FEATURE COMPRESSORS & COMPRESSED AIR THE TOOLS TO MAINTAIN HIGH STATUS
BOGE Compressors describes how it Continuous Improvement Programme (CIP) assists in achieving the most efficient configuration of compressors using the latest internet-enabled tools
T
he Internet of Things (IoT) is becoming ever more widespread in
manufacturing and helps to ensure that air compressors operate more reliably – and with greater energy efficiency. For example, BI Intelligence estimates that, by 2025, there will be more than 55 billion ‘Internet of Things’ (IoT) devices connected to the internet, compared to around 9 billion in 2017. In that same time period (2017-2025), total investment in IoT is expected to approach $15 trillion, says the report. The ability to share
information in an instant is having a huge effect on manufacturing, especially for large companies that have operations across the world. The ability to monitor and control systems remotely, and have instant access to production information, will play a huge part in boosting efficiency and output. Air compressors are a key underlying
technology within manufacturing and are becoming ever more sophisticated. Imbuing cutting-edge compressors with enhanced IoT capability can give manufacturers worldwide control of multiple compressors and allow real-time machine diagnostics. At the same time, it can boost energy management, which is critical, as air compressors can be the largest single consumers of energy in a production plant. Enhanced connectivity is critical in an
area like condition monitoring. There is an increasing move towards preventive maintenance, spotting potential problems before they escalate, and this is further improved by having process data available in an instant, at any location. Maintenance is critical to air
compressors, which need to be available at all times to provide air for a variety of industrial operations. Incorporating IoT capability into the most modern compressors will ensure that they operate efficiently while avoiding breakdowns, in order to maintain uptime. BOGE is one company putting Industry
4.0 and IoT capability at the heart of its offering to customers with its Continuous Improvement Programme (CIP), for
8 FEBRUARY 2019 | PROCESS & CONTROL
instance. A concept that applies the most efficient configuration to a compressor during its lifetime, at no extra cost to the customer, relies heavily on the latest internet-enabled tools. The High Speed Turbo (HST) range of
compressors have built-in diagnostic and monitoring capabilities. Once installed, the compressor logs its own performance, including energy consumption, and sends this back using a secure network. BOGE uses its own simulation tools to evaluate system efficiency and sends regular reports to customers suggesting any system changes that could improve this.
Interconnectivity is crucial to this function. The overwhelming benefit of CIP, from
an operations viewpoint, is that it boosts the system’s overall energy efficiency, helping to reduce what can be the largest energy bill in the factory. BOGE’s remote monitoring system,
called airstatus, gives worldwide access to air compressors or master controllers. By logging in to a secure account, an operator can access, and analyse real-time data via a single controller. It gives ongoing updates on temperature and pressure conditions, operating and idle time, maintenance status and other attributes. The tool’s functions can be controlled
from a smartphone and fulfils four essential compressed air management tasks; firstly, it can act as a fault transmitter, it sends warning messages directly to a smartphone – either as a text, email or voicemail. Secondly, real-
BOGE’s remote monitoring system, called airstatus, gives worldwide access to air compressors or master controllers
The airtelligence provis 2.0 controller (left) allows users to operate up to 16 compressors and up to 24 accessories
time data queries help operators understand the current status of a compressed air system – from anywhere in the world. Additionally, it is a secure data store, airstatus enables deep analysis – and ongoing optimisation – of the compressed air system, and finally web visualisation of the data makes the system completely transparent, providing a simple overview of the entire compressed air system. BOGE’s plan is to incorporate airstatus in all its “Standard” compressor range before the end of 2019. The connectivity itself is only part of the
story. The key to gathering data is the ability to analyse it – and use it intelligently. Enhanced connectivity helps to enable this. If a compressor shows any sign of
The ability to monitor and control systems remotely, and have instant access to production information, plays a key role in the smart factory
abnormal behaviour, it sends a real-time alert to engineers, who can quickly determine the underlying cause, be it a change in how the customer is using the system, or a potential fault that requires more investigation. If service is required, a service engineer
can visit, armed with a ‘first aid kit’ of the most important compressor components and usually solve the problem in a single site visit. If a physical visit is impossible, due to very tight time pressure, for instance, BOGE can instead perform ‘virtual’ support. Here, ‘smart glasses’ help the engineer to see exactly what the customer’s maintenance technician sees, allowing step-by-step guidance through the repair process. Neither of these options would be
available without the kind of connectivity supplied by IoT-enabled compressors. So, while IoT may seem like a nebulous concept at first glance, examples like this show how it can make a real difference to industrial performance.
BOGE Compressors
uk.boge.com/en
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