Industrial Fan System Virtual In-Plant Training

Due the challenges created by COVID-19 pandemic, manufacturers throughout the world have been trying to determine how to safely open and operate their manufacturing plants. To minimize the risk of infection, many manufacturers have reduced the number of people allowed into their plants without compromising the production continuity. This makes delivery of INPLTs challenging in the traditional in-person fashion. To address this challenge and continue providing INPLTs during this difficult time, Better Plants program piloted Virtual cohort In-Plant Trainings (VINPLTs) on process heating systems, ammonia industrial refrigeration systems and wastewater treatment operations. The VINPLT pilots have been very well received and participants have requested for additional trainings on more topics.

The Better Plants program will deliver a VINPLT on industrial fan (FAN) systems from Jun 17 to Aug 5, 2021. The Fan VINPLT will be performed by industrial experts using online video communication technologies. The Fan VINPLT comprises eight (8) 2.5 -hour online training sessions (2-hours formal training and optional 0.5-hour Q&A) that will be delivered on every Thursday 10:00 AM – 12:30 PM ET for eight (8) consecutive weeks. Participating in this VINPLT is free and open to all the Better Plants program partners. This VINPLT event is limited to 25 participants from 6–8 companies or facilities.

Participants will be trained on industrial fan system fundamentals and undertaking of a system-specific energy assessment, including hands-on training on the fan system assessment module within the Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) tool. To maximize the benefits from attending VINPLTs, homework assignments will be given to the participants at the end of each session and will be due by the next session. These homework assignments are designed to enhance participants’ understanding of industrial fan systems, as well as to identify and quantify energy savings opportunities. During the last session of the VINPLT, participants are expected to create a summary presentation based on their assessment, present their findings, and share the scrubbed version with DOE.

At the completion of the VINPLT, Professional Development Hours (PDHs) Certificates will be prepared for the attendees on demand basis. Participants are expected to collect measurements/data from their own fan systems, perform an energy assessment, and identify energy efficiency opportunities with the help from the instructors. To collect the assessment data, in some cases, diagnostic equipment will be arranged and shipped to the partners. The Better Plants diagnostic equipment are available on a first come, first serve basis.

Agenda for Industrial Fan System Virtual in-plant training

Jun 17 to Aug 5, 2021; Every Thursday 10:00 AM–12:30 PM ET (2-hour formal training + optional 0.5-hour Q&A)

Week 1 – Fundamentals of Industrial Fan Systems and Introduction to MEASUR tool; Jun 17, 2021

  • Fundamentals of fan systems
  • Non-energy benefits from fan system optimization
  • Introduction to MEASUR tool

Week 2 – Fan Types and Fan and System Curves; Jun 24, 2021

  • Identify major fan types
  • Develop and interpret fan curves
  • Develop and interpret system curves

Week 3 – Fan Affinity Laws and Fan System Controls; Jul 1, 2021

  • Affinity laws for fan systems
  • Fan control strategies
  • Optimization of fan systems

Week 4 – Measurements for Fan Systems; Jul 8, 2021

  • Develop measurement plan
  • Identify measurement planes
  • Use MEASUR to analyze sample assessment data

Week 5 – Pressure Considerations, Sizing Ducts and System Pressure Losses, Optimization Techniques; Jul 15, 2021

  • Collect system pressure data
  • Create fan and system curve
  • Use MEASUR to analyze top 3 systems

Week 6 – Psychometrics and Air Density for Fan Systems and System Effects; Jul 22, 2021

  • Use MEASUR to estimate air density
  • Calculate savings and estimate costs for top projects

Week 7 – Fan System Optimization Strategies, Fan System Evaluation with MEASUR; Jul 29, 2021

  • Identify energy savings opportunities
  • Use MEASUR to analyze a sample or actual traverse data, refine savings & cost estimate for top projects

Week 8 – Industrial Fan System VINPLT Wrap-up Presentations; Aug 5, 2021

  • Review major take-away points
  • Class presentation
Get to Know the Presenter

Ron Wroblewsk

Ron Wroblewski, PE, is the President of Productive Energy Solutions, LLC, in Madison, Wisconsin. His consulting and training business helps industrial plants and commercial facilities increase productivity and profitability by making more effective use of their fan, pump, and blower systems.

Ron has over thirty-eight years of experience designing, analyzing, specifying, and optimizing industrial and commercial fan, pump, blower, and HVAC systems. One of his specialties is in-situ measurement of fan system performance.

A highly rated professional trainer, Ron is senior industrial fan systems optimization trainer for the US DOE and the United Nations Industrial Development Organization (UNIDO) and he develops and conducts courses for the Air Movement and Control Association International (AMCA International). As part of his work for the DOE, UNIDO, and AMCA, Ron has designed and presented seminars on a national and international basis, including: Using the Fan Energy Index; Applying VFDs in Fan and Pump Systems; Optimizing Fan, Pump and Blower Systems; Fan Systems Optimization Expert level training; and Motor Systems Management

Ron is a licensed Professional Engineer in Wisconsin. He is a member of the American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE), the American Society of Mechanical Engineers (ASME), and the International society of Electrical and Electronics Engineers (IEEE). He earned his B.S.M.E. at the University of Illinois at Urbana-Champaign and his M.S. in Mechanical Engineering at the University of New Mexico.