CABP_2016_08August_LR

The Magazine for ENERGY EFFICIENCY in Compressed Air Systems
Measurement
August2016
36AUTOM
AKER
PROTON
SAVES
ENERGY
12 Managing Pressure Regulator Artificial
Demand, Part 1
18 The Importance of Bi-directional
Compressed Air Flow Measurement
24 Assessing the Impact of Compressed Air
Quality on Food Products

COMPRESSED AIR WITH
A VAST PORTFOLIO
Powering You With
Extraordinary Solutions
Whether the compressed air you need is for machining,
fabrication, material handling or ﬁnishing, we can help you
save money while increasing your productivity.That’s a promise.
www.atlascopco.us – 866-688-9611

30
18
36
COLUMNS
4 From the Editor
6 Industry News
44 Resources for Energy Engineers
Technology Picks
47 Advertiser Index
49 The Marketplace
Jobs and Technology
12 Managing Pressure Regulator Artificial Demand, Part 1
By Murray Nottle, Working Air System Engineer, The Carnot Group
18 The Importance of Bi-directional Compressed
Air Flow Measurement
By Pascal van Putten, VP Instruments
24 Assessing the Impact of Compressed Air
Quality on Food Products
By Dick Smith, Trace Analytics
30 SparksDynamicsOptimizesNISTCompressedAirSystem
By Mac Mottley, Sparks Dynamics
36 Automaker PROTON Attacks Compressed Air Waste
By Abdul Azeem bin Mohamed Mohideen, PROTON
Edited by Ron Marshall, Compressed Air Challenge®
SUSTAINABLE MANUFACTURING FEATURES
Cover photo provided courtesy of VP Instruments.
3airbestpractices.com
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We dedicate one issue per year to this important topic as demand for compressed
air system measurement continues to grow. Plants want to measure the kWh
consumption of the air compressors. They now want to “audit” their compressed
air system all year, by owning tools to measure compressed air leaks and by
installing compressed air flow meters, pressure gauges and other instruments
able to measure quality metrics like pressure dewpoint and oil content.
We have received an exciting compressed air system optimization case study all the way
from Malaysia’s automaker PROTON. Taking measurements was their first step and identified
compressed air as their third largest Significant Energy User (SEU). With a production capacity
of 150,000 cars per year, their Electrical Energy Manager describes the process and actions
taken to reduce compressed air consumption by 31 percent and generate saving of 3.8 million
kWh equaling $255,000 per year.
Bi-directional flow is a little-understood topic presenting a challenge to accurate compressed
air flow metering. VP Instruments CEO, Pascal van Putten, provides us with two very interesting
case studies, where they encountered bi-directional flow, and details how they were able to
nevertheless provide accurate information.
Pressure regulators are installed on most pieces of production equipment. They often are part
of a FRL (filter-regulator-lubricator) package installed to assist the pneumatic circuits. In the first
installment of a two-part article, Murray Nottle, from The Carnot Group in Australia, writes about
how regulators can be “big wasters” of compressed air. The primary waste issue he describes is
artificial demand – regulators forcing the compressed air system to operate at higher pressures
than necessary.
Measuring compressed air quality is critical in the food industry. Trace Analytics Technical
Director, Dick Smith writes, “Being aware of the composition of compressed air used in your
plant is key to avoiding product contamination. Your task is to assess the activities and operations
that can harm a product, the extent to which a product can be harmed, and how likely it is that
product harm will occur.” Readers will find this article worth filing.
Thank you for investing your time and efforts into Compressed Air Best Practices®
.
ROD SMITH
Editor
tel: 412-980-9901, rod@airbestpractices.com
FROM THE EDITORFROM THE EDITOR Compressed Air Measurement
COMPRESSED AIR BEST PRACTICES®
EDITORIAL ADVISORY BOARD
IndustrialEnergyManagers
Doug Barndt
Manager, Demand Side
Energy-Sustainability
Ball Corporation
Richard Feustel Senior Energy Advisor Leidos
William Jerald Energy Manager CalPortland
Jennifer Meier
Global EHS/
Plant Engineering
Manager
Varroc Lighting
Systems
Thomas Mort Senior Auditor
Thomas Mort
Consulting
Brad Reed
Corporate Energy Team
Leader
Toyota
Brad Runda Global Director, Energy Koch Industries
Uli Schild Energy Engineer Darigold
Don Sturtevant
Corporate Energy
Manager
Simplot
Thomas Sullivan
Energy Performance
Manager
Michelin North
America
Bryan Whitfield Sr. Solutions Engineer EnerNOC
CompressedAirSystemAssessments
David Andrews
Director Marketing
Communications
Sullair
Paul Edwards President
Compressed Air
Consultants
Jay Francis
National Sales
Manager, IPG
SPX Flow
Industrial
Tilo Fruth President Beko USA
Chris Gordon President
Blackhawk
Equipment
Erik Arfalk
Vice President
Communications
Atlas Copco
Kurt Kondas President
Universal Air
Gas Products
Frank Langro Director Marketing Festo
Pierre Noack President Aerzen USA
Hank Van Ormer Technical Director Air Power USA
Wayne Perry Technical Director Kaeser
Andy Poplin Sales Manager
Atlas Machine
Supply
Kenny Reekie
Director, Blower
Vacuum Products
Gardner Denver
Compressed Air Gas Institute, Compressed Air Challenge
2016 MEDIA PARTNERS
c Join Mike Flaherty and Chiller Cooling Best Practices Magazine to review issues with
traditional chilled water system design and control strategies – by signing up for our free
August 31st
Webinar titled, “How Traditional Chiller Plant Design and Operation Reduces
System Efficiency” at www.airbestpractices.com/magazine/webinars.
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4 airbestpractices.com
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INDUSTRY NEWSINDUSTRY NEWS
Nano-Purification Solutions
Appoints Adam Wright
nano-purification solutions ltd. (n-psl), the
Gateshead, U.K. - based compressed air
treatment specialists owned by nano-purification
solutions Inc. (n-psi) have hired an experienced
sales professional to head sales strategy in the
UK and Europe. Adam Wright was appointed
Business Development Director in June, 2016
and bringing a wealth of compressed air
purification experience into the business. Adam
has worked in the compressed air treatment
market for over 10 years, formerly heading up
the sales organization for a world leading air
treatment company.
Michael Eccles, UK Technical Director,
commented “We are extremely pleased to
have Adam on board. He brings with him vast
worldwide distribution and OEM experience
and a fresh approach to our sales and
marketing efforts. We have no doubt that this
significant addition to our team will maximize
our growth potential in Europe and beyond.”
Adam also commented, “These are exciting
times at nano. The innovative and proven
desiccant dryer and gas generation products
are a sales professional’s dream and, with
production in a state of the art manufacturing
facility where the test equipment is second
to none, quality is assured. I am delighted to
be part of a team where the company is firmly
focused on exceptional customer service.”
When Adam is not extolling the virtues of nano,
he can be found toiling up the significant hills
of the North Pennines on his bicycle.
For more information,
visit www.n-psi.com/.
FS-Elliott Unveils New
Interactive Educational Website
FS-Elliott Co., LLC, a leading manufacturer of oil-
free, centrifugal air compressors has announced
the launch of their new, redesigned website,
www.fs-elliott.com. The site boasts a clean
layout, improved navigation, and educational
resources aimed at providing visitors with
a more comprehensive understanding of
FS-Elliott’s range of compressed air solutions.
“Our new website is part of ongoing efforts to
provide users with quick and easy access to
product information as well as resources to help
them better understand centrifugal compressor
technology and what decisions they can make
to lower their costs,” stated Neil Owen, Global
Marketing Manager. Key features of the site
include interactive product images, white
papers educating users on how to select an air
compressor and lower their operating costs,
and case studies from current customers. For
first-time visitors, a list of industries displayed
on the home page will take them down a path of
learning how an FS-Elliott compressor could suit
their specific compressed air application.
Adam Wright was named Business Development
Director for the U.K. and Europe for nano-purification
solutions ltd.
FREE SUBSCRIPTIONDIGITAL EDITION FREE WORLDWIDE | PRINT EDITION FREE TO U.S. SUBSCRIBERS
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BEST PRACTICES FOR:
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The newly designed site introduces FS-Elliott’s
AirCompare®
Life-Cycle Costs Calculator
developed to give compressed air users a tool
for making informed decisions about their
compressed air system. By entering their
existing units into the AirCompare calculator,
users can uncover what they are spending
compared to what they can expect to save in
energy and maintenance costs with an FS-Elliott
centrifugal air compressor.
“Over the past 50 years we have seen
firsthand the challenges our customers are
facing in their specific industries; by sharing
the solutions customers are adopting, we
hope to empower others to apply a similar
scenario at their plant,” added Sue Benes,
Polaris+ Product Marketing Manager.
“Personalizing the experience of visiting our
website and providing access to tools like
AirCompare provides compressed air users
the resources necessary for making the best
decisions for their local plant.”
About FS-Elliott Co., LLC FS-Elliott Co.,
LLC, is a leading manufacturer of centrifugal
air and gas compressors with sales, service,
and manufacturing locations around the
world. First introduced to the market over
50 years ago their energy-efficient machines
incorporate the latest aerodynamic and
control system technologies to ensure
optimum performance.
visit www.fs-elliott.com.
Trace Analytics Appoints
David Snee as CEO
Trace Analytics LLC, a compressed air testing
laboratory out of Austin, Texas, appointed
David Snee as their Chief Executive Officer.
After 27 years of continued success, Trace
warmly welcomes David, trusting in his
acumen to increase operational efficiency
in preparation for scaling initiatives and
explosive growth, as well as expansion into
related products and services.
Snee joins Trace Analytics out of the Harvard
Business School MBA program. He earned
a Liberal Arts degree from the Great Books
program at St. John’s College (the coursework
equivalent of majors in History of Math
and Science and Philosophy and minors in
Comparative Literature and Classical Studies)
and a Creative Writing certificate from Exeter
College at Oxford University.
Prior to this, Snee served in the United States
Army, Military Intelligence, deploying in
support of Operation Enduring Freedom and
Operation New Dawn. During this time, he
earned a certificate in Emergency Management
from the Federal Emergency Management
Agency. He is originally from the Maryland-
Pennsylvania area, where he served as a
Market Trainer for independent retailers
of Cingular and T-Mobile.
As CEO of Trace Analytics, David plans to
advance global safety and quality standards of
compressed air testing for the health and well-
being of end users worldwide.
visit www.airchecklab.com
have you Experienced
nano-purification solutions
support@n-psi.com
704.897.2182
“It’sawonderfulchangeofpacetohavea
supplierthatyoucancountonbeingreliable!”
-ApackagerintheMidwest
C
M
Y
CM
MY
CY
CMY
K
QOTM 11.pdf 1 6/30/2016 12:05:20 PM
Trace Analytics appointed David Snee as CEO
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INDUSTRY NEWS



