Compressed Air Best Practices - May 2008 - (Page 16)

| 05/08 Compressed Air Industry AUTOMOTIVE ASSEMBLY | COMPRESSED AIR AUDIT OF THE MONTH Saving Energy in Automotive Assembly Without storage, the system must allow system pressure to decay in order to use it. Without proper storage, the system must operate at a higher-pressure with enough input generation on-line to adequately support any change or event which may occur in the system. No system can afford the financial and operational consequences of not having enough storage (capacity) to adequately satisfy the largest event without requiring additional horsepower. These actions will allow the facility to reduce air consumption by 1,112 cfm, which translates into an air compressor average kW usage reduction of 725 kW/h. The estimated total savings will be $262,553 per year. 50 PSI POWER SUPPLY INDUSTRIES E. Conclusion This automotive assembly facility has tremendous peaks and valleys in compressed air demand. Our audit, using flow meters and pressure transducers with calibrated gauges, has proven this. Our Phase 1 audit recommends the use of storage tanks and flow meters to reduce air consumption while stabilizing pressure. Implementing the recommendations in Phase 1 will provide estimated annual savings of $262,553 with an estimated payback of 10 months and an internal rate of return of 72%. Once completed with Phase 1, we can embark upon Phases 2 and 3 of the audit (not outlined in this article). The Phase 2 audit will examine ways to reduce the significant purge air of the heatless desiccant air dryers (estimated annual energy cost of $312,380). The Phase 3 audit will examine ways to eliminate the significant levels of compressed air leaks in the West Facility (estimated annual energy cost of $487,076). The Phase 1 audit and the preliminary findings for Phases 2 and 3 demonstrate that this automotive assembly facility can significantly reduce the energy costs related to the compressed air system per vehicle manufactured. For more information, please contact Jim Timmersman, Power Supply Industries, tel: 314-277-1777, email: jim.timmersman@psiind.com, www.psiind.com 51 PSI POWER SUPPLY INDUSTRIES This recommendation will convert the plant air system from a “REACTIVE” system to a “MANAGED” system. The combination of proper storage and an intermediate controller will result in energy savings and eliminate excess horsepower on-line while ensuring system integrity. Receiver capacity is needed to absorb the cfm demand spikes and to keep the input source(s) sensing average demand rather than peak demand. Without a controlled pressure differential on both sides of the receiver, there is no useful storage. 16 www.airbestpractices.com http://www.psiind.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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