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Can the right maintenance plan boost air compressor performance?
By employing preliminary, predictive and preventive maintenance, and air compressor’s performance will be maximized
Top 5 Plant Engineering content: August 12-18, 2024
Top 5 Plant Engineering content over the past week covered Product of the Year winners, compressed air service, identifying electrical hazards and more. Miss something? You can catch up here.
Choosing the right rotary compressor oil
The operation of a compressor depends on picking the right rotary compressor oil, which is the lifeblood of the system.
12 reasons why users should monitor air compressor data
Air compressor data monitoring can help users save money, reduce downtime and improve the efficiency of a compressed air system.
Your questions answered: How to Choose Oil-Free or Oil-Lubricated Rotary Screw Air Compressors for Your Application
This webinar provides a comprehensive comparison between oil-free and oil-lubricated rotary screw air compressors to aid professionals in selecting the optimal compressor for their specific needs. Additional questions from this live webcast are addressed here.
Choosing the right rotary screw air compressors for an application
In an upcoming April 18 webcast, Brandon Dial from Kaishan explains how to choose the right rotary screw air compressor and what steps need to be taken.
Pipes and valves are critical in a compressed air system
There is more to an efficient compressed air system than the compressor itself. Piping, valves and fittings all play an important role in the overall health and efficiency of a compressed air system.
Choosing the right compressed air pipes for a facility
This guide details traditional and new compressed air piping options to decide what’s the best fit for a project.
Compressed air systems: Learn how to assess system maintenance
Understand when and how to conduct maintenance on a compressed air system.
Who are the physics police? And can they save compressor energy?
Read this Q&A to get very specific answers to some compressed air questions
Do you know how to ID compressed air leaks?
Learn several methods to find and identify compressed air system leaks
Improve production efficiency with compressed air and eliminate pneumatic emissions
There are many benefits of switching from carbon steel piping to power the natural gas production process with compressed air via buried semi-flexible tubing.
The key to 50% energy savings in compressed air systems revealed
Learn three control types for compressors — load-on-load control, inlet modulation with unloading and variable speed drive control — and understand the energy savings achieved by improving part-load capacity control
How to know the pitfalls of chasing higher pressure for better performance
In this excerpt of a webcast transcript, understand how compressor pressure and performance are related
An essential guide to compressed air system analysis, plus how to cut costs
Learn how to measure and analyze a compressed air system to help save energy and cut costs
What to consider when sizing your compressed air system
There are many factors to consider when sizing compressed air systems such as capacity and pressure, but also its role in the company short- and long-term.
Knowledge and experience actualized by powder processing technology
The fine art of automating powder processing with vacuum conveyors
How compressed air can eliminate pneumatic controller emissions and reporting problems
There are several operational and environmental benefits of powering the natural gas production process with compressed air via buried piping instead of using pneumatic controllers.
Top 5 Plant Engineering content: October 2-8, 2023
Top 5 Plant Engineering content over the past week covered compressed air, asset management systems, Pack Expo and more. Miss something? You can catch up here.
Finding the right process for achieving oil-free compressed air
Achieving quality oil-free air for these applications is vital to help ensure product quality and safety, but there are different methods to achieving this.
Your questions answered: Focus on compressed air systems
Learn from the experts about energy efficiency in compressed air systems
Compressed air vibration monitoring best practices
Vibration monitoring can prove to be an essential predictive tool providing information regarding the health of industrial air compressor equipment and can help prevent unplanned downtime.
Three oil-cooling methods for an industrial refrigeration compressor
Knowing the difference between oil-cooling methods for an industrial refrigeration compressor can help manufacturers avoid downtime in the food and beverage industry.
Quick wins to reduce compressed air use
Explore some quick sustainability wins that can be easily implemented to help quickly reduce emissions and improve energy efficiency on a plant floor.
How oil sampling helps maintain a healthy compressed air system
Lubricant is the lifeblood of heavy machinery and oil sampling can help engineers get the most of their lubricant’s utility.
Top 5 Plant Engineering content: March 27 to April 2, 2023
The top 5 Plant Engineering content from the past week covered compressed air, logistics and automation, digitalization and more. Miss something? You can catch up here.
Leveraging the future of compressed air through automation
Automated, remote and integrated monitoring of systems and machines all play a role in the efficient “smart plant” and automating compressed air systems through remote monitoring plays a key role
Your questions answered: Compressed air systems
In this “back to basics” webcast, the audience learned several aspects of compressed air systems. Here are the answers to many questions.
Back to basics webcast: Compressed air systems
The basics of designing compressed air systems will be covered in this hourlong education session.
Four methods for managing compressed air capacity
Too much compressed air is a major waste of money for manufacturing facilities, but there are ways to manage capacity and reduce costs.
Pneumatics driving energy efficiency
New technology is driving evolution and technology advancement in the pneumatics industry. There is an untapped opportunity to utilize the growth of Industry 4.0 and use it to revolutionize pneumatics.
Dynamics of cavitation in soft porous material
Purdue University fluid mechanics researchers are looking at cavitation in soft porous material and understanding its effects on structures as well as the human body.
Top 5 Plant Engineering content: August 22-28, 2022
The top 5 Plant Engineering content from the past week covered air compression, lubrication, PDO, APS and electric steel. Miss something? You can catch up here.
Ten ways to get an air compression system to meet carbon neutral goals
Carbon neutral status has become the mantra in many businesses’ sustainability team. Air compression systems can help.
Impending regulations, common sense make the case for more energy efficient compressed air systems
Eliminating leaks and energy recovery are two good places to start
Follow service intervals and inspect wearable parts on rotary screw air compressors
When it comes to rotary screw air compressors, it is important to follow the prescribed service and maintenance program.
Top 5 Plant Engineering content: June 13-19, 2022
The most-viewed content from the past week covered compressed air systems, preventive maintenance, Lean manufacturing tools, Product of the Year winners and detecting dangerous gases. Miss something? You can catch up here.
Let’s talk about compressed air systems
Managing leaks (and everything else) in an industrial compressed air system
Compressor filtration best practices delineated
There are many differences and distinctions of oil-free air that need to be understood because choosing the wrong solution and technology can have adverse effects.
How much does a dust collector really cost?
Calculating dust collector ownership costs goes beyond up-front cost
Tiny leaks cause big damage
Detecting air and gas leaks can pay dividends.
Compressed air in the pulp, paper and board industry
The trend is turning from traditional paper to more sophisticated products such as demanding packaging solutions and specialty papers and compressed air will play a role.
Consider modular reed valves for reciprocating compressors
Tips for reliability professionals engaged in due diligence
Top 5 Plant Engineering articles Sept. 27- Oct. 3, 2021
Articles about how to select a dust collection system, best practices in IIoT-based predictive maintenance, make to stock vs. make to order, and more were Plant Engineering’s five most clicked articles from Sept. 27- Oct. 3, 2021. Miss something? You can catch up here.
How to select a dust collection system
For most industrial and manufacturing facilities, having reliable dust collectors is critical to the operational efficiency and employee health
Implement load sharing in a multiple compressor installation
Steps to take for intelligent load sharing system control
Improving the triple bottom line through compressed air leak detection and remediation
Preventative leak detection measures play a vital role in the sustainability in manufacturing environments
Two ways smart pneumatics maximize energy savings
Flow, pressure and temperature data included
How to connect air compressors to the cloud
Distributed low-cost electronic data collection and communication devices monitor and control air compressors and dryers
Detect leaks with acoustic imaging
Consider reaching beyond ultrasonic leak detection to find pesky compressed air leaks
Compressed air audit optimizes efficiency
A compressed air system evaluation can provide owners and facilities engineers with the direction they need to ensure their plant is operating efficiently and reliably
Company president celebrates 50 years of employment on organization’s 65th anniversary
Steve Pendleton, president of VAC-U-MAX, celebrated his 50th work anniversary on the company's 65th anniversary.
Compressed air, vacuum cleaning solution company celebrates 65 years
VAC-U-MAX reached its 65th anniversary, providing material handling and industrial vacuum solutions to a variety of industries dependent on compressed air and cleanliness for their engineering applications.
1/2 NPT Internal Mix 360° by Exair
1/2 NPT internal mix 360-degree hollow circular pattern atomizing spray nozzles that can be used to coat the inside of large diameter pipe or duct
Top 5 Plant Engineering articles March 4-10
Articles about calculating compressed air efficiency, Brexit's impact on manufacturing, 2018 Salary Survey findings, and conveyor maintenance were Plant Engineering’s five most clicked articles from March 4-10. Miss something? You can catch up here.
A new way to calculate compressed air efficiency
Upcoming DOE standards will require new testing
Top 5 Plant Engineering articles, November 5-11
Articles about process safety, Product of the Year finalists, compressor rental, agile thinking, and Manufacturing 4.0, were Plant Engineering's five most clicked articles from last week, November 5-11. Were you out? You can catch up here.
