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Simulations generator startup thanks to update to controller

In today’s world, we rely on electricity for just about anything we do. From uploading this post, charging your phone, or even car, to your entire operation. When we look towards the future, that dependence will only increase because we’re all slowly but surely moving away from traditional fossil fuels.

Increased reliance comes with risks. A loss of power can impact your day-to-day operation more than ever before as well. A loss of power is accompanied by a significant financial impact, inefficient production, and even life-threatening situations. Preparation is critical because these events are often not predictable.

One at a time

A traditional backup generator startup takes time. The first unit needs to reach nominal speed and voltage. As the next generator gets ready, that unit, in turn, has to be synchronized with the previously connected generator to prevent irregularities. This process then has to be repeated until the last backup unit is running.

By adding a new feature to the trialed and tested Atlas Copco Rental generators equipped with the QC 4003 controller, we are able to deliver the required power level in less than 10 seconds. This small change allows for the simultaneous startup of all connected units, bringing voltage to the required levels at the speed it takes to push a button. How are we able to do it?

Up and running before you finish this sentence

When faced with a power outage, and the main breakers are opened, the controllers crank the engines but do not activate excitation yet. As soon as the Atlas Copco Rental generator’s engines are running at around 400 RPM, all breakers are closed at once, connecting the generators to the bus bar. At around 900 RPM, the automatic voltage regulation feature of the controller activates excitation for all connected units, driving up voltage to nominal power in a controlled manner. No matter how many generators are connected to the bus bar, the process can be completed in less than 10 seconds.

When faced with an emergency, you can now have backup power quite literally in no time.

Making maintenance frictionless for major Brazilian paper manufacturer

Maintenance is one of life’s necessary evils. We would all like to do without it but at the same time, we know we can’t. What we can do, however, is ensure its done efficiently, effectively and with minimum impact on “business as usual”.

While most people think only of the direct costs of hiring technicians and buying spare parts, when you consider the full impact and risks associated with maintenance operations, the real costs can be significantly higher!

So when one of Brazil’s largest pulp and paper manufacturers needed to conduct a full overhaul of their process-critical compressors, they needed an absolutely failsafe back-up solution. 

A solution that would ensure a seamless transition, next-to-no production downtime, full compliance with health, safety and environmental guidelines and zero impact on the quality or quantity of their output.

Mission impossible? Not for Atlas Copco Specialty Rental’s team in Brazil. They got the full package set up in just 1 day – albeit after months of meticulous planning!

Maintenance matters

Two simple facts capture the constraints of this challenging project:

  1. compressed air is absolutely critical to the plant’s operations, since it powers the majority of the processing, transport and instrumentation over its 1000-metre-long production line, and
  2. while giving both of the plant’s 13,200m3/hour centrifugal compressors a complete overhaul would take up to 2 weeks, interrupting production for even a few hours was absolutely out of the question. The strict demands of the manufacturer’s predominantly export business simply did not allow for any reduction, let alone stoppage in production whatsoever. Needless to say, reliability was going to be a key factor in choosing the right solution.

Quality as well as quantity

delivering 13,200m3 of oil-free compressed air every hour, 24 hours per day and for what turned out to be 10 days of continuous operation – not to mention ensuring a stable supply of fuel to produce it all – is already quite a mathematical equation!

On top of that, the limited floor space at the plant meant that all that air had to be compressed on a tiny footprint.

But it wasn’t just size that mattered in this particular project. In fact, the quality of the air was at least as important as the quantity. Being able to deliver pure air that was 100% free of oil and other contaminants was not only essential for the quality of the final product but also the longevity of the plant’s highly specialized machinery. Any blockage to one or more of its approx. 1000 valves, instruments and other sensitive components could have had disastrous consequences.

A failsafe solution

To meet the customer’s strict demands, Vanderson Lopes, Business Line Manager and his team designed and coordinated a comprehensive solution that covered every aspect of the switch to back-up air: “We proposed an array of 5 state-of-the-art PTS 1600 100% oil-free compressors to take over the job from the plant’s centrifugal compressors as they underwent maintenance one at a time. At the customer’s request, a 6th unit was added to the package to serve as a back-up in case of a breakdown or other failure. However, that scenario never eventuated, and the back-up was never used.”

