Cost Savings of 42% from New Compressors Supplied and Installed by CPA

CPA were approached by client Mitsubishi who were looking for a cost saving solution within their manufacturing facility. We carried out a detailed audit to determine the current operational costs as well as the energy, electrical and air consumption of their current fixed speed compressors. From the data obtained we were able to predict cost savings of 27-29% by removing the existing compressed air system and replacing it with Gardner Denver variable speed compressors.

The actual savings made from these two variable speed compressors, supplied and installed by CPA, far exceeded the initial cost saving predictions - actual cost saving was 42%.

Our client went from running three compressors to running one compressor (running the two new compressors week about), providing energy savings and reduced servicing costs.

Additional benefits included reduced noise level meaning ear protection was no longer required and the newly installed ducting allowed the normally wasted exhaust heat to heat the plant.


New compressors fitted with heat recovery ducting

 

Are you wasting money on your energy usage due to improperly sized compressors, air leaks or ineffective pneumatic equipment?

Contact us to have an air energy audit carried out on your site.

Tel: 01501 825 024  Email: cpa@cpa-group.com

 

CPA Engineered Solutions Ltd, partners with the Warehouse Technology Group.

The Warehouse Technology Group (WTG) is a unique collaboration of 20+ companies involved in the manufacture and supply of specialist equipment to the warehousing and logistics industry. WTG provides an unbiased insight into the latest technology available to companies operating warehouses and distribution centres. (www.wtglive.co.uk) CPA’s product range with in the WTG includes the Enershield Air Barrier and High Volume, Low Speed (HVLS) destratification fan.
 

Enershield Air Barrier

CPA manufacturers the Enershield Air Barrier and distributes them for the European and UK market. An Enershield Air Barrier is an innovative energy saving entrance solution for all types of buildings. Using an accurate and controlled vertical downward flow of air to produce a 'virtual' door and create up to a 90% seal over an opening. The airflow effectively separates the atmospheres on either side and reduces the transfer of temperature, dust, insects, fumes and odours.  Enershield Air Barriers are designed to be unheated and to recirculate existing ambient air. With greatly reduced running costs and improved effectiveness they provide replacement technology for traditional heated 'air curtain' comfort systems, with energy savings of up to 35%.

 

High Volume, Low Speed Fan

The high volume, low speed (HVLS) ceiling fan which gently distributes the heat trapped at the ceiling back down to occupied levels, equalising the air temperature between floor and roof level. Operating solo or accompanying an Enershield Air   Barrier, HVLS fans are key to meeting thermal comfort requirements in any building. These fans not only provide destratification during the heating season but also benefit the user during the summer when ambient temperature rises; the fan speed can be increased to provide a breeze like cooling effect.

 

Visit the Fully Operational Warehouse

WTG has created a fully working warehouse known as the Logistics Research and Innovation Centre (LRIC) in North Manchester. It comprises a 12,000 square feet unit fitted out by the partners. The equipment is functional, operating and in daily use.  Visitors can come along to view both our demonstration units (Enershield air barrier and HVLS fan) operating in a real life warehouse application. 

  

Tel: 0870 241 2452

Fax: 0870 241 2421

E-mail: cpa@cpa-group.com

Website: www.cpa-group.com

                                         

 

 

                                         

 

 

 

 

CPA Engineered Solutions Ltd supply a new compressed air system giving Oceaneering a lift

 Innovative Compressor Solution Gives Oceaneering a Lift

Customer: Oceaneering Umbilical Solutions

Application: Loading subsea cable systems on to carousels

Oceaneering Umbilical Solutions (Oceaneering), a global leader in the design and manufacture of subsea cable systems is achieving reliable, on-time loading of its cable carousels thanks to a new compressed air system from CPA. The three 250kW, Gardner Denver (GD) compressors are providing an on-demand supply of air to the air skate equipment. This is used to lift the heavy umbilical cables on to the carousels before they are loaded on to the waiting vessels at Rosyth dockyard for delivery to the end customer.

Benefits at a Glance

• · On-demand, reliable air – helping to mitigate the risks of £000s in delivery delays.
• · Efficient, packaged solution – matches air output to demand
• · Comprehensive service maintenance plan – ensuring optimum equipment performance.
• · Robust design and low-noise levels.