Atlas Copco Rental Provides Quick
Solution for Dominican Gold Mine
Atlas Copco Rental provided a quick
solution when unscheduled compressor
maintenance posed a risk to processing for
a Dominican gold mine. A trio of stationary
air compressors produce 630,000 m3/hr of
air for the oxygen plant at the Pueblo Viejo
gold mine in the Dominican Republic. The
oxygen is used by its autoclave processing
facility to treat roughly 24,000 tons per day
of refractory ore for the 60/40 joint venture
between Barrick and Goldcorp Inc., operated
by Barrick as Pueblo Viejo Dominicana
Corporation.
Normal compressor maintenance at the
mine takes one of its three units offline. The
remaining two units share the load while one
compressor undergoes maintenance, though
production dips slightly.
In late 2015, while one compressor was
down for repair, an unexpected motor failure
in another compressor reduced production
capability by 30%. It was too risky to rely
on just one compressor. The plant needed a
backup plan. The failure had occurred right
in the middle of the holiday season, a time of
extended vacations and a burdensome surge
on the international shipping industry.
Barrick’s Capital Project Manager, Barry
Hummer, called the Atlas Copco Rental
sales representative, Paul Morgan, in
Florida. Hummer was relieved to learn Atlas
Copco Rental had an immediately available
solution: seven ZH6000 and seven ZH9000
portable air compressors complete with a
technical team. The units are rented by a
variety of industries for scheduled stationary
compressor maintenance or for emergency
bypass, as in Pueblo Viejo’s case. Response
time was quick. Morgan contacted Clayton
Jones, key account manager of Atlas Copco
Rental centrifugal air compressors. Jones
immediately assembled a four-man technical
team led by David Moessinger, who built the
ZH-series compressors.
“We fill a sort of niche with this product,” Jones
said, explaining that truly oil-free, centrifugal
compressors capable of 6,000 and 9,000 cfm
are hard to find outside of Atlas Copco.
Atlas Copco ZH6000 and ZH9000 units are
self-contained, 100 percent oil-free, three-
stage centrifugal air compressors that fit
completely within a standard 40-foot shipping
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DRYPOINT®
RA CT and VSD
Operating costs determine the cost efficiency of refrigeration dryers – not the purchase price.
With the DRYPOINT®
RA CT and VSD cycling dryer lines, these operating costs are cut in half over
a 5-year period saving considerable sums of money. BEKOMAT®
zero air loss drains are standard
equipment providing users with even greater energy savings and an additional offset to the initial
purchase price through energy rebate incentives.
The dryer that
pays for itself within
just 6-months of
operation.
container. Electrically powered, the units have
zero risk of exhaust contamination that can be
a problem with diesel units.
Jones added: “And, technically, Atlas Copco
is one of a few manufacturers of truly 100
percent oil-free air compressors. Others
reduce oil to a minimum and then filter it
out. But our air has zero oil. There’s no need
for a filter. And as for volume, you just can't
compress that much air with a screw or piston.
A centrifugal is just so much more efficient.”
The fundamental components of a centrifugal
compressor are stainless steel impellers,
efficient turbines that provide constant positive
pressure. The three-stage ZH compressors
have one low pressure impeller closest to the
intake, which feeds primary stage compressed
air to be stepped up by two high-pressure
Atlas Copco ZH6000 and ZH9000 units are self-contained, 100 percent oil-free, three-stage centrifugal air
compressors that fit completely within a standard 40-foot shipping container. Electrically powered, the units have
zero risk of exhaust contamination that can be a problem with diesel units.
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impellers. From inlet to discharge, neither
coolant nor lubrication ever comes in contact
with the compressed air. To manage heat from
compressions, the system uses integrated
stainless steel inter- and after-coolers.
It took just 31 days from the time Hummer
contacted Morgan for the first compressor
to be up and running, with much of that
time taken up by shipping and site prep.
Having determined the job’s specifications
and logistics during onsite visits, the Atlas
Copco team was ready at Pueblo Viejo before
the compressors arrived. The containerized
units make installation and start up simple.
Only a few connections need to be made at
each compressor: the electrical hook up in
back, with hoses for water in/out and an air
discharge pipe in front.
After setup and motor alignment, the
Atlas Copco Rental technicians served as
supplemental labor, joining Barrick’s team in a
time of operational need. They worked around
the clock in two-man 12-hour shifts right
through Christmas and well into the new year.
The containerized units provided plenty
of room to work in comfort, protecting
technicians from the elements while they
cleaned filters, monitored gauges, tuned
performance with digital controls and logged
six-hour readings. Elektronikon control and
monitoring systems are integral to the units,
mounted just inside at eye level for ease of use.
Hummer said, “We’ve worked with Atlas
Copco before. I had no doubt this would
work. And I would do this again, no problem
whatsoever. The self-contained units just
make it go so smoothly. The Atlas Copco team
deserve credit. I can’t say enough about how
this was managed, administrative level on
down. They did very good work and should
be complimented for it.”
For 50 days the ZH compressors ran full
capacity, sustaining a steady 105,000 cfm flow
of ISO-quality, 100-percent-pure air at 75
psi. Production was maintained throughout
the repair. And then as easily as they were
installed, when the original overhauled
stationary compressors came online, the
Atlas Copco containerized compressors were
unplugged and shipped back to the U.S.
About Atlas Copco
Atlas Copco is a world-leading provider
of sustainable productivity solutions. The
Group serves customers with innovative
compressors, vacuum solutions and air
treatment systems, construction and mining
equipment, power tools and assembly
systems. Atlas Copco develops products
and service focused on productivity, energy
efficiency, safety and ergonomics. The
company was founded in 1873, is based in
Stockholm, Sweden, and has a global reach
spanning more than 180 countries.
Specialty Rental is a division within Atlas
Copco's Construction Technique business
area. It serves customers in the industry
segments around the world with temporary
air, nitrogen, steam and power rental
solutions. The specialty rental services are
offered under several brands. The divisional
headquarters is located in Houston, USA.
Visit www.atlascopco.com/
rentalusus
INDUSTRY NEWS
series
Nx Series rotary screw air compressors are designed to provide a high volume
of air continuously and quietly. With the intuitive controls and diagnostics, the
compressor is easy to use and service. This all adds up to make the Nx Series
ideal for applications that require reliable performance in demanding conditions.
• Quiet Efficient
• Superior Package Design
• Reliable Performance
• Smart iCommand Touch Controller
TRUSTED DEPENDABLE RELIABLE
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General Motors Recognized as a
ENERGY STAR®
Partner of the Year-
Sustained Excellence
General Motors Company
(GM) is a global automobile
manufacturer that produces
vehicles in 30 countries
and is driven by its mission
to earn customer loyalty, apply meaningful
technology advances and improve the
communities where it does business. The
company integrates its energy management
program into its business plan and overall
sustainability strategy.
GM received 2016 ENERGY
STAR®
Partner of the
Year—Sustained Excellence
recognition for its ongoing progress in energy
performance and support of ENERGY STAR.
Key 2015 accomplishments include:
pp Achieving nearly a six-percent
reduction in energy use at its U.S.
manufacturing facilities compared
to 2014.
pp Setting an industry-leading record of
73 plants achieving the ENERGY STAR
Challenge for Industry. These plants
have saved more than $237 million in
energy costs while reducing over 1.8
million metric tons of greenhouse gas
emissions.
pp Implementing a climate protection
strategy that—through rigorous
goals—drives energy management,
low carbon energy procurement,
and product design, all while
communicating the need for climate
management to the public.
pp Earning ENERGY STAR certification at
11 of its buildings and investing $104
million on energy efficiency projects
globally—all with a two-year return
on investment.
pp Hosting the first Motor Vehicle Supplier
Energy Management Training Camp.
pp Achieving landfill-free status in 131
facilities worldwide that reuse, recycle,
or convert all waste from operations
to energy.
visit http://www.gm.com
or www.energystar.gov
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c Introduction
Pressure regulators are everywhere
compressed air is used. These simple devices,
essential for safe and steady equipment
operation, can be a big waster of compressed
air. This article shows how with proper
regulator selection, installation and setting
management you can save compressed air
and lower system pressures. This article looks
at regulators on production equipment not
central regulators or Process Flow Controllers.
Artificial Demand
When walking around your factory, look at
what the regulator pressure gauges are doing.
As equipment downstream of a regulator
cycles, is the gauge steady, moving quickly,
or moving up and down slowly? Video fast-
moving gauges then watch in slow motion.
Think of a regulator pressure gauge as a
compressed air use meter. The higher the
pressure the more air is being used. The
Managing Pressure Regulator
ARTIFICIAL DEMAND, Part 1
By Murray Nottle, Working Air System Engineer, The Carnot Group
“Think of a regulator pressure gauge as a compressed air use meter.
The higher the pressure the more air is being used. The more the
needle moves, the more air is being wasted as artificial demand.”
— Murray Nottle, Working Air System Engineer, The Carnot Group
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ELECTRIC CONSTRUCTION COMPRESSORS AVAILABLE
Current ECC inventory is available for sale or rent. Units currently in stock
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more the needle moves, the more air is being
wasted as artificial demand.
The amount of compressed air used
by actuators, including air motors and
diaphragm pumps, varies with gauge
pressure. For nozzles (holes, vacuum
venturis, leaks) compressed air use varies
with absolute pressure (gauge + 14.7 psi).
The table below shows relative compressed air
use at different pressures.
PSIG Actuator Nozzle
100 100 % 100 %
90 90 % 91.3 %
85 85 % 87 %
80 80 % 82.5 %
For most actuators, the actuator port and
regulator outlet pressures that matter most
are while the actuator is moving, not when
it is stopped. This is the lowest pressure
value shown on a gauge during the cycle. Air
is wasted when the pressure rises after the
actuator stops.
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Regulator Droop Observations
Droop:
pp Is how much the regulator outlet
pressure changes with flow. A regulator
outlet pressure set at 100 psig with “no
flow” that drops to 85 psig “with flow”
has a “droop” of 15 psi. It “droops”
from 100 to 85 psig.
pp Is due to how the regulator valve is
piloted, where pressure feedback is
sensed (internally or externally), the
regulator valve design (balanced or
unbalanced) and internal pressure
drop.
pp Wastes air
pp Forces the air compressors to operate
at a higher pressure. The minimum
system pressure is the “with flow”
regulator outlet pressure plus droop.
Less droop allows a lower system
pressure.
Understanding How Regulators Work
The regulator valve is a “hole” whose size
changes with a pressure difference. The
pressure difference is the “no flow” outlet
pressure setting minus the “with flow” outlet
pressure i.e. the regulator droop.
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As the upstream pressure rises and falls, so the compressed air
flow through the “hole” will rise and fall. As a hole is a nozzle,
air flow varies with absolute pressure. A hole with 100 psig
upstream will flow 28% less air that if supplied with 150 psig.
How quickly the “hole” size changes with pressure difference,
depends upon the “spring rate” of the pilot force opening the
valve. Opposing the pilot force (to keep the valve closed) is
the feedback force. The feedback force is usually the outlet
pressure acting on the regulator diaphragm.
Spring rate means a spring compressed to say 2 will have
less force if only compressed to 2 ¼. If this same spring
creates the pilot force on a regulator valve, for the valve to
open ¼ (spring extends from 2 to 2 ¼) the feedback force
(downstream pressure) needs to be less than if the valve was
closed. As flow through the regulator starts and stops, the
valve needs to open and close. To allow this, the downstream
pressure must go up and down.
Most general regulators use coil springs so their droop is
mainly due to spring rate. Air pilot regulators have no spring
and so no droop due to spring rate. This is why they’re used for
precision regulators.
A regulator valve can only open so far. With a fully open valve,
the regulator can’t control the downstream pressure and has
“lost regulation”.
What affects a regulators ability to keep a steady
outlet pressure?
How well a regulator can keep a steady outlet pressure depends
upon many factors.
You’ve already read about spring rate effects and that other
parts of a regulators’ design affects how it operates. These will
Did you know that if you measure the regulator “no flow”
pressure setting and “with flow” inlet and outlet pressure,
you can use the regulator catalogue curves to estimate how
much air is flowing i.e. as a flow meter. Not so good for air
pilot regulators due to the very low pilot spring rate.
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be discussed further in a later article. Supply
pressure effects and the original regulator
sizing are discussed here.
Supply Pressure
Remember that a regulator is part of and
affected by the wider compressed air system
and that a regulator valve is like a “hole”.
If the supply pressure at the regulator drops,
less air will flow through the “hole” so its’
size needs to increase. For the hole size
to increase (valve open further), the outlet
pressure needs to droop further below the
no flow setting. So drops in supply pressure
increase droop from spring rate effects.
Large drops in supply pressure can cause
“lost regulation”.
Pneumatic components have much higher pipe
air speeds at rated flows than are acceptable
in air mains. Based on 43 regulators of
different design, manufacturer and size, port
air speeds are between 200 and 300 ft/sec
(60 - 90 m/sec) compared to the 20 ft/
sec (6 m/sec) considered as best practices
for air mains. Low air speeds result in low
pressure drop, efficient system operation and
stable regulator supply pressure.
Using plastic tube of the same nominal
bore as the regulator port (¼ bore tube
with ¼ NPT port), will result in unsteady
supply pressure to the regulator. This in turn
will increase droop and may result in lost
regulation, all of which will result in air waste
and affect equipment operation.
As a guide the pipe bore, either side of a
regulator, should be 3 to 4 times the port
size of the regulator. This is except where
the regulator is between an actuator and
its control valve where small tube should
be used. If the regulator is part of a service
unit with a filter, the filter element pressure
drop lowers the supply pressure drop to the
regulator.
So before blaming and changing a regulator
for poor pressure control, change the filter
element of its service unit and check the pipe
sizes either side of it. Otherwise a different
regulator may do no better.
Sizing
For easier regulator selection, manufacturers
provide “rated” flows and flow curves - but at
what “rating” conditions?
pp Most spring-piloted regulators are
based on the outlet pressure drooping
from 90 psig to 75 psig. But:
`` Some manufacturers test flow using
a 100 psig supply.
`` Others use a 145 psig supply.
•• Remember a hole supplied
with 145 psig air will flow
around 30 % air more than
if supplied with 100 psig.
•• So a smaller (cheaper)
regulator tested on a 145
psig supply could have the
same rated flow as a bigger
(more expensive) regulator
tested on a 100 psig supply.
•• Which one do you think is
more likely to be bought ?
The smaller, cheaper one.
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| 0 8 / 1 6

