Landis + Gyr
Compressed air energy audit
Written By: Shane Egner Owner of Egnergy
Landis + Gyr
Compressed air energy audit
Written By: Shane Egner Owner of Egnergy
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
Executive Summary
The purpose of this report is to convey the results of the compressed air energy study performed at Landis+Gyr’s Reynosa Mexico facility from Sunday May 25th through Thursday May 29th of 2014.
The compressed air system is operating at 33% efficiency with a potential for energy savings of over $19,000 Pesos annually and a total annual cost savings including maintenance of $23,224.75. This cost reduction can be achieved with a return on investment of less than one year.
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Existing |
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System |
New System |
Annual KWH |
268989.1 |
103958.4 |
Annual Cost (USD) @$.116/KWH |
$31,253.58 |
$12,078.82 |
System Efficiency |
33% |
97% |
Average Flow (CFM) |
54.0 |
54.0 |
Average Power (KW) |
26.7 |
11.9 |
Carbon Dioxide Equivalent (Metric |
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Tons) |
185.0 |
71.0 |
Annual Maintenance Cost (USD) |
$13,550.00 |
$9,500.00 |
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Equipment Cost |
$15,875.00 |
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Energy Audit Cost |
$3,000.00 |
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Installation Cost |
$3,000.00 |
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Annual Energy Cost Savings |
$19,174.75 |
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Annual Maintenance Cost Savings |
$4,050.00 |
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Return On Investment (Years) |
0.94 |
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2
Landis+Gyr Compressed system cost reduction
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 the cost savings, return on investment calculations and data collection were performed.
2: Methodology
Compressed air flow meter:
The compressed air flow in SCFM (Standard Cubic Feet Per Minute) was measured using a CDI Meters
Pressure Transducer:
The compressed air pressure was measured using an Ashcroft Pressure transducer part number
Compressor Power:
Compressor power was measured using a Veris Industries
Data Logger:
The measurements for flow, pressure, and compressor power were recorded one time per second using two Onset
3
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
3: Results
Compressed air leak rate: The leak rate of the compressed air system was calculated using the average flow of compressed air into the distribution system during a time when there was no production in the plant (5/25/2014 1:00 PM – 4:00 PM). The leak rate of the system was found to be 46.8 SCFM. This leak rate represents a large portion of the overall compressed air consumption of the facility, but is the equivalent of flow through an¼” inorificesize. Thebetwleenak 1/8”rate andforthis size of facility is acceptable. One
opportunity to lower the leak rate is to lower overall plant pressure. Lowering plant pressure by 10 PSI will lower the existing leak rate by around 9%.
Compressed air consumption: The actual consumption of compressed air by the plant was calculated by subtracting the leak rate from the overall average compressed air flow rate. The average compressed air flow rate while the plant was operating was found to be 54.2 SCFM. This means that the compressed air flow necessary for production is 7.5 SCFM.
Compressed air system efficiency: The compressed air system efficiency was calculated by comparing the rated CFM/KW of the operating compressor and comparing it to the actual CFM/KW of the compressed air system. The nameplate flow rating for this compressor is 364 CFM with a power rating of 59.7 KW. The data collected shows an average flow rating of 54.2 CFM with an average power of 26.7 KW. This gives us an ideal ratio of 6.1 CFM/KW and an actual ratio of 2.0 CFM/KW. The ratio of actual to ideal gives system efficiency, which is 32.8%.
4
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
Graph 1
Compressor idle time: The average cycle time for the compressor is around 3 minutes. The compressor is loaded (producing air) for approximately 30 seconds and unloaded for approximately 2 minutes 30 seconds. The motor still spins while the compressor is unloaded and consumes around 30% of the rated power of the compressor. The compressor runs unloaded until the load pressure set point is reached. The compressor must run in this matter due to the fact that there is a maximum number of starts and stops an induction motor can perform in an hour without causing damage to the motor. Graph 1 above shows the three full compressor cycles and is representative of the entire week of data.
