Project description:
- Tour of the plant and compressor room, in order to characterize the plant’s compressed air needs.
- Flow rate test and energy survey for the compressed air system, in order to get a complete picture of the air flow rate and energy consumption throughout all of the plant’s work hours.
- In-depth analysis of the test data, drawing of conclusions, and submission of a report to the customer by the company’s engineers.
- Follow-up meeting with the customer to present the report, explain and make it easily understandable for the customer; presentation and proposal of possible solutions to the customer, designed to streamline and improve his compressed air system, both operationally and from the energy aspect.
- Preparation of relevant quotations and guidance until receipt of an order from the customer.
- Characterization and planning of the installation of the new compressor room, arriving at a final characterization and customer approval.
- Guiding the customer through all stages of construction of the new compressor room, until completion and arrival for installation.
- Accompanying the customer during the first month after the system’s installation, to achieve perfect calibration of the system for the plant.
Installation description:
EL-AV Compressors’ installation team performed installation of the entire air system in the new room.
A 6” main manifold manufactured by EL-AV Compressors installed in the compressor room; 2” rigid and flexible piping; dryer including in-line filters and bypass for quick and easy maintenance, and four smart water drain valves: for compressor, manifold, air collector, and in-line filter before air dryer. Proper, professional installation to avoid malfunctions and allow the air to flow properly, thus achieving maximum efficiency. At the end of installation we performed initial operation of the system including calibration, and provided training to the customer’s technical team on operation and preventive maintenance of the system. In the first month we guided the customer, visiting at our own initiative to perform calibration of the system, and thus achieve the best possible results from all system components, maximum energy efficiency, and ensure proper, quiet operation of the air system for years to come.
Summary:
The company had an old compressed air system with a mediocre performance level, calibrated somewhat out of harmony with plant needs; hence, its energy consumption was significantly higher than what could normally be expected using a better technology.
The old compressed air system was based on vane technology compressors. The compressor room contained three compressors, two of which were operating throughout most of the day. The mainstay was a 60 hp (45 kW) inverter, assisted by a 40/50 hp (30/37 kW) compressor as needed. The room also included two in-line micron filters, three timer-operated water drain valves, and an air dryer (refrigeration) for flow rate of up to 19 m3/min of air. The average actual flow rate was about 9.5 m3/min of air, peaking at 14.7 m3/min of air. The minimum flow rate reached about 3 m3/min of air; air pressure at the station in the range of 7.0 to 8.5 bar. Estimated energy costs (of compressors only) were in the range of 76,000$ to NIS 91,000$ a year.
After making calculations and customizing the products for the customer, it was decided to build a new compressor room. The new compressor room is based on a Model ELFD100HPIV 100 HP (75 kW) direct drive screw compressor manufactured by EL-AV Compressors. The compressor has a permanent magnet motor, with high flexibility in transition from minimum to maximum power. The room also includes a refrigerated air dryer for flow rates of up to 30 m3/min of air, micron filters, smart water drain valves that discharge fluids only operated by the fluid level and not a timer. An estimate of savings achieved for the customer by the upgrade was about 26,000$ a year. In real terms, the average now is about 40 kWh; estimated annual savings is currently about 35,000. The ROI is about 16.5 months for the entire system, including installation costs!