Kaeser optimises compressed air systems

Kaeser Compressors Australia has assisted Wilson Transformer Company (WTC), a manufacturer of power and distribution transformers, in meeting its increased demand for compressed air. The Victoria-based manufacturer recently undertook a major expansion of its Glen Waverley facility, which included upgrading the compressed air system.

“In planning the expansion of our production facility, it became apparent that our existing compressor station was not going to be able to meet the new compressed air demand,” said Alan Veitch, improvement manager for the Power Business Unit at WTC. “The ageing compressed air system was also becoming increasingly inefficient and so costly to operate.”

The plant incorporates two main workshop areas, both of which use compressed air to power a number of operations. In particular, the company sought to introduce air skates - equipment powered by compressed air which can move heavy loads on a cushion of air - in order to “lift and manoeuvre the largest transformers into restricted access areas such as the testing bays where the cranes cannot go”, said Veitch.

WTC chose to invest in six Kaeser rotary screw compressors: four CSD T models with integrated refrigeration dryers and two CSD(X) T SFC variable speed drive models. The screw compressors are available with drive powers up to 90 kW, producing free air deliveries from 1.07 up to 16.16 m³/min.

As part of the development of its power and distribution transformer capability, WTC chose to invest in six Kaeser CSD series rotary screw compressors.

At the heart of every CSD(X) T rotary screw compressor lies a low-speed Sigma Profile airend, equipped with flow optimised rotors, which achieves power savings of up to 15% compared with conventional screw airend rotor profiles. In addition, Kaeser rotary screw airends are powered by IE3 drive motors for good performance and reliability.

Combining a rotary screw compressor with a compact integrated refrigeration dryer makes the CSD(X) T units suitable where the user requires an all-in-one solution. The integrated refrigeration dryers in the units provide further energy savings, with a sophisticated control ensuring that the dryers are only active when compressed air actually needs to be dried. Furthermore, by utilising a variable speed drive, the units have been designed to vary the speed of the airend to directly match the flow required by the end user. This saves energy, maximises service life and enhances reliability.

“All of the Kaeser compressors have proven to be efficient and reliable in operation, and we are particularly impressed with their ease of maintenance,” Veitch said.

“The main compressor system is now effortlessly powering the new air skates, which together can lift and manoeuvre some 300 tonnes of weight.”