Compressed Air, Blower and Vacuum Systems: Alternate Design Strategies
Date: March 31, 2021
Time: 2 PM EDT (11 AM PDT)
Duration: 1 hour
Central compressor and vacuum systems are typically placed in the plant, often in their own room or a space shared with boilers or other ancillary equipment. It is common to find these machines plagued by poor ventilation, high heat, high dust, etc.
For plants expanding production, time and space are critical. They may not have existing floor space to accommodate both new production and new compressed air equipment. Design, permitting and construction/renovation of compressor rooms cost real money both in capital outlay and lost productivity.
Join this webinar to learn how, using a different approach, whole compressor rooms can be designed, sourced, built to spec, and commissioned much faster (and at a lower cost) than renovations or building additions. Webinar attendees will learn how flexible alternative designs are increasingly being adopted by innovative companies looking for new solutions to long standing problems.
Register for this webinar to learn about opportunities to improve uptime and safety, increase productivity and make room for new production equipment by packaging compressed air, blower, and vacuum systems and getting them out of the plant.
Compressed Air System Optimization Best Practices
Many facilities and operations teams know how to assess and optimize the supply side of their compressed air systems, but fewer have a handle on the distribution side (i.e., pipe layout and leak detection), and fewer still are able to focus on driving out demand-side inefficiencies. This webinar provides an overview of compressed air system optimization best practices, with special focus on the distribution and demand side of these systems.
Compressed Air Best Practices
Calculating Storage for Demand Events
Join Keynote Speaker, Tom Taranto, Owner, Data Power Services, to discuss design calculations to engineer storage volume for specific applications, rather than using general rules of thumb to estimate the amount of storage volume. He will also review calculating storage volume for the unanticipated shutdown of a compressor and the need to accommodate the permissive start-up time of a stand-by compressor. He will also discuss calculating dedicated storage volume to improve performance of a high speed “flying cut-off cylinder.”
Neil Mehltretter, Engineering Manager, Kaeser Compressors, Inc. is a guest speaker (approx. 10 minutes) and will be discussing How Controls and Piping Affect Large Air Demand Events. During Kaeser’s portion of the webinar, Neil Mehltretter will discuss how single compressor systems and multiple compressor systems operate during high demand events, whether additional measurement points can be helpful, and what impact piping can have on these events.
New Equipment Digest
Reliability & Data Monitoring in the Age of Remote Working
The COVID-19 situation has underscored the importance of reliable communications and the value of having remote access to your business systems, whether from home or across the plant. One silver lining—in this otherwise terrible situation—is that businesses are discovering new ways to leverage networking technology to optimize personal productivity with the important benefit of remaining operational in troubled times.
Tracking your compressed air system remotely is another critical part of this process. Even in normal times, routinely visiting the compressor room to manually check the condition of the system is usually inconvenient and often forgotten—until there are problems. For plant managers, engineers, production, and operations managers, having compressed air system data at your fingertips can help avoid costly downtime.
This webinar will explore:
- What compressed air data points can and should be effectively monitored
- How this information translates to a more reliable compressed air station.
Join Neil Mehltretter, Engineering Manager at Kaeser Compressors, as he covers considerations and practical options for remotely monitoring your critical compressed air systems.
Oversizing: A Widespread Compressed Air Problem That Is Costing You Time and Money
A review of thousands of compressed air systems reveals that, on average, users operate below 50% of system capacity. Regardless of industry and application, oversized compressors are among the most common problems in air systems. Over sizing hits the bottom line in many ways, including higher purchase costs, higher maintenance and repair costs, higher energy costs, lost production due to pressure fluctuation and shorter compressor life. In this webinar, compressed air experts Neil Mehltretter and Werner Rauer will address why oversizing occurs, how to identify oversized systems, how they impact productivity and profitability, and strategies to reduce the effects of this epidemic.
