patented air metering technology reduces pump air consumption

Patented air metering technology reduces pump air consumption

Go Green, Save Green Features Benefits

Self-adjusting air metering system for AODD pumps

Saves energy without sacrificing flow and without manual settings

Lowers maintenance on compressed air systems

Power generation system runs completely off air – no electrical wiring and no battery backup

Enhances productivity. Less compressed air needed to run pump means that more pumps can operate within existing capacity

Drop-in center sections fit competitive models

Enhanced pump performance without complete pump purchase

Explosion-proof ATEX certification Safety options for hazardous duty applications

Compatible with the following models:

Brand Clamp Band Bolted

Versa-Matic E2 ClampedE3 Clamped

E2 Bolted E3 Bolted

Wilden T SeriesM Series P-Series Clamped

Advanced learning program

• Modulates air flow to optimize energy usage

• Adapts to changing process conditions

• Runs without electrical wiring or batteries

AirVantage uses velocity feedback from an embedded sensor to optimize energy usage by restricting air flow during a portion of each pump stroke

AirVantage Operation

WithAirVantage

Without AirVantage

Reduces air consumption by as much as 50%

1. Air enters main inlet to pump

2. PowerGen module powers system without the need of an electrical connection

3. Feedback Sensor monitors stroke velocity

4. Microchip calculates ideal maximization point and controls air regulator valve

Product AvailabilityPump Size

Pump Models

Center Section Model

Material Special Application

2 RE2 YesAL, SS, CI, Hastell C

3 RE3 YesAL, SS, CI, Hastell C

Selling Process

Current EST

Pump Brand Wilden Versa-Matic

Pump Model P15 RE3

Flow (GPM) 110 110

Head (PSI) 30 30

Inlet Air Pressure (PSI)

40 40

# Hrs / wk 120 120

$Kwhr 0.10 € 0.10 € Δ

SCFM 50 30 20

Energy Reduction 40.0%

HP Reduction 4.44

Weekly Savings 46 €

Annual Savings 2,401 €

Energy Savings Calculator (Single Pump)

Air Compressor100 HP

Options

10

10 10

10

10

10

10

10

10

10

10

10

2-IN AODDFLOW: 50 GPMSCFM: 45HP Required: 10 HP

AODD Annual Energy Consumption:

• $2,000 / pump x 10 = $20,000

HP needed: 120

Typical System Layout

Holding Tank

Holding Tank

12 Pumps x 10HP = 120 HP Demand

Going Beyond Energy Savings

Air Compressor100 HP

Holding Tank

Holding Tank

8

8 8

8

8

8

8 8 8

8 8 8

20% ReductionHP needed: 120

Primary Need Benefit

Energy savings 20% savings = $400 per pump$400 X 10 pumps = $4,000

More Throughput / Greater Product

Two more pumps on-line 12 pumps using $1,600 per pump = $19,200 annual energy cost

Avoid Capital Spend New Compressor= $60,000

2-INFLOW: 50 GPMSCFM: 36HP Required: 8 HP

With AirVantage 12 Pumps x 8HP = 96 HP Demand

Air20%

China

Target accounts

IDEX Product's Features

Formula to Monetize Benefit

Monetized Benefit

(Total)

Energy Savings (SCFM reduction) X (# hrs of operation per year) 2,402 €

Lower Air Compressor Demand

More Compressed Air = Greater Productivity

• Run more pumps• Make more batch• Improve throughput

6,240 €

Lower Maintenance Costs

Maintenance Savings

Compressor Parts: 500 €Pump Parts: 1,000 €

1,500 €

Total Monetized Benefit - single pump 10,142 €

Total Monetized Benefit per facility –(50 pumps) 507,100 €

- Villeroy & Boch Headquarters –

Mettlach, Germany

Australia

N. America

Productivity Improvements (2 tiles/hr x 6,240 x €.5)

Note: Villeroy and Boch operates over 30 facilities in 20 countries, including W. Europe, N. America, China, and Australia

Success Story at Villeroy and Boch

Wilden T-Series Installed Product

48% Air Reduction over P1500


Formula to Monetize Benefit

Monetized Benefit

(Total)

Energy Savings

Lower Air Consumption = Energy Savings

35% X 2,080 hrs(SCFM reduction) X (# hrs of operation per year)