•• Which one will have more
droop, is more likely to
“loose regulation” and will
waste more air? The smaller,
cheaper one.
pp Air pilot regulators (low spring rate)
rated flows are with a fully open valve.
However as with the spring piloted
regulators some are tested with a 145
psig supply while others a 100 psig.
You can see how easy it is to select an
undersized regulator by not considering the
test supply pressure compared to the supply
the regulator will use. Before rushing out to
replace a regulator you know is undersized,
make sure you know what, balanced valve,
internal and external feedback and aspirator
tube relate to and how they affect regulator
selection. These terms will be covered in the
following article.
Are Your Regulators Properly Set?
Often over time, the regulator no-flow settings
increase and sometimes regulation is lost.
The regulator doesn’t drift but it is machine
operators trying to keep their equipment
working reliably.
The pressure drop of air compressor room
filters increases, as they clean the air, resulting
in the system pressure falling. Droop increases
and low pressure affects production equipment
operation. To immediately fix the problem,
the operator increases the regulator setting
pressure but the “with-flow” setting is a guess
or a “memory”.
Eventually air compressor settings are
increased and filter elements replaced,
but are the regulator settings adjusted back
down? Best practice would have a regulator
supply pressure gauge fitted and the supply
pressure, minimum “no flow” and “with flow”
pressure settings recorded and displayed
at each regulator. This will help the operator
and maintenance staff to keep the correct
“with-flow” regulator setting.
Conclusion
This article has provided an introduction to
regulators and how you can recognise the
air wasted by artificial demand from their
operation. Some of the causes of this have
been discussed.
A following article will explain more about
the different types of regulators and where
and why you would use them. It will also
describe what “regulator management best
practice” is.
For more information please contact Murray Nottle,
The Carnot Group. mnottle@carnot.com.au,
www.carnot.com.au
To read similar Instrumentation Technology
articles visit http://www.airbestpractices.com/
technology/instrumentation
To read similar Instrumentation Technology
articles visit http://www.airbestpractices.com/
technology/instrumentation
If you select a spring pilot regulator near
its “rated flow” then, you are designing
your equipment to waste compressed air,
have operational problems and need high
compressed air system pressures.
0 8 / 1 6
|

The Importance
of Bi-directional
Compressed Air
Flow Measurement
By Pascal van Putten, CEO, VP Instruments
c Introduction
Technology is available which enables a
compressed air flow meter to measure not
only the magnitude of the flow, but also the
direction. Why is this important? In this
article we will describe two case studies
where bi-directional compressed air flow
measurement plays a key role to come to the
right conclusions. In the first case study, we
will describe an electronics manufacturing
plant, which has a large interconnected
ring network with two air compressor
rooms located in different buildings. The
two air compressor rooms are about five
hundred feet apart. In the second case
study, the effect of compressed air flow
measurement upstream of a local receiver
tank is described.
Thermabridge™
Technology
The worlds first thermal flow sensor made
in a silicon (not silicone!) chip was invented
forty years ago by one of our founders, Anton
van Putten, back in 1974. His unique design
can be seen as the blueprint of many thermal
mass flow sensors, found in automotive,
HVAC and industrial applications. The original
Thermabridge™
sensor combines flow
direction measurement with thermal mass flow
sensing over a full 0…150 mn
/sec range. This
enables you to measure flow in complex ring
networks, where any other flow meter would
deliver very unreliable measurement results.
Who would have thought that his invention
would become so important for accurate
compressed air measurement?
Case 1. Two Air Compressor Rooms
At a large electronic component
manufacturer, compressed air is used for
the entire production process including
injection molding machines, the handling
and packaging of products, picking and
placing of components, and the plating
and galvanizing of metal parts. An energy
management program had been initiated to
reduce the overall energy consumption of the
plant. Compressed air was one of the utilities
that needed attention. The air compressors
in the factory were quite old ( 10 years)
and there was room for improvement, from
Thermabridge™
sensor technology responding to bi-directional flow
| 0 8 / 1 6

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Reliability
an efficiency point of view. To select the right
compressor, the demand profile of the factory
needed to be measured. But the company
realized that permanent monitoring is key
to long-term savings. So instead of hiring
an audit firm to perform a temporarily audit,
they choose to implement a permanent
compressed air flow monitoring solution -
which could eventually be expanded towards
other utilities. The initial goals for phase 1
of the project were:
pp Establish a base line profile
pp Select a replacement air compressor
combination based upon this profile
pp Identify waste and reduce the air
demand of production areas
During phase 1 of the project, we installed
four compressed air flow meters, to get a
clear picture of the average demand. But
after a couple of months, we encountered
an interesting situation where standard uni-
directional compressed air flow meters would
provide useless results. In this particular
situation, back-flow towards the receiver tanks
caused wrong readings, resulting in severe
measurement errors.
System description
The drawing below shows a simplified
layout of the compressed air system. The
compressed air system consisted of two
compressor rooms (A and B). A compressed
air ring network is supplied from these two
separate compressor rooms. The compressor
rooms are controlled with a pressure-based
control system.
At compressor room B, two flow meters are
installed in a ring network to measure the air
delivered to the network by a compressor.
Between this compressor and the network,
a large receiver tank (5 m3
) is installed.
0 8 / 1 6
|

THE IMPORTANCE OF BI-DIRECTIONAL COMPRESSED AIR FLOW MEASUREMENT
In room A, three rotary screw air compressors
were installed. The machines were used for
the daily base-load. Each air compressor is
fitted with a heat of compression drum dryer.
Between the pipes and the compressors,
two large receivers are installed, 5 m3
each.
From the receivers, two separate pipes supply
compressed air to the production processes.
One pipe is connected to another building
where compressor room B is located. The
distance between the two compressor rooms
is approximately 500 feet.
In compressor room B, one relatively new
air cooled ZT 145 machine is located. Air
leaves the air compressor and enters a heat of
compression drum dryer and then into another
large receiver tank. Due to space limitations, it
was not possible to install a single flow meter
between the 5m3
receiver tank outlet and
the network. Instead, two flow meters were
installed further away, in the ring network, just
after a T-junction, where the compressed air
was fed into the ring. Initially, these standard
VPFlowScope flow meters were unidirectional.
In other words: they would not see the
difference between forward and backward flow.
After a couple of days, strange measurements
were observed. The flow meters were showing
considerable measurement values when the
compressor was turned off.
Reverse Flow or Not?
After taking a closer look into compressor
room B’s configuration, we came to the
conclusion that there had to be reverse flow
when the air compressor was turned off. The
following pictures explain this effect in detail.
During unload and off hours, the two uni-
directional flow meters showed consumption,
while one would expect zero flow. The large
receiver tank is filled by the other compressors
(from room A) when the local air demand
in the ring network is low, and it delivers air
to the network when the local demand is high.
You can see the receiver tank as a big balloon
interacting with the network.
When the compressor is running loaded,
compressed air is fed into the ring network.
In the T-junction, the flow merges with existing
“traffic” based on how the consumption in
the ring mains is balanced. If the consumption
is well balanced, it might be perfectly
symmetric (50% left, 50% right), but when
Figure 1: System overview
Room B Air Compressor Off: Receiver Tank Behavior
Room B Air Compressor in a “merging traffic” Situation
| 0 8 / 1 6

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the consumption on one side is much higher,
the air flow will distribute differently. Pulsating
demand can also change the flow distribution
for a short period of time.
The compressed air coming from the air
compressor merges with the air which was
already flowing through the ring network.
This can result in a high or low reading,
depending on the actual demand and the
resulting flow direction.
Uni-directional versus Bi-directional
A uni-directional compressed air flow meter
does not have a clue where the air is coming
from. This results in large errors. This applies
to most thermal mass flow meters based on
thermal dispersion, constant temperature
anemometry and so on. Other examples of uni-
directional flow meters are vortex meters and
turbine meters, which read-out via a standard
pulse transmitter (the actual counter on the
turbine meter will turn backwards). Venturi’s
are also uni-directional. The differential
pressure signal will not change to negative
when flow is reversed. Orifice meters can
also measure reverse flow, but they are not
so suitable for compressed air due to their
permanent pressure loss.
By turning on the bi-directional sensing feature
of the VPFlowScope, the changing of flow
direction is instantaneously revealed. Now the
reverse flow shows up in the graphs as negative
values. Lets take a look at some real data:
In the graphs below, we zoom into a specific
period of the measurements in compressor
room B. The original data, from the
bi-directional flow meters, has been processed
to show the difference between bi-directional
and uni-directional flow.
At the end of this period, the effect can be seen
very clearly: The compressor turns off, in the
left graph where the two bi-directional flow
meters cancel each other out, and the resulting
0 8 / 1 6
|

