Welcome to:
Atlas Machine
& Supply, Inc.
Responsive Solutions for Industry Since 1907
1
2
Machine Shop Division
Maintenance and Repair Machining
Turning
Milling
Line Boring
Spraying
Grinding
Metal Deposition and Reconstruction Welding
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4
Industrial Products Group
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Primary Products
Air Compressors
Air Dryers
Vacuum Pumps
Blowers
Chillers
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7
Compressor Types
POSITIVE
DISPACEMENT
ROTARY
VANE
SCROLL
DYNAMIC
RECIPROCATING
LIQUID
RING
SCREW
LUBRICATED
LUBRICATED
OIL-FREE
CENTRIFUGAL
AXIAL
OIL-FREE
OIL-FREE
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Dryer Types
REGENERATIVE/
DESICCANT
REFRIGERATED
HEATLESS
DIRECT
EXPANSION
HIGH
TEMPERATURE
HIGH
PRESSURE
CYCLING/
THERMAL
MASS
EXTERNALLY
HEATED
BLOWER
PURGE
CLOSED
LOOP
HOC
SLIP
STREAM
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Equipment Selection
A
i
r
C
o
m
p
r
e
s
s
o
r
Flow Rate (scfm)
•Low (0-50 scfm) then small rotary screw, rotary vane scroll or reciprocating
•Mid-Range (50-1500 scfm) then rotary screw
•High (1500+ scfm) then multiple screws or centrifugal
Pressure (psig)
•18-29” Hg then vacuum pump
•15” Hg to 25 psig then blower
•25 psig to 200 psig then rotary screw
•200+ psig then reciprocating
Continuous or Intermittent Service
•Light duty or intermittent operation then reciprocating
•Continuous then rotary screw or centrifugal
Lubricated or Oil-Free
●Driven by industry standards to mitigate risk
●Food and Beverage, Pharmaceutical, and Steel
Fixed Speed, Variable Speed or Variable Displacement
•Steady compressed air consumption then fixed speed
•Compressor to be base loaded then fixed speed
•Compressor must satisfy broad range of flows then variable speed/displacement
•Compressor must serve as base and trim unit then variable displacement or
fixed speed with control storage
REBATES FROM
LOCAL UTILITY
COMPANIES MAY
BE AVAILABLE!!
Air or Water Cooled
•Air cooled is typically more convenient.
•Many plants do not have cooling water
•Water cooled more common with large hp and oil-free
Open Frame or Enclosed
•Enclosures are typically required for noise abatement and outdoor/very dirty
environments
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Equipment Selection
Inlet
A
i
r
D
r
y
e
r
•Flow
•Pressure
•Air Temperature
•Ambient Temperature
Outlet
•Moisture content
+35 to or above then refrigerated
-40 Dew point or below then desiccant
•Hydrocarbon content
•Particle content
11
Equipment Installation
Leave enough clearance so there is at least 36 inches around each compressor in order
for it to be serviced easily and will have proper ventilation
Install block and bypass around dryers and filters to allow for ease of service and
replacement
Ideally each compressor will have a dedicated dryer and filters
Install cooling fans and louvers to allow change of air at least two times per minute;
very simple to calculate the volume of the room and multiply it by two
Know the type of compressor being installed in order to properly size air receiver tanks
♦ Load/No-Load= 4-5 gallons per cfm
♦ Inlet Modulation/Variable Displacement = 2-3 gallons per cfm
♦ Variable Speed Drive = 1-2 gallons per cfm
Keep away from extremely dirty areas or compressor life will be shortened
Do not locate near an office or lab area where noise is going to be an issue
12
Piping Installation
Take time to layout compressor room with consideration for expansion
Minimize the number of bends (tees and elbows); always use long radius
elbows
Install the minimum number of valves to properly service the equipment
Always size piping for maximum flow plus 20%
Avoid gate and globe valves because of high pressure drop
Piping should always be configured in a loop!
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Typical Layout
DRY
TANK
AIR
DRYER
WET
TANK
PRIMARY
COMPRESSOR
BACKUP
COMPRESSOR
OIL/WATER
SEPARATOR
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Lubricated Rotary Screw Detail








