Compressor tutorials-part-2

Compressor tutorials
specific power consumption of air compressor
Specific power consumption of Air compressor
The ratio of power consumption (in KW) to the volume delivered at ambient conditions.

Specific power consumption=

Actual power consumed by the compressor/Measured free air delivery

Specific power consumption of Air

compressor
Specific Power Consumption

Specific power consumption is the ratio of the power consumed by an engine to a certain
force such as the amount of output the engine (equipment) produces. It allows engines
(equipments) of all different sizes to be compared to see which is the most power efficient. It
allows manufacturers to see which engine (equipment) will use the least power while still
producing a high amount of output.
Specific power consumption of Air compressor
The ratio of power consumption (in KW) to the volume delivered at ambient conditions.
Specific power consumption=
Actual power consumed by the compressor/Measured free air delivery
If the measured flow is 250 m3/hr and actual power consumption is 30KW.
Then Specific power requirement = 20 KW/250 m3/hr
=0.08 KW/M3/hr
For find out Air compressors Specific power requirement following procedure is carried out:
1) Find out actual power consumed with the help of electric power analyzer
2)

Find out free air delivery by measuring compressor FAD with the help of pump up method
or nozzle method.

Compressor tutorials-part-3
Compressor tutorials
Benefits of energy conservation measures in compressed air system
Increased Profits
Improved Quality
Minimum Energy Input & Maximum Output
Reduced Energy bills
Increased Profits
Increased Competitiveness
Increased Productivity

Energy Conservation measures in compressed air system

Keep the minimum possible range between load and unload pressure settings.

The compressor(s) with the highest part-load efficiency is placed in trim

service to handle variations in load.
Retrofit with variable speed drives in big compressors, say over 100 kW, to
eliminate the unloaded' running condition altogether.
Reduce compressor delivery pressure, wherever possible, to save energy.
Reducing and controlling system pressure downstream of the primary receiver can
reduce energy consumption, leakage, demand for new capacity, as well as cause
less stress on components and operating equipment.
Use blowers instead of compressed air to provide cooling, aspirating, blow
guns, air lances, agitating, mixing, or to inflate packaging
Provide extra air receivers at points of high cyclic-air demand which permits
operation without extra compressor capacity.
Pressure drop is the reduction in air pressure from the compressor to the
actual point of use. A properly designed system should have a pressure drop of
below 10 percent of the compressor's discharge pressure.
Eliminate inappropriate air users-Use brushes, blowers, or vacuum systems
instead of compressed air to clean parts or remove debris
Cooler air is denser and provides more mass for each compression cycle with
no additional power use. Lower inlet air temperature will result in less compressor
work.
Use outside air for cooling reciprocating and lubricant-free screw
compressors when it is cooler than indoor air.

Compressor tutorials-part-4
Compressor tutorials
Concept of centrifugal pump
Principle of Operation
A centrifugal compressor accelerates the velocity of the gases (increases kinetic energy)
which is then converted into pressure as the gas flow leaves the volute and enters the
discharge pipe.
Centrifugal compressors consist of stationary casing
Containing rotating impeller (imparts a high velocity of air),
Fixed diverging passage (The air is decelerated with rise in static pressure).
Impeller may be single or double-sided

Basic Components
Impellers, Vanes, Volutes, Suction Eyes, Discharge lines, Diffuser Plates, Seals, Shaft,
Casing

Suction Vane Tips = Part of the impeller vane that comes into contact with gas first.
Discharge Vane Tips = Part of the impeller vane that comes into contact with gas last

2 Types of Centrifugal Compressors

Single- Stage: Compress the gas once

Use for high gas flow rates, low discharge pressures

Multi- Stage: Take the discharge of one stage and pass it to the suction of another
stage
Use for high gas flow rates, high discharge pressures
Usually operate at speeds > 3,000 rpm.
Air is sucked into the impeller eye and whirled at high speed by the vanes of the impeller
disc.
The static pressure increases from eye to tip
Remainder of static pressure rise occurs in diffusers.
Normally half of pressure rise occurs in the impeller and 50% in diffuser.
Some stagnation pressure loss occurs.

