TRACK 1: On-Site Utility Sustainability: Energy & Cooling Water Conservation (Room S402A)

Monday, October 23rd

8:00 am – 10:00 am Opening Session

10:00 am – 10:15 am Coffee Break Sponsored by Bobcat

10:00 am – 5:00 pm EXPO Floor Open

10:15 am – 12:15 pm Session #1: CAGI Education Seminar – Case Studies in Maximizing Compressed Air Efficiency

Chair: Chad Larrabee, Product Management Leader, Oil Free Compressors, Ingersoll Rand

• Compressed Air as a Utility and Centralizing a System
  Neil Mehltretter, Technical Director, Kaeser Compressors

Case Study #1 Compressed Air as a Utility: a 20-year-old compressed air system installed in a small, confined space experienced ongoing service-related issues. The system comprised of three 75 hp water-cooled air compressors with one heated desiccant dryer. A compressed air system assessment was performed to determine existing demand, find a more suitable space for the equipment, provide redundancy, increase reliability and reduce carbon footprint. He will share the solutions implemented including an external enclosure, utility contract, plus new VFD and air-cooled compressors.

Case Study #2 Consolidating into One Centralized Compressed Air System: an expanding multi-plant campus experienced reliability and maintenance problems with its aging compressed air systems installed in multiple locations throughout the plant. With multiple compressed air applications throughout each plant, a system assessment found the optimal solutions to be consolidation into a reliable, centralized compressed air station with one master controller. These findings will be presented in detail, as well as the implemented solutions consisting of four 100 hp air compressors with internal refrigerated dryers. Solutions for inadequate installation space and ventilation will also be shared.

As Technical Director, Neil Mehltretter oversees Kaeser’s Technical Department with responsibilities including product management and system design. An authority on compressed air assessments, Neil has conducted and supervised thousands of industrial compressed air studies, helping users achieve significant energy savings and operational improvements. Neil has a bachelor’s degree in chemical engineering from The University of Florida and holds several industry certifications.

• Calculating the Impact of Artificial Demand and Pneumatic Cylinders
  Mark Krisa, Strategic Account Manager, Ingersoll Rand

Case Study #1 Artificial Demand – Getting to the Real Numbers: Artificial Demand is often estimated incorrectly, even with theoretical calculations. In this case study, for a specific compressed air system operating at steady state, we’ll compare empirical data and analysis to theoretical calculations of artificial demand. The discussion will include sources of error and considerations when calculating energy savings and the impact of changes to system pressure. The margin of error can be surprising.

Case Study #2 Pneumatic Air Cylinders – A Simple User of Air with Big Implications: Pneumatic air cylinders are prolific in industry but can be misunderstood when evaluating their impact on the compressed air system. In this study, the theoretical calculations for a simple air cylinder will be reviewed and common errors identified. A high-speed pressure time plot for an air cylinder will be presented to illustrate a practical example of what occurs in a cylinder and considerations for corrective actions and performance.

Mark is Strategic Account Manager at Ingersoll Rand. A graduate with a degree in engineering science from the University of Western Ontario in Canada, Mark has worked in the compressed air industry for over 30 years.  His experience in the industry is diverse ranging from compressor service technician through engineering, compressed air system auditor and product management.  Mark has authored several papers and is a project member with CAGI, ISO and CSA.

• Dryer Purge Air and Tuning Heat of Compression Dryers
  Jarett Lieser, AIRScan Audit Specialist, Atlas Copco Compressors

Case Study #1 Purge Air from Compressed Air Dryers: Dryer Purge Air can be a huge user of compressed air. In this study we will look at how much Purge Air can affect the compressor room and the total electrical cost. We will look at the customer compressor room layout, the total usage of compressed air and total Purge Air, what recommendations were made to the compressed air user and what improvements were made.

Case Study #2 Heat of Compression Dryer: oversized compressors with heat of compression dryers – in this study we will look at how much compressed air the customer needs versus how much they can make. Customer also needs -40°F dew point with a heat of compression dryer and what is done to hit this dew point. We will look at the customer compressor room layout, recommendations and improvements made for the compressed air user.

Jarett is a graduate from Alexandria Technical College with a degree in fluid power. For many years, he worked primarily in the maintenance field before transitioning into the compressed air field. He has worked as a technician, in sales support roles, tech support roles, as a product specialist, and now serves as a compressed air auditor for Atlas Copco.

• Compressed Air Purity Requirements for Plant and Process Air
  Ryan Remington, National Sales Manager, Pneumatic Products, Hankison

Case Study #1 Plant Air Purity Requirements – Solving the Dehydration and Filtration Equation: Plant Air is a common term, but what does it mean when it comes to air purity? This first case study reviews the application of plant air and what levels of dehydration and filtration are required for the end use of a typical general industrial manufacturer. Discussion will include the types of air treatment technology required for the varying dehydration and filtration requirements.

Case Study #2 Process Air Purity Requirements – Assessing the Risk and Delivering the Quality: When compressed air becomes an ingredient in the process, the purity requirements increase as does the risk. This case study reviews the application of high purity users such as pharmaceutical and semiconductor. Discussion will include design best practices for Process Air applications and selection of the right air treatment technology to meet stringent air quality requirements.

Ryan Remington graduated from the University of Florida – Gainesville- with an electrical engineering degree before joining Pneumatic Products Corporation (PPC). With PPC, Ryan specializes in engineered compressed air drying and filtering equipment. Now operating as National Sales Manager for PPC, Ryan works closely with channel partners and end users to develop both standard and specialized air purification solutions for compressed air users across the globe. 

12:15 – 1:45 pm Women in Compressed Air, Vacuum & Cooling Networking Group Luncheon Sponsored by Ingersoll Rand & Quincy Compressor

1:00 – 4:00 pm New Technology EXPO Classroom – EXPO Floor

2:00 – 3:30 pm Compressed Air & Gas Institute (CAGI) Certified Compressed Air System Specialist (CCASS) Exam

4:30 – 5:00 pm Treasure Hunt Raffle

6:00 – 9:00 pm Catered Networking Event at VU Rooftop, on the 22nd Floor of the Hilton Tri-Plex (123 E. Cermak) Host Hotel. Sponsored by BEKO Technologies, Sullair, Mikropor and Aggreko

Tuesday, October 24^th

8:00 am – 10:00 am Plenary Session

10:00 am – 5:00 pm EXPO Floor Open

10:15 am – 12:25 pm Session #2: Big-Impact Energy & Water Conservation Projects in Compressed Air and Cooling Water Systems

Chair: James Bristow, North American Sales Manager, Hanwha Power Systems

• Centrifugal Air Compressor Cooling Water Mitigation
  James Bristow, North American Sales Manager, Hanwha Power Systems

Compressed air temperature management is crucial to efficient and stable operation of all air compressors. This becomes amplified in the typical 3 stage integrally geared centrifugal air compressors used in plants across the US. Interstage cooling is integral to a properly running air system, and I will discuss ways to cool the compressed air without the need for regular water supply. I will look at both open and closed loop cooling systems.

After graduating Magna Cum Laude with a Mechanical Engineering Degree from the University of California, I started my career as a project engineer for Kobelco working on their oil flooded and dry screw compressors. From there, I ended up in centrifugal sales for the last decade, where I finally settled as Hanwha Power Systems North American Sales manager. I have quoted both standard industrial compressors and the large spec driven engineered compressors, selling both small (for centrifugals) to large compressors, in both the Asian and American market.

• Energy Efficient Compressed Air Drying for “Air Over the Fence” Applications
  Chuck Henderson, Vice President, Henderson Engineering

Buying compressed air over the fence has a become a major opportunity for many companies to reduce capital investment while also reducing maintenance costs. There are a variety of options available for this application, some are dramatically better than others. We will explore the choices available and help determine which systems work best.

Chuck has served at Henderson Engineering for 50 years, is the owner of multiple patents for dehydration technology and has published numerous articles about compressed air purification.

