Alcom Reynosa

Compressed air flow audit MD2 Production Area

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 flow study performed in the production area of MD2 on the second floor at Alcom’s Reynosa Mexico facility from Monday August 25th through Wednesday August 27th of 2014.

The production area is using an average flow of 445 SCFM with an average annual cost of $82,000. Changing the venturi type vacuums for electrically operated vacuums can dramatically reduce this flow and cost to operate the compressed air system.

 

 

 

 

 

Alcom Production Flow and Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

Flow (SCFM)

 

 

 

 

Pressure

 

 

 

Line

 

# of Cells

 

Max

Average

 

Minimum

 

Max

Average

 

Minimum

 

 

Honda Fit

 

1

 

25.62

15.27

 

9.55

 

92.24

 

80.81

 

70.63

 

 

PL6 #1

 

5

 

38.03

30.3

 

17.17

 

90.94

 

76.94

 

69.91

 

 

Nissan

 

2

 

20.52

7.94

 

0

 

94.71

 

91.19

 

86.3

 

 

CED 91

 

2

 

25.94

7.76

 

0

 

95.43

 

90.87

 

82.38

 

 

SVS LH

 

3

 

19.04

5.07

 

1.79

 

97.76

 

90.33

 

64.4

 

 

DLS

 

2

 

35.19

31.91

 

29.63

 

82.09

 

79.03

 

76.14

 

 

K2XX DLS

 

1

 

30.28

22.46

 

8.85

 

86.59

 

83.37

 

75.42

 

 

TK8 1,2,4 Key

 

3

 

21.39

8.94

 

4.03

 

95.43

 

92.01

 

86.44

 

 

Mount V36X

 

2

 

37

33.4

 

31.07

 

86.88

 

84.04

 

81.37

 

 

Acura

 

1

 

27.77

15.42

 

8.41

 

94.85

 

87.62

 

77.6

 

 

M-Sport

 

1

 

39.9

12.88

 

4.27

 

96.74

 

91.4

 

79.77

 

 

Heated Cooled

 

1

 

35.39

23.17

 

16.06

 

89.92

 

82.7

 

70.63

 

Line

Worst Case Flow

 

 

Average Flow

Worst Case HP

 

 

Average HP

Average Cost/yr

Honda Fit

25.6

 

 

 

15.3

 

6.4

 

 

 

3.8

 

$2,826.59

PL6 #1

190.2

 

 

 

151.5

 

47.5

 

 

 

37.9

 

$28,043.80

Nissan

41.0

 

 

 

15.9

 

10.3

 

 

 

4.0

 

$2,939.51

CED 91

51.9

 

 

 

15.5

 

13.0

 

 

 

3.9

 

$2,872.87

SVS LH

57.1

 

 

 

15.2

 

14.3

 

 

 

3.8

 

$2,815.49

DLS

70.4

 

 

 

63.8

 

17.6

 

 

 

16.0

 

$11,813.56

K2XX DLS

30.3

 

 

 

22.5

 

7.6

 

 

 

5.6

 

$4,157.52

TK8 1,2,4 Key

64.2

 

 

 

26.8

 

16.0

 

 

 

6.7

 

$4,964.58

Mount V36X

74.0

 

 

 

66.8

 

18.5

 

 

 

16.7

 

$12,365.19

Acura

27.8

 

 

 

15.4

 

6.9

 

 

 

3.9

 

$2,854.36

M-Sport

39.9

 

 

 

12.9

 

10.0

 

 

 

3.2

 

$2,384.19

Heated Cooled

35.4

 

 

 

23.2

 

8.8

 

 

 

5.8

 

$4,288.94

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Total

707.7

 

 

 

444.8

 

176.9

 

 

 

111.2

 

$82,326.59

2

Alcom Reynosa compressed air system Flow Study

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 uncontrolled demand in production can cost an incredible amount of money and also reduce the redundancy of facility systems.

**Power cost calculations are base on an electrical cost of $0.113/KWhr**

2: Methodology

Compressed air flow meter:

The compressed air flow meter used for this study is a one-inch inline flow meter (VPFlowScope® In-line) designed for portable point of use compressed air flow, temperature, and pressure measurements. The meter was installed between the supply compressed air lines and the lines feeding air to the production cells. Flow and pressure were recorded once every 5 seconds and temperature was recorded one time every 10 seconds.

Compressed air consumption:

Honda Fit:

3

Alcom Reynosa compressed air system Flow Study

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

PL6 #1:

Nissan:

CED 91:

4

Alcom Reynosa compressed air system Flow Study

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

SVS LH:

K2XXDLS:

DLS:

5

Alcom Reynosa compressed air system Flow Study

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

Heated Cooled:

M-Sport:

Acura:

6

Alcom Reynosa compressed air system Flow Study

Egnergy

3400 N McColl Suite F11

Mcallen, TX 78501

210-560-6568

TK8 1, 2, and 4 Key:

V36X:

Notes on flow and pressure:

The minimum pressure found during the study was 64.4 PSIG. This pressure occurred on one of the SVH production lines and did not interrupt production. This would infer that the minimum pressure for this line is less than 64.4 PSIG. There is potential for energy savings through reduction in artificial demand by lowering the pressure in the main loop for the second floor. This energy reduction is hard to quantify without further testing.

The main user of compressed air is the venturi vacuum systems. It can be seen from the graphs of TK8, M- Sport, and SVS that when the vacuums are activated they use approximately 15 SCFM. Some of the production lines have intermittent vacuum systems and some of them have the vacuum on constantly.

Recommendations:

 

1.

Replace all venturi vacuum systems with small½

- 1 HP industrial vacuums or install central vacuum

 

system.

 

2.

Lower pressure in the production to the minimum allowable (70 PSI or lower).

7

Alcom Reynosa compressed air system Flow Study