In an era of rising energy costs, UK companies are constantly seeking ways to reduce expenses and enhance efficiency. Air compressor systems, which consume substantial energy, are a key area for improvement.
Implementing air compressor monitoring systems can significantly optimise operations. These systems act as central controllers to enhance equipment performance and efficiency. Atlas Copco offers a range of monitoring systems tailored to various operational needs, helping businesses streamline workflows, reduce costs, and extend equipment lifespan.
Additionally, remote access connectivity provides enhanced oversight capabilities, ensuring better management and maintenance of compressor systems. This guide will explore the benefits and options for air compressor monitoring systems.
Table of Contents
1. Why Monitor Your Air Compressor?
Bar is an air pressure measurement. One reason to monitor your air compressor is that reducing air pressure by one bar reduces energy consumption by 7 per cent.
Operating industrial air compressors using the right air compressor monitoring system saves money. Air pressure settings for a single compressor can be adjusted, especially for variable-speed drive compressors that offer more flexibility.
Monitoring via a keypad, digital compressor equipment display, or a cloud-based system, optimises efficiency and reliability. Access to real-time data allows inefficiencies to be spotted and rectified, decreasing operational costs.
Sophisticated monitoring also permits faster detection of impending failures allowing pre-emptive shutdowns for maintenance and, where required, parts to be swapped out to avoid longer downtime.
2. Types of Air Compressor Monitoring Systems
Selecting the right air compressor monitoring tools is essential for optimizing the performance of your compressor and the entire compressed air system. These systems range from basic to advanced, each offering different functionalities to meet your operational needs.
Basic monitoring systems focus on essential metrics like pressure levels and temperature, ensuring the compressor operates within an optimal range. For instance, Atlas Copco’s Equalizer 4.0 allows real-time monitoring of up to six compressors and multiple air dryers, making it ideal for smaller operations without complex monitoring requirements.
Intermediate systems add advanced features like load balancing, which distributes workloads across multiple compressors to improve efficiency and extend equipment life. The Atlas Copco Equalizer 4.0 PRO can manage up to eight compressors, offering flexibility with variable pressure settings and remote monitoring capabilities.
Advanced systems are designed for smart factory operations, providing continuous oversight, detailed compressor data analysis, and remote monitoring. Atlas Copco’s Optimizer 4.0 includes real-time remote access via SmartLink, enabling operators to monitor and manage performance from anywhere, which is crucial in industrial settings where downtime must be minimized.
For businesses with specific needs, custom monitoring solutions might be required. These solutions can include central control for up to 30 machines, tailored to industry-specific requirements, ensuring scalability and efficient management as operations grow.
3. Key Components of an Effective Monitoring System
Monitoring is only as effective as the data collected and analysed in real time.
High-quality monitoring systems depend on installed sensors to collect data on air compressor flow rates, pressure readings, temperature levels, humidity, and more. Warning systems alert operators to irregular readings. For some systems, an interactive digital touchscreen display is provided – others are more basic.
Data loggers record, save, and analyse performance trends. They then compare them to expected readings based on system settings and historical data. Complex analytics are only part of advanced air monitoring systems.
Depending on the air compressor system installed, remote access is sometimes possible. Advanced analytical software offers alerts about anticipated problems instead of only basic alerts relating to immediate issues.
4. Implementing Your Monitoring System
Getting a central controller installed in your compressor room is more energy efficient. However, an optimal controller must be used.
For example, some controllers support a limited number of air compressors. Some machines do not provide analytical data access or a robust advanced alerting system. Better control and management options lower operating costs.
Talk to our experienced installers to assess how to implement a new or better monitoring system. They can study your operational requirements and potential future growth. Only then will they make any recommendations for new equipment or monitoring systems. This careful approach limits interruptions to existing compressed air operations.
5. Maintenance and Troubleshooting
Advanced monitoring allows operators to examine compressor system performance metrics – not only for optimisation but also to look out for degradation suggesting a component issue. Initial component issues like wear and tear, or a broken part, affect operational efficiency.
Scheduled inspections of components are also important to spot potential issues that may cause larger problems.
Some common issues include:
- A dirty air compressor affects air quality and performance.
- Insufficient power to support the complete air compressor system.
- Persistent and costly air leakage.
- Higher noise emissions than normal.
- Oil contamination.
An optimised compressor installation plan, a power review for existing compressor installations, leakage tracking, frequent cleaning, and noise dampening are all possibilities to address the above issues.