• Hybrid Instrument Air Dryer System Technology Deployment
  Abdulaziz Dulaijan, Senior Engineer, Saudi Aramco

Instrument air dryers, often the single largest air consumer in industrial plants, create a significant concern in terms of energy consumption, instrument air availability, and security of air supply. Most industrial plants in Saudi Arabia use heatless desiccant dryers that require a lot of energy in the form of compressed air. Additionally, frequent valve switching on such dryers (every five minutes) compromises plant reliability, resulting in unpredicted failures. Hybrid air dryers can achieve maximum savings with heated desiccant dryers, where valve switching is extended to 24 hours, resulting in major energy and maintenance savings in addition to ensuring reliable, and high-quality air delivery. Approximately 20 MW of energy could be saved if hybrid dryers are implemented in all company plants, possibly extending to over 50 MW. The payback for hybrid dryer retrofitting is usually between 1-2 years which supports implementation from a financial point of view.

I have 28 years of Water, Oil and Gas industry experience in process systems and rotating equipment engineering, design and troubleshooting. I have engineering experience in compressed air systems, cooling water systems, pump station optimization/design and testing experience in large diameter pipelines and process piping systems. Also, understanding of a variety of international engineering codes/standards and best practices including Saudi Aramco Engineering Standards, ASME ANSI, API, NFPA, and a variety of AWWA standards. I’m a Certified Energy Manager, and ISO 50001 Energy System Auditor. I’m currently working with Saudi Aramco in the Energy Systems Division.

• Demand Side Design Effects on VSD Air Compressor Efficiency
  Josh Wamser, President, Industrial Compressor Solutions

Installing a VSD in our compressor room IS an efficient way to react to plant demand. Unless we are using compressed air as a byproduct only, our most efficient solutions come from the demand side instead. Moreover, a VSD will actually aid in hiding plant inefficiency directly opposing our intentions and design. I will show how to take control of the demand side of the system before addressing the compressor room.

I am the owner of 3 companies in the compressed air industry. I spend the majority of my free time auditing plants and training. I’m an OSHA-30 certified NASCLA General Contractor, Construction/ Project Manager, Commercial Plumber, and Mechanical Contractor. I’m a Veteran of both the Navy (MMN) and the Marines (infantry). I am also a proud husband and father.

10:15 am – 12:15 pm Compressed Air Challenge Level 1 Workshop: Fundamentals of Compressed Air Systems (Part 1)

1:00 – 4:00 pm New Technology EXPO Classroom – EXPO Floor

2:00 – 4:00 pm Compressed Air Challenge Level 1 Workshop: Fundamentals of Compressed Air Systems (Part 2)

2:00 – 3:30 pm Compressed Air & Gas Institute (CAGI) Certified Compressed Air System Specialist (CCASS) Exam

4:30 – 5:00 pm Treasure Hunt Raffle

Wednesday, October 25^th

8:00 am – 10:00 am Session #3: Cooling Water and Compressed Air Demand Reduction Strategies

Chair: Jon Jensen, Energy Efficiency Manager, SMC Corporation of America

• Sustainable Development Goals: Energy Efficiency in Pneumatic Systems
  Jon Jensen, Energy Efficiency Manager, SMC Corporation of America

We will consider the benefits of energy conservation in regard to “Sustainable Development Goals” from topology optimized design to low-cost/no-cost applications where energy conservation in pneumatic systems can be applied. The applications reviewed will benefit plant managers, design engineers and maintenance personnel who have the responsibility to reduce the costs and environmental impact of compressed air use in their facility. The topics covered are also applicable to designers of pneumatic equipment.

Jon Jensen is the Energy Efficiency Manager for SMC Corporation of America. He provides consulting services on energy conservation in pneumatic systems. He is also a Certified Machinery Safety Expert (TUV NORD) and manages machinery safety products for SMC Corporation of America. He is a past president of the International Fluid Power Society, an Accredited Instructor, and holds Pneumatic Specialist and Electronic Controls Specialist Certifications. Prior to managing the Energy Conservation Team, Jon served for nearly 10 years as SMC’s North American Training Manager.

