10 Worst Things You Can Do To Your Air Compressor

By Peter Rhoten

Over the 35 plus years in the business I’ve seen a number of bizarre things that are done to a compressor and the components in the system. People often wonder why their system does not run well, they have high power costs, or have numerous OSHA issues. I've previously shared this list awhile back in my eNewsletter and received a lot of feedback, so, I decided to post it again via blog.

Here is my "Worst Things You Can Do To Your Air Compressor" Top Ten
Worst Offenders List:

#10 - Duct tape should not really be used to repair leaking air tank

#9 - Shipping pallets are not really meant to be the permanent base for your new compressor

#8 - Oil changes are not an every 5-year event

#7 - PVC schedule 40/80 piping should really not be used for compressed air - stand back here it comes

#6 - Just because the air filter is dirty you really should not leave it off

#5 - Using an old baseboard radiator for aftercooler is not a great idea

#4 - If your air tank still has rivets holding it together it's probably a good idea not to use it anymore

#3 - It's not really okay to wire the safety valve together because it is noisy and annoying

#2 - No problem just piping all the oily water down the outside of the building - nobody will notice just because it's near the entrance

#1 - You really shouldn't let employees sleep inside the 400 HP compressor cabinet just because it's warm - really happened

So that's my short recap of things that I saw that I didn't believe. Many of them are still occurring, not as much in the US, but in other parts of the world.

I would love to hear about any unusual air system observations that you may. Of course, all information will remain anonymous.

Be aware and be safe. Visit our Compressor Service Page.

If you need some help with your system, call Frank at 508-351-1817 or email: FLederer@HopeAir.com.

Oil and Water Are Not Your Friend

Is There a Rainstorm
Inside Your Compressor?

Be Legal, Be Green

Water is unavoidable in a compressed air system. Think about it: When you are compressing seven cubic feet of atmospheric air into one cubic foot inside the compressor, this cubic foot of air now contains seven times as much moisture as what existed in the atmosphere. The cubic foot of compressed air in the system is at 100 percent humidity at least 190° Fahrenheit or more, so it literally rains anytime the temperature goes below 190° F in the separators/filters/dryer. The key is how to dispose of it legally and to be conscious of our environment.

In winter conditions, a 200 CFM compressor with 70°F inlet air with 50% relative humidity makes ¾ of a gallon of condensate per hour, or 60 gallons per week in a 2-shift operation. In summer conditions, a 200 CFM compressor with 85°F inlet air with 80% relative humidity makes two gallons of condensate per hour, or 160 gallons per week in a 2-shift operation. (Calculate how much condensate your systems)

Water condenses out of the airstream in the system, as it flows through the wet tank, pre-filter, refrigerated dryer and after-filter. These components remove approximately 95% of the moisture in the system when everything is operating properly.

The remaining water vapor that is condensed inside the compressor is not the real issue, it’s the oil that is carried along with this condensate. The compressor’s lubrication oil contaminates the water being removed and creates hazardous waste that cannot be discharged to ground or most waste removal systems.

The question then becomes: How do you deal with the oily condensate as it is collected from the drains each of these components? (For suggestions to answer this question, read the Four Ways to Deal with Compressor Condensate to Keep Your Company Legal and Green on our website)

The Dryer Light is On...Why Do I Still Have Wet Air

We all assume that if a light is on, then it must be working.

When we take a look at the refrigerated dryer in our compressor room we assume that everything is okay when the light is on. Then later that day or the next morning, someone tells us that water is showing up in the production equipment.

Due to the complexity of an air compressor system, there are a number of reasons why a working air dryer won't dry. So now what? Well, even though the dryer may be working and there are 6 simple checks that you should perform to see what is really going on in your system.

Troubleshoot Your Air Dryer in 6 Simple Steps

Step 1: Feel the cabinet opening

Do what I call the “cough test,” which is reaching to the cabinet opening in your dryer to find the condensate separator or the outlet line. It should feel very cold – around 38° F – and if it isn’t, then the dryer has a problem. Action Item: Have the refrigeration circuit checked and make sure the condenser is clean.

Step 2: Check the valves

Believe it or not, one of the most common issues is that the bypass valves are either left partially open or do not close completely. If they seem to be closed, that is good, but you might want to check further. Action Item: Check by closing all three valves and seeing if the air pressure after the last valve goes to zero - this may take a while if you can isolate system. If it doesn’t, then you need to replace the valve.

