vpvision - innovative instruments · 2017. 11. 3. · to allocate pressure differences in the...

VPVision5 september 2013

© Van Putten Instruments BV

What is it?

•Monitoring system for compressed air•Real time data overview•Historical data overview•Graphical interface•Standardized and scalable

• Standardized hardware • Multiple factories can be

interconnected• Multiple sensors logged in one

system

VPVisionVPVision

Trends:

Global:oThe climate change challengeoEnergy prices increase rapidlyoISO 50001 directiveoISO 11011 directive

Specific to compressed air:oCost allocation of compressed airoMaintenance management oEfficiency monitoring

“Recent climate models suggest that ice-free conditions may happen before 2050, though the observed rate of decline remains faster than many of the models are able to capture,”

Global trendsGlobal trends

Energy prices

Global trendsGlobal trends

Energy Management ISO 50001

Business as usual is not an option.Energy management is key to savings.

System optimization can attain efficiency gains of 20-30%.

http://www.iso.org/sites/iso50001launch/assets/docs/01-Rob_Steele_Introduction_to_ISO_50001.pdf

ISO 50001ISO 50001

6

Why measure?

To allocate pressure differences in the system

To correlate flow vs dewpoint. High flow & high dew point -maybe dryer overloaded? Not sized correct? Low flow vs high dew point, dryer might not be working correct?

To correlate kW in vs pressure and flow out.

Use VPVision as a maintence tool.

Pressure drop point 5,65 barHighest pressure point 6,69 bar.

If you know where P drop is occuring maybe a pressure vessel can solve the problem?

Why should you use the VPVision monitoring system?

•VPVision provides real time data: instant feedback •Permanent monitoring is key to savings persistence•Access any time, any where. Even as an external auditor you can remotely advise your client.

Why VPVision?Why VPVision?

Why should you use the VPVision monitoring system?•It visualizes your complete compressed air system in real time.•Stimulates the awareness •Shows all important data in a understandable overview •Quick access to your data and easy configuration•Specially modified for the technical department responsible for maintenance •Generate detailed reports for management; costs vs production •Alarm options to guard your system •Easy integrated to existing systems

Why VPVision?Why VPVision?

o Centralized database All data is synchronized in a SQL database. This means copy and pasting of separate files into one is something of the past

o Intuitive configurationNo need of complicated PLC or other system to read out sensors. Click, drag, drop.

o Web based interfaceConfiguration of VPVision is made easy. VPVision can be used by everyone within a company network or via smart phone.

o Universal and hardware independent VPVision supports all sensors that communicate through Modbus or 4..20mA. Limitless: feel free to add any sensor you like.

Key featuresKey features

VPVision provides an understandable graphical display of your system.

oPeriodic reportsoPie Charts & Real time line graphsoReal time dashboardsoDemand side monitoringoEfficiency monitoringoCSV export, customized

Functions and optionsFunctions and options

3G

TCP/4..20

ethe

rnet

TCP/485RS485

Converter

IO ModuleTCP/485

RS485

Converter

VPVision MYour PC/ Tablet/ Phone

System architectureSystem architecture

SQL Webserver

Any Modbus/TCP

sensor

RS485

RS485

Depending on the quantity and size of the compressors the return of investment varies from 3 months up to 1 year. The Calculations in the following sheet are based on a estimated percentage of leakages and Kw consumption:

Return On Investment!Return On Investment!

Equipment investment 85.000,00€ Leakage/ savings potential 29%Production hours per day 24kW price 0,15

Kw KW/ YEAR EURO USD EURO/ Year USD/ Year ROI (Days)250 2.190.000 328.500€ 394.200$ 95.265€ 114.318$ 321300 2.628.000 394.200€ 473.040$ 114.318€ 137.182$ 268500 4.380.000 657.000€ 788.400$ 190.530€ 228.636$ 161750 6.570.000 985.500€ 1.182.600$ 285.795€ 342.954$ 107

1000 8.760.000 1.314.000€ 1.576.800$ 381.060€ 457.272$ 80

Savings potentialAnnual electricity bill

DEMODEMO

Project step by stepProject step by step

Step 1: use the worksheetStep 1: use the worksheet

Use the VPVision worksheet, to gather all relevant data:o Compressors: kW, Voltageo Air treatmento Main areas (header)o Demand side machines (buildings, subdivisions)o Get an account at www.vpinstruments.com

Step 2: Project preparationStep 2: Project preparation

System layout-Location of all compressors and other equipment-Location of consumption points-Air treatment equipment, filters, driers


System layout: P&ID styleoLocation of all compressors and other equipmentoLocation of consumption pointsoAir treatment equipment, filters, driers

125 kW

125 kW

75 kW

Drier #1 Filter

Mainreceiver

DP

Mai

n he

ader

Area 1

Area 2

Area 3

Area 4

Dew pointsensor

FPT

FPT

FPT

FPT

FPT

FPT

FPT

FPT VPFlowScope insertion meter (flow, pressure, temperature)


