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SOLUTIONS. ENERGY SAVINGS
Energy Savings is one of the primary features of our control
systems and plant management products, and Bay has a long history of
successfully providing energy solutions for our customers'
operations. In the following case study, Bay installed a large scale
compressed air control and monitoring solution in many plants of a
major US manufacturer and delivered impressive energy savings across
the board.
Goal: Reduce Energy Costs
A large manufacturing company desired to reduce the energy costs
of its compressed air systems. Based on previous energy savings
success with Bay's products, the customer moved forward with a large
scale project, involving 22 facilities and 157 air compressors.
Bay's Solution
Bay has extensive expertise with compressed air systems. We know
that our ProTech advanced compressor control products can reduce the
energy used by compressors using several methods:
- Precise pressure
regulation allows a lower average plant pressure setpoint.
- Distributed capacity control links compressors into a network and
then operates each compressor at its most efficient load.
- Advanced
centrifugal compressor control allows for more efficient operation,
less blowoff and reduced surge for centrifugal compressors.
- Leak
loss reduction is a byproduct of a reduced pressure setpoint; less
air escapes from existing system leaks.
- BayWatch performance
tuning allows further efficiency gains from continuous monitoring
and performance analysis of a compressor system's operation. Bay
proposed an installation of ProTech advanced compressor controls and
implementation of the BayWatch monitoring service.
Project Scope
Bay implemented a state of the art compressed air control system
for the customer's plants. Air compressors at each site were
upgraded with Bay's ProTech control system and integrated with one
another using distributed capacity control technology. In addition
to controls standardization, the project included internet-based
monitoring of all air compressors via Bay's BayWatch service.
Results By utilizing Bay Controls' air compressor control system,
each plant was able to maximize the efficiency of their compressed
air production. The internet-based BayWatch monitoring system
provides the customer with current and historic air compressor
performance information. Additional capabilities included in this
project were auto start/stop, operation logging, and compressor
scheduling software. This project included all engineering, labor,
and training for a turnkey installation.
Standardization of controllers across the customer's facilities,
coupled with the BayWatch monitoring service, has also proved to be
a valuable predictive maintenance tool. Plant powerhouse operators
and Bay technicians at the BayWatch Center have resolved real-time
air generation issues. The reliability and responsiveness of Bay's
products and support team have improved production stability.
Project Highlights
- Energy cost savings of over $3 million annually, or a 13%
reduction in cost
- Total project investment was $3,654,710
- Payback for this project was 15 months
- Productivity, maintenance, and reliability benefits were
also realized
- The BayWatch service was employed to monitor and verify
energy savings
The energy cost reductions from this project were in line with
Bay's predictions prior to implementation. The customer was very
satisfied with the results and continues to work with Bay to reduce
energy costs at other facilities.
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