Step 3: Check the inlet temperature of the compressor

Inlet air temperatures to the dryer should be no more than 100° Fahrenheit.  If you can put your hand on the dryer inlet pipe and it doesn’t feel hot to you, then that is good. If it feels hot to the touch, that may be the problem – Action Item: Check the air-cooled or water-cooled aftercooler on the compressor to make sure it is clean and that the air temperature is no more than 15° F above room temperature . If it the aftercooler is too warm, you may have to remove it and clean it thoroughly.

Step 4: Check the ambient temperature of the compressor room

As mentioned above, your compressor room ideally should not be any hotter than the outside temperature, i.e. 90° F on a 90° F day. If the compressor room is more than 10° F above the outside temperature, you could have a problem for all of the equipment in the room since dryers are designed to run at 100° F ambient temperature. Action Item: Get your HVAC or compressor vendor to review your compressor room ventilation to keep the ambient temperature from reaching 100° Fahrenheit.

Step 5: Check for condensate in the dryer drain trap

If a sizable amount is not accumulating from the trap, it means the dryer may be working but is not removing the water. Action Item: Isolate the drain trap to clean or repair it. If you end up replacing it, REPLACE ONLY WITH A DEMAND TYPE TRAP.

Step 6: Check the low point in the piping system beyond the dryer

If there is any condensate that can be drained out, go back through the other steps. In the meantime, put a drain on this low point to help eliminate moisture in the system

If you’ve taken these six steps and everything checks out, then it’s time to call your compressed air vendor to find out what’s going on. If you can’t get the results you need, you may want to call Hope Air Systems and ask for Frank Lederer at 508-393-7660 or send him an email. (FLederer@HopeAir.com)


 

Is Your Compressor Ready for the Summer?

Summer is a just around the corner and for those who work in a compressor room, they understand that high temperatures can affect the performance of the equipment. 

Most compressor manufacturers rate their equipment at 60° inlet and ambient room conditions. If you have 95° F ambient in the room, the compressor should run okay if properly ventilated, but will lose approximately 8% of its capacity. As the temperature increases beyond 95° F, you lose even more capacity and could start damaging the compressor.

If the coolers are not cleaned, the inlet filter has not been changed, and/or the condensers on the refrigerated air dryers are dirty, you may have operational problems and possible shutdown when the outside thermometer reaches 85° F.

Here is some advice on what you can do:

• Prepare your compressor for the summer by reading the operator’s manual and perform the indicated service needed for high temperatures.
  
• Put a thermometer in your compressor room to monitor the room temperatures. (Anything above 100° F could be damaging for your equipment).
  
• Take a look at current room temperatures and compare it to the operating temperatures of the compressor and the refrigerated air dryer. (If there is more than a 15° F difference from the room temperature on the air dryer inlet air you have a problem with the coolers).
  
• Increase the room ventilation to make sure that you can match outside air temperatures even in the hottest weather. You should move air through the room at least one time every 2 minutes. 

Key Temperatures to Watch: 

• The room temperature should be no greater than 10° F more than the outdoor temperature.
  
• Rotary screw compressors should not operate above 210° F
  (Most shutdown at 215/220° F. Normal operating temp in a 70° F room is 190° F).
  
• The dryer inlet should be no more than 15° above room temperature.
  (95° F room = 110° dryer inlet air). 

If you operate your compressor and dryer over the design temperature you will shorten the life substantially and create wet /oily air. If you have current issues with your compressor, it would be wise to have it serviced now because it will only get worse in the hot weather. If you need assistance please contact Frank Lederer at 508-351-1817 or by email. (FLederer@hopeair.com).

What is a Cycling Dryer and Why Would You Want One?

Most plants currently have a dryer that continuously runs and uses a component called a hot gas bypass valve to keep the unit above 38° F and prevent it from freezing up. But, there are many different types of cycling dryers that accomplish the same result without the dryer constantly running.