$848

Productivity Enhancement



$52,000

Lower Maintenance Costs Maintenance Savings

Pump Parts: $500$500

Total Monetized Benefit - single pump $53,312

Productivity Improvements

(1 more batch / week = 52 add’l batches per year). Let’s say each batch of Feed Energy is worth $1,000 X 52 batches = $52,000

Current EST

Pump Brand Sandpiper Sandpiper

Pump Model S30 RS30

Flow (GPM) 97 97

Head (PSI) 57 57


79 79

# Hrs / wk 40 40

$Kwhr $0.10 $0.10

SCFM 94.1 61.2

Energy Reduction 35.0%

HP Reduction 5.19

Weekly Savings $16

Annual Savings $848


SCFM Savings1-yr $8483-yr $2,5445-yr $4,240

Productivity Enhancement1-yr $52,0003-yr $156,0005-yr $260,000

Maintenance Savings1-yr $5003-yr $1,5005-yr $2,500

Total Savings1-yr $53,3483-yr $160,0445-yr $266,740

35% Air Reduction!

How AirVantage Wins

Performance

•AirVantage achieves energy savings versus traditional competing brands •Doesn’t reduce flow to achieve energy savings

Interchangeability •Fits competitive installed pumps

Operation

•Doesn’t require manual operation•No dials•No monitoring•No Electrical Connection

Installation

•Integral to pump design•Tested 100% on the assembly line for guaranteed performance

Safety

•Designed for intrinsically safe locations

Performance Interchangeability Operation Installation Hazardous Duty

T Series High Air Usage Yes - Clamped only

P Series High Air Usage Yes - Clamped only

X-FactorModerate Air Usage

Flow LossYes - Clamped Only

Manual operation and monitoring

MizA

ir Requires Electrical Connection

Requires Electrical Connection

Not Assembled with Pump

Requires Electical Connection

Not Explosion Proof

Pro Series High Air Usage

EXP Series High Air Usage

Yam

ada

High Air Usage

Competitor

ARO

Wild

en

- Selling Process -

Connect with the customer by identifying their needs:

• What are their current issues?

• What do they value?

• What projects are they working on?

• What is their production capacity?

• Do they have an energy initiative?

• Who are the decision makers?

All the tools you need in obtaining the right information for assessing baseline pump performance:

•Visual assessment

•Annual energy consumption of existing application

•Compare with AirVantage

•Estimate Energy Savings

Selling AirVantage to the end-user:

•Value Selling Examples

•Presentation Materials

•Downloadable Literature

•Pricing Information

•Data Sheets and Owner’s

Manuals

Sometimes it’s necessary to go the extra mile to win over a customer.

The AirVantage trial process takes you step by step toward closing with the customer:

•Obtain end-user trial agreement

•Order trial equipment

•Set up trial equipment

•Measure baseline

•Switch to AirVantage

•Measure AirVantage

•Downloading data

•Providing a test report

Connect with the customer by identifying their needs:

• What are their current issues?

• What do they value?

• What projects are they working on?

• What is their production capacity?

• Do they have an energy initiative?

• Who are the decision makers?

• Are you completely happy with your existing pump systems?

• Do you use AODD and why?

• If there was one thing you could change … …

• How do you evaluate pump performance?• Reliability?• Maintenance?• Flow?• Energy Consumption?

•Do you have a rough estimate on what you spend on energy per pump per year in your facility? On pump maintenance? On Compressor maintenance?

• Is there an active initiative in place where energy savings is the theme?

• Are you evaluating new projects?

Top Questions

Pump Assessment (use guide)

1.Identify total hours run time per day / year. Does it run continuously during this period?

2.Identify make and model number of pump

3.Identify airline size to ensure application is running True-to-Curve

• Two-inch pumps should have a min ½”

• Three-inch pumps should have min ¾”

4.PSI Inlet - Check pressure gauge for inlet pressure

5.Fluid Flow - Count strokes of pump for 1 minute and multiply this number by the fluid displacement found on pump curve.