Motor
Air End (pump)
Lubricant / Coolant
Inlet Filter
Oil Cooler
Oil filter
Oil Separation System
Aftercooler & Moisture Separator
15
DISCHARGE
PORT
DISCHARGE
PORT
SECONDARY
ROTOR
MAIN
ROTOR
A
SECONDARY
ROTOR
MAIN
ROTOR
MAIN
ROTOR
INLET
DISCHARGE
PORT
B
INLET
C
INLET
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Air End
1
3
1
Main Rotor
2
Gate Rotor
3
Housing
4
Bearings
5
Drive
4
2
5
4
17
Air Flow Path
TO PLANT
Inlet
Compression
Oil Separation
Check Valve / MPV
After Cooling
Moisture Separator / Drain
Refrigerated Air Dryer
After Filter
Receiver Tank
Control Valve / Expander
18
Lubricant / Coolant
Multipurpose
• Provides Viscous Sealing Ring
• Removes Heat of Compression
• Provides Rotor Drive Cushing
• Lubricates Gears and Bearings
Routine oil sampling is critical
• Test for Metal Particles, Acid and pH Levels
Operating Temperature
• Every 10 degrees above 200 F decreases lubricant life by 50%
Lubricant must be changed at proper intervals
• Formation of Acid, Varnish and Sludge will drastically shorten the life cycle
of the compressor
• Very expensive to flush out of compressor
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Oil Flow Path
1
Compression
2
Separation
3
Accumulation
4
Cooling
5
Thermal Valve
6
Lube Filter
7
Injection
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Lubricant Types
ATF – Petroleum based
PAO – Synthetic (general purpose)
Polyglycol – forms stable emulsion
Diester- High temperature
Silicon- stable for extended run periods
Food Grade
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Inlet Filtration
5 to 10 micron typical
 Change interval is site dependent
 Influences performance

22
Oil Cooling System
Air cooled
 Water cooled
 2545 btuh
per bhp
 Installation

◦ Ductwork Pitfalls
◦ Heat Recovery
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Oil Filter
10 micron particulate rating
 Internal bypass at high psid
 Maintenance interval - 1000 hours or psid

24
Oil Separation System





2 to 4 ppm typical remaining oil content
Velocity / impingement / coalescing
Appropriate psid (maint cost vs energy
cost)
Velocity - Velocity - Velocity
Maintenance interval - psid or annual
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After cooler and Moisture
Separator
Reduces discharge
temperature (approach)
 Condensation of
water vapor
 Removal of condensate
(first step in clean up)
 Maintenance interval
(site dependent)

