a-'

st26t20t4

s##

Training Session on Energy

n9

Q'e'
30)
!-

:m

8e
u,=.
@=

it\hil

Gompressors &
Gompressed Air
Systems

oE

iE#{*i

Equipment

ffi&)

&sida lffi{ .

oB
S
?i'
JtD
ro-

.
.

.,

?":w

70

90% of compressed air is

lost

U'E,
o

ierlo

lntroduction
Benefits of managed system

a9

i'8.
Jo)

Electricitysavings: 20-50%
Maintenance reduced, downtime decreased,
production increased and product quality

improved

(D=.
o!
cn=
(D

(McKaneand Medads, 2003)

Main Gomponents in Compressed

Air Systems

dF
@"-

6F
64

E_

.,1.

E_

lntroduction

nQ
i'Jo);.

Energy efficiency opportunities

{,tf

Gompressors:5 to > 50,000 hp

o!,
o=

oE=.
o3

gn ifi cant I neffi cienc i es

o!oE
o=
o

ao

Assessment of compressors and

compressed air systems

@ffir

6El
oY-

i..l

:m
u4
o

lntroduction
S

Types of compressors

cD

wwwenergyefficiency:::a.orS

,.,1"o

6'
(J
-o 4

9d'
5o)

"Energy Efficiency Guide for lndustry in Asia"

lntroduction

Presentation from the

Training Agenda: Compressor

.
.
.
.
.
.

lntake air filters

lnter-stage coolerc

After coolerc
Air dryers
Moisture drain traps
Receivers

i..1.

En.y

Training Agenda: Gompressor

5126120t4

ffi#;

Training Session on Energy

Gompressors &
Gompressed Air
Systems

-o

() d
?i'

I50t
!dF
6l

r1"

@sida

ffi{{i}}

Types of compressors

!dF
64
ul!.
OE
o3
o
J

Assessment of compressors and

compressed air systems
Energy eff iciency opportunities

J#H,

",tT';

)
",,".a

l. rlo

wffi

lntroduction

i,{.:f

o9

I30,ii'

wwwenergyerri"i"""y]]1]."js

"Energy Efficiency Guide for lndustry in Asia"

Signifi cant lnefficiencies

m

oB

S
50)?i'

E-

6F
@v_
o

,.,1"o

f,{}t

70

90% of compressed air is

""*'lx{:HT:-

ffil!
ri- *isffi!

oB
9d'
3o)

lost

Electricity savings: 20

50%

Maintenance reduced, downtime decreased,

production lncreased and product quality

E-

6F
6v_

}--l

lntroduction
Benefits of managed system

lntroduction

improved

('9.
OE'
@3

" "1"

Training Agenda: Gompressor

Main Gomponents in Gompressed

Air Systems

(J
-c)4

.
.
.
.
.
.

I3 ?i'It)
E:m
iie
o=,
qP
(h=

i. r)"

Compressors:5 to > 50,000 hp

rr
|

o=o!
at3

tt#

'
.

Training Agenda: Compressor

Presentation from the

(/lEOE
@=

:.

*#ffi
i.i!It'

Equipment

lntake air filters

lnter-stage coolerc

After coolers
Air dryens
Moisture drain traps
Receivers

Assessment of compressors and

compressed air systems
Energy efficiency opportunities

5126/2014

s$ffi

w#

Types of Compressols

.
.

oB

Reciprocating Compressor

Two Basic Compressor Types

oB
9d'
5o)
Eaql
@4

ri'

:JOJ
ro-

6F
@a_

('=.
OE

.
.

(D=.
OE
o=

U'3

Types of Gompressors

Used for air and retrigeranl comprcssion

Works like a bicycle pump: cyllnder volume reduces

while pressure lncreases, wlth pulsating output
Many configurations avallable

Single actlng when using one 3ide ofthe plston, and

double actlng when ueing both slds

i..1"

wffi;

Types of Gompressors

'wsJ

Rotary Compressor
m

Rotors instead of pistons: :ontinuous

discharge

oB
IJo)ii'

Benefits: low cost, compac t, low weight,

!dF
az
(,=-

Sizes between 30

o'r5
o=o

200 hp

Rotating impeller
transferc energy
to move air

oB
I:Jo)ii'
!rAF
6l

Gontinuous duty

oE_
OE
Vr3

Types

GentrifugalGon lpressor

tr
o

Oesigned oil

free

. Lobe compressor

High volume
applications
> 12,000 cfm

. Screw compressor

. Rotary vane / Slide vane

i.ri"o

Sorew

@mpresr

Types of Compressors

ierl"o

(King,

Julie)
"u"d3

q'"gf

sllj
::rll

Types of Compressons

Comparison of Compressons

Efficiency at full, partial and no load

og

IJo)ii'
1t6F
al
at, toE
vr3

6-

IJo)ei'
!-

Oil carry-over

(,=.

