Compressed Air Best Practices - March 2009 - (Page 10)

® | 03/09 Focus Industry ENERGY MANAGEMENT | CO2 O C onth of the M Air Audit d ompresse kW Ma Managing Pressure Fluctuation and Pressure Drop Sys System Overview The facility produces “steel cord” and is a division of a large corporation. The following information was produced from a compressed air system analysis done over seven days in 2008. The compressed air system is an essential utility required for all aspects of operation. Clean, dry compressed air is delivered to two production areas known as HP (half product) and FP (fi (final product). The compressor room is situated between these two production areas. HP receives air through a single 3-inch header, and FP receives air through a 1-inch diameter r loop and a 11⁄2 inch diameter loop. Piping is copper throughout. Point-of-use piping is fed from troughs on the floor to each individual machine. T There is a 1,065-gallon wet compressed air storage tank, two heated desiccant dryers in parallel and a 1,500-gallon dry compressed air storage tank. There are five compressors on the supply side. They are as follows: p rd Steel Cor A Produce s Manage Pressure Tencarva on Wirth, Company By D y Machiner #1 Atlas Copco model GA55VSD lubricant-injected compressor rated 270 acfm which was online #2 and #3 are Atlas Copco ZT45 oil-free compressors each rated for 216 acfm, only #2 was online #4 Atlas Copco model ZT50 VSD oil-free compressor rated for a max flow of 242 acfm and online #5 is a rental, an Atlas Copco model GA55 lubricant-injected, fixed speed compressor rated 312 acfm and online March Audit of the Month p Where: Southeast U.S. Industry: Steel Cord Production Issues: Unstable Pressure and Pressure Drop Audit Type: Supply and Demand Side System Before Audit Operating Hours 8,760 hours Power Cost kW/h $0.04545 Avg. Air Flow 586 cfm Avg. Air Flow, %Cs. 39.6% Peak Demand, kW 148.9 kW Load Factor % 45.3% Annual Energy, kWh 1,251,292 kWh Annual Energy Cost $56,871 System After Audit Operating Hours 8,760 hours Power Cost kW/h $0.04545 Avg. Air Flow 536 cfm Avg. Air Flow, %Cs. 36.2% Peak Demand, kW 101.4 kW Load Factor % 30.3% Annual Energy, kWh 835,544 kWh Annual Energy Cost $37,975 Audit Savings Reduction in Energy Use 415,784 kWh Reduction in CO2 Emissions 296.5 metric tons Equivalent CO2 for Homes 39.3 homes Equivalent CO2 for Vehicles 54.3 vehicles Total $ Savings $18,896 p p During the assessment, the fixed-speed rental GA55 ran fully loaded along with #1 GA55VSD trimming and #4 ZT50VSD trimming. The compressor #3 ZT45 was online but never loaded into the mix. Average flow varied between 500 and 600 scfm. Wet receiver pressure (discharge pressure) averaged 111 psig with a 6-psig loss through filters and dryers. The dry receiver pressure was, therefore, 106 psig. The HP side fed with a 3-inch header had no pressure gradient from supply to demand. The FP side, because of the undersized header system, lost an additional 8 psig from dry tank to end use. 10 www.airbestpractices.com http://www.airbestpractices.com

Table of Contents Feed for the Digital Edition of Compressed Air Best Practices - March 2009

Compressed Air Best Practices - March 2009 Contents From the Editor Utility-Air News Compressed Air Audit of the Month Air Standards Assessment Improves Electroplater Production and Saves Energy Demand-Side System Optimization Seven Sustainability Projects for Industrial Energy Savings Personal Productivity Resources for Energy Engineers Wall Street Watch Advertiser Index Classifieds

Compressed Air Best Practices - March 2009

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