White Papers
Oil-Free, Centrifugal Air Compressors
The Best Kept Secret Surrounding Compressed Air
Does your facility's fluid cooling system really require chilled water?
Photo Optic Sensors - Keep and Eye on Efficiency
Air Flow through an Orifice
Low-Cost, High-Performance Electric Actuators and Robots
New Compressed Air Piping System Results in Lower Costs and Big Savings
Dual audit air compression and fluid cooling
processes take on operating costs
Innovation + Imagination = FLO-TROL
Consistent use of air delivers new sports technology
Introducing Oil-Free, Centrifugal Air Compressors
John Henry Foster Minnesota is pleased to announce a new partnership with FS-Elliott to distribute and service their complete line of Centrifugal Air Compressors. With over 50 years of design and build experience in centrifugal air compressors, FS-Elliott has become a world leader in the oil-free compressor market. Their aggressive capital and R&D programs have been instrumental in the development of new and enhanced product offerings including the following:
- Polaris® Series of oil-free centrifugal air compressors designed for the general industrial market. The Polaris® series state-of-the-art aerodynamic design, which provides unparalleled performance and reliability, has become a leader in industries such as electronics, automobile, mining, pharmaceutical, and food and beverage among others. The POLARIS® Series of centrifugal air compressors feature seven models ranging from 250 hp to 2500 hp and delivering 1175 through 12,000 icfm. The POLARIS® series incorporates the latest technology to ensure high efficiency, economy and reliability with minimal maintenance requirements.
- PAP PLUS® series of centrifugal air compressors. The PAP PLUS® series have been enhanced with a state-of-the-art control system and cutting edge technology. With thousands of installations around the world, this series of centrifugal air compressors is the benchmark for efficiency, reliability and durability. The PAP PLUS® series is the premier supplier of oil-free compressed air solutions required by the API 672 markets such as oil and gas production, refining, chemical and petrochemical.
- REGULUS® - A complete family of PLC based control systems developed to maximize the efficiency of all FS-Elliott centrifugal air compressors. The REGULUS® control systems designed with the latest technology provide plant personnel with not only precise system control and monitoring, but energy efficiency in a user-friendly package.
Through constant investment in leading edge technology and innovation, FS-Elliott has positioned itself to be the global leader in the oil-free centrifugal market. With manufacturing and service facilities in Export, Pennsylvania, FS-Elliott is the only U.S. manufacturer to establish a nationwide distribution and service network to provide local sales and service capability.
To support your productivity and efficiency needs with this innovative product, please contact us at 651.452.8452 or visit www.jhfoster.com.
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The Best Kept Secret Surrounding Compressed Air
When it comes to deciding on air compressors, most people look at rotary screw types that are either lubricated or non-lubricated. This is justified when the horsepower of the compressor falls between 10 and 250 hp, but what about when the compressor is at or above 250 hp? Is the rotary screw the air compressor of choice or are there other options available?
If you are like the majority of people, the centrifugal air compressor is probably not on your list of options. For a compressor type that has been around for 50 years - longer than the rotary screw air compressor - the centrifugal air compressor is relatively unknown. It has been the main workhorse of the process, air separation and energy generation industries where oil-free large horsepower compressors were needed.
However, in the last 20 years, the centrifugal air compressor has been reengineered to meet the demands of the plant air compressor market. The best features of the centrifugal air compressor design were combined with modern electronic controls to interface with or replace rotary screw air compressors.
Centrifugal air compressor highlights:
Oil-free compressed air
The centrifugal air compressor is by nature oil-free. This makes it very adaptable for applications that require oil-free air, but it also reduces the filtration and maintenance requirements in applications that would not normally require oil-free.
Reduced maintenance
The centrifugal air compressor has the lowest maintenance requirement of any of the types of rotary screw air compressors either oil-flooded or oil-free.
Small package
No other air compressor delivers the volume of air per ft² footprint requirement than the centrifugal air compressor. In many cases the floor space required is ½ that of a comparable rotary screw air compressor.
