Why you should focus on compact and easy-to-maintain plug-and-play compressors in your planning
Modern compressors incorporate all the necessary components
Not so long ago, in addition to the compressor, you had to buy and install an electric motor, engine starters, an aftercooler, and an intake filter to get a complete machine. The requirements and the control interface had to be discussed with each supplier to ensure that all parts could be assembled and that the compressor worked properly. Nowadays, most manufacturers supply compressors ready to plug in, or turnkey units for the requirements of larger projects.
A modern compressor has a base frame on which all components are mounted. The necessary internal piping and cabling between the various components are already provided as standard by the factory. Optionally, a refrigeration dryer - or an adsorption dryer in the case of oil-free compressors - or a heat exchanger for a planned heat recovery system can be integrated into the housing as well.
The entire compressor is covered with an acoustic hood to reduce the noise level and thus prevent sound pollution. This has made the installation of a compressor system much easier and you can now be sure that all parts are correctly designed and will function reliably.
Modern compressors like those from Atlas Copco are designed for energy-efficient operation, reliability, and ease of maintenance. All components are grouped sensibly and arranged to be easily accessible, which reduces the duration of service interventions and minimizes downtime. The new GA 90+ - 160 (VSD+) series of oil-injected rotary screw compressors are a good example. These machines feature newly developed, high-performance screw elements with intelligent injection technology, highly efficient, oil-cooled motors, and maintenance-free gearboxes.
The variable speed interior permanent magnet motors of the GA VSD+ models already meet the upcoming IE5 standard in terms of efficiency. They are dust-tight in observance of the industrial protection class IP66 and resistant to strong jets of water. This means that Atlas Copco compressors operate extremely reliably even in demanding, dust-laden industrial environments - for example in mining, metal processing, or power stations.
The design of components influences frequency of compressor maintenance
The components of modern compressors are developed for speedy service and thus reduced maintenance times. This means that many compressors no longer need to be laboriously dismantled during maintenance, and spare parts can be changed in just a few minutes.
The modular design of Atlas Copco compressors, for example, makes it easy to access all the components when necessary. This reduces the maintenance time by half compared to previous designs. Atlas Copco offers its customers a comprehensive 5-year warranty program for the entire compressor ("Warranty+") to ensure smooth operation even in the toughest conditions. In this case, Atlas Copco will take care of all preventive maintenance, overhaul, repairs, and possible downtime.
Higher level control systems prevent standstill production lines
Downtime can also be avoided by using a higher-level control system, such as the new Optimizer 4.0 from Atlas Copco. The central control system regulates all compressors in an installation and utilizes them efficiently. This is because several compressors are usually combined to form a larger compressed air installation.
This allows operating times to be divided between different compressors, which reduces the risk of failure and facilitates maintenance work.
If one compressor stops - whether as a breakdown or for maintenance purposes - the control system automatically starts another one, thus preventing both a drop in operating pressure and a standstill in production.
