JCI Shell Fab Building 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 Saturday May 9th through Friday May 15th 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 and look for opportunities for energy savings.

Energy savings potential for the Shell Fab building is below:

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JCI San Antonio York Plant Shell Fab Building 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 and gives recommendations and analysis of system parameters.

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 1060 gallon tank and the 670 CFM compressed air dryer and the dew point and pressure sensors were installed a production cell inside the building. The flow 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.

Compressor Power:

Compressor power was measured using a Veris Industries H8042-0300-2 power transducer. The power transducer monitored the incoming power of the compressor in KW and was recorded one time per second. The power transducer measures voltage and current and calculates power to be output to the data logger via a 4 – 20 mA signal.

Data Loggers:

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

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JCI San Antonio York Plant Shell Fab Building 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 power used and the flow from the 75 HP compressor. The power supply to the power sensor was unplugged during the first day of recording by plant personnel. This period that the power was recorded is a good representation of the production of the plant and will be extrapolated for the purposes of this report. The average power was found to be 42.6 HP which was used to generate an average compressed air flow of 56 CFM.

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JCI San Antonio York Plant Shell Fab Building 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 over the course of the study. The shell fab building does not use enough air to justify a 75 HP air compressor.

The graph below shows a period of relatively high flow for the system. The average flow during this time was found to be 246 CFM and it lasted for a period of 25 minutes.

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JCI San Antonio York Plant Shell Fab Building Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Compressed air quality:

The compressed air dryer in the shell fab building does not seem to be operating. During the time the monitoring equipment was being installed the refrigeration compressor in the dryer did not turn on once (which is probably why the dew point is as high as it is). There is also no inline filter installed inline between the air compressors and the piping going to production. The 1060 gallon “wet” tank had to be depressurized to be able to install the compressed air flow meter. It was drained from a 2” ball valve connected to a tee in the discharge of the air compressor. Approximately 50 – 100 gallons of water was drained from the tank due to the automatic drain valve not functioning properly.

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 8 CFM, which is an outstanding 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 dryer is serviced to determine the cause of the high dew point in the system and a drain valve be installed in the 1060 gallon tank. These actions should help to minimize the amount of moisture in the air.

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JCI San Antonio York Plant Shell Fab Building 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 Shell Fab Building Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Proposed system:

4: Conclusions

A facility that has more than one compressed air system on the same sight screams “opportunity”. The Johnson Controls San Antonio York Plant is no exception. It is time to set up a compressed air system for the entire facility and not operate individual systems for each building. The facility has plenty of storage capacity installed in different locations that should be relocated to one central location along with all compressed air generation and clean up equipment.

The facility has 325 HP worth of compressed air generating equipment installed in the form of 4 air compressors and only two compressors are functioning. It is time to redesign the system and make a change

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JCI San Antonio York Plant Shell Fab Building Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

of service providers. The system should be designed so there is 100 % redundancy in the generation and the clean up equipment. This will allow a piece of equipment to be down for maintenance or repair without effecting production.

5:Recommendations

1.Make one compressor room for all buildings

a.The shell fab building has a large area designated for compressed air equipment. This is a logical location for new equipment to be installed.

b.Run a 4” pipe underground from the shell fab building to the main building. This will allow for the flow of both installed air compressors with minimal pressure drop.

c.Enclose the area. The installation at the battery plant is a great example of how a compressor room should look – neat, clean, and orderly.

2.Replace all compressed air equipment

a.The data from both buildings shows that a 150 HP variable speed drive air compressor will provide adequate air for production in the facility. JCI should install two 150 HP variable speed drive air compressors.

b.Install two 1200 CFM cycling compressed air dryers in parallel.

c.Install a high flow – low pressure drop mist eliminator filter.

d.Install no loss condensate drains on all condensate drain points.

e.Use existing tanks to reduce overall equipment cost.

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JCI San Antonio York Plant Shell Fab Building Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Daily Graphs:

5/9/2015

5/10/2015

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JCI San Antonio York Plant Shell Fab Building Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

5/11/2015

5/12/2015

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JCI San Antonio York Plant Shell Fab Building Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

5/13/2015

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JCI San Antonio York Plant Shell Fab Building Compressed air system

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

5/14/2015

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JCI San Antonio York Plant Shell Fab Building Compressed air system