Significant Savings for Aerospace Customer

Glaston Compressor Services Ltd is a UK leading specialist in air compressor intelligent control, nitrogen generators and energy management systems. With a comprehensive portfolio of energy efficient products, Glaston works with a diverse range of industries including – Power Stations, Recycling, Automotive, Food, Nuclear Power and Aerospace.

One such Aerospace customer is Marshall Aviation Services.  Drawing on over eight decades of aviation experience they provide a comprehensive offering of business aviation services.

As part of Marshall Aerospace and Defence Group, they benefit from the resources and expertise of the UK’s largest independent aerospace company and are trusted for the sale, operation, management, support and modification of new and pre-owned business aircraft.

From aircraft purchase, through operational, maintenance and engineering services, to aircraft sale, their capabilities are enhanced by key OEM partnerships. Marshall Aviation provides a vital service and support role in Europe, the Middle East and Africa.  Their engineering capability extends to complex modifications, including interior and exterior refurbishment and avionic and cabin upgrades and their operational support covers aircraft management and charter, as well as hangarage and airport handling services.

Situation

Marshall Aviation contacted Glaston to review the performance of their compressed air system.  As part of the review process a data logging survey was undertaken.  Glaston conducted a week long data logging exercise and presented the results and specification details together with their recommendations back to Marshall Aviation.

The specifics of the site were inefficient. There were 2 x 45kW compressors running as duty standby. This means one compressor will cope with duty as the other compressor sits in standby should air demand increase or a fault occur.

The existing compressors were over sized and therefore carrying much more capacity than the site was actually using. This was resulting in long periods of offload running. Offload running is using electricity to run a motor when no compressed air is created and therefore costs the bill payer money. The key is to have a compressed air system that is suited for site dynamics. i.e. if the compressed air demand is constant then a fixed speed compressor running flat out is the most efficient way of supporting such a demand, if the compressed air demand is constantly changing from one moment to the next then a variable speed compressor is more suited as they do not have any offload running as previously outlined.

Recommendations

Glaston recommended the HPC Kaeser ASK 34 SFC T compressor, a high quality, robust self contained unit. It has a 18.5kW motor driving a high efficiency belt drive system. This compressor has the benefit of a built in refrigeration dryer so a high quality of compressed air is constantly achieved.   HPC Kaeser Compresssors are renowned for their reliability and longevity due to their excellent build quality and second to none after sales support.

 

The compressor is compact and will fit into a small area saving space, and operates so quietly it can be used directly in the work place thus greatly reducing noise pollution.  It also comes with a 5 year warranty which is unique in the industry as many other manufacturers have restrictive terms and conditions.

 

Results

 

Massive savings can be made by the introduction of a variable speed drive air compressor. In this example Glaston’s recommendations saved the customer over £19,000 in running costs in the first year alone.  Mr Simon Jones, Site Facilities Manager at Marshall Aviation comments “We are delighted with the performance of the air compressor, not only have we seen a huge reduction in energy running costs, but by also utilising the heat generated by the compressor we have seen a massive reduction in our gas heating bills”.

 

AIR COMPRESSOR Heat Recovery

 

Heat Recovery is available from the compressors as the heat generated from them is usually blown into the atmosphere. Glaston is able to harness this heat and utilise it in the hangers by means of ducting.

 

By ducting the air into the work area it is possible to generate 72,000 kWh of heat over the winter period. This will greatly alleviate the demand on the current heating system thus reducing the expenditure on natural gas year on year.

Through expertise in identifying energy saving opportunities, Glaston has made a substantial contribution to increasing the energy and efficiency ratings of many manufacturing plants throughout the UK.

Danny Jones, Efficiency Engineer at Glaston comments “Glaston is proud to be an authorised UK distributor of HPC Kaeser Compressors.  We offer our clients bespoke solutions and our service engineers are committed to delivering a first class service.  Air Compressor heat recovery is a cost effective, innovative way of reducing our customers’ carbon footprint”.