Compressed Air Systems – Summer Running

Posted on May 9, 2012 by Michael

As we start to approach the warmer summer months compressed air systems need to be adjusted for the warmer ambient temperatures.

Just as we need to ensure compressors and ancillary equipment, such as dryers and filters, run in ambient conditions that prevent frost damage during the cold winter months the opposite is true when the weather turns warm.

It is essential that compressors and dryers are all serviced in accordance with the manufacturer’s recommendations. Old oil that is past its working life loses some of its thermal properties and it becomes more difficult to remove the heat generated during compression. Blocked oil filters also restrict oil flow around the compressor which again prevents the cooling system from working. A common missed service item is the cleaning of the oil and air coolers. If the oil cooler is blocked the compressor will run hot and if the air cooler is blocked the temperature of the compressed air leaving the compressor will be too hot and this will put a lot of strain on the filtration systems, often leading them to fail.

Compressors that are running over the ideal design temperature will also suffer from additional oil consumption. This impacts the system in two ways. Firstly it means that the compressor needs constantly topping up with oil (this is costly) and secondly it puts more strain on the filtration systems as they have to remove this additional oil passing through with the compressed air.

Compressors running hot will also suffer from increased bearing degradation in the airend and motor. Premature bearing failure of this type is extremely costly. IF you are fortunate enough to have an HPC compressor then we can offer special exchange AirEnd prices at a significantly reduced cost provided the airend still rotates. However, if you operate other manufacturer’s units then you may be forced to buy new AirEnds at full cost which represents a large portion of the cost of a new compressor!

Obviously, even if the compressor is serviced to the manufacturer’s recommendations it is imperative that the ventilation of a compressor room is suitable to allow fresh air in. Warm ambient conditions coupled with poor ventilation will soon result in overheating problems. A suggestion to improve room ventilation is extraction fans used in conjunction with room thermostats (so they only run when required) or ductwork systems to duct out the warm air and draw cool air in.

For further advice on running compressors in the summer please contact us at www.glaston.com

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A reliable solution to portable compressed air requirements

Posted on April 16, 2012 by Michael

HPC KAESER Portable Screw Compressors are powerful, mobile machines for providing compressed air on a construction site or in industry for applications such as road breakers. In addition the reliability of these portable compressors makes them ideal as temporary machines for situations where compressed air requirement is greater than the current capacity i.e if you current compressor is out of action for any reason a HPC KAESER diesel driven portable unit may be the ideal short term solution. A wide range of models and options covers every demand from power tools to auxiliary electrical supplies for lighting and welding.

The HPC KAESER partnership provides a wealth of experience and expertise with a range of portable compressors and accessories providing ideal solutions to the varied needs and demands of the U.K. portable compressor market.

From the small compact M13 with a capacity of 1.2m3/min (42cfm), that can be transported in the back of a small vehicle right up to the high-performance M270 delivering 27m3/min (953cfm) at 7bar we can help.

As an option, all machines can be fitted with a tool lubricator for picks and breakers, two of the standard uses for a portable compressor. Especially designed for this purpose the unit adds a biologically degradable lubricant and defrosting medium to the compressed air. This reduces wear on pneumatic tools, increases their life and guarantees reliable operation. As well as lubricated air for tools, dry, cool or heated air can be produced for sand-blasting and concrete repair.  Another treatment unit can even provide air of breathing quality. If a special distributor is fitted, air of differing qualities can be supplied in parallel.

Several models are available with an integrated generator for applications requiring mobile electric power (for example PE welding of plastic piping, powering electric tools and submersible pumps or site illumination). The generator can supply both three-phase and single-phase power via an overload protection switch. With this equipment, the unit becomes a versatile mobile power station.

Over the years Glaston have supplied units to the UK as well as export for use on oil fields and off shore oil rigs as spark arrestors and chalwyn valves are freely available for the HPC KAESER units.

For any further information on portable compressors and how we can help you please contact us at Glaston Compressors – www.glaston.com

Posted in hpc, HPC Compressors, kaeser, Kaeser Compressors, Portable Compressors | Tagged , , | Leave a comment

Benefits of Storage in a Compressed Air System

Posted on February 17, 2012 by Michael

Storage in a compressed air system performs several functions, and is a critical part of any properly designed air system. When correctly applied, storage can improve energy savings, air quality, and pressure stability; as well as reduce maintenance costs and extend the life of the air compressors.

