COMPRESSED AIR NEWS COMVAC ASIA solution was required: the new station was installed in a container, on the roof of the company building. This required precision work down to the exact millimetre during installation, yet once installed, the system could begin its work immediately. Detailed analysis results in a tailored solution Following a detailed compressed air audit to identify the company’s exact compressed air needs, Scholz’s compressed air station was designed to incorporate the very latest technology, including all of the features that today’s advanced stations should offer. Of course, first and foremost, this includes outstanding reliability, quality and Demand-oriented Collection and analysis of performance data makes it possible to revolutionise system servicing and maintenance: compliance with fixed intervals is no longer necessary, as service is performed only as required. When service is needed, the master controller simply sends notification accordingly and the material-flow infrastructure is managed in parallel through the manufacturer’s worldwide data centre. In practice, this means that orders of materials can be automatically forwarded to the distribution centre, which then coordinates delivery of materials with the manufacturer’s production or subcontractors. This both ensures a ready supply of materials and The new concept has delivered the promised significant energy cost savings efficiency, as well as impressive energy savings. In addition, ease of maintenance together with networking and integrated control features consistent with the Industry 4.0 environment also play a key role, not least in laying the foundation for predictive maintenance. A safety concept was also devised. The data gathered during compressed air system analysis were input into the controller of the new system, in this case a Sigma Air Manager (SAM 2), and provided the foundation for highly efficient operation of the entire station. Since the compressors and compressed air treatment components are equipped with integrated industrial PC technology, they are able to forward their data to the master controller. As a result, the master controller can monitor all components, as well as the environmental and production conditions, and is also able to precisely adapt compressed air production to match the company’s actual compressed air requirement. Furthermore, amongst many other key benefits, the SAM 2 optimises pressure values, automatically adjusts compressor system air delivery to accommodate fluctuating air demand and optimises system efficiency through constant analysis of the relationship between control losses, switching losses and pressure flexibility. This advanced controller also enables the compressed air station to benefit from future services, such as predictive maintenance and allows remote diagnostics capability. If requested by the customer, this option means that performance data are constantly sent to a data centre operated by the compressed air system provider for monitoring. The master controller independently analyses the situation at all times and if appropriate, sends a message to the service team, directly to the local installation technician or the central data centre. The air system provider’s central data centre then acts as the dispatching point for all further activities – worldwide. Fast and secure with Sima Network To ensure rapid, secure transmission of data both internally and externally, the compressed air station at Scholz is additionally equipped with Sigma Network. This powerful and secure closed network is Ethernet-based and guarantees optimal monitoring and efficient control of the compressed air station as well as maximum data security. keeps costs to a minimum, since unnecessary production is avoided; the materials can be delivered directly to the customer. All of these innovative measures help to enhance operational reliability and efficiency, and, at the same time, reduce both energy and total lifecycle costs. The master controller is already designed to accommodate potential future growth of the compressed air station. A straightforward software update is all that’s required for expansion, with no need for additional investment in new hardware. Heat recovery reduces energy costs Karl-Herbert Ebert, Head of Technology and Development at Scholz, is more than happy with the compressed air solution: “The entire compressed air supply ran smoothly right from the outset,” he says. “The container was delivered and once connected, we had our air supply”. In this case, the predictive maintenance capability is only indirectly beneficial to Ebert personally, since the company is not responsible for any aspect of servicing under this contracting plan. Yet he says with satisfaction, “The service is excellent. The technicians came overnight to perform the required maintenance and really didn’t notice a thing.” He is especially pleased that the new concept has also delivered the promised significant energy cost savings. The new compressed air station provided Scholz with the opportunity to take advantage of the benefits of heat recovery for the first time. Scholz now uses the recyclable heat from the compressors that occurs as a result of the compressed air production process to heat the company’s facilities; a measure that has already resulted in a reduction of some 50 percent in oil consumption in the first year alone. The ability to perform energy management in compliance with ISO 50001 is yet another major advantage for Ebert. Overall, he’s extremely satisfied. “We now have a convenient compressed air supply solution that offers a wide range of benefits. Not only can we now directly offset the compressed air costs, we no longer have to perform service work ourselves and have an excellent overview of our air consumption.” www.kaeser.com 64 MDATechnologies 4/2015
Product News Screw compressors with asymmetric profile for intense industrial use The Renner RS Range is shown amongst other Renner compressors at the ComVac Asia. Nowadays, for the relevant output range, oil-injected screw compressors represent the most modern and cost-effective method of generating compressed air. This type of compression highlights Renner’s advanced knowhow. With a range of performance from 3.0 to 355 kW, the compressors reach a final pressure of up to 15 bars. Renner screw compressors with their asymmetric profile are designed for intense industrial use. When developing a product, Renner places great importance to cost-effectiveness, long service life as well as low maintenance at low cost. Advantages RS-serie are: 2-year fully functional guarantee. Encapsulated air end: Compact design eliminates unwanted pipe work and potential oil leaks, as well as the need for pressure test certificates. Spin on & off separators save time and reduce maintenance costs. Easily removable doors: Very good access to individual components and ease of maintenance result in low costs for the user. Standard components: High quality German made parts and use of standard mineral oils ensure long life and low running costs. www.renner-kompressoren.com Precise flow measurement for compressed air and gases Due to its robust design, the aluminum die cast housing, the robust sensor tip made from stainless steel 1,4571, the new flow sensors VA 550/570 are suitable for demanding industrial applications. An ATEX version is available for applications in explosive areas. For flow measurement e.g. of natural gas there is a version with a DVWG admission. VA 550/ 570 has an integrated Modbus output as a standard with which all parameters like Nm³/h, Nm³, Nm/s, Nl/min, Nl/s, kg/h, kg/min, ft/min, °C etc. can be transferred. All parameters can be adjusted directly at the instrument (via display) or via the PI 500 hand-held measuring instrument resp. the Service Software. Of course there are also 2 x 4...20 mA analogue outputs available for flow and temperature and a galvanically isolated pulse output for the total consumption. A remote diagnosis can be carried out via Modbus and all relevant parameters can be checked and changed if necessary. So it is possible to change e. g. the gas type, the inner diameter, the scaling and so on or the zero point resp. the leak flow volume suppression in case of changed process conditions. The application range is wide: Compressed air measurement and distribution, leakage measurement of compressed air and gases, flow measurement of gases, flow measurement in vacuum systems, flow measurement of explosive gases with ATEX approval, flow measurement of corrosive, acid gases, measurement of oxygen and natural gas at gas burners and flow measurement of gas mixtures. The sensors can also be used in the outdoor area. www.cs-instruments.com FAD Measurement of Compressors Measuring the FAD (Free Air Delivery) of a compressor can be challenging. Standard methods used by the compressor manufacturers in their factories are not convenient or practical in the field. However, with a proper flow meter and some mathematics this task is manageable. CS-iTEC’s pitot tube flow meter S 430 is designed for this purpose of the discharge flow measurements at compressors to evaluate the FAD and monitor performance. The installation is through a 1/2” ball valve and can be done even under operation. Through an optional color display, the discharge flow and the FAD can be displayed and various settings are available. It comes with 4-20 mA, pulse and Modbus interface. In combination with a S 331 data logger, several flow sensors can be connected to one display. By adding a power meter to measure the compressor power, a complete performance solution is in place. www.cs-itec.com MDATechnologies 4/2015 65
