Brunswick Bowling Mexico Compressed air energy audit

Written By: Shane Egner

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Executive Summary

The purpose of this report is to convey the results of the compressed air energy study performed Brunswick Bowling Mexico’s Reynosa Bowling Ball facility from Monday June 15th through Monday June 23rd of 2015.

The main focus for the study was to look at the dew point of the compressed air entering the distribution system and find potential for energy savings.

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

1:Introduction

Cost reduction is an essential part of a manufacturing facilities sustainability and continued success. This report shows in detail how the cost savings, return on investment calculations and data collection were performed.

**Power cost calculations are base on an electrical cost of $0.068/KWhr**

2: Methodology

Compressed air flow and dew point meter:

The compressed air flow in SCFM (Standard Cubic Feet Per Minute) was measured using a VP Instruments Differential Pressure flow meter. The flow meter was installed in the pipe between the compressor room and the tank installed in the facility. This meter measures both pressure and flow and transmits this data to the logging unit via Modbus. Dew Point was measured using a Michell Instruments SF- 52 dew point transmitter. The dew point was transmitted to the logger using a 4-20 mA signal.

Compressor Power:

Compressor power was measured using a Veris Industries E50C2 power meter. The power transducer monitors the incoming power of the compressor in KW and was recorded one time per 10 seconds. The power transducer measures voltage and current and calculates power to be output to the data logger via a modbus signal.

Data Loggers:

The measurements for flow, pressure, and compressor power were recorded one time per second using two Onset UX120-006M and one LogicBeach IL80. The data is read and graphed through Onset’s software called HOBOware.

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

3: Results

Compressed air consumption:

No Production:

The graph below is a representation of compressed air flow and the power to generate the flow for Friday 6/19 through Sunday 6/21. The average flow of the system was 83 SCFM and the average power was 43 HP. This compressed air usage can be contributed mostly to leaks. It is strongly suggested that a leak study be performed and corrective actions taken to minimize the impact of leaks on Brunswick’s energy bill. These leaks cost the company around $19,000 annually.

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Compressed air consumption:

With Production:

The graphs below show the parameters recorded in the compressor room: Total Power, Flow, and Pressure. The average power during production was found to be 141 HP with an average flow of 365 SCFM. The maximum flow of the system was 755 SCFM. The header pressure varied from 111 PSI to 82 PSI with an average of 95 PSI. There is potential for energy savings with lowering header pressure.

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Dew Point:

The dew point in the compressed air system is less than desirable. The maximum dew point is 97 F and the minimum dew point is 77F. The graph below shows system dew point measured in the pipe that supplies air to the dust collectors installed outside the compressor room. The elevated dew point can be due to dirty aftercoolers, improperly functioning dryers, or drain valves not operating properly.

***When the dew point sensor was removed from the system there was condensed water in the lines.***

Opportunities:

Quality:

The first and most obvious opportunity with the compressed air system is quality. The dew point of the air is at a level where it is impossible to not have condensed moisture in the compressed air lines. The recommendation of this report is to install two correctly sized compressed air dryers in parallel along with one high efficiency filter. This will ensure there is a back up dryer in case of breakdown or maintenance and will help to eliminate the moisture and oil content in the compressed air system.

Efficiency:

The rule of thumb for increased pressure at the outlet of an air compressor is 1% per two PSI increase. The pressure at the outlet of the air compressors should be as close to plant pressure as possible. This can be achieved with the removal of the current inline filters and the installation of a high efficiency mist eliminator filter. About 80 CFM of air that is being generated by the air compressors is not travelling to the production equipment to perform work. This air is being lost within the compressor room due to electric drain valves.

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

System Drawings

Existing system:

Proposed system:

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

4: Conclusions

The compressed air system installed in Brunswick’s Reynosa facility has the air compressors necessary to be an extremely efficient system. It just needs some auxiliary equipment to make everything work together. Around 80 CFM from the compressors is being lost from the point of generation to the production floor. This is most likely due to inefficient electric drain valves. The plant pressure should be lowered to the minimum possible. The graphs show that the pressure falls to 82 PSI with no loss of production.

5:Recommendations

1.Fix the leaks in the plant.

2.Install two new appropriately sized cycling refrigerated dryers.

3.Install one high efficiency filter before the dryers and one after the compressor with the integrated dryer.

4.Replace all electric drain valves with no loss drain valves.

5.Install master system control.

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Daily Graphs:

6/15/2015

6/16/2015

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

6/17/2015

6/18/2015

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

6/19/2015

6/20/2015

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Brunswick Bowling Mexico Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

6/21/2015

6/22/2015

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Brunswick Bowling Mexico Compressed air system