Unfortunately storage is often seen as a non-functioning part of the air system, as it does not require, nor deliver, electrical or mechanical energy. This could not be further from the truth. Just as a capacitor or coil in a cars ignition system is required for operation and control, storage is required for proper operation and control of a compressed air system.

Storage in an air system is not a tank or receiver; it is the accumulation, retention, and distribution of energy. Energy is stored in an air system with pressure differential and receivers or tanks to create a larger volume of air at the differential. Pressure differential and volume are both critical for storage, and are in an inversely proportional relationship. As one decreases, the other must increase to maintain the same level of storage.

Like the capacitor mentioned above, receiver tanks store energy – in the form of compressed air. Also similar to a capacitor, it is not only the size of the capacitor that matters, but the difference in energy levels – in the form of pressure differential.

Air system storage is required to absorb and release energy as needed, in an instant, to adjust to changes in system demand, thus providing time for compressor controls to react.

For a rapid increase in demand, storage will supply the system with the required volume to maintain the system while additional compressor capacity is brought online. In the event of a rapid decrease in demand, the opposite holds true; storage will absorb the energy of excess online capacity, while compressor capacity is taken offline, keeping the system from exceeding pressure safety levels.

With slow or no changes in demand, storage provides time for the compressor(s) controls to cycle properly, and less frequently, thereby decreasing energy consumption and maintenance costs.

For more information please contact us at www.glaston.com for all your compressed air needs.

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Power is nothing without control – new 3D control takes compressor control to a whole new dimension.

Posted on January 26, 2012 by Michael

 

HPC / Kaeser compressors are widely acknowledged as the most efficient and reliable compressors that money can buy. Built in Germany to rigorous standards HPC / Kaeser compressors will give decades of satisfaction. However, to maximize the efficiency of any compressor system proper control is essential, after-all, if you have an efficient car why would you negate this by taking the long route on every journey?

HPC / Kaeser Compressors new generation of Sigma Air Manager (SAM) now features adaptive 3D Control. Active rather than reactive, the new self-adjusting 3D software responds to the three crucial dimensions that effects air system efficiency: switching losses, control losses, and pressure flexibility. The result is significant energy savings through reduced compressor run and idling time; and reduced leaks and artificial demand. At the same time, it provides the lowest average system pressure for better operation of plant equipment.

This controller includes an integral Web-server for remote monitoring of system activity. The optional Sigma Air Control Plus stores and analyzes system data for reporting, system audits, control optimisation and long-term trend analysis. SAM can operate multiple compressors, blowers or vacuum pumps. Integrating the SAM into your server allows for additional remote capabilities, including control.

Even if you are not lucky enough to run HPC / Kaeser compressors the SAM unit can be still be used to control other makes of compressors resulting in excellent energy savings. Furthermore, by running the minimum amount of compressors to satisfy your air demand you may find that you actually reduce the compressor running hours. Less compressor running hours = less servicing and improved reliability.

For more information please contact Glaston Compressor on how we can make any compressor system run even more efficiently.

 

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Completely Redesigned ESD Compressors with SFC Options

Posted on January 6, 2012 by Michael

Increased Efficiency, Improved Specific Performance

Introducing HPC / Kaeser redesigned ESD rotary screw compressor series. Available in 160kW and 250 kW variants providing flows from 816-1522 cfm and pressures to 15 bar.

The ESD series has been redesigned for increased efficiency and improved specific performance, as the one-to-one direct drive design includes a premium efficiency drive motor with three PT 100 temperature sensors. All models come standard with the new Sigma Control 2 intelligent compressor control for enhanced communications capabilities and equipment protection. Also standard is a variable speed fan for the fluid cooler that helps save energy by adjusting to cooling demands. Maintenance points are more easily accessible than ever before with five access doors and a removable panel.
Options include water-cooled and SFC variable frequency drive. ESD units with optional SFC are now 19 inches shorter than the previous design, with a footprint reduced by an impressive nine square feet!
To learn more about the new ESD series please contact Glaston via www.glaston.com

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SIGMA Control 2 – Integrated Intelligence – Power is nothing without control

Posted on November 17, 2011 by Michael

HPC KAESER’s revolutionary modular concept takes compressor controller technology to the next level and beyond. Welcome to the world of SIGMA Control 2.

It’s now over a decade since HPC KAESER introduced its ground-breaking SIGMA Control internal compressor controller, the innovative “PC in a compressor.” The integration of an industrial PC as standard in every energy efficient rotary screw compressor not only enabled cost-effective control, but also allowed networking capability between individual units and with master control systems. This breakthrough provided the keystone for today’s integrated system approach to compressed air production by enabling continuous advances in energy performance and improved reliability of complex compressed air systems.

