Compressors & Compressed Air Systems

Training Session on Energy
Equipment
Electrical Equipment/
Compressors &
Compressors
Compressed Air
Systems
1
Training Agenda: Compressor
Introduction
Types of compressors
Compressors
Assessment of compressors and

compressed air systems
Energy efficiency opportunities
2
Introduction
Significant Inefficiencies
• Compressors: 5 to > 50,000 hp
• 70 – 90% of compressed air is lost

Compressors
3
Introduction
Benefits of managed system

• Electricity savings: 20 – 50%

Compressors
• Maintenance reduced, downtime decreased,

production increased and product quality
improved
4
Introduction
Main Components in Compressed

Air Systems
Compressors
• Intake air filters

• Inter-stage coolers
• After coolers
• Air dryers
• Moisture drain traps
• Receivers 5
Introduction
Compressors

6
Types of Compressors
Two Basic Compressor Types

Compressors
Type of
compressor
Positive
Dynamic
displacement
Reciprocating Rotary Centrifugal Axial
7
Reciprocating Compressor
• Used for air and refrigerant compression

• Works like a bicycle pump: cylinder volume reduces
Compressors
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
8
Rotary Compressor
• Rotors instead of pistons: continuous

discharge
Compressors
• Benefits: low cost, compact, low weight,

easy to maintain
• Sizes between 30 – 200 hp
• Types
• Lobe compressor
• Screw compressor
Screw compressor
• Rotary vane / Slide vane 9
Centrifugal Compressor
• Rotating impeller
Compressors
transfers energy
to move air
• Continuous duty
• Designed oil
free
• High volume
applications
> 12,000 cfm
10
Comparison of Compressors
• Efficiency at full, partial and no load

Compressors
• Noise level
• Size
• Oil carry-over
• Vibration
• Maintenance
• Capacity
• Pressure 11
Introduction
Compressors

12
Assessment of Compressors
Capacity of a Compressor
• Capacity: full rated volume of flow of

Compressors
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
Simple Capacity Assessment Method

• Isolate compressor and receiver and close receiver

outlet
Compressors
• 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
Compressor Efficiency
• Most practical: specific power

Compressors
consumption (kW / volume flow rate)

• Other methods
• Isothermal
• Volumetric
• Adiabatic
• Mechanical 15
Isothermal efficiency
Compressors
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
Volumetric efficiency
Compressors
Volumetric efficiency
= Free air delivered m3/min / Compressor displacement
Compressor displacement = Π x D2/4 x L x S x χ x n
D = Cylinder bore, meter

L = Cylinder stroke, meter
S = Compressor speed rpm
χ = 1 for single acting and 2 for double acting cylinders
17
n = No. of cylinders
Leaks
• Consequences
Compressors
• 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
Leak Quantification Method

Compressors
• 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
Quantifying leaks on the shop floor

• Shut off compressed air operated equipments

Compressors
• 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

Example
• Compressor capacity (m3/minute) = 35

Compressors
• 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
Introduction
Compressors

22
Energy Efficiency Opportunities
1. Location
• Significant influence on energy use

Compressors
2. Elevation
• Higher altitude = lower volumetric
efficiency
23
3. Air Intake
• Keep intake air free from

Compressors
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 24
4. Pressure Drops in Air Filter

• Install filter in cool location or draw

Compressors
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
5. Use Inter and After Coolers

• Inlet air temperature rises at each

Compressors
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
6. Pressure Settings
• Higher pressure
Compressors
• More power by compressors

• Lower volumetric efficiency
• Operating above operating pressures
• Waste of energy
• Excessive wear
27
a. Reducing delivery pressure

Operating a compressor at 120 PSIG instead of 100
Compressors
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
28
Pressure reducing valves no longer needed
d. Design for minimum pressure drop in

the distribution line
Compressors
• 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
d. Design for minimum pressure drop in

Compressors
the distribution line
Typical pressure drop in compressed air line for

different pipe size (Confederation of Indian Industries) 30
7. Minimizing Leakage
• Use ultrasonic acoustic detector

Compressors
• 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
9. Controlled usage
• Do not use for low-pressure

Compressors
applications: agitation, combustion air,

pneumatic conveying
• Use blowers instead
10. Compressor controls

• Automatically turns off compressor
when not needed
32
9. Maintenance Practices
• Lubrication: Checked regularly

Compressors
• Air filters: Replaced regularly

• Condensate traps: Ensure drainage
• Air dryers: Inspect and replace filters
33
Training Session on Energy
Equipment

Compressors &
Compressors
Compressed Air
Systems
THANK YOU FOR YOUR ATTENTION
34

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Training Session on Energy

Assessment of compressors and

• 70 – 90% of compressed air is lost

Benefits of managed system

• Electricity savings: 20 – 50%

• Maintenance reduced, downtime decreased,

Main Components in Compressed

• Intake air filters

Assessment of compressors and

Two Basic Compressor Types

Reciprocating Rotary Centrifugal Axial

• Used for air and refrigerant compression

while pressure increases, with pulsating output

• Rotors instead of pistons: continuous

• Benefits: low cost, compact, low weight,

• Efficiency at full, partial and no load

Assessment of compressors and

• Capacity: full rated volume of flow of

Simple Capacity Assessment Method

• Isolate compressor and receiver and close receiver

• Empty the receiver and the pipeline from water

• Most practical: specific power

consumption (kW / volume flow rate)

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

P1 = Absolute intake pressure kg / cm2

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

D = Cylinder bore, meter

• Energy waste: 20 – 30% of output

• Common leakage areas

Leak Quantification Method

• Total leakage calculation:

Leakage (%) = [(T x 100) / (T + t)]

T = on-load time (minutes)

• Well maintained system: less than 10%

Quantifying leaks on the shop floor

• Shut off compressed air operated equipments

• Run compressor to charge the system to set

System leakage (m3/minute) = Q × T / (T + t) 20

• Compressor capacity (m3/minute) = 35

• Cut in pressure, kg/cm2 = 6.8

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

Assessment of compressors and

• Significant influence on energy use

• Keep intake air free from

contaminants, dust or moist

• Keep ambient temperature low when

4. Pressure Drops in Air Filter

• Install filter in cool location or draw

air from cool location

5. Use Inter and After Coolers

• Inlet air temperature rises at each

stage of multi-stage machine

• More power by compressors

a. Reducing delivery pressure

PSIG: 10% less energy and reduced leakage rate

b. Compressor modulation by optimum

c. Segregating high/low pressure

d. Design for minimum pressure drop in