Comprehensive Compressed Air Assessments: The 5-Step Process
The U.S. Department of Energy estimates that air compressors use as much as 10% of all electricity generated in the United States, and that as much as 50% of compressed air demand is for non-productive uses including leaks, artificial demand, and improper uses. Compressed air leaks alone account for 25-30% of compressed air use. On top of that, additional power is wasted in the creation of compressed air through improper sizing, pressure selection, and controls--which also has significant impact on equipment reliability.
Unfortunately, most compressed air users have not seriously assessed their system efficiency. With minimal cost and interruption (sometimes none), accurate compressed air assessments can quickly determine the critical KPI of Specific Performance of your system and help identify sources of inefficiency. The collected data can then be used to calculate ROI for alternative improvement initiatives.
Join compressed air system design expert Neil Mehltretter as he lays out the five steps in a compressed air assessment and presents a real-world example in which a compressed air user achieved a 42% reduction in annual energy costs.
Compressed Air Best Practices
Control Strategies for Multiple VFD Air Compressors
Join Keynote Speaker, Ron Marshall, Chief Auditor, Marshall Compressed Air Consulting to discuss control strategies for multiple VFD air compressors. Compressed air systems have evolved from simple cascaded control strategies to more sophistical central control with both fixed speed and VFD air compressors combined. Some of these systems have been installed with two or more VFD air compressors. This webinar will discuss some of the benefits and pitfalls of using multiple VFDs in a combined system and how to best control these scenarios. Mr. Marshall will also share case studies to illustrate those strategies.
The Sponsor Speaker is Werner Rauer, Rotary Screw Compressors Product Manager, Kaeser Compressors, Inc. His presentation, “Control Strategies for Multiple VFD Air Compressors Part 2”, will complement Ron Marshall's presentation with some practical considerations for applying VFD compressors. He will also discuss some real-world installations of multiple VFD air compressors with a focus on the impact of proper controls.
Examine Key Design Considerations That Contribute to an Efficient Compressor System
The real estate mantra, “location, location, location,” rings true for getting the energy savings and reliability you’re expecting from your compressed air system. To obtain the envy of all your friends and neighbors, there are a couple of key design considerations that greatly affect your compressors’ performance and therefore your system’s performance.
Join compressed air experts Neil Mehltretter and Wayne Perry as they examine key design criteria when planning your compressed air system, including ventilation, equipment clearance, compressed air storage and piping, and the overall compressor room environment. This webinar reviews the key design considerations that contribute to an energy-efficient, reliable, scalable compressed air system.
Webinar attendees will be able to answer:
- How does ventilation impact compressor performance?
- Why is my compressed air system constantly shutting down?
- Are my compressed air storage tanks sized correctly?
- Is my piping designed to deliver air with maximum efficiency?
- How can I tell if my station is efficient?
- Can system design affect compressor reliability?
Water & Wastes Digest
How to Evaluate Blowers by Application
Blowers are a critical resource for WWTPs, so choosing the best blower is vital for plant operational success. No plant is stagnant, so a one size fits all approach often provides less than ideal operational scenarios that plant operators must constantly adjust to. Taking the time during the blower selection and evaluation stage can go a long way to improving performance and control of the process.
Join Stephen Horne, Blower Product Manager for Kaeser Compressors, Inc., in this webinar as he explores how to evaluate blowers in wastewater applications to ensure the best blower is chosen as well as control options for these applications.
Blower & Vacuum Best Practices
Techniques for Determining Savings from Aeration Blowers
Join Keynote Speaker, Tom Jenkins, P.E., President, JenTech Inc., to learn how to calculate savings from aeration blower and control upgrades. This presentation will include techniques for determining blower duty cycles, typical utility billing procedures and their impact on operating costs. He will also discuss strategies for evaluating life cycle cost, comparing alternatives and project justification through present worth analysis and simple payback methods.
