New vacuum pump range boasts 50 per cent energy savings

21 August, 2015

Dirk Ville, general manager of Atlas Copco Compressors UK, commented: “With clear synergies between compressed air and vacuum, which represent the ‘Yin’ and ‘Yang’ of air movement, Atlas Copco has been able to use its advanced compressor technology experience to design the GHS VSD+, leading to a breakthrough in energy efficiency, capable of dramatically reducing UK manufacturers’ lifecycle costs. Approximately three-quarters of companies who use rough vacuum require oil-injected pumps, which are traditionally fixed-speed, so the potential for energy savings across UK industry is massive.”

Step-change

Mark Taylor, marketing manager, Vacuum Solutions Division, Atlas Copco, commented that a step-change in performance tends to come from a breakthrough in innovation. He explained that when Atlas Copco began the GHS VSD+ project it set out to develop the first generation of frequency driven oil injected screw vacuum pump. “We took the most efficient compressor element with the goal of making it suitable for vacuum operation, together with some important modifications,” he said. “Those modifications included changing the oil flow rates into the vacuum pump. This was because if you put in too much oil you drive the power up and if you put in too little you drive the temperature up. So we wanted to achieve the fine balance between the right quantity of oil while also achieving the right temperature and the minimum amount of power in the element.”

Taylor explained that Atlas Copco also wanted to have the oil sucked around the vacuum pump, rather than pumped around the vacuum pump. “That means we can have increasing reliability and reduce the number of parts in the machine,” he said, adding that the company also worked on achieving an ultimate pressure.

However, Taylor pointed out that Atlas Copco didn’t just work on the element; establishing various patents on different components in the vacuum pump. “For example, we have a patented inlet control valve, which is one of the features that allows us to run GHS VSD+ without an oil pump. This is because the valve is partially closed when it’s at atmosphere and gradually opens to 400 mbar. This means we can suck oil around the circuit. A lot of vacuum pumps use an over pressure on the discharge side to force the oil around, but that is quite inefficient from an energy point of view.”

State-of-the-art VSD technology

The GHS 350-900 VSD+ range, generating nominal displacement of up to 900m3/h, incorporates state-of-the-art VSD technology that enables users to precisely adapt their vacuum generation requirements to match the demands of their process. Coupled with an innovative motor design and inlet control valve, the new range sets new standards for energy efficiency in rough vacuum pumps, leading to a dramatic reduction in total cost of ownership. Other compelling benefits depend on the application, including increased production for food packaging lines.

As a result, Atlas Copco comments that UK manufacturers can now achieve significantly better performance against benchmarked oil-sealed and dry vane vacuum pumps, which are predominantly fixed speed machines that react to variations in demand by switching on and off. Comparatively, the GHS VSD+ vacuum pump only delivers energy and performance when and where it is needed. If demand drops to half it only delivers half, and the power consumed is halved. This is one of the main reasons why the GHS VSD+ is capable of providing energy savings of 50 per cent on average.

50 per cent reduction in noise levels

When benchmarked against oil-sealed and dry vane vacuum pumps currently available on the market, the GHS VSD+ pump is said to offer a 50 per cent reduction in noise levels, down to a whispering level of 51 dB(A), meaning it can be placed on the factory floor without disturbing operators. From a design viewpoint, the new range is based on Atlas Copco’s proven compressors, and provides a fully wired, complete system in a single housing, with all access points for service on the same side. Due to its plug-and-play design the GHS VSD+ Series is easy and fast to install, which saves time and space. The footprint is one of the smallest on the market, being no larger than a standard pallet.

Monitoring system

The complete GHS VSD+ range is equipped with Atlas Copco’s state of the art Elektronikon monitoring system and SMARTlink data monitoring. Elektronikon can integrate with the customer’s plant management system and control other vacuum pumps, helping with energy savings.

The efficiency credentials of the range are evidenced by conformance with ISO 50001 and 14001 standards, while environmental impact is reduced as a result of impeccable oil retention at all operating pressures – from ultimate pressure to atmospheric pressure.

www.atlascopco.com/vacuum