Why centrifugal compressor?

Centrifugal compressors are extremely popular because most are close to being oil-free.
Although oil is used in the compressor which can create an aerosol, the special sealing
systems used in most centrifugals reduce the level of oil contaminants to very low levels.
Centrifugals are also popular because of the very large capacities (> 100,000 CFM) that
are possible with a single compressor, combined with fairly high pressures (100 to 350
Kg/cm2). Centrifugals are economically attractive when flows are high.

Basic concept of centrifugal compressor

Principle of Operation
A centrifugal compressor accelerates the velocity of the gases (increases kinetic
energy) which is then converted into pressure as the gas flow leaves the volute
and enters the discharge pipe.
Centrifugal compressors consist of stationary casing,

Containing rotating impeller (imparts a high velocity of air),

Fixed diverging passage (The air is decelerated with rise in static pressure).

Impeller may be single or double-sided

Basic Components
Impellers, Vanes, Volutes, Suction Eyes, Discharge lines, Diffuser Plates, Seals,
Shaft, Casing

Suction Vane Tips = Part of the impeller vane that comes into contact with gas
first.

Discharge Vane Tips = Part of the impeller vane that comes into contact with gas
last

2. Types of Centrifugal Compressors

Single- Stage: Compress the gas once

Use for high gas flow rates, low discharge pressures

Multi- Stage: Take the discharge of one stage and pass it to the suction of
another stage

Use for high gas flow rates, high discharge pressures

Usually operate at speeds > 3,000 rpm.

Air is sucked into the impeller eye and whirled at high speed by the vanes of the
impeller disc.

The static pressure increases from eye to tip.

Remainder of static pressure rise occurs in diffusers.

Normally half of pressure rise occurs in the impeller and 50% in diffuser.

Some stagnation pressure loss occurs.

Why centrifugal compressor?

Centrifugal compressors are extremely popular because most are close to being
oil-free. Although oil is used in the compressor which can create an aerosol, the
special sealing systems used in most centrifugals reduce the level of oil
contaminants to very low levels. Centrifugals are also popular because of the
very large capacities (> 100,000 CFM) that are possible with a single
compressor, combined with fairly high pressures (100 to 350 Kg/cm2).
Centrifugals are economically attractive when flows are high.

If other compressors are available which will meet the same pressure/flow
requirements, centrifugals are preferred when the process requirement allows for
a fixed pressure ratio and requires oil-free gas.

Centrifugal units often have higher installed costs than reciprocating and screw
compressors for the same pressure/flow range, and they are inflexible to changes
in pressure ratios.

Stall

Defined as the (aerodynamic stall) or the break-away of the flow from the suction
side of the blades. A compressor stall occurs when the pressure of air entering
the engine drops below the pressure in the compressor or air within the
compressor drops momentarily as a result of stalling air (disruption in air
pressure). When this happens the compressed air expands and travels toward
the area of less pressure. This happens quite fast and can be explosive.

Stall is a local disruption of air flow within the compressor which continues to
provide compressed air but with reduced effectiveness

Stall happen due to too much suction feed but less discharge and will prevent
by implemented inlet guide vanes,
Surge
Surge is associated with a sudden drop in delivery pressure and with violent
aerodynamic pulsation which is transmitted throughout the whole machine.

Surge happen due to less suction feed at operating speed and will prevent by
installing recycle line or anti surge line.

For a given discharge pressure a compressor has a certain minimum flow rate.
Below this flow rate the compressor becomes unstable. a decrease in flow below
the minimum flow can cause a series of momentary reversal of flow through the
compressor. This situation is called surge.

Surging results in violent fluctuations in discharge pressure. When an electric

motor is used as driver surging can cause extreme variation in motor current.
Symptoms of surging are low gas flow, excessive vibration and banging sound
inside compressor

Compressor Controls
Compressor controls typically match compressed air output to compressed air
demand by maintaining discharge air pressure within a specified range. There
are five primary control strategies for maintaining the pressure within the desired
range.

