Compressed air is a crucial utility for the manufacturing sector, playing a significant role in various industrial processes. However, energy costs associated with compressed air systems can be substantial, comprising 73% of the total system cost over a 10-year lifecycle. To address this challenge, we offer a data logging service that helps identify and achieve significant energy savings. In this article, we will explore the benefits and process of data logging, highlighting how it can optimise compressed air efficiency.
As energy costs continue to rise, manufacturers are increasingly focusing on energy efficiency as a means to reduce operational expenses. According to a report from Sustainability Victoria, compressed air systems are accounting up to 10% of total industrial electricity use in Australia. This presents an opportunity for significant energy savings. Understanding and tracking energy usage by air compressors through data logging can lead to substantial cost reductions.
- Frequent Load-Unload Cycling: If your compressor frequently goes through load and unload cycles, it may indicate inefficiencies in your system's operation.
Data logging can help identify the causes and optimise energy usage. - Prolonged Unloaded Status: If your compressor remains in an unloaded state for a significant amount of time, it could be an indication of underutilisation and energy wastage.
Data logging can pinpoint these periods and provide insights to improve system efficiency. - High Energy Costs and Efficiency Optimisation: If you believe your energy costs are high and you aim to maximise the efficiency of your compressed air system, data logging can offer valuable information about energy consumption patterns, helping you identify areas for improvement and achieve optimal efficiency.
As the leading global manufacturer of compressed air systems, we recognise the importance of energy optimisation in compressed air operations. Our free data logging service allows our customers to track and simulate energy use in their compressed air systems. As Roshan Kumbla (product manager) explained, the system is flexible and can be applied to compressors of any size and brand.
We can do the data logging for any compressor in the market, independently of the size and brand of the compressor. The idea of data logging is to get a full picture of the compressor system’s behavior, and to provide recommendations for a more efficient and reliable system for the customer.
The free service is carried out by our sales engineers and our authorised distributors The system is flexible for all manufacturing businesses and is designed to work in the best interest of the customer.
The data logging process begins by attaching a data logger device to the incoming electrical input of the air compressor for a period of seven to ten days. This non-invasive procedure measures real-time current consumption and collects data on compressed air utilisation. The collected data is then analysed to assess system performance, identify potential inefficiencies, and calculate energy usage patterns.
Using the logged data from the one-week period, a simulation is conducted to extrapolate the air usage for the entire year. Our sales engineer walks the customer through the reports generated by Airchitect. Airchitect is a simulation system that translates all data to flow profile, it gives a comprehensive picture of your system. Based on the analysed data and simulation results, our expert provides scientific recommendations for system improvements. These recommendations may include adjusting pressure settings or considering the implementation of VariablFe Speed Drive (VSD) compressors to optimise energy usage.
Once the data from the data logger has been collated, our sales engineer or authorised distributor provides a consultancy service for businesses, regardless of whether they are already Atlas Copco customers.
The data logging process culminates in the generation of a detailed report that includes the current system scenarios and its behaviors, conclusions, and recommendations. This comprehensive report serves as a valuable tool for customers to make informed decisions and take appropriate actions to enhance their compressed air system's efficiency. Implementing the recommended improvements can also contribute to energy efficiency incentive schemes and compliance with ISO 50001 standards.
Data logging enables companies to identify operational inefficiencies and opportunities for energy savings. By implementing the recommended improvements, businesses can achieve substantial reductions in power consumption, leading to cost savings and a reduced carbon footprint.
Analysing the data collected during the logging period allows for proper sizing of air compressors. Understanding demand fluctuations and usage patterns helps determine the appropriate compressor size, minimising energy waste and improving overall system performance.
Taking into account a business’s needs for compressed air, another solution to more closely match input and output of a compressed air system is the installation of a variable flow system.
Comparing the typical profile of a fixed speed machine against a variable speed machine, the savings are going to be 30 to 35 per cent. If you add that to a new technology, you get a jump of 15 to 20 per cent, but for the top of the line we can deliver for the customer up to 60 per cent.
Data logging can help identify air leaks within the compressed air system, especially during periods of plant shutdown. By addressing these leaks, businesses can reduce energy losses and optimise maintenance schedules, resulting in further cost savings.