6. Industry Applications
Air compressor monitoring systems are essential across various industries, each with specific needs for optimizing performance and reducing costs.
Manufacturing
In manufacturing, consistent air quality and pressure are crucial for powering tools and compressed air equipment. Monitoring systems help identify inefficiencies, maintain consistent air pressure, and optimize energy use, reducing operational costs. Advanced systems with features like multiple compressor control and remote monitoring allow for seamless management of production across all machines, minimizing downtime.
Healthcare
In healthcare, maintaining consistent air pressure and high air quality is critical for patient safety. Monitoring systems, including those with central air compressor controls, ensure that equipment operates flawlessly by sending email alerts when equipment needs attention. This helps avoid unnecessary disruptions and ensures compliance with strict regulatory standards.
Food and Beverage
The food and beverage industry relies on contaminant-free compressed air for packaging and processing. Monitoring systems equipped with high-efficiency air filters and pre-filtration mats ensure air purity, preventing contamination and ensuring product safety. Real-time monitoring and alerts allow operators to address issues quickly, maintaining smooth production lines.
Automotive
In the automotive industry, air compressors power tools and machinery used in assembly and painting. Monitoring systems with energy monitoring capabilities optimize efficiency by balancing loads across multiple compressors and diagnosing issues early. This helps maintain production schedules and reduce downtime, ensuring that the status of your machines is always optimal.
Energy Sector
In the energy sector, air compressors often operate in harsh environments. Robust monitoring systems with advanced functionalities like central pressure measurement ensure reliable operation even in ambient conditions with dust and humidity. Remote monitoring allows operators to monitor equipment from a distance, enhancing safety and ensuring uninterrupted energy production.
7. Choosing the Right System for Your Needs
System requirements vary between companies and sectors. Whereas one company might select a single air compressor to replace a costly compressed air leasing contract, others have larger and growing requirements.
Indeed, some manufacturing operations, such as food or beverage production facilities, use so much compressed air that numerous air compressors, dryers, and other equipment are required. They may also wish to monitor the performance of AIRnet pipe ducting around the facility which few monitoring systems offer.
Both current and future compressed air needs are relevant considerations – do not ignore scalability concerns. Some compressed air monitoring systems provide valuable additional data and a greater ability to manage performance. However, real-time data analytics via a cloud-enabled software capability are not always available as an upgrade.
8. Future of Air Compressor Monitoring
There are constant advances in air compressor monitoring capabilities. As with other equipment, the impact of artificial intelligence (AI) and machine learning is present.
AI implementation and machine learning allow intelligent systems to actively review air compressor system data. Operators are then alerted to potential issues. Depending on the operator’s response to this prompting, the machine learning function alters its approach to future issues. Such systems are actively being developed, with software upgrades and new releases expected.
Predictive analysis is another area of increasing sophistication. Reviewing trends enables greater foresight and future planning.
Conclusion
Air compressor monitoring is necessary to operate more efficiently, reduce power consumption, and increase reliability. Critical air systems must operate at the lowest possible cost with minimal potential downtime. Only through detailed monitoring and analysis is this made possible.
Sophisticated monitoring systems allow operators to extend the life of air compressor systems. This is achieved using control systems that monitor compressor performance and proactively resolve maintenance issues.
Contact us today to discuss your air management needs with our expert team.
FAQ
What are the benefits of using a remote monitoring system for air compressors?
A remote monitoring system allows you to monitor your compressor and entire compressed air equipment from any location, providing real-time data and alerts. This ensures that you can quickly address any issues before they escalate, reducing downtime and maintenance costs. It also helps maintain consistent air pressure and improves the overall efficiency of your operation, making it an essential tool for compressed air users in smart factory environments.
How does a central controller help in managing multiple compressors?
A central controller can help optimize the performance of multiple compressors by balancing loads and controlling up to 30 machines based on a central pressure measurement. This not only improves efficiency but also reduces the total cost of ownership by ensuring that each air compressor unit operates within its optimal range. Additionally, it provides advanced functionalities like email alerts when your equipment needs servicing, helping you maintain smooth and uninterrupted operations.
Why is it important to improve air quality with pre-filtration in compressed air systems?
Improving air quality with pre-filtration mats and high-efficiency air filters is crucial in industries like food and beverage, healthcare, and manufacturing, where air purity is essential. These components help remove contaminants from the compressed air, protecting sensitive equipment and ensuring product safety. By incorporating pre-filtration, you can maintain consistent air quality, reduce equipment wear, and avoid costly production issues related to poor air quality.
