Case Study - Food and Beverage Production
With an aged and unreliable compressed air system, mb air systems were approached to provide a best in class energy efficient solution.
Starting with a thorough system ScoreCARD Analysis, validated by airINSITE (SCADA) monitoring, mb air systems provided a brand new and optimised for energy efficiency compressed air system.
The Problem
The installed compressors were oil flooded compressors, which provided a risk
of oil carry over into the compressed air system.
The current system was between 14-28 years old and estimated to be 15% less efficient due to their age. They were also becoming obsolete and regular breakdowns were incurring high repair and backup rental costs.
The Solution
A comprehensive evaluation of the compressed air system was completed to help give focus on sustainability, reliability, and improved air quality to meet the site ISO specification. This was backed up with 2 weeks of advanced data logging -
including volts, current as well as audit system pressure, and flow data.
With all the required data analysis completed, three new efficient oil-free compressors and dryers were selected and installed. The system was completed with new pipework, increased air storage, a master system controller, and Ingersoll Rand Intelliflow valve to further enhance downstream control.
The Results
The system's overall efficiency and reliability was improved by installing correctly sized oil free compressors with variable speed motors which will vary the compressors output and eliminate the offload running costs.
Key Takeaways
Best In Class Equipment
The standout key takeaway from the project was the due to the energy efficiency of the new equipment, it is estimated that 1,317,364 kWh will be saved and 334 CO2 Tonnes will be avoided year on year. Giving a simple payback of under 4 years!
This was mainly down to Ingersoll Rand’s Best in Class equipment:
E250n: 2-Stage, oil free, rotary screw compressor with a state of the art airend and premium efficiency IE3 motors with fully integrated VSD for maximum efficiency.
D5400ec: Thermal mass, high efficiency refrigerant Dryer with filtration to ensure ISO class 1-4-1 air quality, meeting stringent food production requirements.
+£135,000
realised energy savings per annum!
Case Study - New Gasification Plant
mb air systems worked in partnership with Ingersoll Rand to provide a complete backup Instrument Air System for a new Gasification Plant, Singapore.
A high specification packaged skid was designed, assembled, factory tested and delivered. This critical backup system was dispatched on time and on budget, allowing our client no delays to the new plant. The packaged skid included SS316L enclosures, ASME VIII Div1 U Stamped and MOM registered vessels, ASME flanged process pipework and was designed for an outdoor harsh environment.
The Problem
In case of normal IA supply failure an uninterruptible IA Back-up Unit was required. It was critical that the packaged skid was delivered within the set timeframe as the remainder of the plant was dependent on its installation.
The Solution
mb air systems managed the project on behalf of Ingersoll Rand to provide a high spec and reliable packaged skid. With a proven Ingersoll Rand compressor, customised with SS316L enclosures and suitable outdoor modifications, and a reliable twin tower desiccant dryer, with customer specified ASME VIII Div1 U Stamped & MOM registered vessels, this package was designed to succeed.
The Results
A complete solution designed, assembled, witness tested, and dispatched on time and on budget.
Key Takeaways
Fit For Purpose
A key requirement for this package was for the client to be able to rely on the system in an emergency. mb air systems accommodated this by designing a control philosophy with this in mind:-
- Diesel Generator supply combined with UPS Control Feed.
- Power supply monitoring with custom controller software to ensure the system is always ready.
Client DCS monitoring via Modbus TCP
Duplicate Order Placed For 2022 Supply!
Case Study - Gas Terminal
mb air systems were approached to provide a solution for their old and unreliable Instrument Air System.
Working to the restrictions of the old package base, we provided a comprehensive solution that started within the project design office. Our workshop capabilities allowed a full system mock build and functionality test to give our customer the confidence in our design and equipment.
The Problem
The Gas Terminal’s ageing compressed air equipment came with reliability issues to the critical Instrument Air system. Any new system had to fit within the existing package battery limits and be delivered as soon as possible to relieve the existing equipment.
The Solution
New Ingersoll Rand highly efficient variable speed compressors combined with extensive air treatment to provide ‘oil free’ air and a bespoke piping system with maintenance kept in mind.
The Results
A complete solution designed, mock built, witness tested, and ready to be installed on time. Complete with a custom control philosophy to minimise manual change over achieved by the Ingersoll Rand X8i common controller and interconnecting control.
Key Takeaways
Customised Control Philosophy
A complete control system was provided including:-
- Remote Pressure Transducer – Installed in a large air receiver to avoid compressor cycling.
- Ingersoll Rand X8i Common Controller – Ensuring automatic compressor load changeover and equal run hours for improved reliability and reduced manual operator tasks.
- Interconnecting Control between the state of the art Ingersoll Rand compressor and dryer controllers – Ensuring automatic switch over from Duty to Standby incase of failure.
Customised Control Philosophy
Master Case Study
MB Air Systems were approached by ZTL Drilling Ltd to provide a solution for their new workshop with an Integrated Compressed Air System.
MB Air Systems were able to provide our client with a comprehensive solution that started within the project design office. From start to finish the installation was complete after 10 months. 3 weeks ahead of schedule.
The Problem
ZTL Drilling Ltd had recently won three big multi national contracts that meant, bigger premises, more air pressure controlled tools across the entire 9000 Square Metre workshop in Dyce, Aberdeen. Required within 10 months.