26
Rotary Screw General
Maintenance
27
28
Daily checks
Oil level
Separator differential pressure
Oil leaks
Discharge air temperature
Air filter vacuum
Check condensate drain traps
Check discharge pressure
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Quarterly Maintenance
Change oil filter (or 1000hrs)
Check oil level
Check air filter (replace if needed)
Check belt tension
Take an oil sample
Measure motor amps
Adjust controls
Clean minimum pressure valve
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Quarterly Maintenance
Check separator delta pressure
Check for oil leaks
Verify proper operation
Check oil temp (160-180 deg.)
Check discharge air temp (175-190 deg.)
Ispect thermal bypass valve
Clean oil cooler (if needed)
Clean after cooler (if needed)
Adjust controls
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Annual Maintenance
Complete quarterly maintenance
Replace separator element
Grease motor
Change oil
Verify all safety shutdowns are functional
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Aftercooler Maintenance
Keep it clean
- Blow out using dry compressed air
- Pressure wash
- Steam clean
Every 20 deg. increase in air temp doubles it’s ability to hold
water vapor
Check condensate drains
Clean Y strainer
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100 psig maintained
105.5 bhp = 84 KW
8000 hrs/yr of operation
$0.05 Kwh
$450 / Separator
Pressure
Drop at Compressor Percentage of
KW
Annual
Cost
Separator
Pressure Increased Power Consumed Hrs/Yr $/KwH Operation Differential
0
100
0.0%
84.0
8000 $0.05 $ 33,600 $
1
101
0.5%
84.4
8000 $0.05 $ 33,768 $
2
102
1.0%
84.8
8000 $0.05 $ 33,936 $
3
103
1.5%
85.3
8000 $0.05 $ 34,104 $
4
104
2.0%
85.7
8000 $0.05 $ 34,272 $
222
5
105
2.5%
86.1
8000 $0.05 $ 34,440 $
390
6
106
3.0%
86.5
8000 $0.05 $ 34,608 $
558
7
107
3.5%
86.9
8000 $0.05 $ 34,776 $
726
8
108
4.0%
87.4
8000 $0.05 $ 34,944 $
894
9
109
4.5%
87.8
8000 $0.05 $ 35,112 $
1,062
10
110
5.0%
88.2
8000 $0.05 $ 35,280 $
1,230
11
111
5.5%
88.6
8000 $0.05 $ 35,448 $
1,398
12
112
6.0%
89.0
8000 $0.05 $ 35,616 $
1,566
13
113
6.5%
89.5
8000 $0.05 $ 35,784 $
1,734
14
114
7.0%
89.9
8000 $0.05 $ 35,952 $
1,902
15
115
7.5%
90.3
8000 $0.05 $ 36,120 $
2,070
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Assuming: 100 hp fully loaded
114 psia maintained
105.5 bhp = 84 KW
8000 hrs/yr of operation
$0.05 / Kwh
$85 / Inlet Filter
14.2 psia = Absolute
Inches of Water
Column
Differential
0
5
10
15
20
25
Compression Ratio
8.03
8.13
8.24
8.35
8.46
8.57
Dyn/Eff
(SCFM/KW
)
5.23
5.17
5.10
5.03
4.97
4.90
Quarterly
Cost
$ 8,408
$ 8,516
$ 8,627
$ 8,741
$ 8,858
$ 8,979
Quarter
Differential
$
$
108
$
219
$
333
$
450
$
571
Red Represents Alarm Point
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Condensate Removal
36
37
Aftercooler
100 deg F pressure
dew point typical
 68% of available
moisture removed
(32% moisture
remaining)
 Proper function is
crucial to performance
of dryers

38
Filtration
Particulate
 Coalescing
 Vapor
 Special Purpose

39
Refrigeration Dryers
35-39 ºF pressure
dew point
 28% of remaining
moisture removed
(4% moisture remaining)
 Design function review
 Thermal mass (cycling) vs
direct expansion
 Maintenance - condenser,
auto drains

40
Dryer Maintenance
Refrigerated






Check inlet air temp daily (100 deg. max
inlet)
Clean condenser when needed
Check auto-drain valves
Clean Y-strainer (if needed)
Check gauges (suction and discharge)
Check inlet filtration
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42
Adsorption Dryers (Regenerative)








-40 to -100 ºF
pressure dew point
Removal of moisture
to <1% remaining
Design overview
Heatless
External heater
Blower, Heat of
Compression, Split Stream, Closed Loop
General Rule: operating costs decrease as
upfront costs increase.
Maintenance, (valves, filtration, desiccant)
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Adsorption Drying
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Compressed Air Quality
ISO 8573-1 Specification
Solid Particles
Class
Water
Oil
Maximum
Maximum
Maximum
Maximum
Size
(micron)
Concentration
(ppm)
Dew point
(ºF)
Concentratio
n
(ppm)
1
0.1
0.08
-94
0.008
2
1
0.8
-40
0.08
3
5
4.2
-4
0.83
4
15
6.7
37
4.2
5
40
8.3
45
21
6
-
-
50
45
Condensate Management
Automatic Drain Options
 Oil / Water Separation Systems

◦ Gravimetric
◦ Thermal (distillation)
EPA Fines – willful violation for polluting
the water table – start at $9,000 per
offense!
 Low cost
insurance
policy

