Compressed Air Best Practices-August 2008

| 08/08 Focus Industry COMPRESSED AIR AUDITS | CO2 O kW A. Introduction Introd The audit w initiated to investigate methods for increasing vacuum delivery to production CNC was cutting/ro cutting/routing machinery. Better vacuum delivery is needed due to an elevated level of part slippage o the routing tables. This situation is hurting productivity and increasing waste costs. on The solut to part slippage on routing tables is to eliminate or reduce the vacuum solution differentia in the distribution system and within point-of-use routing equipment. Elimination differential of differe differential pressures will result in more holding force available for parts. However, reducing pressure differential will also allow for more air to enter the vacuum system resulting in the need for additional supply capacity. There ar two alternatives to solve this issue. First, the site can elect to purchase additional are rotar screw vacuum pumps. This will provide enough capacity to keep site vacuum above rotary 15" HgV. This action will require capital funding and additional operating expenditures for en energy. The second alternative is to replace the existing rotary screw vacuum pumps ro with rotary lobe blowers. This alternative will reduce energy expenditures, provide for highe capacity at lower vacuum levels and generate a payback on production machinery higher modif modifications and capital investments. C onth of the M Air Audit d ompresse A Vacuum m Audit Syste ott By Dan B August Audit of the Month Where: United States Industry: Furniture Manufacturing Issues: Insufficient vacuum causing part slippage on routing tables. Creating product rejects and production downtime Audit Type: Vacuum Supply and Demand B. Vacuum Distribution Issues The vacuum distribution system was analyzed from the supply source (the rotary screw vacuum pump outle to the point-of-use (the routing tables). outlet) Measurem Measurement There are six primary locations where vacuum measurements were taken: 1. 2. 3. 4. 5. 6. The 12" diameter supply header loop Inlet filters located in each drop leg The vacuum feed to the table where the table isolation valves are located The mechanical arm to each table The vacuum inlet to each table located at the end of the mechanical arm The far side of each table opposite from the vacuum inlet Financial Summary Investment: $458,725 Energy Cost Before Investment: $338,759 Energy Cost After Investment: $199,255 Energy Savings/Year: $139,504 Incremental Energy Cost Avoidance: $98,000 Power Cost/kWh: $0.065 Operating Hours/Year: 6760 Simple Payback: 3.3 years System Before Audit Average Air Flow: 11,020 ACFM System Vacuum Level: 16" HgV Eight Rotary Screw: Vacuum Pumps 790 BHP Proposed System After Audit Average Air Flow: 16,000 ACFM System Vacuum Level: 12" HgV Three Rotary Lobe Blowers: 530 hp 10 www.airbestpractices.com http://www.airbestpractices.com

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

Compressed Air Best Practices- August 2008 Contents From the Editor Utility-Air News The August Audit of the Month: A Vacuum System Audit Energized for Savings at Seattle City Light and Tacoma Power Know Your System CASE: Compressed Air Supply Efficiency Ecos Air: Managing Incentive Programs Kaeser Compressors: Loyalty, Energy and Growth Building Relationships at Cummins-Wagner McIntire is Moving Forward The 2008 A.I.C.D. Conference & Exhibition Tuthill Vacuum and Blower Systems Resources for Energy Engineers: Training Calendar & Product Picks Wall Street Watch Advertiser Index Job Market

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