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2006 LE Meeting

Andy Lyczak – LE, Lockport-IL

July 20, 2006Miami, FL

Best Practice: How to Sell and Conduct a Mobil Air Leak Inspection

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So How Do I Sell This?

• Know what your customer already knows!

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BONUS QUESTION ! !Question: The U.S. Department of Energy has determined that _______ ______ are one of the largest users of electrical energy.

Answer: AIR COMPRESSORS! They constitute 7-40% of total electrical plant use.

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Conditions for Conducting a Mobil Air Leak Inspection Study• Compressor demand increases under static production

conditions• Plant operators notice sluggish operation of pneumatic

controlled machines• Plant personnel report increased noise levels in production

areas

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So How Do I Sell This?

• Know what your customer doesn’t know!

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BONUS QUESTION ! !Question: In a typical plant, air leaks account for ___% of total air usage.

Answer: 18. Also, one 1/8” air leak for standard plant air system operating at 100 psi will lose about 26 cfm. At $0.06 kw/hr, this will cost about $2,600 for one leak!

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Air Leak Cost ChartDiameter of Leak CFM Loss ($/Yr)

1/64” 576 $48

1/32” 2,304 $186

3/64” 5,270 $424

1/16” 9,288 $744

3/32” 20,880 $1,674

1/8” 37,152 $2,981

3/16” 83,952 $6,738

1/4” 148,320 $11,904

5/16” 233,280 $18,721

3/8” 336,960 $27,036

Based on 100 PSIG, $0.22/MCF & 8,760 hours/year

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So How Do I Sell This?

• Know what your competition knows!– Typical Fee is $10,000 and up for this

service– Our fee is $2,000/eng-day

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So How Do I Sell This?• Scope work for time estimate

–Typically 50 machines/day

• Utilize PES DB/IRL for Collateral–Suncast, Batavia-IL–Pactiv, Wheeling-IL

• Present & Obtain Advance

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Conducting the StudyStep 1: Getting Baseline Information....

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Conducting the StudyStep 1: Getting Baseline Information....

• Identify machines and compressors for study• Record machine make, model, age, and maintenance history• Log hours of operation• Obtain electrical utility cost• Estimate/calculate maintenance hours spend due to additional

compressor demand

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Conducting the StudyStep 2: Assemble the Toolkit.....

• Amprobe model ULD-300 ultrasonic leak detector or equivalent• Tags for air leak points• Secure use of plant hydraulic lift for inspection of overhead air

lines• Plant required safety gear (safety shoes, glasses, and fall

protection are minimum)• Digital camera

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Conducting the StudyStep 3: Planning the Study

• Schedule the event during outage (external plant noise affects detector operation)

• Arrange for a mechanic to assist• Allow for at least 10 minutes per machine

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Conducting the StudyStep 4: Find the Leaks

• Begin search for leaks by scanning compressed air lines from air storage vessel to plant machines. Adjust sensitivity of detector.

• Utilize hydraulic lift to inspect overhead plant air lines• Photograph and tag air leaks.

– Log location– Estimate diameter size of hole (translates to CFM loss)

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Follow the LED light

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Tag those Leaks for Future Repair!

Other examples............

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Leak at valve block divider

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Leak at hole on ALO regulator

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Leak at fitting to grease pump

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Conducting the StudyStep 4: Document Results to Customer

• Prepare a TCO Engineering Report• Benefits Include:

– Reduced electrical energy consumption (big $)– Less compressor maintenance to maintain system load– Potential avoidance of additional compressor purchase to

meet production demands– Improved plant safety through noise reduction

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Questions..................