Michael Masny, P.E.
Track H | Industrial Energy Management
Garlock Sealing Technologies (Garlock) is an EnPro Industries, Inc. company headquartered in Palmyra, NY. The Palmyra site is a campus of buildings totaling over 550,000 square feet, with a wide a range of building sizes and ages. It is a dynamic and diverse manufacturing campus operating 24/7 with approximately 500 employees. The typical annual utility consumption is approximately 1.3 million therms of natural gas and 20 million kWh. Peak electric demand is approximately 4,000 kW. Over the past few years Garlock has accomplished significant energy reductions of electric, natural gas and water through improvements to the steam, compressed air and chilled water systems. A white paper discussing these events was published and presented last year at the WEEC in Washington DC. Many owners may be intimidated by the first cost and complexity of energy monitoring systems. This presentation will focus on low cost, do-it-yourself options that can provide monitoring, trending, and improved site energy management. The opening section will be a brief overview of Garlock and its recent energy reductions. The second section will review several typical utility systems at manufacturing facilities such as steam, compressed air, chilled water, and lake water to identify the key characteristics that need to be monitored and displayed to operators to ensure peak efficiency. The third section will review the low cost SCADA system set up at Garlock and present the costs, challenges, opportunities and rewards involved with the system. A fourth section will exhibit specific cases where the monitoring system proved useful in identifying a performance reduction and how the collected data, when overlapped with production data, can prove useful in troubleshooting root causes. The final section of the presentation will list the lessons learned and key attributes required in building and maintaining a utility monitoring data acquisition system.
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