flow is nearly zero. In the right graph, the flow
is not cancelled out, resulting in a ghost signal
of nearly 13 m3/minute.
Is Uni-directional Good Enough?
One could say, why not correlate this with
load/unload data from the air compressor?
When the compressor is in unload or off-
state, you know the flow is zero, so you can
compensate for it. We think this is not the
best way to solve the reverse flow problem,
as there might be other (real) reasons for
reverse flow, which would remain unnoticed.
For example, a leaking non-return valve, a
leaking seal or blow-off valve. In this particular
case, we found a leaking compressor seal. This
leak cost 1,314 Euro per year and it took only
500 Euro to fix it. Another leak was found in
a dryer. Again, this compressed air dryer leak
was upstream of the flow meter, so it would
have remained unnoticed if the flow meter was
uni-directional. The result was a leak savings
of 2,102 Euro per year fixed with a cost of only
100 Euro by replacing a hose.
Case 2. Decentralized Receivers
In some cases, a decentralized receiver tank
is used to “shave off” the peak load on the
network. For example, when a machine has
a large intermittent consumption profile.
A question is often asked: where to place the
flow meter, and what will the flow meter show
us when the machine has been turned off? This
part of the article is based on an older audit at
a potato food-processing plant, where we used
a standard thermal mass flow meter without
bi-directional sensitivity. The picture below
shows the setup.
The auditor called us after a couple of days,
to discuss the results. The compressed air
flow meter showed significant consumption
while the machine was isolated from the
network. The receiver tank was simply
acting as a local buffer for machines further
downstream the line. It was filled, and
emptied at the pace of their consumption,
causing significant readings on the thermal
mass flow meter. In this case, the issue was
finally resolved by ignoring the data during
the period when the machine was shut off.
But in other cases, there might not be a way
to correlate local actions or events with data.
In those cases, when looking at data from a
THE IMPORTANCE OF BI-DIRECTIONAL COMPRESSED AIR FLOW MEASUREMENT
Test setup: The point of use flow meter was installed in between the receiver tank and the ring mains.
Why? Because there was not enough straight length downstream of the shutoff valve.
| 0 8 / 1 6

uni-directional flow measurement device can
lead to wrong conclusions.
Other Issues You Can Discover with
Bi-directional Sensors
Bi-directional flow meters can reveal important
issues in many compressed air systems.
In this article we described two cases where
bi-directional sensors were crucial to draw the
right conclusions.
Other examples where you can reveal issues:
Leaking non-return valves just after the
compressor, or leaking condensate drains.
The bi-directional flow meter will tell you when
it happens.
pp Leaking drains in the oil-demister
or under the wet receiver tank
pp The non-return valve does not shut
off completely
pp The blow-off valve does not close
completely
pp Oscillations in the pipe network are
seen as consumption instead of near
zero flow
Combining the Results Using Virtual
Channels
In the central VPVision energy monitoring
software, using a virtual channel, data of two
(or more) flow meters can be combined
into one signal. The channel adds/ subtracts
all measurement values, based on their flow
direction. The resulting values can be used
in real-time graphs and reports.
Conclusions
pp For flow measurement in ring
networks, bi-directional flow meters
are key to correct results.
pp Only bi-directional flow meters can
provide correct data when installed
between receiver tanks and the
compressed air network.
pp Uni-directional flow meters will show a
positive flow when reverse flow occurs,
which can lead to wrong conclusions
about the system behavior.
pp With modern energy monitoring
software, bi-directional flow meters
can be combined in a virtual channel.
About VPInstruments
Founded in 1999, VPInstruments offers
energy management solutions for compressed
air and technical gases. Our flow meters
are based on the original Thermabridge™
technology, as invented in 1974 by our
co-founder Anton van Putten. Thanks to
our monitoring solutions and flow meters,
companies worldwide measure, monitor and
manage their compressed air system, from
supply to demand side.
For more information contact Pascal van Putten, VP
Instruments, tel: 31-15-213-1580, email: pascal.van.
putten@vpinstruments.com, www.vpinstruments.com
Interestedin
Becominga
Distributor?
To read similar Compressed Air
Measurement articles visit http://
www.airbestpractices.com/technology/
instrumentation
To read similar Compressed Air
Measurement articles visit http://
www.airbestpractices.com/technology/
instrumentation
Using a virtual channel, data of two (or more) flow
meters can be combined into one signal.
0 8 / 1 6
|

Assessing the Impact of Compressed Air
QUALITY ON FOOD PRODUCTS
by Dick Smith, Technical Director, Trace Analytics
c Compressed air is a critical utility widely
used throughout the food industry. Being
aware of the composition of compressed
air used in your plant is key to avoiding
product contamination. Your task is to assess
the activities and operations that can harm
a product, the extent to which a product
can be harmed, and how likely it is that
product harm will occur. Assessing product
contamination is a multi-step process in
which you must identify the important risks,
prioritize them for management, and take
reasonable steps to remove or reduce the
chance of harm to the product, and, in
particular, serious harm to the consumer.
Source of Potential Product Harm
Normal ambient air contains millions of
inert particles, 5-25 grams of water, 1-5
micrograms of oil, and tens to hundreds of
bacteria per cubic meter. In addition, the
system itself can be a source of possible
contamination, including pipe scale and rust,
polymer shredded particles, rubber gasket
pieces, sealing tape, metal shavings from
pipe cuts, and even particles from charcoal
filters and desiccant canisters. Sometimes
condensed water or liquid oil already present
in the system forms into an aerosol or vapor,
creating yet another source of contamination.
Risk Assessment
Generally, the steps of assessing the risks
of product contamination are as follows:
1. Identify potential hazards
2. Assess the risk of harm
3. Assess existing control measures
for adequacy
4. Assess if extra controls are needed
5. Schedule regular reviews to see
if the controls are working
Dick Smith is the Technical Director for Trace Analytics
| 0 8 / 1 6

Identifying Hazards
A number of the components of ambient
air become contaminants once they enter
the compressed air stream. For the sake
of this discussion, we will omit airborne
microbes, as they were thoroughly discussed
by Lee Scott in the Jan/Feb 2016 Issue of
Compressed Best Practices®
Magazine: http://
www.airbestpractices.com/standards/food-
grade-air/compressed-air-gmps-gfsi-food-
safety-compliance.
When a compressed air component has
a deleterious effect on the product, it is
considered a compressed air contaminant.
ISO 8573.1:2010 contains purity classes
for components/contaminants in compressed
air as shown in Table 1.Further, the British
Retail Consortium (BRC) and the British
Compressed Air Society (BCAS) have worked
together to author a code of practice for
the food and beverage industry. This code
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TABLE 1. ISO 8573-1:2010 — PART 1: CONTAMINANTS AND PURITY CLASSES
PURITY CLASSES FOR PARTICLES
MAXIMUM NUMBER OF PARTICLES PER CUBIC METER (m3
)
AS A FUNCTION OF PARTICLE SIZE, db
PURITY CLASSES FOR HUMIDITY AND LIQUID
WATER
PURITY CLASSES FOR OIL
(LIQUID, AEROSOL, AND VAPOR)
CLASSa
MAXIMUM NUMBER OF PARTICLES PER m3
CLASS PRESSURE DEW POINT ˚C CLASS
Concentration of Total Oil
mg/m3
0.1 d ≤ 0.5 µm 0.5 d ≤ 1.0 µm 1.0 d ≤ 5.0 µm 5 µm
0 As specified by the equipment user or supplier and more stringent than class 1
1 ≤20,000 ≤400 ≤10 None 1 ≤-70 1 ≤ 0.01
2 400,000 ≤6,000 ≤100 None 2 ≤-40 2 ≤ 0.1
3 not specified ≤90,000 ≤1,000 None 3 ≤-20 3 ≤ 1
4 n/s n/s ≤10,000 None 4 ≤+3 4 ≤ 5
5 n/s n/s ≤100,000 None 5 ≤+7 5 5
— Particles by Mass Concentration, CP, mg/m3
6 ≤+10
6 0 CP ≤ 5
Class
Concentration of Liquid
Waterb, CW g/m3
7 5 CP ≤ 10
X CP 10
7 CW ≤ 0.5
a
To qualify for a class designation 8 0.5 ≤ CW ≤ 5
b
At reference conditions: 20˚C, 100 kPa; 0 rel. water vapor pressure 9 5 CW ≤ 10
c
See ISO 8573-1:2010 A.3.2.2 X CW 10
0 8 / 1 6
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incorporates selections from the ISO
8573-1:2010 purity classes to arrive at
recommendations for compressed air that
comes into direct contact with the product,
as well as compressed air that comes into
indirect contact with the product, as seen
in Table 2.
These two specifications encompass most
identifiable hazards. According to the
Guideline, compressed air quality shall
be tested and verified at least twice per year
or per the manufacturer’s recommendations.
Additional testing is also warranted whenever
maintenance work or any activity that may
affect the air quality is performed on the
compressed air system. The Guideline
recognizes the importance of compressed
air quality and states that compressed air
should now be part of the Pre-Requisite
Program (PRP) in addition to the Hazard
Analysis Critical Control Points (HACCP)
plan. Whenever maintenance is performed a
representative selection of the air outlets shall
be tested to confirm that the compressed air
meets the relevant Purity Classes.
Assessing Risk of Harm
It may be helpful to catalog the elements of the
compressed air system using something like
the checklist in Table 3 below. The table allows
you to assign the level of risk for each element
with a numerical value (0 being no risk and 5
being certain risk).
In order to implement a monitoring plan, we
must take stock of the compressed air system.
Table 3 (pg. 28) shows information that is
not atypical of first-time air testing customers,
although many of the entries made relating
to piping, seals, sealants, and valves are not
usually discovered prior to initial sampling.
Based on this information, sampling can begin.
Table 4 (pg. 29) lists materials for parts of
a compressed air system, in order of what
creates the best sampling environment. This
table may be useful in assessing a system’s
current risk of exceeding specifications.
ASSESSING THE IMPACT OF COMPRESSED AIR QUALITY ON FOOD PRODUCTS
TABLE 2. A BRIEF SUMMARY OF FOOD AND BEVERAGE GRADE COMPRESSED AIR BEST PRACTICE GUIDELINE 102
PRODUCED BY THE BRC AND BCAS, JULY 18, 2013
PRODUCT CONTACT
PARTICLES, MAXIMUM NUMBER PER CUBIC METER BY PARTICLE SIZE RANGE
HUMIDITY
(WATER VAPOR), PDP °C
TOTAL OIL,
mg/m3
ISO 8573-1
:2010 EQUIVALENT0.1-≤0.5 µm 0.5-≤1 µm 1-≤5 µm 5 µm
Direct ≤400,000 ≤6,000 ≤100 None ≤-40 ≤0.01 2:2:1
Indirect ≤400,000 ≤6,000 ≤100 None ≤+3 ≤0.1 2:4:2
0 8 / 1 6
|

