VPVision
5 september 2013
© Van Putten Instruments BV
VPVision
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
Global trends
Trends:
Global:
oThe climate change challenge
oEnergy prices increase rapidly
oISO 50001 directive
oISO 11011 directive
Specific to compressed air:
oCost allocation of compressed air
oMaintenance 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 trends
Energy prices
ISO 50001
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
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 bar
Highest pressure point 6,69 bar.
If you know where P drop is occuring
maybe a pressure vessel can solve the
problem?
6
Why VPVision?
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 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
Key features
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 configuration
No need of complicated PLC or other system to read out sensors. Click, drag,
drop.
o Web based interface
Configuration 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.
Functions and options
VPVision provides an understandable graphical display of your system.
oPeriodic reports
oPie Charts & Real time line graphs
oReal time dashboards
oDemand side monitoring
oEfficiency monitoring
oCSV export, customized
System architecture
VPVision M
Your PC/ Tablet/ Phone
RS485
Webserver
ethernet
SQL
3G
RS485
TCP/485
TCP/
4..20
Converter
RS485
IO Module
TCP/485
Converter
Any
Modbus/TCP
sensor
RS485
Return On Investment!
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:
Equipment investment
€ 85.000,00
Leakage/ savings potential
29%
Production hours per day
24
0,15
kW price
Annual electricity bill
EURO
Savings potential
Kw
KW/ YEAR
250
2.190.000
€
328.500
$
USD
394.200
EURO/ Year
€
95.265
$
USD/ Year
114.318
ROI (Days)
321
300
2.628.000
€
394.200
$
473.040
€
114.318
$
137.182
268
500
4.380.000
€
657.000
$
788.400
€
190.530
$
228.636
161
750
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
DEMO
Project step by step
Step 1: use the worksheet
Use the VPVision worksheet, to gather all relevant data:
o
o
o
o
o
Compressors: kW, Voltage
Air treatment
Main areas (header)
Demand side machines (buildings, subdivisions)
Get an account at www.vpinstruments.com
Step 2: Project preparation
System layout
-Location of all compressors and other equipment
-Location of consumption points
-Air treatment equipment, filters, driers
Step 2: Project preparation
System layout: P&ID style
FPT
Dew point
sensor
FPT
Area 1
Main header
oLocation of all compressors and other equipment
oLocation of consumption points
oAir treatment equipment, filters, driers
D
P
125 kW
FPT
Area 2
FPT
Area 3
FPT
FPT
Area 4
Drier #1
Filter
125 kW
Main
receiver
FPT
FPT
75 kW
VPFlowScope insertion meter
(flow, pressure, temperature)
Step 2: Project preparation
System layout: P&ID style
-Location of all compressors and other equipment
-Location of consumption points
-Air treatment equipment, filters, driers
Area 1 supply
FP
T
M4
M1
M2
M3
VPFlowScope in line meter (flow, pressure, temperature)
M1
Production machine
FPT
Tool shop
Step 2: Project preparation
Basic ingredients
ƒVPVision M
ƒVPFlowScope’s
ƒAmp meters
ƒModbus JB
Options:
ƒDew point
ƒDifferential P
ƒTemperature
ƒDemand side
Step 2: Project preparation
FPT
FPT
1
A
A
FPT
FPT
GA45
ΔP
ΔP
2
FPT
FPT
Cdp
Cdp
3
A
A
FPT
FPT
GA90
4
FPT
FPT
5
6
A
A
SRMM75
7
8
Wet air receiver
Twin driers
Carbon filter
Dry air receiver
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?
Step 2: Project preparation
Part
Part nr
nr
Step 2: Project preparation
Part
Part nr
nr
Step 2: Project preparation
System layout
oDetermine cable lengths
oSplit up of sub-networks (RS485, Ethernet, Analog signals)
oPower supply (mains) locations: accessible
oVPVision location: avoid hot environments (fan-less PC)
oNetwork:
o List of IP addresses
o VPN accessibility for remote support
Cable tips & Tricks
- > 5 flow meters?
- > 50 meter length?
Call a specialist!
Step 2: Project preparation
Electrical schematic for subcontractor
Tip
Electrical scheme helps
to visualize the
complete
project before
installation
and can be used as
project
documentation.
Note:
Power supply up to 8
VPFlowScopes and 8
4- 20 mA sensors.
For more sensors
additional power
supply is needed.
Remote input options
Three main options:
Analog inputs
For 4..20 mA sensors
Ampere/ Current meters
Pressure sensors
Temperature, dew point sensors
RS485 (Modbus) inputs
VPFlowScope meters,
Some kW meters
Ethernet use
RS485- Ethernet converters
kW meters
VPVision M contents
o 8 RS485 signals on one port
o 8 analog signals
o Report module
Power terminal
Analog input module
Modbus terminal
Computer
Power supply
Modbus 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 modules
RS485/
TCP
Model
4..20 mA
VPA.5030.011
VPA.5030.111
VPA.5030.311
X
Application
X
Power extension
X
VPFlowScope via
ethernet
X
X
Analog input via
ethernet
X
X
VPFlowScope +
Analog via ethernet
X
VPA.5030.211
Power
supply
VPA.5030.01
1
VPA.5030.11
1
VPA.5030.21
1
VPA.5030.31
1
RS485 versus Ethernet
Important
RS485 or Ethernet?
oSize of the site
oInstallation time
oMax. 1200 meter cable length
oInterference issues, safety
oNumber of VPFlowScope devices (max 8 per
subnetwork)
oCosts for cable installation
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: Implementation
1. Mechanical installation
1. Flow meters/ Insertion points
2. Power meters, other sensors
3. Cabinets, junction boxes
2. Wiring/ Electrical installation
1.
2.
3.
4.
Main cables (Ethernet, RS485)
Junction boxes
VPFlowScopes
Analog sensors
3. Configuration
1.
2.
3.
4.
5.
VPStudio Æ VPFlowScope
Modbus devices
VPVision M
Web interface
Report configuration
Software Architecture
Tip
Real time
Reports
Pages
Reports
Widgets
Report widgets
Input Devices
Alarms
Alarm
functions
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 Architecture
Report 1
Real time
Page 1
Report 2
Page 2
Widget
Input
Device
Widget
Input
Device
Report widget
Input
Device
Report widget
VPVision M – main unit
Included in any project:
oVPVision M, pre-installed software
oReport module
oUser manual (PDF and hard copy)
oInstruction manuals for individual components (Digital format, PDF)
oSimplified schematic of the compressed system (PDF)
VPVision M options and exclusions
Optional items
oFlow sensors
oDew point sensors
oCurrent clamps
oJunction boxes
oRemote IO boxes
o3G module
oAdditional software
functions
Excluded in any project:
oField cabling
oPower cable (mains)
oElectrical installation labor
oMechanical installation labor
oSmall mounting items (screws, nuts, bolts,
patch wires, ethernet patch cables)
oVPN connection hardware & VPN Installation
Alarms preview!