Compressed Air Best Practices - November 2008 - (Page 14) | 11–12/08 Focus Industry STEEL & METALS | COMPRESSED AIR AUDIT OF THE MONTH Steel Processing Shutting off the air supply to these leaks when the area is idle would save significant energy use. Reducing the overall system pressure would also reduce the impact of the leaks, when air to the system cannot be shut off. Repairing the leaks can save additional energy. With a few minor exceptions, most of the leaks could not have been found without the use of an ultrasonic leak detector and a trained operator. Leak locating during production time with the proper equipment is very effective and often shows leaks that are not there when idle. However, a regular program of inspecting the systems in “off hours” with “air powered up” is also a good idea. In a system such as this one, some 90 to 95% of the total leaks will be in the use of the machinery, not in the distribution system. The area surveyed in the leak study included a great deal of high background noise from steam leaks that shield many of the smaller leaks. In continuing the leak management program, plant staff should perform leak detection during non-production hours in order to eliminate some of the high ultrasonic background noise. Estimated reduction of air flow with proposed project Recoverable savings from air flow reduction [Section 2.3] Annual electric cost savings with proposed project Cost of leak detection equipment (if required) Unit cost of leak repairs ($15 materials per leak and $35 labor per leak) Estimated total project cost (materials and installation) — 154 leaks Total project cost 1,082 cfm $82/cfm year $88,724/year $2,800 $50 $7,700 $10,500 “The investment will be $160,000 to generate a savings of $360,000.” 14 http://www.teseoair.com http://www.teseoair.com
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