Extended oil life
Due to the low operating oil temperature, normally 120 °F, and the fact that the oil does not mix with process air, the life of the lubricating oil can extend as long as 2 years. The less strenuous oil requirements not only allows for an increase in oil life, but also a decrease in oil and disposal costs.
Efficiency
When it comes to cfm/kW, no other air compressor technology can match the performance of the centrifugal air compressor.
Reliability
The non-wearing basic design of the centrifugal air compressor makes it one of the most reliable compressor available and the compressor of choice for industries where reliability is of utmost importance.
For more information on centrifugal air compressors please contact us at 651.452.8452 or visit www.jhfoster.com.
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Does your facility's fluid cooling system really require chilled water?
Over the last 25 years there has been a heightened awareness to reduce the consumption of both water and energy. Federal, state and local laws, rising costs of water and energy, and a growing need to reduce operational costs have pushed this awareness to the forefront of all industries. Most companies are trying to cut expenses and become more efficient. It’s smart business and it’s urgent.
Water and energy are not an unlimited resource. And as regulations concerning the use and disposal of water have intensified, industrial applications that utilize both resources have come under scrutiny. One such application is industrial fluid cooling, which consumes as much as 7 percent of the energy and 15 percent of America’s water consumption (excluding the energy-generation industry).
While this high water usage makes industrial fluid cooling a prime target for energy and water conservation, the rush to reduce or eliminate it has in many instances actually increased energy consumption. Inappropriate fluid cooling, particularly the misapplication of chillers for cooling many industrial processes and equipment, has led to a large increase in fluid cooling costs and widespread inefficiency.
In the manufacturing industry, nearly all industrial facilities utilize chillers in some capacity, typically operating with an average water temperature ranging from 45°F - 60°F. But the question begs to be asked … is utilizing chilled water always the best choice? Creating a cold temperature, in general, is an expensive use of energy. Therefore, cooling temperatures below what is necessary has a direct relationship to an increase in costs.
By simply increasing the amount of water, it is well documented that many fluid cooling applications can operate successfully with cooling media temperatures between 70°F - 90°F. This temperature variance makes it possible to utilize other fluid cooling technologies, such as dry cooling or evaporative cooling, which would result in a reduction in energy costs, as well as a reduction or elimination of the use of water.
If a facility is to increase efficiency by reducing in energy and water usage, then fluid cooling applications need to be evaluated based on the highest allowable cooling media temperature. The increase in cost to supply additional water flow to an application would be quickly offset by either reducing the chiller load or eliminating additional chiller capacity.
Building managers can find out about alternative fluid cooling technologies and applications by simply conducting a fluid cooling audit. Engineers can evaluate how to maximize the performance, reliability and efficiency of a fluid cooling system. As experts examine each application, they can also determine the suitability of utilizing higher-temperature fluid cooling media.
Every single degree costs money. By learning how to improve efficiencies through an energy audit, businesses can reap the rewards of taking charge of their facility costs.
Ron Nordby
Vice President, Sales and Marketing
John Henry Foster
651-681-5724
Ron.Nordby@jhfoster.com
www.jhfoster.com
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Photo Optic Sensors - Keep and eye on Efficiency
In today’s business environment, there is unrelenting pressure to manufacture products faster, more precisely and at a lower cost per unit. Industrial manufacturers are charged to find new ways to increase production rates, while eliminating any unnecessary costs, including line downtime, scrap and rework. In order to meet these demands, factory automation has become, and will continue to be, a top priority.
One of the key elements of efficient factory automation is photoelectric sensors, which allow machine designers to measure, monitor and control machine functions quickly, precisely and reliably. The high-tech sensors become the eye of the machine, generating specific inputs to control its function. They are also the latest and most innovative way to optimize automation requirements, particularly sensing surfacing and distance performance.
Types of Photoelectric Sensors and Applications
A photoelectric sensor is simply an optical device that detects a visible or invisible light beam and responds to a change in received light intensity. The light source is either an LED (light emitting diode) or laser, depending on the requirements of the application.
Photoelectric sensors are available in numerous sizes, sensing modes and configurations that provide solutions to virtually any application in industries such as packaging, food processing, semiconductor and material handling.