(i.e. 90 strokes per minute at .5 displacement = 45 GPM)

Links to Tools

1.Versa-Matic Guide2.Competitor Curves3.AirVantage Curves4.Energy Calculator

Make Calculations (use calculator)

1.Using flow and inlet pressure, locate the condition point on the curve

2.Identify head (discharge) pressure on curve

3.Identify SCFM

4.Identify same condition point (using flow and head pressure) on Sandpiper Calculator

5.Compare the differences

6.Enter values on energy calculator

Step 1Identify baseline condition point

Step 2Compare with AirVantage

Step 3Enter data into calculator

Step 4Monetize Results

Wilden T15

Selling Process


Current AirVantage

Pump Brand

Pump Model

Flow (GPM) 0

Head (PSI) 0


# Hrs / wk 0

$Kwhr $0.00

SCFM

Horsepower Required

0.000 0.000

Air Cost per year -$ -$

-$

#DIV/0!

HP Reduction 0.00

Annual Energy Savings

Energy Reduction

Materials

Pump Size Currently Available in following models: E2, E3 (bolted) E2, E3 (clamped)

Air Treatment

Hazardous EnvironmentPlease indicate (x) if application requires explosion proof product rating

Proper Airline Hose Size

Submersible Application AirVantage is not suitable for submersible applications

Suction ConditionsPlease indicate if application is Flooded Suction (FS) or Suction-Lift (SL)

Site Assessment Form (Versa-Matic)

Ap

plic

ati

on

Cri

teri

a

Please ensure that the existing application has clean / dry air. Application recommendations: 40F DewPoint Air Filtration of 20 microns or better

Suitable for Aluminum, Stainless Steel, Cast Iron and Hastelloy C. AirVantage center section stays aluminum construction

Product availability for 2" and 3" pump sizes only

For maintaning pump performance and flow capacities, please ensure that airline size is:

Min 1/2" for 2-inch pumpMin 3/4" for 3-inch pump

Wkly Hrs of Operation Total hours of operation per w eek

Flow (GPM)Count strokes and multiply by pump displacement (data found on performance curve)

Air Inlet PressureEnsure that reading is taken as close to pump application as possible to overcome misleading data caused by pressure drops

Total HeadIf f low and air inlet pressure know n, this f ield is determined by follow ing the pump curve (see tabs)

SCFM Determnined by pump curve

Cost per Kwh Found by asking customer

Site Assessment Form (Versa-Matic)

Dat

a E

ntry


Current AirVantage

Pump Brand Sandpiper

Pump Model

Flow (GPM) 0

Head (PSI) 0


# Hrs / wk 0

$Kwhr $0.00

SCFM

Horsepower Required

0.000 0.000

Air Cost per year -$ -$

-$

#DIV/0!

HP Reduction 0.00

Annual Energy Savings

Energy Reduction

Wilden T15

1. Compare Performance to AirVantage

2. Enter Data into Calculator

Steps to creating a winning value proposition

1.Ensure that the customer is interested in reducing air consumption while maintaining flow for any one of the following purposes:

• Saving energy / reducing cost or

• Increasing productivity by having more available air compressor capacity

or• Increasing their air compressor capacity without

buying a new air compressor or

• Reducing air compressor maintenance or

• All of the above

2.Quantify air volume reduction at the pump (using calculations from site assessment)

3. Quantify horsepower reduction at the air compressor

4. Identify additional benefits from having improved performance (ties with needs analysis)

5. Monetize total value

Worksheet

AirVantage Product Features

Formula to Monetize BenefitMonetized Benefit

(total)

Energy Savings (SCFM) X (# Hrs of operation per year) based on $KwHr



Run more pumpsMake more batchImprove throughputAvoid new Air Compressor


% Air Savings = Lower maintenance costs

Other Additional Benefits

Total Monetized Benefit - Single Pump -$

Total Monetized Benefit per Facility (# of pumps)

Determined by needs analysis

Determined by needs analysis

Value Trial Steps

1.Obtain end-user trial agreement

2.Order trial equipment

3.Set up trial equipment

4.Measure baseline

5.Switch to AirVantage

6.Measure AirVantage

7.Download data

8.Provide a test report

Links to Documentation

1.Trial Agreement Form

2.Installation and Test Instructions

AirVantage over WildenVilleroy and Boch AirVantage Trial


Formula to Monetize BenefitMonetized

Benefit (Total)





6,240 €


Maintenance Savings


1,500 €







Benefit (Total)





6,240 €


Maintenance Savings


1,500 €




Product Trial Objective:

To close with the customer and generate sales

Essential Elements:• Properly executed site assessment• Customer commitment to purchase

A request for a free trial must contain the following:

- Launch Details -

Launch Kits

Primary Audience: Distributor Principals and Champions

Each kit consists of a mailer / case which houses the following physical items:

1. Brochures on the product2. Promotional giveaways (mouse pad)3. Promotional CD that contains:

• Product Video• Training Presentations• Value Selling Tools and Examples• Product Data Sheets and TSM Manuals• Price Sheets•Electronic Media Kit for printing banners, posters, logo artwork.

