SmartAir Master helps improve compressor performance

The SmartAir Master,from CompAir is a simple-to-install control system that provides detailed management reports to help plant engineers improve the performance and efficiency of a compressor network.

The SmartAir Master will intelligently control up to 12 compressors, fixed or variable speed and can reduce energy consumption by up to 35%, by operating all of the compressors in the network to the narrowest pressure band. 

It is considered that the easier a controller is to install and commission and the more comprehensive the data it provides, the more efficient the compressor network can operate.

CompAir has therefore designed the controller to be very easy to install, with a series of on-screen prompts that guide the commissioning engineer through the set up and confirm when each parameter has been programmed correctly.  

Some controllers require a high degree of technical input and detailed information about each compressor in the network in order to be installed correctly.  In contrast, once each compressor is connected to the SmartAir Master, the engineer needs to enter only minimal information as the controller will identify all the units in the system and will self-programme many stages.

In addition, unlike conventional controllers, which need numerous interface cards to communicate with each compressor, the SmartAir Master has just two options, helping to improve the speed and ease of installation.

These functions combine to ensure that the most efficient compressor combination is selected, thereby avoiding the risk and associated cost of offload running. 

In addition, where compressors of the same capacity are installed, the system will equalise running hours so that no machine is over or underused, reducing maintenance concerns and costs. 

SmartAir Master provides a variety of performance data on a visual touchscreen, giving plant managers a comprehensive overview of the complete system, including downstream equipment to help improve network performance.  This can include information such as the status of each compressor connected, as well as network pressure, compressed air consumption and pressure range, all of which can be presented in graphs or tables.

In addition, SmartAir Master is available with a removable SD memory card, enabling data to be transferred to and analysed on a pc and management reports produced.  A local network connection is also provided, allowing system data to be viewed using the optional web server module.

Benefits at a glance: 1) Step-by-step operation and programming via full colour touch screen.  2) User-friendly and self-explanatory, with "commissioning wizard" for easy programming. 3) Fault and warning messages for each compressor are listed along with exact time and date. 4) Service technicians can immediately analyse the cause of any maintenance required. 5) Simple installation with low cabling costs using a data cable with a "bus structure". 6)  An on-screen user manual is also available.

Accessories such as dryers, filters and condensate drains are easily connected to the SmartAir Master directly or via an extension module.

CompAir in profile
CompAir is a leading global manufacturer of compressed air and gas solutions, providing high performance and low operating cost compressors and ancillaries for a broad range of applications. CompAir is present in many industries including chemical, pharmaceutical, food and beverage, automotive, construction and CNG. 

CompAir has an extensive network of dedicated sales companies and distributors across all continents, offering global expertise with a truly local service capability. With a complete range of world-class rotary screw, piston, centrifugal and vane compressors, including high-pressure, oil-free and portable models, CompAir has the innovative solution to all compressed air and gas requirements.

For further information, view website: www.compair.com  Refer to page 199 

A fireproof enclosure solution that
saves space and cuts installation costs

Two UK-based companies have been working closely together to provide the oil, gas and petrochemicals industry with a unique fireproof enclosure solution that protects critical electrical control components in a fire up to 1,093 deg C for 30 minutes, whilst the internal temperature of the enclosure does not exceed 87 deg C.
 
The fireproof enclosures, co-developed by COOPER Crouse-Hinds and Thermal Designs UK Ltd, are based on COOPER Crouse-Hinds' 316 stainless steel STB enclosure (600mm x 400mm x 220mm) that is coated externally with Thermal Designs' world-renowned K-MASS® fire resistant coating. This is the only relationship of its type in the world, whereby an enclosure or electrical junction box not manufactured by Thermal Designs, is directly coated with K-MASS®.

The fireproof enclosures, co-developed by COOPER Crouse-Hinds and Thermal Designs UK Ltd, are based on COOPER Crouse-Hinds' 316 stainless steel STB enclosure (600mm x 400mm x 220mm).

