“The folks at Industrial Controls always come back with solutions.”

“Industrial Controls worked with me and our electricians, and within a 24-hour turnaround, we installed fully calibrated pressure and temperature compensated flow meters that fed accurate information directly into a computer program indicating how many cubic feet of natural gas we were using,” says Lawonn. We needed to do something NOW so we turned to Industrial Controls.” The Solution: We wanted to make permit changes but the flow meters we had on the boilers were not giving us an accurate measure of our natural gas usage. “The original permits with the DNR indicated our run hours at 100% - we never run at 100%. “This plant’s typical gas bill is upwards of $200,000 per month, so a $5,000 to $10,000 swing is a really big deal,” says Lawonn. If either the pressure or the temperature of the gas varies, and the measuring device is not compensated for these changes, errors greater than +/- 5% can occur rather easily. You pay a mighty big penalty if you go over – usually 4- to 5-times the normal price.” “Since most of our gas is used for production, we had some serious concerns about usage and boiler efficiency. “To make things even more interesting, we are also on interruptible service with the gas company, which means we can only use so many cubic feet of gas on those particular days,” continued Lawonn. “Variable gas pressures and temperatures, and short pipe lengths make it very difficult to be accurate.” “Our boilers are all on usage permits with the Department of Natural Resources (DNR) and we have to keep an accurate record of how much natural gas we burn per month,” says Kerry Lawonn, Building Services Manager for the Lomira facility. Considered the largest single production site in the Northern Hemisphere with well over 2-million square feet, the Quad Graphics printed materials plant in Lomira, Wisconsin, has to be extremely conscientious about their natural gas usage.

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