Website

Primary Audience: End-Users & Distributors

Public Site• General promotional vehicle

Distributor Site

• Product Video• Training Webinars• Value Selling Tools and Examples• Product Data Sheets and TSM Manuals•Electronic Media Kit for printing banners, posters, logo artwork.

www.airvantagepumpvm.com

Needs Analysis Site Assessment

Value Proposition

Product Trial&

Closing

Value Trial Steps

1. Obtain end-user trial agreement

2. Order trial equipment

3. Set up trial equipment

4. Measure baseline

5. Switch to AirVantage

6. Measure AirVantage

7. Download data

8. Provide a test report

Documentation

1. Trial Agreement Form

2. Installation and Test Instructions

3. Using the data-loggers

4. Sample Test Reports




Benefit (Total)





6,240 €


Maintenance Savings


1,500 €




Frequently Asked Questions

What is the expected life of the AirVantage?

Is there a separate warranty for AirVantage?


No - The standard pump warranty includes the new AirVantage system. It covers material defects and workmanship for up five years.

The AirVantage energy system is manufactured to last the life of the pump. There are certain wear components that will require more frequent servicing depending on application specific conditions. These items are the Pilot Valve, Regulator and Feedback Sensor.

Are the AirVantage components transferrable to other pumps?

As it stands today, the AirVantage control module is different for every unit (RE2, and RE3). The poppet valve, power gen and patch cable are interchangeable.


How much does AirVantage cost when compared to traditional AODD pumps?

When compared to standard base product it costs more, so it is important that you learn to sell the added value.

How do I order an AirVantage pump?

Since AirVantage is a product enhancement to an existing pump series, the base product model number is still intact. Just add an “R” as a prefix.

E2AA1D110-OEE-Series Aluminum pump with neoprene diaphragm, balls, and seats

RE2AA1D110-OEE-Series upgrade with AirVantage to save energy

E2AA1D110-OE

$1,352

RE2AA1D110-OE

$2,602

When a diaphragm fails and material invades the pump center section, will we have additional components to replace?

The sensor body is sealed by an intermediate gasket to prevent product from submerging the component. The sensor rod is also sealed by Buna seals and u-cups. After exposure to aggressive material, seals my begin to wear and eventually the sensor will need to be replaced – but only after repeated exposure to aggressive material.The AirVantage regulator body itself is designed to withstand fluid ingress as long as pump as been installed per standard manual guideline.

Why is there a special 20 micron filter-regulator requirement?

Both the Pilot and PG Pressure Regulator have small ports that require a higher level of filtration.The Regulator is helping to smooth-out air pulsations.


Why does AirVantage require a dry air specification?

If the existing application/pump is prone to freeze, then AirVantage may not work in this application.The AirVantage unit extracts more energy out of the air by letting the inner chamber pressure drop to a very low pressure. This causes the exhaust temperature to become much cooler than during normal pump operation. If there is moisture present, the colder exhaust temperature amplifies icing issues.To help combat this, we went with the high flow muffler and stainless/brass sleeve/spool.

– Recommend maximum Dew Point of 40F.• Refrigerate Dryers → 35F• Regenerative Desiccant Dryers → (-40) F

Is there a fluid viscosity limitation to AirVantage?There are no fluid restrictions. What covers the applicability of AirVantage is the pump speed. The slower the pump velocity, the lesser the savings potential


A 2” pump that is operating at 200 SPM, is cycling 3.3 Strokes per second, or once every 300 milli-seconds. And of that 300 m-s, only a portion of that is the air actually fully open to the pump. So, we are using a poppet valve that can open or close in 10 milli-seconds.When the Poppet Valve opens, we need as much air flow as possible, as quick as possible, to maximize air savings.We have observed this condition when the air inlet line size restricts the air coming into the pump. This commonly occurs when using ¼” quick-connector

Why do we have to pay special attention to the air-line to ensure proper sizing?