Application Details

 

Robust and reliable compressed air is an essential requirement for the loading process as delays in loading mean that the installation vessels cannot leave the port. Resulting costs can costs be thousands of pounds.

 

Oceaneering’s existing compressors from a previous supplier were around 15 years old and, although maintained by CPA’s service team for the past four years, it was becoming difficult to source components without long lead times.

 

CPA carried out a full air energy audit, analysing air demand and energy consumption and, following a tender process, was awarded the contract to supply new GD equipment.

 

Charlie McCartney, manufacturing support manager at Oceaneering explains: “CPA has been providing high-quality service for our existing compressors for a number of years now, so we were confident that the support infrastructure would be in place to ensure equipment reliability. However, we also found that the Gardner Denver compressors offered superior technology to some of the other models we considered, making CPA a natural choice of supplier.”

The CPA Total Air Solution

The new compressor package incorporates two fixed-speed ESN250 models and a VS250 variable-speed unit running at 8-bar pressure. A bespoke control interface helps distribute running hours evenly across the units and refrigerant dryers provide dry, quality air.

Previously, Oceaneering was using three fixed-speed compressors running continuously, which as Charlie McCartney explains, was very wasteful:

“Our old compressed air system was, at times, generating too much air for our requirements meaning that we were wasting energy. Now the two 250kW fixed-speed compressors meet the majority of our air demand, with the variable speed model coming on line to meet peaks in production. We can also alter the pressure band through the control system to cater for variations in demand.

“In addition, because we have invested in the latest compressor technology, the machines are running much more efficiently than before, helping us to reduce our electricity consumption too.”

The GD compressors combine reliable and easy-use operation with high efficiency. Designed to meet the rigours of continuous 24/7 operating demands, the compressors also feature a robust design and low noise level operation.

CPA will also be maintaining the new compressors under a new planned maintenance service agreement which includes the supply of genuine spare parts.

 

 

"CPA has been providing high-quality service for our existing compressors for a number of years now, so we were confident that the support infrastructure would be in place to ensure equipment reliability."

Charlie McCartney, manufacturing support manager at Oceaneering

 

  

 

Maximise the efficiency of your compressor

AVOID CATASTROPHIC MACHINE FAILURE THIS SUMMER

Get your cooler cleaned by CPA.

 

 

WHY?

The Cooler is the principle component which allows heat to be removed from the lubricating oil (coolant) and discharge compressed air .  As the lubricating oil  passes through the cooler, atmospheric air is forced through the fine fins of the cooler, transferring the heat to atmosphere and lowering the temperature of  the lubricating oil. As a guide, most oil injected screw compressors like to operate at a temperature of between 82 to 86°C. The compressors coolers are similar in design to  your car’s radiator but working in more extreme environments, overtime, the Cooler can become choked with dust and debris, which restricts the airflow and stops the all important transfer of heat.  As a result, the compressor runs at increased temperatures.  When the seasons change and ambient temperatures increase, the problem is compounded.  Warmer air is being drawn into the compression process and the air available for cooling is also warmer.  During the summer months, the cooler is working hardest and risk of failure is greatest, temperature’s in excess of 115°C can be reached, causing the activation of safety devises and emergency machine shut down.

 

  CONSIQUENCES OF A DIRTY COOLER

· Halted production and H&S implications from catastrophic machine failure as a result of both overheating and failure of temperature safety systems.

· Production stoppage from compressed air plant shut-down triggered by over temperature.

· Increased bearing wear from heat degradation of lubricating oil resulting in premature Airend failure.

· Damage to the cooler resulting in expensive replacement.

· Increased service requirements and costs due to prolonged overheating of components E.G. hoses, belt.

· Increased workload on air dryers through higher discharge air temperature.

 

BENEFITS OF HAVING YOUR COOLER CLEANDED

· One possible risk to production now eliminated.  

· Prolonged equipment life.

· Servicing costs back to planned maintenance routines.

· Improved machine efficiency and performance.

· Increased equipment uptime.

· Proactive maintenance which allows you to focus on improvements rather than repair.  

· Peace of mind.

· Improved energy efficiency through higher air density.

 

 

WHAT IS THE SOLUTION? 

CPA will attend your site to drain the coolant, dismantle the compressor, mechanically remove the cooler, carry out off-site cleaning, reassemble equipment, renew coolant and oil filter and run and test the machine.