LED Sensors
LED sensors are one of the most widely applied with the most versatile range. They are cost effective and adaptable to virtually any application.
Applications:
Sensing objects from opaque to transparent
Sensing parts in clean to contaminated environments
Counting parts
Sensing small parts that are not in a repeatable position
Sensing parts of varying reflectivity and ignoring backgrounds
Sensing parts in a defined depth-of-field
Laser Sensors
Laser sensors offer excellent repeat accuracy and performance, especially in applications where long-sensing range and narrow beams are required. Laser sensors can be used in the same applications as LED sensors, plus they are very effective in high-accuracy measurement requirements.
Fiber Optic Sensors
Fiber Optic sensors offer superior performance where the sensing environment is harsh and extremely confined.
Applications:
High vibration and shock tolerance
Applicable in high heat, wet and corrosive environments
Compact design for tight sensing locations
Complete immunity to electrical noise
Explosion proof design EMI and RFI
Sensing very small objects
Furthermore, the photoelectric sensors are relatively inexpensive and operate well in challenging environments. They perform tasks that other “more conventional” sensors can’t such as color identification, distance and thickness measurement. These highly sensitive sensors can be programmed to read an extremely specific and limited area, ensuring the highest accuracy. And because they are usually impervious to noise/dust/false signals, they are very long-lived.
Improving industrial performance is a top objective. High-precision photoelectric sensors help manufacturers optimize productivity, while helping their customers improve their products and their processes.
James J. Lavota, CFPS
Electro-Pneumatic Automation
John Henry Foster
651-681-5729
Jim.Lavota@jhfoster.com
www.jhfoster.com
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Air Flow through an Orifice
See chart
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Low-Cost, High-Performance Electric Actuators and Robots
Continuing John Henry Foster’s (JHF) mission to promote a progressive culture by seeking opportunities for cutting edge technology, we are excited to announce the addition of the Intelligent Actuator America, Inc. (IAI) product line.
IAI designs and manufactures a complete line of motion control systems providing linear and robotic component solutions to businesses around the world. These markets include automotive, consumer products, electronics, food, medical, inspection and examination, to name just a few. They are the world leader in linear actuators and low cost, high performance SCARA robots, as well as a leading source of advanced plug and play automation throughout North America.
With the recent introduction of the ROBO Cylinder® linear actuators product line, IAI has become a standard in cost effective, low maintenance, and fully programmable electric cylinders. The ROBO Cylinder® linear actuator was designed to accomplish the simple tasks usually assigned to air cylinders, but with greater flexibility and custom control over position, speed, acceleration, deceleration and torque.
Our goal at JHF continues to be our dedication to serve our clients with the most cutting-edge products available on the market. We bring customized client solutions in consistency, reliability, and profitability, while continuing to demonstrate our tradition of the latest industry trends and solutions in world-class compressed air automation. Specializing for over 70 years in air compressors, electrical motion controls, and aluminum framing systems.
Our team of experts in our Electrical Engineering Department are positioned to support your productivity and efficiency needs with this innovative product and can determine how best to fill your automation needs. Please contact us at 651.452.8452 or visit our website at www.jhfoster.com if you have any questions or would like further information regarding the IAI product line.
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New Compressed Air Piping System Results in Lower Costs and Big Savings
To be cost effective, compressed air needs to be delivered with enough volume, appropriate quality and pressure to properly power the components that require air to operate. Unfortunately, a poorly designed compressed air distribution system can increase energy costs, promote equipment failure, reduce production efficiencies and increase maintenance requirements. That’s the bad news.
The good news is that John Henry Foster has a solution – one that is quick to install, energy efficient and provides long-term savings: Transair® Aluminum and Stainless Steel Piping System.
Transair® Piping System is available for use on compressed air, inert gases and water in various sizes up to 4”. Its innovative technology is effortless to install and easier to modify than either black iron or copper piping. The push to connect and unique clamping systems provide airtight and secure connections with a minimum of assembly tools. Transair® requires no threading, soldering or gluing and once the connection is made it is ready to be pressurized.