Appendix B

Component Details

Embedded Sensor

• Non-contacting Capacitive Coupled Resistance Sensing (CCRS) –Patented Technology

• CCRS uses capacitance as a method of picking up a signal

• Probe tips ride on inner diaphragm plates. O-ring under probe tip accommodates manufacturing variation.

Probe Tips

Sensor HousingSensor Rod

Control ModuleAnodized Aluminum Housing

1. Muffler2. Connection for Patch Wire3. Micro-processor PCB4. Power Generation PCB5. Wire Linkage to Pilot Valve6. Wire Linkage from Micro-Generator7. Green LED (on-front)8. On-Off Switch

Power Generator

• Self-contained 12 VAC power

• Uses Pre-Popetted Compressed Air (regulated to 16 psi)

• Mini Turbine or Rotor rotates at about 6,000 RPM

• Coupled to a Micro Generator that rotates

Poppet Module

1. Anodized Aluminum Housing

2. Pilot Valve

3. PG Pressure Regulator

4. Poppet Valve located inside housing

5. Plastic enclosures are attached to top and bottom of housing and sealed with an gasket/o-ring. (40% GF Polypropylene)

Appendix B

Trial Instructions

Trial Kit

Purpose: To demonstrate actual air consumption to the customer and record it over time.

Contains

• Flow and pressure sensor

• Removable USB data loggers (2) to capture air flow and air pressure

• Nine feet of 1” flex air line to attach to pump air inlet

• Water resistant electrical enclosure

• 20 micron filter-regulator

• 110V AC standard wall-plug

• Additional length of Pipe

Trial Installation Steps

1. Assemble test kit

• Attach additional length of pipe on flow meter section (air inlet side of the meter) to the coupling already installed.

• Three sections of 3ft long x 1” air lines are provided. One 3-feet section at a minimum is required on either side of the flow meter piping. An additional one is provided to help with installation.

2. Mount test kit

• Use Zip-Ties to mount kit in a convenient location for viewing and pump attachment using the mounting feet provided

• Pipe located opposite pump

•Electrical box is water resistant, but not recommend for submersion

Mounting Feet

Measuring baseline of existing pump

Purpose: Document current air consumption and inlet pressure of the application.

• Install Flow Meter Kit.

• Do not remove any non-essential or under-sized air-line components. You want to get a true picture of what the customer currently is consuming.

• Special caution--- Undersized air line components will restrict the flow of air (not to our advantage)

• Install 20 micron filter-regulator at the actual pump air inlet. (Necessary to have accurate inlet pressure.)• REMEMBER TO HAVE REGULATOR WIDE OPEN.

You only want to measure pressure.

• Come prepared to mate-up with the customer specific fittings for air.

• Record Air inlet pressure and air consumption at all relevant process points.

Measure AirVantage performance

Purpose: Demonstrate AirVantage savings to the customer

• Swap out current pump with the AirVantage pump.

• Maintain air flow meter kit

• If air-line is not properly sized, you must replace all air-lines as far back as necessary.

Airline size guidelines:

≥ ½” ID for 2” pumps ≥ ¾” ID for 3” pumps

• Eliminate any unnecessary air restrictions.

• Wall mount 20 micron filter-regulator. This can be either side of the flow meter. Adjust regulator till desired flow rate is achieved.

• Come prepared to mate-up with the customer specific fittings for air and flow.

• Record Air inlet pressure and air consumption at all relevant process points.

• COMPARE THE BASELINE READINGS WITH AIRVANTAGE

• Be Careful --- Make sure pump has stabilized before taking readings.

Filter-regulator

After 30 days of recording data it is time to retrieve the data-loggers within the test kit and send the information to our engineering group for a complete test report

Steps:

• Remove data-loggers (2) from kit

• Plug into computer USB ports and download data.

• Email data to [email protected]

• A detailed report will be returned to you within 5 business days

Thank you for your time

For additional information, please contact:

Application Engineering(419) 526-7296

patented air metering technology reduces pump air consumption

Documents

air reduction

air metering system

pump air consumptiongo

tileshr x

energy usage

hrsscfm reduction x

batch of feed energy

greater productivity