• Cycling type with a thermal mass is cooled down to the required temperature and the compressor shuts off – this works much like your refrigerator – if no load, the unit does not come back on until required – very effective and the most reliable
  
• VFD cycling uses a variable speed drive on the refrigeration compressor that varies the amount of power/refrigeration used based on the temperature of the air – operates much like a variable speed air compressor – most have a range of 100% to 30% – not good in low range applications – fairly complicated electronically
  
• Load/unload cycling compressors – works much like larger refrigeration systems and can be effective when they are fairly steady medium loads – can short cycle with low loads – sometimes not as power cost effective as a true cycling dryer

With that being said, if you purchase a 500 CFM dryer ($8,000) for your plant and left it on while your compressor is running (or maybe you forget to shut it off at the end of the second shift), it would use 2.5 HP continuously. If you purchase the same 500 CFM thermal mass cycling dryer ($10,200) for the same application, it would require 2.7 HP. But, in an average plant it would be on only 20-25% of the time. The cost difference between the two is $2,200 and the savings is $1,490 for $6,000 a year at $.15 a KW. Using simple math, the ROI is 1.5 years.

Other advantages of using a cycling dryer are:

• You do not have to remember to turn the dryer off when you turn the compressor off as it shuts down
  
• Potential freeze up at low load conditions almost eliminated
  
• It can be used with lower CFM compressors while maintaining the same dew point
  
• It will tolerate higher ambient/higher inlet temperature conditions more readily over standard dryer.

Remember all dryers are rated at 100 PSI/100° F inlet air/100° F ambient temperature. If you increase the air pressure dryer performance gets better. If the ambient air temperature or the inlet air temperature gets above 115° F your dryer could be in big trouble and moisture will soon be invading your system.

If you would like to know more about how a cycling dryer would be a better fit for you than what you have we be happy to help or if you have any moisture issues let us know. Contact Frank Lederer: flederer@hopeair.com.

Rotary Screw and Piston Compressors On Display at No. Haven Parker Store

Jeff Haynosch
Sales Engineer


It’s exciting that in addition to the fluid power products we have been representing at Connecticut Fluid Power over the years, our joining up with The Hope Group last year has meant that we have expanded our product offering to include fluid connectors, and now, compressed air systems and service.

At the Open House and Technology Seminars on May 10, 2017, at our new Parker Store in North Haven, we will have a display as part of the Trade Show of Kaeser rotary screw compressors and Hope Air Systems’ own brand of piston compressors. Our customers always need a power source, whether it’s a generator, a hydraulic power unit, or an air compressor, and so it’s great to introduce this new line of products to the North Haven area.

You can learn more about the Technology Seminars and the Open House by visiting the website.

Don’t Leave Fluid Analysis Until It’s Too Late

Henry St. John
Parts Mgr, Hope Air Systems


Without proper preventive maintenance, your system could experience failures ranging from small to fatal. Routine fluid analysis is important and should be conducted on a schedule to monitor wear, determine potential failures in process, and to schedule fluid changes accurately.

Fluid analysis should not be an optional procedure left to whenever you “get around to it”. It must be routinely conducted by engineers and technicians as a tool to measure and monitor principal fluid characteristics that include metal content, water content, and viscosity.

Hope Air Systems’ engineers and technicians are ready to help with a fluid analysis to prevent costly failures and breakdowns. If you have any questions, please contact me at 508-351-1827 or by email (hstjohn@hopeair.com).

How to Save Energy/Money By Controlling Your Air Compressors

We recently released our monthly eNewsletter. It contained two important topics about your air compressors that I would like to share with you.

The first article deals with properly controlling your air compressors to save energy and money. Unfortunately, electrical costs are not going down and it is important that one person is responsible for conserving energy in your plant. There are some simple things that you can do to ensure you are controlling your systems properly. To learn more, read the entire article titled: Turn It Off (Your Air Compressor)

Avoid Filter Confusion
The second article talks about avoiding filter confusion. Are you selecting the correct filter? How many filters do you actually need? When tackling this topic, I discuss a basic filter that every system needs down to a filter that may be used in breathing air or biotech firms. To learn more, read the entire article titled: Filters - How Many and What Do I Need

If you didn’t already know, Hope Air Systems releases a monthly eNewsletter on a wide range of informational topics, such as these, that can help you in your compressor room. If you would like more information on these topics, or would like to receive the newsletter, please contact Frank Lederer at 508-351-1817 or by email (flederer@hopeair.com) and he would be happy to assist you.

New Reciprocating Compressors Added to Hope Air Product Line

Henry St. John

Parts Mgr, Hope Air Systems

As you know, Hope Air Systems is a proud distributor of Kaeser and Champion Air Compressors. I am excited to announce we are launching our own line of industrial-grade reciprocating air compressors to add to our product line.