46
SYSTEM TROUBLESHOOTING
Common Complaints
Low air pressure
Water in air lines
Compressor shutting down
Oil in air lines
Oil Carryover
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Energy Conservation
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Total Cost of Ownership
•Reduce Electrical
Costs by 15 to 50%
•Reduce Maintenance
Costs by 10 to 60%
Slide taken from US Department of Energy Compressed Air Challenge
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✓ Reduce operating and maintenance costs
✓ Reduce vulnerability to energy price increases
✓ Meet customer expectations
✓ Enhance productivity
✓ Improve environmental quality
✓ Increase customer loyalty
✓ Increase overall profit
✓ Audit documents can be submitted for energy rebate programs (IF local power
company offers a rebate program)
✓ Audits are conducted by a Lean certified Mechanical Engineer.
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Four steps involved in developing a plan
1. Initial Assessment: A visual inspection of the compressed air system and its
components will indentify best location for hot tap(s) and customer needs/
expectations.
2. Install Process: A single hot tap includes: saddle clamp, nipple, ½” ball valve.
Once these are in place; the line is drilled, pressure transducer and flow meter
are inserted, kW meter attached, data logger programmed and begins
recording data.
3. Evaluate Data & Opportunities: Identify compressed air energy-related
improvement opportunities, such as compressor(s) operating strategy, overall
plant pressure band, plant leak load, master-controls, piping, storage, filters,
dryers, FLR(s) etc…
4. Implementation: Data is gathered and analyzed to generate a full report to
show overall energy savings for the recommended design implementations.
51
Benefits of Hot Tap method and kW Metering
Hot tap insertion method of mass flow meter(s) and
pressure transducer(s) give real time system flow
demand and pressure profiles.
Actual flow measurement versus calculated flow
provides a more accurate and thorough assessment of
the current system.
Power metering coupled with flow and pressure
readings will paint a complete picture of how efficiently
your plant is producing and consuming compressed air.
Allows for a more effective strategies and solutions to
be recommended and implemented.
52
Artificial Demand
Every 2 psig increase in pressure increases power consumption
by 1%
Causes increased leak rate
Undersized plant header is one cause for artificial demand
Insufficient compressed air storage and control pressure often
leads to excessive artificial demand
Lack of system controls is another reason for artificial
demand
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Artificial Demand
Supply
Pressure
1/8” orifice
¼” Orifice
90 psig
23.7 scfm
94.8 scfm
125 psig
31.6 scfm
128.0 scfm
+7.9 scfm (33%)
Approx 2 hp $628/yr
+33.2 scfm (35%)
Approx 8 hp $2540/yr
Demand created by supplying a compressed air system with higher than required operating
pressures. Results in excessive demand, and greater wear on pneumatic equipment.
54
Pressure Cost $$$
200 hp air compressor at 100 psig, 8000/year at $0.05/kWH
= 175kW x 8000 hrs/yr x $0.05/kW
= $70,000/year in energy
Same compressor at 80 psig (20 psig = 10% hp savings)
= 157kW x 8000 hrs/yr x $0.05/kW
= $62,800/year in energy
Annual energy savings $7200
55
Leaks
Types of air leaks:
Intentional: these are leaks that have been designed into
the system for blowing, drying, sparging and cooling.
These leaks are usually designed as a quick fix for a
production issue. Most of these leaks can be fixed with a
properly designed blower or vacuum system.
Unintentional: these are leaks that naturally occur in the
system over time and require an ongoing Leak Detection
Program.
56
Plant Leak Load

The Department of Energy recommends a maximum leak load of 10%-15%
of total system demand.

If your total system demand is 600 scfm then 600*.15 = 90 scfm (15%) leak
rate.

90 scfm is the same as running a 20 hp compressor or:
(20*.746)/.95 * 8,736 * 0.065 = $8,918.00 per year to fill leaks.