Assessing Existing Controls
Staying current on regulations and
publications will ensure knowledge of
relevant standards. As for the present state
of existing controls, there are two ways to
monitor the quality of compressed air, either
by testing all critical points of application,
or by testing a random representative portion.
While it can cost more to test all points, it is
the only completely accurate method, since
contamination can occur at any specific point
without effecting others nearby. It may happen
that the one point that isn’t tested ends up
being the one that is contaminated.
Sampling strategies should be robust to ensure
that the air provided to all points of use is of
consistent quality. There are several sampling
options to consider when assessing your
system and its controls:
pp Determine the percentage of sampling
points to be tested over a given time
period, e.g., 100%, 50%, 25%, etc.
pp Take three samples: one close to the
compressor, one midway through
the system, one as far away from the
purification as possible
pp Sampling immediately before and after
filter changes to weigh worst case
scenarios against best case scenarios.
Data obtained after 3-4 filter changes
can be used to establish a trend
analysis.
Reviewing Efficacy of Controls
After receiving air sample test results,
control efficacy will be made apparent. If the
contaminant quantity falls within an acceptable
threshold, by industry, then controls are
adequate. However, if contaminants meet or
exceed set standards, the options are to either
ASSESSING THE IMPACT OF COMPRESSED AIR QUALITY ON FOOD PRODUCTS
TABLE 3. COMPRESSED AIR SYSTEM RISK ASSESSMENT CHECKLIST
AREA ITEM DESCRIPTION PER SOPA
OTHER ISSUES RISK
Compressor
Room
Air Compressor
Yes
What about regularly
scheduled maintenance
or lack of maintenance,
food grade oil vs non-
food grade oil
2
Make PJ’s Compressors
Model
Serial Number 4592222
Compressor Hours 22,600
Hours Per Week Unknown
Inlet Filtration Yes
Unknown 2
System Pressure 130 psig
Aftercooler Yes
Air Receiver Yes
Bulk Liquid Separator Yes
Particle Filtration 1 5 micron
Yes 2
Particle Filtration 2 0.01 Micron
Refrigerated Dryer Yes
Yes 2Refrigerated Dryer Pressure
Dew Point
38˚F
Desiccant Dryer No
N/A 3
Pressure Dew Point N/A
Piping
Air Compressor
Unknown 4
Piping Fitting Cast Iron
Fitting Type Threaded
Seal Type Thread to Thread
Sealant Type Pipe Putty
Valving Ball Valve
Pipe Chase/Run
Unknown 4
Piping Fitting Unknown
Seal Type Thread to Thread
Sealant Type Tape Pipe Putty
Valving Ball Valve
Point of Use
Unknown 1
Piping Fitting Stainless Steel
Seal Type SS
Sealant Type SS Ferrules
Valving Ball Valve
Point of User
Application
Point of Use Tubing Yellow Hose
Unknown 4
Point of Use Filtration None
Point of Use Desiccant Dryer No
Point of Use Pressure 50 psig
Number of Outlets 16
Sampling
Connection
Fittings Quick Connect
N/A
Sampling not yet
performed
1Valves SS Ball Valve
Tubing Particle Free Polymer
A
Operated and maintained per written SOP
B
Risk, 0-5; 0 being no risk and 5 being a certainty that the specification will be exceeded
Total 25
| 0 8 / 1 6

reassess if the limits were set inappropriately,
or to add additional controls, such as point
of use filters.
Assessing Whether Additional Controls
Are Needed
If, in the previous step, control efficacy proved
inadequate to achieving the desired air purity
rating, additional controls are, obviously,
called for. Information about options may
be available by industry or across industries,
but the principle is to either add controls
where none are in place, like adding a
refrigerant dryer where there is none, or to
add controls to existing controls, like adding
a desiccant dryer to a refrigerant dryer. If,
in the previous step, even the bottommost
standards aren’t met, then basic controls need
to be implemented immediately.
Scheduling Regular Review
This pertains to periodic reviews, the
timeframes of which are designated by
industry standard setters (BCAS recommends
semi-annual). Quarterly testing is a good
place to start in industries and geographies
where testing is not strictly enforced. This
can provide a baseline where no historic data
exists, or, in cases where records already
exist, can provide an accurate current
assessment. Compressed air systems are
not static, but dynamic—always changing.
Component parts breakdown and malfunction,
requiring maintenance or replacement, and
there is not always an obvious indication that
a device which is plugged in and running
is not performing to standard. Regular
testing hedges against the possibility of
underperformance or non-performance.
Compressed air quality is a critical aspect
of sanitation in the food industry. While
regulation is still in its infant stages in
some places, the core desire to protect
consumers is enough to warrant regular air
testing, as well as to ensure that equipment
and processing environments are operating
efficiently. Testing, while it does cost, stands
to safeguard against the possibility of greater
cost of damage or incident.
For more information please contact Trace Analytics
at tel: 800-247-1024 x 4, email: TraceAnalytics@
AirCheckLab.com or visit www.AirCheckLab.com.
To read similar Food Industry articles visit
http://www.airbestpractices.com/industries/
food or to learn about similar Food-Grade Air
Standards visit http://www.airbestpractices.
com/standards/food-grade-air
To read similar Food Industry articles visit
http://www.airbestpractices.com/industries/
food or to learn about similar Food-Grade Air
Standards visit http://www.airbestpractices.
com/standards/food-grade-air
TABLE 4. MATERIAL PREFERENCES FOR BETTER AIR SAMPLES
BASED ON LASER PARTICLE COUNTER AND CUSTOMER EXPERIENCE
ITEM BEST BETTER GOOD NOT SO GOOD POOR
Piping Fittings Stainless Steel Conductive Polymer Nylon Polyester Vinyl Polyethylene Copper Glass PTFE Aluminum Black Iron
Seal Type Welded SS Compression Rubber O-Ring Compression Threaded
Sealant Type Welded SS Ferrule Polymer O-ring PTFE Tape Putty
Valving Particle Free SS SS Shut-off Ball Valve w/ Conductive Polymer Seal Ball Valve w/ Rubber Seal Valve with Rubber Seal
(Mostly relating to particles, but has some applicability to water and oil.)
“Quarterly testing is a good place to start in industries and
geographies where testing is not strictly enforced. This can provide
a baseline where no historic data exists, or, in cases where records
already exist, can provide an accurate current assessment.”
— Dick Smith, Technical Director, Trace Analytics
0 8 / 1 6
|

Sparks Dynamics
Optimizes NIST
Compressed
Air System
By Mac Mottley, CEO, Sparks Dynamics
c The National Institute of Standards and Technology (NIST), founded
in 1901 is a measurement standards laboratory, and a non-regulatory
agency of the United States Department of Commerce. Its mission is to
promote U.S. innovation and industrial competitiveness by advancing
measurement science, standards, and technology in ways that enhance
economic security and improve our quality of life. NIST employs
about 2,900 scientists, engineers, technicians, and support and
administrative personnel.
Sparks Dynamics, a leading cloud based remote monitoring and data
analytics technology company, entered into a Cooperative Research
and Development Agreement (CRADA) with NIST researchers to
develop industrial compressed air pattern analysis to enhance system
efficiency and reliability. The following is the CRADA objective from the
statement of work:
“The objective of this project is to help the building automation
industry develop novel products that more cost-effectively identify
faults (unwanted conditions) and inefficiencies in the operation
of the compressed air plants of industrial facilities. More cost-
effective fault detection and diagnostics (FDD) products can come
to the building automation marketplace only after that industry
makes very significant advances in the state-of-the-art of its FDD
software tools from what it currently offers. Those advances require
making common practice of rules-based artificial intelligence (AI)
methods that the building automation industry has shown little to
no familiarity with in its technology so far. This project will utilize,
under controlled conditions, the compressed air plant of the NIST
campus as a facility for test and development of an embedded rules-
based FDD tool based upon NIST expertise.”
“During the first 30 days of monitoring, Sparks Dynamics
developed algorithms with NIST researchers to detect system
anomalies. At the Sparks Server, an analyst can use the ViewMaster
software application to perform an analysis of the existing system.”
— Mac Mottley, CEO, Sparks Dynamics
| 0 8 / 1 6

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General Manager of tekWorx, to review
how traditional chilled water system
mechanical design goals and control
strategies have focused on meeting
design-day loads with little consideration
for efficient cooling production.
Changes to these traditional systems can achieve
significant energy reduction and cost savings, with
short ROI’s, using pragmatic optimization techniques
such as adaptive control techniques and minor hydronic
modifications. The presentation will review successful
application of these techniques at a major pharmaceutical
RD campus along with the resulting project payback
analysis and a substantial utility rebate. The presentation
will also discuss guidelines for determining the potential
optimization project opportunity at other sites.
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Wed., August 31, 2016 – 2:00 PM EST
How Traditional
Chiller Plant Design
and Operation Reduces
System Efficiency
Mike Flaherty is
the General Manager
of tekWorx.
ReMASTER Monitoring Installation
As part of the CRADA, Sparks Dynamics installed a ReMASTER remote
monitoring and data analytics system to measure system KPIs in the
compressed air plant, which supports the compressed air needs in the
research labs as well as control air for the facility-wide HVAC system
and control air for the operation of the boiler and chilled water
plants. It is a critical utility to maintain the operational status of this
federal laboratory.
The ReMaster system uses the Tridium (Honeywell) Niagara AX data
acquisition system at the plant level where all sensor data is collected in
a JACE (Java Application Control Engine) processor. Initial Sensor data
included compressed air mass flow (SCFM), pressure and temperature
downstream of the drying / cleanup equipment and actual KW meters
on each compressor. A value of specific power is also calculated in the
JACE by dividing total system kilowatts by total system CFM/100. Data
is collected every second by the JACE and then every 30 seconds three
values for each data stream (average, max, and min) are pushed to
Sparks Dynamics cloud servers. For seven data streams that amounts
to 42 points of data a minute or over 1.8 million data points a month.
Baseline Situation
The existing system at the NIST compressed air plant included (4) four
Cameron TA-2000 centrifugal air compressors rated for 550 ICFM @
125 PSIG using 150 HP motors. They were installed in 2002, had been
overhauled and in 2014 had new Maestro control panels installed. At
least three air compressors operated continuously and at times all four
air compressors were necessary. The compressed air plant also included
(4) four Zeks refrigerated cycling compressed air dryers.
During the first 30 days of monitoring, Sparks Dynamics developed
algorithms (system rules) with NIST researchers to detect system
anomalies. At the Sparks Server an analyst can use the ViewMaster
software application to perform an analysis of the existing system. The
NIST FDD analytics software is under continuous development utilizing
Bayesian probability theory to be a learning tool that adaptively
becomes better at what it does as it gains experience... that is, as it
gains user feedback concerning its classifications (detection calls).
One of the available system views is a chart of all Key Performance
Indicators (KPI) over a specified time selected by the user (Figure 1,
pg. 33).
This chart reflects the month of May 2015, the ReMaster system has
been streaming data for over a year as of the writing of this article.
The total month’s data is represented by the blue bar near the top
0 8 / 1 6
|

of the screen, the main viewer shows an
exploded view of the data in more detail as
defined by the user designated viewing window
represented by the triangle sliders and grey
area on the blue bar. This area also shows
in more detail identified anomalies using data
analytics such as flow or pressure moving
outside of a predefined window for that time
period or an abnormal operating condition
such as compressor short cycling. A few basic
patterns emerged:
pp System flow fluctuated between 1100 –
1550 SCFM, the compressed air system
runs 24/7/365 days out of the year –
a critical campus utility
pp Each centrifugal compressor seemed
only to be generating approximately
450 SCFM (seems low even taking into
account ICFM to SCFM conversion,
seal losses, and manufacturer’s typical
performance tolerances)
pp The air compressors had within the last
year been retrofitted with new control
panels that allowed them to be centrally
controlled through a sequencing system
internal to the new panels (they would
act in a master / slave role). This
allowed for the reduction in wasted air
through bypass control as they moved to
a control scheme that would base load
three machines and trim with the fourth
in an online/offline type of mode. The
customer established a system pressure
control of 102 to 108 psig - but since
they had a relatively small receiver tank
(1,000 gal) for the system when the
system called for the fourth compressor
it went into a short cycling mode which
was about half the time.
pp The system specific power averaged 33
to 38 KW/100 CFM which is relatively
high for this sized compressed air
system.
Optimization
NIST Facilities Management was getting ready
to write a requisition to rerate or add a new
air compressor because they were concerned
that at times all four compressors had to run
and if they lost a compressor they could not
maintain the pressure on campus without
having to source a rental compressor. Sparks
Dynamics used the energy analysis / report tool
to develop a plan to replace the entire system
taking advantage of the Pepco (local utility)
rebate program.
SPARKS DYNAMICS OPTIMIZES NIST COMPRESSED AIR SYSTEM
Commissioning of the ReMaster System at NIST
“Sparks Dynamics used the energy analysis / report tool
to develop a plan to replace the entire system taking
advantage of the Pepco (local utility) rebate program.”
— Mac Mottley, CEO, Sparks Dynamics
| 0 8 / 1 6

