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‘Having carried out a data logging survey for this customer, we identified that the existing Atlas Copco 37kW compressor was far too big for their actual requirements.
The data clearly showed that the company could run a machine of 15kW and still meet their production demand adequately and still have some room for future growth.
By removing this machine and replacing it with an HPC AIRCENTRE24 (Integral dryer and receiver mounted package) the customer was able to reduce their power cost and service bill by £3,200 per year. This gave the machine a payback period of just over 1 year.
In addition to the annual savings above the customer received a full 5 year parts and labour warranty plus the new machine was half the foot print size of the previous machine and as such giving them back valuable production space’.
‘In 2004 a Thetford based engineering company selected Premiair to provide a number of compressor and cost saving recommendations. The ideal situation would have been to gather information by data logging but there was no data to utilise at the point of start up.
After detailed discussions and utilising our experience, we arrived at a suitably sized compressor package 2 x 30kW fixed speed compressors with refrigerant dryer and with a distribution network of Transair Pipework.
The plan for the installation was to run 1 x 30kW compressor as the base machine, with the second 30kW compressor as the standby machine. These machines would rotate on a weekly basis to even out the running hours and service costs.
4 years later, even though the company has expanded enormously, we were able to data log the existing compressors to see if the sizing replicated the growth and discussions we had 4 years ago
The data logging clearly showed the accuracy of the original planned system in that there was no benefit to be gained by replacing either of the 2 x 30kW fixed speed machines, with a variable speed machine. Thus, proving the original system was correct in terms of predicting their future requirements.
Other than power costs, the only other costs consumed by the company were routine service costs, and as such, we have had a trouble free installation that has never left them without air, for one minute during the 4 year timescale’.
‘Two years ago, a new factory was built at Saxham (near Bury St Edmunds) and our customer installed 2 HPC 40kW fixed speed compressors to meet the total demand of the new site.
This year they moved an existing facility into the new Bury St Edmunds site and along with it a further 2 x HPC 40kW fixed speed compressors. However, this does create its own problem in that when you are trying to control more than two compressors on a pressure cascade basis, significant control issues can occur. This can have an enormous effect on the energy consumed in trying to meet a given compressed air demand.
To rectify this Premiair Solutions recommended an HPC Sigma Air Manager Controller (SAM) to control exactly the right amount of compressors required for the given demand. By installing this controller an immediate impact was made on power consumption and a reduction in power costs of £4200 per annum was achieved.
In simple terms, the controller paid for itself in under 6 months.
This is a clear example of how alternative control methods can be utilised to achieve the same goal as replacing a given installation with a variable speed machine’.
‘We were called to investigate an issue on site where an old part of the factory was experiencing a major problem with water in the compressed air system even though a refrigerant dryer was installed.
Through discussion and various site investigative visits, we determined that the pipe work system ran under ground externally for some considerable length and thus was subject to very low ambient temperatures.
From this we were able to advise that a refrigerant dryer was not suitable for the application as it was only capable of achieving a +3C dew point and that the ambient temperature was falling well below this (during seasonal periods) on the exposed pipe work. This was clearly an application for a heat regenerative desiccant dryer where a -40C dew point would be achieved.
In simple terms this meant that provided the pipe work was not subject to ambient temperatures of less than minus 40C, 100% dry air was guaranteed to the whole plant. This will have a dramatic effect on the down time currently being experienced on down stream valve cylinders etc.
In addition to this, we were able to fit the dryer with an energy saving controller which reduces the amount of power consumed by the dryer, dependent on flow rate through it. If there is no compressed air demand, the dryer consumes no power’.
Following a data logging survey which we carried out on the existing 6 Broomwade Watercooled Piston Compressors, which were spread over two compressor houses, it was clear that there were massive potential savings to be gained by utilising newer compressors.
Prior to the survey, the customer was manually turning compressors on and off to meet the demand. This led the customer to believe that he needed 1500-2000 cfm to meet the peak demand.
With the benefit of using the very latest data logging equipment we identified the actual peak demand was well below this, but more surprisingly the average demand was no more than 400 cfm, nearly 75% less than the customer thought.
We were able to provide a solution that saw a £30,000 REDUCTION in power cost by utilising a 75kw HPC variable speed compressor, backed up by 2x 45kw fixed speed compressors all controlled by a Sigma Air Manager controller all in one central location.
In addition to these power cost reductions, the customer was able to re-deploy one member of staff who was responsible for testing and checking cooling water, oil levels as well as the constant turning on/off compressors as and when required.
The total project cost was near £100,000 but the actual payback period was a little over 2 years.