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Spotlight on Industrial Chillers

What are they?

Industrial chillers are designed to continuously cool and circulate a chilled fluid through process equipment, most commonly in a closed loop circuit. The goal is to bring down and manage the heat created during a variety of manufacturing processes.

Many different industries require process cooling.  From chemical processing plants to food and beverage manufacturers, industrial chillers are essential to ensuring continuous operation. Any process or product that needs cooled below the temperature of ambient air can use a chiller.

How do they work?

Chillers take advantage of the fact that heat is transferred from areas of high temperature to areas of low temperature.  As water flows through the fluid circuit, it is alternately warmed (by the heat-generating process) and cooled (by the chiller).

Within the chiller, a refrigerant compressor circulates refrigerant in a closed loop between two heat exchangers: the evaporator and the condenser.

In the evaporator, heat flows from the warm process water to the refrigerant, which changes state from a liquid to a gas.  That is, the warm process water is cooled and the refrigerant is heated and vaporized.

Conversely, in the condenser, heat from the refrigerant is released to the ambient air,  thus, cooling the refrigerant. Here, the refrigerant changes  from a gas to a liquid, a process known as condensation. Refer to Diagram below.

As an analogy, think of your home air conditioner, which also uses a typical refrigeration circuit.  Inside the house, a blower forces warm return air through the evaporator, producing the cool air that flows into each room.  Outside, a fan draws ambient air across the condenser and heats it; place your hand above the fan and you can feel the rejected heat from the system.  This is the heat that has been extracted from your home.

How do I decide what’s best for me?

Because industrial chillers come in many different sizes and configurations, choosing the unit that is best for your application can be difficult.  Fortunately, CASCO USA has the best industry professionals ready to work with you to define exactly what your system needs for optimum performance.

How to start the new year off right

Need some help with your resolutions? Contact our industry professionals, here.

Exploring the Efficiency of Air Compressors

On average, only 45-60% of energy used to run compressed air systems reaches production. The remaining consumed energy is lost via poor maintenance, improper use, and wasted time.

Luckily, this loss is not an inevitable component of using compressed air. There are ways to increase your system’s efficiency. With the right tools and plan, your compressor system could see an energy savings jump.

The graphic below (click to make full-size) outlines the biggest sources of energy loss in compressed air systems; most are due to human negligence.

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Basic Definitions:

Artificial Demand occurs whenever a system runs at a higher pressure than is necessary (Average Energy Loss = 10-15%)

Inappropriate Uses are tasks that could easily be accomplished through others tools, but compressed air is used instead. Examples: sweeping, blowing off, personal cooling (Average Energy Loss = 5-10 %)

Idle Time causes extra costs when the machine is running but production is not (Average Energy Loss = 5-10%)

Leaks are breaks in the compressed air delivery method, often in the last 30 feet of a system. (Average Energy Loss = 25-30%)

Heat is generated as a byproduct of the compressed air process. Up to 85% of the incoming energy is used lost due to heat compression. Up to 30% of this heat could be recaptured.

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How to Increase Efficiency:

With some basic behavioral changes, effects could be seen immediately in your system.

• Reduce your system pressure
  • According to the US. Department of Energy, every 2 psig reduction could save about 1% in compressor efficiency
• Only Use Compressed Air when necessary
  • Monitor how worker’s use
• Turn Compressors off on the weekends and after hours
  • Savings could be as high as $18,000 a year!
• Schedule regular maintenance to inspect and fix leaks
  • CASCO USA service technicians available here
• Recapture & Repurpose heat loss

To put this problem in perspective, the US Department of Energy estimates that 30% of a facility’s electrical bill is compressed air related. That’s a huge chunk of money you could be saving by increasing your system’s efficiency!

Sources:
http://us.kaeser.com/Services/Analysis-and-advice/default.asp
https://www.airbestpractices.com/technology/air-compressors/heat-recovery-and-compressed-air-systems
http://www.jhf.com/home/services/air-compressors/cost-of-air-leaks
http://www.industryweek.com/energy-management/renewable-energy-powers-jobs-almost-10-million-people
https://kaesertalksshop.com/2017/04/24/is-compressed-air-a-utility-or-a-production-input/
http://www.industryweek.com/energy-management/4-surprisingly-simple-ways-cut-your-energy-costs-today

The Future of Industry: Industry 4.0 and the Industrial Internet of Things

What exactly is the Industrial Internet of Things? The phrase or IIoT has been surfacing more frequently in recent months, accompanied by a lot of excitement and hype. It has been heralded as “pervasive” and “transforming industry” by GE, appearing in a variety of systems from air compressors to irrigation. Yet despite its extensive potential, the IIoT remains an unknown and mysterious entity to many.

The IIoT lacks one simple definition, for it  is not the only term used to describe the changing way industry regulates itself. The German government began using the term “Industry 4.0” to refer to the  integration of automation and data collection while working on a high-level state manufacturing project. The term caught on and is often used alongside the “Industrial Internet” to describe the current technological moment. Roughly, IIoT refers to the evolving connectivity among machines, computers, and people. Machines and equipment collect data and, then through the IIoT, these machines transfer and interpret it. The information gathered in one spot is not isolated to that machine, but rather through the IIoT communication occurs between machines and environments. By transforming individual machines into a whole system, insights can be used to create better business solutions for industrial organizations in sectors such as manufacturing, logistics, oil and gas, transportation, and energy.

Though the ultimate goal of the IIoT would be to create an entire smart factory where every component of operations is monitored, that day remains in the future. Still, a wide mix of current applications are now possible. Even by integrating just one IIoT capable element into an organization’s process can yield a huge return. For instance, organizations that have included smart air compressors into production have seen 60% reduction in unscheduled equipment downtime (Click here for the full case study). If such a large operational improvement is possible with just one element change, imagine the system productivity increase for an entire transformation.

Smart machines allow for constant system monitoring by utilizing the IIoT. The collected data provides insights into the internal status of operations and can be accessed by authorized administrators. With access to so much information, system maintenance is much easier. Often, systems are built with the ability to auto-adjust based on historical data to ensure optimal performance. Even if autocorrect abilities are not possible, having a system that is able to recognize problems makes maintenance easier. Preventative maintenance can quickly turn into predicative maintenance through the insights gained from the IIoT. Before a technician even visits the machine, the specific part and problem area have been identified. Alerts for maintenance and potential system failures ensure a more efficient production cycle, with less overall downtime and greater productivity.

Despite the many obvious benefits of utilizing the IIoT, a 2016 Genpact study found that only 25% of industry have a clear IIoT strategy (Click here for more details).Though the benefits are great, several barriers exist for organizations. Many industrial companies find the complicated nature of sorting through the data to be overwhelming, with 64% citing data integration as their number one concern. Indeed, the process of figuring out how to integrate all the data interpretations into a usable format can be complex.

Luckily, there are many available examples of industrial companies who have successfully integrated the IIoT into their operations for those organizations just beginning. These companies have established data sensors, machine communication, and integrated interpretation. Some of their established products can easily be integrated into your own systems to begin the process of establishing that smart factory.

One such company on the Internet of Things Institute’s list is Kaeser Compressors. They have integrated digital communications into almost all of their products with their special Sigma Air Manager 4.0 control panel. It supports predictive maintenance, analysis of energy costs, and customization of units by collecting information on temperature, humidity, and vibrations. The controller transforms the ideas of Industry 4.0 into a usable format with reliable, real-time updates and system wide controls. The Institute further credits Kaeser Compressors with incorporating the ideas of IIoT into its very business model (For the IOTI’s complete list, click here).

Companies on the IOTI’s list and others demonstrate how common the IIoT is becoming. This connectivity and system integration is slowly becoming the norm for industrial processes. Though not every organization can afford to switch over suddenly to the IIoT and change all machines to smart ones, a transition is certainly happening. As the IIoT continues to develop and technologies strengthen, the provided insights are simply too valuable for companies to ignore.

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Sources:
https://www.i-scoop.eu/internet-of-things-guide/industrial-internet-things-iiot-saving-costs-innovation/
https://www.ge.com/digital/blog/everything-you-need-know-about-industrial-internet-things
https://www.hpe.com/us/en/customer-case-studies/kaeser-iiot.html

Kaeser Releases New Oil-free Rotary Screw Compressor

Kaeser’s new oil-free rotary screw compressor is the latest in their inventory of lasting and efficient products. With its special rotor treatment coating and its smart Sigma Control 2, these compressors are 9% more efficient than competitor’s.

Watch the video below to learn more about these new models that are “trouble-free, oil-free, and built to last a lifetime.”

For more information, visit KAESER’s product page at http://us.kaeser.com/Products_and_Solutions/oilfree-air/ or click here to request your quote from CASCO USA

The New Kaeser Sigma Air Manager 4.0

The new Kaeser Sigma Air Manager or (SAM 4.0) collects information from each compressor and builds a complete picture of the requirements of your system. Using this information, the SAM 4.0 runs the specific compressors best suited for the conditions in your facility. Per Kaeser, the SAM 4.0 actively monitors compressed air systems to:

•significantly reduce energy costs

•lower maintenance costs and improve up-time

•provide predictive alarms, warnings, and equipment health status

•improve equipment reliability by

•systematically optimize critical compressed air system components

If you think your air system could benefit from a Kaeser Sigma Air Manager 4.0, contact us or request a quote.

