New device helps gauge energy consumption of compressor systems

12th July 2013

By: David Oliveira

Creamer Media Staff Writer

  

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Compressor hire company Rand-Air is investigating the introduction of the MBox Lite, a device that measures the peaks and troughs of compressed-air energy consumption.

“All derived information can be used to suggest a prudent choice of compressor to promote energy efficiency, thus, further enhancing our ability to customise environment-friendly solutions for our customers,” says Rand-Air marketing manager Byrone Thorne.

“By focusing on meeting the need of our customers to become more aware of saving and reducing energy consumption, Rand-Air has been able to introduce alternatives to traditional methods of operating,” says Rand-Air sales manager Kim Coetzee, highlighting that, as government implements rebates for those companies prepared to introduce energy-reduction processes, there will be a greater demand for technology and solutions that assist in the process.

One such possible future solution is the MBox Lite study from international industrial productivity solutions provider Atlas Copco, of which Rand-Air is a division.

The MBox Lite study, running constantly for a week, provides a profile of a company’s individual compressed-air production requirements and the cost. Operations can continue normally during the audit process, while the Mbox Lite records the activity of a compressor. A detailed report is compiled, comprising the compressor’s scope of supply; profile graphs and charts; data pages, including power and air consumption, load cycles and running hours; as well as an executive summary.

The Mbox Lite records factual data based on the actual measurements of air-compressor use. It shows exactly where improvements can be made in the compressed-air system to reduce operating costs and plots simulations using the data to show the benefits of upgrading to new technology. The unit is beneficial in that it projects payback periods to justify a cost-saving capital investment and provides professional audit and/or profile reports.

“Energy savings in compressed-air systems are important, as energy consumption typically represents more than 80% of a compressor’s life-cycle cost and compressed-air systems, on average, account for about 10% of industrial electricity consumption. For this reason, Atlas Copco has been developing energy efficient compressed-air solutions for many years,” says Thorne.

An example is the Atlas Copco ZR series of water-cooled oil-free air compressors, with built-in energy-recovery systems, which was the first in the world to be Technischer Überwachungs-Verein- (Technical Inspection Association-) certified for net zero energy consumption in specific design conditions.

Coetzee explains that during extensive trials on the compressors, it was proved that 100% of the electrical power input could be recov-ered in the form of hot water. “With these carbon-zero compressors, sectors that typically use a great deal of hot water and steam, such as the food and bever-age, pulp and paper, pharmaceuticals, chemi-cals and petrochemicals, power generation and textile industries, can dramatic- ally reduce their energy consumption.

Another product identified by Rand-Air as contributing to energy efficiency on site is the variable-speed drive (VSD) compressor. “VSD compressors consume up to 35% less energy than similar fixed-speed compressors by varying their output continually and automatically to precisely match the demand for air,” Thorne notes.

The converter in Atlas Copco’s GA VSD system performs a soft start and stop function, automatically controlling the acceleration and deceleration levels, eliminating current peaks of traditional-star-delta or direct-on-line starters. The power factor of a GA VSD compressor remains high throughout the complete speed range, while standard compressors fall to typically 0.53 in no-load running conditions.

Atlas Copco’s patented Elektronikon monitoring system continuously and accurately monitors the status of the compressor and automatically regulates it for economic and efficient operation. The system will automatically shut the compressor down should it detect a fault in its vital functions.

Compressors for Kusile
State-owned power utility Eskom enforces stringent safety measures at its power stations, which ensures that only those suppliers that maintain equipment and provide services complying with gazetted occupational health and safety (OHS) regulations are acceptable, says Rand-Air.

“Along with a select few companies, Rand- Air has been an on-site supplier at Eskom’s Kusile coal-fired power station, in Mpuma- langa, since the project’s inception in 2009,” says Rand-Air GM Louwrens Erasmus.

“As part of the Atlas Copco group, Rand- Air has adopted an ongoing policy of com- pliance with the highest local and international OHS rules and regulations. This protects not only our own employees but also our clients’ employees and the environment in which we work.”

The Kusile project’s main civil contractor is the Kusile Civil Works (KCW) joint venture (JV), consisting of construction companies Stefanutti Stocks, Wilson Bayley Holmes-Ovcon, Group 5 and Basil Read.

“Each of the individual companies in the JV previously hired equipment from Rand-Air. Our decision to select a variety of compressors from the Rand-Air fleet, including 12 Atlas Copco D400 units, was motivated by the company’s safety record, its reputation for excellent service delivery and competitive pricing,” explains KCW JV section manager Theo Kuhl.

The scope of work for the KCW JV entails all the civil works in terms of the earthworks and concrete works for the power station’s six 800 MW units, as well as the purification works and other ancillary works. “We are using the Rand-Air compressors for construction activities, including concrete preparation, cleaning activities and driving the pneumatic equipment,” he says.

“Rand-Air provides extremely reliable and productive equipment, which is supported by service levels that are currently rated the highest on our supplier list,” Kuhl adds. Further, he notes that Rand-Air employees pay customers at least one weekly site visit, with fast and efficient response times, should further assistance be required.

“All the projects of this nature centre on providing the customer with a plant that is built according to specifications in the allocated time and within the predetermined budget. “By surrounding ourselves with suppliers that uphold a customer-centric business philosophy, we are better equipped to achieve these goals,” says Kuhl, noting that Rand-Air’s equipment plays a major contributing role in the overall success of the KCW project.

Edited by Tracy Hancock
Creamer Media Contributing Editor

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