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