JCI San Antonio 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 at Johnson Control’s San Antonio York facility from Friday May 1st through Friday May 8th of 2015.

The main focus for the study was to look at the compressed air system as a whole to determine the proper equipment needed to provide clean dry redundant compressed air for the facility. This study does not contain energy data due to the fact that one of the sources of compressed air was a portable diesel air compressor.

**This is a partial report of the compressed air system. This report will be combined with the report from the other building once the data is collected from that building**

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

1:Introduction

Compressed air quality and redundancy are an essential part of a manufacturing facilities sustainability and continued success. This report shows in detail how the data collection was performed.

2: Methodology

Compressed air flow and dew point meter:

The compressed air flow in SCFM (Standard Cubic Feet Per Minute) was measured using a CDI Meters Thermal Dispersion flow meter. The flow meter was installed in the pipe between the compressed air dryers and the 300 Gallon and the dew point and pressure sensors were installed in the 300 gallon tank nearest to the portable diesel compressor. This meter measures flow and transmits this data to the logging unit via 4-20 mA Signal. 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.

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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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

3: Results

Compressed air consumption:

The graph below shows the flow from the 75 HP compressor (red), the portable diesel compressor (black) and the total flow into the system (green). The portable diesel is manually started when pressure falls too low for production to be able to run and is left running until someone turns it off for the day. The maximum flow of the system is 909 CFM, and the average is 164 CFM.

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

The graph below shows pressure of the system and flow of the 75 HP compressor. The compressor is cycling excessively due to lack of compressed air storage and potentially high pressure drop across clean up equipment.

The graph below shows that there is a problem with the 75 HP compressor. The compressor is running in online/offline mode. The flow should be either maximum or zero. When the compressor is unloaded it has a flow of around 100 CFM.

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Compressed air quality:

The dew point in the compressed air system is less than desirable. The graph below shows system pressure, compressed air flow and dew point. The large dryer that is connected to the portable diesel is locked out and the dryer that is connected to the 75 HP compressor is not functioning. There is 650 CFM inline filter inline between the portable diesel compressor and the dryer. This filter has a drain that is not functioning.

Compressed air leak rate:

The leak rate was calculated using the decay in pressure when there was no flow into the facility. The leak rate was found to be approximately 23 CFM, which is a good number, based on the size of the facility.

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. It is recommended that the large dryer is turned on so the portable diesel does not add additional moisture to the air, the small dryer (connected to the 75 HP) is serviced to determine its operational condition and the drain on the inline filter is replaced with a no loss drain. These actions should help to minimize the amount of moisture in the air.

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Redundancy:

The system should be designed such that a compressor comes on automatically before pressure falls to the point were production is effected. The system should also have a compressor/dryer in standby in case of failure.

Drains:

The drain valves seem to be inoperable or removed. Without an adequate condensate removal system the water will flow into the plant with disregard to how well the dryer is working. It is recommended that all drains (filters, dryers, tanks) be replaced with no loss drain valves.

System Drawings

Existing system:

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Proposed system:

TBD

The proposed system will be determined upon completion of audit of other 75 HP system.

4: Conclusions

This compressed air system is in bad need of redesign. Once the data is collected from the other building we will have a complete picture of compressed air usage at the facility and can make informed recommendations.

5:Recommendations

1.Service the small dryer connected to the 75 HP compressor

2.Reconnect the large dryer connected to the portable diesel

3.Install drain valve on inline filter between portable diesel and dryer

4.Check operation of 75 HP IR compressor to see why it is not unloading completely

5.Install automatic drain valve on tank installed closest to the portable diesel and connect to oil water separator.

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Daily Graphs:

5/1/2015

5/2/2015

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

5/3/2015

5/4/2015

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

5/5/2015

5/6/2015

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JCI San Antonio York Plant Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

5/7/2015

5/8/2015

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JCI San Antonio York Plant Compressed air system