Vibration

Types of

6F
a4
o!
o3

Maintenance

Capacity
)

i. rlr

Pressure

r.,1"

Training Agenda: Gompressor

lntroduction

m
, ()
-o4

Size

Nolse level

qe#s}

5t26t20t4

ffiffi

Assessment of Gompressols

@ffi

Gapacity of a Compressor

oB
I ii'
JO)

!-

.
.

:m
34
('!-

o!,
o3

Capacity: fult rated volume of flow of

compressed gas

Actual flow rate: free air detivery (FAD)

FAD reduced by agelng, poor maintenance,

fouled heat exchanger and altitude

dF

oz
('!.
oIt
t1ia

Assessment of Compressots

og

JO'?i'
E-

AF
64
o!.
or

Most practical: specific power

consumption (kW / volume flow rate)
Other methods

. lsothermal
. Volumetric
. Adiabatic
. Mechanical

- P.-P I
Q : sa:

ffiffi

!nu,

jvisk

t.is?iir

Assessment of Compressor

Gompressor Efficiency
Volumetric efficiency

Gompressor Efficiency

o8.

lsothermal efficiency

50,ei'
E'_
TM

H4
u, toTt
o3o
J

Pl . Abolute lntrke pr6suE kg , cm2

: Fe air deltE ed m3 , ht
t = Pa*surc ratio Pmt
Ql

ffi*hr
m
6-

og

Assessment of Compressors
Leaks

dF

6F

6t
(,!,
OE

cn=
o
O

- Cylinder

bo.e,

mlFr

L=
S-

Cyllnder stoke, m6te,

n.

Compl@r 6ped tph

to. .lrglo *tng .nd 2 tor ddbtc *0ng cylhdE
cylinder

No. ot

a4
(/l=.
OE
vr3
o
5

ierl"o

Consequences

. Energywaste: 20-90% of output

. Drop ln gystem prsssuts
. Shorterequlpment llfe

r58
!-

=o
JO'
!t-

pl

ts.mFtl.eerf,{q0r&nal
Pl.m Fsln{r!&dt ilr Ntry)
F.rtu'lr*
Fs@{re@)
Vr!b{. Mhdftn!fu..cdw.
tuc4dd.{ky#!
l. tubhtow
u?F.s. bzb nlllrc

Assessment of Gompressors

i e r)r

ierluo

Calculatethecapacity FAD:

:f

Gompressor Efficiency

Empty tho receiyer and the plpolin. from water

Start tho compresaor and activato tho stopwatch
Noto tims taksn to attaln the normal operational
pressure P2 (h tll6 rcceiverl trom lnifial prcssure

i.rlro

o9.

.
.
.

bolate compressor and recelver and close receiver

outlgt

w#

oB
IJo)ii'

Energy loss: percentage deviation of FAD

capacity

i.tl" '

wffi

Simple Capacity Assessment Method

tr
o

tt3

Assessment of Gompressols

Common leakage areas

. Coupllngs, hoses, tubes, nt0ngs

. Pressurcregulators
. Open condensate traps, shut-off valves
. Plpe Jolnts, disconnects, thread sealants

5/26t2014

s#ffi

Assessment of Compressols
Leak Quantification Method

Quantifying leaks on the shop floor

.
.

tr
o

og

Xo
JOr
E-

Assessment of Gompressors

gg

Total leakage calculation:

tA
OE=OJ

T E

.
{

i.r1r.

tim

(minutesl

tire

(minutesl

onJoad

t 3 off-load

.
.

Well maintained system: less than iO%

leakages

Assessment of Compressors

Shut off compressed air openated equipments

Run compressor to chafge the system to
set
pressur of operaflon
,,Load',
,,Unload,,
Note the time taken for
and
cycles
Calculate quanflty of leakago (prevlous
slidel
lf Qls actual free alr supplted durlng trtal
(m3/minl, then:

Training Agenda: Compressor

Example

. Compressorcrpacity(m3/ninute)
=f,5
'Cutinprsssure,kg/cm2 =6.E
. Cutoutprssure,l<glcm2
=7.5
' Load kW drawn
= l8g kW
. Unloadkwdr|wn
=54kW
' Average'Load' time
=1.5 min
. Average'Unload'time = 10.5 min

lntroduction
Types of compressoni

Assessment of compressor ancl

Energy Efficiency Opportunities

Energy Efficiency Opportunities

1. Location

Significant influence on energy use

3.