Centrifugal air compressors by design are
a good application for larger compressed
air systems that have relatively stable flow
demand ranges that can be met within the
throttle limits of the compressors. They
have the advantage of providing oil free air
at constant pressure and have relative good
specific power performance over 300 HP or
so. The installed air compressors and their
control systems, however, were not matched
appropriately to this load profile resulting
in a high system specific power range
of 33 to 38 kW/100 cfm.
A compressed air system was designed
that would replace the existing inefficient
system with a system that would incorporate
fixed speed and variable speed drive (VSD)
oil-free rotary screw compressors. Using
manufacturer’s published CAGI data sheets
it was engineered so that the system could
always operate in an efficient specific power
envelope of approximately 20 -21 KW/100
CFM. The actual data for 30 days is used
to model a new system by entering energy cost,
demand reduction, and new system projected
specific power. (In this case there was no
reduction in projected demand – a follow up
project will sub meter compressed air in major
air user buildings.)
Implementation
The new installation consists of two (2) 150
HP oil-free rotary screw air compressors rated
for 674 CFM @ 125 PSIG and two 200HP VSD
oil-free rotary screw air compressors. The
system is rated for 849 CFM @ 125 PSIG @
MAX RPM and 272 CFM @ MIN RPM.
The proposed (now installed) system will
continuously run one fixed speed 150 HP
oil-free rotary screw air compressor and trim
with one 200HP VSD oil-free rotary screw
compressor. During periods of increased
demand a second 150 hp fixed speed air
compressor will become part of the base
load. The units are controlled through a
manufacturer supplied integral sequencer.
The plant air is critical so there must be
at least one back up VSD air compressor
available at all times. The project to replace
all four air compressors was done under
“hot conditions” where the compressed air
system was operated continuously and one
compressor replaced at a time.
Project Finance Structure
Sparks Dynamics funded this project through
two separate sources to ensure a total
replacement compressor system complete
with controls and monitoring could be
provided. Sparks Dynamics submitted the
energy analysis report as part of a Pepco
custom rebate application on behalf of the
Figure 1: Key Performance Indicators from the ViewMaster Reporting Tool
0 8 / 1 6
|

SPARKS DYNAMICS OPTIMIZES NIST COMPRESSED AIR SYSTEM
New Air Compressors at NIST
customer. The customer assigned the rebate
to Sparks Dynamics allowing us to provide the
compressed air system solution at half the price
of the previously budgeted proposal. A NIST
certified small business contractor provided the
turn-key installation of the project.
NIST Compressed Air Replacement
Project Summary
The total cost of the oil-free rotary screw air
compressor equipment and turnkey Installation
was $875,000. This cost was reduced by the
Pepco Rebate of $375,000 to make the total
NIST project costs $500,000. The annual
savings (confirmed with post installation
monitoring) were $144,000 with a simple
payback of 3.5 years.
Verification
After system installation, the ReMaster
monitoring system confirmed the projected
energy savings and continues to monitor the
system. Additionally the compressor control
panels were integrated into the ReMaster
System through the Modbus interface and now
all of the compressor panel data is streamed
to the Sparks cloud service for continuous
monitoring and anomaly identification
for predictive maintenance purposes.
For more information call tel: 443-543-5420
or email info@sparksdyamics.com or visit
www.sparksdynamics.com
To read similar Air Compressor
Control Technology articles visit
http://www.airbestpractices.com/technology/
compressor-controls
To read similar Air Compressor
Control Technology articles visit
http://www.airbestpractices.com/technology/
compressor-controls
| 0 8 / 1 6

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AUTOMAKER PROTON ATTACKS
COMPRESSED AIR WASTE
By Abdul Azeem bin Mohamed
Mohideen, Electrical Energy
Manager, PROTON
Edited by Ron Marshall for the
Compressed Air Challenge®
c Project Background
PROTON Tanjung Malim Sdn Bhd (PTMSB) is an automotive
manufacturing plant located at PROTON City, a ten minute drive from the
Tanjung Malim town of Perak, Malaysia. It is one of three manufacturing
facilities owned and operated by Perusahaan Otomobil Nasional Sdn.
Bhd. (PROTON) with a production capacity of 150,000 cars per annum.
Measurements were taken as a result of PTMSB’s adoption of the IS0
50001 Energy Management System (EnMS) tool from United Nations
Industrial Development Organization (UNIDO), which revealed annual
electricity consumption from compressed air as the third largest
Significant Energy User (SEU). This accounts to about 12 GWh or 18
percent of 66 GWh total facility annual electricity consumption (Figure 2).
As a result of this insight, the company’s management set a goal to
optimize the compressed air system by reducing compressed air leaks,
artificial demands, and inappropriate uses in the plant.
Key Findings
Compressed air optimization measures adopted by PTMSB have
reduced the consumption of compressed air by 31 percent resulting in
savings of about 3,761,000 kWh per year in energy consumption. The
monetary savings are MYR 1,090,627 per year ($255,000 USD). The CO2
reduction is estimated at 2,735 ton per year.
Overview of Air Compressors in PTMSB
There are eight large water-cooled centrifugal air compressors located
in the Energy Centre of PTMSB. These units are not connected to any type
of control system and are manually operated on a schedule controlled by
the system operators.
Energy Conservation Opportunities Identified through
Compressed Air System Optimization (CASO)
The PTMSB plant maintenance services set specific goals in addressing
their compressed air system. They include:
pp To reduce energy consumption (electricity) of
compressed air system through Compressed Air System
Optimization (CASO).
Figure 1: PTMSB Plant Layout
| 0 8 / 1 6

Join Compressed Air Challenge for the next session of
Fundamentals of Compressed Air Systems WE
(web-edition) coming soon. Led by our experienced
instructors, this web-based version of the popular
Fundamentals of Compressed Air Systems training uses
an interactive format that enables the instructor to diagram
examples, give pop quizzes and answer student questions
in real time. Participation is limited to 25 students. Please
visit www.compressedairchallenge.org, to access online
registration and for more information about the training.
If you have additional questions about the new web-based
training or other CAC training opportunities, please contact
the CAC at info@compressedairchallenge.org
Fundamentals
of Compressed
Air Systems WE
(web-edition)
pp To reduce electricity cost and energy consumption
by 10% from year 14/15. (baseline)
pp To reduce carbon footprint of PTMSB through CO2
emission reduction.
CASO activities that were carried out, are as follows:
pp Energy Saving Awareness Compressed Air Leak
Rectifications
pp Compressed Air Leak Monitoring Air Leak Isolation
at certain production shops
pp Compressed Air Conservation (reduce number of
compressors running at one time)
pp Compressed Air Pressure Reduction from 7 bar to 6
bar (100 psi to 87 psi)
pp Improvement on Control Panel Cooling (To replace
Vortex Cooler using compressed air with Force
Convection Fan)
Results of Implementation of CASO activities
Figure 4 shows that the efforts of the energy management team caused
a progressively decreasing reduction in energy consumption at the
Energy Centre.
Figure 2: PTMSB Energy Consumption (kWh) for 2014/15
Figure 3: Specification of air compressors in PTMSB
0 8 / 1 6
|

AUTOMAKER PROTON ATTACKS COMPRESSED AIR WASTE
Energy Savings Awareness
Compressed Air Leak Rectifications
As part of the UNIDO training in Energy
Management, PTMSB staff learned that Energy
Conservation is the first step towards Energy
Efficiency, and from past studies it was proven
that behavior changes of people and reducing
wastage in current practices can lead to 10%
or more savings.
Hence, PTMSB launched the PROTON Green
Policy and rolled out awareness campaign
to all workers on conserving energy. PTMSB
trained their staff to inform maintenance
team whenever they find any air leaks nearby
their work areas. The maintenance team also
organized dedicated sub-groups to aggressively
find all leaks and fix compressed air leaks
found in all areas.
Compressed Air Leak Monitoring Air
Leak Isolation
Since you can't manage what isn't measured,
PTMSB installed thermal mass flow meters
with data loggers at all production shops
to monitor the compressed air flow during
non production weekends. As a result of
this monitoring method, PTMSB managed
to identify which production shop had high
compressed air leakage levels and focus their
energies on those areas. They then arranged
to isolate the compressed air supply for any
particular shop not requiring compressed
air during non-production weekends by
closing motorized valves at the outlet of air
receiver tanks. As a result, this approach has
enabled PTMSB to run only one 336 kW air
compressor instead of two large 522kW units
during non-production operation on weekends
and holidays.
Air Compressor Optimization
Furthermore, by running only three air
compressors during day shifts instead of
five units, and smaller total capacity during
Figure 5: The PTMSB Maintenance Staff are serious about reducing waste!
Figure 4: Savings from CASO Initiatives
Learn more about optimizing compressed air systems
This 325 page manual begins with the considerations for analyzing
existing systems or designing new ones, and continues through
the compressor supply to the auxiliary equipment and distribution
system to the end uses. Learn more about air quality, air dryers and
the maintenance aspects of compressed air systems. Learn how to
use measurements to audit your own system, calculate the cost of
compressed air and even how to interpret utility electric bills. Best
practice recommendations for selection, installation, maintenance
and operation of all the equipment and components within the
compressed air system are in bold font and are easily selected
from each section.
Best Practices for
Compressed Air
Systems Second
Edition
| 0 8 / 1 6

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night shift, PTMSB managed to achieve better
compressed air production efficiency and
reduced blow-off. Add to this the benefit
of reduced maintenance costs due to lower
number of operating hours.
Compressed Air Pressure Reduction
PTMSB also studied the demand side
requirements for the compressed air pressure.
Initially, the air compressors at the Energy
Centre were supplying compressed air at
a pressure of 7 bar (100 psi) to the whole
plant. It was thought this level could be
reduced. However, when reducing the supply
pressure from 7 bar to 6 bar (100 to 87 psi),
it was found that some pneumatic machines
in the Painting shop and Trim Final shop
started to malfunction, affecting the quality
of the painting process due to low pressure
events. Some machines in the two production
shops required higher pressure than other
production shops. In order to save energy for
the air compressors, PTMSB purchased and
installed compressed air powered boosters
that compress 6 bar compressed air to the
required 7 to 9 bar pressure for the Painting
shop, spray robots and Trim Final shop’s
pneumatic manipulators.
This initiative resulted in PTMSB being able to
reduce the overall header pressure in the plant
by 1 bar (14.5 psi). The reduced pressure
and the changes as a result of other energy
conservation measures reduced the flow of
compressed air to the point where the number
of running centrifugal air compressors could
be reduced. The system was reconfigured
so that the air compressors can run based
on actual demand of plant.
Improvement on Control Panel Cooling
PTMSB also identified the usage of vortex
coolers which have been using compressed
air at a flow rate of 6,000 m3
/h (3,500 cfm)
to cool down accumulated heat from the
circuitries inside the control panels. The plant
engineers came up with a replacement cooling
method, using a Force Convection Fan (see
the “Control Panel Cooling” article in the July
2016 Issue of Compressed Air Best Practices
Magazine) to cool down the control panel
instead of using a vortex cooler powered
by compressed air.
The impact was that PTMSB could shut
down one unit of 522kW air compressor by
improving the control panel cooling using the
Forced Convection Fan method which does
not require compressed air to cool the panels.
Management asked for a detailed financial
analysis on the return of investment (ROI) and
technical evaluation to be conducted before
deciding to go for a full scale replacement
of all vortex coolers in the plant by Forced
Convection Fan. Upon the completion of the
study, it was found the vortex cooler, for normal
control panels, could be replaced with a low-
cost forced convection fan cooling system. This
concept will use hi–delivery of clean ambient
air at 32˚C forced entry into the control Panel
at 235CFM and exit at 210CFM. This will
Figure 6: Compressed air flow monitoring system identified problem areas
Figure 7: Fewer air compressors run as a result of conservation measures.
| 0 8 / 1 6

