|
The book covers common sense techniques for effective and efficient operation of air operated equipment that can be found in most industrial plants. These ideas and procedures were developed by knowledgeable plant personnel, over the course of many years. The author has combined these ideas with photos, drawings and charts to provide you with an excellent resource for solving problems and making improvements. Free SampleYou can evaluate the quality of the information in this book, by reviewing a free sample. The first step is to pick 1 of the 34 chapters from the table of contents listing below. Then, simply send an email to redbook@compressorwise.com with the chapter you want to read. We will send you a pdf file of the chapter
you choose, and you will see why everyone involved with air operated
equipment should have this book. Table of ContentsThere are many subjects covered in this
book. They have been organized into sections to make it enjoyable to read
and easy to use for future reference. I. Compressed Air Supply Chapter 1: What Type of Industrial Air Compressor Should I Use? Basic guidelines relevant to selecting an
industrial air compressor. Considerations as to type of unit with regard to
capacity (cfm); pressure (psig); cooling medium (air or water); duty cycle
(impact of full load operation on the hourly cost of maintenance); and
quality of air (lubricated or oil-free). Chapter 2: Centrifugal Compressors. They Aren't Built Like the Old Days. They are a lot Better! Comparing the significant improvements in
basic centrifugal compressor design and performance that has taken place
from the 1970's through 2008. There is significant improvement in
performance and flexibility between current units and the units prior to the
year 2000. These improvements usually offer better specific power with
increased turndown. This article also reviews the net economic effect of
modern capacity control syntax and new magnetic bearing designed units. Chapter 3: Guidelines to Evaluate a 2-Stage Lubricant-Free Rotary Screw or Multi-Stage Centrifugal for a Specific Application A review of the basic operating parameters, design criteria, and efficiency performance of both these type of compressors as applied in the 200-hp / 1000 cfm to 900-hp / 3500 cfm range. Both of these types of compressors are excellent products, and, when well applied and maintained, will serve the use well. To develop this baseline data, we used the basic performance manufacturer's data from 200-hp to 800-hp or 900-hp covering nine manufacturers, some of which offer both types. The summation of this data, along with the basic operating differences between a positive displacement and dynamic compressor (mass flow), create some very interesting situations. Particularly with regard to the effect of inlet air conditions on both, and the basic turndown range and capabilities of both. The basic conclusion is, one is not "better" than the other, but certainly one may fit a given set of conditions better than the other. Chapter 4: Starting Air for Centrifugal Compressors Many centrifugal compressors require a
compressed air source to startup whenever there is a total shutdown. This
article reviews what the most acceptable sources are for this air. Which
types of units need starting air? How to size the proper air supply when
this is a question. Chapter 5: Selecting a Variable Speed Drive (VSD) Rotary Screw Compressor. A complete look at the net economic effect
from operating a variable speed drive on lubricant cooled and oil-free
rotary screw compressors. Includes lubricant cooled rotary vane compressors. Chapter 6: Selecting a Compressed Air Central Air Management System A review of the basic operating parameters of
a multiple air compressor central control system. Looks at the operation of
lubricant cooled and oil-free rotary screws, reciprocating compressors and
centrifugals. High pressure loss between the compressors discharge and
system entry, i.e., loss of effective storage are highlighted. Guideline of
questions to ask to determine if the central air management system being
reviewed fit the target air system. Chapter 7: PET Plants Using Boosters for High Pressure Air A look at the two basic installation scenarios for boosters used in PET bottling plants. Dedicated booster and primary low pressure compressor team or boosters pulling from a common low pressure collection storage headers. Also shows an electric energy economic analysis for high pressure blow molding compared to some 3-stage and 4-stage reciprocating compressors and 4-stage centrifugals. Reviews typical recommended booster installation guidelines. II. Compressed Air Treatment and Distribution Chapter 8: Overview of Basic Compressed Air Dryers: Part 1 – General Guidelines Many dryers are selected and applied without
