Download AIRScan - Atlas Copco

Atlas Copco Air Optimization
AIRScan
AIRScan - tangible information
for real solutions
A complete AIRScan audit includes a full survey of important
compressed air net parameters, and the solutions that emerge from it.
Using the logged information, a detailed report is compiled, including
cost analysis, graphs and a list of recommendations for improving your
system’s performance.
AIRScan is not only an accurate compressed air system diagonstics
PURPOSE OF INVESTIGATION
package, it’s very flexible as well. It allows customers to select the
Plays a fundamental role in your production process and as the operation is continuous the
supply of high quality, reliable compressed air is both critical and costly.
depth of audit and to tightly control the budget they are willing to
allocate to the audit. From a complete audit solution - with an initial
baseline audit, a complete evaluation report with solutions, and a final
validation-, to individual and specific audit services tailored to the needs
Compressed air represents approximately 10% of all industrial electricity usage and is present
on all most all-industrial sites.
With this in mind, Atlas Copco has invested in, and developed a number of tools to help
identify, reduce and control these costs.
Facts about compressed air
Energy can also account for up to 70% of the lifetime
cost of generating this compressed air so any
savings that can be made, must be considered
substantial.
Each kW of compressed air is between 7 & 8 times
more expensive than a kW of electricity
Every 1 bar or 14,5 psi reduction in the pressure
output can reduce the energy consumption by 7%
Typically, 20% of the total compressed air
consumption can be attributed to leakage in systems
older than 5 years
When we also consider that it is estimated that on average 30% of these costs are wasted, the
opportunities for energy savings become even more significant.
About our audit services
of each customer and his installation.
As independent auditors, we seek to develop cost-saving recommendations that reduce air
system operating cost while improving system performance.
Our compressed air system audit have
highlighted the true costs of compressed
air and identified simple opportunities to
improve efficiency and productivity.
Our compressed air systems Auditors
have included an examination of both air
supply and usage and the interaction
between the supply and demand.
All components of the compressed air
system have been inspected individually
and problem areas have been identified.
Our Auditors have measured the output of
your compressed air system, over a
typical 7-day period establishing the
operating pattern of your compressors
and calculating the energy consumption in
kilowatt-hours, determining the annual
cost of operating the system
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Features
Benefits
Non intrusive measurements
No production interruptions.
Can be performed at any time.
“Real” measurements
Accurately measured data. Not calculated
based on design conditions.
Comprehensive and read friendly
reports
Valuable document that outlines the
energy savings opportunities.
Independent analysis
Not linked to equipment sales.
Flexible and totally configurable
Taylor made solution. From basic
inspections to a full audit survey.
Can be combined with the
traditional service plan
Can be included in the yearly maintenance
budget allowing a yearly check of the
compensation realization.
METHOD OF INVESTIGATION
Many assumptions are made about the demands and costs for compressed air in actual
working environments. In order to remove the elements of guesswork and assumption, Atlas
Copco have developed and built tools that can provide the following:
Base lining a system requires measurement of power, pressure, flow and temperature under
different operating conditions, and also estimating the leak load.
Power measurement
Power measurements are used to identify the real power consumption of the compressed air
installation.
Both RMS and true RMS values can be logged.
The loggers log voltage, current and power factor via
electromagnetic field. They use a current clamp to see when
the machine is in load or unload cycle. They can also be
combined with 4-20mA signals.
Actual consumed power is measured at all loaded/unloaded
conditions of the compressors. This gives an accurate analysis
of actual power cost incurred to generate the compressed air.
For three-phase systems, power can be calculated by the following equation:
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AIRScan report
Atlas Copco Air Optimization
AIRScan
An audit consists of:
Flow check
This test accurately measures and logs the delivered flow of compressed air on any compressor make or type. The flow
meter can be inserted into an existing point or the system can be “hot tapped”, without interrupting the production.
Power check
Where other audits use clamps or rely on originally installed power meters to estimate power usage, Atlas Copco’s
method measures the actual consumed power, non-intrusively. This check is available for all types of compressors over a
pre-determined period, usually 7 days. The results give an accurate overview of the money that is spent annually on the
production of compressed air.
Leak check
Compressed air leakages are synonymous for throwing money away. Between 10 and 25% leakage is typical in most
systems. Atlas Copco’s leak check identifies, tags and quantifies these leaks throughout the compressed air system.
To immediately start saving money, repairs can be performed during the audit.
Air quality check
This audit measures the quality of the air and compares it with the specific needs at any point in your system.
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Real Power Measurement (3 Phase) 2 Real Flow Measurement 3 Pressure Measurement
Compressed Air Temperature Measurement 5 Current Measurement 6 Dew Point Measurement
Measurement Ambient Conditions 8 Pressure Drop Check 9 Oil Spot Check 10 Quality Air Check
Leakage Scan 12 Thermal Scan
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© Atlas Copco Airpower n.v., Belgium. April 2010 - 2935 0060 20 - Subject to alteration without prior notice.
Maintenance review
This audit assesses the effectiveness of the service programme for equipment, including compressors, filters,
dryers and ancillaries.