Industrial Utility Efficiency    

System Assessment

Great Plains has carved a global reputation for producing world-class seeding equipment since it first opened its doors in 1976. Great Plains manufactures a range of products from grain drills and planters, to compact drills and tillage equipment. They have established an international business built on expertise, knowledge and a commitment to producing products meeting the rigorous demands of the agricultural sector.

Compressor Controls

A large mining complex in a remote northern region of the world invited a compressed air auditor in to assess the efficiency of a problematic system. Site personnel and their air compressor supplier were concerned a system in one of the buildings was not running optimally, and wanted to know what size of compressor to install in the facility. The auditor found significant savings in this target system, but even larger potential savings were found in other ancillary systems in the complex, as part of an extra investigation conducted while at the site. Overall, the potential energy savings total more than half of a million dollars, if all recommendations are implemented.

Piping Storage

The company specializes in fabrication of precision assembled customized parts for OEM’s and system integrators. Since 1997 the company has steadily grown in size and capacity as the demand for its high quality fabrications has increased.  Through the years, many new CNC machines, laser cutters and powder coat painting operations have been added, but with all the expansion the facility has amazingly kept the plant compressed air consumption low. This has been achieved by following excellent “best practice” compressed air efficiency principles and by keeping watch on system waste.

End Uses

A meat processor, located in Canada, hired a consultant to assess their compressed air system as part of a company-wide energy conservation effort. The assessment and analysis showed, despite having a modern compressed air system using a VSD air compressor and pressure/flow control, the system was running inefficiently and had significant levels of leakage and inappropriate use.

Pressure

A Canadian chemical plant installed a large heated blower-purge style compressed air dryer, years ago, to condition the instrument air system against freezing temperatures.  The dryer selected was oversized for the connected air compressors and had unused on-board energy savings features.  A compressed air assessment revealed the site air compressors and compressed air dryers were running inefficiently and causing in-plant pressure problems.  Repairs to a compressed air dryer and the replacement of aging air compressors and dryers has reduced compressed air energy costs by 31 percent.

Air Treatment/N2

This plant has three production lines producing snack food. Depending on the time of year and production demand the plant can operate anywhere from no production lines to all three production lines. A thorough supply and demand-side system assessment was done at this plant. This article will focus on some recommended demand-side reduction projects including nitrogen generation, air vibrators, leaks and vacuum venturis.

Leaks

Petro Chemical Energy, Inc. (PCE) specializes in energy loss surveys for the refining and chemical industries. We’ve been providing Compressed Air Leak Surveys, Nitrogen Leak Surveys, Steam Leak Surveys and Steam Trap Surveys – for over twentyfive (25) years. We operate totally independent of all equipment manufacturers to ensure our clients receive a complete and unbiased report of the leaks in their facility. PCE has conducted compressed air leak surveys for hundreds of customers at thousands of sites. Undetected, compressed air and gas leaks rob efficiency in manufacturing and processing industries. As a result, businesses lose millions of dollars annually in energy costs and lost production time.

Pneumatics

Energy, in all forms, has always been a key Lantech focus. It was, in fact, a key element of the core packaging problem the company’s founders set out to address. They saw an opportunity to capitalize on an inexpensive and under-used resource – stretch film – to displace a high materials cost and energy intensive way of unitizing pallet loads of products – shrink bagging.

Vacuum Blowers

Every municipality and utility is facing the reality of rising energy costs. In 2010, the Town of Billerica, MA, which is located 22 miles northwest of Boston with a population of just under 40,000 residents, engaged Process Energy Services and Woodard & Curran to conduct an energy evaluation of the Town’s Wastewater Treatment Facility (WWTF) and pump station systems sponsored by National Grid. The objective of the evaluation was to provide an overview of each facility system to determine how electrical energy and natural gas were being used at the facility and to identify and develop potential costsaving projects.
When Compressed Air Consultants was starting, in 2003, we were approached by a company experiencing significant problems with their compressed air system.  They had compressed air pressure problems causing production interruptions.  They had moisture issues causing all kinds of havoc throughout the facility and appeared to be using far too many air compressors for what they wanted to accomplish. 
The intent of this article is to provide readers with simple examples of calculations one can perform to evaluate two sample energy efficiency projects for compressed air systems; pressure sensing vortex vacuum generators and outside air intake (for air compressors).
Compressed air optimization measures adopted by PTMSB have reduced the consumption of compressed air by 31 percent resulting in savings of about 3,761,000 kWh per year in energy consumption. The monetary savings are MYR 1,090,627 per year ($255,000 USD). The CO2 reduction is estimated at 2,735 ton per year.
Pressure regulators are everywhere compressed air is used. These simple devices, essential for safe and steady equipment operation, can be a big waster of compressed air. This article shows how with proper regulator selection, installation and setting management you can save compressed air and lower system pressures. This article looks at regulators on production equipment not central regulators or Process Flow Controllers.
Technology is available which enables a compressed air flow meter to measure not only the magnitude of the flow, but also the direction. Why is this important? In this article we will describe two case studies where bi-directional compressed air flow measurement plays a key role to come to the right conclusions. In the first case study, we will describe an electronics manufacturing plant, which has a large interconnected ring network with two air compressor rooms located in different buildings. The two air compressor rooms are about five hundred feet apart. In the second case study, the effect of compressed air flow measurement upstream of a local receiver tank is described.
The objective of this project is to help the building automation industry develop novel products that more cost-effectively identify faults (unwanted conditions) and inefficiencies in the operation of the compressed air plants of industrial facilities.  More cost-effective fault detection and diagnostics (FDD) products can come to the building automation marketplace only after that industry makes very significant advances in the state-of-the-art of its FDD software tools from what it currently offers.  Those advances require making common practice of rules-based artificial intelligence (AI) methods that the building automation industry has shown little to no familiarity with in its technology so far.  This project will utilize, under controlled conditions, the compressed air plant of the NIST campus as a facility for test and development of an embedded rules-based FDD tool based upon NIST expertise.
As a result of compressed air awareness training and a focus on energy management, two facilities in different parts of the world have reduced their compressed air demand substantially by removing vortex style cabinet coolers from some of their electrical panels and reworking the cooling systems.  These facilities were previously unaware of the high cost of compressed air and how much could be saved if other methods of cooling were used. This article describes some of their efforts in demand reduction.
When a successful Midwestern United States-based packaging company reached out to Cleveland, Ohio-based Diversified Air Systems, Inc. (Diversified), it was simply looking to fulfill its need for backup air. Compressed air is a vital component of the packaging company’s business, used for a variety of purposes, such as in its corrugating machines, conveyors, actuators, and more. In the end, the company received much more than just air redundancy, including a new variable speed drive, two-stage air compressor, a completely reconfigured and upgraded piping system, improved system efficiencies, energy savings, and a significant energy rebate.
In aerospace manufacturing, tiny details matter most. For instance, if proper torque is not applied to the screws and bolts fastening an aircraft fuselage, catastrophic failures can result. Compressed air is used to power the tools needed to apply that torque, making the compressed air system a critical part of the facility, though it largely stays behind the scene.
During an Energy Review at a relatively new health care garment factory, in the Southwest, we found all three of the 100 psig nominally rated rotary screw air compressors were operating at 115-120 psig continuously. We asked the Production Superintendent if this was normal or if something had recently changed. He explained that initially they operated two air compressors but had to begin running the 3rd unit in ‘trim’ mode after some converting machines were up-graded. Then, a new larger converting machine was recently installed and air pressure quickly became a production issue. Since capital funds were tight, the project engineering team determined the third air compressor had sufficient capacity.