Machining & Assembly Facility Reduces Operating Costs More Than 38% And Turns Off A Compressor

A U.S.-based machining and assembly plant was looking for an opportunity to reduce air system operating costs and improve system reliability. While the air system pressure was elevated to support widely varying production demand—it was also increasing operating costs, forcing a second compressor to operate, and causing the system pressure to fluctuate. The compressed air supply system was composed of two 60 hp rotary screw air compressors, a refrigerated dryer, and a coalescing filter.

1) THE QUINCY EQ RATING SYSTEM: Identified The Potential For A >35% Reduction In Operating Costs

The 2 hour EQ Rating survey identified the most significant cost reduction opportunities as:

• Accurately controlling header pressure
• Eliminating artificial demand and other waste
• Turning off one part loaded compressor

2) THE QUINCY EQ ANALYSIS: Based on the EQ rating, the EQ analyzer was installed to record system performance

A local EQ trained distributor installed the EQ Analyzer at the plant and collected critical system information.

• Data collected by the EQ Analyzer and the site information was then uploaded to the EQ website.
• Patent-pending technology calculated existing performance of the system and modeled multiple system configurations to determine the optimal system solution.
• The results of the EQ Analysis indicated the existing Power$ync compressors were appropriate if header pressure was accurately controlled.

3) THE EQ ANALYSIS REPORT: Calculated the ROI at <14 months for implementing the action plan

• A Quincy Pressure Flow Control was installed to provide accurate control of header pressure.
• An additional 2500 gallon receiver was also recommended and installed.
• The existing Power$ync compressors were put in network mode, allowing one of them to turn off.
• The increased storage and pressure control supports peak air demands without turning on the second compressor.

THE RESULTS: Operating costs reduced by more than 38% ($11,936/yr), stable header pressure, one compressor turned off for backup use

• The plant header pressure is now stable to within 1 psi vs. 28 psi before the system upgrades.
• With the second compressor turned off, the plant now has a redundant system.
• The original EQ System Rating took less than 2 hours and accurately predicted >35% operating costs savings and an attractive ROI.

Financial Summary

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