Unique solution for energy and energy saving during compressed air systems operation in the enterprise.
Company "EKNIS-ENGINEERING" offers the following solutions for energy and energy savings in the compressed air systems operation.
Master Air Control
At any enterprise in any industry that uses compressed air, its consumption is uneven and constantly fluctuates due to the switching of the used pneumatic equipment . When the consumption of compressed air increases, the compressor responds to a low pressure signal and turns on. However, there is always a delay between when the compressor receives a start signal and when it creates the necessary pressure. It is possible that by then the need for air may disappear. As a result, the compressor pumps air into the system until its pressure reaches its preset value. This additional air, the compressor pumps into the system assuming artificial (false) demand for air.
As a result, air compressor operators (or used control system) are forced to maintain a higher pressure in the system so as to satisfy any sudden changes in air consumption. Thus, artificial or non-existent (false) demand is embedded in the system. Reducing pressure is also not a solution to the problem, as this causes a negative impact on the production and operability of actuators. This can lead to reduced efficiency and problems associated with the quality of the product.
As a result, the company is faced with losses due to inefficiency and receives high bills for electricity used for generating air. In this situation, proper balance between supply and demand of compressed air is required.
The offered by company "EKNIS-ENGINEERING" HW&SW complex Master Air Control (MAC) Forbes Marshall is a mechanism that actively helps to control the balance of consumption and generation of air in the factory.
It maintains a pressure differential between consumers and the generating side, and thus creates a high-pressure air storage. It helps to protect compressors from false triggering until real consumption occurs. Peaks in demand are handled by the MAC, rather than being directed towards the compressors. This allows compressors to stay longer on no-load, and as a result, the mass of air decreases and compressor load cycles are reduced. This decrease in compressor load cycles is directly proportional to the decrease in energy consumed by the compressors.
Thus, by installing the MAC, compressors are protected from artificial (false) demand and they have to cater only to base demand, resulting in savings on compressed air energy consumption, that leads to savings in the generation of compressed air energy.
The introduction of MAС in the compressed air system at the enterprise can lead to savings of tens of thousands of US dollars only on consumed energy and at the same time reduce the number of cycles of air compressors, and, consequently, their wear.
MAC is compatible with compressors of any type. In addition, the MAC has the following functionality:
MAC can also be used in individual areas where compressed air is generated at a higher pressure, and different pressures are required in different areas of production. This is especially relevant for car factories and the glass industry (blown glass production). At the same time, several different MACs can be used to maintain different compressed air pressures for differentiated users of the enterprise.
CountAIR is a complete network monitoring solution of compressed air networks.
Air compressors are used in various industries to meet technological needs, operate pneumatic tools and equipment, and to meet the needs of measuring instruments.
Only 10 - 30% of the energy reaches the final point of use. About 90 - 70% of the energy spent on generating compressed air is lost in the form of thermal energy, and to a lesser extent in the form of friction, misuse, leaks and noise.
There is potential for converting more than 40% of energy losses into usable form by appropriate compressor maintenance.
Inefficient use and loss of compressed air are available in various parts of the network. In terms of compressed air generation, this can be facilitated by such components as:
Air compressors are used in various industries to meet technological needs, operate pneumatic tools and equipment, and to meet the needs of measuring instruments.
Only 10 - 30% of the energy reaches the final point of use. About 90 - 70% of the energy spent on generating compressed air is lost in the form of thermal energy, and to a lesser extent in the form of friction, misuse, leaks and noise.
There is potential for converting more than 40% of energy losses into usable form by appropriate compressor maintenance.
Inefficient use and loss of compressed air are available in various parts of the network. In terms of compressed air generation, this can be facilitated by such components as:
In terms of distribution and transportation of compressed air through the network:
On the consumer side:
Leaving the compressed air network without control, you allow the possibility of inefficient use of resources.
Monitoring the compressed air network from generation to consumer is a step towards energy savings.
Most compressed air networks are usually outdated - production often exceeds consumption, and in the vast majority of cases, air distribution management for consumers and processes is based on approximate data or intuitive guesses about consumption volumes. This is mainly due to the lack of control in the compressed air network. And as a result, compressed air systems face problems such as:
The company “EKNIS-ENGINEERING” proposes to introduce a integrated system for monitoring the state of the compressed air network. Such system will allow operational monitoring of the main network parameters, such as flow, pressure, flow on the consumer side, and energy consumption on the generation side will help you identify and reduce leaks, thereby saving energy.
The implementation at the enterprise of precisely integrated monitoring will allow you to control the efficiency and productivity of your network.
Such system will have the following components:
CountAIR is the ideal solution for complete monitoring of the compressed air network - from compressors to consumption points. CountAIR constantly monitors the generation from each compressor and the flow rate to each consumption point, and keeps you updated on the overall system performance. CountAIR also offers advanced web monitoring features and a mobile app.
CountAIR offers in its functionality:
Video review of web monitoring function CountAIR - https://www.youtube.com/watch?v=5v_u4I1-9f4
AirMon from Forbes Marshall is an innovative, cost-effective flowmeter for controlling compressed air in plant lines. With features like online pressure and temperature compensation and accuracy of ± 3% - AirMon allows you to constantly monitor the exact flow rate for each individual consumer in the line.
Advantages:
Free Air Delivery (FAD) - advanced flowmeter.
There is only way to find out how much air your compressor actually generates is to effectively measure the rate of airflow. With a Forbes Marshall FAD flowmeter installed downstream from your compressor, you'll know exactly at what point in time how much air gets into your system. In addition, its own software automatically compensates for the relative air humidity in your facility (RH) and the compensates for compressor shaft speed, which ensures 100% accuracy in reading the sensor.
Advantages:
So that we can offer МАС for your specific application - we need to know the following information about your compressed air network:
After analysing the data provided to our specialists, we will provide you with recommendations on the implementation of MAC in your compressed air network and calculate the economic effect of MAC introduction in your system.