The Magazine for ENERGY EFFICIENCY in Compressed Air, Pneumatics, Blower and Vacuum Systems Air Compressor December 2013 Controls 8 TIGG Corporation Audit Reduces Energy Costs 16 Three Compressed Air Demand-Reduction Projects at a Glass Plant 22 Your Compressor May Be Smarter Than You Think 38 Types of Compressed Air Dryers SHOW REPORT: 2013 PROCESS EXPO 34 Atlas - Fast Forward Ad 8.375 x 10.875:Layout 2 10/3/13 5:21 PM Page 1 Fast. Forward. Now. Are you ahead of the curve? Efficiency boosts your bottom line, and no one does efficiency like Atlas Copco. To keep our products at the leading edge of innovation and in tune with our customers’ needs, the Atlas Copco Group invested more than $330 million into research and development last year. This relentless focus on innovation gives rise to exciting new energy saving technology. Whether your energy bill is $1,000 or $100,000 a month, Atlas Copco has the products that could save you 15% to 50% on these energy costs. Let us prove it to you! Check out the 2013 game changing lineup at www.atlascopco.us/gamechangerusa or call 866-688-9611. Air compressors, blowers, generators, vacuum, quality air solutions and more. © Copyright 2013 Atlas Copco Compressors LLC. All rights reserved. | 12/13 COLUMNS SUSTAINABLE MANUFACTURING FEATURES 8 The Compressed Air System Assessment TIGG Corporation and Entergy Arkansas Reduce Energy Costs By Kevin Conley, Arkansas Industrial Machinery 16 The Compressed Air System Assessment Three Compressed Air Demand-Reduction Projects at a Glass Plant By Don van Ormer, Air Power USA 8 22 Your Air Compressor May be Smarter Than You Think By Ron Marshall for the Compressed Air Challenge® 28 Energy Savings Result from Compressed Air Dryer Selection By Christopher Ursillo, Ingersoll Rand 34 SHOW REPORT Compressed Air & Pneumatics at PROCESS EXPO 2013 By Rod Smith, Compressed Air Best Practices® Magazine 38 Types of Compressed Air Dryers: Refrigerant and Regenerative Desiccant By the Compressed Air & Gas Institute 28 COLUMNS 5 From the Editor 6 Compressed Air, Pneumatics, Vacuum & Blower Industry News 44 Resources for Energy Engineers Technology Picks 46 Advertiser Index 34 49 The Marketplace Jobs and Technology 4 airbestpractices.com COLUMNS 12/13 | FROM THE EDITOR Air Compressor Controls We have a broad variety of articles this month. The first is about COMPRESSED AIR BEST PRACTICES® EDITORIAL Advisory Board Manager, Demand Side a plant owned by TIGG Corporation (yes, the custom tank people) Doug Barndt Ball Corporation down in Arkansas. Kevin Conley, from Arkansas Industrial Machinery, Energy-Sustainability Eric Battino Productivity Senior Manager PepsiCo conducted a system assessment that took TIGG from a retrofitted 350 William Jerald Energy Manager CalPortland hp compressor to two new 75 hp rotary screws with one serving as Global EH&S/ Varroc Lighting Jennifer Meier back-up! The project received a utility incentive from Entergy and also Plant Engineering Manager Systems Archer Daniels led to other energy conservation projects getting done. Thomas Mort Energy Director Midlands Corporate Energy Team Ron Marshall provides us with a true “air compressor controls” article this month on Brad Reed Toyota Leader ® Industrial Energy Managers behalf of the Compressed Air Challenge . With the fun title, “Your Air Compressor May Energy/Asset Reliability Greg Rhames Verallia Be Smarter Than You Think”, the article makes clear what many of us know. As with any Manager technology, the main issue with controls is not whether it exists rather if it’s actually used Brad Runda Global Director, Energy Koch Industries and applied appropriately. Don Sturtevant Corporate Energy Manager Simplot SAIC/Wisconsin Richard Feustel Senior Energy Advisor I’m always looking for demand-side audit information and it’s once again provided by Focus on Energy SPX Flow Jay Francis Vice President Marketing Air Power USA. Don van Ormer provides us with examples of three demand-side projects Technology they recently did at a glass plant. Speaking of the demand-side, Process Expo 2013 was Tilo Fruth President Beko USA held in November at McCormick Place in Chicago. As you know, food processing and Blackhawk Chris Gordon President packaging machines rely upon pneumatic circuits, vacuum circuits and chillers. I hope Equipment Clint Hodge National Accounts Manager ASCO Numatics you enjoy my “roving reporter” article as I review the compressed air and pneumatic Paul Edmac General Manager technology at the show. Humphreys Compressor Parts Paul Johnson Global Sales Manager Parker Hannifin We have two good articles on compressed air dryers in this issue. One article is supplied Universal Air & Kurt Kondas President by Chris Ursillo from Ingersoll Rand and the other from the Compressed Air & Gas Institute Gas Products Director Global Service (CAGI). When should a factory use a refrigerant or a desiccant dryer? What dew point Mark Krisa Ingersoll Rand Solutions requirements do our processes have? What are the associated energy costs? These are Director Marketing / Frank Langro Festo important questions each compressed air user should understand. Product Management Customer Engineering Compressed Ron Marshall It’s hard to believe this is the last issue of 2013. I’m looking forward to starting next Services Air Challenge® Compressed Air System Assessments year with a bang at the 2014 International Production & Processing Expo (www.ippexpo. Pierre Noack President Aerzen USA Kaeser org) scheduled for January 28-30 at the Atlanta Convention Center. We are proud to be a Wayne Perry Technical Director Compressors Supporting Publication and hope you can visit the show. Please stop by the Compressed Atlas Machine & Andy Poplin Sales Manager Air Best Practices® Magazine booth (7662 B Hall) and say hello! Supply Senior Manager, Nitin Shanbhag Hitachi America ROD SMITH Industrial Division Richard Compressed Air & Editor Technical Director tel: 412-980-9901, [email protected] Stasyshan Gas Institute Hank Van President Air Power USA Ormer supports: airbestpractices.com 5 | 12/13 COLUMNS COMPRESSED AIR, PNEUMATICS, VACUUM & BLOWER INDUSTRY NEWS Atlas Copco Acquires U.S. Oil & Gas Service Company over seeing all current and future projects at BOGE America. Michael Atlas Copco has purchased the operational assets of Archer Troyer brings years of experience in the compressed air industry, Underbalanced Services, a leading service provider of down-the-hole customer service attitude, and a strong mechanical and electrical hammers, drill bits and compressed air packages to U.S. land-based aptitude to BOGE. At BOGE, he will manage all warranty and technical oil and gas drilling companies. support for the BOGE Distributor Network across North and South America. Michael’s work ethic, interpersonal skills, and compressed air Archer Underbalanced, a part of Archer Well Services, based in Houston, knowledge will be a great addition to the team at BOGE America. Scott Texas, had sales in 2012 of MUSD 34 (MSEK 230). The acquired assets Woodward, General Manager for BOGE America commented, “Having include five service locations near major oil and gas reserves, and a drill Michael Troyer join the already strong team at BOGE America will be bit manufacturing facility in Carlsbad, New Mexico. A total of 75 Archer a great addition in our effort to deliver superior Customer Service and Underbalanced employees is expected to transition to Atlas Copco. Technical Support to our Distributor Network.” “We are very pleased with this acquisition as it greatly enhances our Visit www.boge.com/us distribution and support presence in the U.S. land-based oil and gas drilling industry,” said Johan Halling, Business Area President, Dost Kompresör Becomes Part of Atlas Copco’s Compressor Atlas Copco Mining and Rock Excavation Technique. “This creates Technique Service Division opportunities for adding several complementary Atlas Copco product Atlas Copco Internationaal B.V. has acquired Dost Kompresör ve lines in the future such as state-of-the-art compressed air solutions Endüstri Makinalari Imal Bakim ve Ticaret A.S., a distributor and through this new distribution channel.” service provider of compressors and related equipment in Turkey. The acquired business will become part of Atlas Copco’s business area Dost Kompresör, based in Istanbul, Turkey, has 16 employees and is Mining and Rock Excavation Technique. active in industrial compressor sales and service. “This acquisition will Visit www.atlascopco.com expand our presence in the increasingly important Turkish market,” said Stephan Kuhn, President of Atlas Copco’s Compressor Technique Business Area. “It supports our strategy to focus on service relations BOGE America Appoints New Service Manager with our customers”. Boge Kompressoren, manufacturer of rotary and oil-free screw compressors, is pleased to announce that Michael Troyer has been appointed as Service Manager. Josh Chabot, current Service Manager To read more Industry News articles, visit www.airbestpractices.com for BOGE America, is moving into a new position as a Project Manager “ A total of 75 Archer Underbalanced employees are expected to transition to Atlas Copco.” 6 airbestpractices.com THINK H ANKISON For Your Energy Saving Solutions Where Ideas Meet Industry Hankison, an SPX Brand, is globally known for compressed air treatment products delivering time proven reliability, premium performance and sustainable energy savings. For over 60 years, we continue to develop innovative technologies to best serve our valued customers.