The Solution
A bespoke design engineered solution from the team at MB Air Systems to work around the shift patters of the clients production team, causing as little down time as possible. (they were down for a total of 12 hours - over 10 months).
The Results
A complete installation without the fuss, with workarounds over a complex floor plan providing their team with enough compression to run lines to 15 stations over a distance of just over half a mile. The savings from their previous installation one year on. Were quite staggering! 39.5%
Key Takeaways
A Full Ingersoll Rand Compression System
The standout key takeaway from the project, was not just that we delivered ahead of shedule, but the savings year on year for the system install. 39.6%
The Savings were 39.6% Year on year – mainly due to two factors
Heatless 'Zero Loss'
Fitting a soft starter to the compressor (providing the low start up current. representing a saving of approx. 38%)
Air Reciever
Desiccant Dryer with Zero Purge (a further saving of 25% on compressed air).
39.6%
Year on year overhead savings for client
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With over 40 qualified engineers sited across the UK we provide a responsive, competent and efficient service
Get in touch to find out how we can make your life better
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Our Locations
Contact Details
Glasgow / Wishaw (Head Office)
Newcastle / Boldon
Inverness
Aberdeen
Southampton / Fareham
Energy Saving
Compressed air is a versatile, reliable and safe way of transmitting energy, is often considered as the fourth utility after electricity, gas and water and is used by almost all industrial businesses.
mb air systems has a key focus to help our customers optimise their energy usage and assist in driving down operational costs and make their compressed air systems as efficient as possible.
Click the image links below to learn more about what we have to offer.
The industry standard of compressed air leakage rate is 10-30% of the compressors annual energy consumption and can be one of the biggest costs to a system's efficiency. We utilise an ultrasonic leak detector to identify the source of leaks in your system and provide a detailed report showing the location, estimated size and cost of the leaks. We can provide costs for repairing each issue and reducing wasted energy.
Ingersoll Rand System ScoreCARD
mb air systems can complete a comprehensive evaluation of your compressed air system. We will use the System ScoreCARD to identify opportunities for a more reliable and energy efficient system. Your system will be scored based on supply & demand side efficiencies and equipment reliability. A grade card will be issued to help you focus on sustainability, reducing CO2 emissions, energy savings, reliability, and to give you a better understanding of your site's compressed air system.
airINSITE
mb air systems can provide an advanced data logging solution - airINSITE - that enables compressed air systems to be easily audited for energy efficiencies.
Data loggers incorporate high quality sensors to collect and store information including volts, current and true power from individual air compressors as well as audit system pressure, temperature, moisture dew point and flow data.
mb air systems then analyse the date to provide our customers with the most energy efficient and practical solutions.
To contact our team and book an audit click here.
Servicing and Repair
Our service teams’ mission is to make your life better. We are trusted by the country’s largest brands who a recognise our responsive, competent and efficient service. Get in touch to find out how we can make your life better.
Our service teams’ mission is to make your life better. With over 40 qualified engineers sited across the UK we provide a responsive, competent and efficient service.
mb air systems offer a genuine 24/7, 365 days a year call out service to meet our customers needs at the most critical time. We understand that an emergency breakdown in your compressed air system can be critical to your business operation, so we are here to help.
We at mb air systems recognise the importance of a dependable system at our client’s sites and through a structured approach we develop tailor made maintenance solutions that utilise skills, knowledge, latest technology, best practices & processes to deliver a best in class service. Our service contracts consist of preventative maintenance in line with OEM recommendations carried out by authorised service professionals using genuine OEM parts.
SelectCARE™ is the perfect solution for our customers. An all-in-one maintenance program for new Ingersoll Rand rotary compressors and air dryers helps you to keep your system running at maximum efficiency 24 hours a day, 7 days a week. This covers regular maintenance, spare parts, consumables, lubricants and emergency breakdown service.
SelectCare provides total peace of mind, bringing together contract maintenance and preventative
Our material handling division is recognized and respected throughout the Oil & Gas Industry as one of the leaders in developing new ideas with our particular strength in man-riding winches.
We provide regular lifting and man-riding training for the Oil & Gas and Drilling Contractors' personnels from our Aberdeen Branch. The training includes all applicable Health & Safety matters and best practice guidelines as well as new designs and innovation relating to offshore lifting activities.
Power Tools & Starters
Along with Air Starters & Air Motors, Ingersoll-Rand has provided tools for Assembly, Impact, Finishing and Construction applications for more than 125 years, combining the best engineering talent, top quality materials, and the strongest support in the business.
Click the image links below to learn more about what we have to offer.
300,00+
Products Available
2799+
Number of Projects
80+
Employees
5+
Locations In UK
Winch and Hoists
Ingersoll Rand specialise in the design, manufacturing and marketing of a comprehensive and modern range of chain hoists and winches; air, electric or hydraulically powered, with lifting capacities from 150 kg up to 200 metric tonnes.
The IR hoist and winch range incorporates the best ideas and innovations to solve the most challenging lifting, pulling and positioning applications in the world’s toughest industries.
Click the image links below to learn more about what we have to offer.
300,00+
Products Available
2799+
Number of Projects
80+
Employees
5+