System modernization with KappaFit - fitness program for ventilation systems, for the life of the system
Changing process conditions, increasing performance, reducing operating costs, increasing system safety, improving system availability, etc.
plant availability, etc. - there are many reasons for modernizing a plant.
Roland Brandl, project manager at Kappa Filter Service for many years, has a lot to say about this, and he finds something to improve in almost every existing system. Regardless of whether the aim is to reduce operating costs or increase function, safety and convenience. “Systems are designed according to the initial situation at the time of purchase. However, production and process conditions change constantly over the years. It is expanded, downsized, adapted, converted, machines are added or removed, the piping and air routing is changed and much more. The condition of the system also changes continuously due to natural wear and tear. The consequences are The systems do not work properly and consume an unnecessary amount of energy,” says the experienced project manager.
This is exactly what Roland Brandl and his Kappa colleagues experience time and again. And this was also the starting point for the development of the KappaFit program for system modernization. It comprises numerous intelligent performance packages with which existing ventilation systems can be operated better, more economically, more safely, more comfortably and for longer.
Fitness for your systems - the KappaFit service packages:
The ACTUAL and TARGET parameters of the following variables are determined and optimized together: Performance, efficiency, safety, comfort and service life of the ventilation system. This is based on our comprehensive understanding of the process and our many years of experience in the planning, implementation and servicing of ventilation and energy technology systems. If necessary, individual components are added, removed, replaced, extended or modified. The automation - the heart and brain of the system - is also brought up to date.
The following five service packages can be used to maximize the benefits of a system modernization:
1. Function packages
Ventilation systems have numerous functions to fulfill: emissions must be captured, removed and separated, production and work processes must be supplied with fresh air and much more. Air is a very dynamic element - it always follows the slightest resistance and is sometimes missing in confined spaces - even the smallest changes have a significant influence on the function. The KappaFit function packages aim to increase, expand and optimize the performance of existing systems.
Examples of this are:
- optimization of capture, air routing, filter technology, air treatment
- supply of work areas and halls with fresh air
- heating work areas and halls
- cooling of work areas and halls
2. Economic efficiency packages
The lifetime operating costs of ventilation systems often exceed the acquisition costs many times over. The KappaFit packages therefore aim to reduce and optimize the operating costs of existing systems.
Examples of this are:
- demand-based capacity control - optimization of system operation (adapting system operation to actual demand, replacement of spare parts at the most economical time, use of energy-efficient components, etc.)
- energy recovery - recovering and using residual energy
3. Safety packages
Safety-related framework conditions also change during operation. Even small changes can lead to the system no longer being operated within the intended use or outside the risks under consideration. Measures must be taken immediately, especially in the case of flammable and explosive emissions and environments.
The KappaFit safety packages aim to ensure that existing systems are operated safely and in compliance with standards and regulations.
Examples of this are:
- inspection of safety-related components
- conformity assessment - assessment of CE conformity for modifications
- fire protection assessment
- EX protection assessment in accordance with the ATEX directive
4. Comfort packages
The convenience of existing systems is a key factor in their acceptance and benefits for the operator. Intelligent automation is of central importance, as the full benefits of system modernization can only be achieved with a certain level of digital maturity. However, the other service packages listed here are also supported or made possible by system modernization.
The KappaFit convenience packages aim to significantly improve the use of existing systems by ensuring optimum transparency of all processes.
Examples of this are:
- System Operation - operation via different control stations, from the foreman's office to mobile devices
- System Communication - provision of all required information on the system and its transfer to defined control systems
- System Monitoring - transparent display of all system performance parameters and analyses of the system history, including forecasts and recommendations for safe and economical system operation
5. value retention packages
Ventilation systems are high-value assets and often a prerequisite for industrial production. Alongside the building and the corresponding machinery, they are therefore part of the basic infrastructure. The KappaFit stable value packages support users in meeting their compliance obligations towards their employees, neighbors and the environment and aim to extend the economic life of existing systems.
Examples of this are:
- emission tracking - real-time overview of the emission load in the hall and in the exhaust air
- Predictive maintenance - predictive maintenance based on plant data and intelligent forecasts before shutdowns or reduced output occur