knowing what levels of air treatment are required. Review identifies some
basic contaminants, discusses atmospheric and pressure dewpoint, the effect
of temperature and air pressure, and general guidelines to identify a
specific requirement for air treatment. Chapter 9: Overview of Basic Compressed Air Dryers: Part 2 – Basic Deliquescent (Chemical) and Refrigerated Air Dryers Review looks at the basic types and
application of deliquescent and refrigerated dryers including non-cycling
and heat sink type cycling. Evaluates basic heat sink material. A practical
application guide for dryers, filters, etc. Contains comparative annual
electrical energy cost of operation chart. Chapter 10: Overview of Basic Compressed Air Dryers: Part 3 – Desiccant and Membrane Dryers Review looks at the basic types and application of regenerative desiccant dryers including single tower, heatless, internal heat, external heat, blower purge and heat of compression. Contains comparative annual electrical energy cost of operation chart. Review looks at application and appropriate use of deliquescent, membrane and split stream heat of compression dryers. Chapter 11: Overview of Basic Compressed
Air Dryers: Part 4 – Primary Main Review covers all types of main line filters
– particulate, coalescing, combination particulate/coalescing, pleated
coalescing, loose packed, deep bed type, and carbon. Covers installation
type, piping guidelines, etc. Chapter 12: Compressed Air Drying in Hot Ambient (over 100˚F) with Air-Cooled Equipment Recommended procedures to offset the higher
inlet compressed air temperature to the dryer in high ambient location with
air-cooled equipment. Reviews use of oversized refrigerated dryers and the
operational expectations of non-cycling and heat sink type full cycling
dryers. Correctly selected and installed operating heat sink type
refrigerated dryers can remove about 88% of the water vapor in the air even
when the saturated entry temperature is 120˚F. Chapter 13: Loose Packed, Deep Bed Filters Before and After a Refrigerated and Desiccant Dryer Reviews the performance and lowest total operating cost of the special high performance long life (10 years) low pressure loss (<1-3 psid total) loose packed, deep bed coalescing particulate filter or "mist eliminator". Proper use will reduce pressure loss and increase effective storage. Expands dryer filtration requirement guidelines to include modern rotating compressors and to optimize modern filter technology. Chapter 14: Measuring Pressure Dewpoint in a Compressed Air System A close look at modern pressure dewpoint
controllers; particularly the different types of sensing hardware. There
have been significant improvements in this technology over the last decade.
Today, they are very reliable and predictable compared to older equipment.
This article also provides recommended applications, selection, and
installation guidelines. Chapter 15: Compressed Air Condensate and Automatic Condensate Drains This chapter reviews the general regulations regarding the proper handling and disposal of compressed air condensate. It also looks at representative costs of various methods. Current "best available technology" for condensate water and oil separation is reviewed in detail along with basic operating procedures and limitations. Chapter also includes a review of all types
of automatic condensate drains and their importance in establishing an
acceptable compressed air supply with regard to adequately dry air. The
article looks at mechanical, dual timer electric, and level activated
electric or pneumatic actuated. Identifies expected levels of condensate for
proper automatic drains selection and general installation guidelines. III. Compressed Air Supply to Users Chapter 16: Compressed Air Piping Review types of piping – acceptable and
non-acceptable – compared thermoplastic to various types of metal piping –
threaded, compression and Victaulic connections. Specific guidelines by type
of compressor and use of pipe (inlet or discharge), interconnecting and
distribution piping, sizing, configuration, loop system, and common errors.