• Most Chillers Are Operating Above Their Design Efficiency! 
  Dan Mizesko, President, Dalkia U.S. Chiller Services

I will present on the benefits of re-retrocommissioning chilled water plant liquid chillers. The evidence is clear, most chillers and chilled water plants operate above their intended design efficiency (kW per Ton). Most chillers operate above efficiency design 20%, 25%, 30%, and even higher. I have seen chillers operating 60% above their kW per ton design. Most equipment operators and owners do not even realize their equipment is operating inefficiently and consuming excessive power. Just because you are performing the maintenance as per the OEM manual does not mean your chiller is running efficiently. It takes substantially more than the recommended maintenance procedures to ensure your chillers operate as efficiently as possible. Our presentation will lay out the case that proves this. We will present re-retrocommissioning procedures as well as examples of successful re-retrocommissioning and the savings achieved in the Gulf Region (Dubai and Qatar) as well as New York.

Dan is the President of Dalkia U.S. Chiller Services. He holds a Bachelor of Science Degree in Air- Conditioning and Refrigeration Engineering Technology, has completed a 5-year UA Training program for Field Service Chiller Engineers in the USA, is a New York City Licensed Operating Engineer and is a Graduate of Babson University’s Mechanical Contractors of America Advanced Leadership Institute. Dan has over 45 years of “Hands On” extensive experience in the HVAC industry on a wide variety of air conditioning and refrigeration equipment utilized in high rise buildings and industrial facilities throughout the United States, Middle East, Mexico, Latin America, Africa and the Caribbean. Dan has held management positions for Carrier Corporation, Honeywell, Siemens Building Technologies, Bechtel Construction, U.S. Dept. of Energy, Gannett Publishing and is currently President of all Dalkia U.S. Chiller Services operations in the USA, UAE, Bahrain, KSA and Qatar. Dan is an industry recognized expert on Large Tonnage Liquid Chillers and Industrial District Cooling plants.

• Water Consumption and Environmental Impact: How to Reduce Water Usage While Maintaining Production Goals
  Rebecca Moore, Strategic Account Manager, Aggreko

In this non-promotional presentation, we will share case studies of applied technology solutions to address water conservation concerns for the pulp and paper industry. And will also discuss ways that your facility can reduce water consumption while maintaining production goals and meeting ESG targets – and without CAPEX.

Rebecca Moore is a national large enterprise accounts manager specializing in manufacturing for Aggreko, a global temporary power, heating and cooling company. Rebecca is an expert at managing corporate relationships and ensuring clients have reliable and cost-effective solutions to boost profits and productivity.

• Next-Level Food-Industry Automation Using Edge Computing on Pneumatics
  Tom Taranto, Owner, Data Power Services

Using edge computing to establish the operating envelope for critical control points (CCPs) and key process indicators (KPIs) necessary to validate operation of pneumatically power equipment. Expanding capability of machine controls allows monitoring compliance verification to improve production up time improving both reliability and safety. Learn how edge computing techniques are applied to define process major factors (PMFs) and apply operating limits for process control. Once identified, CCPs and KPIs are used to establish air specifications and to set operating limits at the machine controls to confirm process compliance.

Tom Taranto, President of Data Power Services, LLC is an independent fluid power system professional with more than 45 years of experience. He has extensive experience in design and application of fluid power systems both hydraulic and pneumatic. Compressed Air Challenge (CAC) qualified instructor, and instructor for Qualified AIRMaster+ Specialist training. Tom is Chair and team member for ASME Standard EA-4-2010 “Assessment for Compressed Air Systems”. Tom has authored compressed air articles, and peer reviewed conference proceedings. He is published both nationally as contributor to Encyclopedia of Energy Engineering and Technology, Taylor & Francis Group; and internationally as UNIDO Compressed Air Expert co-author and co-trainer for UNIDO Motor System Energy Conservation Program.

