High-Pressure Air: Big Headaches?

One of the areas that we have specialized in at Hope Air Systems is high-pressure air primarily as a result of applying over 300 PET bottle blowing systems which produce 500 to 600 PSI. This has caused us to review all the available equipment on the market and select the most logical and reliable piece for each industrial application.

There are various high-pressure applications Hope has supplied are as follows:

• High pressure gauge and safety testing – 3000 psi
• Laser cutting – 500 PSI
• Nitrogen boosting – 300 PSI
• Torpedo testing – 5000 psi
• PET bottle blowing – 400/550 PSI
• Power plant breaker application – 800/1000 psi

Many of these applications require flows under 150 CFM, required in a particular location for an unusual use. Sometimes we can use boosters from plant air but usually require a minimum of 125 PSI to 145 PSI dependent on the discharge pressure. In the right application we've had excellent luck with boosters.

When appropriate plant air pressure is not available we have found an excellent compressor from a German manufacturer by the name of Sauer Compressors who have a number of different units that go from 230 psi to 7250 PSI. After trying a number of different brands we found that the Sauer product is not only extremely dependable has excellent technical and part support from Maryland.

This may sound like a bit of an advertisement that it really is meant to let people know that there are reliable alternatives to small specialty high-pressure units which cause big headaches for a little compressor application.

Bring us your issues with high-pressure air and we will have a realistic solution. Please call Frank at 508-351-1817 or email: flederer@hopeair.com.

Power Company Audit Funding 2013!

What if an unbiased third party could tell you how to save money and their advice was almost free?

About a year ago in a previous article I made the statement "would you be only interested in how much you earned but didn't care how it was spent?" Well now a number of power companies have programs for 2013 which are providing auditing services for a number different areas including compressed air/natural gas/solar heating/cogeneration which could help you reduce spending.

The two major power companies in New England are NSTAR and NGRID which have programs that will pay up to 100 percent of an audit dependent on the savings and the commitment to implement the recommendations. Many of the other power companies are following suit with similar programs.

What type of audits are available?

1.    Demand-Side Air System Audits – which include leak detection/storage/piping pressure drop reviews/inappropriate use/alternative solutions as part of the program

2.    Supply-Side Air System Audits – which include compressor power and capacity auditing/control evaluation/air quality analysis/condensate management would be part of a comprehensive audit program

3.    Heat Reclamation Opportunities – utilizing waste heat from compressors/furnaces/molding equipment/hydraulic systems could be part of the program

4.    Alternative Heat Sources – evaluating passive and active solar heating as well as potential of integrating cogeneration to create heat and power are the most complex audits

Consider looking at your major energy expense buckets for your company that will help you focus on what areas to audit so you could reduce your operating costs. Example – air system leaks can be up to 25 percent of your capacity – cost for a 75 hp system with 25 percent leaks operating 4000 hours at $.15/KW is $13,225 per year. If you had an audit that found these leaks along with other cost reduction opportunities and it was less than $8000 net cost that would be a real win!

NSTAR and NGRID, as well as some of the other New England power companies, have more rebate dollars to provide industry in 2013 than they did in 2012. They are very anxious to find opportunities now to get rebates in process early in the 2013.

You know these issues exist but realistically you can't get to them. Visit the Hope Air Systems website, or call us and we would be happy to do a quick walk-through to identify areas that you would benefit from an audit. Then you would invite the power company to discuss the potential of your compressed air/heat reclamation cost saving opportunities initially identified. Also, you can contact your power company representative and have him bring in an engineer or a site review.

If you don't know you can't correct it. Contact Frank Lederer at 508-351-1817 or flederer@hopeair.com.

New Year's Resolutions for 2013

Honest, this year I really will try to do better…

I know that I've not always done all the right things, so this year I promised to do the following for my compressed air system.

·         Lose KW by reducing my air leaks and promise to stay on that diet.

·         Don't leave stuff on especially the compressor when I don't need it

·         Spend my air wisely by making sure I don't use any electric drain valves and other things that use too much air - I know some of what they are.

·         Make sure that periodic checkups are really done to make sure my compressor is healthy.

·         Budget the amount of air I use by installing a flow meter.

·         Have an annual checkup on the whole air system with a different set of eyes to be sure all is okay.

·         Call a specialist when I don't know all the answers - i.e. ask for directions.

Sure this is simple stuff but I always seem to lose my way by the third month.

To my silent partner, please check back with me to make sure I'm on the straight and narrow in keeping my resolutions. Contact Frank Lederer at 508-351-1817 or flederer@hopeair.com.