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Compressor and Compressed Air System

The document discusses energy efficiency opportunities in compressed air systems. It covers types of compressors, assessing compressor performance and capacity, identifying leaks, and opportunities to improve efficiency such as proper pressure settings, minimizing leaks, maintenance practices, and control strategies.

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rashm006ranjan
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262 views34 pages

Compressor and Compressed Air System

The document discusses energy efficiency opportunities in compressed air systems. It covers types of compressors, assessing compressor performance and capacity, identifying leaks, and opportunities to improve efficiency such as proper pressure settings, minimizing leaks, maintenance practices, and control strategies.

Uploaded by

rashm006ranjan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Training Session on Energy

Equipment

Compressors &
Compressed Air
Systems

Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities

Introduction
Significant Inefficiencies
Compressors: 5 to > 50,000 hp
70 90% of compressed air is lost

Introduction
Benefits of managed system
Electricity savings: 20 50%
Maintenance reduced, downtime decreased,
production increased and product quality
improved

Introduction
Main Components in Compressed
Air Systems
Intake air filters
Inter-stage coolers
After coolers
Air dryers
Moisture drain traps
Receivers

Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities

Types of Compressors
Two Basic Compressor Types
Type of
compressor

Positive
displacement

Reciprocating

Rotary

Dynamic

Centrifugal

Axial

Types of Compressors
Reciprocating Compressor

Used for air and refrigerant compression

Works like a bicycle pump: cylinder volume reduces


while pressure increases, with pulsating output

Many configurations available

Single acting when using one side of the piston, and


double acting when using both sides

(King, Julie)8

Types of Compressors
Rotary Compressor
Rotors instead of pistons: continuous
discharge
Benefits: low cost, compact, low weight,
easy to maintain
Sizes between 30 200 hp
Types
Lobe compressor
Screw compressor
Rotary vane / Slide vane

Screw compressor9

Types of Compressors
Centrifugal Compressor
Rotating impeller
transfers energy
to move air
Continuous duty
Designed oil
free
High volume
applications
> 12,000 cfm

10

(King, Julie)

Types of Compressors
Comparison of Compressors
Efficiency at full, partial and no load
Noise level
Size
Oil carry-over
Vibration
Maintenance
Capacity
Pressure

11

Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities

12

Assessment of Compressors
Capacity of a Compressor
Capacity: full rated volume of flow of
compressed gas
Actual flow rate: free air delivery (FAD)
FAD reduced by ageing, poor maintenance,
fouled heat exchanger and altitude
Energy loss: percentage deviation of FAD
capacity
13

Assessment of Compressors
Simple Capacity Assessment Method
Isolate compressor and receiver and close receiver
outlet
Empty the receiver and the pipeline from water
Start the compressor and activate the stopwatch
Note time taken to attain the normal operational
pressure P2 (in the receiver) from initial pressure P1
Calculate the capacity FAD:
P2 = Final pressure after filling (kg/cm2a)
P1 = Initial pressure (kg/cm2a) after bleeding)
P0 = Atmospheric pressure (kg/cm2a)
V = Storage volume in m3 which includes receiver,
after cooler and delivery piping
T = Time take to build up pressure to P2 in minutes
14

Assessment of Compressors
Compressor Efficiency
Most practical: specific power
consumption (kW / volume flow rate)
Other methods
Isothermal
Volumetric
Adiabatic
Mechanical

15

Assessment of Compressors
Compressor Efficiency
Isothermal efficiency
Isothermal efficiency =
Actual measured input power / Isothermal power

Isothermal power (kW) = P1 x Q1 x loger / 36.7

P1 = Absolute intake pressure kg / cm2


Q1 = Free air delivered m3 / hr
r = Pressure ratio P2/P1

16

Assessment of Compressors
Compressor Efficiency
Volumetric efficiency
Volumetric efficiency
= Free air delivered m3/min / Compressor displacement

Compressor displacement = x D2/4 x L x S x x n

D = Cylinder bore, meter


L = Cylinder stroke, meter
S = Compressor speed rpm
= 1 for single acting and 2 for double acting cylinders
n = No. of cylinders

17

Assessment of Compressors
Leaks
Consequences
Energy waste: 20 30% of output
Drop in system pressure
Shorter equipment life