Sponsor Speaker: Stephen Horne, Blower Product Manager, Kaeser Compressors, Inc. He will include a real-world example on some of these strategies in his presentation titled “Case Study: Savings from Aeration Blowers.” Stephen will explain how these techniques were able to help a wastewater treatment plant in a small West Virginia town. This case study will specifically explain how a blower controller was able to help the plant save energy, automate the DO controls, and verify the power savings for an energy rebate.
Using Predictive Technologies with Compressed Air
Compressed air has a major impact on production, with downtime a chief concern for industrial plants. The move towards IoT connectivity offers opportunities to better monitor and manage mission critical equipment, such as compressed air systems. Incorporating predictive technologies into day-to-day operations has the potential to improve reliability, increase up-time, and reduce maintenance costs.
Compressed Air Best Practices
5 Tips on optimizing VFD air compressors
Join Keynote Speaker, Loran Circle, Senior Consultant for Compressed Air System Training & Consulting, to learn 5 tips on optimizing VFD air compressors. He will explain how these air compressors work and how to properly integrate them within a compressed air system. This presentation will also examine how pressure setpoints, site conditions, storage and flow controllers impact VFD air compressors and system optimization.
Werner Rauer, Rotary Screw Compressors Product Manager for Kaeser Compressors, will present "Proper Application of Variable Frequency Drive Compressors.” He will discuss key points to consider when designing compressed air systems with variable frequency drive technology.
Water & Wastes Digest
How to build a better blower station
Designing a blower aeration system for a wastewater treatment plant has many moving pieces. Each contributes to the overall health and efficiency of the system and the impact of poorly addressing one area can have far-reaching implications for many years to come. In order to achieve reliable and energy efficient operation, it's vital to consider technology, station sizing, the installation room, communications, and more. This culminates in writing a clear specification that can help streamline the bidding process.
Body Shop Business
Compressed Air for Body Shops
A reliable supply of clean, dry compressed air is vital for body shops. Taking the time to understand air quantity and quality requirements can keep energy costs in line and prevent the costly re-work caused by contaminants in the compressed air supply.
Join compressed air experts Michael Camber and Neil Mehltretter as they discuss best practices for compressed air systems in body shops.
Components in a compressed air system necessary for bodywork and spraying finishes
Types of dryers and tips on selecting the right one
Air treatment components to ensure clean, dry air that won’t ruin paint jobs
Common types of contaminants and how to remove them
Key design factors for evaluating a compressed air system
How piping material selection impacts air quality
Blower & Vacuum Best Practices
Blower Controls for Aeration Efficiency
Learn how to optimize blower power consumption while meeting variable aeration demands.
There are many types of blowers used for supplying aeration systems and many methods for modulating blower flow rates. The flow rate and discharge pressure for aeration blowers are determined by fluctuating process demands. This webinar will discuss the methods appropriate for each blower type. The trade-offs of each method in efficiency, reliability, and energy consumption will be covered. Techniques for analyzing and comparing wire-to-air power consumption will be explained with illustrative examples provided.
Stephen Horne, Blower Product Manager for Kaeser Compressors, presents: “Blower Master Controllers – How the IIoT can Optimize Blower Station Performance.” This presentation will cover how proper communications between blower packages and a master controller can truly optimize performance, predict future requirements, and increase reliability.
Compressed Air Best Practices
IoT and Compressed Air Management Systems
Join Keynote Speaker, Tim Dugan, President and Principal Engineer of Compression Engineering Corporation to learn how IoT is driving compressed air monitoring and control to become easier than ever before within a plant. His presentation will review compressed air master controls, compressed air room monitoring and demand-side monitoring. He will also discuss how IoT has made it easier and less expensive for end users to implement air compressor room and demand-side monitoring.
Jarno Manzke, Technical Director for Kaeser Compressors presents: “How the IIoT Will Change the Face of Compressed Air in Industrial Environments.” The Industrial Internet of Things (IIoT) has proven to have far-reaching consequences both in terms of technology and in challenging the way we think. This presentation will put the IIoT in the context of compressed air, describing the current situation and what compressed air suppliers, service providers, and end-users may expect to see in the future.