The effect of high velocity and poor configuration. Chapter 17: The Art of Using Storage Effectively A complete review of compressed air storage
and the relationship of volume to pressure. Explains flow rate versus rate
of flow; "pump up or decay" calculations; effective storage for compressor
control, used to supply a timely compressor response; and general
installation piping guidelines. Storage buys time for peak demand without
increasing supply. Chapter 18: Design and Implement a Demand Side Control System A complete review of the benefits and design considerations utilizing a full demand side control system to stabilize system pressure; establish effective storage to convert high, short duration flow rate to a lower average flow rate. Article covers the effect of eliminating artificial demand, receiver sizing, regulator flow controller sizing, and piping selection and design. IV. Compressed Air Uses Chapter 19: Applying Air Hose and Quick Disconnects for Optimum Performance Explores the effect of too low pressure at
the work site; the expected losses of too small air hoses and quick
disconnects. Methods to troubleshoot and correct problem areas. Chapter 20: Compressed Air Line Lubricators / Oilers Complete guidelines for compressed line
lubricators: type of lubricator, sizing the lubricator, various types of
lubricators and their optimum application. Proper location, piping, effect
of compressed air velocity, etc. Chapter 21: Control Cabinet Cooling A complete review of all types of cabinet cooling. Identifies proper application and selection of each type of their projected net economic impact. Guidelines to determine the need or not for auxiliary cabinet cooling. Chapter 22: Air Operated Double Diaphragm Pumps (AODD) Establishing the annual electric energy cost
of operating air operated pumps. Methods to control this, both old and new
technology. Air versus electric operating cost versus modern electronic
based control systems Chapter 23: Supplying Pulse Jet Compressed Air for Dust Collectors Effectively and Efficiently A review of dust collector operation, sizing
of piping, storage, various types of modern electronic controls and this
effect on air usage, annual electrical energy operating cost, bag life, etc. Chapter 24: Material Conveying with Pneumatic and Vacuum Systems A look at the operating parameters of dilute phase, dense phase and vacuum material conveying systems. Calculating the optimum annual electric energy operating cost for each. Modernizing and troubleshooting older out of adjustment systems. A case study with appropriate data and calculations. Chapter 25: Blowing Tubes and Hoses Clean with Compressed Air Sizing proper flows for cleaning tubes and
hoses effectively with compressed air. Volume (cfm) and pressure (psig)
selection depending on the cleaning process. Compare annual electrical
energy operating cost with compressors, air amplifiers, blowers, and pushing
a "pig". Chapter 26: Boiler Soot Blowing Guidelines to apply and size compressed air
and/or steam for soot blowing. Review the advantages and disadvantages of
each method. Optimizing the high pressure (300-400 psig) compressed air for
soot blowing with the normal low pressure (90-125 psig) plant control air
uses. Case study shows economics of an effective review. Chapter 27: Applying and Utilizing Blow Air in Production Many plants use high pressure air as "blow
off" air to remove cleaning agents, waters, debris, etc. It is also often
used to move products on a conveyor line and remove rejected pieces. This
review looks at many energy savings opportunities in lieu of using straight
high pressure including controlled dispersion nozzles; venture amplification
nozzles; and the effect of inlet pressure on flow. It also reviews use of
"blower air" and electric eye automatic shut off. Chapter 28: Using and Applying Air Motor Driven Mixers Air motor driven mixers use almost eight times the electrical energy (kWh) than a comparable electric motor driven unit. Review identifies these parameters and calculates the relative operating cost of each type. Chapter 29: Liquid Driven Venturi Agitation System Instead of Compressed Air at a Lower Energy Cost Agitation of many large volumes of product is
often accomplished with high pressure compressed air reduced to low pressure
or even blower supplied air at a lower cost. The most economical method to
do this when an electric driven propeller is not appropriate will be a
liquid venture amplifier. Review addresses all types – application and the
relative electrical energy operating costs. Chapter 30: Utilizing Venturi Vacuum Generators Effectively and Efficiently Vacuum generators are very convenient and
very responsive, but may be less efficient as applied to larger positive
displacement pumps (e.g., larger rotary screw, vane, or reciprocating
pumps), which may be the better choice when conditions require large flow,
and allow potentially slower response time. The review looks at proper
application and control and offers significant examples with calculations of
