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

| 06–07/08 Focus Industry PHARMACEUTICALS | COMPRESSED AIR AUDIT OF THE MONTH A Pharmaceutical Compressed Air System Audit It is important to have a leak remediation campaign in place to keep leaks from consuming unnecessary compressed air. A proactive approach to leak detection should include all individuals within the plant and the education of machine operators on the cost of leaks. Machine operators could then combat leaks as they develop by immediately tagging them and notifying maintenance. This approach to leak remediation is perfect for leaks that can be easily felt and heard. Some leaks, unfortunately, cannot be detected by the human ear. We utilize ultrasonic leak detectors to find leaks that are out of range and hard to hear or feel. Chart 1: Leak locations in % at the facility E. Capture the Savings The demand-side audit made it possible for us to reduce average air demand from 307 cfm to 121 cfm. We fixed leaks (120 cfm), closed open drain valves (36 cfm) and will reduce overall plant pressure (30 cfm). We now need to look at how the compressors are operating and if the controls are set to capitalize on the new compressed air demand profile. The “Before” Situation was this to produce 307.3 cfm: 1. 2. 3. Compressor #1 ran 100% loaded in modulation mode. At 100% power it had 90 bhp, which equated to $74,292 in annual costs of operation. Compressor #2 ran 20% loaded in modulation mode. At 78% of power it consumed 67.3 bhp equating to $11,106 in annual energy costs of operation. Total annual energy cost of operation was $85,398. Air leak on FRL The “After” Situation was this to produce 121.3 cfm: 1. 2. Compressor #1 was placed on standby for emergency situations. $0 energy cost. Compressor #2 was capable of having its’ controls modified to Load/No-Load. We ran the machine 37% loaded to meet the demand. At 55% of power, it had 47.45 bhp equating to $39,168 in annual energy costs of operation. Total new annual energy cost of operation was $39,168. Multiple holes/leaks in tubing 3. The new annual energy costs to run the air compressors represents a savings of $46,230 per year. Conclusion Understanding pneumatics is core to conducting a strong demand-side audit. Pneumatic circuits were where the audit was able to discover the dew point problem and the opportunities to reduce air consumption and pressure. Understanding air compressors and air compressor controls then allowed the installations’ energy costs to be reduced as a result of the demand-side improvements. For more information, please contact Mike Nagy, SMC, tel: 216-406-5698, email: MNagy@smcusa.com, www.smcusa.com Air leak on hose/fitting connect 16 www.airbestpractices.com http://www.smcusa.com http://www.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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