Dryer: The compressed air dryer that was operating during the study is a 600 CFM cycling type dryer. This dryer consumes 4.82 KW and was taken into account in the energy calculations.
Lower plant pressure: One opportunity for savings for Landis+Gyr is to reduce the pressure in the distribution system to the minimum possible without affecting production. The minimum plant pressure during the study was found to be 88 PSI. It is reasonable to assume that 88 PSI is a good starting point for plant pressure, but it may be able to be lowered beyond that. A pressure control valve is included as part of the equipment in the implementation. This control valve will allow the pressure on the supply side to cycle between the set points of the compressor and maintain a relatively constant (+/- 1 PSI) pressure within the distribution system. This will reduce the leak load of the plant because there will be less force to push the air through the leaks.
5
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
Online/offline curve:
The curve above is a representation of online/offline controlled compressor efficiency. The curve is used by first calculating the ratio of compressed air storage to maximum compressed air flow. This ratio is used to determine which line the compressor efficiency falls on. The capacity of compressed air storage for Landis+Gyr is 800 gallons while the compressor capacity is 364 CFM. This gives a gal/cfm ratio of approximately two. It is fairly obvious from the graph above that a ratio for gal/cfm of two is less than desirable. The proposed compressor will have a gal/cfm ratio of 10. The addition of a new, correctly sized, compressor will bring the efficiency of the system to its maximum.
6
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
System Drawings
Existing system:
Proposed system:
Pressure differential: Another parameter that was examined was the differential in pressure between the compressor room and the facility. This differential pressure is important because if it is large it can cause an inflated pressure at the compressor room to compensate for the pressure drop in the distribution system. The pressure differential at the Landis+Gyr facility is not only acceptable it is desirable. The maximum pressure drop in the system is less than 2 PSI.
Carbon Footprint: The carbon footprint of the Reynosa Landis+Gyr facility can be reduced by the Carbon Dioxide equivalent of 114 Metric Tons.
*This number generated by the Environmental Protection Agency’s website www.epa.gov
7
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
4: Conclusions
The main conclusion that can be drawn from the compressed air efficiency study is that the compressed air consumption of the plant has shrunk considerably from the time the compressed air system was installed. If there were no leaks in the distribution system the plant could operate on a small 5 HP compressor.
5: Recommendations
It is recommended that Landis+Gyr install a smaller, correctly sized compressor and a pressure regulator to regulate pressure within the distribution system. By following these recommendations the facility will save over $23,000 per year.
8
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
CDI 5400
FLOWMETER FOR
SYSTEMS Rev. 2.0
●Easy to install
●No moving parts
●Digital display
●Milliamp and pulse outputs
●No calibration or setup required
●Complete flowmeter in one package
●Optional
●Housing rotates to suit vertical or horizontal installation
The CDI 5400 clamps onto a pipe, with two
The meter measures flow by maintaining one probe warmer than the other. It calculates the mass velocity from the amount of heat required, and then calculates the flow on the basis of pipe area. The flow rate, in scfm, is shown on a large,
AVAILABLE SIZES
Nom |
Calibrated |
Model No. for |
Model No. for |
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range b |
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Size a |
Sch 40 Steel |
Type L Copper |
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(scfm) |
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2 in. |
4 |
- 400 |
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2.5 in. |
5 |
- 500 |
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3 in. |
12 |
- 1200 |
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4 in. |
20 |
- 2000 |
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5 in. |
20 |
- 2500 |
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6 in. |
50 |
- 5000 |
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8 in. |
100 - 6000 |
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SPECIFICATIONS
Accuracy:
5 percent of reading plus one percent of full scale at air temperatures between 40 and 120 degrees Fahrenheit
Accuracy, extended range:
7 percent of reading from rated full scale to 150 percent of calibrated range, at air temperatures between 40 and 120 degrees Fahrenheit
Fluids:
Compressed air and nitrogen
Operating pressure:
200 psig maximum on Sch. 40 steel and on Type L copper below three inch; consult CDI for other materials and higher pressures.
