Compressed Air Best Practices - May 2008 - (Page 10)

| 05/08 Compressed Air Industry AUTOMOTIVE ASSEMBLY | CO2 O kW A. Introduction Introd This Midw Midwestern automotive assembly factory has two major production areas called the “East” and “West facilities. The objective of the engineering staff at this company is to optimize the “West” compress compressed air energy costs as they relate to the number of vehicles manufactured per day. The task at hand is to continue to ensure the reliable supply of compressed air to all processes, a while reducing the energy costs. redu This article will describe the actions taken to reduce the energy costs. We are not at liberty artic to disclos the numbers pertaining to the numbers of cars manufactured. The facility operates disclose “24/7” s we have 8,760 operational hours per year. The average electrical rate at this facility so is $0.04134 kW/h. The energy formula used is: $0.04 kW = bhp *.746 * (1/Motor Efficiency) Due to the size of the compressed air installations, we have broken the audit into three phases based upon our initial observations. This article details the system configuration, measu measurements and recommendations of our Phase 1 audit whose objective it is to reduce air co consumption while stabilizing air pressure and capture the energy saving benefits doi of doing so. P Phase 1: Reduce Air Consumption While Stabilizing Air Pressure Ph Phase 2: Optimizing the Air Treatment System Ph Phase 3: Managing Air Leaks C onth of the M Air Audit d ompresse Saving Energy in ve Automoti Assembly mersm By Jim Tim an May Audit of the Month Where: Midwest U.S. Industry: Automotive Assembly Issues: Flow and Pressure Fluctuation Audit Type: Supply and Demand Side Financials Investment: $206,325 Energy Cost Before Investment: $1,662,557 Energy Cost After Investment: $1,400,024 Energy Savings/Year: $206,325 Input kW Before Investment: 4,591 kW Input kW After Investment: 3,866 kW Input kW Reduction: 725 kW Power Cost/kWh: $0.04134 Operating Hours/Year: 8760 Project Life (years): 10 Power Cost Escalation (per year): 2% 10-Year Summary Energy Savings Before Tax: $2,668,557 Payback Period Before Tax (years): 0.79 Energy Savings After Tax: $1,387,650 Internal Rate of Return After Tax: 72% B. Air System Configuration Review Sys The powerhouse supplies compressed air to both the East and West Facilities. There is a mix of centrifugal and reciprocating air compressors. The 600 hp (horsepower) recips are older and we observe a significant consumption of lubricant. The cycling refrigerated air dryers are rated for 20,000 cfm each. The air goes into a 12" header, which takes the air to the different facilities. The quality of the air leaving the powerhouse is an issue that will be part of our “Phase 2” audit looking at air quality. The powerhouse has the following air compressors and air dryers installed: 1. Powerhouse Air Compressors a. Five (5) 600 hp reciprocating compressors. They are water-cooled, oil-injected, twin-horizontal piston compressors. Each unit is capable of producing 2,500 cfm for a total of 12,500 cfm b. Five (5) centrifugal compressors producing a total of 27,184 c. Total plant air capability for the West Facility is 39,684 cfm 2. Powerhouse Air Dryers a. Two (2) thermal mass, cycling refrigerated air dryers rated for 20,000 cfm each b. One (1) heatless regenerative air dryer rated for 165 cfm c. One (1) refrigerated air dryer rated for 100 cfm d. Total powerhouse drying capability for 40,265 cfm 10 www.airbestpractices.com http://www.airbestpractices.com

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

Compressed Air Best Practices - May 2008 Contents From the Editor Utility-Air News The Compressed Air Audit of the Month Pneumatics Real World Best Practices Delta Industries: Doing What is Right for Customers Delta Industries: Six Truths You Need to Know about Really Putting the Customer First Power Supply Industries Resources for Energy Engineers Wall Street Watch Advertiser Index Job Market

Compressed Air Best Practices - May 2008

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