Components are reusable and interchangeable, and allow for immediate and easy layout modifications. Alterations of an existing system such as adding a new drop or moving an existing drop, requires very little expense or downtime. The large number of connectors, pipe sizes and piping accessories available within the Transair® Piping Systems make it possible to accommodate even the most complicated of piping designs.
Optimum efficiency of the compressed air distribution system is assured with the airtight, full flow and corrosion resistant properties of the Transair® Piping System. The corrosion resistant characteristic of Transair® allows for consistently clean process media to be delivered to system components. Due to its ability to deliver high quality process media, downstream components such as air valves and cylinders are able to deliver long service life and reliable operation.
Overall savings
Perhaps the most attractive measure of the Transair® piping system is the overall savings it provides. Typically, any additional money spent improving a compressed air piping system will pay for itself many times over. Transair® piping system is no exception, offering sound solutions for all compressed air, liquid and inert gas applications.
For further information on Transair® Piping System or Installation information, please contact us at 800.582.5162 or visit our website at www.jhfoster.com.
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Dual audit air compression and fluid cooling
processes take on operating costs
A large printing company contacted JHF’s engineering department to perform an energy audit of its compressed air and fluid cooling systems. The goal of the audit was to evaluate the existing compressed air and fluid cooling systems to improve performance, reliability and efficiency.
Challenges
Fluid Cooling System:
Reduce demand on the current chiller system. The chiller system was operating at maximum capacity. With the addition of a new printing press a capital expenditure of $300,000.00 for an additional chiller would be required.
Reduce operational costs.
Reduce production dependence on chiller system.
The chiller system cooled virtually all process equipment supporting production and any loss of chiller capacity would result in a partial or complete shutdown of production.
Compressed Air System:
Increase system efficiency.
Stabilize system air pressure level. The current system demand is handled with on-line horsepower resulting in the system going dynamic. This allowed the system pressure to fluctuate at approximately 25 psig.
Reduce operational costs by lowering system pressure levels.
Solutions and Benefits
Fluid Cooling System:
It was determined that the air compressors, air dryers and vacuum pumps could be separated from the chiller system and cooled by a more efficient dry cooling system. The implementation of a dry cooling system reduced operational and maintenance costs, as well as removing 120 tons of chiller demand from the existing chiller system. The reduction of chiller demand resulted in the ability to assume the chiller load needed to operate the new printing press, eliminating $300,000.00 in capital expenditures. The separation of the air compressors and vacuum pumps from the chiller system also reduced the dependence of process equipment on the chiller system.
Compressed Air System:
Data logging of the compressed air system during the audit process revealed that the maximum demand could be handled with current compressor horsepower. It also identified areas of the compressed air system that could be changed to improve system efficiency. One area is the installation of demand regulation and 3,000 gallons of general storage which would allow the reduction in system pressure from 113 psig to 88 psig, as well as eliminate the wide system pressure swings, reduce leakage rate and power costs by 12%. The other area would be the installation of a Centralized Compressor Control System which would automatically maintain compressor horsepower necessary to match demand requirements.
Results
Fluid cooling system:
Savings of over $53K in yearly operational and maintenance costs.
Reduced dependence on chiller system.
Eliminated a $300K capital expenditure.
Immediate payback on the cost of required modifications.
Compressed air system:
Operational and maintenance costs reduced by $40K annually.
Stabilized plant pressure.
Increased reliability of compressed air system.
Return on Investment realized in approximately 1.2 years.
For further information regarding compressed air efficiency auditing, please contact us at 651.452.8452 or visit our website at www.jhfoster.com.
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Innovation + Imagination = FLO-TROL
The Department of Energy has estimated that 10% of all electrical energy use in the United States is consumed in the generation of compressed air. This has added significance since 70% of all manufacturing facilities utilize compressed air in some aspect of their manufacturing process. These facts highlight the reason why companies with compressed air systems have a compelling reason to investigate the potential for energy savings.
