Compressed Air Best Practices - January 2008 - (Page 20)

| 01/08 Focus Industry ENERGY MANAGEMENT | COMPRESSED AIR AUDIT OF THE MONTH Energy Savings in Peru Air Compressor Packages. Therefore these dryers are already undersized by 138 scfm or 11% undersized. This means several things. The natural design point pressure differential, across the dryer automatically increases artificially, plus the dryer cannot produce the specified pressure dew points to remove water from the system, even as a brand new, out of the box dryer package. This new and increased artificial pressure rise is never good. It restricts airflow. It either artificially lowers the natural plant pressure, or causes additional H.P. to be added to overcome the natural resistance of under sizing, which increases the electrical bill unnecessarily. It also assists in premature blockage, causing short life, of all assigned filtration such as Coalescent Filters and Particle Filters to prevent dusting. The poor maintenance practices at the facility, have also caused contamination of the entire desiccant bed causing a complete collapse of any Dew Point (Moisture Removal) you are trying to achieve and make an entire desiccant change out mandatory. The cost for the facility to operate these heated desiccant air dryers under normal conditions will be 25.40 kW each dryer, which includes the 36 scfm needed for each piece, to correctly dry each desiccant bed. This amounts to an operating cost of $25, 324.90 per unit, or x 4 = $101,299.96 total to run all 4 dryers under normal operating conditions in the North Compressor Room. We are recommending a refrigerated air dryer system, which will cut kW costs to $43,072 annually under normal operating conditions. Last but not least, the air compressors have to overcome an unusually high pressure-drop of 35 psig caused by the obstructed filter elements and desiccant tower bed, which causes a radically increased electrical bill. Current and modern air treatment system designs demand that pressure drops never exceed 5 psig. This makes any type of pressure control at the plant level virtually impossible. The extreme pressure drop of 35 psig is causing the facility to waste an additional 17.5% electrical energy on a system that costs $744.00 per hp. The hp this FROM LITTLE TO BIG AND EVERYTHING IN BETWEEN • Air & Gas* Compressors and Boosters • 3 to 206 SCFM • Pressures from 200 to 6000 PSI • 3 to 125 Horsepower • Sound Attenuated Enclosures Available • Standard and Custom Designs • Mobile Designs Available *Inert gases and pipeline quality natural gas BAUER COMPRESSORS Inc. Telephone: 757-855-6006 • Telefax: 757-857-1041 E-Mail: sls@bauercomp.com • www.bauercomp.com/norfolk/industrialair 20 www.airbestpractices.com http://www.bauercomp.com/norfolk/industrialair http://www.bauercomp.com/norfolk/industrialair 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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