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Technology, Service, Parts & Maintenance

Compressed Air Best Practices: Innovation Profile

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The following is an excerpt from the article, Innovation Profile: Atlas Copco’s iPM Interior Permanent Magnet Motor and SMARTLink Service by contributing editor Scott Williams, which was recently published in the December issue of Compressed Air Best Practices.

The Department of Energy estimates that compressed air systems in the U.S. consume about 30 trillion Watt-hours of energy per year. Of all the energy used in manufacturing, compressed air systems have the greatest potential return for implementing energy efficiency practices, according to the DOE.

One approach to access some of that return is to eliminate waste by producing compressed air efficiently and only in the amount demanded. Another approach is to leverage compressed air system data to assess the impact of any system changes on energy consumption and productivity.

Atlas Copco Compressors offers new solutions that employ both of these approaches. This article examines the new GA 7-37 VSD+ air compressors and SMARTLink data monitoring system, and includes application insights from two independent distributors of Atlas Copco compressors.

SMARTLink Data Logging and Monitoring

In most production settings, servicing a compressor is largely reactive: an unforeseen event triggers an immediate need for a service technician. Even when compressors run reliably, they rarely run at the same level around the clock, so it can be difficult to know exactly when any given compressor is due for maintenance that can prevent such reactive measures. If maintenance activities go overdue—and production demands have a way of taking priority over downtime for system maintenance—both energy consumption and risk of breakdown increase.

Even though compressed air auditing activity has become commonplace, the majority of air compressors have still not been “audited” and demand profiles and energy use is not available to the owners of most units. Even systems that have been audited were data-logged for a one or two-week period only – and one thing we know for sure about compressed air systems is that demand profiles and component performance are always changing.

SMARTLink is Atlas Copco’s data logging, monitoring and communication system that enables compressed air users to see how much air they are producing, how much energy they are using, how their compressor is performing and when it’s due for service.

Reliable operation can be enhanced as this system analyzes air compressor operating data continually, and automatically sends alerts in advance so customers can plan their service interventions. By tracking and analyzing usage and maintenance information, the program gives customers both a quick snapshot and a complete in-depth analysis of their air supply, helping them learn from their activities. The customizable system tracks a wide range of information about compressors in operation to predict potential problems, shows how and where the production can be optimized, and identifies ways that energy can be saved. Real-time compressor performance data can be transmitted to any mobile phone number, email address or computer desktop, so secure access can come from across the plant or across the globe.

You can read the full article, which provides more detailed information on the GA VSD+ and SMARTLINK, in addition to two distributor interviews from the field, by visiting the Compressed Air Best Practices website: Innovation Profile: Atlas Copco’s iPM Interior Permanent Magnet Motor and SMARTLink Service. If you would like to learn more about these technologies, contact us or leave a comment below.

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