Technology/IT | IDM 4-5 2016 | international-dairy.com · 13 The data generated by the components are first delivered to a master controller, such as the Sigma Air Manager 2 (SAM 2). This controller fulfils two roles: it acts as an actual management system for the compressed air station as well as a central node for the forwarding of relevant data. Advanced management systems such as these must successfully meet some highly demanding challenges. Not least, they must be capable of efficient and, most importantly, predictive compressor control, taking into account a range of contributing factors, such as switching losses, control losses, etc. Another key requirement is the ability to handle the sheer volume of incoming data from the compressor station – these data must be compiled appropriately, then sent on to a superordinate service centre. Multiple levels of functionality These advanced controllers allow for varying levels of involvement by external service providers, so compressed air system operators can still choose to perform all of the maintenance, evaluation and servicing of the system themselves. In this case, the master controller is integrated into the operator’s control system and the data can be requested by any desired part of the company. Alternatively, system operators can simply opt for a conventional service agreement. Or, in order to take advantage of further services, they can choose a predictive maintenance service model, and then there’s the option of remote diagnostics. Real-time monitoring of a full range of sensor data enables immediate response to unusual operating statuses and also lays the foundation for optimal service planning. Thanks to intelligent predictive tools, operators will already know what’s actually going to occur in the compressed air station. Advanced solutions such as these therefore represent the highest level of operational reliability and offer some key advantages: Firstly, operators are released from the burden of performing maintenance and service on the compressed air station. This saves fixed costs in the form of payroll expenses, as well as the cost of investment in their own service management system. Secondly, outsourcing of these services allows customers to benefit from the very latest knowledge and expertise in the compressed air technology sector. The value of this should not be underestimated, since the field of compressed air engineering is now so complex that normal industrial companies are rarely able to maintain such high-level knowledge in-house. Thirdly, outsourcing of these services to a compressed air specialist delivers clear-cut cost advantages. The data from the compressed air station are requested, transmitted and analysed in real-time. This of course translates into a huge amount of data, which, in turn, requires significant investment in IT infrastructure in order to handle and utilise such large data volumes. For most operators, such an investment would be neither possible nor economical. Always up-to-date Moreover, real-time monitoring gives the service provider a detailed picture of what is happening in the compressed air station – whenever desired. Such detailed monitoring is not restricted to the main system components, but can be extended to peripheral equipment as well, such as control louvres, etc. If irregularities occur, a notification is automatically generated in the service provider’s service centre; this then triggers preventative measures to avoid system disruption or failure. In addition, sophisticated algorithms developed by compressed air engineering experts allow specialists to predictively estimate whether potential disruptions may In the station itself, the individual components communicate with the master controller for optimal coordination of compressed air production. The Sigma Air Manager 2 (SAM 2) master controller acts both as a management system for the compressed air components and as a central node for secure data transmission.
IDM_04_05_2016
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