Compressed Air Best Practices - January 2008 - (Page 19)

Focus Industry ENERGY MANAGEMENT | 01/08 | Controller is set below the set points of the Compressor Packages, say 90 psig. Currently the installation is getting 77 psig by our logger readings. This will drop the current electrical costs by an additional 33% and completely stabilize the unstable current pressure readings we are getting down stream in the actual Demand Side. Poor maintenance led to blocked air filters and dryers creating a pressure drop of 35 psig Compressed Air Dryers, Filters and Condensate Drains This facility has operated for many years with no air treatment products. This led to so many problems that critical use areas of the facility signed an Air-over-the-Fence contract with the on-site utility company for clean, dry compressed air. The annual cost of this auxiliary supply is $60,000 per year. The new or up-to-date rule of thumb is that for every 1 scfm available you must have between 2 and 10 gallons of air receiver. In this case, the North Compressor Room currently has 6511 scfm available. Using only the short 2 gallon per scfm rule, the facility needs 13,000 gallons of available storage. Air receivers can completely correct this condition by accomplishing the following: a proper combination of Air Receivers and Steady Pressure Controller will allow controllers and, in particular, Automation Control Panels to completely control the compressors to the extent it will keep off what is not needed and bring on only what is needed. An Automation Panel will select the specific compressor it needs while monitoring the downstream (Demand Side) pressure to within 1% of set point. It allows for compressor controls to be set on Full Load/No Load control when a Steady Pressure Controller is added after the Air Receivers. This Control Scheme will allow the compressors to operate at 100% output or no output, but the plant will never see this up/ down pressure swing as the Steady Pressure A year ago, the engineering firm contracted to install air treatment equipment provided a specification of ISO Grade 1.2.1. This specification requires desiccant air dryers capable of producing a -40 ºF dew point. This dew point specification is common in the mountainous regions in the Andes of Peru, due to the low ambient temperatures. Since the smelter facility is at sea level and never sees ambient temperatures below freezing, we believe this specification to be unnecessary and recommend an ISO Grade 1.4.1 for air treatment. This allows a lower-energy cost refrigerated air dryer which produces a +38 ºF dew point. The dryers installed were five twin-tower, heatreactivated, desiccant air dryers. These dryers are 1225 scfm dryers installed on 1363 scfm THREE DEFINING STRENGTHS ONE EXCEPTIONAL COMPANY Engineering and ingenuity from around the globe. 150 years of experience. And a new partnership with Fu Sheng, a precision manufacturer of some of the world’s most respected brands. Experience what the power of our new partnership can do for you. VISIT WWW.DISCOVERCURTIS.COM DISCOVER ©2007 Curtis-Toledo, Inc. www.airbestpractices.com 19282d CTGNL GENRL Wrap Up.indd1 1 9/4/07 19 4:23:45 PM http://WWW.DISCOVERCURTIS.COM http://WWW.DISCOVERCURTIS.COM http://www.airbestpractices.com

Table of Contents Feed for the Digital Edition of Compressed Air Best Practices - January 2008

Compressed Air Best Practices - January 2008 Contents Focus Industry Features Compressed Air Industry Articles From the Editor Real World Best Practices: Selecting A VSD Rotary Compressor Audit of the Month: Energy Savings in Peru The Low-Hanging Fruit in Pneumatic Systems Mikropor America, Inc. Wireless Sensor Networks: Improve Efficiency in Compressed Air Systems Special Report: The Chicago Pneumatic Compressor Launch in North America The Importance of Measuring Vacuum The Comp-Air Service Co. Special Report: The 2007 NAACD Wall Street Watch Advertiser Index Job Market

Compressed Air Best Practices - January 2008

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