Interview with the Author
Why has your company embarked
on this energy management effort?
Our company embarked on the energy
management effort as part of our cost savings
initiatives. The increase of energy cost in
Malaysia is a result of a reduction of energy
subsidies by the government of Malaysia
starting 1st Jan 2016 caused by incomes that
are badly affected by the oil crisis (Malaysia
is a net exporter of oil). Our management
has decided to push ahead for cost savings
and Proton's high utility cost (RM 75mil
per year based on 2014/15 utility bill) is
another reason for embarking on the energy
management effort.
Why have you chosen the compressed
air system for study?
Compressed air is the third largest significant
energy user in our production plant after
the painting shop, which consists of few
systems. Hence, if we look at just a single
system alone, the compressed air system is
the largest energy user. A reduction in energy
usage for compressed air will translate to
immediate huge savings for Proton as we
run some of our compressors 24/7 a day to
maintain pressure to some equipment like
the stamping machines. Furthermore, quick
fixes such as identifying and rectification
of the compressed air savings will result in
immediate savings without huge investment.
What is your role in this program?
As an Energy Manager registered under
the Energy Commission, I played the
role of planning and coordinating the
implementation of energy savings projects
such as the compressed air optimization
programme that Proton embarked on since
January 2015. Furthermore, I also monitored
the monthly energy consumption for the
whole plant and provide energy reports with
energy consumption trending graphs and
breakdown of energy usage on a monthly
basis to the management. Under EMEER
2008 (Efficient Management of Electrical
Energy Regulation 2008), our plant is a big
user of electricity which consumed over
3mil kWh consecutive 6 months and we
need a Registered Electrical Energy Manager
(REEM) to report to Energy Commission
on the energy saving initiatives and energy
consumption, etc. Hence, it is my role to
prepare this report, sign off, and submit
to Energy Commission every 6 months.
What is the biggest surprise you
encountered?
When we started our energy savings
initiatives on compressed air system, we
never expected to have monetary savings
over RM 1 Million in utility bills just from
this project.
Has it been easy to persuade your
personnel to improve your system?
As with all organization, change is
something not everyone is comfortable with.
The challenge lies in motivating and getting
the people around you to move out of their
comfort zone and change the way they use
and operate the equipment and machines.
I would not say it is easy but with concerted
efforts from other energy managers in our
sister plants in Shah Alam and Casting plant
in Glenmarie, we managed to start the
Green Initiatives Campaign (Kempen Hijau
in Malay language) and slowly we get more
and more participation from all levels of
people. Currently, most of our maintenance
people and our management are aware
of our green initiatives and energy savings
programme in particular. We are slowly
gaining momentum as when people
started seeing the savings in monetary
terms, their awareness level increased
and so are their interest in pursuing or
supporting the energy savings programme.
What will you focus on next?
We are just half way through the compressed
air system optimization programme as there
are yet many air leaks not fixed along the
distribution pipes and in the production
floor. We also planned to change all
vortex cooler for panels in our plants to
conventional force convection fan (FCF)
which will bring further savings by reducing
the demand for compressed air. I would say
our focus this year (2016 to 2017) would
be to focus on identifying more air leaks
and rectifying them and to reduce overall
compressed air demand by changing the
vortex cooler to FCF fan system.
“When we started our energy savings initiatives on compressed
air system, we never expected to have monetary savings
over RM 1 Million in utility bills just from this project.”
– Abdul Azeem bin Mohamed Mohideen, Electrical Energy Manager, PROTON
0 8 / 1 6
|

keep a positive pressure to eliminate dust
entry and maintain the temperature inside the
control panel at 34±2˚C. It was estimated the
electricity bill to operate a Forced Convection
Fan is around RM14 per Month ($3 USD per
month). Furthermore, the replacement of the
vortex cooler by the Forced Convection Fan
method also provided the added benefit such
as a reduction of noise providing a quiet work
environment to workers.
For the High Inductive Distribution (HID)
panels, we required higher cooling capacity
above the cooling capacity generated by
the Forced Convection Fan. Hence, PTMSB
decided to install industrial air conditioning
systems for all the HID panels in the
plant because these HID panels produce
large amounts of heat and the electronic
components are vulnerable to overheating.
Conclusion
In short, the important element contributing
to the success of the Compressed Air System
Optimization (CASO) project at PTMSB
in reducing both energy consumption of
3,760,784 kWh and monetary savings of MYR
1,090,627 was the continuous support extended
by the UNIDO Energy Management System
(EnMS) and System Optimization (SO) program
operating in Malaysia, coordinated by Ms.
Kaveta Chelliah. With the training and guidance
provided by UNIDO EnMS, Mr. Bill Meffert and
Erik Gudbjerg; and CASO international trainers,
Ron Marshall and Bo Kuraa, with local experts,
Ahmad Zafuan and Ch’ng Eng Yong, PTMSB
Energy Manager, En. Azeem and other staff were
able to implement the EnMS tools to monitor
and track the plant’s electricity costs through
a proper method in accordance to the ISO
50001 system. The EnMS system also helped in
measuring and verifying savings made through
the CASO project and other various initiatives
carried out in the plant.
Note from Ron Marshall: The UNIDO CASO
awareness program was conceived and written
using the Compressed Air Challenge's training
materials and methods as guidance. This
successful effort at PTMSB, still not yet complete,
is a shining example of what awareness and
focused efforts can achieve! The physics
of compressed air knows no international
boundaries. What works to save money
in Malaysia will work in North America.
For more information about the Compressed Air
Challenge®
, contact Ron Marshall, email: info@
compressedairchallenge.org.
To read more Auto Manufacturer System
Assessment articles, please visit http://www.
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Atlas Copco Expands VSD+ Technology to GA 37-75
Atlas Copco has added their ground-breaking variable speed drive
plus (VSD+) technology to its entire range of GA oil-injected rotary
screw compressors. VSD+ is now available worldwide in all pack
and full feature versions of GA compressors. The technology was
previously only offered on the GA 7-37 models.
“The GA series is already a customer favorite,” said Erik Arfalk,
vice president of communication and branding for Atlas Copco
Compressors, LLC. “Adding VSD+ technology drastically decreases
operational costs by providing up to 50% more energy savings
compared to traditional compressors.”
VSD compressors adjust motor and element speed to meet the
demand of a plant or facility, making them ideal for applications
with variable demand. Because they are only running at the minimum
required speed, VSD compressors cut energy use and associated
costs. Atlas Copco VSD+ compressors offer further advantages,
including an iPM (Permanent Magnet) motor, a new compression
element and a sentinel valve, allowing them to deliver significantly
improved energy savings. With free air delivery (FAD) and specific
energy requirement (SER) both improved by 9%, customers get 9%
more air while using up to 9% less energy than with first generation
VSD compressors.
The GA VSD+ line provides a smaller footprint than traditional GA
VSD compressors and produces low noise levels of only 67dB(a),
making them ideal for a range of facilities and applications.
Atlas Copco is a world-leading provider of sustainable productivity
solutions. The Group serves customers with innovative compressors,
vacuum solutions and air treatment systems, construction and mining
equipment, power tools and assembly systems. Atlas Copco develops
products and services focused on productivity, energy efficiency, safety
and ergonomics. The company was founded in 1873, is based in
Stockholm, Sweden, and has a global reach spanning more than 180
countries. In 2015, Atlas Copco had revenues of BSEK 102 (BEUR 11)
and more than 43,000 employees. Learn more at www.atlascopco.com
Atlas Copco Compressors LLC is part of the Compressor Technique
Business Area, and its headquarters are located in Rock Hill, S.C.
The company manufactures, markets, and services oil-free and
oil-injected stationary air compressors, air treatment equipment,
and air management systems, including local manufacturing of
select products. The Atlas Copco Group, which celebrated its 140th
anniversary in 2013, is among the Top 100 sustainable companies
in the world and a member of the Dow Jones World Sustainability
Index. Atlas Copco has also been recognized by Forbes, Thomson-
Reuters and Newsweek, among others, for its commitment to
innovation and sustainability. Atlas Copco Compressors has major
RESOURCES FOR ENERGY ENGINEERSRESOURCES FOR ENERGY ENGINEERS
TECHNOLOGY PICKS
Atlas Copco has added VSD+ technology to the entire range of GA oil-injected
rotary screw compressors.
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TECHNOLOGY PICKS
sales, manufacturing, production, and distribution facilities located
in California, Illinois, Massachusetts, North Carolina, South Carolina,
and Texas. www.atlascopco.us
For more information and a GA VSD+ energy savings
calculator, visit http://webapps.atlascopco.com/
Industrial_air_animations/accalculator/#.
Kaeser Launches New
Secotec TE Refrigerated
Dryer Models
Kaeser Compressors, Inc. has
expanded their high-efficiency
Secotec line of refrigerated
dryers with the addition of
three new TE models. Available
in three sizes—TE 102 (325
cfm), TE 122 (410 cfm) and
TE 142 (470 cfm)—these new
TE dryers feature the same
Secopack LS thermal storage
system as our larger, award-
winning Secotec TF models.
Kaeser’s innovative Secopack LS thermal storage system contains
a phase-changing material (PCM) with 98% higher thermal storage
capacity than conventional storage media. Thermal energy is stored
as the PCM cycles from a solid to a liquid state that maintains a
more stable outlet dew point for better moisture control. This also
makes the Secotec TE units much lighter than other thermal storage
dryers and reduces package footprint. In addition to reducing
refrigerant compressor run time, the dryers’ internal design also
makes it possible to reduce pressure loss across the dryer to 1.8 psi
(compared to 2.9 and higher for conventional models).
These dryers also include Sigma Control Smart, a micro-processor
based controller which controls the thermal storage process. It has
an alarm and service message memory, as well as remote on/off
control capability. An optional Ethernet interface for connecting
to a master control system is also available.
To learn more about the new Secotec TE dryers or to be connected
to your local representative for additional information, please call
877-586-2691.
For more information, visit www.us.kaeser.com.
New Vaisala viewLinc Wireless Monitoring System
Vaisala viewLinc Environmental Monitoring System has been
redesigned to offer long-range wireless communication, ease of use,
and fast deployment.
The previous version of the viewLinc system has long been used by
pharmaceuticals, but it is also ideal for monitoring other high-value
assets that are affected by environmental conditions, such as air
temperature or humidity. It is used in museums, galleries, and in IT
server rooms, says Vaisala Product Manager Jon Aldous.
viewLinc provides trends, alarming, and customizable reporting that
ensures accurate environmental information via a wide selection of
Vaisala devices that monitor temperature, humidity, CO2
, and other
variables. For GxP compliance, validation documents are available.
The new viewLinc system leverages cutting-edge wireless
communications capabilities in order to utilize logging devices that
communicate reliably in obstructed environments.
We licensed a new long-range wireless specification to create VaiNet,
a proprietary wireless technology for viewLinc, tells Aldous. The
Secotec TE dryers feature Kaeser's
innovative Secopack LS thermal storage
system.
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Compressed Air Best Practices®
is a technical magazine dedicated to
discovering Energy Savings in compressed air systems — estimated by
the U.S. Department of Energy to represent 30% of industrial energy use.
Each edition outlines Best Practice System Assessments for industrial
compressed air users — particularly those managing energy costs in
multi-factory companies.
“We’re in 75 to 80 locations. We’ve done literally hundreds of compressed
air modifications, changes, upgrades and audits.”
– William Gerald, CEM, Chief Energy Engineer, CalPortland
(feature article in August 2015 Issue)
“Compressed air is essential to any manufacturing process, particularly
in the automotive industry, and it accounts for about 23 percent of total
energy costs at our powertrain facility.”
– Mike Clemmer, Director/Plant Manager-Paint Plastics, Nissan North
America (feature article in October 2015 Issue)
“Demand Side” and “Supply Side” information on compressed air
technologies and system assessments is delivered to readers to help
them save energy. For this reason, we feature Best Practice articles on
when/how to correctly apply air compressor, air treatment, piping,
storage, measurement and pneumatic control technology.
Industrial energy managers, utility incentive program managers,
and technology/system assessment providers are the three
stakeholders in creating energy efficiency projects. Representatives
of these readership groups guide our editorial content.
“Each of our 10 production plants has an Energy Coordinator who
is part of the corporate energy team.”
– Michael Jones, Corporate Energy Team Leader, Intertape Polymer Group
(feature article in July 2014 Issue)
2016 FOCUS INDUSTRIES!
Poultry Meat Packaging • Plastic Extrusion Molding • Food Processing Conveying • Chemical Plants Refineries • Energy-Efficiency System Assessments
Woodworking • Compressed Air Measurement • Wastewater Aeration • Commercial Bakeries, Snack Foods, Breads • Metal Fabrication Machining • Air Compressor Controls
Sustainable Energy Savings with Compressed Air Best Practices®
To subscribe visit airbestpractices.com

