Digital retrofitting of ventilation systems

Kappa Digital RetroFIT

When you have ventilation systems retrofitted with digital technology, you are not replacing the system, but rather making it possible to see what is happening inside it. For plant management, maintenance and energy management teams, this means that filter condition, fan operation and power consumption can be accessed at any time. You can see when maintenance is actually required. Kappa takes care of the assessment, retrofitting and support.

Lack of transparency regarding existing facilities

Many existing systems run reliably but without feedback. Problems only become apparent when they disrupt operations.

• The filter will be full before the next service is due.
• A fan runs unevenly, but you only notice this when it has stopped.
• Electricity costs are rising, but nobody knows how much each system uses.
• No one can say for certain whether the latest optimisation has made any difference.

Why is a
regular maintenance not enough?

A routine maintenance check inspects the system on schedule. Anything that happens in the meantime – such as a gradual increase in the differential pressure across the filter – goes unnoticed.

Retrofitting the system to connect it to a control system or process control technology is the usual alternative. This requires engineering work, coordination with the IT department and often involves a disruption to operations. Older systems frequently lack the necessary interfaces for this.

How does digital retrofitting work?

Kappa digital RetroFIT™ creates a separate monitoring layer for your plant, independent of the control system. Sensors record the relevant operating data and transmit it in encrypted form to the Kappa Scopic® software platform. There, you can view real-time values and trends and set warning thresholds.

The difference compared to a pure monitoring solution: Kappa understands the air and energy-related dynamics of your system and translates the data into decisions. If the differential pressure rises, the filter is replaced when it is actually full, not on a fixed schedule.

What Digital RetroFIT can do for you

You see problems coming instead of being surprised by them. The extent of the effect depends on the system and operating mode.

• Fewer unplanned downtimes
• Changed vibrations or an increasing differential pressure become apparent before the system fails.
  Your maintenance orders spare parts in time and schedules repairs during quiet phases.
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• Maintenance based on condition instead of calendar
• Interventions occur when they are needed. Unnecessary filter changes and inspections are eliminated, while necessary ones are not missed.

• Regular monitoring
• Monthly analyses and reports provide a continuous overview of the system, including optimization suggestions.
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• Investments you can justify
• The plant management sees where maintenance and energy costs arise and makes decisions based on data regarding continued operation, optimization, or replacement.
  The existing system will be used as long as it is economically sensible.

How does the Digital RetroFIT project work?

From enquiry to ongoing monitoring in three steps. Kappa takes care of the planning, installation and set-up; you provide access to the system.

1. Review

Kappa will assess your system and work with you to determine which questions the data should answer and where the sensors should be placed. You will receive a clear scope proposal.

2.  Retrofitting and fitting out

The sensors will be installed by Kappa or by the customer themselves. Kappa will set up the dashboard and establish the warning thresholds with you.

3. Support

Die Daten laufen kontinuierlich ein. Bei Auffälligkeiten unterstützt Kappa per Remote-Support und hilft bei Wartungs- und Optimierungsentscheidungen.