While there are a number of areas within compressed air or vacuum systems to analyze for energy savings, centralized control systems for multiple compressor installations is one that provides a great opportunity for significant savings. Energy savings of 30% can be realized on multiple compressor systems that currently do not have some form of centralized control system. Energy savings of 10-15% can be realized even with multiple compressors systems utilizing the cascading pressure band system, which is probably the most common control scheme.
Flo-Trol, the industry’s first flow-based centralized compressor control system was developed to address this issue. Flo-Trol eliminates many of the limitations that currently exist with compressor control systems offered by compressor manufacturers. Some of Flo-Trol’s advantages include:
Flo-Trol is non proprietary, using off the shelf components.
Flo-Trol is able to control and monitor all types and manufacturers air compressors and vacuum pumps.
Flo-Trol eliminates the need to designate a lead compressor or establish a cascading pressure band system.
Over the last 15 years and 200 installations, Flo-Trol has evolved into a very powerful and sophisticated control and monitoring system. Our Electro-Pneumatic Control department has applied the expertise and knowledge, gained through experience to develop a complete family of U.L. Listed controllers under the Flo-Trol name. We are utilizing state-of-the-art hardware and software such as Allen Bradley’s MicroLogix and CompactLogix controllers and Panelview touch screens to provide our customers with all the benefits this new technology has to offer. John Henry Foster is also well versed in the integration of Flo-Trol with Building Management Systems. We have extensive experience with Local Area Network technologies, such as Ethernet.
Today Plant Managers are looking to not only control their systems, but are looking for data such as energy, pressure, temperatures, dew point and flow measurements, which Flo-Trol provides. This information has become instrumental in analyzing and benchmarking system performance which is critical in maintaining and documenting the quality and cost of these systems. In many instances they are looking for this data to be incorporated into their own building management systems and formatted for internal and external use. Flo-Trol was designed to be customized to any level of sophistication required. We realize that individual requirements can vary tremendously and we are committed to providing whatever expertise is required.
If you would like further information regarding Flo-Trol and how we can assess your Company’s potential energy saving opportunities, please contact Ron Nordby.
Ronald K. Nordby
Vice President, Sales & Marketing
Direct 651.681.5724
ron.nordby@jhfoster.com
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Consistent use of air delivers new sports technology
In 1997, Doug Campbell and his brother Jeff decided to start their own business. Doug was an avid volleyball player and wanted to develop a product that would provide him with a convenient way to train on his own. Doug asked Jeff for his engineering expertise and together in their garages they designed a volleyball throwing machine called AirCAT. The Campbell brothers knew that other volleyball machines existed but most lacked consistency, caused ball wear, and none were operated with the help of an air system. This was the beginning of Airborne Athletics.
“Our goal when developing the AirCAT was to improve player’s skills by allowing the coach freedom to coach rather than being a ball tosser. With our patented ‘Consistent Air Technology’, the AirCAT will deliver with consistency, up to 1100 volleyballs per hour automatically for all types of drills,” explains Mr. Campbell.
The AirCAT volleyball machine was introduced in 1998 and with JHF’s help has become very popular within the athletics industry.
Over the past 11 years, there has been constant communication between JHF’s account manager, Chris Garding, and Airborne Athletics. Being a small company, Airborne Athletics has utilized the expertise of JHF in the product development area. JHF has been providing Airborne Athletics with several innovative design and product suggestions since the very beginning and continues to assist by streamlining Airborne’s purchasing, staying deeply involved in engineering changes and developing new product ideas.
In 2003, building on the success of AirCAT, Airborne Athletics decided to take advantage of the growing popularity of basketball and create Dr. Dish, a basketball game simulation machine. Currently about 60% of Airborne Athletics sales are in the basketball industry, and 40% are in the volleyball industry. This is mainly due to the larger amount of basketball programs available and the greater popularity for both genders in schools.
Over the years, Airborne Athletics has gone from two employees to twelve and plans to keep expanding in the future.
Through JHF, Airborne Athletics continues to look to Chris Garding for new products and engineering expertise to improve their current designs. The relationship between Chris and Airborne Athletics is truly a mutually beneficial partnership that will continue into the future.
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