Input power:
250 mA at 18 to 24 Vdc
Output resistance:
400 Ohms max.
Materials exposed to measured fluid:
Stainless steel, gold, thermal epoxy and Viton (seal)
Ring material:
Aluminum
(a)Meters are also available for several sizes of Aluminum pipe. For metering smaller pipe sizes, please see our Series 5200 flowmeters.
(b)Accuracy will be reduced when flow is outside of the specified range. Milliamp scale ranges differ.
(c)Flowmeters for 2”, 3”, and 4” copper have smaller calibrated ranges.
Display:
Response time:
One second to 63 percent of final value
US Patent 6,802,21
Figure 1
9
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
Model G2 Pressure Transducer
Cable
Connection
Hirschmann
Connection
Connection
Flying Lead
Connection
LOOK FOR THIS
AGENCY MARK ON
OUR PRODUCTS
APPLICATONS
The G2 pressure transducer combines performance with value to meet the demanding needs of the original equip- ment manufacturer in applications found in:
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•Construction Machinery
•Performance Racing
•Railroad/Transportation
•Compressor Control
•HVAC and Refrigeration
•Agricultural Implements
•Process Automation and Control
•Hydraulic & Pneumatic Sensing
•Pump Monitoring
FEATURES
•1% Total Error Band Accuracy
•Broad Temperature Capability
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•High EMI/RFI rating
•Ranges 30 psi through 20,000 psi
•IP 67 Ingress rating
•Diagnostic rails
The Ashcroft® Type G2† pressure transducer has been specifically designed with the high volume OEM in mind.
A ±1% Total Error Band accuracy is accom- plished by marrying a high performance ASIC to a very stable, field proven polysilicon thin film pressure sensor. The sensor is electron beam welded to a pressure fitting of stainless steel, which provides excellent overpressure capability and outstanding durability in the presence of shock and vibration.
The circuitry is held within an internal cage and housed in an enclosure of reinforced Nylon.
TOTAL ERROR BAND (TEB)
Error limits of all points
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2.0% |
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1.5% |
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of span) |
1.0% |
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0.5% |
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0.0% |
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0 |
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Ambient Temperature (C) |
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Pos Error Limit |
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Neg Error Limit |
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All specifications are subject to change without notice. |
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All sales subject to standard terms and conditions. |
BULLETIN G2 |
© 2013 Ashcroft Inc., Rev. 08/13 |
PERFORMANCE SPECIFICATIONS
Ref. Condition 21°C ±1°C (72°F ±2°F)
Accuracy:
Total Error Band includes combined effects of temper- ature,
±1% of Span: From
±1.5% of Span: From
Note: Static accuracy ±0.25% of span BFSL (Best Fit Straight Line Method); includes
Stability: Less than ±0.25% span/year Durability: Tested to 50 million cycles
ENVIRONMENTAL SPECIFICATIONS
Temperature: |
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Compensated |
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Operating |
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Storage |
Humidity: 0 to 100% R.H., no effect
FUNCTIONAL SPECIFICATIONS
Select from over 25 pressure ranges starting at 30 psi and running through 20,000 psi gauge. Compound (vacuum & pressure) ranges are also available, see “To Order” on back.
