Compressed Air Best Practices - May 2008 - (Page 15)

Compressed Air Industry AUTOMOTIVE ASSEMBLY | 05/08 | The readings indicate significant changes in air flow demand during the day. The powerhouse air compressors are averaging 96 psi, but at times are producing 99 psi. This is well above the requirements of the facility. The flow demands are the biggest issue as we see tremendous peaks and valleys in flow production in the powerhouse. The Base Coat area has a relatively stable demand situation while the powder coat area has some very large demand events. This is causing big swings in the 6" paint feed lines in each facility. The body shops #1 and #2 are also showing significant peaks and valleys in air demand. EXISTING CONDITIONS POTENTIAL SAVINGS Average Flow Horsepower On-Line Pressure Range Avg. kW Usage Compressor Energy Costs* 22,221 cfm (6,107 (East) + 16,204 (West)) 5,662 bhp 87-108 psig 4,591 kWh $1,662,577 cfm Savings bhp Savings kW Savings Operational Hours *Cost Per kW Total First Year Savings 1,112 cfm 894 bhp 725 kWh 8760/Year $0.04134 $262,553 PROPOSED AIR SYSTEM EQUIPMENT REQUIRED: Average Flow Horsepower On-Line Stable Pressure Avg. kW Usage Compressor Energy Costs* 21,109 cfm 4,786 bhp 95 psig 3,866 kWh $1,400,027 25,000 gallons additional storage for the East Facility 25,000 gallons additional storage for the West Facility Two (2) flow controllers — one for each Facility Investment: ROI Estimate: $ 206,325 10 months D. Recommended Actions We can reduce the artificial demand of the air system through the use of storage and a flow controller to maximize horsepower on-line. Please note, the facility’s rotary screw air compressors are set to run at 110 psig, yet we are operating equipment from 87–108 psig in the main distribution system. Artificial demand is demand created by increasing the pressure above the point actually necessary to run the plant. We recommend that each facility (East and West) have a 25, 000 gallon receiver tank installed with a flow controller. The receiver tank will provide the air system with air during the frequent demand swings and protect the air compressors. The air compressors will be set to simply maintain a 95 psi pressure level in the receiver tanks. Motorized Ball Valves THE CONDENSATE MANAGEMENT SPECIALISTS JORC offers a product range that covers ALL condensate requirements. We provide total quality and reliability so that you don’t have to compromise—our range of versatile and cost-effective solutions are designed to meet all of your condensate management needs. Through continued investment in research and development, we offer up-to-date solutions that you can count on. At JORC we never compromise on Quality or Reliability—why should you? Magnetic Zero Air Loss Drains Electronic Zero Air Loss Drains Contact us today: JORC Industrial LLC. 1146 River Road • New Castle, DE 19720 Phone: 302-395-0310 • Fax: 302-395-0312 E-mail: info@jorc.com See our new online catalog at www.jorc.com Timer Drains Compressed Air Leak Detector Oil Water Separators www.airbestpractices.com 15 http://www.jorc.com http://www.jorc.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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