Compressed Air Best Practices - January 2008 - (Page 37)

Focus Industry ENERGY MANAGEMENT | 01/08 | MEASURING VACUUM BY DOCTOR VACUUM It seems that there is a new rule of thumb in the vacuum industry: the less money you spend on a vacuum gauge, the more likely it is that you will attain perfect vacuum. When I get phone calls or emails about vacuum systems, my first question is always the same, “what is the level of vacuum in the system or at the process?” In other words, what amount of vacuum is doing the work for you? The answers I get are varied but can be placed into three general camps. The first and most common answer is that the level of vacuum is “unknown” and they really do not know exactly what they have or what they need. The second most common answer is an “around” number. For example, someone will say they have around 26" HgV to 28" HgV based on a gauge somewhere in the system. The gauge may not have been calibrated since the late 1970’s but at least it is there. The third answer category, which is very rare, is they know exactly what they have and exactly what they need. because compressed air systems can easily have a 20 psig swing and production can still function normally. Vacuum systems only have the equivalent of about 15 psig total to work with, so accuracy in vacuum processes has to be that much greater. It is prudent to place a couple of high-quality gauges at your process so that accurate metrics can be established. This way, trouble-shooting is streamlined when there are hiccups and improvements can be implemented with complete and accurate information. Attaining the “perfect” vacuum for your production systems then becomes much easier. My second recommended location for high-quality gauges is directly at the inlet to the supply vacuum pump or at the manifold in multiple pump systems. With accurate gauges in two locations, you are provided with a simple yet effective diagnostic tool. Lastly, when new piping systems are put in place or modifications are made to existing systems, I recommend installing threaded gauge ports in other strategic locations where gauges can be installed for system analysis and monitoring when necessary. The most severe example of a lack of measurement that I have seen was in a production system that was generating vacuum at 26" HgV and using vacuum at 4" HgV. That particular system was using over three times the horsepower that it needed to do the work. Accurate demand information also allows you to make the necessary changes in production machinery for increased throughput or scrap reduction. Knowing exactly what levels of vacuum are typical in your production systems allows you to fine tune your supply and distribution systems to optimize your ratio of energy input to work output. BP For more information contact Dan Bott, Dan Bott Consulting LLC, tel: 251-609-1429, email: dan@dbott.com, www.danbottconsulting.com Measurement of Vacuum is Critical Install Gauges at the Process Install Gauges at Pump Inlet Your process is critical to your success as a manufacturer and knowing the benchmarks for vacuum supply at the process is essential. Saying your supply is around 26" HgV to 28" HgV is an equivalent magnitude to stating that your compressed air supply is 100 to 200 psig — a very large range. This is where the compressor workers have an easier time Compressed Air Best Practices Magazine has introduced the AIR BEST PRACTICES symbol (at left) to represent the tremendous opportunity for dollars to be saved in electrical costs of compressed air systems. These projects have very attractive ROI profiles for corporations. The reductions in kW consumption by industry will have correspondingly positive benefits to the ambient air in the form of reduced carbon dioxide emissions and greenhouse gases. ROD SMITH www.airbestpractices.com 37 http://www.danbottconsulting.com http://www.airbestpractices.com

Table of Contents Feed for the Digital Edition of Compressed Air Best Practices - January 2008

Compressed Air Best Practices - January 2008 Contents Focus Industry Features Compressed Air Industry Articles From the Editor Real World Best Practices: Selecting A VSD Rotary Compressor Audit of the Month: Energy Savings in Peru The Low-Hanging Fruit in Pneumatic Systems Mikropor America, Inc. Wireless Sensor Networks: Improve Efficiency in Compressed Air Systems Special Report: The Chicago Pneumatic Compressor Launch in North America The Importance of Measuring Vacuum The Comp-Air Service Co. Special Report: The 2007 NAACD Wall Street Watch Advertiser Index Job Market

Compressed Air Best Practices - January 2008

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