Overpressure (F.S.): |
Proof |
Burst |
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750 psi & below |
200% |
F.S. 1000% F.S. |
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1500 psi |
200% |
F.S. |
500% F.S. |
3000 psi |
200% |
F.S. |
500% F.S. |
5000 psi |
150% |
F.S. |
500% F.S. |
7500 psi |
120% |
F.S. |
500% F.S. |
10,000 psi |
120% |
F.S. |
240% F.S. |
20,000 psi |
120% |
F.S. |
240% F.S. |
Vibration: Random vibration (20 g) over tempera- ture range
Shock: 100gs, 6 ms
Drop Test: Withstands 1 meter on concrete 3 axis
Response Time: Less than 1 msec
ELECTRICAL SPECIFICATIONS
Output Signals Available: |
Supply |
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Voltage Output |
Excitation |
Current |
5mA |
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5mA |
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4mA |
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4mA |
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4mA |
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Ratiometric Output: |
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5 Vdc ±0.5 Vdc |
3.5mA |
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Current Output: |
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Reverse Polarity & Miswired Protected: Yes Insulation Breakdown Voltage: 100 Vac
Insulation Resistance: Greater than 100 megohms at 100 Vdc
CE Marked: Per DoC
EMC Directive 2004/108/EC
IEC/EN
IEC/EN
Ashcroft Inc., 250 East Main Street, Stratford, CT 06614 USA Tel:
email: [email protected] • www.ashcroft.com
Figure 2
10
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
Figure 3
11
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
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Compressor Room Pressure |
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Flow (CFM) |
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Plant Pressure (PSIG) |
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(PSIG) |
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Compressor Power (KW) |
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Std |
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Std |
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Std |
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Std |
Date |
Max |
Min |
Avg |
Dev |
Max |
Min |
Avg |
Dev |
Max |
Min |
Avg |
Dev |
Max |
Min |
Avg |
Dev |
5/25/14 |
159.9 |
22.5 |
49.3 |
35.2 |
102.2 |
87.7 |
94.6 |
4.1 |
102.5 |
87.9 |
94.8 |
4.1 |
49.8 |
21.6 |
27.5 |
8.7 |
5/26/14 |
175.7 |
22.7 |
52.7 |
36.5 |
102.3 |
87.5 |
94.5 |
4.1 |
102.4 |
86.8 |
94.7 |
4.1 |
152.3 |
19.3 |
26.6 |
9.4 |
5/27/14 |
166.9 |
23.8 |
52.8 |
36.5 |
102.3 |
0.0 |
94.1 |
6.7 |
102.3 |
87.8 |
94.7 |
4.1 |
57.3 |
17.9 |
26.2 |
9.2 |
5/28/14 |
166.7 |
24.4 |
57.3 |
37.6 |
102.3 |
87.3 |
94.5 |
4.1 |
102.4 |
87.7 |
94.8 |
4.1 |
49.7 |
18.7 |
26.8 |
9.4 |
5/29/14 |
162.2 |
0.0 |
57.2 |
37.8 |
102.4 |
0.0 |
93.3 |
11.6 |
102.4 |
21.4 |
94.6 |
5.3 |
153.4 |
0.0 |
26.6 |
10.6 |
Full |
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Week |
175.7 |
22.5 |
54.2 |
37.0 |
102.4 |
87.3 |
94.2 |
6.5 |
102.5 |
86.8 |
94.7 |
4.3 |
175.7 |
17.9 |
26.6 |
9.5 |
12
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
13
Landis+Gyr Compressed system cost reduction
Egnergy
19718 Ranch Meadow
San Antonio, TX 78258
Technical Information:
Capacity:
83cfm @ 125psig
Maximum Operating Pressure:
125psig
Weight:
1186 lbs.
Connection Size: 1.0” NPT
Dimensions (L x W x H): 51” x 36” x 41”
Additional Engineering Data available upon request.
Image for reference only
The design of the Ingersoll Rand Rotary screw air compressor combines a high efficiency integrated compression module, simple diagnostics, quiet operation and a compact footprint. Options include integrated air treatment and advanced controls.
These features deliver unparalleled reliability, ease of operation and flexibility in placement and application. The addition of the integrated dryer increases the life and enhances performance of down stream tools and equipment.
Key Features included as Standard: |
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x |
ODP Motor / FV Starter |
x |
Low Sound Enclosure (68 dba) |
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x |
Load / No |
Load with Auto Start/Stop |
x |
Ultra Coolant |
Controls
14
Landis+Gyr Compressed system cost reduction