 

 

For more information please contact us. Tel: 0870 241 2452 or email sales@cpa-group.com.

 

Web: www.cpa-group.com

 

 

 

 

At CPA, our mission to bring quality products to our customers goes back to source.

Pictured here is our Service Manager Rodger Kerr and Sales Manager for Scotland, John Haddow at the GD Bottarini factory in Lonate, Italy where they witnessed flow testing in action.

Every compressor that CPA brings to the UK market is tested in accordance with ISO1217 to compare the power output against the power input and to prove the efficiency rating.  Energy is a scarce and expensive resource and CPA works to ensure that your efficiency is maximised.  To do that, we consider very carefully the equipment that we promote.  We hope that you will consider this too when you are evaluating not just purchase cost, but lifetime cost, against quality.

How to prevent the ingress of harmful air pollution from entering your building through an open doorway.

It was reported today that sand and dust from the Sahara mixed with local emissions has resulted in high levels of air pollution across parts of the United Kingdom causing potential health problems for all. In particular, individuals with lung or heart problems have been advised to minimise their exposure to this polluted air.  Staying indoors does not necessarily protect you from this harmful and potential life threatening air as when a doorway is open there is nothing to stop it from entering a building and pollution your indoor air. 

According to the BBC, Joe Hennon, the European Commission's spokesman on pollution, said around 30,000 people in the UK die prematurely every year from problems associated with air pollution and described it as a "silent killer". http://www.bbc.co.uk/news/uk-26856285

Protect yourself and stop this polluted air from entering your building through an open door by installing an Enershield Air Barrier!

The Enershield Air Barriers creates a “virtual door” by re-circulating ambient air and forcing it across an open doorway to create up to a 90% seal.  The seal separates the atmospheres on either side and prevents the transfer of temperature, humidity, dust, pollution, odours and insects whilst allowing pedestrians and vehicles to pass freely.  See the diagram below.

 




For more information on Enershield or to see how an Enershield Air Barrier could protect you whilst saving you money on energy bills visit www.enershield.eu

Engineer Vacancy

Service Engineer - Maintenance and Repair

CPA Engineered Solutions Ltd is a progressive engineering service company.  We provide an innovative range of products and services including industrial air compressors, air barriers, energy recovery fans and HVAC equipment.  We deliver production maintenance solutions to a wide range of clients in sectors ranging from manufacturing to retail.

As a result of continuing growth, we require experienced multi-disciplined engineers to join an established service team.  Enthusiastic, energetic and self-motivated, you will be charged with providing clients with first class service in the maintenance and repair of their equipment.

Essential attributes:

• ONC/HNC in Electrical or Mechanical engineering.

• A minimum of 5 year experience as a service engineer/multi-skilled engineer in the Electro/Mechanical maintenance industry, working with 3 phase power systems.

• Excellent fault finding skills.

• The ability to deliver customer satisfaction and build long-term customer relationships.

• Effective and accurate communication with customers and colleagues.

• Excellent organisational and time management skills.

• Ability to operate with minimal supervision yet successfully interface with various departments and personnel in potentially stressful situations.

• Clean UK driving licence.

• IT literacy - job reports, timesheets and product documentation are all handled electronically.

Experience with the following equipment would be beneficial: Industrial air compressors, refrigeration systems, medium pipework, HVAC and rotating equipment.

Reporting to the Service Manager, you will be based at our head office in Shotts, Lanarkshire.  The majority of our work is within the Central belt and is spread between our workshops and client sites, occasional travel throughout the UK and Ireland will be required.

The varied nature of our product offering and the diversity of our client base will ensure that this is an interesting and challenging role.

Working hours are 8.00 to 4.30, Monday to Friday.  Occasional overtime may be required.  The package will reflect ability and experience. Vehicle, tablet PC and mobile phone will be provided.

This is a fantastic opportunity for an individual with a drive to succeed and become an integral part of a forward thinking Company’s plan for the future.

Apply in writing enclosing CV to Rodger Kerr, hrs@cpa-group.com or visit www.totaljobs.com. Only successful candidates will be contacted for interview.  Closing date for applications: 9^th December 2013

 

For more information on CPA Engineered Solutions visit www.cpa-group.com