Course Details

Objective

This training program is designed to provide an understanding of engineering related problems related to industry globally and a clear sense of what is required to effectively  structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem solving initiative within their organization.

Content

Module 1 : Will the Stand-By Air Compressors Start-Up?   

• Initial Investigation
• Detailed Investigation
• Problem Identification
• Solutions
• Lessons Learnt

Module 2 : Sequencing Control

• Why is measuring flow important to measure demand?
• What is wrong with using pressure to calculate flow?
• Does the SC work with any type of air compressor?
• The SC interface to each air compressor
• SC’s software
• Remote monitoring capabilities

Module 3 : Compressed Air Controls for Industry – Problem and Solutions

• Controls and System Performance
• Individual Compressor Control Strategies
• Multiple Compressor Control
• Multiple Compressor Control with VSD

Module 4 : Compressor Sequencer: Problems and Solutions for Industrial Applications

• Introduction to Sequencers
• Cascade Sequencers
• Target Sequencer
• Custom Sequencers
• Common Sequencer Problems
• Problems Unique to “Vendor Sequencers
• Problems Unique to “Third-party Sequencers”
• How to Select, Install, Operate & Maintain a Sequencer Correctly

Module 5: Automating & Monitoring Your  Compressed Air System: Problems and Solution for Industrial Applications

• Managing Multiple Compressors for Maximum Energy Efficiency
• Monitoring your compressed air system made easy
• Maintaining efficiency and energy cost savings

Module 6 : Environmentally Considerate Compressor Fluids

• Why do compressors need fluids?
• Base stocks commonly used in compressor fluids
• Study of Biodegradability

Module 7 : Evaluating Central Compressed Air Management Systems

• Cascade Control Settings
• Case Study
• Operating Sequence
• Results of Continuous Monitoring
• Design Faults
• Recommendations

Module 8 : Easy-to-Implement Master Control and Monitoring Systems

• Compressor Controls
• The Key Performance Indicator (KPI): kW/100 cfm
• Factories Should Use kW/100 cfm as a Key Performance Indicator
• Accumulated Intelligence makes it Easy to Save
• Control Strategies
• Data Collection
• Communicating the Data

Module 9 : Partially-Loaded Air Compressors in Industry

• Step #1: Measure energy costs of air compressors
• Step #2: Manage Compressed Air Demand Events
• Step #3: Identify Inappropriate Uses of Compressed Air

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions