Kaeser helps Wilson Transformer Company optimise the energy efficiency of its compressed air systems

Rotary screw compressors from Kaeser Compressors Australia were
installed at a Victorian transformer manufacturing facility to meet their
increased demand for compressed air in an energy efficient way.

Kaeser Compressors worked with Wilson Transformer Company (WTC), a
leading Australian manufacturer of power and distribution transformers to help
them meet the increased compressed air requirement at their new
state-of-the-art facility in Glen Waverley, Victoria. Six Kaeser CSD series
rotary screw compressors were installed to optimise the energy efficiency of WTC’s
compressed air systems.

Alan Veitch, Improvement Manager for the Power Business Unit at WTC
explained that during the planning of the production facility’s expansion, they
realised their existing compressor station would not be able to meet the new
compressed air demand. The ageing compressed air system was also becoming
increasingly inefficient and costly to operate. The expansion therefore
presented WTC with the ideal opportunity to address the issue at the same time.

The plant at Glen Waverley incorporates two main workshop areas: While
one is used for the electrical operations of core cutting, insulation
preparation, coil winding, control wiring, transformer assembly, processing and
testing, the other handles the mechanical operations encompassing fabrication,
welding, grit blasting and painting.

Compressed air is used to power a number of operations across the two
workshop areas from breathing air used in the blasting facility to general
purpose pneumatic control systems on the drying ovens and oiling systems.

However, air skates accounted for the biggest requirement for compressed
air at the new facility. Air skates are used to lift and move heavy loads on a
cushion of air, and are powered by compressed air. WTC planned to use the new
air skates to lift and manoeuvre the largest transformers into restricted
access areas such as the testing bays where the cranes couldn’t go.

To meet the increased compressed air demand and ensure optimum energy
efficiency, WTC chose to invest in six Kaeser rotary screw compressors
comprising of four CSD T models with integrated refrigeration dryers and two
CSD(X) T SFC variable speed drive models.

Delivering premium quality compressed air and superior efficiency, the CSD(X)
T series from Kaeser features a low-speed Sigma Profile airend equipped with
flow optimised rotors. Developed by Kaeser, the Sigma profile achieves power
savings of up to 15 percent compared to conventional screw airend rotor
profiles. In addition, all Kaeser rotary screw airends are powered by premium
efficiency IE3 drive motors for maximum performance and reliability.

The compact integrated refrigeration dryer in these compressors offers
users an all-in-one solution. The integrated refrigeration dryers in these
units also provide further energy savings, with a sophisticated control
ensuring they are only active when compressed air actually needs to be dried.

Where compressed air demand fluctuates, the CSD(X) T SFC series utilises
a variable speed drive to vary the speed of the airend to directly match the
FAD (flow) required by the end user, saving energy, maximising service life and
enhancing reliability.

WTC chose these compressors on the basis of Kaeser’s reputation for
manufacturing high quality, reliable and efficient compressor solutions. The
main compressor system is now effortlessly powering the new air skates at the
WTC facility, helping to lift and manoeuvre some 300 tonnes of weight.

According to Veitch, all of the Kaeser compressors have proven to be
efficient and reliable in operation, with WTC operators particularly impressed by
their ease of maintenance. Since the installation of the compressors, WTC has
continued to rely upon the Seaford, Victoria-based Kaeser Partner, Air
Maintenance Pty Ltd, for its ongoing compressor maintenance requirements.

Kaeser’s CSD series rotary screw compressors are available with drive
powers up to 90 kW producing free air deliveries from 1.07 up to 16.16 m³/min.