Compressed Air Best Practices - April 2008 - (Page 15)

Focus Industry PLASTICS BLOW-MOLDING | 04/08 | Piping Pressure Drop Piping pressure drop created by excess velocity can also be a contributing factor in the loss of pressure to the blow-molding machine. Normally the header sizes are appropriate at 6" and 8", which have sufficient capacity at these pressures to support the plant requirements. However, the drop sizes have become a problem as heat-set processes have become more common. The typical 2" drop is at its design limit with 1500 scfm at 500 psig but many of the same blow-molding machines now require in excess of 2000 scfm. This excess velocity does not create much pressure loss due to friction because the length of pipe is relatively short, however, the resistance to flow does allow the pressure to fluctuate more dramatically because of the restriction. We recommend that for new installations, 3" pipe drop should become the standard to avoid additional operating costs due to pipe restrictions. Headers should be 6" or greater to avoid the same problems on a systemic basis. It is very difficult if not impossible to develop the long-term trending that is required to predict problems in a system this complex without a SCADA system (system control and data acquisition). A system designed by compressed air professionals will provide the proper information at a glance and trend performance against the Best Practice for the system to allow management to maintain the gains in efficiency (see attachments). For example: a. A trend of efficiency in scfm delivered to compressor kW which is relative to the Best Practice standard developed for this specific system is an extremely valuable management tool for maintaining performance over the long term b. Data on the operating condition of all supply side equipment can be trended to predict developing problems and it can be used to track preventative and predictive maintenance c. Compressor kW and valve temperatures provide indication of deteriorating performance prior to failures which will also allow the maintenance of the compressors to be scheduled based on deteriorating performance which will prevent a dependency on portable/rental compressors d. Inexpensive flow meters at each molding machine provide the data to indicate air leaks and/or improper setup on mold changes. Confirming pressure and flow should be a critical setup parameter Motorized Ball Valves THE CONDENSATE MANAGEMENT SPECIALISTS JORC offers a product range that covers ALL condensate requirements. We provide total quality and reliability so that you don’t have to compromise—our range of versatile and cost-effective solutions are designed to meet all of your condensate management needs. Through continued investment in research and development, we offer up-to-date solutions that you can count on. At JORC we never compromise on Quality or Reliability—why should you? Maintaining System Efficiency In our experience, preserving the operating costs savings created by upgrading the compressed air system in this type facility is the most difficult challenge. It requires diligent attention to the performance of the compressors and the process to prevent a gradual decline in efficiency and a return of the previous methods of operation. The long-term integrity of this system will be best protected by accurate and appropriate information regarding the systems performance and efficiency over time. Magnetic Zero Air Loss Drains Electronic Zero Air Loss Drains Contact us today: JORC Industrial LLC. 1146 River Road • New Castle, DE 19720 Phone: 302-395-0310 • Fax: 302-395-0312 E-mail: info@jorc.com See our new online catalog at www.jorc.com Timer Drains Compressed Air Leak Detector Oil Water Separators www.airbestpractices.com 15 http://www.jorc.com http://www.jorc.com http://www.airbestpractices.com

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Compressed Air Best Practices - April 2008 Contents From the Editor Utility-Air News The Compressed Air Audit of the Month: Minimizing Blow-Molding Pressure Fluctuations AF Compressors: Focused on 40 Bar, Oil-Free Air for the PET Industry Real World Best Practices: PET Plants Using Boosters for High-Pressure Air Guaranteeing Audit ROI for Blow-Molders Managing Vacuum Pressure Differential Are You Taking Full Advantage of Pneumatic Valve Technology? Are You Strategic? Resources for Energy Engineers: Training Calendar & Product Picks Wall Street Watch Advertiser Index Job Market

Compressed Air Best Practices - April 2008

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