Automatic learning and management
A compressed air system monitoring and control network
based on an article by Andrea Milia, Business Development Manager at Ecoplant
Ecoplant is a stand-alone and plug-and-play solution that can be connected to all compressed air technologies. It offers a distinctive dynamic control system for managing any compressor room by analysing multiple variables. This data feeds into an algorithm that enables fast decision-making.
The proper management of compressed air remains a significant challenge for industrial companies operating in markets characterised by high energy cost volatility and a need to minimise unpredictable events, such as equipment failures or system outages. Notably, the electricity required to power compressors can account for up to 30% of a facility’s total energy consumption.
In addition to energy costs, expenses related to routine and extraordinary maintenance, as well as the risks posed by malfunctions and system interruptions, including potential plant downtime, represent a substantial portion of a company’s operating expenses.
To address the demand for optimal compressed air management, Compair has developed Ecoplant, a monitoring and control system for the compressed air system based on Machine Learning models.
Ecoplant is a machine agnostic solution: it can work with any brand and type of compressor. It features a distinctive “dynamic control” capability, which manages compressor rooms through the real-time analysis of multiple variables. These variables continuously feed into an algorithm that enables fast, reliable decision-making.
Operation
To better understand how Ecoplant works, it is helpful to introduce its physical components. Sensors monitor key variables required by the algorithm, such as pressure, flow, dew point, and others. These readings are then transmitted to the dynamic controller.
The cloud-based algorithm receives, analyses, and processes the data from the plant’s sensors with the aim of optimising system efficiency. After a baseline period, Dynamic Control is activated. At this stage, artificial intelligence takes over system management to ensure the lowest possible specific energy consumption.
This optimisation is made possible through the continuous adjustment of set-points and the selection of the optimal operating configuration for the compressors, based on real-time air demand and conditions.
Energy savings are even greater in systems with centralised compressor rooms, equipped with variable speed or centrifugal compressors, and where the air demand fluctuates greatly over time.
Compair aims to combine a strong commitment to customer support with a forward-thinking approach, seeking to enhance the value and performance of its equipment through flexible, future-ready solutions.
Beyond energy efficiency
The benefits of Ecoplant go beyond electricity savings, says Compair. Users have continuous access to a user-friendly monitoring platform that provides real-time insights into the performance of the entire compressed air system, including individual variables, compressors, and dryers of interest. The platform also allows for unlimited access to and download of plant data and data from all connected components.
Through machine learning, Ecoplant not only issues timely warnings and alerts but also supports predictive maintenance. This helps reduce both routine and unplanned maintenance interventions, thereby minimising the risk of production downtime.
Additional energy-efficiency features include a leakage detection function. During scheduled downtimes, Ecoplant can measure discrepancies between the flow rate delivered by the compressor activated by the algorithm and the flow measured downstream of the air treatment components. Based on this information, users can take appropriate actions to identify and reduce leakages within the compressed air system.
Versatility of use
As already mentioned, Ecoplant is compatible with any brand and type of compressor, including centrifugal, screw, reciprocating, and other technologies. This flexibility makes it suitable for a wide range of industrial applications. Other components of the compressed air system, such as dryers, can also be integrated into the platform. This allows for comprehensive monitoring and supports predictive maintenance strategies. Beyond standard alerts and alarms, the system also offers the possibility to implement personalised alerts based on specific customer requirements.
A case in point
As an example, Compair considered a major customer in the industrial inks and dyes sector. Ecoplant was installed at their facility, which includes three compressor rooms housing a total of nine screw compressors from multiple manufacturers, seven of which are equipped with variable speed drives.
Each compressor in the plant has a power rating of between 200 and 250 kW. The average compressed air demand ranges from 30 to 35 Nm³/min, within a maximum plant capacity of 135 Nm³/min. Before installing Ecoplant, the measured average specific power was 8.94 kW/Nm³/min.
Following the installation, the average specific power was reduced by 26% over the baseline period. In just one year, thanks to improved energy efficiency, 615,000 kWh were saved and carbon emissions were reduced by 431 t of CO2.
In addition to the energy savings, Ecoplant issued 17 alerts, insights, and alarms during the reporting period. These included four system risk alerts (involving components such as compressors, dryers, or valves left open unintentionally), six predictive maintenance warnings, and seven energy-efficiency insights (including high pressure drops, excessive air leakage from filter and dryer drains, and discrepancies indicating potential component replacements within the network).
The Ecoplant system can be integrated with Compair’s Care maintenance programme, allowing it to be customised for various operational needs. This bundled solution aims to reduce overall plant costs and to transfer a portion of the operational risk from the customer to the service provider.