The new Hope Air Systems’ stationary vertical or horizontal electric two-stage, belt-driven compressors deliver up to 33.6 CFM at a maximum pressure of 175 PSI and 35.0 CFM at 100 PSI. They are built for commercial and industrial applications and are equipped with an electric Baldor Motor (single phase and 3 phase available), magnetic starters, and cast iron pumps. The patented pump design provides for a cooler running pump. We are also offering gas engine (powered by Honda) and portable compressors.

You can view our brochure (PDF) for details and pricing. Or, if you have any questions call me at 508-351-1827 or email me (hstjohn@hopeair.com). 

In the meantime, take a look at all our reciprocating compressors on our website!

Hope Air Systems V-120 Compressor now displayed in our Northborough showroom

Why Blow Offs Are The Newest Secret Saver

We all know that a pinched copper tube blowing onto a product is a really inefficient way of using compressed air. 

How bad is it? A 1/8 inch hole will flow 26 CFM at 100 psi, which uses at least 6 HP on your air compressor. If you run three shifts five days per week and pay $0.10 per KW, that little piece of copper blow off tube probably cost you around $2900 per year. Many blow offs have smaller openings than 1/8 inch.

There are really three solutions out there to save energy and costs associated with air blow offs.

#1 is to convert to a blower, which may not be feasible in some applications. 

#2 is to put a nozzle on the end of the tube to reduce the flow and the sound level, which works just fine but many of the nozzles disappear after period of time.

#3 is to reduce the amount of air by changing or and inserting a control valve.

Solution #3 is the direction that Parker's Air Saver Unit has taken. It is a valve that converts a continuous air blow to a pulsed air blow without the need for any other external control. Air is blown with a series of ON and OFF pulses. When the blow is OFF, there is no air consumption. By using switching valve technology the Air Saver Unit can reduce air consumption by up to 50%, which translates into:

• Large reductions in air consumption.
• Savings in compressor power consumption.
• Reduction in plant CO2 emissions.
• Big contribution to energy-saving activities.
• Improved efficiency.

When you consider that air blowing accounts for up to half of all compressed air used in plants, the potential energy and cost savings is considerable. In the example outline below, the application of Air Saver Unit valve on four nozzles with a one minute below per four minute cycle operating for three shifts, five days per week saved plant operators $3,500 annually.

Sample Application	—›	4 nozzles 6 mm dia.	+	$0.10/ kWh	+	1 min blow per 4 min cycle	+	3 shifts 5 days/ week	=
Air Saver Unit Valve Calculator Summary Sheet
VALUE IMPACT SUMMARY
Reduced Total Annual Air Discharge per Blowing Nozzle (cfm) by:							3,232,005
Reduced Annual CO2 Emissions Generated (per Blowing Nozzle, in tons) by:							5.77 tons
Reduced Annual Air Generating Costs Per Blowing Bozzle by::							$892.03
Quantity of Air Blowing Nozzles with Same Application Specifications:							4
Reduced Annual Air Generating Costs For All Nozzles by:							$3,568.13
Reduced Annual CO2 Emissions Generated (For All Blowing Nozzles) by:							23.07

This is the only the tip of the iceberg for air conservation. To find out more about how to properly use this Air Saver valve and other energy conservation components click on the link below to register for the Introduction to Industrial Pneumatics seminar being held from 8:30AM to 12PM on October 20 at the Parker Store in Lewiston, Maine.

www.TheHopeGroup.com/workshops

Need a system engineer to look at specific air use problem in your plant? Please call Frank Lederer at 508-351-1817 or email: Frank Lederer at FLederer@HopeAir.com.

Your Compressor Should Play Well With Others

Many plants today have multiple rotary screw compressors running at the same time. This is a result of requiring additional air and adding another machine.

Unfortunately, often times compressors do not play well together and unless properly set up, this can cause excessive run time on equipment that now requires more maintenance as well as running up the power bill.

The following is an extreme case seen earlier this year of two 300HP compressors that did not play well with each other.

Two 300HP air compressors are operating in tandem to load and unload. The air compressors are rated for 1,325 at 150 PSI and the average flow meter readings from these two machines were 720 CFM or 54% of full load of one air compressor. Both compressors consume a total of approximately 379 kW. At $0.14 per kWh this would equal a yearly cost of $38,000 using a yearly operational load of 8,400 hours. One compressor should be set as lead and the other one as lag with the second compressor only coming on when needed – the potential annual savings of $60,000 from conservation and reduction of pressure can save 115 CFM by shutting off one compressor, which is a total potential savings of approximately $100,000 per year. Investment would be less than $2000 in maintenance or service cost.

