FAD Appl note

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Computation of the FAD (Free Air Delivery) of a Compressor using the Krohne Vortex FAD Meter Model VFM5090 FAD.

Brief Description of the FAD of a COMPRESSOR

Although FAD stands for Free Air Delivery, it is the amount of Atmospheric Air (Free Air) that can be sucked in by the Compressor at inlet conditions( Suction Side ) of
Atmospheric Pressure at 1 atmosphere. Atmospheric Temperature at 20C/15C. Relative Humidity at 0% (100% Dry Air) & The motor RPM at 100% of its rated value

The Krohne Vortex FAD meter VFM 5090 FAD is installed at the outlet (Discharge Side ) of the compressor, where the Operating pressure is typically 7 to 10 Bar (g). Operating temperature may be close to 35-40C or higher (in case of no after cooler) Relative humidity is 70% to 100% & The RPM of the Motor Shaft may be 80% of its rated RPM value.

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The Krohne Vortex FAD meter VFM 5090 FAD measures the Air flow at the Discharge Side i.e. V(op) , P(op) , & T(op) and compensates for the same at the Suction Side i.e. V(nor) , P(nor) & T(nor) , RH at the Inlet & actual RPM

READ ON to Understand HOW the Krohne Vortex FAD meter VFM 5090 FAD does so

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AIM To Compute the FAD Free Air Delivery of the Compressor To do this, we need to ESTABLISH a relationship between the MASS of Free Air Qm ( Inlet ) being taken in or sucked by the Compressor and the MASS of Air Qm ( Outlet ) being delivered at the Outlet of the Compressor

To do so, we need to carry out a MASS BALANCE of the Air at the Inlet to that at the Outlet MASS of Free Air Qm ( Inlet ) MASS of Air Qm ( Outlet ) The Krohne Vortex FAD meter VFM 5090 FAD is installed at the Outlet & we first need to compute the MASS of Air Qm ( Outlet ) at the Outlet. MASS of Air Qm ( Outlet ) = V(op) * r( op )

The Krohne Vortex VFM 5090 FAD measures the Operating Flow V(op) , while the Density operating r( op ) is a function of
Operating Pressure P(op) & and Operating Temperature T(op) - the Krohne Vortex FAD meter VFM 5090 FAD has a PT 219 Pressure Sensor & PT 1000 Temperature Sensor built in, to continuously monitor the same. Molecular Weight of the gas ( built into the software of the FAD meter ) Real gas constant R . Compressibility factor Z ( op ) Correction and Wet gas mixture computation (to accommodate Relative Humidity changes)

Thus using the GAS LAWS the Density operating r( op ) is computed. P(op) * V(op) V(op = Mass Density operating r( op ) = & n * R * T (op) * Z ( op ) n = Mass Mol Wt. of the wet gas

Rearranging, we get Density operating r( op) = P(op) * Mol Wt. of wet gas R * T(op) * Z(op)

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In the above equation, the Compressibility factor Z(op) is computed using the Redlich Kwonk equation and needs to be corrected for, as the error can be close to 0.4% for Air at an operating pressure of 10Bar (g) & the Relative Humidity factor is corrected for , as the error at 70 % RH & 100 % RH can be - 4.0 % & - 5.6 % respectively. Now, the MASS of Air Qm ( Outlet ) at the Outlet can be computed using the equation. MASS of Air Qm ( Outlet ) = Volumetric Flowrate V(op) * Density operating P ( op ) Since, the MASS of Air at the INLET MASS of Free Air Qm ( Inlet ) V ( nor ) ( Inlet ) = = = MASS of Air at the Outlet MASS of Air Qm ( Outlet ) Qm ( Outlet ) Density Normal r ( nor ) Inlet

Similarly , the Inlet Density r ( nor ) Inlet , like the Density operating r ( op) , is a function of Relative Humidity , Compressibility factor Z Temperature &, Pressure at the Inlet Conditions & can be computed. V ( nor ) ( Inlet ) is the amount of FREE AIR being sucked in by the compressor

V ( FAD ) ( actual )

V ( nor ) ( Inlet * RPM rated RPM specified

Compare the V ( FAD ) ( actual ) against the value given by the Compressor manufacturer V ( FAD ) ( specified ) The Krohne Vortex FAD meter VFM 5090 FAD is the Ultimate in Performance

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Power Cost of Compressed Air

Every Compressor manufacturer specifies the FAD of the Compressor vis a vis the KWh Rating of the Motor ( Refer the Table on the following page ) As per the Table 1474 cfm Compressor requires a 275 KWh motor

1474 * 60 cubic feet of Air ( Free Air ) require 275 KWh Power per hour
Therefore , Cost of 88,500 ( 1474 * 60 ) cubic feet per hour of Air ( Free Air ) is 275 * Rs 3/- ( 1 KWh costs Rs 3/- )

88,500 cubic feet of Air ( Free Air ) costs 82,500 paise 1 cubic feet of Air ( Free Air ) costs approx 0.95 paise
Very simple to compute the Monthly Bill of your compressor Example : Your s is a 2,340 cfm ( Free Air ) Compressor then, your Monthly Electricity Bill is In Rupees = = = = 2,340 * 0.95 * 60 * 24 * 30 / 100 Rs 9,36, 000 /Rs 1, 15, 24, 000 /- per Year approx Rs 1 Crore 15 Lacs per year

An Investment of close to 1% of this 1 Crore 15 Lacs is worth investing to monitor this 1 Crore 15 Lacs

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This is not cfm or m3/min., because it is at Reference Conditions of 1 Atm & 200C It is therefore

cfm or

m3/min.

Customers also use the WRONG TERMINOLOGY and we do the incorrect sizing in turn.