Ford and Bay Controls implemented a state-of-the-art compressor control system for Ford’s Vehicle Operations plants (22 facilities and 157 air compressors). Air compressors at each site were upgraded with the Bay Compressor Controller and integrated using distributed capacity control technology. In addition to the controls standardization, the project included internet-based monitoring of all the air compressors via Bay’s BayWatch service.
By utilizing the Bay Controls air compressor control system, each plant was able to optimize their compressed air requirements relative to energy use. The internet-based BayWatch monitoring system provides Ford with continuous real-time and historic air compressor performance information. Additional benefits included in this project were Bay Controls’ auto start/stop, performance log, and scheduling software. This project included all engineering, labor, and training for a turnkey installation.
Projected annual energy cost savings is $3 million (50,779,601 kWh) or a 13% improvement.
Total project cost was $3,654,710.
The payback period for this project was 15 months.
Productivity, reliability, and maintenance benefits were realized with this project as well as energy savings.
The BayWatch service was employed to monitor and verify energy savings.