Monitoring System Used to Optimize Compressed Air System Efficiency, Cut Costs

Abstract

In 1994, Thomson Consumer Electronics (RCA), an international manufacturer of electronics equipment purchased a UtillTRACK® Monitoring System for a plant in Indianapolis, Indiana. The system monitored gas and electric meters, substations, main feeders, and major equipment and systems including compressed air. For the compressed air system, monitored data included compressor amps, electrical demand and consumption, pressure and airflow. The resulting UtiliTRACK® reports and graphs showed a significant variation in system efficiency depending upon the demand for air (day of week, time of day, production schedule) and which compressor or compressors were operating. By working with the boiler plant operators and making minor modifications to the existing compressor controls, the operating sequence was modified to maintain high system efficiency under all operating conditions. Monitored data after the changes were made showed a 20% reduction in compressed air system operating costs.