Optimization
Solutions
Sarawut Thitithornnara
Dated: June 10, 2024
Topics Presenters
Optimization Cycle
Central Controllers
Energy Recovery
AIR Leak Detection
AIR Quality
Agenda SCADA (Connectivity)
SMARTVIEW (Connectivity)
SMARTLINK (Connectivity)
AIRnet
Atlas Copco’s Optimization Cycle consists of three main steps
Analyze
• Identifying potential areas
for energy
savings/Improvement
Proactive Approach 1. ANALYZE
Implementing Optimization
Connecting to monitor Offer Energy Savings
• 100% connected 2. OPTIMIZE
• Connect all brands 3. MONITOR
Guarantee the Savings
@ Generation @ Distribution
Offering Total Solutions
DISTRIBUTION via AIRNET
Guide to the most CENTRAL CONTROL
sustainable solution RECOVERABLE ENERGY
SYSTEM MAINTENANCE
SYSTEM MONITORING - SMARTLINK
Action Saving
Central Controllers 15% depending on
machines and flow pattern
Energy Recovery 70-90% kw
Leaks Detection 10-50%
Lower Pressure -1 bar 5-7% kw and reduce leaks
13% of existing leaks
AIRnet volume increase 3%
Correct AIRnet Design Lower Delta P
VSD compressor 30-50%
Green Product Offer
Monitoring
Compression Technologies Pressure Air & Gas quality Service
& control
Screw Dryers
Oil
lubricated Central
Filters control
0.1 bar - 1000 bar
Piston Largest Condensate
pressure range treatment
Global presence
Energy
recovery
Scroll Ancillaries
Power Genuine Parts
Centrifugal N2 Nitrogen Certified technicians
100% Connectivity
Oil free O2 Oxygen
Lobe Service plans
1 Kw - 20 MW H2 Hydrogen
Industry 4.0
Largest CO2 Carbon Dioxide integration Diagnostic services
Tooth power range
Others
What can we analyze?
Flow rate and
Airscan- Compressed air audit pressure
FAD
(Efficiency) Flow rate and
pressure
Air quality
Pressure Pressure
Power logger
Flow rate and
pressure
Pressure
Compressors Leaks
operation
Central controllers Energy efficient unit selection
SMARTLINK
Reduced switching cost
Functionality :
• Energy efficient unit selection
• Forced Sequence Control
• Equalize the running hours Equalize the running hours
• Prevents blow-off
• Lowest possible pressure
• Reduces the amount of load/unload cycles
• Extend lifetime of the machine
2x
Lowest possible pressure
Multiple compressors
1 bar Extend lifetime of the machine
7% energy saving
13% less leakages
Parts for connecting machines to Optimizer, and for connectivity
SMARTLINK
4G Router
(+ local SIM card) Pressure transmitter
4...20 mA cable
REMOTEVIEW/
SMARTVIEW
CAN connector
Modbus TCP, CAN cable
Ethernet IP
Gateway 4.0
Modbus RTU/TCP,
EtherNet/IP, PROFINET,
OPCUA,BACNET
Central Controller
Single point pressure control
Steady Flow
Variable Flow Variable flow based on shift Patterns
Portfolio
*Each machine communicates via EQUALIZER 4.0 EQUALIZER 4.0 PRO OPTIMIZER 4.0
mobile connection its own data
**on request Equalizer 4.0 2i/4i/6i Equalizer 4.0 2/4/6 Equalizer 4.0 PRO 4/8 Optimizer 4.0 / Optimization Plan
Type of controller Sequencer Sequencer Advanced Sequencer Advanced energy optimizer
Installation Integrated in Mk5(touch) Wall-mounted Wall-mounted Wall-mounted
# air nets 1 air net 1 air net 1 air net Up to 3 air nets
# compressors 2/4/6 compressors 2/4/6 compressors 4/8 compressors Up to 30 machines
Machines type LNL, VSD LNL, VSD LNL, VSD LNL, VSD, Turbo, Blowers
Screen size 4.3’’ 4.3’’ 12.1’’ 12.1’’
Monitoring Compressors Compressors Compressors & Dryers Compressors & Dryers
Atlas Copco Turbo control No No No Yes
Competitor L/UL, VSD control Yes Yes Yes Yes
Competitor Turbo control No No No Yes**
REMOTEVIEW No No Yes Yes
SMARTVIEW No Optional Optional Yes
SMART2SCADA No No Optional Optional
SMARTLINK No Optional* Optional Optional one-off/ Included in Optimization Plan
Energy Recovery
How much the heat of a compressor can be recovered?
How much energy input of a
94 kW
Cooling Air
compressor is converted to Oil-Injected compressor
heat?
ER S1-5
90c Max
Compressed Air
ER90-900
4 kW
100 kW
Radiation to Ambient
2 kW
90c Max
Oil-free water-cooled compressor
Energy Recovery System Design
Sample Savings:
• 30 kwh output through Energy recovery from GA55VSD Air Compressor.
• = 30kw x 20hr x 5d x 48wk x 4.72 THB/kwh = 679,680 THB/Year
How much more should we pay for air leakage than usual?