The Kaeser Half Day Conference 2016

Our partners at Kaeser are coming to Pittsburgh to host a half-day conference at Heinz Field designed to educate and network manufacturing and engineering professionals in compressed air best practices. Hosting will be two highly experienced engineers: Wayne Perry is Kaeser’s Senior Technical Director and Werner Rauer is The Product Manager for Kaeser’s Screw Compressors. Werner is also the author of many of the articles at kaesertalksshop.com, an excellent resource for compressed air advice.

The Conference will host two seperate learning tracks for attendees:

Elegant and Efficient: Compressed Air System Design In this track, Werner Rauer takes the first hour to walk through the ideal design – what you need and why. In the second hour, he acknowledges that the opportunity to put together a system from scratch, where even the size and location of the compressor room are in an engineers’ control, does not come along very often. We put together compressed air systems in less than ideal conditions in the real world. So the issue we need to consider is how we move in the direction of the ideal in actual situations we face.

Leaking Money: Optimizing Compressed Air Systems for Sustainable ProfitabilityWayne argues for a paradigm shift in the way we think about compressed air systems. Typically, they are conceived in terms of machinery meant to deliver a particular result on the demand side of the system. This, he believes, is precisely the problem. Instead, we need to think of a compressed air system as a utility, not unlike electricity. And when we do, there is demonstrable evidence that we will not only decrease our carbon footprint, but increase our bottom line.

The schedule is as follows:

8:30 am    Registration and Breakfast
9:15 am    Plenary Session and Breakfast
10:00 am  Breakout Session 1
11:00 am  Breakout Session 2
12:00 pm  Interview and Q&A over Lunch
12:45 pm  Closing Session
1:00 pm    End of Conference

We encourage people of all backgrounds to join us at this incredible event. To sign up follow the below link.

Event Page and Sign Up Form

Compressed Air Efficiency Webinar Enrolling Now!

Join our friends at KAESER Compressors for an informative webinar!

Presents . . .

CASCO USA Awarded Oil and Gas Industry Supplier of the Year

Press Release, March 26, 2015

CASCO USA honoured with Industry Supplier of the Year in the Northeast Oil & Gas Awards

The Oil & Gas Awards announced this year’s annual Northeast Oil & Gas Awards recipients in recognition of those companies who excel in the key areas of Health & Safety, Operational Excellence, Innovation, Corporate Social Responsibility and Environmental Stewardship.

CASCO USA attended the 3^rd Annual Northeast Oil & Gas Awards and received the Industry Supplier of the Year on Wednesday, March 25, 2015. The annual Northeast gala ceremony was held at the The Westin Convention Center – Pittsburgh, 1000 Penn Avenue, Pittsburgh, PA, 15222, where hundreds of oil and gas executives gathered together to celebrate Operational Excellence, innovations in technology, CSR, Health & Safety and Environmental Stewardship.

The Industry Supplier of the Year Award recognizes suppliers of materials and equipment to the oil and gas industry. Companies who have demonstrated reliability, gone the extra mile to provide the oil and gas sector with impressive customer service and can show details of their CSR initiatives are rewarded. CASCO USA scored highest in the category with such remarks from the judges as:

“Great supplier in the Northeast region, offering seminar education sessions and a tailored approach to the provision of compressed air systems.”

 “Leading equipment supplier with audited bespoke solutions. Extremely comprehensive submission, with strong supporting documentation.”

About the Oil & Gas Awards 

The Oil & Gas Awards recognize the outstanding achievements made within the upstream and midstream sectors of the North American oil and gas industry. The Awards are a platform for the industry to demonstrate and celebrate the advances made in the key areas of environment, efficiency, innovation, corporate social responsibility and health and safety. The Awards show the industry’s motivation to develop by recognizing and rewarding the efforts of corporations and individuals. For more information about the Oil & Gas Awards, all regional awards and award categories can be reviewed on their website at www.oilandgasawards.com.

CASCO USA Named Oil and Gas Awards Supplier of the Year Finalist!

 

CASCO USA has been named a Northeast Region Supplier of the Year Finalist by the Oil and Gas Awards!

This honor is in recognition of our quality products and services provided to the oil and gas industry, including:

• KAESER Service and Instrument Air Compressor Systems
• Yamada Air-Operated Diaphragm Pumps
• Weir High Pressure Pumps
• Goodyear Hydraulic and Industrial Hoses and Assemblies
• Sauer Medium and High Pressure Compressed Air Systems
• Custom Engineered and Fabricated Packaged Systems

And More!

 

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