Introduction
Modern compressed air systems are critical to the efficient operation of production facilities. However, older systems often do not meet modern energy efficiency and safety standards. According to the EU ecodesign directive (2009/125/EC) and requirements for energy audits, enterprises in Ukraine must switch to modern technologies to reduce energy costs and increase the service life of equipment.
Evaluation of the old system
Before upgrading the compressed air system, a detailed evaluation must be carried out. The main criteria include:
| Criterion | Assessment |
|---|---|
| Efficiency of energy use | ≤ 75% (for old compressors) |
| Noise level | ≥ 85 dB |
| Number of leaks | ≥ 10% of the total volume |
| Mean Time Between Failure (MTBF) | ≤ 5000 hours |
| Cost of energy | ≥ 0.15 €/kWh |
Modern alternatives
System upgrades are possible with highly efficient variable speed compressors (VSDs), leak detection diagnostic systems, and intelligent piping. Below is a comparison of the old and new technology:
| Indicator | Old compressor | Modern compressor (Parker 140H-8 1FY40BB150-AB) |
|---|---|---|
| Efficiency | ≤ 75% | ≥ 92% |
| The power | 150 kW | 150 kW |
| Noise level | ≥ 85 dB | ≤ 75 dB |
| Air consumption | 1000 l/min | 1000 l/min |
| Cost of energy | ≥ 0.15 €/kWh | ≥ 0.15 €/kWh |
| Mean Time Between Failure (MTBF) | ≤ 5000 hours | ≥ 10,000 hours |
Calculating return on investment
Upgrading your compressed air system can significantly reduce energy costs and increase efficiency. Below is an example of calculating return on investment:
| Indicator | old man | New | The difference |
|---|---|---|---|
| Annual energy (kWh) | 50,000 | 30,000 | -20,000 |
| Cost of energy (€/kWh) | 0.15 | 0.15 | 0 |
| Annual energy costs (€) | 7,500 | 4,500 | -3,000 |
| Repair costs (€/year) | 2,000 | 500 | -1,500 |
| Installation cost (€) | 0 | 12,000 | +12,000 |
| Amount of expenses (€) | 9,500 | 16,500 | +7,000 |
| Annual savings (€) | 0 | 3,000 | +3,000 |
| Return on investment (years) | 0 | 2.33 | 2.33 |
Implementation routing
The upgrade of the compressed air system should be organized in phases to minimize the impact on production:
- Planning: Detailed system evaluation, needs analysis and component selection.
- Orientation: Collection of information about the foreign market, selection of reliable suppliers (for example, UNITEC-D).
- Supplies: Preparation of components and equipment including Parker 140H-8 1FY40BB150-AB compressor.
- Installation: Installation of a new system taking into account engineering standards (ISO 1219, EN 1219).
- Preparation: Testing, debugging and staff training.
Technical challenges
The following technical challenges may arise when upgrading a compressed air system:
- Air leakage: Using diagnostic systems to detect and eliminate leaks.
- Choosing the right compressor: Choosing a VSD compressor that meets the requirements EN 1219.
- Synchronization with other systems: Ensuring harmonious interaction with other equipment and control systems.
Use case
The compressed air system was modernized at the production facility in Ukraine. Here are the before and after updates:
| Indicator | Until the update | After update |
|---|---|---|
| Efficiency | 72% | 91% |
| Noise level | 88 dB | 74 dB |
| Mean Time Between Failure (MTBF) | 4800 hours | 10,200 hours |
| Energy costs (€/year) | 7800 | 4700 |
| Repair costs (€/year) | 2200 | 500 |
| Installation cost (€) | 0 | 12,000 |
| Return on investment (years) | 0 | 2.33 |
Preparation and verification
After the system is installed, it must be tested according to ISO 1219 and EN 1219. standards. The main steps include:
- Testing: Measurement of pressure, power and efficiency of the system.
- Confirmation: Verification of compliance with the requirements of standards and regulatory acts.
- Acceptance: Completion of system acceptance documentation.
Conclusion
Upgrading your compressed air system is critical to improving production efficiency and safety. The use of modern technologies, such as variable speed compressors (VSD), diagnostic systems and intelligent pipelines, ensures a significant reduction in energy costs and an increase in the life of the equipment. You can find all the necessary components and tools to implement the upgrade in the UNITEC-D E-Catalog.
UNITEC-D E-Catalog
Sources
- EU Ecodesign Directive (2009/125/EC)
- Standards ISO 1219, EN 1219
- Guide for the migration of manufacturers
- Official requirements for energy audits
