Sparks Dynamics and Stanley Black & Decker find Money in Compressed Air System Inefficiencies, Results in a $15,000 BGE Energy Rebate
Customer Profile
Founded in 1843, Stanley Black & Decker is the world’s largest
tools and storage company, the world’s second largest
commercial electronic security company, and a world leading
provider of engineered fastening systems, with unique and
powerful growth platforms in the oil & gas and infrastructure
industries. Stanley Black & Decker is committed to improving
the sustainability of their operations, their products, their
communities, their suppliers and their customers through the
corporate ECOSMART™ strategy - identifying ways to ensure it
stays ahead of climate-related influences and reduces the
environmental impact of its operations. Stanley Black & Decker’s
Hampstead plant typically operates three shifts per day, 360
days per year. They contacted Sparks Dynamics to implement
an Industrial Internet of Things (IIOT) project to reduce energy
expense and enhance reliability.
The Solution
The ReMASTER Compressed Air Monitoring system was
installed in August 2016 to monitor the Hampstead plant’s two
200 HP compressors. This system is capable of monitoring
compressed air system key performance indicators (KPIs) on
a continuous basis and streaming that information to a cloud
server which can be accessed by Stanley Black & Decker
personnel and Sparks Dynamics. This information was
collected into a database which was scanned by data analytics
to detect anomalies, with alarms and graphs available for
viewing using Sparks Dynamics’ ViewMaster Software. The
average annual compressed air electricity expense was
estimated to be approximately $140,000. This is based on an
electric rate of $.08 per KWh and an estimated compressed air
energy consumption of 1,768,000 KWH. It was discovered that
compressed air flow spikes were due to excess high pressure
air used to blow off/ clean machines. The implementation
phase of Energy Conservation Measures (ECMs) for the
Compressed Air System included:
Identification and correction of misapplications of
compressed air to include- air guns, excess blow offs
and pressure regulator settings
Identification and repair of compressed air leaks on an
ongoing basis
Control System review and potential reduction of
system pressure and fine tuning of compressor
pressure set points to maximize efficiency.
The Results
Pre and Post ECM system monitoring has verified that the
implementation of the ECMs is saving over $25,000 and over
300,000 KWH per year. These savings will be increased as
the continuous leak management policy is implemented.
Analytics have been developed that continuously run on the
data streams to ensure the system maintains an efficient
performance envelope
Contact Us
To discover how we can put our expertise to work for you,
call us today at 1-443-543-5420
or email us at Info@sparksdynamics.com
