The majority of the wasted energy found on the production lines came from leaks in the compressed air system.
The company purchased an ultrasonic leak detector and a leak detection program will be put in place. Five active production lines were checked for leaks throughtout the entire system. A total of 454 leaks were found, totaling loss of 1,053 cfm, 1,721,000 kWh and a cost savings of $68,800. Each leak found was tagged and a list was given to the line pipe fitters for repair. Two 250 HP oil-free compressors currently operate on line 2, with the capability of running 1,100 cfm of air. Once the air line leaks were repaired, the production lines only require 400 cfm of air flow. A 160 HP variable speed compressor is recommended to replace the two 250 HP oil-free compressors for an annual savings of $43,200 and 1,080,000 kWh. The air compressor will pay for itself in 1.13 years. The compressors on line 3A currently operate with a 125 HP or a 150 HP compressor. Data logging results indicate that once all leaks are repaired, the line will only require a 75 HP compressor to supply the demand. Installation of a 75 HP variable speed compressor would save $27,672 and 691,800 kWh annually. The payback for this compressor would be 1.33 years. To ensure the leak repair program continues in the future, mechanical and facilities engineering personnel were trained about efficient use of the leak detector and associated use of the newly developed cost analysis spreadsheet to calculate costs and justify leak repairs.
Details of Reductions
Additional Information :
American Ordnance, is the operating contractor for the Iowa Army Ammunition Plant. It operates on a 19,000-acre facility in Middletown, IA. American Ordnance has several processing operations for ammunition production, which include inspection, testing, cleaning, painting, heating, filling, curing and assembly.