Air conditioners
Hoffman’s T Series air conditioners are designed to provide positive cooling for wall-mount and stand alone enclosures. This new line of air conditioners offers a wider range of protective capabilities and more BTUs of cooling to protect electronic controls and equipment from potential failure caused by heat, humidity, dust and other contaminants.
Plastic repelletizers
Precision AirConvey introduces its 21-model line of plastic repelletizers. They enable plastic film processors to capture edge trim, roll scrap and other film waste, convert it to pellets and reintroduce it into the extrusion process in a closed reclamation loop that safeguards the purity of the material.
Compressor rental: 7 myths and facts
A flexible approach to air requires fresh thinking.
Compressed air and VFDs: Get the most from your system: Your questions answered
Webcast presenter Jarrett Affolter answered questions about topics such as cost benefits of a compressed air system, recommended volume for an air tank, and when to use fixed speed or variable speed.
Best practices for compressor storage
Understanding best practices for compressor storage for a lubricated trim compressor with load/unload controls is critical for optimized performance.
Industrial energy training and certification
Oak Ridge report details available how to find and use industry resources. Training on efficient operations can contribute to whole-facility energy performance.
Four ways to manage a compressed air system’s efficiency
There are many factors affecting the bottom line of your facility. A leak or inefficiency in a compressed air system may spell much higher costs. Follow these tips to ensure your compressed air system is running efficiently.
Rotary screw air compressor
The CSG-2 SFC, DSG-2 SFC, and FSG-2 SFC variable speed, oil-free air compressors are available from 75 to 450 hp and cover flows from 125 to 1788 cfm at 125 psig and are designed to deliver part load efficiency and steady pressure for applications.
A fresh approach to compressed air savings
Take a systematic approach to uncovering and fixing waste .
Five overlooked compressor truths
There are many aspects of compressed air that are overlooked. A large amount is wasted. Small changes can impact your compressed air efficiency and minimize costs.
Refrigerated air dryer series
The FLEX Series refrigerated air dryer is designed to efficiently remove liquid from compressed air by harnessing latent heat produced as it converts from solid to liquid or liquid to solid.
Wireless digital flowmeters
A line of digital flowmeters with wireless capability use a Zigbee mesh network protocol to measure and monitor compressed air use, trends, and historical data.
Rotary screw air compressor series
The RS185 to RS260 oil-flooded rotary screw air compressors provide a more energy-efficient solution for customers with high-capacity air requirements.
Mobile portable compressor
The M58 mobile portable compressor is designed for demanding applications such as demolition, sandblasting, and construction.
Pneumatic lubricators for compressed air systems
Pneumatic lubricators aren't commonly used for compressed air systems today, but they still serve a purpose for specific applications and settings.
Compressed air leaks leads to lost money
Compressed air leaks are expensive in a facility, and too often overlooked, which can have a detrimental effect on overall costs.
Top 5 Plant Engineering articles, January 16-January 22: lowering compressed air costs, VFD efficiency, keeping DC motors healthy, more
Articles about lowering compressed air costs, VFD efficiency, keeping DC motors healthy, motor current analysis, and the importance of motor winding analysis were Plant Engineering's five most clicked articles from last week, January 16-January 22. Were you out? You can catch up here.
Oil-free air compressors
The oil-free standard air compressors have achieved high efficiency and a thorough reduction in energy loss. Through a cloud service, energy use and operating conditions can be visualized.
Oil-injected rotary screw compressors
Atlas Copco has enhanced three compressors in its GA series. The improved GA 30+, 37 and 45 compressors offer better performance, lower noise, and a smaller footprint.
Air cooled refractive index transmitter
The IPRB3 covers the refractive index range from 1.32000 to 1.52000 and the Brix scale from 0-90% and is suitable for a wide range of process fluids and applications in food and pharmaceutical processing.
Getting verified performance from compressed air dryers
CAGI testing shows standards don’t always equal performance.
Sampling conditioning unit for use in industrial applications.
The Sampling Conditioning Unit is designed for ensuring accurate emissions monitoring in industrial applications.
Mobile odor control system for freezing temperatures
OdorBoss 60G, a mobile odor control system, to manage outdoor odor vapor from landfills, waste treatment facilities, livestock operations, paper mills, and food processing plants.
Air knives that resist temperature and corrosion
Air knives that can withstand temperatures up to 800 F and are ideal for blowing corrosive chemical off parts, drying food products, and cooling hot materials such as molten glass, casting, and molded parts.
Geared centrifugal compressor for various applications
The Turbo-Air NX 8000, a geared centrifugal compressor, features lubrication and cooling systems designed to optimize flow and efficiency.
Take a total system approach to compressed air reliability
Understanding how systems work together can lead to energy savings in compressed air systems.
Rotary screw compressor
The UP6S rotary screw compressor series is designed to power pneumatic tools and equipment and can operate in harsh environments.
CAGI marks its centennial
Compressed air management has a rich legacy after 100 years.
Preventing compressed air leaks: Taking a proactive approach
Much has been written about leak management programs, best practices and the like, but little has been offered in terms of a proactive approach. That is, when installing a new system or expanding or rerouting an existing one, what can be done to prevent leaks? The pipe-joining method is an important decision that will impact maintenance programs down the road. Press-to-connect pipe-joining systems can be a means to prevent air loss in compressed air systems.
Stainless steel pneumatic cylinders
Constructed of 303 and 304 stainless steel, these cylinders can be used in wash-down and caustic environments.
Atomizing nozzles
Internal Mix Atomizing Spray Nozzles mix liquid and air inside the nozzle and produce the finest atomization of liquids up to 300 centipoise. T
Compressed air flow meter
The ST50 Flow Meter provides precision flow measurement to reduce the consumption of pneumatic air, helping manufacturing, assembly and process plants reduce air consumables and the energy required to support compressed air systems.
How National Guard members and veterans can help close the Skills Gap in manufacturing
Steve Nowlan, spoke on behalf of the American Jobs for America’s Heroes Campaign about the potential of reducing the manufacturing skills shortage by hiring highly trained National Guard members and veterans.
Energy recovery offers ways to reduce compressor heat
Poorly designed compressed air systems waste vast amounts of energy—and waste money in the process. Energy recovery can be an effective way to utilize all energy created for the compressed air system.
Tie your supply chain to energy efficiency
There are numerous opportunities throughout the supply chain to reduce energy consumption and deliver a more sustainable plant such as HVLS fans, dock doors, and LED lighting.
White Paper: Vaisala: Four things you need to know about compressed air dew point sampling
This white paper explains how to get an accurate sample of process gas and how to avoid potential sources of error.
Swap sale purchase earns loyal Klein customer $5,000
Finding 109-year-old pair of side cutting pliers in working order wins company contest
‘Go-to’ strategies for energy management
Condition-based maintenance will allow you to assess your building envelope and plug your leaks
Active filter cleaning technologies extend filter life, improve efficiency
Indoor air quality: Active filter cleaning has evolved from passive filtration to more active methods like mechanical and reverse air methods
Compressed air dryers
The D-EC Energy-Saving Refrigerated Compressed Air Dryer series are designed for small commercial use and manufacturing applications
White Paper: Vaisala: Dew point sensing technologies
This white paper explores the differences between chilled mirror, metal oxide, and polymer sensors and compares how these technologies perform in the four most common challenges to measuring dew point in compressed air.
Atlas Copco opens NASDAQ trading day
CEO rings opening bell to mark company's 140th anniversary
Dual hazardous location vortex
The HaxLoc Vortex AC model 7570 cools large enclosures with a 2-stage cooling process and can operate in hazardous environments.
Compressed air: Find the leaks, lower the pressure, and measure the results
Create "good practices" around continuous monitoring of system leaks
Neodyne Industries emerges from Hamilton Sunstrand acquisition
New company includes Sullair, Milton Roy and Sundyne brands
Manufacturers can get grants, contacts through STEP program
Partnership with Hannover Messe, SBA delivers results to small businesses around the country
2012 POY Finalists: Fluid Handling
Finalists in the Fluid Handling category for the Plant Engineering 2012 Product of the Year competition.
White Paper: Vaisala: Dew Point Measurement in Compressed Air: Top 9 FAQs
This white paper answers the 9 most frequently asked questions about dew point in compressed air leading to a better understanding and a better operating compressed air system.
Air treatment products
Refrigerated and desiccant regenerative dryers and filters
AHR attendees are optimistic about new year
According to a recent survey of more than 1,000 AHR Expo exhibitors worldwide, nearly three-fourths of the total respondents expect a better year in 2012.
2011 POY Finalists: Compressed Air
Finalists in Compressed Air in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Air nozzle
Finalist in Compressed Air in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Compressed air filter
Finalist in Compressed Air in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Spray nozzles
Finalist in Fluid Handling in Plant Engineering’s 2011 Product of the Year competition
POY Finalist: Platform and stair system
Finalist in Safety in Plant Engineering’s 2011 Product of the Year competition
Implementing “time-of-day” energy load shed project reduces costs
Valuable lesson learned at huge aero-structures fabrication plant about energy conservation projects from the maintenance department.