It is common to find most plants with a 30-40% leak rate therefore, 600 * .40 =
240 scfm leak rate. This is the same as running a 50 hp compressor or:
(50*.746)/.95 * 8,736 * 0.065 = $22, 295.00 per year to fill leaks.
57
Pressure
1/64”
1/32”
1/16”
1/8”
1/4”
3/8”
70 PSIG
$ 25
$ 100
$ 400
$ 1,574
$ 6,185
$ 14,080
80 PSIG
$ 28
$ 112
$ 447
$ 1,765
$ 6,990
$ 15,510
90 PSIG
$ 31
$ 124
$ 495
$ 1,975
$ 7,855
$ 17,477
100 PSIG
$ 35
$ 136
$ 546
$ 2,165
$ 8,676
$ 19,398
NOTE: YEARLY LEAKAGE COSTS BASED ON $ 0.05 PER KW-HOUR
The best way to detect leaks is to use an ultrasonic acoustic detector, which is
capable of recognizing the high frequency hissing sounds leaks make. These
small, portable units consist of a directional microphone, amplifiers, audio
filters and ear phones to detect leaks.
Ultrasonic leak detection equipment follows the white noise generated by the
turbulent flow an air leak creates. Since the ultrasound has a short wave signal
the sound level will be loudest at the leak site.
The advantages of using ultrasonic detectors are versatility, speed, ease of use
and the ability to perform tests while equipment is running and the wide
variety of leaks that can be detected. Ultrasonic equipment can also be used
for detecting electrical arching and bearing inspection.
59
Inappropriate Uses of Compressed Air
We will discuss what to look for in your plant when identifying
inappropriate uses of compressed air. Below is a list of inappropriate
uses of compressed air and a recommended alternative.
VENTURI VACUUM PUMPS
AIR DIAPHRAGM PUMPS
PERSONAL COOLING
• ELECTRIC MOTOR DRIVEN PUMPS ARE MORE EFFICIENT
• UNLESS IN HAZORDOUS LOCATION ELECTRIC MOTOR DRIVEN
PUMP IS A BETTER CHOICE
• FANS OR BLOWERS ARE MUCH MORE EFFICIENT
LARGE ELECTRICAL
ENCLOSURE COOLING
• REFRIFERATION TYPE COOLERS ARE FAR MORE ENERGY EFFICIENT
PARTS CLEANING AND
COOLING
•ENGINEERED NOZZLES CAN REDUCE AIR CONSUMPTION 3 TO 6 TIMES
•HIGH VELOCITY BLOWERS ARE 10 TIMES MORE EFFICIENT
LOW PRESSURE BLOWING
SPARGING
• TYPICALLY 20 PSIG OR LESS
• RECOMMEND BLOWERS
•AERATING, AGITATING, OXYGENATING OR PERCOLATING FLUIDS CAN BE
ACCOMPLISHED MORE EFFICIENTLY USING HIGH PRESSURE BLOWERS
60
Inappropriate Uses of Compressed Air
Include applications for compressed air that have other
more efficient options.
It costs on average 10 – 15 times more to deliver the same
relative work with pneumatic energy than with electric
energy.
Pneumatic energy is further down the supply chain, and
thus contains more electro-mechanical losses.
Compressed air is a by-product of the heat generated by the
compressor.
61
Compressor Performance Curves
Positive Displacement Compressors
100%
90%
80%
% of Full load Pow er
70%
60%
50%
40%
30%
20%
10%
0%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% of Full Load Capacity
Reciprocating/VSD
Load-No Load Screw
Variable Displacement Screw
Upper Range Modulation Screw w ith blow dow n
Upper Range Modulation Screw w ithout blow dow n
62
Compressor Capacity Controls
Production demand rarely matches exactly the output of the
compressor(s) therefore it is essential to have some form of capacity
control. Capacity control are designed based on number of compressors
in the system, type, size and application of the compressor.
Start/Stop: uses a pressure switch to start the compressor at
minimum pressure and stops the compressor at maximum
pressure
.
Load/Unload: inlet valve closes reducing mass flow of air through the
