Energy Consumption – kW / Hours
TEC = Average kW input x hours for measurement period
Optional EnPls
SEC - Specific Energy Consumption
PNPU - Portion of Non-Productive Use
Relevant Variables
Since changes in relevant variables can have an impact on the result of the EnPIs, the data collector
should quantify and record the following variables, if available, during the baseline and reporting period:
• Average pressure
• Compressed air production equipment selection
• Operating hours
• Operating parameters (ambient conditions)
• Production routine variations
• Raw material routine variations
• Product type routine variations
• Process routine changes
• Volumes and quantity routine changes
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Topic 5 Compressed Air System Parameter Measurements
Measurement Parameters
Required Optional
• Power • Production output
• Flow • Non-productive compressed air flow
• Pressure • Other
• Operating hours
Amps to Kilowatt
The most common indirect measurement uses average amps as the input to calculate kilowatts:
amps × line to line voltage × √3 × power factor
kW (sample) =
1000
± 10% is the allowable variation on any electrical system
Measurement Points
Most often schematics are not available. If this is the case, the input wires need to be carefully followed
to ensure the measurement captures the required components. The best point of measurement is
usually the compressor disconnect switch which is external to the compressor.
Local safety rules must be followed when conducting electrical testing. This requires a licensed
electrician to place the electrical measurement probes.
Average Power
Where data logging is used to capture the readings, the average power can be calculated by totaling all
the samples in the reporting period and dividing by the number of samples. The input to this calculation
needs to be kilowatts, due to the differences in power factor when the main motor is loaded or
unloaded. This calculation is not valid using straight input amps.
Ave kW = (kW sample 1) + (kW sample 2) + … (kW sample N)
N
Power from Compressor Status
The rated power in each loading condition needs to be measured or estimated from the manufacturer’s
data and then the percentage time in each status condition calculated.
Ave kW input = (kW LD1 x LD factor1) + (kW LD2 x LD factor2) + (kW LD3 x LD factor3)
• Depending on the compressor installation conditions, discharge pressure, or the age of the
compressor, the actual readings might differ from rated values.
• For lubricated screw compressors running in load/unload mode, the calculations do not include
switching losses that occur as the compressor loads and unloads.
• Inaccurate but simple and inexpensive way to monitor SSP and TEC when no other methods are
available.
• Valuable in detecting errors in direct measurement should data loss occur.
Measuring Total System Power
Compressed air system related loads:
• Should not exceed 10% of the average reading during periods of normal compressed air
production.
6 © 2020 Canadian Standards Association
Non-compressed air system related loads:
• If more than 10%, they should be sub-metered and subtracted from the final reading.
Common Errors
• Unexpected full-scale readings when probes become saturated with water during air dryer
failures
• False readings when the flow of air enters or exits the receiver when the pressure changes
• Secondary check calculations derived from compressor power or status are recommended
Flow from Power
All positive displacement compressors have a specific power/flow characteristic curve that can be
modelled in a repeatable manner. When this characteristic curve is known, or can be determined by
testing, the flow in any condition can be estimated by measuring compressor input power or amps and
relating it to the characteristic curve.
Special Testing – Receiver draw down test
• Fc = correction factor to account for declining pressure in the receiver. Frequently, a factor of
1.25 is used where (P1 – P2)/P1 = 0.5
• T = minutes between P1 and P2
• V = system volume in cubic feet
• P1 = receiver pressure at start of test
• P2 = receiver pressure at end of test
• Pa = absolute pressure of ambient (usually 14.5 psia)
Example Draw Down
Equation 1 – Average flow
V x (P1 − P2 )
Average flow (cfm) = Fc
T x Pa
Equation 2 – Volume in cubic feet
Volume (gallons US)
Volume (cubic feet) =
7.48
2,500(gallonsUS)
Volume(cubicfeet) = = 334 cubic feet
7.48
Equation 3 – Total volume
Total volume = receivers + piping = 334 + 23 = 357 cf
Equation 4 – Average flow example
357 cf × (100 psi − 50 psi)
Ave flow = 1.25 × = 770 cfm
2 min × 14.5
Topic 6- Reporting
Resource: CSA C837-16 Table B1 Data collection and recording
Energy performance should be reported in a way that satisfies the data user’s needs.
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Reporting Requirements
• Clarity
• Ability to determine system energy performance
o Is it improving?
o Does it need attention?
• Assess the overall efficiency, conditions and results of changes
• Mandatory and optional EnPIs
Other reporting requirements:
• Method of measurement used to obtain and calculate primary reported values
• Clear definition of measurement boundaries including all input and output items to be measured
• Methods used to determine:
o Flow
o Power
o Pressure
o Ambient conditions
o Production status
• Changes in static factors
• Raw data spreadsheet
Resources
• CSA C837-16 Standard available on the CSA online store https://store.csagroup.org/
• CSA C837 Monitoring and Energy Performance Measurements of Compressed Air Systems -
for Data Users
• Manufacturers websites have CAGI data, reports and guidebooks
• CEATI compressed air guide
• Compressed Air Challenge
• USDOE
• ANSI