Get the most out of your compressed air system
While we only work about 40 hours a week, a compressed air system is, in most instances, much more dependable and loyal, taking breaks only for routine scheduled maintenance.
Gas Technology: Gas turbines spell opportunity for industry
Getting Much More for Your Energy Dollar
U.S. suppliers to connect with manufacturers at NTMA fair
The NTMA Contract Manufacturing Purchasing Fair will be held Sept. 7-8, 2011 at the Intercontinental Chicago O’Hare Airport Hotel.
Removal of non-condensable gases, air is critical in a steam system
Learn where air and non-condensable gases come from, how they affect a system’s operation and performance, and best practices for eliminating them.
It’s time to turn optimism into action
As real as the recession was, the end of the recession should be just as real. Taking all the lessons we learned, we have to move away from the shallow end of the pool and ramp up for growth.
ISC West 2011, key themes From the show
At what was a busy show in Las Vegas, there were three key themes that stood out: PSIM Software, HD transmission over coax, no "wow" factor.
Gas Technology: Direct-contact water heating
Saving energy and reducing your footprint
Gas Technology: Natural gas-powered fuel cells make friends
Solutions for a greener environment
Gas Technology: Renewable natural gas
A green solution adds to fuel resources
Weigh the benefits of on-site nitrogen generation
Many facilities are turning to on-site nitrogen generation as a more effective problem-solver that helps operations run efficiently.
AHR Expo sees big crowds, bigger innovation
Manufacturing had some major innovations at the show designed to deliver increased performance, better energy management and a quicker return on investment.
Air Conditioners featuring filter-free, energy-efficient design, broad range of cooling capacities
Pentair Technical Products McLean brand SPECTRACOOL air conditions deliver cooling to sensitive electronics within enclosures. SPECTRACOOL Air Conditioners provide a broad range of cooling capacities, power input, and mounting options.
BEST PRACTICES: Condition monitoring
Top concerns for businesses are directly related to reliability risks, which can be every bit as devastating to a corporation's financial health as an unexpected rise in borrowing costs or the failure of a new product launch.
BEST PRACTICES: Steam and condensate leaks
Steam and condensate leaks cost industrial plants millions of dollars in lost energy, while increasing emissions, creating safety hazards, and lowering the reliability of plant operations.
2010 POY Finalists: HVAC
Plant Engineering's 2010 Product of the Year finalists featured in the HVAC category.
2010 POY Finalists: Maintenance Tools and Equipment
Plant Engineering's 2010 Product of the Year finalists featured in the Maintenance Tools and Equipment category.
Video: IMTS 2010: Atlas Copco talks air compressors
Content Manager Peter Welander with Control Engineering talks with Allen Kuhlman from Atlas Copco about air compressor technologies, annual energy costs, and the technological advancements that make compressors more efficiency than years past.
A predictive maintenance road map to energy savings
The successful integration of standard PdM technologies can capture significant energy savings and simplify ROI calculations. By the way, any associated benefits of increased safety, reliability and enhanced facility capacity are purely coincidental.
Atlas Copco acquires Clayhill distribution channel
Atlas Copco Compressors LLC, has purchased the Clayhill compressor distributorship from American Air Products, Inc. Clayhill operates in Minnesota, North Dakota, South Dakota and areas of Wisconsin. “Feet on the street and maintaining the closest relationship with the customer continues to be a high priority for us in the US,” said Stephan Kuhn, business area president for Atlas Copco Compressor Technique. “This acquisition gives us the opportunity to bring some experienced sales and aftermarket people into Atlas Copco, and will allow for an even greater customer focus.” Approximately 18 employees will join Atlas Copco from American Air Products as a result of this acquisition.
AMT elects new board members; Janka named chairman
Daniel Janka was named chairman of Association for Manufacturing Technology (AMT) at its annual meeting on Oct. 23 in Orlando. Also elected were board members and other positions for the association, which represents more than 400 American manufacturers of machine tools, manufacturing machinery and related products.
Janka named AMT chairman at annual meeting
Association elects new board members for 2009-10
Compressor
Gardner Denver’s new Paradigm is ideal for applications with intermittent duty and a low noise requirement. The quiet Paradigm compressor package delivers powerful performance, easy maintenance and reduced noise for maximum customer satisfaction. Sound levels are as low as 67 dBA. Gardner Denver www.
Oil injected compressors
The entry-level GA FIT oil injected compressor meets diverse market needs in the 110-160kW (150-200 hp) category by providing air compressor technology for customers in need of standard efficiency levels. "We conducted in-depth conversations with our customers and found there was a gap in the market," said Paul Humphreys, vice president of communications and branding, Atlas Copco Compressors LLC. "The GA FIT was tailored for this market with one goal - to provide outstanding value to our customers in these tough economic times."The GA FIT utilizes the latest generation of Atlas Copco's oil-injected screw element in order to provide reliable service in the harshest environments, even in ambient temperatures up to 115°F /46°C. The GA FIT can be customized with several popular options to ensure the facility's compressed air needs are met in the smallest, most reliable and efficient package.Completing Atlas Copco's GA 110-160 range are the GA Standard, GA +, and GA VSD (variable speed drive) versions.
Kaeser president to head CAGI
Frank Mueller, president of Kaeser Compressors Inc., was recently named president of the Compressed Air and Gas Institute (CAGI). Mueller will serve a two-year term. “CAGI has done an excellent job of raising awareness on the importance of compressed air,” said Mueller. “During my term, we will continue to make CAGI the credible voice of the industry ensuring that end-users un...
Ultrasound pinpoints compressed air leaks
For more than 30 years, ultrasound technology has been the preferred diagnostic technology of maintenance departments throughout the world.
Condensate filter
The Kaeser Condensate Filter is designed to remove oil and other contaminants, making the water safe for disposal. Now available in five sizes, the KCF is designed to handle most compressor lubricants. These models are lightweight, have multiple inlet connections and handle flows from 55 to 1800 cfm.
Hannover Messe wooing U.S. manufacturers
Hannover Messe has a reputation as the world's leading manufacturing trade show. They are working to get this part of the world to come to Hannover Fair for this year's event.
Contact-cooled compressors offer increased efficiency
With features such as a smaller footprint than previous offerings, easy installation and intelligent controls, the family of contact-cooled compressors from Ingersoll Rand can assist in the ongoing quest for energy efficiency in a variety of high-use markets.
Contact-cooled compressors
Designed for use in automotive, metal fabrication, conveyance, textile manufacturing and other applications, contact-cooled compressors feature a proprietary Intelligent Controller.
Tri-lobe blower family
The DB 166C and DB 236C offer a reduced footprint, simple installation and maintenance, and reduced noise and vibration.
Free compressed air guide
A free eight-page guide has been updated to include tips on system maintenance activities, maintenance solutions for various compressor types and practical solutions for common problems.
From audit to implementation: Saving energy in a manufacturing environment
Manufacturers these days are being asked to produce products that are “green” to satisfy corporate sustainability goals.
Atlas Copco opens new distribution facility in South Carolina
Compressor company relocates North American headquarters relocates to Rock Hill, SC
Lean conservation: Energy consulting practice offers shop-floor techniques
Wasted energy often results from improper machine conditions, lack of standard work, excessive inventories, and unnecessary processing. TBM Consulting Group , a global business improvement leader for the manufacturing and service sectors, says its new Lean Energy Practice now assists companies worldwide in applying Lean principles to reduce energy consumption and waste.“The manufacturing community urgently needs to exert control over rising energy costs,” says Anand Sharma, CEO, TBM Consulting Group. “To improve financial performance particularly during turbulent times, it’s crucial for manufacturers to conserve their energy resources.”Through TBM’s Lean Energy Process, which enables companies to rapidly achieve energy productivity, key processes lead to conservation of resources such as water, gas, compressed air, oil, and electricity.
Direct-drive compressors
Designed for efficiency, reliability and minimal maintenance, direct drive compressors are available from 25 to 450 hp, in flows from 72 to 2,003 cfm and pressures of up to 217 psig.
Blower
Com-paK Plus rotary lobe blower packages offer 5- to 200-hp designs with flows from 60 to 2,295 scfm. All maintenance points, including the automatic belt-tensioning device, oil drains and filter elements, are accessible through the canopy on the front of the machine. All power and process connections are at the rear, allowing multiple units to mount side by side without additional access clear...
Air system analyzer
The Air Demand Analysis program monitors and charts air flow, power consumption and system pressures during normal operation hours over a period of 10 days. The system is available in large and small sizes, and displays the air requirements including the relationship between peak and base load compressors, along with each compressor’s duty cycle.
Gasket makers
Permatex gasket makers are non-corrosive, form-in-place compounds that require no mixing and cure at room temperature.
