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Artificial demand is defined as the excess volume of air that is required by unregulated end uses as a result of supplying higher pressure than necessary for applications. AFD Flow controllers can help to minimize artificial demand For more information visit:
The supply side refers to how the compressed air is generated and treated. Compressor Package. The compressors are evaluated in terms of appropriateness for the application and general appearance and condition. Compressor efficiency is usually estimated based on manufacturer-supplied data, corrected to site conditions. The installation is also evaluated in terms of its location, connection to cooling water, and ventilation. A general appraisal and any recommendations for alternative systems are also made. Filters. Filters are examined for cleanliness and suitability for the application. Pressure drop across the filters is measured to estimate energy losses from the filter. A maintenance schedule for changing the filters, and possibly higher performance filters, may be recommended. Aftercooler. Aftercooler and separator efficiency, cooling effectiveness, and condensate separation effectiveness are all measured and evaluated, and feasible modifications or alternative systems are recommended. Dryer. Dryer appropriateness is assessed based on the facility's end-use applications. Dryer size, pressure drop, and efficiency are measured and evaluated. Modifications and replacements are recommended if needed. Automatic Drains. Location, application, and effectiveness of both supply-side and demand-side drains are evaluated and alternatives recommended if necessary. Air Receiver/Storage. The effectiveness of the receiver tank is evaluated in terms of location and size, and the receiver drain trap is examined to see if it is operating properly. Storage solutions to control demand events should also be investigated. For more information visit:
The demand side of the system refers to how compressed air is actually used in the plant. Distribution System. The overall layout of the distribution system (piping) is examined. Pressure drop and efficiency are measured or estimated, and the effectiveness of the condensate removal system is evaluated. Simple changes that can enhance system performance are suggested if appropriate. Load Profile. Auditors typically estimate the compressed air load profile in terms of how the demand in cubic feet per minute (cfm) changes over time. A facility with a varying load profile will likely benefit from advanced control strategies. A facility with short periods of heavy demand may benefit from implementing storage options. To establish the load profile, an auditor will measure system flow and pressure across the system under different demand conditions, while observing the loading effect on the existing compressors. This may require a number of measurements over a 24-hour period (or even several days) if demand varies significantly over time. Auditors may use data logging equipment to obtain both demand and power consumption profiles. End-Use Equipment. The equipment and processes that use compressed air will also be examined. In some cases, recommendations such as specifying equipment that operates at a lower pressure will be made. An auditor may also recommend replacing existing compressed air-powered equipment with equipment that uses a source of energy other than compressed air. Critical pressure applications are examined in detail. Local storage and other modifications may be recommended. For more information visit:
Flow controllers are system pressure or density controls used in conjunction with the individual compressor or system controls described previously. A flow controller does not directly control a compressor and is generally not included as part of a compressor package. A flow controller is a device that serves to separate the supply side of a compressor system from the demand side. This allows compressors to be operated at or near their optimum pressures for maximum efficiency while the pressure on the demand side can be reduced to minimize actual usage requirements. Storage, sized to meet anticipated fluctuations in demand, is an essential part of this control strategy. Higher pressure supply air enters a storage tank at a predetermined rate and is available to reliably meet fluctuations in demand at a constant, lower pressure level. A well designed and managed system integrates control strategy, demand control, signal locations, differentials, compressor controls, and storage. The goal is to operate demand at the lowest possible pressure, support transient events as much as possible with stored air, and take as long as possible to replenish storage. This should result in the lowest possible energy consumption. For more information visit:
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