Air measurement survey reveals energy saving for manufacturing plant

When Orica, provider of commercial explosives and blasting systems, wanted to reduce operating costs and improve efficiencies at its manufacturing plant in Helidon, Queensland, the company went to Atlas Copco to seek advice.

As a first step, Atlas Copco organised an air measurement survey at the plant. A key component of the survey is a graph of measured current (A) vs time, which clearly indicates when the compressor is loaded and producing air, and when the compressor is unloaded and not producing air; representing energy wasted by the compressor.

Atlas Copco is able to convert the raw data shown on the graph into a compressed air flow profile and simulate its VSD compressors against the measured flow to find the power consumption and establish the potential savings.

Based on the results of the air measurement survey, Orica purchased the GA55VSD machine. “And following the success of that compressor, we have purchased another GA55VSD from Atlas Copco,” said Trevor Luck, maintenance superintendent at the Helidon facility.

“When production slows, or we stop for a lunch break, for example, the compressor slows to an idle, rather than churning on, consuming expensive electricity.

Luck explained that the Helidon manufacturing site produces initiating systems used in mining applications for ignition of detonation devices.

“We basically have two production facilities on site; an extrusion plant and an assembly plant, with around 140 people in total.

“We extrude the signal tubes and then assemble the detonators to the end, before the bulk explosive initiation.

“And, as this is an explosive plant and air is a lot safer than electricity, we use a lot of pneumatics here.

Luck explained that the two Atlas Copco GA55VSD machines are “our workhorses”.

“While the two manufacturing sites are not connected, we are able to link the compressed air lines and keep the plant running when we are servicing the compressors,” he explained.

“The air measurement survey said we would save ‘x’ thousands of dollars every year, and that is exactly how much we are saving, every year,” Luck said.

Duncan Vaughan, Sales Engineer with Atlas Copco Compressors says the first step for any company interested in reducing their power bill is to have an air measurement survey, or an air audit.

 Vaughan describes the Atlas Copco VSD compressors as the ultimate energy savers.

“The compressors feature integrated VSD technology which reduces energy consumption by 35%, on average; for Orica it was 45%.

Since 2008, the Atlas Copco GA55VSDs have returned Orica over twice their total purchase cost in power savings.

“Atlas Copco’s VSD pressure band optimisation technology closely follows the customer’s air demand by automatically varying the motor speed. Basically the machine adjusts it output in line with demand.

“With over 70% of a compressor’s life cycle cost taken up by the energy it consumes, the move to an Atlas Copco VSD air compressor can lead to major energy savings,” Vaughan said.