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Friday, April 8, 2011

Compressed Air System Energy-Reduction Case Study (Part 2)

Let's continue from [Compressed Air System Energy-Reduction Case Study (Part 1)]

Compressed Air Energy-Reduction Strategy

Project Goals and Implementation

Following the IAC assessment, FUJIFILM’s maintenance team formulated project goals and an implementation plan that centered on the utilization of existing facility infrastructure and equipment. The team’s implementation strategy was divided into three phases and focused on increasing the system’s storage capacity to handle production peaks and valleys; lowering air compressor operating pressure; repairing system leaks; and ultimately, operating the facility with one compressor. The team’s strategy was also aided by the company’s closure of its Orange Park, Florida, operations. This facility housed a 75 horsepower (HP) air compressor, a dryer, and a receiver, which the Dayton facility incorporated into its efforts.

Project success, then, depended on the accomplishment of four specific goals:
  • To increase system redundancy, therefore increasing
    system reliability
  • To reduce system maintenance costs
  • To reduce overall facility energy use
  • To eliminate the use of nitrogen when compressed air
    systems are down.
Phase I
Phase I was justified using maintenance-cost-reduction estimates. Labor was billed as a maintenance expense to the existing budget. During this phase, the facility installed Orange Park’s 75 HP air compressor in Building 5, a receiver in Building 6, and a 2-inch airline from Building 5 to Building 6. The 60 HP air compressor in Building 6 was then shutdown for repair and established as a backup unit. The building’s piping was also combined with its heat installation. Phase I was completed in May 2008.

Phase II
The Dayton facility justified Phase II to FUJIFILM Corporate by utilizing total project energy-saving estimates. During this phase, piping was installed from Building 5 to Buildings 1 and 6, and an additional receiver was installed in Building 1. The existing 50 HP air compressor and dryer in Building 1 were
shutdown for maintenance and repair and established as a backup unit. This established the 75 HP air compressor in Building 5 as the facility’s central unit. Phase II was completed in March 2009.

Phase III
During Phase III, the maintenance team developed and implemented a Leak Detection and Repair (LDAR) program (completed in the fall of 2009), and developed a quarterly preventative maintenance program to repair system leaks and reduce the amount of compressed air losses. Additionally, the facility gathered data that indicated a 2 PSIG drop in pressure resulted in a 1% reduction in cost. The team reduced compressor set pressure to 105 PSIG, which resulted in POU delivery of 98 PSIG.


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