Module 4 – Point of use pressure profile

• Multi point pressure profile (data logged)

The pressure profile employs multi-channel data loggers installed into the system at strategic points and synchronized in real time and sampling rate alignment. Test run times include entire shifts or shorter durations at the discretion of the audit team engineer.  Collection points generally include:

SUPPLY SIDE

•  The discharge of the compressor room or rooms.

•  The discharge of the compressors, upstream of the dryers.

DISTRIBUTION SYSTEM

•   Points furthest from compressor(s).

•   Immediately upstream of critical production machinery.

•   Immediately upstream of mass flow dependent equipment.

•   Immediately upstream of points of use that have been historically identified as problem areas, or governed by low pressure alarms and shutdowns.

 PRODUCTION EQUIPMENT

•   Connections to cylinders having high cycle rates.

•   Connections to pressure sensitive clutches, brakes and clamping devices.

The pressure profile identifies

•   Maximum and minimum pressure levels

•   Pressure stability bands

•   Possible velocity based flow gradients and restrictions in the distribution network

•   Transmission time from generation to points of use

•   The effects of uncontrolled demand, defined as demands that are not equipped with operating,  modulating control regulation.

•   The effects of leakage

•   The level of flow balance, between demand points to enable the specification of situational controls and subsystems.

•   The existence of individual demand points that require pressure levels that are determining the supply pressure to the entire system.

•    The effects of the speed of response by regulation and flow control on the performance of high-speed production equipment.

Module 5 – Total package

 Impact RM technicians will install flow, pressure Kw and pressure dew point data loggers at the required multiple points in the compressor room. Issues including compressor performance and control, consumed power versus air delivery, air treatment performance, flow restriction and consumed energy are evaluated for several production days. Air leak management and complete review of all point of use practices and verification of ancillary equipment throughout the plant.  This encompasses:

• Visual inspection of all points of use (after air treatment)
• The condensate discharge system analysis
• Air leak detection
• Air leak tagging (three levels)
• Delivered mass flow is measured and recorded, (SCFM)
• Compressor performance test (FAD - Free air delivery)
• Delivered pressure to the system is measured and recorded (PSIG)
• Plant air leak test (if plant can be briefly shut down)
• Power consumption of each compressor is measured and recorded (Kwh)
• Pressure dew point is measured and recorded

Module 6 – Application study

• Specific point of use application studies

Module 7 – Special applications

• Installation of pipe markers to meet all of the ANSI standard size and color requirements, in and outdoors
• blower and low pressure equipment analysis
• vacuum system analysis

Module 8 – System Design

• design the piping and mechanical configurations that are dictated by the project scope
• perform takeoffs of existing systems.
• generate system P&ID drawings.
• generate equipment mechanical drawings
• generate electrical drawings
• drawings are generated on AutoCadd 2000, or Microstation Cadd systems

Module 9 – Education

In house compressed air training seminars that cover the full scope of a compressed air system

• basic compressed air theory
• compressor type analysis
• air dryers
• filtration and ancillary equipment
• piping, installations, heat recovery, environment
• compressed air energy efficiency