Reference HORSCH

PROJECT/REQUIREMENTS

For the project ‘New construction of a hall for the powder coating plant’, great importance was attached to high operational reliability of the compressed air supply and compressed air treatment. The requirements for the treatment line included a redundant design and compliance with compressed air quality in accordance with DIN ISO 8573-1, class 1:4:1.


For the energy-efficient compressed air supply, evenly utilised, regulated compressors were used that operate with minimal idle times. In addition, a heat recovery system was to be integrated which, in combination with an intelligent control system for the supply and exhaust air in the compressor room, utilises the waste heat efficiently. Continuous monitoring of the energy values should enable fast response times for maintenance and fault messages.

SOLUTION

Project discussions were held in advance with Horsch and the specialist dealer Janetschek regarding compressed air consumption, quality, compressor room management, energy balance and heat recovery.

Based on this, room plans and technical drawings were drawn up. The feasibility was checked with regard to statics, water pressure testing and monitoring of the compressor station.
Operational reliability is ensured by three compressors, each of which generates 50% of the compressed air. In addition, two refrigeration dryers with energy-saving control and a pressurisation system are used to ensure the quality of the compressed air in the event of pipe bursts.

IMPROVEMENT

Bei der Umsetzung des Projekts konnten mehrere Verbesserungen erzielt werden. Die Steuerung der Kompressoren wurde optimiert, um die beste Auslastung in Bezug auf Energieeffizienz, Betriebssicherheit und Langlebigkeit zu gewährleisten. Zudem wurde eine umfassende Visualisierung integriert, die das System Industrie 4.0 möglich macht.

Ein effektives Stör- und Alarmmanagement sowie ein integriertes Energiemanagement sind ebenfalls implementiert worden. Das Projekt erfüllt die Anforderungen des DIN ISO 50001 Audits und umfasst zudem eine Raumtemperaturüberwachung, um die Betriebsbedingungen kontinuierlich zu optimieren.