While this is an extreme example, he gives you an idea of what could happen if two compressors are running together without any kind of evaluation and control set up. Here are some of the common scenarios that I have seen over the years:

• Big/little compressor both with modulation control—the big compressor should be set up as a baseload and the little compressor should be taken out of modulation if possible and set to load and unload. It’s very inefficient to load and unload the larger compressor.

• Two compressors with modulation load/no load controls—modulation unit should always try to be used as a baseload as it is least efficient in any part load situation. The system may need to have an appropriately sized receiver at least three times the volume of the machine. For example, 50HP 200 CFM load unload compressor should have a 660 gallon receiver.

• VFD compressor used with load/no load or modulation control compressor—always have the load/no load or modulation control compressor as a base load and trim with the VFD unit.

• Control gap can occur in any system when a VFD unit cannot turn down enough to meet a lower demand and goes to a load/unload scenario being less efficient—this also can cause a second machine to start up due to a pressure drop, which causes the two machines fight each other.

If you are running a 50HP and a 75HP compressor and they are both sharing loads for two shifts five days a week with power at $0.15 per KW, you could potentially be wasting 30 HP or $20,000 in energy costs per year. The savings goes up and down with the connected horsepower of two machines that are not playing well with each other.

The first step is to have your compressor technicians set up the compressors to operate most efficiently for the controls that they have for the average load in your plant. Unfortunately plant loads vary and a control set up done this month may not be appropriate 90 days from now.

A more comprehensive solution would be to evaluate your compressor system for usage and determine if the existing units can be run efficiently with a simple microprocessor control panel. You may also have to add receiver capacity and certainly look for air abuse as well as leaks in the plant.If you have a big compressor and a little compressor and they both seem to be working their hearts out and they didn’t use to, then you may have a control problem. Take the time to get a qualified person to look at them and give you the best advice on how to run your system. This could save you a substantial amount money over the next three years.

There will be more articles on screw compressor control types to follow.

Need some assistance? Please call Frank Lederer at 508-351-1817 or email: FLederer@HopeAir.com.

Avoid Making a Bad Choice When Installing a Compressor

Making choices about where and how to install your new compressor or how to re-install an existing unit as part of an expansion or relocation will have impact many months and years after the initial installation. Knowing what to do, and perhaps more importantly what not to do, can make all the difference. 

Some key points on what to do include leaving enough space around the equipment, keeping it close to an exterior wall, installation of cooling fans, and keeping it away from people bothered by noise. 

Things to be sure not to do include placing it near loading docks, remote areas, unheated areas or near the manager’s office. When you give these considerations some thought they make sense, but unless you plan properly you may inadvertently make choices that you will regret later. 

My Compressor Room planning article addresses what to do and what not to do when installing a compressed air system. Following the guidelines spelled out in the article will go a long way toward making the installation or relocation of a compressed air system less painful.

I Did My Air System Audit and Fixed Everything, So I'm Done - Right?

Supply-Side:
Let's say that you did a supply-side audit and upgraded your compressor room with the latest and greatest VFD compressor along with a cycling dryer along with the appropriate sized receivers with zero loss drains. You might have even put a demand controller and system flowmeters in place. Here is the supply side checklist:

1. Flowmeter - Record and track your air system data at the flowmeter - preferably by having it integrated into your system or at least downloading it on a weekly basis - any changes go find the reason why


2. Controls - As good as your system controls started out they can get out of sequence or improperly adjusted. There have been cases where the VFD compressor is supposed to be the trim machine but ended up being the base load machine. This completely ruins any energy savings originally planned. Do a weekly check for all shifts.


3. Drains - Any air system efficiency upgrades include zero loss strains. Check to see if they're still working properly. Establish a monthly maintenance program


4. Maintenance - Lack of maintenance can diminish the efficiency of any good compressor system. Be sure that the inlet filter/coolers/dryer condensers are cleaned regularly based on the compressor room environment. This should be done by expert maintenance staff and not wait for the service company.


5. Demand Controller - This unit regulates the air pressure out into the system creating storage in the compressor room tanks. Sometimes the air compressor pressure elf makes adjustments without other people knowing and the reduced pressure /increased storage savings goes away. Check monthly and lock if possible.