RESOURCES FOR ENERGY ENGINEERS
TECHNOLOGY PICKS

ADVERTISER INDEX
Company Page Web Site
Kaeser Compressors Outside
Back Cover
www.us.kaeser.com/cabp
Atlas Copco Inside
Front Cover
www.atlascopco.us
DV Systems Inside
Back Cover
www.dvcompressors.com
ELGI Compressors 5 www.elgi.us
Nano Purification Solutions 7 www.n-psi.com
Relevant Solutions 8 www.relevantsolutions.com
BEKO Technologies 9 www.bekousa.com
FS Curtis 10 us.fscurtis.com
JORC Industrial 11 www.jorc.com
Sullivan-Palatek 13 www.sullivan-palatek.com
Clean Resources 14 www.cleanresources.com
CDI Meters 15 www.cdimeters.com
SKF 16 www.skfusa.com
VP Instruments 17 www.vpinstruments.com
Sullair 19 www.sullair.com
Summit 21 www.klsummit.com
Anest Iwata 23 www.anestiwata.com
Compresyn Lubricants 25 www.compresyn.com
SMC 26 www.smcusa.com
ENMET 27 www.enmet.com
IWF 2016 35 www.iwfatlanta.com
WEFTEC 2016 39 www.weftec.org
World Energy Engineering
Congress 2016
43 www.energycongress.com
signal strength between network access points and data loggers can
travel over 100 meters indoors. It's not affected by walls, equipment,
Wi-Fi networks, or other usual signal impediments.
We worked with several long-time customers, collecting a wish-list
of system functions that could be either simplified or automated.
We eliminated or improved aspects of system deployment that were
time-consuming or complex, and updated the software interface with
embedded help to guide users through common tasks, says Aldous.
The result is a monitoring system that can be installed in minutes,
maintains compliance for years, and eliminates almost every issue
related to wireless data logging.
To view a 3D Video on the new wireless viewLinc
system visit www.viewlinc.vaisala.com
New ASCO Numatics 651 Series FRL
ASCO has introduced the new ASCO Numatics 651 Series filter,
regulator, and lubricator (FRL) line of air preparation products. This
new FRL line broadens the company’s high flow-rate 650 Series family
to include products with 1/8-inch and ¼-inch port sizes.
“The 651 Series FRLs require less space and are designed to fit
in compact applications and in machines that require less air
The new ASCO Numatics 651 Series filter, regulator, and lubricator (FRL)
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(USPS# 17130) is published monthly except
January-February combined by Smith Onandia Communications LLC, 37 McMurray
Rd., Suite 106, Pittsburgh, PA 15241. Periodicals postage paid at Pittsburgh, PA and
additional mailing offices. POSTMASTER: Send address changes to: Compressed
Air Best Practices®
, 37 McMurray Rd, Suite 106, Pittsburgh, PA 15241.
is a trademark of Smith Onandia Communications, LLC.
Publisher cannot be held liable for non-delivery due to circumstances beyond its control. No
refunds. SUBSCRIPTIONS: Qualified reader subscriptions are accepted from compressed air
professionals, plant managers, plant engineers, service and maintenance managers, operations
managers, auditors, and energy engineers in manufacturing plants and engineering/consulting
firms in the U.S. Contact Patricia Smith for subscription information at tel: 412-980-9902 or email:
patricia@airbestpractices.com. REPRINTS: Reprints are available on a custom basis, contact
Patricia Smith for a price quotation at Tel: 412-980-9902 or email: patricia@airbestpractices.
com. All rights are reserved. The contents of this publication may not be reproduced in whole or in
part without consent of Smith Onandia Communications LLC. Smith Onandia Communications LLC.
does not assume and hereby disclaims any liability to any person for any loss or damage caused by
errors or omissions in the material contained herein, regardless of whether such errors result from
negligence, accident, or any other cause whatsoever. Printed in the U.S.A.
COMPRESSED AIR BEST PRACTICES®
w w w . a i r b e s t p r a c t i c e s . c o m
Advertising :
Editorial
Rod Smith
rod@airbestpractices.com
Tel: 412-980-9901
Subscriptions :
Administration
Patricia Smith
patricia@airbestpractices.com
Tel: 412-980-9902
A Publication of : Smith Onandia Communications LLC
37 McMurray Rd. Suite 106
Pittsburgh, PA 15241
Contact Rod Smith for ad rates: rod@airbestpractices.com, Tel: 412-980-9901
RESOURCES FOR ENERGY ENGINEERS
TECHNOLOGY PICKS
consumption,” said Robert W. Kemple, Jr., executive vice president,
sales and marketing – Americas, ASCO. “With the highest flow
rates for their sizes, these highly reliable air preparation products
are ideal for packaging and other applications that require space-
saving designs.”
The 651 Series extended high- and low-temperature capabilities
(-40˚C to 80˚C) permit its application across a broad range of
operating conditions, including those with harsh environments.
The modular FRL products feature robust construction and are easy
to assemble, mount, and position. New manifold endplate flanges
allow a maintenance technician to pull the manifold assembly out of
service without disconnecting the piping. Front-facing, low-profile
gauges are easy to read, and the 651 Series is the only product of
its type that comes with these gauges on its shut-off isolation valves
and slow-start/quick exhaust valves.
Optional integral pressure range indicators added to the low-profile
gauges allows users to easily set the red/green color indicators to the
desired pressure range.
Additionally, an optional 3-micron pleated pre-filter has been
added to the line’s coalescing filters and coalescing filter/regulator
combination units. This filter eliminates the need for a separate
particulate filter unit, reducing cost, size, and weight.
About ASCO
ASCO, an Emerson company, offers comprehensive solutions of fluid
automation products for a broad range of process and manufacturing
industry applications. The company’s global scale increases speed to
market, its deep expertise across applications transforms ideas into
measurable outcomes, and its people create solutions that maximize
efficiencies and optimize customer applications. ASCO’s fluid
control and pneumatic product lines include a full range of solenoid
valves, angle body piston valves, valve manifolds, cylinders, filters,
regulators, lubricators and a complete range of accessories. For more
information, visit www.asco.com.
About Emerson
Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a
global leader in bringing technology and engineering together to
provide innovative solutions for customers in industrial, commercial,
and consumer markets around the world. The company is comprised
of five business segments: Process Management, Industrial
Automation, Network Power, Climate Technologies, and Commercial
Residential Solutions. Sales in fiscal 2015 were $22.3 billion.
For more information, visit www.Emerson.com.
For more information, contact ASCO by phone at
1-888-686-2842 or 1-248-596-3300, by e-mail at
an.insidesales@emerson.com, or visit www.asco.com.
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T H E M A R K E T P L A C ET H E M A R K E T P L A C E
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T H E M A R K E T P L A C ET H E M A R K E T P L A C E
TECHNOLOGY
Heavy-Duty 100%
aluminum pipe
ﬁttings
Seeking master
distributors
in uncovered
regions in the
Americas
Contact Paolo Nardi
sales@teseoair.com
www.teseoair.com
Aluminum modular piping for
compressed air, nitrogen and
vacuum (¾ “- 4 ½”)
www.Coalescing.com
AlliedGroup,Inc.5ColdhillRd.,Bldg19MendhamNJ07945
800-728-8311-973-543-4994–info@coalescing.com
1-800-728-8311
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Thousands of Installations Worldwide.
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Tel: 203-270-1400 • Toll free: 800-979-9156
Email: sales@stdpneumatics.com
www.stdpneumatics.com
www.Edgetechinstruments.com
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BUILTBETTER
With over 125 years of manufacturing excellence it’s
not only our products that are built to last, we strive to
build lasting relationships. Contact us to learn more.
DV Systems Ltd. 128-B Talbert Rd., Mooresville, NC 28117
1-877-687-1982dvcompressors.com
JOIN US, BECOME A DISTRIBUTOR
IT'S NOT ONLY THE PRODUCTS,
BUT PEOPLE AT DV SYSTEMS
THAT MAKE THE DIFFERENCE
FOR MY BUSINESS.
DENNIS BERMANI, OAK STREET CLASSICS, MOORESVILLE, NC
AIR COMPRESSORS 5 TO 200 HP

COMPRESSORSkaeser.com
Kaeser Compressors,Inc. • 866-516-6888 • us.kaeser.com/CABP
Built for a lifetime is a trademark of Kaeser Compressors, Inc. ©2016 Kaeser Compressors, Inc. customer.us@kaeser.com
KAESER SUCCESS STORY
Let us help you measure and manage your compressed air costs!
PROBLEM:
At a plant manufacturing turbines for hydro-electric power plants,
excess capacity had been a source of comfort for many years despite
recommendations for system updates. Four modulating, twenty-year
old compressors, two 75 hp, two 25 hp, supplied the system—without
central controls—causing excessively high energy costs. When a new
plant engineer came on board, he took a closer look at the energy
efficiency. Having attended a Kaeser Compressed Air Seminar, he knew
a systems approach could unlock significant savings.
SOLUTION:
Kaeser ran a KESS (Kaeser Energy Saving Simulation) using supply
side audit data and designed a complete system solution that would
dramatically reduce the specific power from 62.0 kW/100 cfm to 17.5
kW/100 cfm. New energy efficient compressors, an air receiver, as well
as a system master controller were installed. The new system has the
same number of compressors and total horsepower as before, but it
provides even more flow.
RESULT:
The Sigma Air Manager (SAM) master controller monitors the four new
compressors and selects the most efficient combination of units to meet the
plant demand.With its built-in SAC Plus software, SAM continually tracks
energy consumption so the plant benefits from having an ongoing com-
pressed air energy audit. As a matter of fact, the specific power has been
reduced more than anticipated—all the way down to 16.7 kW/100 cfm.
Annual Energy Costs of Previous System: $59,780 per year
Reduction in Specific Power: 45.3 kW/100 cfm
Annual Energy Cost Savings: $22,680 per year
Additional Savings in Maintenance Costs: $7,240 per year
TOTAL ANNUAL SAVINGS: $29,920
Simple Payback Period: 14 months
Seize the Savings!
A fresh approach yields sweeping savings for a quick ROI

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