Compressed Air Best Practices - March 2009 - (Page 11)

Focus Industry ENERGY MANAGEMENT | 03/09 | ® Measurement Methodology Measurements creating a baseline of the compressed air system are required to gain a basic understanding of the dynamics occurring in the plant. This compressed air analysis consisted of three days of on-site study and seven days of data collection. The running compressor power was recorded and supply-side pressures were recorded at the common discharge of the compressor (wet receiver) and after the cleanup equipment (dry receiver). Demand-side pressures were recorded in four areas: at a remote receiver on the HP side, at wastewater treatment, at a remote receiver on the FP side and on column F53 in FP. With this data we were able to create a pressure profile and identify where the pressure drops or draw-downs were taking place. We needed to identify whether or not the main header was at fault (possibly undersized for the flow) or if the reported pressure drops were at the endusers local piping or from the diaphragm pumps that run each day. Two thermal mass-type flow meters were installed: one at the discharge of the dry receiver for total flow and one in HP for that area only. The data collection lasted for seven days and sample intervals were at three seconds with an average of every seven samples. This equates to a 21-second interval. A total of 28,801 readings were taken at each test point with the 45-second averaged interval. AirMaster+ Software was used to analyze the data collected in this system. AirMaster+ is a Windows-based software tool used to analyze industrial compressed air systems. AirMaster+ is intended to enable auditors to model existing and future improved system operations and evaluate savings from energy efficiency measures with relatively short payback periods. More information on AirMaster+ Software can be found at www.compressedairchallenge.org. Annual Electricity Costs The data was tabulated within the AirMaster+ Software tool. A weighted average of $0.04545/kWh was used. Using the seven days of data, we have extrapolated them to provide a profile of one year of energy costs. These costs do not include maintenance fees, labor or water/sewage use. ANNUAL ENERGY, kWh ANNUAL ENERGY COST, $ COMPRESSOR AVG. AIR FLOW, ACFM AVG. AIR FLOW, %CS. PEAK DEMAND, kW LOAD FACTOR, % #1 GA55VSD #2 ZT45 #4 ZT50VSD Rental GA55 Total 211 0 75 300 586 78.1 0.1 30.8 100 39.6 55.9 18.1 20.4 55.2 148.9 78.2 32.8 30.9 101.8 45.3 438,213 156,667 174,871 481,541 1,251,292 19,917 7,121 7,948 21,886 56,871 11 http://www.mikroporamerica.com http://www.compressedairchallenge.org http://www.mikroporamerica.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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