Demand-Side:
You have done all the right things in the compressor room with the latest and greatest equipment and the proper receivers etc. You went out into the plant and looked for air hogs/bad piping/incorrect low pressure air use along with other opportunities. What you to do now is check on the following quarterly:

1. Regulator - If you did not put locking regulators on stations to reduce the air from line pressure to an appropriate pressure for the operation I would bet you $10 that the regulator is cranked all the way up. Check them and replace them with locking regulators if necessary


2. Blow Offs - Many locations that originally had copper or a pipe nipple were converted to engineered blow offs to conserve 60% of the year. Unfortunately they are quiet and many operators take them off and go back to the old ways.


3. Blowers - Compressed air oftentimes replaced by blowers that operate on 10% of the KW used for the same application by an air compressor. Unfortunately blowers need maintenance to continue to run efficiently and sometimes fail without replacement. The operator then goes back to compressed air. Maintain your blowers monthly and to replace as appropriate.


4. Piping - Many times a new piece of equipment is installed quickly creating problems with the redesigned air system. No unit should be piped into the system without the Air System Sheriff approving.

This all may seem obvious but unfortunately the day-to-day business of running a facility and putting out fires takes her attention away from what was well-intentioned. It is absolutely critical to have the Air System Sheriff who is responsible for maintaining the efficiency. It is also critical that the team understand that if the company spent $100,000 to upgrade the air system to save $30,000 annually it is their responsibility maintain the savings.

Just keep in mind that the air system is like a bridge and you need to continuously keep after it or it's going to deteriorate. The challenge is making the time and energy available to maintain the air system efficiency.

If you need some help in organizing this please call Frank Lederer call at 508-351-1817 or email him at flederer@hopeair.com.

The Hope Group Sponsoring Motion Technology Workshops

To keep things in motion, we use hydraulics and pneumatics. On the pneumatic side of things, that includes compressed air and that’s a specialty of Hope Air Systems, a subsidiary of THG Corporation. During the first week of October, The Hope Group and Hope Air Systems are sponsoring workshops to help our hydraulic and pneumatic customers meet their motion and control requirement. We are bringing in the Parker Tech Tour Truck to anchor this week-long series of workshops.

The Energy Conservation workshop is scheduled for Tuesday, October 7, 2014, from 1:30 PM to 4:30 PM at THG’s headquarters in Northborough, MA. Expert instructors will take participants through an overview on how air compressor controls work and how to measure air usage. We will also discuss how rebates can be obtained from local utilities as a method for making the investment in new equipment a more economic venture.

This workshop has been well attended in the past, at The Hope Group, and I recommend that you register early to be assured of a seat. To register, log on to www.TheHopeGroup.com/workshops. You may also call Cathy Donohue at 508-351-1809.

The Energy Conservation workshop is just one of five offered during the visit of the Parker Tech Tour Truck to THG Corporation. Other workshops will be Hands-on Thread ID, VMI and Integrated Supply, Pneumatic/Automation Fieldbus and Hands-on Hydraulic Workshop, featuring filtration, VSD, and diagnostic techniques for hydraulic systems. 

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.

The Incentive Clock is Ticking for 2012

Tick...Tick...Tick...

This is the last time this year that you will hear about opportunities for additional power company incentives.

Why?  Because within the next 30 days it will be too late for most power company incentive application processes. 

A number of utilities are continuing to be aggressive in their incentive programs within the guide lines set up by DOE.  As examples:

·         NGrid is aggressively pursuing equipment replacement incentive with an additional incentive with the equipment installed by December 1, 2012. Heat reclamation saving natural gas can be combined for even more rebate funds

·         NStar programs are just as aggressive in equipment and system upgrade including demand-side improvements. All work must be done by the first week of December. Heat reclamation saving natural gas can be combined for even more rebate funds

·         PSNH is currently looking for projects for 2013 as all funds have been allocated at this point

·         CT Light & Power will offer additional incentives based on each application including low pressure blowers to replace compressed air as well as piping system changes.

·         Efficiency Maine is actively looking for additional projects to finish their year with strong rebates so that the program can continue in 2013

·         Efficiency Vermont is looking for combined projects for air conservation and heat reclamation that need to be completed by early December for substantial rebate monies

You do not have to buy new compressor equipment to receive an incentive from your local power company.  What they also want help you save energy by making changes in your demand side of the compressor or cooling system that will reduce the load and save kw.

