Compressed Air Best Practices - January 2008 - (Page 21)

Focus Industry ENERGY MANAGEMENT | 01/08 | A damaged filter element There are no auto drains of any kind visible except for the four antiquated float type drains installed under the centrifugal compressor. Most drain points are 100% manual, so if maintenance doesn’t open the drain two or three times per day it’s all headed for the desiccant or downstream. We will recommend 22 zero-loss smart drains. The drains will include a sensor to allow for complete PLC monitoring and triggering if necessary. Properly sized and maintained air treatment products save $255,000 per year is stealing is 262.5 x $ 744.00= $ 195,300 in waste energy. Add that to the $60,000.00 annual expense for the Over The Fence Compressed Air and the total unacceptable cost penalty on this system is $255,000 in actual waste energy attributed directly to the Air Compressor Clean Up Equipment (Dryers & Filtration) and does not include the annual maintenance or needed overhaul listed below. To overhaul all five dryers the facility will require 8,000 lbs. of desiccant at a cost of $12,480, plus 10 new filters at a cost of $5,800, plus 2 men 2 days each dryer for 10 days total [2] men. Plus all switching valves shall require cleaning and replacement where necessary. The total overall, not counting labor or unforeseen issues, will be $18,280.00 plus taxes, freight, etc. Routine maintenance on these dryers under the conditions that they are expected to operate will be three filter changes per year x 10 = 30 filters for a total of $17,400 annual plus one desiccant change of $12,480 annual not including labor. The total to maintain these dryers will be $29,880 annual. The total annual operating cost of this air treatment system (which does not provide quality air) is $386,479. This represents a tremendous opportunity for energy savings. Conclusion The new compressed air system will have an oil-free air compressor which can turn down to match partial air loads. The air purification system will provide reliable ISO Grade 1.4.1 quality air. The pressure losses will be greatly reduced and air storage tanks along with flow controllers will allow pressure to be closely managed at 100 psig. The Over-the-Fence contract can be cancelled for the resulting savings. Finally, control over-the-air system will be placed in the hands of a competent outside service organization, which will be the only authorized party to perform maintenance and make changes to the system. Financially the project requires $384,000 in capital to implement. The first year savings are $305,000 with a project payback of 9.5 months. It is projected that the smelter facility will save almost $3 million dollars over the first five years. These financials do not add into the equation the larger benefits of reliable pressure and contaminant-free compressed air. BP For more information, please contact David Smith, Senior Compressed Air Auditor, Comp-Air Service Company, tel: 305-687-8787, email: dsmith@comp-air.com “Energy costs . now totaled $1,359,000 per year. The facility is looking for ways to reverse this trend and drive down energy costs.” www.airbestpractices.com 21 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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