INDUSTRY FOCUS CHEMICALS & PHARMACEUTICALS UPGRADE HALVES TRANSFER TIME
Atlas Copco equipment has been used in the upgrade of Sika’s compressed air and nitrogen system, and has delivered improved capacity, quality and reliability
S
ika, a company manufacturing and supplying chemical based products for
the construction and industrial markets, has virtually halved its batch transfer time after installing a centralised and remotely monitored compressed air and nitrogen system from Atlas Copco. The system, which was installed, and is being serviced, by Atlas Copco subsidiary Compressor Engineering, is proving essential in the safe and efficient production procedures at the company’s facility in Preston, UK. It has also allowed full centralisation between adjacent plant installations and provided capacity for expansion. The company operates out of two
manufacturing facilities and five sites including Ireland. The six–acre site in Preston produces Sika’s Liquid Applied Membrane products. Over the years, Sika has invested in both plant and premises, of which the Atlas Copco system upgrade is the latest development. Dry compressed air and a supply of
nitrogen are essential components of the batch mixing production process. Both gases are also used to top off the bulk containers of chemicals prior to sealing them before they are shipped to customers. Airflow is required for valve actuation and to feed the on-site nitrogen generators. The end products have a moisture sensitivity and require nitrogen to assist moisture management while, conversely, ensuring the liquid components aren’t susceptible to combustion. The overall role of these utilities is to maintain product quality and to provide a safe production environment. In Sika’s production processes, the batch
mixing procedure for large volumes of liquid materials is conducted under vacuum in vessels with capacities in excess of 5,000 litres. Batch transfer operations involve removing the vacuum under a nitrogen atmosphere in equally large volumes. The new utilities system, with increased capacity, allows more rapid generation and availability of the blanketing gas. This reduces batch transfer times and virtually halves the transfer cycle duration; improving system productivity and energy efficiency. There is an important safety
consideration too. Much of the material involved within the process presents a flammable and explosive potential. The ready availability of nitrogen offsets that risk. At the same time, and in combination
24 FEBRUARY 2019 | PROCESS & CONTROL
with a dry air supply, it helps to extend the lifetime of valves and solenoids while protecting them from corrosion, thereby minimising repair downtime. The equipment upgrade programme was
initiated after a review of the performance of the site’s entire compressed air and nitrogen system with a view to improving productivity. Following this internal assessment, it was decided that the original installation lacked the capacity to meet peak production demand in the future, with upgrades to the existing equipment impractical. The system was also deemed inefficient. Following a decision to look for a new
provider, responsibility for maintaining the existing system was transferred to Compressor Engineering who conducted an iiTrak peak performance and flow monitoring exercise to determine the best solution for Sika’s production needs. The audit revealed the most logical solution was to centralise the two plant supplies and to replace all of the existing units. Although potential energy savings alone
provided justification for a new equipment purchase, the primary objective was to re- establish system reliability, ensure
The new system has allowed full centralisation between adjacent plant installations and provided capacity for expansion
Dry compressed air and a supply of nitrogen are essential components of the batch mixing production process
adequate back up capacity and deliver a high level of service. Commenting on the need for an upgrade, Lisa Baines, operations manager explained: “It was clear from the beginning that the old system could not cope in terms of capacity, quality or reliability. We also had to pay due regard to the power loading aspect as a cost component.” The final recommendation was to install
three Atlas Copco GA 26+ rotary screw, fixed-speed compressors. This was in addition to a GA30VSD+ variable speed drive unit equipped with a BD250 desiccant air dryer, ancillaries, filters and air receiver. Nitrogen production is provided via two NGP30+ generators with corresponding filtration and individual receivers. Both the compressors and the nitrogen generators were fitted with flow meters as an integral part of the system to help apportion costs between the conjoined sites and assist the remote monitoring operation. The entire system is fitted with Atlas
Lisa Baines said of the improvements: “Capacity, reliability, safety and productivity – every element of the operation has plus points.”
Copco’s SMARTLINK data monitoring programme, which intelligently gathers, compares and analyses data to increase maintenance and service efficiency. SMARTLINK provides Sika UK with a complete insight of its compressed air and nitrogen production, helps to predict potential problems and shows how and where operations can be optimised, and energy can be saved. All components of the centralised
compressed air and nitrogen supply are connected to two new ring mains comprised of AIRnet modular, corrosion resistant aluminium pipework and fittings. The whole system is protected under an Atlas Copco 5-year extended warranty service plan, carried out by Compressor Engineering. Baines is complementary of Compressor
Engineering’s service and aftermarket care. She said: “We have established a relationship whereby they understand the needs of our business and work with us to ensure that the service levels meet our requirements.”
Atlas Copco
www.atlascopco.co.uk/compressorsuk
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52