Reliable equipment is one thing. But even the best compressors in the world can’t run without energy. “Our service went beyond just the rental of the machines. We offered a genuine total solution that included transport, installation, 24/7 operation, comprehensive monitoring and testing and meticulous fuel management,” explains <Cesar Avanci, Technical consult of Atlas Copco Rental>. “We took care of the delivery, storage and constant supply of diesel without any shortages, spillages or leakages. Also important to note is that our solution fit comfortably and safely within the plant’s limited floorspace, whereas most competitor solutions would have required twice the footprint to deliver the same flow rates.”

Speed = profit

The full package of 6 PTS 1600 compressors including auxiliary fuel tanks, hoses and connections was delivered, assembled, tested and commissioned by our local team in just 1 day. And after the successful completion of the project, it was all disassembled and removed with the same level of speed and efficiency.

Given that process speed often has a far greater impact on profitability than most cost-cutting measures, that level of agility should always be an important consideration in any processing or production environment. All in all, it was just the icing on the cake of a flawlessly executed project that resulted in one very satisfied customer.

Atlas Copco Rental Italy delivers oil-free air quickly

Breakdowns always happen when you least expect them. In this case on a late Thursday afternoon. Two of their compressors decided to call it quits. Our Italian team took on the challenge, and everything was up and running again quickly.

Our customer is a large multi-utility company in Italy and operates in a variety of sectors ranging from electricity, thermal energy for district heating and gas, to the management of integrated water services, environmental services, and technological services.

Race against the clock

Of course, everything has to happen as soon as possible. However, in Atlas Copco Rental’s case, our soon is very soon. And, it’s always possible.

In about 20 hours our equipment was on our customer’s site.

100% right solution with 100% oil-free air

The high-end ZT160 VSD uses state-of-the-art screw technology, cooling and pulsation dampers and provides you with the highest reliability.

The ZT offers you 100% pure, oil-free air that complies with ISO 8573-1 CLASS 0 (2010) certification. This means zero risk of contaminationZero risk of damaged productsZero risk of losses from operational downtime. And zero risk of damaging your company’s hard-won reputation.

Even when you have to rely on temporary equipment, you do not have to compromise! Thanks to the coordination between Rental Desk, Sales, Logistic, and Service team, the equipment was delivered on time and we met, and exceeded our customer’s expectations!

Atlas Copco Rental provides large volumes of compressed air – fast!

When a global leader in specialty chemicals needed help generating large volumes of compressed air — with extremely little time available for getting the needed equipment in place — Atlas Copco Rental had a powerful answer, and was able to provide it quickly.

After the company’s chemical facility in northeastern Mississippi suffered a stationary compressor failure, the need for supplemental air was urgent — without it, the plant would have to be completely shut down. Time was of the essence, and only the right equipment could meet the need.

A successful solution

Fortunately, Atlas Copco Rental’s Covington, Georgia, branch had the needed equipment on hand, and could get it to the plant on short notice. Personnel from Atlas Copco Rental delivered and installed a ZH 9000 oil-free centrifugal air compressor within 10 days of getting the call.

Provided as a plug-and-run package, the ZH 9000 was delivered directly to the worksite in its integrated, 40-foot-long, weatherproof transport container to become a stand-alone mobile air power plant, with only electrical and water hookups needed for the equipment to spring into action. Once placed, the high-volume compressor was capable of providing compressed air at 140 psi (10 bar), offering a maximum flow of 9,000 cfm (254.9 m3/min) — and could do so with an energy-saving design and guaranteed reliability. Further, the provided unit was able to meet needs for constant air or could handle processes with fluctuating air demands. And with its ISO 8573-1 Class 0 certification, the 100% oil-free air supplied by the ZH 9000 was guaranteed not to contaminate the plant’s end products.

When the client needed powerful, high-quality equipment in a short period of time, Atlas Copco Rental met the need fast — and kept the plant’s work on track.

