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Compressor

UNEP 2006 Training Agenda: Compressor Introduction Types of compressors Assessment of Compressors and Compressed Air Systems energy efficiency opportunities. Benefits of managed system Electricity savings: 20 +50% maintenance reduced, downtime decreased, production increased and product quality improved.

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Paras Palsatkar
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385 views

Compressor

UNEP 2006 Training Agenda: Compressor Introduction Types of compressors Assessment of Compressors and Compressed Air Systems energy efficiency opportunities. Benefits of managed system Electricity savings: 20 +50% maintenance reduced, downtime decreased, production increased and product quality improved.

Uploaded by

Paras Palsatkar
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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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

(McKane and Medaris, 2003)

Introduction Benefits of managed system


Electricity savings: 20 50% Maintenance reduced, downtime decreased, production increased and product quality improved

(eCompressedAir)

4 UNEP 2006

Introduction Main Components in Compressed Air Systems


Intake air filters Inter-stage coolers After coolers Air dryers Moisture drain traps Receivers
5 UNEP 2006

Training Agenda: Compressor

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

6 UNEP 2006

Types of Compressors Two Basic Compressor Types


Type of compressor

Positive displacement

Dynamic

Reciprocating

Rotary

Centrifugal

Axial

7 UNEP 2006

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)

UNEP 2006

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 compressor
9 UNEP 2006

Types of Compressors Centrifugal Compressor


Rotating impeller transfers energy to move air Continuous duty Designed oil free High volume applications > 12,000 cfm
(King, Julie)
10 UNEP 2006

Types of Compressors Comparison of Compressors


Efficiency at full, partial and no load Noise level Size Oil carry-over Vibration Maintenance Capacity Pressure
11 UNEP 2006

Training Agenda: Compressor

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

12 UNEP 2006

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 UNEP 2006

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 UNEP 2006

Assessment of Compressors Compressor Efficiency


Most practical: specific power consumption (kW / volume flow rate) Other methods Isothermal Volumetric Adiabatic Mechanical
15 UNEP 2006

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 UNEP 2006

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

xn

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 UNEP 2006

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 UNEP 2006

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 UNEP 2006

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

UNEP 2006

Assessment of Compressors
Example
Compressor capacity (m3/minute) = 35 Cut in pressure, kg/cm2 Cut out pressure, kg/cm2 Load kW drawn Unload kW drawn Average Load time Average Unload time = 6.8 = 7.5 = 188 kW = 54 kW =1.5 min = 10.5 min

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


21 UNEP 2006

Training Agenda: Compressor

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

22 UNEP 2006

Energy Efficiency Opportunities 1. Location


Significant influence on energy use

2. Elevation
Higher altitude = lower volumetric efficiency

23 UNEP 2006

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 24 compressor UNEP 2006

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 UNEP 2006

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 UNEP 2006

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 UNEP 2006

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 UNEP 2006

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 UNEP 2006

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

UNEP 2006

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

UNEP 2006

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 UNEP 2006

Energy Efficiency Opportunities 9. Maintenance Practices


Lubrication: Checked regularly Air filters: Replaced regularly Condensate traps: Ensure drainage Air dryers: Inspect and replace filters

33 UNEP 2006

Training Session on Energy Equipment

Compressors & Compressed Air Systems


34 UNEP GERIAP

THANK YOU FOR YOUR ATTENTION

Disclaimer and References


This PowerPoint training session was prepared as part of the project Greenhouse Gas Emission Reduction from Industry in Asia and the Pacific (GERIAP). While reasonable efforts have been made to ensure that the contents of this publication are factually correct and properly referenced, UNEP does not accept responsibility for the accuracy or completeness of the contents, and shall not be liable for any loss or damage that may be occasioned directly or indirectly through the use of, or reliance on, the contents of this publication. UNEP, 2006. The GERIAP project was funded by the Swedish International Development Cooperation Agency (Sida) Full references are included in the textbook chapter that is 35 available on www.energyefficiencyasia.org
UNEP 2006

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