DOE Save Energy Now reaches milestone
The Dept. of Energy's Save Energy Now program has completed its 500th Energy Saving Assessment.
Cooling and heating units
The Apex series of 15- to 25-ton packaged cooling and heating units is equipped with independent scroll compressors with individual refrigerant circuits to provide part-load operation.
Air cleaning unit
The T-Series packaged air-cleaning units collect dust, smoke and other air particulates with a 95% efficient, two-stage filtration system.
Garlock honored for environmental leadership
The company's Palmyra, NY manufacturing facility was recognized for its leadership efforts in reducing its affect on the environment.
Plugging in the numbers
Some days, it takes all the energy we can muster just to deal with all the energy issues. We’re facing another summer of making the best of escalating energy costs. The issues of sustainability and energy efficiency are top of mind for manufacturers, and they were key issues at this month’s Plant Engineering Manufacturing Summit.
Air filter
The MERV 8 30/30 air filter has low initial resistance and a low maintained resistance to airflow.
Drain trap
The AMD 1550 removes condensate and contaminants from air systems while protecting equipment. An automatic magnetic drain, it offers working pressures of up to 230 psig and a discharge capacity of 53 gallons per hour. Installation is accomplished through top or bottom connections, and the unit’s modular construction facilitates maintenance.
Variable-speed air compressors
The VST series of variable-speed air compressors expands with the new VST 110, VST 150 and VST 180 (150, 200 and 250 hp) rotary-screw compressors. The direct-drive compressors can be configured as air- or water-cooled and offer a variety of features, which include standard variable-speed control, gear-free design and variable-speed cooling fans to optimize cooling and energy efficiency.
Compressor system
The ES-6 is a complete AirMetrix performance air system for small horsepower applications that includes an encapsulated compressor, an optional SRS dryer/SCF filter and an 80- or 120-gallon storage tank. Part of the S-Energy line of compressors, it features horizontal tank mounts and has a streamlined design that uses 40% fewer parts than conventional models for reliability and low maintenance.
Compressor package
The new SK AirCenter series features energy-saving rotary screw compressors and refrigerated dryers. It is available in 15-20 hp models, producing 40-78 scfm at pressures to 217 psig. All models are tank-mounted and have a small footprint. The split-cooling air-flow design and insulated enclosure provide quiet operation, with noise levels as low as 65 dB(A).
Germany’s Hannover Fair to showcase subcontracting
In an age of global competition, subcontractors assume an important role as competent supply chain partners. Hannover Fair 2008 (April 21–25 in Hannover, Germany) will showcase subcontractors in a number of industrial sectors, focusing on their versatile share in the value creation process.
Low-profile evaporative coolers/heaters
KUBE low-profile evaporative coolers use slinger wheel technology to evenly distribute evaporative atomized water across the air inlets. The coolers can provide from 3,000 to 30,000 cfm with variable-speed control. Heating can be provided via an indirect heat exchanger, up to 400,000 BTUs per unit. Other features include network capability and touch screen controls.
Airless metal sorter
The ProSort metal sorter uses a traditional conveyor belt and sensors to detect metals and 2-inch-wide electro-mechanical paddles to reject material. The sorter requires no air compressor and is available in sizes as large as 128 inches. The control circuit energizes the paddles and diverts the inappropriate metal away from the product stream.
Reader Feedback – 2007-11-15
Don’t overlook minor air leaks, and look for energy savings “Finding the miss-ssssssss-ing air loss in your compressor system” (Plant Engineering Live) really highlights the concern in our industry. As a compressed air distributor, many of our customers don’t realize that the initial cost of the compressor and maintenance is minor when compared to electrical costs.
Process air heater
The SKORPION process air heater features a closed-loop PID temperature control system and produces air temperatures from 1,200 to 1,400 F. Air temperature is regulated to +/-2 degrees of the set point. Heater voltage is regulated by a solid-state relay, and the heater element is protected with a resistive photo detector and a thermal resistor mounted at the heater inlet.
Oil purifier
The continuous bypass compressor oil purifier is a proactive maintenance contamination control system specifically designed for oil-flooded rotary-screw air compressors. The unit installs on most compressors to continuously remove acids and ultra-fine solids. Its patent-pending Dual-Core Cartridge combines mechanical and chemical separation technologies.
Asset condition management solution
InFusion condition manager provides the ability to collect real-time condition data from a range of plant data sources. It provides tools for analyzing and contextualizing data and applies a rule set that triggers and manages the appropriate operations, engineering or maintenance actions. The solution also balances asset availability and combines plant performance with business objectives and a...
Air distribution system
The SmartPipe modular compressed air distribution system is made of calibrated aluminum with a low-friction coefficient. The system is rust and corrosion-resistant due to its full-bore fittings that minimize pressure drop. Push-to-fit connectors eliminate threading, welding or sweating. Kaeser Compressors www.
Emerson honored for heating, air conditioning, and refrigeration technologies
Products from both commercial and residential categories recognized.
Finding the miss-ssssssss-ing air loss in your compressor system
Data loggers, quiet inspection turn up the source of lost air, energy
Maintenance strategies for effective operations
The Energy Efficiency and Renewable Energy division of the U.S. Department of Energy offers a series of fact sheets on its Website (www.eere.doe.gov) that focus on best practices in many areas of energy efficiency. This fact sheet takes a look at maintenance on compressed air systems. A brewery neglected to perform routine maintenance on its compressed air system for years.
Ultrasound World IV speakers announced
Experts within predictive maintenance technology fields, as well as plant managers who utilize ultrasonic detection equipment for condition-based maintenance, will present case histories, educational lectures and informational sessions at the event scheduled for Jan. 27-30, 2008, at the Hilton Beach Resort in Clearwater Beach, FL.
Harvey Research, Inc.
Harvey Research, Inc. Official Internet Survey Sweepstakes Rules 1. TO ENTER : You must be 18 years of age or older . NO PURCHASE NECESSARY .
Easy install temperature sensor
These flexible temperature sensors install in minutes using a pair of pliers and wire cutters, have rapid response times and are available in popular RTD and thermocouple configurations.
Compressors
The S-energy Series comes with an integrated inlet valve.
Cycling air dryers
The refrigerated dryer series is now available for flows from 20 to 885 scfm, in pressures up to 230 psig. The cycling dryers provide efficiency by using a thermal mass medium for storage and operating the refrigerant compressor only when necessary. An air-to-air heat exchanger reduces the load on the refrigeration system by pre-cooling the inlet air.
PLANT ENGINEERING April issue preview
Through the use of infrared thermography, manufacturers can more accurately predict where maintenance is needed, preventing costly downtime and the accompanying drag on the bottom line.
Air compressor controller
The Sigma Air Manager Basic controller is designed to optimize compressed air system performance in small to medium installations. The master controller provides superior pressure band control, balancing service hours, tracking preventive maintenance requirements and preventing simultaneous motor starts. It can be adapted to most systems and manage up to four compressors or vacuum pumps, including multiple types and brands.
Variable speed air compressor
The SFC 18S rotary screw compressor combines the proprietary Sigma Profile airend and Sigma Control Basic system to offer 21 to 114 scfm in pressures to 217 psig. The SFC 18S features a space-saving cabinet and a split-cooling airflow design for easier ducting and low noise levels. Access doors allow frontal access to all major components and reduce access clearance and footprint.
Air transfer tubes
TT Series transfer tubes are air-powered and provide a maintenance-free method for conveying materials at high speed. Featuring a smooth bore that lets materials pass freely, they operate using the Venturi principle, creating a powerful vacuum from compressed air. Designed to instantaneously provide air movement, the tubes’ transfer speed and output can be infinitely controlled by regulating the input air pressure.A selection of tube sizes is available to match product and flow requirements, ranging from 0.375 to 1.0 inches I.D., with 15 to 95 SCFM air flow.
Labelmaster hosts successful dangerous goods shipping symposium
Labelmaster , a U. S.-based manufacturer of dangerous goods compliance products, recently sponsored a symposium specifically targeting instructors responsible for dangerous goods training. The two-day symposium, held at the Embassy Suites Miami Airport, featured attendees representing airlines, cargo companies, commercial training firms, government trainers and instructors within private industry who ship dangerous goods. "When we looked at industry forums, there wasn't anything focusing on the unique needs of the hazmat instructor,” said Neil McCulloch, manager of international products for Labelmaster.
New drying system strategies balance costs and effectiveness
Plant managers are constantly faced with the challenge of finding new ways to reduce costs, increase throughput and meet established quality standards. One of the biggest areas for improving plant operations could be one of the most easily overlooked: the use of compressed air in drying and blow-off applications.
Anemometers measure temperature
The AN200 and AN100 airflow anemometers with built-in infrared thermometer are actually three meters in one: they measure air flow, air velocity and air temperature. Features include a laser pointer to identify the target area; ability to measure remote surface temperatures up to 500 F; an 8:1 distance-to-spot ratio; 0.
