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Subsequently, Glaston were invited to review the high pressure system following a successful project to overhaul the general purpose 7 bar air which resulted in the installation of four 160kW HPC energy efficient compressors. 350 bar and 40 Bar Compressor installation

As opposed to offering two new 350 bar compressors it was deemed more cost effective, from both a purchasing and operating perspective, to supply a 350 bar compressor to fulfill the 350 bar requirement. A 40 bar unit was supplied to fulfil the 40 bar air requirement. 350 bar and 40 Bar Compressor installation

Once the site understood the benefit to generating compressed air at the pressures actually required, Glaston put forward a 350 bar SAUER piston compressor and a 40 bar SAUER piston compressor. SAUER are renowned worldwide for the superior build and reliability of high pressure compressors. Additionally, SAUER compressors are used extensively though out the world serving general industry, shipping and many navies. 350 bar and 40 Bar Compressor installation

Following a rigorous tendering process, two SAUER units were installed in the summer of 2010 and have been successfully used since.

If you have any questions about this case study or you would like any help with your compressed air system, old or new, whatever the air pressure, then please contact us.

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Just as we need to ensure compressors and ancillary equipment, such as dryers and filters, run in ambient conditions that prevent frost damage during the cold winter months the opposite is true when the weather turns warm.

It is essential that compressors and dryers are all serviced in accordance with the manufacturer’s recommendations. Old oil that is past its working life loses some of its thermal properties and it becomes more difficult to remove the heat generated during compression. Blocked oil filters also restrict oil flow around the compressor which again prevents the cooling system from working. A common missed service item is the cleaning of the oil and air coolers. If the oil cooler is blocked the compressor will run hot and if the air cooler is blocked the temperature of the compressed air leaving the compressor will be too hot and this will put a lot of strain on the filtration systems, often leading them to fail.

Compressors that are running over the ideal design temperature will also suffer from additional oil consumption. This impacts the system in two ways. Firstly it means that the compressor needs constantly topping up with oil (this is costly) and secondly it puts more strain on the filtration systems as they have to remove this additional oil passing through with the compressed air.

Compressors running hot will also suffer from increased bearing degradation in the airend and motor. Premature bearing failure of this type is extremely costly. IF you are fortunate enough to have an HPC compressor then we can offer special exchange AirEnd prices at a significantly reduced cost provided the airend still rotates. However, if you operate other manufacturer’s units then you may be forced to buy new AirEnds at full cost which represents a large portion of the cost of a new compressor!

Obviously, even if the compressor is serviced to the manufacturer’s recommendations it is imperative that the ventilation of a compressor room is suitable to allow fresh air in. Warm ambient conditions coupled with poor ventilation will soon result in overheating problems. A suggestion to improve room ventilation is extraction fans used in conjunction with room thermostats (so they only run when required) or ductwork systems to duct out the warm air and draw cool air in.

For further advice on running compressors in the summer please contact us at www.glaston.com

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HPC KAESER Portable Screw Compressors are powerful, mobile machines for providing compressed air on a construction site or in industry for applications such as road breakers. In addition the reliability of these portable compressors makes them ideal as temporary machines for situations where compressed air requirement is greater than the current capacity i.e if you current compressor is out of action for any reason a HPC KAESER diesel driven portable unit may be the ideal short term solution. A wide range of models and options covers every demand from power tools to auxiliary electrical supplies for lighting and welding.

The HPC KAESER partnership provides a wealth of experience and expertise with a range of portable compressors and accessories providing ideal solutions to the varied needs and demands of the U.K. portable compressor market.

From the small compact M13 with a capacity of 1.2m3/min (42cfm), that can be transported in the back of a small vehicle right up to the high-performance M270 delivering 27m3/min (953cfm) at 7bar we can help.

As an option, all machines can be fitted with a tool lubricator for picks and breakers, two of the standard uses for a portable compressor. Especially designed for this purpose the unit adds a biologically degradable lubricant and defrosting medium to the compressed air. This reduces wear on pneumatic tools, increases their life and guarantees reliable operation. As well as lubricated air for tools, dry, cool or heated air can be produced for sand-blasting and concrete repair.  Another treatment unit can even provide air of breathing quality. If a special distributor is fitted, air of differing qualities can be supplied in parallel.

Several models are available with an integrated generator for applications requiring mobile electric power (for example PE welding of plastic piping, powering electric tools and submersible pumps or site illumination). The generator can supply both three-phase and single-phase power via an overload protection switch. With this equipment, the unit becomes a versatile mobile power station.

