Alcom Reynosa
Compressed air flow audit MD2 Production Area
Written By: Shane Egner
Alcom Reynosa
Compressed air flow audit MD2 Production Area
Written By: Shane Egner
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
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.
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Alcom Production Flow and Pressure |
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Flow (SCFM) |
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Pressure |
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Line |
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# of Cells |
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Max |
Average |
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Minimum |
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Max |
Average |
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Minimum |
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Honda Fit |
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1 |
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25.62 |
15.27 |
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9.55 |
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92.24 |
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80.81 |
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70.63 |
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PL6 #1 |
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5 |
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38.03 |
30.3 |
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17.17 |
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90.94 |
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76.94 |
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69.91 |
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Nissan |
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2 |
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20.52 |
7.94 |
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0 |
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94.71 |
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91.19 |
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86.3 |
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CED 91 |
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2 |
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25.94 |
7.76 |
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0 |
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95.43 |
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90.87 |
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82.38 |
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SVS LH |
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3 |
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19.04 |
5.07 |
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1.79 |
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97.76 |
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90.33 |
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64.4 |
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DLS |
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2 |
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35.19 |
31.91 |
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29.63 |
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82.09 |
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79.03 |
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76.14 |
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K2XX DLS |
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1 |
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30.28 |
22.46 |
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8.85 |
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86.59 |
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83.37 |
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75.42 |
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TK8 1,2,4 Key |
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3 |
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21.39 |
8.94 |
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4.03 |
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95.43 |
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92.01 |
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86.44 |
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Mount V36X |
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2 |
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37 |
33.4 |
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31.07 |
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86.88 |
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84.04 |
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81.37 |
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Acura |
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1 |
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27.77 |
15.42 |
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8.41 |
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94.85 |
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87.62 |
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77.6 |
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1 |
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39.9 |
12.88 |
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4.27 |
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96.74 |
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91.4 |
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79.77 |
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Heated Cooled |
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1 |
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35.39 |
23.17 |
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16.06 |
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89.92 |
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82.7 |
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70.63 |
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Line |
Worst Case Flow |
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Average Flow |
Worst Case HP |
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Average HP |
Average Cost/yr |
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Honda Fit |
25.6 |
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15.3 |
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6.4 |
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3.8 |
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$2,826.59 |
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PL6 #1 |
190.2 |
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151.5 |
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47.5 |
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37.9 |
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$28,043.80 |
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Nissan |
41.0 |
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15.9 |
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10.3 |
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4.0 |
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$2,939.51 |
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CED 91 |
51.9 |
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15.5 |
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13.0 |
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3.9 |
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$2,872.87 |
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SVS LH |
57.1 |
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15.2 |
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14.3 |
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3.8 |
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$2,815.49 |
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DLS |
70.4 |
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63.8 |
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17.6 |
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16.0 |
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$11,813.56 |
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K2XX DLS |
30.3 |
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22.5 |
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7.6 |
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5.6 |
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$4,157.52 |
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TK8 1,2,4 Key |
64.2 |
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26.8 |
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16.0 |
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6.7 |
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$4,964.58 |
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Mount V36X |
74.0 |
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66.8 |
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18.5 |
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16.7 |
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$12,365.19 |
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Acura |
27.8 |
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15.4 |
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6.9 |
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3.9 |
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$2,854.36 |
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39.9 |
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12.9 |
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10.0 |
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3.2 |
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$2,384.19 |
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Heated Cooled |
35.4 |
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23.2 |
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8.8 |
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5.8 |
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$4,288.94 |
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Total |
707.7 |
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444.8 |
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176.9 |
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111.2 |
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$82,326.59 |
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2
Alcom Reynosa compressed air system Flow Study
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
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
Compressed air consumption:
Honda Fit:
3
Alcom Reynosa compressed air system Flow Study
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
PL6 #1:
Nissan:
CED 91:
4
Alcom Reynosa compressed air system Flow Study
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
SVS LH:
K2XXDLS:
DLS:
5
Alcom Reynosa compressed air system Flow Study
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
Heated Cooled:
Acura:
6
Alcom Reynosa compressed air system Flow Study
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
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: |
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1. |
Replace all venturi vacuum systems with small½ |
- 1 HP industrial vacuums or install central vacuum |
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system. |
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2. |
Lower pressure in the production to the minimum allowable (70 PSI or lower). |
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7
Alcom Reynosa compressed air system Flow Study