Condensate system
Disposing of compressed air system condensate is an environmental concern that the company’s new Aquamat condensate management system addresses. The unit uses a unique, four-stage separation process to automatically separate oil from condensate. It eliminates the need for expensive disposal by outside contractors, the company reports.
Condensation management system
Disposing of compressed air system condensate is an environmental concern that the company’s new Aquamat condensate management system addresses. The unit uses a unique, four-stage separation process to automatically separate oil from condensate. It eliminates the need for expensive disposal by outside contractors, the company reports.
Oil-free compressed air
TheZ Series of oil-free, rotary-screw air compressors is TÜV certified ISO 8573-1 CLASS 0. Risk of oil contamination is eliminated during food and beverage processing, pharmaceuticals manufacturing and packaging, electronics manufacturing, automotive paint spraying and powder coating as well as textile manufacturing, the company reports. Certification wascarried out using stringent test methods designed to simulate realistic industrial installation environments.
Johnson Controls to sell Scroll, buy Berg
Milwaukee-based Johnson Controls, Inc. announced plans to sell its 50% interest in Scroll Technologies, Inc., a joint venture with Carrier Corp. The company also announced the acquisition of Berg Inc., a Shreveport, LA-based mechanical services company. Scroll Technologies manufactures scroll compressors at its Arkadelphia, AR facility.
Finding energy resources online
To help American manufacturing facilities save energy and continue to thrive during this time of diminished supplies and rising energy costs, the U.S. Department of Energy has launched the Save Energy Now initiative. The initial focus of the initiative is on reducing natural gas consumption. As a key element of Save Energy Now, DOE is sending its own energy experts to conduct 200 Energy Saving...
Atlas Copco offers 100%-certified oil-free compressed air
Atlas Copco's Oil-free Air division reports that its Z series of oil-free, rotary screw air compressors is the first in the world to be TechnischeÜberwachungs-Verein-certified ISO 8573-1 CLASS 0. Risk of any contamination by oil is effectively eliminated during food and beverage processing, pharmaceuticals manufacturing and packaging, electronics manufacturing, automotive paint spraying and powder coating as well as textile manufacturing. Certification was carried out using stringent test methods, simulating realistic industrial installation environments.
EnPro Industries, Inc. acquires Canadian compressor parts manufacturer
EnPro Industries, Inc., a manufacturer of engineered industrial products, announced Wednesday the acquisition of Allwest Compressor Services, a privately-held manufacturer of compressor components located in Western Canada. Terms of the transaction were not disclosed. Allwest manufactures and services compressor-related parts and components for the natural gas and oil production industries, including compressor pistons and rods, piston rings and rider bands, and compressor valves. In addition, Allwest offers reconditioning services for reciprocating compressor components. The operations of Allwest and its 36 employees will be managed as part of France Compressor Products.
PE POLL: Our March question at www.plantengineering.com:
Go to www.plantengineering.com for April's poll question: A plant-floor manufacturing execution systems is:
Voice your views
Preparing for a capital purchase in 2006? What’s at the top of your list? This month’s PE Poll question at www.plantengineering.com asks, “What capital purchase does your plant need to make next: Motors, drives, software, pumps, HVAC or compressors?” Check out the March issue of PLANT ENGINEERING for the results of February’s PE Poll question.
PE Poll
Go to www.plantengineering.com now and voice your views on this month's question: What capital purchase does your plant need to make next: Motors, drives, software, pumps, HVAC or compressors?
Air compressors
A new series of air compressors from Sullair is designed for point-of-use facility installations. The Sullair 3000 is a 40-hp model; the Sullair 3700 is 50 hp; and the Sullair 4500 is 60 hp. They are designed to make service and routine maintenance faster, simpler and more efficient. All standard compressor maintenance can be performed from one side of the machine, and the compressor's fluid le...
Voicing your views
Preparing for a capital purchase in 2006? What’s at the top of your list? This month’s PE Poll question at www.plantengineering.com asks, “What capital purchase does your plant need to make next: Motors, drives, software, pumps, HVAC or compressors?” Check out the March issue of PLANT ENGINEERING for the results of February’s PE Poll question.
Tips on dealing with water damage and electrical equipment
In the popular mind, water and electricity are considered incompatible, and for good reason. With the presence of dissolved ions, water provides an excellent conductor... but not generally where current is intended to go.
Compressed air and vacuum pipework.
HBS is the aluminum modular pipework system with a full range of diamaters (from 1" to 4") and accessories made in Italy. The lightweight, high-tech design offers speed of installation and quick modification, which are advantages over traditional piping. No welding, threading or painting is required.
Miss a story? There’s two ways to find them
For almost 60 years, PLANT ENGINEERING has provided outstanding technical information to plant managers, and for the last decade, the best of those technical articles are also online. With the creation of the Engineer's Resource Guide, there are now two ways to find past stories that have appeared in PLANT ENGINEERING: 1.
Airgas acquires two companies
Airgas, Inc. has acquired Oxygen Service Company, Inc., headquartered in Macon, GA with four other locations in central and southern Georgia. In a separate transaction, it also acquired Alabama Cylinder Gas, Enterprise, AL.
High power ac drive market growth expected
A recent ARC Advisory Group study, "High Power ac Drive Worldwide Outlook," indicates that strong global economic growth and buoyant consumer demand contributed to robust growth of the high power ac drive market. Manufacturing companies in a variety of industries invested heavily to create additional manufacturing capacity and in capital equipment to upgrade existing plants. The worldwide market for high power ac drives exceeded $3.2 billion in 2004 and it is expected to grow at a Compounded Annual Growth Rate (CAGR) of 8.9% over the next five years, according to the ARC study. Escalating energy costs experienced in recent years has forced manufacturers to focus on energy conservation measures.
Efficient centrifugal compressor is compact
Turbo Air 2020 centrifugal air compressor offers big performance in a compact package. It provides oil-free, reliable, efficient operation and ease of maintenance in a two-stage 250 to 400 hp air compressor. It brings lower maintenance costs with greater efficiency and all the advantages of oil-free compressed air.
Compressor delivers air and nitrogen
GN range of dual output air compressors generate nitrogen and compressed air simultaneously. 4 kW, 7 kW and 18 kW units are available with several levels of nitrogen output for each unit. Nitrogen flow starts at 0.6 cfm and goes up to 18 cfm with a purity of 95%. The dual output compressor system uses a screw compressor, tank mounted, an integrated refrigerant dryer and filters and a membrane t...
System maintains consistent air quality
Air Main Charging System is an innovative solution to ensure consistent compressed air quality when operating under conditions that require routine system shutdowns. AMCS prevents excessive air velocity at system start-up by automatically opening and closing to maintain a set minimum pressure in the supply side and slowly charging the main distribution piping.
Selectable full-load operating pressure
VS/VST Series of single- and two-stage variable speed air compressors optimize energy efficiency, averaging a 37% energy savings over standard base-load models. Selectable full-load operating pressure from 70 to 175 psig can be made with the touch of a button. Units perform with 2 to 3 ppm of oil carryover throughout the operating range.
Hard lessons from the Big Easy
First comes the storm. Then comes the media, and a second storm erupts. Then, when the water and the TV crews and the volunteers and the president have all receded, when the fingers stop being pointed and the bottled water has been passed out and the power comes back on and the jazz starts to play again, comes the rebuilding of New Orleans.
Corrosion monitoring in hydrogen bromide
For years, a major processor of hydrogen bromide has had a corrosion problem. The compressor that pushes hydrogen bromide gas through their plant required regular repairs and replacement, and each compressor was only able to provide five years of operation. Hydrogen bromide is a highly corrosive gas, especially with water present. In this application compressors are used to push the gas throughout the plant for processing.
The business case for compressed air systems
Do you operate a compressed air system as a business, understanding the financial consequences of your actions or as a misunderstood necessity? Do you carefully consider additions and changes as you would with electricity or water? Is the current book value, depreciation life and trendable cost part of the formula for making normal operating decisions? If the answers to these questions are no, ...
CAGI offers “SmartSite” learning center
The Compressed Air and Gas Institute (CAGI) activated its “SmartSite,” on-line center for learning and technical information. A key feature of SmartSite is its E-Learning courseware. Titled Introduction to Compressed Air Systems, this courseware offers users industry-standard training, available 24/7, that is manufacturer and product neutral.
Seminar focuses on compressed air efficiency
A one-day seminar on compressed air offered insights on ways to improve energy efficiency and reduce costs throughout the compressed air process. The Compressed Air Challenge (CAC), ComED, Atlas Copco, and the Department of Energy sponsored the seminar in Oak Brook, IL. The purpose of the seminar was to make compressed air systems more efficient by improving plant productivity, cost savings fo...
Create an inplant training center by design
Do any of these training experiences sound familiar? "I don't know if I can sit in this chair for another hour, let alone another day!" "Why don't they arrange these chairs so I don't have to sit sideways half the time?" "I wish the guy in front of me would sit still so I could see what's going on." "That glare on the screen sure makes it hard to see the slides.