8:00 am – 12:00 pm Compressed Air Challenge Level 1 Workshop: Fundamentals of Compressed Air Systems (Part 3)

8:30 – 10:00 am Compressed Air & Gas Institute (CAGI) Certified Compressed Air System Specialist (CCASS) Exam

10:00 am – 5:00 pm EXPO Floor Open

10:15 am – 12:15 pm Session #4: Advanced Compressed Air Energy Efficiency Measures

Chair: Tim Dugan, President, Compression Engineering Corporation

• Compressed Air System Measurement and Data-Collection in all Project Phases
  Tim Dugan, President, Compression Engineering Corporation

This presentation will focus on engineering and measurement in the air compressor room, focusing on instrumentation and data-collection methods for energy plus thermal, at the various project phases.

Tim Dugan has 22 years of independent industrial compressed air systems consulting and 13 of OEM design. He is known for robust, full system mechanical and automation design for complex, large compressed air systems. He also sets the standard for rigorous energy savings and reliability modeling and integration of all aspects of a complex compressed air project, including concept, controls, monitoring, mechanical systems, and commissioning. His firm is 100% independent from compressor OEMs.

• Keeping Energy Improvement Projects on Track with Measurement
  Pascal van Putten, CEO, VPInstruments

How do you know if you are taking the right measurements in your performance improvement project? In this presentation, Pascal van Putten will show how a 4-in-1 flow meter will provide a baseline for your system’s performance, allowing you to continuously check if you’re on the right. A single flow meter can be a real eye-opener and already have a major impact on your energy savings project. By taking a step-by-step approach, you can achieve and maintain energy savings. User case examples, including from the food & beverage industry, will be shared to illustrate the real-world benefits of utilizing a flow meter.

Pascal van Putten, CEO and founder of VPInstruments studied Mechanical Engineering at Delft University of Technology. Pascal founded VPInstruments in 1999. VPInstruments offers industrial clients Energy Management solutions for compressed air, technical gases as well as other utilities. Pascal has 25 years of experience in flow measurement, compressed air monitoring and industrial energy management. Pascal lives in Delft together with his wife and three daughters.

• Compressed Air Demand: The Final Frontier
  Paul Edwards, Principal, Compressed Air Consultants

Paul Edwards walks through several applications to show both the value and the difficulty of doing demand side work. Eliminating or reducing the air consumption at the point of use can have a leveraged impact on the entire air system – supply, distribution and demand which translates to money. Done well, the value brought to the plant’s bottom line can be significant. But demand side work is messy. Reality and theory often collide and if done poorly, it can increase costs, create product quality defects and banish your company from the customer. The presentation will provide multiple examples of applications and potential solutions and the challenges in determining the best path. It also shows how some rules of thumb and copy/paste engineering can be hazardous to everyone’s bottom line.

Paul earned a BSME from the University of Virginia, and has been in the business for 41 years. He spent 22 years with Ingersoll Rand and held positions as an application engineer, field sales engineer, global product manager for rotary screw compressors, North American Marketing manager as well as starting up the audit business for IR (with Gary Shafer). He started an independent audit organization, Compressed Air Consultants, Inc twenty years ago and 80% of his work has been in demand side improvements. CAC has done audits in over 30 countries in industries such as offshore platforms, petrochemical facilities, cement and lime, paper, corrugated, power plants, food and beverage, electronics, steel, iron, underground coal, aerospace, corn processing, chemicals, plastics, etc.

• Compressed Air Leak Detection: Acoustic Cameras vs Traditional Leak Detectors
  Brian Kavanagh, Sales Director, Sonotec

With the advent of acoustic cameras, ultrasonic leak detection has never been easier. However, are acoustic cameras a complete replacement of the more traditional ultrasonic leak detectors available in the market? When considering factors such as the leak rate algorithm and environments with significant amount of extraneous noise, sometimes the traditional technology can work better. In this presentation, we will do a deep dive on the pros and cons of each type of equipment and discuss where each one excels.

Brian Kavanagh is the sales director for SONOTEC’s North and South American markets, based out of Long Island, New York. He is heavily involved in the predictive maintenance industry, particularly when it comes to ultrasound technology.

1:00 – 4:00 pm New Technology EXPO Classroom – EXPO Floor

2:00 – 3:30pm Compressed Air & Gas Institute (CAGI) Certified Compressed Air System Specialist (CCASS) Exam