2. Elevation

Higher altitude = lower volumetric

efficiency

Air lntake

Keep intake air free from contaminants,

dust or moist

Keep intake aar temperature low

Everyt 4 oC rise
h ig her

in intet air tempet]ture = lyo

energy consum ption

Keep ambient temperature low when

an intake air filter is located at the

5/26t2014

Energy Efficiency Opportunities

Energy Efficiency Opportunities

4. Pressure Drops in Air Filter

5. Use lnter and After Coolers

Install filter in cool location or draw

. fr"p pressure drop across intake air

filter to a

air from cool location

minimum

e^y9r11Z.SO

2% higher

mm WC pressure drop
=
energy consumption

Energy Efficiency Opportunities

6. Pressure Settings

Higher pressure

a. Reducing delivery pressure

. More power by compressors

. Lower volumetric efficiency

Use water at lower temperature:

reduce power

Energy Efficiency Opportunities

6. Pressure Settings

lnlet air temperature rises at each

stage of multi-stage machine
lnter coolerc: heat exchangers that
remove heat between stages
After coolers: reduce air temperature
after final stage

Operating a compressor at l20 pSlG

lnstead of 100
PSIG: 10% less energy and reduced
leakage raie

b. Compressor modulation by optimum

pressure settings

Operating above operating pressures

. Waste of energy

Appllcable when dlfferEnt compressons

connected

'Excessive wear

c. Segregating high/low pressure

requirements
Pressure reduclng valves no longer
needed

ww
i

Energy Efficiency Opportunities

ir"i)

l.

Energy Efficiency Opportunities

6. Pressure Settings

lo

6. Pressure Settings

for minimum pressure drop in

*_D::i.Sl
the distribution

I o4
g6'

Jo)
!to-F
U, I
(/,!-

.
.

OEt

U,=

J
a
I

,..i,'l

line

for minimum
*rheDg.:i.Sl
distribution line

Pressure drop: reducuon in alr pressure

from
the compressor discharge to thl point

otuse

Pressurodrop<lO%

Plpr r-orDtu.t BoR (rnb)

Prssuredrops caused by
. corrosion
. inadequate sized piping,
coupllngs
. choked

tilterelements

65

hoses

t04
I

^,,^,.t*l

pressure drop in

5/26/2014

Energy Efficiency Opportunities

Energy Efficiency Opportunities

7. Minimizing Leakage

.
.
.

9. Gontrolled usage

Use ultrasonlc acousilc detector

TightenJolntsandconnecflons
Replace faulty equlpment

8. Gondensate Removal

C.ondensate formed as after+ooler

reduces

pneumatic conveying
Use blowers instead

10. Compressor controls

r Automaticalty turns off compressor

discharge air temperature

'

Do not use for low_pressure

applications: agitation, combustion

lnstall condensate separatortrap

to remove
condensate

Energy Efficiency Opportunities

Training Session on Energy

Equipment
9. Maintenance practices

. Lubrication: Checked regularly

' Air filters: Replaced regularly
. Condensate traps: Ensure drainage
. Air dryers: lnspect and replace filters

m
o-

og

I ii'
50,
Eo-F
o!
Ut!oEt
o3

.t'ff;:"="T#
Systems

THANK YOU FOR YOUR ATTENTION

Disclaimer and References

This Powqpoint fialnhg sxion
wu prepared 6 pail of
lhe pruject 'Grcenhouse Gu
Emission nbaou*ro1ro^ayio nd the pacfrc,,(GERrepl.
rc6:n?ble-qlns have been madi to
enwrc that the
@nten_ts of this pablicotibn
arefaauattX

Iylso.y

unili-"'

oi-o:!.r-!:::""q
tne

-accurrcy

or

T-tP,,!:t": ":.y

correct ii
IJNEp do& not rccept rsponsibilityfor

compldux of the contuts, ina shsA iot

try or damfe tha may be orcwioned
through the use of,' or retiance

::yry.ototthit
!!!ectt!
conteilts
publicarlon,

@ UNEq 2006.
The GERIAPprojea wwfunded
b! the Swedirh
rntenalianol Development Coopuuion,lgency

*"

otl the

6iaa1
inctuded tn the texrhook chsptq
that is

l:l!:!::*"*
availableonw.energtefrclencyuiaory

ri'

air,