Submission Entry Form for TOP PLANT
Download submission entry form now! Purpose The Plant Engineering TOP PLANT awards recognize industrial plants that effectively utilize the plant engineering function to achieve outstanding operational results. More specifically, TOP PLANT seeks to: Demonstrate the contribution of the plant engineering function in supporting overall plant profitability and performance Identify plants that have achieved a high level of operational excellence Identify best practices in plant engineering management Identify quantifiable levels of excellence for manufacturing/processing plants and the plant engineering function. Eligibility All industrial plant sites engaged in manufacturing or processing operations are eligible to apply for recognition. (In the United States, these plants fall within SIC codes 20-39 or NAICS codes 311-339.) Recognition will be given to individual plant sites, not to companies, divisions, or departments. A plant site receiving “TOP PLANT” recognition may not reapply the following year. Confidentiality and nondisclosure All applications, data, and evaluation information submitted will remain proprietary and confidential. Plants selected for recognition will be contacted for the release of information and data. Plants not selected for recognition will remain anonymous. Each applicant will be identified by a code released only to the applicant to which it is assigned.
Outsourcing partnerships for utility operations and maintenance
Outsourcing is one of today's industrial mega-trends as identified by industry leaders, groups, and organizations. Brought on by economic gymnastics over the past several years, outsourcing is resulting in creative new management options as the economy calls for further resource optimization.
Compressed Air Challenge
Compressed Air Challenge manual "Best Practices for Compressed Air Systems" ("Choosing a compressed air dryer," May 2004) can be ordered at compressedairchallenge.com.
Kaeser compressors reduce energy costs and peak demand charges.
Pearl Leather in Johnstown, NY uses compressors for process and control air in their leather treamtent operations.
MAROX uses Atlas Copco compressors
MAROX Corporation is a contract manufacturer specializing in high precision machining servicing the medical industry with implants, external fixations, and surgical instruments.
Managing compressed air
The December 2003 article on "Managing compressed air systems" mislabeled the two curves shown in Fig. 1. The flat red curve should be for variable speed air ends and the V-shaped red curve should be for fixed speed air ends.
Compressed Air – 2004-01-10
Get rid of mist Mist Eliminators trap, collect, and remove liquids and soluble particulate matter from compressed air. They use depth of bed coalescing technology instead of conventional pressure drop technology which achieves 100% efficiency in removing particles over 3 microns. Elements have an 8—15-yr life with a minimum pressure drop of 0.5 psi. Airtek , airtek.com , Write 309 on PE card Nozzles use less air Energy Saver nozzles force compressed air through a 0.002-in.
Solutions – 2003-12-10
Pick up chips Problem: After drilling and tapping a blind hole, chips are left in the bottom of the hole. Is there an easy way to remove the chips short of trying to blow them out? Solution: Hold an allen wrench with a bar magnet. Lower the long end of the wrench into the blind hole.
Compressed Air – 2003-11-01
Dryer uses existing energy source CDA alternate cooling source dryers enables facilities that have an ammonia or glycol circuit with excess capacity to treat compressed air with no additional energy consumption. Benefits include: optimum utilization of cooling energy supply, corrosion-resistant air circuit, low compressed air pressure drop, and uncomplicated selection and installation procedures. ZEKS Compressed Air Solutions : zeks.com , TO VOTE, WRITE 42 ON BALLOT For more information, write 42 on card Dryer has 100% zero purge PNEUDRI MAXIplus zero purge, vacuum, heat-regenerative dryer represents a cost effective, energy-efficient solution for providing high-quality, clean, dry compressed air. Zero purge means no compressed air is wasted during regeneration, so additional compressor capacity is not needed.
Improving dust collection
When it comes to dust collection, the first consideration is what type of collector best fits the application. The choice comes down to the baghouse collector—which some refer to as the grand daddy of filtration technologies—or its offspring, the cartridge dust collector. For some filtration projects, there really is a choice.
What to expect from an air audit
To stay competitive, most plants are required to continuously increase production while reducing costs. This requires identifying productivity and quality improvements that result in lower operating costs. Compressed air and vacuum system audits offer an excellent opportunity to achieve these goals with a viable return on investment.
Self-cleaning filters
Manufacturers are using self-cleaning filters to minimize waste and maximize profits
Compressed air site
Need to know what critical pressure means? Or maybe you need to locate a company that manufactures rotary screw air compressors. A new web site, cagi.org, provides organizational information as well as direct links to member web sites and a host of valuable resource material. It also includes a toolbox with terminology definitions, common formulas, and data sheets.
HVAC – 2003-06-12
Mold remediation A 3-day symposium on mold remediation, sponsored by ACGIH, will be held November 3-5 in Orlando, FL. The objective is to provide a forum for the exchange of knowledge and for sharing organizational perspectives. The symposium will consist of lectures, panel discussions, and question and answer sessions.
Compressed Air – 2003-05-06
Membrane air dryers Membrane air dryers provide pure, dry compressed air and offer an economical, efficient alternative to pressure swings from adsorption and refrigerant dryers' technologies. The dryer provides dewpoints as low as -40 F at flow rates up to 100 scfm. No moving parts means reliable and efficient operation without operator attention and minimal maintenance.
The risk/cost of oil in the air supply
For many sectors of process and energy industries such as food and drink, pharmaceutical, electronics, textile manufacturing, as well as nuclear and offshore engineering, there is a need for pure process air without the additional costs, limitations, and risks related to in-line filtration systems.
Membrane air dryers fill a gap
Over the past few years pneumatic equipment and pneumatic dependent processes have become more sensitive to contaminants such as oil, water, and pipe scale. Thus, there is a growing requirement for better quality compressed air than most air pretreatment systems currently offer.
Automated controls improve compressor efficiency
To keep your plant running, you must provide electricity, chilled water, air handling, compressed air, heating, cooling, and perhaps other services to your production line. Without them, you can't make product, much less profit. In a basic economics course, these are referred to as "fixed costs." But nothing could be further from the truth.
Maintenance Tips and Tricks
Time-conserving, money-saving, aggravation-avoiding ideas for solving typical maintenance problems should be shared with others in the plant engineering profession. This idea-exchange concept serves as the basic philosophy for PLANT ENGINEERING magazine's 14th annual "Tips & Tricks" article.
Reader Forum – 2002-01-15
An air in judgment?Plant Engineering is a fine magazine and I've been reading it for years. One of my favorite sections has been "Simple Solutions" ...until the December issue.Once in the main magazine and once in the 'Special Supplement,' suggestions were made to use compressed air in a wasteful manner.
Simple Solutions – 2001-10-01
Sidebars: SAFETY FIRST Getting a long reach Problem: When a tool or part falls through grating into a deep pit or sump it is difficult to retrieve. Is there a way to get the item back without going into the pit? Solution: Make a "grabber." Jam one handle of a pair of pliers into a length of 1/2-in. thin wall conduit.
Reader Forum – 2001-08-01
Agitating action alert! I have a comment concerning the Simple Solution, "Agitating action," (PE, May 2001, p 12). Using air to mix a vessel has been around as long as I've been practicing, and that's 42 yr. If one follows the drawing shown, all you get is a single stream of air bubbles. With the holes in the top, the sparger fills with the fluid.
Customizing environmental control with unitary rooftop packages
This article describes the benefits of installing a tightly controlled unitary rooftop package HVAC system to control a plant environment. Key topics include how packaged units save installation costs, zone controls to improve indoor air quality, and simplified maintenance.
Reader Forum – 2001-07-01
Agitating action feedback While I agree that air agitation as described in "Agitating action" (Simple Solutions, PE, May 2001, p 12) is a good, effective means of agitating the contents of storage vessels, there are two points that should be noted. Do not use the plant compressed air system as the source of the air.
How to optimize an instrument air system
Short-term solutions to maintain compressed air source equipment and distribution piping can become long-term problems in your plant. Here are a few areas deserving attention to sustain the quality of compressed air systems for the actuation of control valves.
Simple Solutions – 2001-05-01
Agitating action Problem: Chemical or other types of storage vats often need continual agitation of the contents to prevent settling. Is there an easy, economical approach to this problem? Solution: Consider a sparger tube. Drill dozens of tiny holes along the length of the tubing, which has a capped end.
Recovery and reheat process simplifies compressed air drying
Key concepts Warm, dry air is critical to many manufacturing processes.
Using ultrasonics to locate compressed air leaks
Compressed air systems use $1.5 billion a year in electricity, according to recent U.S. Department of Energy statistics. That amount equals 1% of all U.S. power generation or all of the annual electricity consumption of the state of Connecticut.
Heating/cooling package has dual compressors
Predator packaged heating and cooling units are available in 6-1/2, 7-1/2, 8-1/2, 10, and 12-1/2-ton capacities. Several configurations are available: cooling only, cooling with electric heat, and cooling with gas heat.
