Compressed air costs can be reduced by comprehensive system monitoring. Costs are rising year by year: A 200 kW compressor with a normal maintenance plan and power cost at R0,84 kWh running 24/7/365 will cost R1,3 million a year to operate.
The factors surrounding air compressor cost reductions are numerous and challenging, and include waste of thousands of Rand’s worth of energy per annum. The problems and energy wasters can be summarised as;
* Compressors that under deliver on air volume, but still consume vast amounts of energy.
* Systems that have excessive leak losses.
* Dryers that malfunction and feed wet compressed air into the distribution system.
* Distribution pipe lines that restrict air flow and incur pressure drops that waste energy.
* Operators that increase compressor operating pressures to compensate for undersized piping systems.
* Undersized compressor room manifolds that restrict air flows and create back pressures that force compressors to waste energy.
* Compressor rooms that inflict high temperatures on the compressors causing a reduction in efficiency.
* Inappropriate applications and misuse of compressed air.
Many engineers, when asked the operating costs of their own compressors, are often unable to provide accurate figures. Artic Driers International in conjunction with CS iTEC are able to provide engineers with instant information delivered to their laptop, smartphone or scada system.
The CSM-2G system allows engineering staff to monitor a factory’s compressed air system 24/7/365. It provides information on total power consumption in kWh, flow, velocities, pressure, dew point performance, water flow rates and temperatures. Cumulative air flows and velocities are also logged.
The system may be started off small and scaled up as budgets become available. Alarm setpoints are easily set and SMS alerts provide instant notification of a compressor or dryer fault. A Wi-Fi communication system makes installation around the entire plant fast and painless.
Software and data are cloud based, making data, security and software upgrades quick and easy. Data can be exported, imported and merged with ease and is displayed on screen in real time in multi-axis graph or table form. Units of measurement can be changed at will.
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