You can do the following and receive incentives:

1.     Re-pipe for lower pressure drop.

2.     Add receiver to reduce compressor loading.

3.     Replace timed drain traps with demand traps eliminating air loss.

4.     Install a flow meter to determine current and future flows as well as monitoring leaks.

5.     Install reduced volume blow off nozzles and solenoid valves on production equipment to reduce air flow in use and shut off when not in use.

6.     Reclaim waste heat the either by ducting or hot water to reduce natural gas usage

Most projects that we have looked at are carrying a 1½ year ROI once the power company has had a chance to review.  This is an incredible opportunity that should not be missed in 2012 as we know budget cutbacks will occur in these programs will shrink. You need to act now if you have any viable projects

Contact your local power company below or call Frank at 508-351-1817 or e-mail flederer@hopeair.com so that you can get into a 2012 rebate program.

·         MassSaves (includes all MA power companies)  http://www.masssave.com/business/

·         Efficiency Vermont  http://www.efficiencyvermont.com/pages/Business/RebateCenter/

·         Public Service of NH  http://www.psnh.com/Business/Efficiency/Rewards.asp

·         Unitil/NH  http://services.unitil.com/nh/energy_efficiency.asp

·         Efficiency Maine  http://www.efficiencymaine.com/at-work/business-programs/cash-incentives

·         NGrid/RI https://www.nationalgridus.com/narragansett/business/energyeff/energyeff.asp

·         CT Light & Power  http://www.cl-p.com/Business/SaveEnergy/AboutCEEF.aspx

Did You Save Money Last Winter?

Heat Recovery Revisited

A properly designed heat recovery system can conserve 50 to 80 percent of this wasted energy and put it to work heating a space or a process. Why don't we do this? Possibly because most people are too busy and do not realize the potential savings. Do not lose out for 2013.

·         An air cooled rotary compressor produces 2552 BTUs per horsepower which means that 100 hp produces approximately 250,000 BTUs of waste heat

·         70% recovery would give approximately 175,000 BTUs that are absolutely free to use for room heating or liquid heating

·         A typical home requires approximately the same 175,000 BTUs to heat it on the 20° F day

·         175,000 BTUs of gas at $.80 per therm would cost $1.40 an hour for 4000 hours equaling $5600

The next question is what kind of heat recovery systems make sense and are relatively simple to implement?  Some of these points were covered in the previous newsletter but are important enough to recap again for air cooled rotaries:

Simple Method:

Exhaust heat from the compressor room in the winter into an adjacent area being sure that there is enough makeup air so the room does not go negative. In the summer an exterior wall exhaust fan would have to be used to keep the room cool. This is especially effective for cold warehouses and loading docks. The ROI on this solution would be normally under one year.

Moderate Method:

Duct the output from your cool compressor to a manually operated Y diffuser, which allows the direction into the plant in the winter and outside in the summer. The ducting has to be designed properly to prevent back pressure, which could cause compressor overheating. The normal back pressure is .25 inches of water. Again the room has to have proper makeup air so a negative pressure is not created, which affects compressor operation. This more complex solution normally has a two-year or less ROI.

Complex Method:

Most often used in a new compressor room, a fully automated inlet and outlet damper system is designed to maintain constant compressor temperature as well as discharge temperature to the plant area year-round. The system requires engineering for the specific compressor(s). Many power companies offer additional rebates for secondary gas energy savings, which help bring the ROI for a complex system below two years.

What happens if you do not have use for the heat from a compressor in the immediate area? With air cooled rotary you can use small horsepower duct blowers with flexible tubing or engineered ducting to carry the heat to the areas that will benefit most.

Many people do not realize that a compressor running between hundred and 180°-190° F can also effectively heat hot water. A properly designed oil to water heat exchanger can be used on both an air cooled and water-cooled machines to carry the waste heat to a process or a remote area. Great care has to be taken to properly engineer the heat exchanger for each compressor so as not to affect oil system pressure.

Hot water heat recovery is used extensively in Europe. Examples are:

·         Washroom water in a major foundry

·         Hot water for the bleaching process and a paper mill

·         Pre-heating of water for boiler applications for an automotive plant

·         Feed water for humidification systems in textile weaving rooms

Again many power companies offer additional rebates for secondary gas energy savings which could bring the ROI to below two years.

If it's free or at least has a two-year ROI why don't we use it and be more efficient as well as adding to the bottom line? Let us know what you have for a heat recovery requirement application so we can review it with you. No concept should be considered too wild.

For more information please contact Frank at 508-351-1817 or e-mail him at flederer@hopeair.com