The core strengths of the HPC KAESER SIGMA Control compressor controller are its ability to optimise energy efficiency and to communicate seamlessly both internally with the compressor as well as externally with master control systems. Unsurprisingly therefore, that the HPC KAESER development engineers also applied these outstanding features to the new generation SIGMA Control 2, or SC2 as it is referred to more succinctly. However, wishing to make the SIGMA Control 2 even more versatile than its predecessor, what the design engineers developed for the SC2 was an innovative modular design that creates a “division of labour” between the main control unit and the separate input/output modules. As a result, this unique concept makes the SC2 even easier to maintain and to communicate with.

For more information contact Glaston

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Leading From the Front – the New SK Series Compressors

Posted on November 16, 2011 by Michael

Discerning compressed air users expect maximum availability and efficiency, even from smaller compressors. In addition, there is growing demand for seamless connectivity with master control systems, so that users can benefit from the enhanced efficiency and load distribution that this technology has to offer compared with simple, stand-alone systems.

Featuring energy-saving SIGMA Profile airend rotors and the latest internal SIGMA Control 2 compressor controller as standard, HPC Kaeser’s new SK series rotary screw compressors meet all of these needs. Moreover, users will be impressed by their significantly increased free air delivery and even greater efficiency.

A further important efficiency-enhancing component is the new SIGMA Control 2 internal controller: This advanced system not only enables demand-oriented performance matching and dependable monitoring, but ensures even greater flexibility through its numerous interfaces and innovative plug-in communication modules. Therefore, connection to energy-saving master control systems, computer networks and / or remote diagnostics and monitoring systems could not be easier. A large display and an RFID reader located on the control panel make on-site communication with the system simple.

The new SK series models are able to deliver up to 2.5 m³ of compressed air per minute at 7.5 bar (11 and 15 kW versions). Therefore, depending on the particular model, these figures represent an increase of 11% or even 14%, compared with their predecessors. This impressive performance boost has been achieved both through airend optimisation and the minimisation of internal pressure losses. In turn, these improvements have lead to a reduction in specific power of up to 5 percent. The use of premium efficiency IE3 electrical motors has also contributed to additional energy savings.

In addition, the enclosure features four inlet openings for separate airflow cooling of the compressor, the motor and the switching cabinet and for compressor intake air. HPC Kaeser’s unique cooling system is equipped with a patented premium-efficiency dual-flow fan with separate cooling air flows for the motor and compressor.

This not only achieves optimum cooling performance, low compressed air discharge temperatures and minimal sound levels, but also promotes efficient air compression. The SK series’ modular design concept provides further advantages: In addition to the standard versions, which have a compact footprint of only 0.65 m², the SK22 and SK25 are available as “T” models that feature an integrated, thermally shielded refrigeration dryer. SK series 11 and 15 kW versions with an integrated frequency converter (Sigma Frequency Control – SFC) are also available for variable demand applications suited to speed control.
Users that require not just an efficient compressor, but an all-in-one, compact compressed air system need look no further than an SK Aircenter. This space-saving combination of a compressor, refrigeration dryer and horizontal air receiver provides dependable and efficient compressed air production, treatment and storage within a smart, compact single unit. The SK Aircenter is the ideal choice for smaller businesses and workshops where space is at a premium, or for decentralised compressed air supply applications.

For further details and information please contact us.

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Which type of Nitrogen Generation is suitable for you?

Posted on October 27, 2011 by Michael

Dependent on purity, flow rate and a number of other considerations there are many options to supply nitrogen. The indicative optimal supply options are shown below. Consultation with Glaston Compressors will result in the preferred solution for your specific on-site nitrogen supply needs.


Membrame Nitrogen Generators

Optiminal purity range: 90% to 99.0%
Optimial flow rate: 1-600 Nm³/h
Cost advantage over vendor-supplied liquid: up to 50%

A Membrane Separation module with its fibre bundle and the permeation rate of various gases can be seen in the diagrams.
Membrane nitrogen separation became commercially available in the early 1980s. It is the most robust of the nitrogen separation technologies. Compared to Pressure Swing Adsorption (PSA) technology, membranes use more energy, but have lower maintenance costs. Membranes are best suited for purities up to approx. 99% and nitrogen demand of up to around 600 Nm³/hr.
Oxygen and nitrogen in compressed air are separated by the relative speed of permeation through the side wall of hollow polymer fibres. Oxygen molecules permeate through the fibres faster than nitrogen molecules, enabling them to be selectively exhausted. Nitrogen gas purity increases as the flow proceeds down the fibres. Depending on the residence time in the membrane nitrogen purity of better than 99.99% can be achieved. However at higher purities other separation technologies are more cost effective.

