Compressed Air Best Practices - March 2009 - (Page 15)

Focus Industry ENERGY MANAGEMENT | 03/09 | ® Demand-Side Recommendations Demand Side — Air Leaks A leak survey was not performed, however. We were told that during maintenance with no production running, one ZT45 rated at 215 acfm can just about hold header pressure to 100 psig. We would consider this the gross leakage rate. This equates to about 35% leakage. Leakage could be occurring under the troughs that feed all production machines. Pictured here (in green circle) is poly flow tubing that comes up to feed each machine. Push-to-connect or ferrules could be leaking. Since they are inaccessible, the leaks never get fixed. If the company eliminates only 50 scfm of air leaks, it would amount to an additional savings of $4,700 per year. Demand Side — Diaphragm Pumps The flow increase from our charting shows an approximate 150-scfm increase when a diaphragm pump is running. With the minimal piping diameters and less than desirable response from the compressors, we need to either change the pumps to electrical type or repair all piping/volume and compressor control response. To reduce energy and optimize the system, we need to use less compressed air. To do so means finding other methods besides compressed air to perform the functions occurring now. One way is to replace the culprit diaphragm pumps with an electrical equivalent. Centrifugal pumps are commonly used in place of diaphragm pumps when the viscosity of the fluid is not an issue. Where viscosity is an issue, there are electrically driven “peristalic hose pumps.” They are capable of the same pumping characteristics as the pneumatically driven diaphragm pumps. Although this report does not endorse any particular product, I recommend that the firm investigate this type of pump along with any others that can replace the air-intensive diaphragm pumps presently in use. Distribution Header Pressure Drop The existing 1-inch and 11⁄2-inch diameter piping that makes up the FP loops are undersized for the flows that are required to support production. Now remember that leakage is a real flow and is taking up some valuable real estate in the pipes. If leakage was reduced by 50%, there is a good chance that the flows would be okay in the existing piping scheme, but for now let’s look at what size piping can handle the flows required to FP. If we use 600 scfm minus the 150 going to HP or 450 scfm as a maximum peak flow, we can calculate what size pipe is needed. The more flow you try to put through a pipe the greater the pressure drop will be. Pressure drop in a pipe increases with the square of the increase in flow. This means if you double the flow, the pressure drop will increase four times what is was! 15 http://www.fscurtis.com http://www.fscurtis.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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