compressor but, increases compression ratio. Blow down valve opens
progressively lowering compressor discharge and compression ratio. This
results in reduced energy requirement.
63
Compressor Capacity Controls
INLET MODULATION
INLET VALVE
e
es
et
en
e.
ent
64
Compressor Capacity Controls
VARIABLE DISPLACEMENT
TURN VALVE
65
Variable Speed
66
Inlet
Valve
Vent
Valve
• Capacity controlled by opening and closing valve as pressure
falls and rises
• Butterfly valve or inlet guide vanes
• 20% Efficient control range “turn-down”
• Capacity controlled by opening and closing valve as pressure
rises and falls
• Butterfly or V-Notch ball valve
• Very inefficient type of pressure control
• Optimal design minimizes venting or “blowing off”
• Also critical in preventing compressor surge
67
Compressed Air Storage
Provide compressed air capacity to meet peak demand events and help control system
pressure
Storage is used to control peak demand events by regulating system pressure and its
of decay
Wet tank located between compressor and dryer
Dry tank located down stream of all cleanup equipment
Load/No load requires minimum of 4-5 gallons of storage per cfm
Inlet modulation/Variable displacement require 2-3 gallons of storage per cfm
Variable speed compressors require 1-2 gallons of storage per cfm
68
Flow Control Valve
69
130
ARTIFICIAL
DEMAND
Typical Pressure
120
110
Series2
Series3
100
90
Controlled Pressure
80
1/19/2006
13:48
1/19/2006
13:49
1/19/2006
13:50
1/19/2006
13:51
1/19/2006
13:51
100 SCFM
100 PSIG
90 SCFM
102 PSIG
0 SCFM
105 PSIG
Where is the energy savings???
71
Layout With Flow Control
TO PLANT
PT
DRYER 6
VSD 1
DRYER 1
BASE 1
DRYER 2
BASE 2
DRYER 3
BASE 3
ACES
PANEL
DRYER 4
TRIM 1
DRYER 5
TRIM 2
72
Heat Recovery
Air Cooled Compressor
Exhausted Outside in Summer
Air or Water Cooled Compressor
Self-Contained with inlet and outlet
Connected between airend and oil cooler
Diverted Inside in Winter
Can heat water or other fluids up to 165 F
73
Demand Profile of Pre Treated Bag
House
74
Treatment of Bag House
75
Demand Profile of Bag House
Before and After Treatment
BEFORE
AFTER
76
77
SYSTEM
INTEGRATION
MASTER
OEM
OEM CONTROLS
PROS
-INEXPENSIVE
-SATISFIES PRINCIPLE OEM
SUPPLIER
CONS
-LIMITED FUNCTIONALITY
-LIMITED COMMUNICATION
OPTIONS
-BRAND SPECIFIC
-VERY LITTLE FLEXIBIITY
-LIMITED FACTORY SUPPORT
OEM Controls
80
MASTER SEQUENCER
PROS
CONS
-NOT BRAND SPECIFIC
-BETTER PRODUCT SUPPORT
-CAN QUOTE TO PLANT PLC
STANDARD
-MORE EXPENSIVE
-MORE INVOLVED INSTALLATION
-UNLIMITED COMMUNICATION
OPTIONS
-QUICKER ROI
`
Master Sequencer
82
INTEGRATION PACKAGE
PROS
-NOT BRAND SPECIFIC
CONS
-BETTER PRODUCT SUPPORT
-MORE EXPENSIVE
-HIGHLY SOPHISTICATED
SOLUTION
- FEWER VENDORS TO CHOOSE
FROM
-UNLIMITED COMMUNICATION
OPTIONS
-MORE COMPLICATED AND
TIME CONSUMING STARTUP
- HISTORICAL TRENDING FOR
MAINTENANCE AND ENERGY
MANAGEMENT
Integration Package
AIR DRYER SCREEN
TYPICAL TREND
COMPRESSOR CONFIGURATION
84
Recommended Websites
Industry Standards:
 www.cagi.org
 www.compressedairchallenge .org
 www.airbestpractices.com
Power Provider Rebate Programs:
 http://www.dpandl.com/save-money/business-government/rapidrebates/
 http://www.duke-energy.com/ohio-business/smart-saverincentive-program.asp
 http://www.dsireusa.org/incentives/incentive.cfm?Incentive_Code
=OH38F&re=1&ee=1
 http://www.lge-ku.com/rebate/
85
For more information on today’s material:
Visit www.atlasmachine.com
86