PSA Nitrogen Generators

Range Purity: 99% to 99.995%
Flow rate: 1-1000 Nm³/h
Cost advantage over vendor-supplied liquid: up to 50%


Pressure Swing Adsorption (PSA) is cost effective for on site-nitrogen generation at purities higher than 99% (purities as high as 99.995% are possible) and in high energy cost regions for lower purities down to 97%.
Air is separated by compression on a bed of carbon molecular sieve (CMS) which preferentially adsorbs the oxygen. At the same time in a second drum of CMS, the pressure is lowered, thus releasing the adsorbed oxygen which is exhausted. This bed of CMS now denuded of oxygen is again ready for a further compression cycle of adsorption.

For help with your Nitrogen Generation needs please contact Glaston Compressors at www.glaston.com

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New Energy Efficient HPC Compressors Released to Market

Posted on September 7, 2011 by Michael
HPC is part of a global operation through its long established and extremely successful partnership with KAESER Kompressoren GmbH.

As part of the continual drive to improve the specific power and drive down user costs HPC and Kaeser have released two new updated compressor models, the CSD and CSDX.

In all cases the specific power is improved by up to 5% meaning more air for less running costs, simpler design features, improved ease of serviceability, improved temperature control, the use of speed drive cooling fans (where meaningful) as well as incorporating the latest revolutionary Sigma Control 2 compressor controller.

As part of the environmental responsibly these new compressors also come with environmentally friendly oil filter elements which are metal free allowing for thermal disposal after use without the requirement for pre treatment.

In keeping with the recent philosophy of offering the most economically efficient compressors the new models come with the highest IE3 efficiency class motors as well as integral dryers that use the latest scroll compressor technology.

Comparing the new CSD and CSDX compressor to competitors such as Atlas Copco running efficiency savings between 4.8% and a massive 11.6% are achievable when comparing the 55kW variant compressors. As over 70% of the total life cycle cost of compressors is related to energy these savings are hugely beneficial giving the end user a competitive advantage in lowering overhead costs.

Production on these units has now begun and if you are interested in operating the market leading energy efficient compressors then please contact us at www.glaston.com

If owning the most efficient compressors is appealing but raising capex is a problem here at Glaston we are able to offer funding packages to meet any requirements.
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Chemical Industry Awards June 2011

Posted on June 30, 2011 by Michael

Glaston Compressors were kindly invited to a prestigious awards ceremony by their client Rockwood Additives. The Chemical Industry Awards ceremony was held in Birmingham in the historic Great Hall in the University of Birmingham on June 23rd 2011.

Rockwood Additives Limited were shortlisted for the EDF Energy Low Carbon Award due to the significant 37% improvement in specific power used to manufacturer inorganic chemicals. Part of the reduction in energy usage came from the reduction in compressed air costs following a successful project by Glaston Compressors back in 2007.

As part of the continual improvement process at Rockwood Additives a full review of the compressed air usage on site was undertaken in 2007. Rockwood invited Glaston Compressors to analyse the site air usage and suggest any performance improvements that could be made to benefit the site.

After a comprehensive compressor audit it was determined that the installation of a 160kW variable speed drive compressor, in this case a HPC DSDX302SFC, along with a zero purge desiccant dryer would save Rockwood over £30,000 per annum. The new zero purge dryer would supersede the six heatless regenerative desiccant dryers used on site that were so costly to run. The new 160 kW compressor would enable Rockwood to generate air in the most efficient method possible to meet the production requirements.

As part of Rockwood’s energy monitoring and control philosophy both the new dryer and the new compressor were installed onto the profibus network so site can comprehensively monitor the compressed air.

As part of the ongoing energy reduction process Glaston visit Rockwood on a regular basis to ensure that the equipment is maintained to the highest level and is working as efficiently as possible.

Unfortunately Rockwood Additives didn’t win the EDF Energy Low Carbon Award on this occasion but a great night was had by all and the recognition for making the final six on the short list for this award was an honour in itself.

If you would like further information on how Glaston can drive down the cost of your compressed air please visit www.glaston.com.

If you would like to know more about Rockwood Additives please visit http://www.rockwoodadditives.com/

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