Pneumatic air gun
Model 1400 pneumatic air gun uses standard shop compressed air to create a vacuum. The tool is static resistant, lightweight, and generates twice the average suction compared to typical shop vacuums. Guardair Corp. www.guardaircorp.
Compressor control reduces costs
Smart Sequencer MIC-4000 controls multiple compressor installations and maintains stable system pressure. It prevents simultaneous startup and loading of compressors, which reduces current spikes and offers considerable power savings.
Fill drums fast
Drum Devil II is a low-cost product with a two-way action to pick up liquids. It fills a 55-gal. drum in less than 2 min., and a simple turn of a knob empties it just as quickly. The unit has no moving parts and requires no maintenance.
Filtration products
Catalog discusses the process of filtering, drying, and conditioning compressed air.
Air filtration system
Air Fountain self-contained, portable air purifier eliminates chemical fumes and odors, tobacco smoke, and airborne contaminants. Ocean Air Filtration Systemswww.oceanairfiltration.com
Compressed air accessories
New FRL series of compressed air filters, regulators, lubricators, and manual control valves are designed to provide efficient moisture and contaminant removal, accurate pressure regulation, and precision lubrication. La-Man Corp. www.laman.
Air dryer
SMD membrane air dryer provides pure, dry compressed air and offers an efficient alternative to refrigerant dryer technology. The product dries compressed air to dew points as low as 35 F at flow rates up to 600 scfm. Balston/Whatman, Inc.
Supplied air purification
Supplied-Air Purification and Regulation Panel (SA PRP 200B) connects to standard shop compressed air systems to supply four welders with breathable air. The panel removes oils, particulates, and odors from the air supply. Hornell Speedglas, Inc.
Making good compressed air
The Principles of Air Compression video explains the theory for the compression of air. It shows how compressors operate and introduces key terms such as psig, scfm, relative humidity, and dew point.
Vent removes air in hydronic systems
Spirovent eliminates all free and entrained air and up to 99.6% of dissolved air in hydronic system fluids. The need for frequent bleeding, purging, and venting is eliminated along with air related system noises, such as gurgling and the waterfall effect.
Air knife resists corrosion
Super Air Knife offers an efficient way to dry, clean, or cool food, parts, webs, or conveyors. A uniform sheet of high velocity air across the entire length of the stainless steel knife pulls in surrounding room air.
Compressor control matches performance to demand
Sigma Control system matches the performance of the SK series of rotary screw air compressors to system demand. The Sigma profile airend produces up to 20% more air/hp. Units are available in 15 and 20-hp models with variable pressures from 100-190 psig.
Basic guide to fans and blowers
Fans are used throughout the industrial plant. They are found in an infinite number of components and used in a variety of systems from heating, ventilating, and air conditioning to industrial processes (Fig. 1).
Air dryers cycle to save energy
Secotec cycling, refrigerated compressed air dryers are designed to effectively match airflow to energy usage.
Air dryers reduce operating costs
A family of refrigerated compressed air dryers features high reliability resulting from an innovative, all stainless steel, CFX heat exchanger and modular layout and lower compressed air system operating cost due to low pressure drop of 3 psi or less and cycling operation. The environmentally friendly, conservatively sized system uses rugged components to operate under extreme temperatures and loads. Zeks Air Drier Corp.; www.zeks.com TO VOTE, WRITE 112 ON BALLOT For more information, circle 373 on card.
Packaged air compressors have optional cooling
GA90-160 series single-stage, oil-injected rotary screw air compressors include drive motor, oil system, air system, and an electronic regulation system. The compressors can be air or water cooled.
Air compressors save energy
GA 50-VSD Series oil injected, rotary screw compressors are completely enclosed to run at sound levels from 69-77 dBA.
Rental package installs outdoors
TSR-20 rental air compressor package is designed specifically for outdoor installations. It saves 11-13% in energy over single stage compressors and has a 5-yr warranty on the air end and variable speed drive system.
Compressor requires less maintenance
C950 centrifugal air compressor has an internal corrosion resistance system, which allows longer operating time at original design pressures and flows with less maintenance. A mounted aftercooler reduces installation time and cost.
Large capacity oil-free compressor resists corrosion
Sierra 250-400 hp large-capacity, rotary screw air compressor is designed to provide years of troublefree service. The rotor/housing coating resists corrosion, wear, and degradation.
Aftercoolers handle dirty coolant
Model SAR aftercoolers effectively cool compressed air when dirty or corrosive liquid coolant must be used. A removable tube bundle allows for ease of inspection, cleaning, and maintenance.
Rent-a-maintenance service
Free directory of service providers lists companies offering inspection, training, and other maintenance-related activities. Typical services are mechanical inspection, leak detection, electrical inspection, and compressed air, valve, and steam surveys.
Cycling air dryer provides efficient operation
Secotec cycling dryer controls provide maximum efficiency by operating the refrigerant compressor only when necessary by using a thermal mass medium for storage.
Estimating compressed air consumption
The proper design and operation of air compressors, receivers, and dryer-filter assemblies are critical.
Lamp kills air conditioning bacteria
UV-C ultraviolet germicidal lamp accessories for rooftop units, fan coils, air handlers, and vertical packaged air conditioners provide a centralized way to kill odor-causing molds, bacteria, and bioaerosols known to cause sick building syndrome and building related illness. The lamps are optimized for 40-50°F temperatures and high humidity found in air conditioning systems. Carrier Corp. www.carrier-commercial.com Circle 390.
Keep your air cool and save
Literature on EMD Series energy management dryers outlines how users realize significant energy savings under low flow conditions while avoiding the dew point variations of standard cycling dryers.
Magnetic drain saves air
AMD-6550 automatic magnetic drain discharges contaminated condensate but not compressed air. A large orifice drain valve eliminates clogging and maintenance repairs.
Noise solutions
New 8-p brochure explains how Prospec foams, barriers, and composites absorb and contain noise in industrial environments.
Treat compressed air right
Meeting Your Compressed Air Treatment Needs, an 8-p guide, clearly explains different types of dryers and filters, and discusses other key components, such as aftercoolers and traps.
Cycling air dryer saves energy
Secotec compressed air dryer cycling control maximizes efficiency by operating the refrigerant compressor only when necessary. This action is achieved by using a thermal mass medium for storage.
Addition to listing
The manufacturer's box in the cover article, "Wringing water out of compressed air" (PE, June 1999, p 64, File 4030/5540) should have included Atlas Copco Compressors, Inc. For information on the company's product lines, visit www.atlascopco.
Lubricants extend compressor life
Sigma compressor lubricants resist degradation while performing their job. Omega blower lubricants are nontoxic and compatible with other oils. Both products provide long life to reduce the frequency of oil changes.
Refrigerated air dryer eases maintenance
KRD Series compressed air dryers includes a filtered separator and automatic, no-loss drain trap. All maintenance items are easily accessible. Capacities range from 5-3000 scfm with a maximum working pressure of 200 psig.
Compressor enclosures cut noise levels
DS Series rotary screw air compressors come with sound enclosures that reduce noise levels to as low as 69 dBA. Features include NEMA 4 instrument panel, EPAct compliant TEFC motor, and Sigma Control System. Kaeser Compressors www.kaeser.
Cooler handles small electrical enclosures
Vortex Kooler uses compressed air to cool electrical enclosures, particularly small and medium sizes where heat loads are below 2500 Btu/hr.
Vacuum package reduces energy usage
Rotary screw vacuum packages are available in six models from 10-40 hp with capacities from 168-555 cfm. Switchable modulation/dual control offers maximum flexibility and efficiency to meet changing demands or applications.
Passive cooling brings economic and environmental benefits
Before the turn of this century, buildings were designed to exploit naturally available cooling.
Steam turbine serves several applications
PYR single-stage steam turbine has ratings up to 200 hp/150 kW, speeds up to 5000 rpm, input steam pressures up to 600 psig, and temperatures up to 752 F. The turbine is used to drive fans, pumps, generators, and compressors. Elliott Co.
Correction – 1999-03-01
The dates for "Fundamentals of Compressed Air Systems" were listed incorrectly in our January issue (p 76, Circle 251). The correct dates are Chicago, Feb. 18; Las Vegas, Feb. 22; Dallas, March 1; Newark, March 8; and Atlanta, March 15.
Guide to air compressors
Getting the Most for Your Money provides a step-by-step approach for selecting and protecting your air compressor investment. The 8-p guide covers types of compressors, evaluating systems, and maintenance and troubleshooting tips.
Amplifier vents air quietly
Super Air Amplifiers offer a low-cost way to move air, smoke, fumes, and light materials. Units minimize compressed air consumption and noise while producing high volume outlet airflows up to 250 mph. There are no impellers or moving parts to wear out.
Is your compressed air system all wet?
Is your compressed air all wet? If you answered yes, you are not alone. Moisture, either liquid or vapor, is present in compressed air as it exits the system.