Common leakage areas


Couplings, hoses, tubes, fittings
Pressure regulators
Open condensate traps, shut-off valves
Pipe joints, disconnects, thread sealants

18

Assessment of Compressors

Leak Quantification Method


Total leakage calculation:
Leakage (%) = [(T x 100) / (T + t)]
T = on-load time (minutes)
t = off-load time (minutes)

Well maintained system: less than 10%


leakages
19

Assessment of Compressors
Quantifying leaks on the shop floor
Shut off compressed air operated equipments
Run compressor to charge the system to set
pressure of operation
Note the time taken for Load and Unload
cycles
Calculate quantity of leakage (previous slide)
If Q is actual free air supplied during trial
(m3/min), then:

System leakage (m3/minute) = Q T / (T + t)

20

Assessment of Compressors
Example
Compressor capacity (m3/minute) = 35
Cut in pressure, kg/cm2

= 6.8

Cut out pressure, kg/cm2

= 7.5

Load kW drawn

= 188 kW

Unload kW drawn

= 54 kW

Average Load time

=1.5 min

Average Unload time

= 10.5 min

Leakage = [(1.5)/(1.5+10.5)] x 35 = 4.375 m3/minute


21

Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities

22

Energy Efficiency Opportunities


1. Location
Significant influence on energy use

2. Elevation
Higher altitude = lower volumetric
efficiency

23

Energy Efficiency Opportunities


3. Air Intake
Keep intake air free from contaminants,
dust or moist
Keep intake air temperature low
Every 4 oC rise in inlet air temperature = 1%
higher energy consumption

Keep ambient temperature low when


an intake air filter is located at the
compressor
UNEP 2006
24

Energy Efficiency Opportunities


4. Pressure Drops in Air Filter
Install filter in cool location or draw
air from cool location
Keep pressure drop across intake air
filter to a minimum
Every 250 mm WC pressure drop =
2% higher energy consumption
25

Energy Efficiency Opportunities


5. Use Inter and After Coolers
Inlet air temperature rises at each
stage of multi-stage machine
Inter coolers: heat exchangers that
remove heat between stages
After coolers: reduce air temperature
after final stage
Use water at lower temperature:
reduce power

26

Energy Efficiency Opportunities


6. Pressure Settings
Higher pressure
More power by compressors
Lower volumetric efficiency
Operating above operating pressures
Waste of energy
Excessive wear
27

Energy Efficiency Opportunities


6. Pressure Settings
a. Reducing delivery pressure
Operating a compressor at 120 PSIG instead of 100
PSIG: 10% less energy and reduced leakage rate

b. Compressor modulation by optimum


pressure settings
Applicable when different compressors connected

c. Segregating high/low pressure


requirements
Pressure reducing valves no longer needed

28

Energy Efficiency Opportunities


6. Pressure Settings
d. Design for minimum pressure drop in
the distribution line

Pressure drop: reduction in air pressure from


the compressor discharge to the point of use

Pressure drop < 10%

Pressure drops caused by


corrosion
inadequate sized piping, couplings hoses
choked filter elements

29

Energy Efficiency Opportunities


6. Pressure Settings
d. Design for minimum pressure drop in
the distribution line

Typical pressure drop in compressed air line for


different pipe size (Confederation of Indian Industries)

30

Energy Efficiency Opportunities


7. Minimizing Leakage

Use ultrasonic acoustic detector

Tighten joints and connections

Replace faulty equipment

8. Condensate Removal

Condensate formed as after-cooler reduces


discharge air temperature

Install condensate separator trap to remove


condensate

31

Energy Efficiency Opportunities


9. Controlled usage
Do not use for low-pressure
applications: agitation, combustion air,
pneumatic conveying
Use blowers instead

10. Compressor controls


Automatically turns off compressor
when not needed
32

Energy Efficiency Opportunities


9. Maintenance Practices
Lubrication: Checked regularly
Air filters: Replaced regularly
Condensate traps: Ensure drainage
Air dryers: Inspect and replace filters

33

Training Session on Energy


Equipment

Compressors &
Compressed Air
Systems
THANK YOU FOR YOUR ATTENTION
34

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