Energy Efficiency Improvements for Process Utility Systems at Garlock Sealing Technologies

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Over the past two years, Garlock Sealing Technologies has taken on a comprehensive energy management program to improve the overall energy efficiency of the process utility support systems from both a supply and demand standpoint, resulting in in savings of over 2.8 million kWh in electricity and 500,000 therms of natural gas.

Garlock Sealing Technologies (Garlock) is an EnPro Industries, Inc. company headquartered in Palmyra, NY (Reference Figure 1). Garlock is a global leader in providing innovative fluid sealing solutions for process industries. Garlock’s manufacturing complex is comprised of several buildings totaling over 600,000 square feet. The buildings are of various age and condition; some have been in operation for over a century. Manufacturing is operational 24 hours per day, seven days a week with approximately 525 employees.

The facility manufactures gaskets, mechanical and oil seals, bearing isolators, and expansion joint and hydraulic components. The process utility support systems and equipment include air compressors, steam boilers, and chillers.

Total annual electric consumption is approximately 23.0 million kWh, with a peak electric demand of 4,171 kW, and annual cost of $1.35 million. Natural gas annual consumption is approximately 1.7 million therms at a cost of $1.1 million.

This presentation will begin with a historical overview of the Garlock facility and energy performance of the process utility support systems. It will continue to discuss the approach for identifying energy efficiency improvements through the use of a team approach in executing comprehensive energy studies with local staff, energy consultants, and state and utility program support.

The session will discuss the energy conservation measures identified, the selection process for moving forward with implementation of the selected measures, and the overall implementation method. It will also discuss the measurement and verification process that was followed to confirm actual energy efficiency improvements attained. For the compressed air, steam, and chilled/process water process utility support systems, savings of over 2.8 million kWh in electricity and 500,000 therms of natural gas have been achieved.

Finally, the presentation will close with lessons learned and keys to success in implementing a comprehensive and sustainable energy management program.