Industrial Utility Efficiency    

Compressor Controls

When a system has the right combination of VFD and base-load air compressors, how do you coordinate their control? What tells the air compressors to run and load, to have just enough (or no) base-load air compressors and a VFD running, all the time air is needed? Appropriate master controls are needed. These controls are often called “sequencers” or “master control systems”.
The purpose of this article is to investigate the cause and effect that can occur when you reduce demand with no supply changes and the alternative which will produce positive, long term results which you can take to the bank.
This textile plant uses compressed air in their knitting, sewing, and dye house operations and needed a system designed for the significant fluctuations in demand. Compressed air demand profiles were placed into four segments; 1st shift peak demand and minimum demand, and 2nd shift peak demand and minimum demand.
Compressed Air Best Practices interviewed Mr. John Malinowski, Senior Product Manager-AC Motors, Baldor Electric Company.
Compressed Air Best Practices interviewed Richard Feustel, the Corporate Energy Manager of Briggs & Stratton.
This article presents a case study of Grimmway Farms; a carrot growing and packing firm located in California’s Central Valley that was able to improve its compressed air system efficiency after implementing system automation and making relatively small equipment and piping changes.
Easy-to-implement master control and monitoring systems provide crucial system information including the key performance indicators required to manage air compressors and their associated energy costs.
We are finding significant changes in industry with regards to which managers are involved with our discussions.
Productivity and profits are very directly linked to the compressed air system, as is waste elimination. High performance central compressed air management systems can respond quickly to even extreme system fluctuations, improving productivity and minimizing energy waste.  This is accomplished with modern software systems analyzing and processing appropriate data and triggering proactive actions - before the dynamics effect the compressed air production system.
In today’s world, where “green” is “gold”, the efficient operation of multiple air compressors has taken on a new sense of urgency. In an era where giant manufacturing campuses with huge compressed air systems are fast disappearing, the emphasis shifts now to improving the efficiency of the higher numbers of installed small and medium size air compressors.
The NPE2009 international plastics showcase was held June 22-26 in Chicago’s McCormick Place. While attendance was down from NPE2006, the preliminary total of visitor registrations numbered 44,000. Sustainability and energy efficiency was a prominent topic in the booths of exhibitors. Manufacturers of compressed air and injection molding equipment had many developments with Sustainability to show the visitors to NPE2009.