Hole diameter: mm
1 3 5 10
Leakage, (l/s) at 6 bar 1 10 27 105
Power loos, kW 0.3 3.1 8.3 33
10 years
At the compressor
8th Edition Compressed Air Manual (Atlas Copco)
9,345,600
33 kW x 6,000 hr/year x 4.72 THB/kWh THB
= 934,560 THB/year
Leaks Detection – Ultrasonic Camera
Feature Benefits
• Leaks detection using ultrasonic • Leakage report with priority of leaks
scanning lists leakages in compressed air • Proposed how to fix leaks
system • Estimated cost of leaks
Air leak detection
Air leak detection- Sample report
ISO8573 - Contaminants and purity classes
Purity classes
The lower the class, the higher the air quality
Class 2.4.2 For example, class 2.4.2. means
Dirt : max 400.000 particles in the range of 0.1 – 0.5 µm; 6.000 of 0.5 – 1 µm; 100 of 1 – 5 µm
Water : max 3 °C PDP
Particles Class Oil Class
Water Class Oil : max 0.1 mg/m³
Air Quality Analysis
Tools and Applicable Standards
Multi-Air Tester tool F4504 Air Quality Analyzer
+ Isokinetic Sampling Device
Airscan Tools
Measurements
European Pharmacopoeia ISO 8573-1
compliant with
AIR Quality Analyzer
Always measure at points of use!
Particles
Oil
Dewpoint
Air Quality Analyzer Isokinetic sampling device
Multi Air Tester F4504
• Consumables
• Multi Air Tester F4504 ‒ CO2 tubes
‒ Measures • 100 - 1000 ppm
• CO ‒ CO tubes 10 pcs
• CO2 • 2,5 - 150 ppm
• Water vapour ‒ Water vapour tubes
• Oil content • 5 – 250 mg/m3
• Nox ‒ Oil impactor tubes
• SO2 • Can only measure oil aerosol (not vapour)
• H2S • 0,05 - 1 mg/m3
‒ NOx tubes
• 0,5 – 10 ppm
‒ SO2 tubes
Video • 1 -25 ppm
YouTube ‒ H2S tubes
• 0,5 – 15 ppm
Monitoring solutions
Local
Industrial Monitoring Remote
Networks Monitoring
REMOTEVIEW
SMART2SCADA SMARTLINK
SMARTVIEW
Gateway 4.0 to PLC/DCS/SCADA system Remote user-interface Remote monitoring solution
This year’s study shows that the industrial network market is expected to grow
by 7% in 2023. (HMS Networks 05/2023)
Industrial Ethernet
=68% of Total
+10% growth in 2023
+22% growth since 2017!
Fieldbus
=24% of Total
-5% growth in 2023
-24% growth since 2017!
PROFINET
EtherNet/IP
SCADA Solutions
Gateway 4.0 SMART2NET+ Equalizer 4.0 PRO Optimizer 4.0
SMARTVIEW – Monitor, Analyze, Advanced Report, eMail, Proactive Maintenance
SMARTLINK
SMARTLINK captures live data from your compressed air equipment and translate them in clear insights.
2. Data storage & processing
1. Data upload
3. Data visualization
SMARTLINK
cloud
SMARTLINK 2.0
Compressed air Equipment's
1. Remote 2. Advanced 3. Proactive
monitoring reporting maintenance
SMARTLINK
AIRNET CORE PRODUCTS
ALUMINUM STAINLESS POINT OF USE POLYAMIDE
• Pipes: Blue, Green, Grey S- • Pipes • Filter and Regulators
• Pipes: Polyamide Pipes
bends • Fittings: Adapters, • Hose Reels
• Fittings: Adapters, Elbows,
• Fittings: Elbows, Equal Sockets, Compensators, Elbows, End • Hoses
End Caps, Equal Sockets,
End Caps, Tees, Flanges, Caps, Equal Sockets, • Quick Release and
Nipple Sockets, Tees,
Manifolds, Nipple Sockets, Flanges, Quick Drops, Connectors
Threaded Adapter, Valves
Quick drops, Reducing Reducers, Nipple Sockets, • Socket Boxes
• Pipe support: Clamps /
Connections, Reducing Tees, Swan neck, Tees, Valves, Clips
Valves, Wall mounted Nipples Wall-mounted Nipples
Key takeaways
If compressor >20% unload, check for VSD feasibility.
Use a central controller to improve the air compressor room.
Identifying and fixing leakage will save minimum 10% of energy.
If you have hot water application, contact us for pre-assessment (ER).
SMARTLINK – Monitoring system, its available for every Atlas Copco Customer.
Key takeaways
Learn more about science-based target: Science-based targets - Atlas Copco Group
All about central controllers: Air Optimization (atlascopco.com)
Energy recovery- recover heat from your air compressor : Energy Recovery (atlascopco.com)
AIRScan - Air compressor audit : AIRScan (atlascopco.com)
SMARTLink- remote monitoring solution: Smartlink (atlascopco.com)
Learn about Industry 4.0 in Atlas Copco: Industry 4.0 - en (windows.net)
AIRnet optimized Compressed air piping solution: AIRnet Piping system (airnet-system.com)
OPTIMIZATION
Thank you for your participation!
