Analysis and optimization of compressed air networks with model-based approaches Susanne V. KRICHEL, Oliver SAWODNY Abstract: Compressed air is one of the basic energy sources in several industrial areas. It is used during manufacturing processes, commonly as driving force for actuating pneumatic cylinders and in power tools such as pneumatic screwdrivers. The widespread use of compressed air justifies efforts to reduce losses within its infrastructure. The two main loss sources are the consumption of electrical energy for the production of compressed air and the distribution through piping networks with non-negligible leakage effects and pressure drops. In order to reduce losses and optimize the generation and transport of compressed air, model-based approaches are used. The paper presents dynamic models for highlighted network components. Two applications of those models on an abstract level are under research for (1) leakage detection and (2) topological network optimization. The work presents our progress as part of project EnEffAH. Keywords: compressed-air networks, component modeling, leakage detection, topology optimization, simulation, pressure measurements ■ 1 Introduction The efficient usage of energy resources in production processes is nowadays one of the primary business goals in modern companies. Reference [1] states that a considerable percentage of the total European electrical energy consumption goes to the production of compressed air. Therefore, novel engineering concepts are required to enhance the efficiency of the compressed air infrastructure consisting of generation, distribution and application. In order to study the potential of efficiency improvements in that area, the Institute for System Dynamics, University of Stuttgart, joined efforts with industrial partners, and takes part in the project EnEffAH. The pro- Dipl.-Ing. Susanne V. Krichel, Prof. Dr.-Ing.Oliver Sawodny, University of Stuttgart, Institute for System Dynamics ject is aimed at reducing energy losses in both pneumatic and electrical systems using simulations and system theory techniques. Model-based simulations of the pneumatic infrastructure support a better understanding and help both identifying and quantifying saving potentials. The project focuses not only on minimizing the consumption by optimizing drive applications or reducing leakage losses and pressure drops (bottom-up approach) but also to enhance the efficiency by studying the generation part (top-down approach). Design and dimensioning of drive applications is currently done with simulation programs, aiding choice of components in size and type, computation of controller parameters and allowing more accurate prediction of energy costs [2]. Simulation programs require dynamic models for physical components that represent both their steady-state and transient behaviour. A lot of Optimization < Mathematical modeling Validation —»^Diniensianing^^—Ope rat ion J Energy efficiency Minimization of ■ Air consumption ■ Electrical pov/er Components ■Type > Dirmensioning Generation Distribution Application Size and type of compressors Operation/control of station Piacement and diameter of pipes Additionale storages Control of preumatic cylinders Sizing of handling systems Figurel. Research areas of project EnEffAH: generation, distribution and application with generalized model-based optimization tool chain applied to each sub-group. research has been done on efficient design and operation of water or pipeline networks using mathematical procedures. Even if the generation and distribution are stated to offer the highest and easy achievable saving potential, theoretical analysis of compressed air networks has not been a priority so far. Aspects such as leakage losses, dimensioning of pipes and low-energy generation of compressed air are currently under active research [3]. The detailed mathematical description of pneumatic drive components might be a reasonable approach for machine design and small networks, but it is inadequate for large industrial-grade networks. By implementing different model-based analysis approaches, the challenges and prospects of system theory within the framework of efficiency improvements are studied in this paper. The focus is here in the detection/reduction of leakage losses, the optimization of the generation unit and the development of monitoring concepts for compressed air networks. The model-based approach is schematically presented in Figure 1. The paper is structured as follows: Section 2 lists selected modeling approaches for compressed air network components under different levels of abstraction. Novel modeling approaches for oil-injected screw compressors and long pneumatic tubes are referenced. In Section 3.1, an abstract network model is shown based on electrical analogies. It is studied in Section 3 under system theory aspects such as parameter sensitivity, operating point accuracy and dynamic behaviour of its states. First, a leakage detection algorithm is implemented based on an extended Kalman filter and evaluated in Section 3.2. Second, the abstract network model is presented as basis for our current research on model-based topology optimization of compressed air networks in Section 4. A detailed conclusion is given in Section 5 with an outlook into future research. ■ 2 Modeling of compressed-air network components For the implementation of system theory concepts such as model-based fault diagnosis and isolation (FDI) techniques [4], the use of the signal-flow oriented simulation program Matlab/Simulink is chosen here. Further details on this kind of simulation software compared to object-oriented ones are given in [5], [6]. Two main variables for describing pneumatic systems are pressure p and mass flow rate rh. In the following, selected network components are listed and described by simplified models. Different levels of abstraction are chosen for changing simulation requirements. 2.1 Generation units Generation models include the modeling of one or several compressors, the air treatment unit and the central storage. The goal of the generation in a compressed air network is a) to deliver the consumed air instantly and b) to keep the pressure level everywhere constant within a defined pressure band, but as small as possible. To study the efficiency of each compressor and the station itself, dynamic models are developed. Previous v\/ork w/vithin thi^ EnEff^H project dealt v\/ith the (d eriv^tion of a dynamic model for oil-flooded screw compressors [2]. The model represents in detail the thermodyna-mic, electrical and mechanical parts. This model is currently used for detailed study of loss sources within one compressor block and an optimization of the operational strategy in general. Simpler models consider the fact that most compressors are running in on/off strategy [6]. Nowadays, compressor stations consists of a mix of several compressor types that are able to deliver as much mass flow as needed within a reasonable time delay dependent on the overall control. This can then be either represented simply by an unlimited mass flow model or by a PI-controller for the pressure within the storage. The input is the pressure in the storage and its output is a limited mass flow. The air treatment unit is not considered in the following but can be split into two models: filters cause a pressure drop in the system; dryers mainly cause a loss of air flow. They are modeled as resistance and consumer, respectively. Storage is placed after the compressors and air treatment unit to a) buffer high-dynamic pressure changes in the network and b) to keep some reservoir in case of failure of the production system. The air temperature Ts within the volume is normally assumed to be constant (isothermal behaviour). The complete dynamic equations for pressure pS and temperature TS look as follows nR Ps (t) = (Vprod^prod - Vconsm&cons ), Vv^ (t) = nRV, / f \ Vprod r&proä - vcon -S cons V V n J V n J J Ps (1) with R as general gas constant, th as consumed mass flow,hiprod as produced mass flow, n as polytropic coefficient and ,as temperature of mass flow rates (wit^^ =r,5 for most applications). Pipe with diameter D and length L C,b Pi., 0.0029/;' J/ '"+510 Calculation of mass flow with flow function 474 if