Capitalizing on synergies to commission Omani plastics project in record time

Getting process piping ready for commissioning typically involves a complex array of tasks. And since they usually come at the end of an equally complex construction process, those tasks also typically involve extremely tight deadlines!

In such situations, being able to count on a reliable partner with a proven track record often means the difference between making or missing your project deadline. So it’s little wonder that GS Engineering & Construction called on Atlas Copco Rental to work around the clock – and often against the clock – to help complete their contribution to Oman’s ambitious Liwa Plastics Project.

A high-profile project

The Liwa Plastics Industries Complex is the cornerstone of a major expansion project within the Suhar Industrial Port Area refining and petrochemicals cluster. Once operational, it will not only boost Oman’s export trade but most importantly, stimulate the development of a whole new downstream processing industry within the sultanate. As such, this flagship project has been the subject of considerable media attention. As the main EPC contractor for the project, GS Engineering & Construction was under significant pressure to deliver the project on schedule.

Multiple challenges

GS Engineering & Construction is responsible for the construction of a NGL extraction plant within the Liwa complex. The plant had already incurred significant delays during the construction phase. Now the South Korean-based contractor faced an uphill battle to fast-track the commissioning phase and get the project back on schedule. The lack of time, however, was not the only obstacle in their path. Getting the plant online meant performing multiple testing and commissioning tasks simultaneously. Which in turn meant that demand for the nitrogen and other gases required for drying, purging and pressure testing was difficult to predict and subject to significant fluctuations. On top of that, the plant’s remote location ruled out the possibility of obtaining a sufficiently stable supply of liquid nitrogen. And so an urgent request for quote was launched.

One solution, multiple applications

GS Engineering & Construction came to us with an urgent request for equipment and personnel to perform a wide array of functions. From air blowing and dewatering to purging and high-pressure leak testing… These diverse tasks all call for different gases at a wide range of pressures, flow rates and levels of purity and dryness. Nevertheless, we were able to propose a flexible and modular solution that capitalized on certain synergies to complete the project effectively, efficiently and most importantly, on time.

Ahmad Khader

Area Rental Supervisor Qatar & Oman, Atlas Copco Rental Middle East

The required 8,000m3/h of dry, oil-free air required for air-blowing and dewatering, for example, was delivered by a package of 3 x PTS 916 100% oil-free air compressors which worked in tandem with 3 x PHS 1600 dryers. At the same time, 3 x XRVS 1000 compressors fed our state-of-the-art NGM 2000 mobile nitrogen-generating membrane package for purging the plant’s tanks and process piping.

This same package was also used for a comprehensive high-pressure leak test thanks to the addition of a B7 nitrogen booster, delivering the required 1,500m3/h of 98% pure N2 at an impressive 100 bar of pressure!

The solution also included all accessory hoses, manifolds, fuel tanks and so on, as well as an on-site team who took care of transport, assembly and round-the-clock operation for the duration of the project.

Clear added value

Our solution for a reliable, stable, cost-effective and fully mobile source of dry, oil-free air and pure, high-pressure nitrogen proved to be a critical element in completing the commissioning of the Liwa plant successfully:

We compared multiple options during the bidding stage. Finally we selected Atlas Copco Rental’s nitrogen generating membrane package because it was much more effective and economical.

Chang-Hee Kim

Commissioning Lead Engineer, GS Engineering & Construction.

What really earned us the praise of GS Engineering & Construction, however, was our speed and efficiency at every stage of the project. From our quick response in providing a quotation to the flexibility and versatility of the solution itself and the expertise and proactivity of our on-site operators… Our local team ensured that every single piece of the puzzle fit together with precision, and always with a view on the bigger picture.

A long-standing partnership

The Liwa project is just a part of a long-standing partnership with GS Engineering & Construction in the Middle East. And it was yet another opportunity for us to demonstrate that we not only have the state-of-the-art equipment they need to get the job done, but also the knowledge, expertise and experience to add maximum value to their large-scale projects. We are already looking forward to the next challenge!

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