Compressed Air Best Practices - June 2008 - (Page 11)

Focus Industry PHARMACEUTICALS | 06–07/08 | CO2 O kW A. Introduction Introd This West Coast pharmaceutical facility has a very clean and organized compressed air system. All equipm is in good working order in the compressor room. The compressor room itself equipment is very cle and well ventilated. The management requested a compressed air system audit clean for two re reasons: 1. Production problems and downtime resulting from the presence of moisture Pr in the compressed air lines. The compressor room dryers were functioning properly so how could this happen? pr Awareness of the high cost of compressed air and a desire to find ways Aw to reduce compressed air demand. C al maceutic A Phar r ressed Ai Comp em Audit Syst agy By Mike N onth of the M Air Audit d ompresse 2. This article will describe the actions taken to address these two issues. The facility oper operates “24/7” so we have 8,760 operational hours per year. The average electrical rate this at thi facility is $0.12 kW/h. The power cost formula used is based upon the facility’s curren operating conditions of 3.89 cfm/bhp and 95% average motor efficiency. current Powe Cost = (bhp *0.746 * 8,760 hours x $0.12 per kW/h)/Avg. Motor Efficiency (95%) Power The fo of this audit is on the “Demand Side” with the very top priority being to identify focus the root cau of the presence of moisture in the compressed air lines. cause June/July Audit of the Month Where: Western U.S. Industry: Pharmaceutical Issues: Dew Point Problems and Energy Cost Audit Type: Supply and Demand Side Financial Summary Investment: $20,000 Energy Cost Before Investment: $85,398 Energy Cost After Investment: $39,198 Energy Savings/Year: $46,230 Elimination of Dew Point-Related Production Downtime: est. $250,000 per year Power Cost/kWh: $0.125 Operating Hours/Year: 8,760 System Before Audit Average Air Flow: 307.30 cfm Average Working Pressure: 99.45 psi Rotary Screw Compressor #1: 100% Loaded Rotary Screw Compressor #2: 20% Loaded 1,080-gallon Storage Tank Two Refrigerated Air Dryers: Dew Point 35–39° F Dew Point Problems Downstream: Yes System After Audit Average Air Flow: 121.3 cfm Average Working Pressure: 75 psi Rotary Screw Compressor #1: 0% Loaded Rotary Screw Compressor #2: 37% Loaded 1,080-gallon Storage Tank Two Refrigerated Air Dryers: Dew Point 35–39° F Dew Point Problems Downstream: No B. Compressor Room Review Compre The Compressor Room is extremely clean and well ventilated. There are two rotary screw compressors, Compres which are oil lubricated and air-cooled. The air is dried by two parallel refrigerated air dryers. The air then goes into a common header and flows into a 1,040-gallon air storage tank. The air then flows into an Intermediate Flow Controller. From here, the compressed air leaves the compressor room and enters the facility. The average cfm per bhp between the two air compressors is 3.80 cfm per bhp. ROTARY SCREW AIR COMPRESSORS MOTOR SERVICE FACTOR WORKING/RATED PRESSURE (PSI) CFM PER BHP RATIO HP/BHP FLOW (CFM) ROLE Compressor #1 Brand X Compressor #2 Brand Y 75 hp/86.25 bhp 75 hp/90 bhp 1.15 1.20 100/125 psi 125/135 psi 360 cfm @ 110 psi 326 cfm @ 125 psi 4.17 cfm per bhp 3.62 cfm per bhp Back-up Base Load Upon entering the compressor room, we noted an audible air leak in Compressor #2. We found the leak to be coming from the air end and recommended that the air compressor service provider be contacted immediately. Both air compressors are operating via modulation control. Compressor #2 acts as the base load machine while Compressor #1 is the back-up machine when pressure falls to a predetermined set point. The two refrigerated air dryers are in good working condition and functioning properly. They are designed to produce a dew point range between 33° F and 39° F at a maximum flow of 330 cfm at 100 psi. We took dew point measurements at the compressor room outlet (for one week) and found that the average dew point achieved was 36º F. This correct dryer performance is what has the facility bewildered by the presence of water in the compressed air lines in the factory. It is worth noting that the dryers are not capable of drying the full air output capacity of the air www.airbestpractices.com 11 http://ww.airbestpractices.com

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Compressed Air Best Practices - June 2008 Contents From the Editor Utility-Air News A Pharmaceutical Compressed Air System Audit Talking Dew Point Puerto Rico, Pharmaceuticals and Airequipo Inc. Oil-Free Rotary and Oil-Free Centrifugal Compressor Comparison SMC: Managing Energy and Dew Point in Pneumatic Systems Utility Grade Compressed Air Systems Training Calendar & Product Picks Wall Street Watch Advertiser Index Job Market

Compressed Air Best Practices - June 2008

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