 K-MASS® is an intumescent, moulded-on protective coating that is certified to UL 1709. Upon exposure to fire, the material begins to intumesce (expand rapidly) in response to heat by beginning a process of evaporative cooling and charring on the surface of the coating. The surface char deepens in successive layers filling voids, insulating the critical equipment within the enclosure, cooling and reflecting the heat back into the fire. This process continues until the fire is extinguished or the material is consumed.
 
In the presence of heat, K-MASS® expands to many times its original size. This pyrolytic reaction shileds wire insulation, solder connections, circuit boards, terminal blocks, relays and metallurgy, enabling critical control components to continue operating during the fire.
 
The STB enclosure from COOPER Crouse-Hinds is an ATEX-certified heavy duty junction box solution that is fully compliant with the impact, thermal and ingress protection requirements of EN50014. The STB is available in a wide range of sizes to meet a diverse range of applications.
 
Custom fittings are available such as cable glands, breather drains and blanking plugs. Certified components such as instrument transmitters, fieldbus modules can also be fitted to provide customers with a fully certified solution.
 
Andrew Bragg, General Manager at Thermal Designs Ltd comments: "For end users, installers and EPC contractors, the fireproof enclosure is a unique, very compact solution for onshore and offshore oil and gas installations, where space is at a premium. Directly coating the STB junction box with K-MASS® means that the customer's junction box doesn't have to be housed in a separate enclosure. This would take up valuable space and create further issues with regard to cabling and conduit. If the end user requires an ATEX-certified junction box that is fire-protected up to 2,000°F with K-MASS®, our single box solution is ideal."
 
Richard Gipp, Operations Manager at COOPER Crouse-Hinds Enclosures Division (UK) Ltd, comments: "The partnership with Thermal Designs is a great working relationship based on mutual trust and collaboration. We've already had lots of interest from oil and gas companies in the Middle East and we recently supplied 12 UL-approved fireproof enclosures for a petrochemicals plant in Saudi Arabia."
 
"The message we want to send out to end users, installers and EPC contractors is that enclosures or junction boxes should not be the last consideration when designing new oil refineries or petrochemicals plants, or when updating existing plant. If critical electrical control components require fire protection, then our single junction box solution saves space and minimises installation, maintenance and servicing costs."
 
For further information, view website: www.ceag.de or e-mail: Gordon.Low@CooperIndustries.com  Refer to page 175

Atlas Copco launches new retrofit compressor energy recovery solutions

Atlas Copco Compressors has launched a new range of retrofit energy recovery kits for its GA11-90 rotary screw compressor range which enable up to 94% of the energy from wasted compression heat to be recovered.

For use across a broad spectrum of process industries, the new range of stand alone, plug and play energy recovery units, ER  S -1,-2, and -3, can achieve between 72  to 94% of energy recovery in the form of  hot outlet water, at temperatures of up to 90°C.

The recovery kits comprise a complete stainless steel oil/water heat exchanger designed for simplified installation, fast commissioning, reduced service downtime and increased safety and environmental conditions. All major mechanical parts of the units are pre-mounted within the canopy allowing easy access to the thermostatic valve housing and to the motor for service operations. The all-in-one-box configuration eliminates the possibility of incorrect connection of flexible hoses and parts and no structural beam adaptation of the compressor is necessary to accommodate water inlet and outlet connections.

Over 45% of all industry applications use hot water in their processes. Atlas Copco's ER units enable pre-heated water to be used in these processes to reduce the use of traditional energy sources and, at the same time, to lower the amount of CO₂ emissions. Running cost reductions can be achieved both in applications involving intermittent use, such as central heating, or in the continuous duty of providing process hot water.

With up to 94% of the electrical energy employed in compressed air production being converted into heat and subsequently lost through radiation, the introduction of these retrofit kits will enable operators to make substantial reductions in fuel consumption. At the same time, it is possible to achieve indirect process savings by reducing the maintenance costs of associated equipment and, in specific applications, overall process efficiency can be boosted by up to 20%.

For further information, e-mail: gba.info@uk.atlascopco.com or view website: www.atlascopco.co.uk   Refer to page 173