Pressure booster saves compressors
Pressure booster satisfies higher requirements of specific workstations while allowing the main compressed air system to operate at the lowest optimal delivery pressure. Benefits include energy savings, improved product quality, and less downtime.
Aftercoolers deliver high heat transfer rates
Water-cooled aftercoolers ranging from 40-2800 scfm use copper heat exchangers to provide high transfer rates and lower compressed air to within 15 deg F of the cooling water temperature. Smooth surface tubes minimize fouling and pressure drop.
Get good compressed air
Extractor/dryer system filters, dries, and conditions compressed air. Capacities range from 15-2000 scfm and dewpoints from 10-35 F. The units are modular for easy installation, maintenance, and expandability to four stages for additional filtration.
Blower offers high efficiency and low noise
Omega blowers for continuous service are available in gear diameters from 2 1/2-8 in. with flows from 30-4000 icfm at pressures to 15 psig or vacuums to 15-in. Hg. The units are suited for pneumatic conveying, aeration, and soil remediation.
Welder helmet supplies filtered air
Fresh-air II G9000 air-purifying respirator blows a cooling supply of filtered air over a welder's face, creating a positive atmosphere within the helmet's face seal that helps keep out harmful particulates, fumes, and vapors.
TPM awards
At the annual JIPM-TPM Conference last month in Atlanta, four American plants distinguished themselves by being the first from this country to win the "TPM Excellence" award for plants having over 500 employees.
Air distribution nozzle
AirDirect Nozzle for spot cooling, heating, or ventilating personnel, equipment, or processes is explained in a 4-p brochure. The literature includes airflow adjustment information, performance data, dimensional tables, and color photographs.
Compressor lubricant extends system life
Sigma compressor lubricants reduce the frequency of oil changes and are easily separated from condensate, minimizing disposal and maintenance costs.
Prepare compressed air proposals
A software program was developed exclusively for product sizing, selection, presentations, proposals, budgeting, planning, and training of compressed air equipment.
Air compressor has 100% duty cycle
SSR 50-100 hp rotary screw air compressor provides pulsation-free air 24 hr/day. Microprocessor control has load/unload and automatic start/stop capabilities.
Portable compressor reduces size and weight
XAS 96JD portable air compressor is compact, lightweight, and features an airend that has high efficiency. A water-cooled diesel engine has a two-stage, cartridge intake filter with replacement indicator. An extraction system reduces oil consumption.
Electric drive minimizes space, maximizes efficiency
LiquiFlo ac drive uses the cooling medium from HVAC equipment such as chillers and compressors to cool with liquid instead of air. This approach reduces the size of horsepower drives by 70% and provides for greater power density at reduced cost.
Compressor control saves energy, maintenance
Sigma-Control uses reliable PC components to match compressor performance to demand and save energy. Monitoring and storage of events enhance preventive maintenance.
Rotary vacuum uses oversize intake filter
Rotary screw vacuum packages are available in six models from 10-40 hp with capacities from 168-555 cfm.
Wrapping rubber
Problem: The metal fitting at the point of attachment between air-operated tools and the compressed air piping system often cuts the rubber hose, leading to countless, expensive leaks.
Booster raises compressed air pressure
N series booster compressors increase air pressure to as high as 580 psig. The compressors include a TEFC motor, motor starter, aftercooler, prefilter, and anti-vibration pads. The units are piped and wired, ready for installation. Kaeser Compressors www.
Oilless air compressors have long ring life
PureAir and PureAir II series of oil-less air compressors are available in many configurations, including multiple packages that meet NFPA99 guidelines. The line ranges from 5-15 hp and features a totally dry crankcase.
Synchronizing compressors
Problem: Summer workloads may cause the main air compressor to overheat. How can you synchronize the backup with the main machine? Solution: Hook up a repeat cycle timing relay with an on/off switch to the backup compressor and adjust.
Bar code label printer not sensitive to air pressure changes
Cimjet 331 printer/applicator applies labels as small as 1 sq in. to the top or side of a product using an air box applicator.
Managing multiple sites with a single BAS
As technological advances add features and enhance performance of plant BASs, systems are being harnessed for wider application.
Dryer provides instant response using thermal mass
Eco-smart cycling compressed air refrigerated dryer is suitable for use with any compressor type, including oil-flooded. A pressure dewpoint of 37 F at 100 psig is possible, which is equivalent to -6 F at atmospheric pressure.
Compressed air dryer doesn’t use energy
MicroGen dryer combines the desiccant regeneration theory of compressed air drying with the efficiency of microwave technology. Microwave energy strips moisture from activated alumina desiccant to produce dewpoints as low as -60 F.
System removes condensate automatically
Condensate Management System, with six stages of separation, automatically separates oil from condensate and allows it to be discharged directly into sanitary drains. Models are available in six sizes.
Compressed air treatment
A 4-p brochure presents compressed air treatment equipment, including refrigerated, regenerative, and single tower dryers; filters; automatic drains; aftercoolers; desiccants; and oil/water separators.
Customize compressors
A catalog covers a variety of air compressor models and accessory components. If a product is not in the catalog, it can be built to customer specifications.
Multiple compressor control reduces power costs
Smart Sequencer MIC-4000 controls multiple compressor installations and maintains stable system pressure. The unit prevents simultaneous startup and loading of compressors, reducing current spikes and saving power costs.
Level-sensing drain removes air condensate
A level-sensing drain that removes condensate from compressed air systems offers constant self-monitoring to ensure reliability and a potential-free contact that makes it possible to relay fault signals to a control center. No maintenance is required.
Switching to synthetics
Literature on synthetic compressor oils and heavy-duty gear oils includes information on oil analysis benefits and a worksheet to calculate synthetic cost savings.
Blower package offers high efficiency, low noise
Omega-paK blower package and optional sound enclosure ensures smooth running and personnel safety. Blowers are available in flows up to 3300 cfm and pressures up to 15 psi.
Controller reduces compressor energy cost
Flow controller separates the supply side -- compressors, dryers, and filters -- from the distribution system. The product creates storage within the receiver tanks and delivers needed flow at a constant system pressure.
Air filter extends service intervals
M73 Microglass air cleaner provides ambient capture, or can be ducted for source capture applications. Extended service life is accomplished through a large filter media surface area of 400 sq ft.
Fixing fluid products?
New service offers a broad range of maintenance-related activities worldwide to users of fluid handling products. Equipment handled includes pumps, control valves, turbines, regulators, mechanical seals, actuators, compressors, and mixers.
Postcards from the show
Dear Bud, Wow! You missed a rocking Show in Chicago! Remember when I told you I was going to McCormick Place March 16-19 for the National Plant Engineering and Management Show? Well, this was definitely the place to be! Excellent exhibits, conferences, and demonstrations of all the products and services affecting the plant engineering function were available in this one spot. I joined nearly 24,000 other plant engineering and management professionals in walking countless miles checking out about 800 exhibitors. Let me tell you, my tired feet and legs were a small price to pay for what I learned. I'm sending along some postcards of a few of the booths, speakers, and activities so that you can see what you missed. You should start planning now to be at the next NPEM Show. Write down these dates: March 15-18, 1999, so you can be there next year! Lou Nearly 350 people attended a black-tie reception at Chicago's Ritz-Carlton Hotel to honor the winners in Plant Engineering magazine's 10th annual Product of the Year contest.
How to handle air
1998 Air Handling Systems Catalog helps those involved in HVAC, dust, fume, and pollution control, and many other industrial applications.
Oil mist eliminator provides ultra clean air
Oil mist eliminator removes 99.98% of particles 0.1 micron and larger and reduces liquid content to 0.5 ppm by weight in compressed air systems. Pressure drop is between 0.5-1 psi, while average cartridge life is 8-15 yr. Kaeser Compressors
Air doors
A 24-p catalog portrays a full line of air doors, including light, medium, heavy, and extra heavy industrial models.
Air handling components
An air handling systems catalog details components for dust, fume, and pollution control; HVAC; and other industrial applications. The 32-p publication contains thousands of fittings, spiral pipe, and flexible hose selections. Air Handling Systems www.
Selecting Quick-Connect Couplings For Compressed Air Service
Most manufacturing plants using compressed air apply quick-connect couplings. Proper selection and sizing of these inexpensive, ubiquitous devices are usually not given the consideration they deserve.
System improves air compressor performance
Sarlin Balance compressed air management system improves performance and reduces costs by controlling multiple compressors as if they were one. Sensors monitor output pressure at the compressors and within the piping network.
Blower handles high airflows
Omega 82, positive displacement, lobe blower features an 8-in. nominal gear diameter with 10-in. diameter flanged inlet and outlet ports to provide airflow rates up to 3050 icfm at 15-psig pressure or 15-in. Hg vacuum.
Compressor provides variable pressure
M12 portable rotary screw compressor delivers variable pressures from 70 to 190 psig, with output rated at 43 cfm at 100 psig. Features include the power-saving SIGMA profile airend and air-cooled oil cooler with fan. Kaeser Compressors
