Case Study: Medical Industry Compressed Air Plant Room Equipment Upgrade (Sydney Children’s Hospital)

medical compressed air

(After) Mechanical installation of 3 x new Gardner Denver oil-free 55KW rotary screw compressors, 2 x 5,000 litre receiver tanks, 2 x refrigerated air dryers and filtration.

Medical compressed air machinery upgrades & system replacement.

» THE PROBLEM

An obsolete compressed air system providing medical compressed air required urgent replacement at a Sydney children’s hospital.

We were recently called upon to assess the existing compressed air equipment for a major Sydney children’s hospital in Western Sydney.

Upon inspection, we found their existing equipment was nearing the end of its viable usage life. The compressors, supplying both medical and dental air, had been installed for over 30 years and had undergone multiple re-builds during that time.

medical compressed air machinery upgrades

(Before) The existing equipment was nearing the end of its viable usage life.

 

The downstream treatment equipment had obsolete parts that were no longer readily available. Due to the age of the equipment, replacement was unfortunately not a practical option.

In addition, the plant room ventilation was very poor which often led to overheating during very hot summer days.  This can lead to compressor failure and shutdown. This is not a risk the client was willing to gamble as compressed air is required at the hospital on a 24/7 basis.

The decision was made by the Local Health Authority to invest in new compressed air generation plant and treatment equipment along with the upgrade of the plant room ventilation system.

The challenge was how to decommission the old system, install a new one and commission – all without interrupting the compressed air to the hospital.

replacement of old compressed air equipment

(Before) The equipment, supplying both medical and dental air, had been installed over 30 years ago.

» THE SOLUTION

Decommission the old equipment, provide a temporary compressed air backup, and install a new compressed air system.

The team at Compressed Air Technology were selected to work, in conjunction, with the equipment suppliers to both project manage and complete turnkey mechanical installation of a new compressed air system for the client.

Our scope of works included :

  • Design, supply, testing and commissioning of a temporary medical compressed air supply with back up redundancy as required per AS 2986-2011
  • Demolition and removal of old piston compressors, after coolers, dryers, filtration, piping and condensate systems
  • Demolition of existing equipment plinths
  • Design and installation of new concrete equipment plinths to suit 3 x new oil free screw compressors and 2 x new dryers
  • Positioning of compressors to plant room with supply of materials handling equipment as required
  • Mechanical installation of 3 x new Gardner Denver oil-free 55KW rotary screw compressors, 2 x 5,000 litre receiver tanks, 2 x refrigerated air dryers and filtration
  • Design, fabrication and installation of 1 x new compressed air distribution manifold/pressure regulating station with 100% back up redundancy
  • Installation completed per AS 2896-2011 Installation & testing of non-flammable medical gas pipeline systems
  • Design, supply and installation of plant room ventilation system to remove hot
  • Testing and commissioning of new compressed air plant and integration with hospital reticulation piping
  • Decommissioning and removal of temporary medical compressed air system
  • Client handover and training
new compressed air equipment

(After) Installation completed per AS 2896-2011 Installation & testing of non-flammable medical gas pipeline systems

» OUTCOMES

After 30 years of continuous operation, the ageing piston compressors were replaced with new technology, high-efficiency oil-free screw compressors from a world-renowned brand with years of experience supplying equipment to the medical compressed air industry.

Refrigerated air dryers were replaced along with coalescing micron and sub-micron filters to ensure the compressed air supply met rigorous national and international standards for Medical Grade Compressed Air Systems

A new distribution manifold was installed with 100% back-up redundancy to ensure air was delivered to the relevant departments at the designated pressure and volume

A new ventilation system was installed with control logic to ensure the ambient plant room temperatures were strictly controlled on event the challenging days during the height of summer when temperatures can easily reach 45 degrees Celsius.

The project was completed on-time and on budget, without any unplanned interruptions to the hospital medical and dental compressed air systems

medical compressed air equipment installation

(After) Design and installation of new concrete equipment plinths to suit 3 x new oil free screw compressors and 2 x new dryers.

» FURTHER READING

Compressed air quality testing for the medical and dental industries

Does your plant or equipment use compressed air for critical applications? If so, are you are aware of the relevant standards to which your system should comply? More information about compressed air quality testing for ISO 8573-1 (2010 Compressed Air Contaminants & Purity Classes), AS/NZ 1715 (2009 Selection, Use & Maintenance of Respiratory Protective Equipment) and AS 2568 – 1991 Medical Gases (Purity of Compressed Medical Breathing Air).

