Industry 4.0 and predictive maintenance
How a local company
is preparing pakistani textile industry.
Energy used for Compressed Air can account for up to 72% of
the electricity used in the textile industry. In order to keep
costs in control and stay competitive, Compressed Air merits
The new iConn service from CompAir provides compressed air
users within-depth and real-time knowledge about their system,
essential for accurate production planning, reliability and
peace of mind. TheiConn system generates and delivers insight
and statistics that keeps compressed air managers informed of
the performance of their installation, highlighting potential
issues before they become a problem.
Compressor performance has a key role to play in the overall
cost efficiency and productivity of a process or plant.Industry
figures estimate that many compressed air systems can waste up
to 30% of the compressed air through leaks, poor control or
maintenance. Add to this the fact that the older the machine the
less energy efficient it is likely to be and it becomes clear
that implementing a thorough maintenance programme can pay quick
generation Connectivity Platform
iConn is a flexible platform enabling extended data
analytics and pattern recognition algorithms
leveraging CompAir‘s application know-how.
Choosing the Correct Program
Typical maintenance cover can range from reactive or
breakdown maintenance, where the compressor is left to run until
any fault is identified and subsequently repaired, through to
predictive maintenance, where sensor devices provide data to
help predict when maintenance is required or when a part may be
under stress and could fail.
An independent survey indicates that a comprehensive planned
maintenance system, whereby maintenance is carried out at
scheduled intervals, can result in a 70-75% elimination of
breakdowns, a 35-34% reduction in downtime and a productivity
increase of up to 25%.
Further improvements can be made with a predictive
maintenance programme. By fitting a compressor with a range of
sensor devices, which are connected to a remote monitoring
system operated by the compressor OEM, the system can monitor
the compressor around the clock and can use the data to predict
when maintenance is required or when a part may be under stress
and could fail.
In comparison to using reaction-based breakdown maintenance,
organisations can easily reach savings of up to 30-40% through
the use of predictive maintenance.
As well as choosing the right type of maintenance schedule to
suit the operation, plant managers should also ensure that their
service provider is incorporating the following checks into its
Firstly, filter elements should be changed at least once a
year to help reduce pressure drops, meaning that the compressor
will consume less energy to supply the required air pressure. In
addition, poorly filtered intake air can raise the compressor’s
internal temperatures which will have the effect of increasing
the overall power consumption.
In oil-lubricated machines it is also essential to carry out
regular oil changes, with the appropriate grade of oil to ensure
machine longevity and reliability.
Regular checks for air leaks should also be carried out. As
air is non-hazardous, leaks in the pipework will not affect
process safety and can often go undetected. However, any leak in
the network means that energy is being wasted, sometimes by as
much as 20% - put simply, the compressor is having to work
harder to produce the required air pressure at the point of use.
A simple leak detection survey can identify any problems
quickly, with remedial action undertaken at little cost.
Determining the right size of compressor for an application
is an important consideration; especially as the capital cost of
buying it is just a small part of the overall equation. What
matters most is what it will cost to run the compressor over its
whole operational lifetime.
Operating at a higher pressure than is necessary or with a
poorly designed, leaky system will use more energy than required
and lead to higher running costs.
One of the simplest ways to achieve this is to carry out an
air audit that will identify potential and current compressed
air demands and assess energy usage.
Where there is an existing compressed air system the site can
be monitored over a fixed period of time to gather quantifiable
data via a data-logging unit attached on each compressor in the
The results enable real time data to be analysed to ensure
the selection of the most energy-efficient compressors. This
will include the size and mixture of fixed and variable-speed
compressors. The audit may also determine if a multiple
compressor installation requires better control via a dedicated
management control system.
ReplacementParts – A Genuine Concern
Operators should carefully consider their spare parts supply.
Choosing non-genuine or third party spares can have a negative
impact on compressor efficiency and energy consumption.
Non-genuine spares and lubricants are generally a cheaper
alternative to the manufacturer’s original parts and, when cost
is an issue, can appear to be a sound investment.
However, as well as a shorter operational life and the
associated issues of compressor downtime, the wrong spare part
can in some cases, cause real damage to the compressor,
ultimately meaning the machine can fail completely. This won’t
just result in an expensive repair bill, but will affect
productivity with unscheduled machine downtime.
Replacement Is Necessary
Any compressor, whether brand new or one that has been
performing well for many years will, in the normal course of
operation, require components to be periodically replaced. These
can include items such as filters, valves, seals and oil.
Unless a genuine, like-for-like replacement part is used,
there can be no guarantee that the original performance will be
maintained. Non-genuine parts are not manufactured to the same
specification as the manufacturers’ original. By virtue of the
fact that they are engineered to cost less, they will typically
incorporate inferior components that cannot offer the same
levels of energy efficiency or performance reliability.
In contrast, genuine parts have been manufactured to meet the
same standards as the compressor they are intended for. This
means that they have passed the same stringent manufacturers’
testing regimes, in a quality-controlled environment, to offer
the repeatable, dependable operation that plant manager’s need
to keep production costs down.
For further information
please visit: http://rastgar-co.com/iconn/