Section 1:  Compressed Air Your Most Expensive Utility

The first section of the book gives you a summary of the main types of compressors (reciprocating, rotary screw, centrifugal).  It also introduces how to calculate the cost of your compressed air, and the topic of how to recover energy expenses.

Review of Cost of Compressed Air
Air Energy Cost vs Electric Energy Cost
Computing Energy Cost per CFM and per PSIG
Computing Energy Cost for a Compressor
Basic Terminology
Positive Displacement Compressors
            Reciprocating
            Oil Cooled Screw & Vane
            Single Screw
            Water Jacket - Rotary Vane
            Non-Lube Screw and Lube
Dynamic Compressors
            Centrifugal
            Axial Flow
Compressor Capacity Controls
Comparing Advertising Claims to the Real World

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Section 2:  Compressed Air Drying

This section provides the facts about dew point, and the sources of moisture.  You will find information on the different types of compressed air dryers including tips on how to select the most cost effective dryer for your application.

Definition of Air Quality
ISO 8573.1 Quality Classes
Where the Water Comes From
Dew Point
Introduction to Compressed Air Drying
Deliquescent Dryers
Refrigerated Dryers
Desiccant Dryers
Membrane Dryers
Desiccant Dryer Types
Limitations

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Section 3:  Supply Side Air Treatment

The various filters in a compressed air system are discussed in this section.  The type of filtration has an impact on the amount of energy wasted before the compressed air makes it to the process.

Overview of Dryer Pre and After Filters
Filter Selection and Pressure Drop
Categorizing Contaminants
ISO Quality Classes
Oil Contamination
Water Contamination
Particulate
Coalescing Filters
Installation and Selection of Air Dryer Filters
Point of Use Filters
Proper Use and Selection of Air Line Lubricators

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Section 4:  Condensate Drains

This section describes the pros and cons of the different types of drains on the market.  It also describes some of the common installation mistakes discovered during air audits. 

Overview of All Types
Case Studies of Air Saving Opportunities
Avoid Air Lock with No Loss Drains
Cost of Dual Timer Drains Compared to No Loss Drains

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Section 5:  Demand Side Distribution

The proper design and installation of the air piping system can lower the annual energy cost of a facility.  It can also reduce the maintenance of the system when done right.  This section gives the details on air piping system.

Establishing the Air Demand (CFM)
Establishing a Proper Pressure Profile
Sizing Piping and Drain Lines
Sizing Interconnecting Pipe by Velocity
Pressure Drop Charts
Case Study:  Turbulence with Small Pipe
Piping Materials

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Section 6:  Practical Use of Storage

This section explains how to avoid wasting energy, and creating problems, when storing compressed air. 

Supply and Demand Side Receiver Selection and Sizing
Control and Regulation Support
Flow Rates
Demand Side Control
Case Study:  Improper Demand Side Control
Case Study:  Storage for Changing Demand
Other Uses of Stored Air
Receiver Tank Connections

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Section 7:  Other Common Air System Operations That Create Opportunities

This section uses case studies to illustrate how to avoid problems, and how to lower your energy costs. 

Case Study:  Too Small Pipe
Case Study:  Dead Head Piping
Case Study:  2 Step Control Short Cycling
Case Study:  Crossing Tee Connection
Case Study:  Demand Side Control System
Case Study:  Can’t Hold Pressure
Case Study:  Reciprocating Unloading Problem
Case Study:  Poor Piping Affects Centrifugal
Case Study:  Centrifugal and Reciprocating Running Together
Case Study:  Inlet Piping Too Long
Case Study:  Leaks and Chokes in Abandoned Piping
Case Study:  Sizing Pipe According to Opening Size of Air Equipment
Heat Recovery, Air Cooled
Heat Recovery, Water Cooled
Converting BTU Recovery to Annual Energy Savings
High Efficiency Motors

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Section 8:  Compressed Air Savings Opportunities in the Air Using Side

This section provides the true energy cost of using compressed air instead of alternative utilities. 

Open Blow, High Pressure Air
Venturi Amplifier, Explanation and Installation
High Pressure Air used Instead of Low Pressure
Types of Blowers, CFM to HP Performance
Agitation and Aeration
Air Volume Movement
Pneumatic Conveying
Air Operated Diaphragm Pumps
Air Motors
Compressed Air Leak Control

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Section 9:  Flow Measurement

It is helpful to know the air flow in CFM to trouble shoot a problem or to determine if more compressors are needed in a plant.  However, there are many instances each year when decisions are made based on incorrect or misinterpreted data taken from flow meters.  This section provides details on the operation of the main types of flow meters. 

Field Measuring Compressed Air Flow
Flow Reading Charts
Differentials
What is the V Cone?
Inline Flow Meters?
Vortex Shedding
Thermal Mass Flow
Commercial Flow Sensor

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Section 10:  Ask The Experts

This chapter covers some of the most interesting questions received by the author.  The questions illustrate how often customers are given poor information from vendors in the compressor industry.  And, the answers provide insight on a variety of topics.

Constant Speed Compressors and Variable Speed Drive
Oversized Air Receiver and Flow Controller
Full Voltage Starting
Modulation Controlled Lubricant Cooled Rotary Screw Compressors
Lowering Discharge Pressure to Save Energy
Amperage Measurement to Estimate Air Flow
Centrifugal Compressor Inlet Guide Vanes
Reciprocating Foundation
Inlet and Discharge Piping Material Selection
Condensate Levels in Winter and Summer

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Section 11:  Terminology & Technical Support

The final section gives you a summary of terms and more than 30 charts on issues relating to compressed air.  This information is a resource that can be referred to for years to come.

Terminology, Definitions, Rules of Thumb, Helpful Formulas
            Conversion Factors
            Conversion Chart - Inches/Decimal/Metric
            Terminology, General Terms
Useful Formulas
            What is CFM, ICFM, ACFM, SCFM
Rules of “Thumb”
            Water Cooled Aftercooler
            Compressor Discharge Temperature
            Horsepower to Pressure - Horsepower to Power Cost
            Electrical - Horsepower to Amperage
            Heat Rejection
            Ventilation Required
            Horsepower per CFM per Pressure Reading
            Piston Speed
            Apply 60 Hz Motor to 50 Hz Applications
            Time, Capacity to Draw Vacuum
            Install Compressor - Intake to Coolest Location, Effect on Efficiency of
                       Dirty Intake Filter
            Cylinder Clearance and Compression Ratios Effect on Volumetric
                       Efficiency - Reciprocating Compressors
            Oil Carryover
            Centigrade to Fahrenheit Conversion Table
            Air Cylinder Chart
            Single Phase and 3 Phase Electric Motor - HP to Volts to Amps
            Miscellaneous Electrical Formulas (Shaft BHP to Input Kw)
            Vertical Air Receiver
            Storage Volume of Piping
            Electrical Energy Cost per CFM, per PSIG
            Weight of Dry Air
            Barometric Pressure vs. Altitude
            Water Content of Air
            Dew Point at Pressure
            Calculating Velocity of Compressed Air in Pipe
            Discharge Air Through Orifice Table
            Air Flow Table
            Flow of Air Through Orifices Under Vacuum
            Pressure and Vacuum Equivalents
Conversion Factors
Decimal and Metric Equivalents - fractions of an inch

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