Compressed air system upgrades and installation

A compressed air system is only as effective as the installation allows it to be. A properly installed compressed air system will deliver a return on investment time after time. Understanding compressed air and its unique characteristics is the key to our success. More information about our compressed air equipment upgrades »


We are Sydney’s leading compressed air specialists

Compressed Air Technology are specialist consultants and contractors for the compressed air industry. Working with industrial compressed air operators to maximise efficiency, reliability and productivity. We design, supply, install, monitor and certify compressed air systems for a wide range of industries Australia wide.

Our independence is the key to our success

Huge increases in the cost of energy has seen the company start to focus on energy management. We are now regularly called upon in a consulting capacity to design compressed air systems that are efficient as well as reliable and safe. Our independence is key to our success, we are not encumbered by the constraints of a typical compressor dealer, we design each system with an open mind and scour the market for equipment that best suits our clients needs.

Helpful links : Compressed air system design | New air compressor installations | Compressed air system sales

We use specialist compressed air equipment

The company has invested heavily in specialist instrumentation equipment and the training of personnel to operate and understand measurement and monitoring methods for compressed air and gas systems. Our whole approach sets Superior Compressed Air Solutions apart from the crowd, we believe in what we do, are passionate about compressed air and strive to build long lasting, mutually beneficial relationships with a wide range of clients across a variety of sectors.

Helpful links : Air compressor services | Compressed air evaluation & audits | Compressed air leak detection | Compressed air quality testing

air compressor equipment sales

Medical industry compressed air equipment sales

Buying a new air compressor? Do you really understand the compressed air requirements of your plant? Do you know how much air your equipment consumes and at what pressure? Are you aware that the single biggest cost associated with owning and operating an air compressor system will be the electricity costs required to run it?

Over a typical 10 year air compressor life cycle, the cost of energy will account for around 75%-80% of total costs, dwarfing the initial costs associated with equipment purchase, installation and maintenance.

Independent air compressor sales advice

Before you contact the usual air compressor dealers, consider getting your current or proposed new system properly appraised, so that you can be sure you are buying what you actually need as opposed to what you are being sold.

At Compressed Air Technology, we make the effort to actually measure and monitor your system BEFORE you proceed with a high value purchase, ensuring the lifetime ownership costs are kept to a minimum.

As an independent operator, not tied to any particular brand, we have access to a huge range of premium quality equipment that is selected to ensure compressed air is supplied to your plant at the correct volume, pressure and quality, with a heavy focus on reliability.

We also supply a range of piping systems including aluminium, copper, stainless steel, HDPE and many more

Contact us for an obligation free compressed air system assessment on 1300 663 113

compressed air system design

Medical industry compressed air system design

Too often we see the wrong compressors installed for the application.  A great deal on a larger compressor may look appealing initially, but seldom does anyone point out the additional electrical costs incurred to run it over the ten or so years it will be in operation.

Our approach tends to differ from that of a traditional compressor dealer, we believe in spending time with our clients to get to know the true compressed air requirements so that the correct equipment can be evaluated and selected accordingly.

We take a similar approach to designing your piping and distribution systems. Remember, a compressed air system is only as efficient as its installation. We often hear clients complain they are ‘running out of air’, when the fact is their compressors are perfectly cable of supplying their processes, but restrictions in piping and poor design are leading to pressure drop and subsequent equipment malfunction.

More information about air compressor design »

commercial air compressor installation

Medical industry compressed air machine installation

A compressed air system is only as effective as the installation allows it to be. A properly installed compressed air system will deliver a return on investment time after time. Understanding compressed air and its unique characteristics is the key to our success.

Our team of dedicated compressed air installers are true industry specialists. Installing compressed air systems on a daily basis ensures we are kept up to speed with the latest advancement in technologies.

More information about air compressor installation »

compressed air system efficiency audit

Medical industry compressed air efficiency audits

Have you considered how much your compressed air system costs to run? Many business owners haven’t and it’s a common misconception that compressed air is free.  It’s only air, right? Wrong!

Compressed air is expensive!

Did you know that compressed air is one of the most expensive forms of energy used in industry today?

Often termed the ‘Fourth Utility’, compressed air is just as important to some businesses as electricity, water or gas. It is also very expensive to produce when you consider it takes approximately 7hp of electrical power to produce just 1hp of compressed air power…

10-15% of all industrial electricity is used to general compressed air.

More information about air compressor efficiency audits »

compressed air system monitoring audit

Medical industry compressed air repairs and leak detection

Did you know that most compressed air systems have leaks? Studies show that system leaks typically account for between 20-50% of compressor output, potentially wasting thousands of dollars every year. Most leaks are quick and easy to fix. Ask us how…

At Compressed Air Technology we offer a range a leakage detection and repair programs to suit all businesses and budgets. Our state of the art Ultra Sonic Leak Detectors and factory trained technicians are used to detect system leaks, and repairs can often be carried out on the spot, generating instant savings.

More information about air compressor repairs and leak detection »