Over the years Glaston have supplied units to the UK as well as export for use on oil fields and off shore oil rigs as spark arrestors and chalwyn valves are freely available for the HPC KAESER units.

For any further information on portable compressors and how we can help you please contact us at Glaston Compressors – www.glaston.com

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Unfortunately storage is often seen as a non-functioning part of the air system, as it does not require, nor deliver, electrical or mechanical energy. This could not be further from the truth. Just as a capacitor or coil in a cars ignition system is required for operation and control, storage is required for proper operation and control of a compressed air system.

Storage in an air system is not a tank or receiver; it is the accumulation, retention, and distribution of energy. Energy is stored in an air system with pressure differential and receivers or tanks to create a larger volume of air at the differential. Pressure differential and volume are both critical for storage, and are in an inversely proportional relationship. As one decreases, the other must increase to maintain the same level of storage.

Like the capacitor mentioned above, receiver tanks store energy – in the form of compressed air. Also similar to a capacitor, it is not only the size of the capacitor that matters, but the difference in energy levels – in the form of pressure differential.

Air system storage is required to absorb and release energy as needed, in an instant, to adjust to changes in system demand, thus providing time for compressor controls to react.

For a rapid increase in demand, storage will supply the system with the required volume to maintain the system while additional compressor capacity is brought online. In the event of a rapid decrease in demand, the opposite holds true; storage will absorb the energy of excess online capacity, while compressor capacity is taken offline, keeping the system from exceeding pressure safety levels.

With slow or no changes in demand, storage provides time for the compressor(s) controls to cycle properly, and less frequently, thereby decreasing energy consumption and maintenance costs.

For more information please contact us at www.glaston.com for all your compressed air needs.

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HPC Compressors and Kaeser Compressors new generation of Sigma Air Manager (SAM) now features adaptive 3D Control. Active rather than reactive, the new self-adjusting 3D software responds to the three crucial dimensions that effects air system efficiency: switching losses, control losses, and pressure flexibility. The result is significant energy savings through reduced compressor run and idling time; and reduced leaks and artificial demand. At the same time, it provides the lowest average system pressure for better operation of plant equipment.

This controller includes an integral Web-server for remote monitoring of system activity. The optional Sigma Air Control Plus stores and analyzes system data for reporting, system audits, control optimisation and long-term trend analysis. SAM can operate multiple compressors, blowers or vacuum pumps. Integrating the SAM into your server allows for additional remote capabilities, including control.

Even if you are not lucky enough to run HPC / Kaeser compressors the SAM unit can be still be used to control other makes of compressors resulting in excellent energy savings. Furthermore, by running the minimum amount of compressors to satisfy your air demand you may find that you actually reduce the compressor running hours. Less compressor running hours = less servicing and improved reliability.

For more information please contact Glaston Compressor on how we can make any compressor system run even more efficiently.

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All models come standard with the new Sigma Control 2 intelligent compressor control for enhanced communications capabilities and equipment protection. Also standard is a variable speed fan for the fluid cooler that helps save energy by adjusting to cooling demands. Maintenance points are more easily accessible than ever before with five access doors and a removable panel. Redesigned ESD Compressors with SFC Options

Options include water-cooled and SFC variable frequency drive. ESD units with optional SFC are now 19 inches shorter than the previous design, with a footprint reduced by an impressive nine square feet! Redesigned ESD Compressors with SFC Options

To learn more about the new ESD series please contact Glaston via www.glaston.com

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This breakthrough provided the keystone for today’s integrated system approach to compressed air production by enabling continuous advances in energy performance and improved reliability of complex compressed air systems.

The core strengths of the HPC KAESER SIGMA Control compressor controller are its ability to optimise energy efficiency and to communicate seamlessly both internally with the compressor as well as externally with master control systems. Unsurprisingly therefore, that the HPC KAESER development engineers also applied these outstanding features to the new generation SIGMA Control 2, or SC2 as it is referred to more succinctly. However, wishing to make the SIGMA Control 2 even more versatile than its predecessor, what the design engineers developed for the SC2 was an innovative modular design that creates a “division of labour” between the main control unit and the separate input/output modules. As a result, this unique concept makes the SC2 even easier to maintain and to communicate with.

For more information on HPC Compressors and Kaeser Compressors contact Glaston

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