I Did My Air System Audit and Fixed Everything, So I'm Done - Right?

Supply-Side:
Let's say that you did a supply-side audit and upgraded your compressor room with the latest and greatest VFD compressor along with a cycling dryer along with the appropriate sized receivers with zero loss drains. You might have even put a demand controller and system flowmeters in place. Here is the supply side checklist:

1. Flowmeter - Record and track your air system data at the flowmeter - preferably by having it integrated into your system or at least downloading it on a weekly basis - any changes go find the reason why


2. Controls - As good as your system controls started out they can get out of sequence or improperly adjusted. There have been cases where the VFD compressor is supposed to be the trim machine but ended up being the base load machine. This completely ruins any energy savings originally planned. Do a weekly check for all shifts.


3. Drains - Any air system efficiency upgrades include zero loss strains. Check to see if they're still working properly. Establish a monthly maintenance program


4. Maintenance - Lack of maintenance can diminish the efficiency of any good compressor system. Be sure that the inlet filter/coolers/dryer condensers are cleaned regularly based on the compressor room environment. This should be done by expert maintenance staff and not wait for the service company.


5. Demand Controller - This unit regulates the air pressure out into the system creating storage in the compressor room tanks. Sometimes the air compressor pressure elf makes adjustments without other people knowing and the reduced pressure /increased storage savings goes away. Check monthly and lock if possible.

Demand-Side:
You have done all the right things in the compressor room with the latest and greatest equipment and the proper receivers etc. You went out into the plant and looked for air hogs/bad piping/incorrect low pressure air use along with other opportunities. What you to do now is check on the following quarterly:

1. Regulator - If you did not put locking regulators on stations to reduce the air from line pressure to an appropriate pressure for the operation I would bet you $10 that the regulator is cranked all the way up. Check them and replace them with locking regulators if necessary


2. Blow Offs - Many locations that originally had copper or a pipe nipple were converted to engineered blow offs to conserve 60% of the year. Unfortunately they are quiet and many operators take them off and go back to the old ways.


3. Blowers - Compressed air oftentimes replaced by blowers that operate on 10% of the KW used for the same application by an air compressor. Unfortunately blowers need maintenance to continue to run efficiently and sometimes fail without replacement. The operator then goes back to compressed air. Maintain your blowers monthly and to replace as appropriate.


4. Piping - Many times a new piece of equipment is installed quickly creating problems with the redesigned air system. No unit should be piped into the system without the Air System Sheriff approving.

This all may seem obvious but unfortunately the day-to-day business of running a facility and putting out fires takes her attention away from what was well-intentioned. It is absolutely critical to have the Air System Sheriff who is responsible for maintaining the efficiency. It is also critical that the team understand that if the company spent $100,000 to upgrade the air system to save $30,000 annually it is their responsibility maintain the savings.

Just keep in mind that the air system is like a bridge and you need to continuously keep after it or it's going to deteriorate. The challenge is making the time and energy available to maintain the air system efficiency.

If you need some help in organizing this please call Frank Lederer call at 508-351-1817 or email him at flederer@hopeair.com.

Power Company Audit Funding 2013!

What if an unbiased third party could tell you how to save money and their advice was almost free?

About a year ago in a previous article I made the statement "would you be only interested in how much you earned but didn't care how it was spent?" Well now a number of power companies have programs for 2013 which are providing auditing services for a number different areas including compressed air/natural gas/solar heating/cogeneration which could help you reduce spending.

The two major power companies in New England are NSTAR and NGRID which have programs that will pay up to 100 percent of an audit dependent on the savings and the commitment to implement the recommendations. Many of the other power companies are following suit with similar programs.

What type of audits are available?

1.    Demand-Side Air System Audits – which include leak detection/storage/piping pressure drop reviews/inappropriate use/alternative solutions as part of the program

2.    Supply-Side Air System Audits – which include compressor power and capacity auditing/control evaluation/air quality analysis/condensate management would be part of a comprehensive audit program

3.    Heat Reclamation Opportunities – utilizing waste heat from compressors/furnaces/molding equipment/hydraulic systems could be part of the program

4.    Alternative Heat Sources – evaluating passive and active solar heating as well as potential of integrating cogeneration to create heat and power are the most complex audits

Consider looking at your major energy expense buckets for your company that will help you focus on what areas to audit so you could reduce your operating costs. Example – air system leaks can be up to 25 percent of your capacity – cost for a 75 hp system with 25 percent leaks operating 4000 hours at $.15/KW is $13,225 per year. If you had an audit that found these leaks along with other cost reduction opportunities and it was less than $8000 net cost that would be a real win!

NSTAR and NGRID, as well as some of the other New England power companies, have more rebate dollars to provide industry in 2013 than they did in 2012. They are very anxious to find opportunities now to get rebates in process early in the 2013.

You know these issues exist but realistically you can't get to them. Visit the Hope Air Systems website, or call us and we would be happy to do a quick walk-through to identify areas that you would benefit from an audit. Then you would invite the power company to discuss the potential of your compressed air/heat reclamation cost saving opportunities initially identified. Also, you can contact your power company representative and have him bring in an engineer or a site review.

If you don't know you can't correct it. Contact Frank Lederer at 508-351-1817 or flederer@hopeair.com.

New Year's Resolutions for 2013

Honest, this year I really will try to do better…

I know that I've not always done all the right things, so this year I promised to do the following for my compressed air system.

·         Lose KW by reducing my air leaks and promise to stay on that diet.

·         Don't leave stuff on especially the compressor when I don't need it

·         Spend my air wisely by making sure I don't use any electric drain valves and other things that use too much air - I know some of what they are.

·         Make sure that periodic checkups are really done to make sure my compressor is healthy.

·         Budget the amount of air I use by installing a flow meter.

·         Have an annual checkup on the whole air system with a different set of eyes to be sure all is okay.

·         Call a specialist when I don't know all the answers - i.e. ask for directions.

Sure this is simple stuff but I always seem to lose my way by the third month.

To my silent partner, please check back with me to make sure I'm on the straight and narrow in keeping my resolutions. Contact Frank Lederer at 508-351-1817 or flederer@hopeair.com.