energy costs to compare various vacuum options. Chapter 31: Using Venturi Air Driven Air Movers or Air Horns In many industries, compressed air venture driven air horns, air movers or ventilators are used to handle "short term" situations. Their significant flexibility and portability combined with safe operation in volatile environments makes them an excellent choice. When the operating hours are more significant, electric driven models offer great savings. This review outlines operating procedures and offers methods to identify electric driven energy savings. Chapter 32: PET High Pressure Air – High Pressure Air Recovery from the Blow Molder Units The new high pressure air recovery system for
PET blow molders is reviewed in detail. This system, when applied, captures
exhaust high pressure air (350-600 psig) from the blow mold machine and
re-circulates it to the low pressure system to be used thus reducing the low
pressure air demand on the air supply. Chapter 33: Achieving Air Cylinder Compressed Air Savings Opportunities Air Cylinders are a significant use of
continuing air demand in many plants, particularly those with packaging
lines. There is a detailed look at the effects of too high a pressure to the
cylinder and proper regulated control. The NEW return air recovery system is
reviewed in detail which can reduce the air demand by 50% or more and often
increase cycle time. Chapter 34: Heat of Compression Recovery and Converting to Energy Savings Installation of a lubricant-cooled rotary compressor will allow potential recovery of 85-90% of the motor horsepower in the form of heated air or water, depending on the type of oil/after coolers. Reciprocating and centrifugal compressors will discharge heated cooling water at a maximum temperature at 130˚F and allow similar heat recovery in the form of heated water. If the heated air (or water) from the compressor can be used to offset another source of energy used to heat (e.g., space heaters in the winter, heating process water, heating boiler make up water, etc.), the savings can be calculated based on the current cost of alternative heat sources. Review addresses concept basic heat recovery method and process for and calculating payback. About the AuthorThis book is published by the author, Hank Van Ormer, who also wrote the majority of the articles. Mr. Van Ormer has been associated with the Compressed Air and Gas Business and its allied industries for almost 40 years. While attending Gettysburg College he worked summers in the research and development department of a rotary and reciprocating compressor manufacturer. After graduation in 1959, he began full time work with them and handled various areas of Industrial and Construction Equipment product development, marketing and sales. Over the years, he has worked with several leading manufacturers in similar areas with particular emphasis on rotary and centrifugal compressors. In 1986, Mr. Van Ormer started his own independent consultant company, Air Power USA, Inc. which specializes in Air Compressors, Compressed Air Equipment and Compressed Air Systems for the industrial and construction markets. Mr. Van Ormer has developed several accredited training courses for continuing education and complete curriculum or technical colleges. Air Power USA offers complete plant surveys and problem solving analysis of compressed air systems including energy management studies. The last several years, Mr. Van Ormer has been very active in the Department of Energy “Compressed Air Challenge Program”. As a charter member of the Compressed Air Efficiency council, he worked with the basic program development and was a member of the Training Committee. In December of 1998, Mr. Van Ormer was selected as one of “Twelve Core Trainers” from applicants all over the United States.
Free Newsletter
Subscribe today! Just fill in the following and click the submit button.
You can unsubscribe at any time, but fewer than a dozen subscribers have
done so since 1999. Also, we respect your privacy and will keep your
subscription data confidential. “Common Sense Answers” can help you save money, and get better performance from your air operated equipment. This 230 page book was assembled to share ideas that have been proven in industrial plants across the country. The text is easy to understand with charts, graphs and photos that illustrate the topics. It is a hardcover book with 8-1/2” x 11” size pages. The book is $85.00 US with Free Shipping. Order today and start benefiting from this resource. Ordering with a Credit Card
Orders are accepted and shipped to customers anywhere in the United States of America. Ordering is easy and secure on this website. All major credit cards are accepted and processed by our authorized online retailer, CCNow – which is a Delaware, USA financial corporation – on a secure server. We do not see your credit card number and your account will not be charged until your order is shipped.
Thank You We appreciate your order because book sales help us cover the cost of our free services. We know that you will be pleased with the savings ideas and valuable resource information contained in the book. If for any reason you are not satisfied, we will refund your money if the book is returned within 30 days in saleable condition. Send us an e-mail to redbook@compressorwise.com if you have any questions or comments about this book. ©Copyright and All Rights Reserved. No
information located at
http://CompressorWise.com may be copied or reproduced, in whole or
in part, without prior written consent. Contact
Webmaster@CompressorWise.com
for more information.
|
|