System layout: P&ID style-Location of all compressors and other equipment-Location of consumption points-Air treatment equipment, filters, driers

Area 1 supply

M1 M2 M3

VPFlowScope in line meter (flow, pressure, temperature)

M1 Production machine

M4

Tool shop

FPTFPT


Basic ingredients

VPVision MVPFlowScope’sAmp metersModbus JB

Options:Dew pointDifferential PTemperatureDemand side


ΔPΔP

CdpCdp

1

2

3

4

5

6

7

8

Carbon filter Dry air receiverWet air receiver Twin driers

FPTFPT

FPTFPT

FPTFPT

FPTFPT

FPTFPT

GA45

GA90

SRMM75

AA

AA

AA

Equipment list

•VPS.R150.P400: 5pc•Dew Point: 1pc•DP sensor: 1 pc•P sensor: 1pc•Amp meter 3 pc•VPVision M: 1 pc•Service contract!

Don’t forget-Check Amp meters-Check pipe sizes-Power supply?-VPVision location?


Part nrPart nr


System layoutoDetermine cable lengthsoSplit up of sub-networks (RS485, Ethernet, Analog signals)oPower supply (mains) locations: accessibleoVPVision location: avoid hot environments (fan-less PC) oNetwork:

o List of IP addresseso VPN accessibility for remote support

Cable tips & Tricks- > 5 flow meters?- > 50 meter length?

Call a specialist!


Electrical schematic for subcontractorTip

Electrical scheme helpsto visualize the completeproject before installationand can be used asproject documentation.

Note: Power supply up to 8

VPFlowScopes and 8 4- 20 mA sensors.

For more sensors additional power supply is needed.

Remote input optionsRemote input options

Three main options:

Analog inputsFor 4..20 mA sensorsAmpere/ Current metersPressure sensorsTemperature, dew point sensors

RS485 (Modbus) inputsVPFlowScope meters,Some kW meters

Ethernet useRS485- Ethernet converterskW meters

VPVision M contentsVPVision M contents

o 8 RS485 signals on one porto 8 analog signalso Report module

Power terminal

Analog input module

Modbus terminalComputer

Power supply

Modbus junction box for RS485 networksModbus junction box for RS485 networks

Tip

Each Modbus junction box has a built-in

termination switch. This switch activates the termination resistor. You should only use ONE Resitor at the end of the chain.

Available IO modulesAvailable IO modules

Model RS485/TCP 4..20 mAPower supply Application

VPA.5030.011 X Power extension

VPA.5030.111 X X VPFlowScope via ethernet

VPA.5030.211 X X Analog input via ethernet

VPA.5030.311 X X X VPFlowScope + Analog via ethernet

VPA.5030.011

VPA.5030.111

VPA.5030.211

VPA.5030.311

RS485 versus EthernetRS485 versus Ethernet

RS485 or Ethernet?

oSize of the siteoInstallation timeoMax. 1200 meter cable lengthoInterference issues, safetyoNumber of VPFlowScope devices (max 8 per subnetwork)oCosts for cable installation

Important

Contact the experts when having daisy chains of 1200 meter and multiple sensors attached. We need to take power loss into account and might advise an extra power supply in the chain.

Step 3: ImplementationStep 3: Implementation

1. Mechanical installation1. Flow meters/ Insertion points2. Power meters, other sensors3. Cabinets, junction boxes

2. Wiring/ Electrical installation1. Main cables (Ethernet, RS485)2. Junction boxes3. VPFlowScopes4. Analog sensors

3. Configuration1. VPStudio VPFlowScope2. Modbus devices3. VPVision M4. Web interface5. Report configuration

Software ArchitectureSoftware Architecture

Input Devices

Widgets

Pages

Report widgets

Reports

Real time Reports Alarms

Alarm functions

Tip

Input devices are the core of VPVision. As long as an input device is active, it’s data will be stored in the data base, in SI format. Widgets and reports are just views on the data.

Software ArchitectureSoftware Architecture

Input Device

Widget

Page 1

Report widget

Real timeReport 1

Input Device

Input Device

Widget

Page 2

Report widget

Report 2

VPVision M – main unitVPVision M – main unit

Included in any project:oVPVision M, pre-installed softwareoReport moduleoUser manual (PDF and hard copy)oInstruction manuals for individual components (Digital format, PDF)oSimplified schematic of the compressed system (PDF)

VPVision M options and exclusionsVPVision M options and exclusions

Optional itemsoFlow sensorsoDew point sensorsoCurrent clampsoJunction boxesoRemote IO boxeso3G moduleoAdditional software functions

Excluded in any project:oField cablingoPower cable (mains)oElectrical installation laboroMechanical installation laboroSmall mounting items (screws, nuts, bolts, patch wires, ethernet patch cables)oVPN connection hardware & VPN Installation

Alarms preview!Alarms preview!

vpvision - innovative instruments · 2017. 11. 3. · to allocate pressure differences in the...

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