Variable-Speed Control
Rotary-screw air compressors can be equipped with variable frequency drives to
vary the speed of the screws and the corresponding compressed air output. As in
other fluid flow applications, the variation of speed to vary output is extremely
energy efficient.

On/Off Control
In on/off control, the compressor turns on and begins to add compressed air to
the system when the system pressure falls to the lower activation pressure. The
compressor continues to run and add compressed air to the system until the
system pressure reaches the upper activation pressure when the compressor
shuts off. Reciprocating compressors typically employ on/off control. On/off
control is the most efficient type of part-load control, since the compressor draws
no power when it is not producing compressed air.

Modulation Control
In modulation control, the position of the inlet air valve is modulated from full
open to full close in response to compressor output pressure. Inlet modulation is
a relatively inefficient method of controlling compressed air output.

Blow-off Control
In centrifugal compressors, the quantity of air flow through the compressor can
only be controlled by modulating the inlet air valve over a relatively small range.
When flow is reduced below this range, the flow becomes unstable in a surge
condition. To avoid surge, centrifugal compressors may discharge compressed air
to the atmosphere to control compressed air output to the system. Blow-off
control is the least efficient method of controlling compressed air output, since
input power remains constant as the supply compressed air to the system
decreases.

Load/Unload Control

In load/unload control, the compressor loads and begins to add compressed air
to the system when the system pressure falls to the lower activation pressure.
The compressor continues to run and add compressed air to the system until the
system pressure reaches the upper activation pressure. It then unloads and
does not add compressed air to the system until the system pressure drops to
the lower activation pressure. When unloaded, rotary screw compressors
typically partially close the air inlet valve and bleed the remaining compressed
air in the sump to atmosphere.

Power draw when fully unloaded varies from about 60% of full load power to
about 30% of full-load power, depending on compressor design and on the length
of time the compressor runs unloaded. To fully unload, the load/unload cycle time
must be long enough to allow the compressed air in the sump to bleed to
atmosphere when the compressor unloads. Thus, load/unload control works best
when coupled with adequate compressed air storage, which lengthens
load/unload cycles while modulating pressure variation to end uses.

Compressor tutorials-part-5
Compressor tutorials
Energy conservation opportunities in compressed air system
Compressed air leakage of 30 40 percent is not uncommon. Carry out periodic leak
tests to estimate the quantity of leakage. Detection and repair can reduce leaks to less
than 10 percent of compressor volume. Leak repair, when combined with adjustments to
compressor controls, can reduce compressor run time, increase equipment life and
reduce maintenance.

Keep the minimum possible range between load and unload pressure settings.

The compressor with the highest part-load efficiency is placed in trim service to handle
variations in load.
Retrofit with variable speed drives in big compressors, say over 100 kW, to eliminate the
unloaded' running condition altogether.
Reduce compressor delivery pressure, wherever possible, to save energy. Reducing and
controlling system pressure downstream of the primary receiver can reduce energy
consumption, leakage, demand for new capacity, as well as cause less stress on
components and operating equipment.

Use blowers instead of compressed air to provide cooling, aspirating, blow guns, air
lances, agitating, mixing, or to inflate packaging
Provide extra air receivers at points of high cyclic-air demand which permits operation
without extra compressor capacity.
Pressure drop is the reduction in air pressure from the compressor to the actual point of
use. A properly designed system should have a pressure drop of below 10 percent of the
compressor's discharge pressure.
Eliminate inappropriate air users-Use brushes, blowers, or vacuum systems instead of
compressed air to clean parts or remove debris.

Energy Conservation measures in

compressed air system
Is compressed air expensive?

Compressed air is actually very expensive because only 10 to 30 percent of the

electric energy input reaches the point of end-use. The remaining input energy
converts to wasted heat or is lost through leakage. For example, to generate 8
M3/hr it takes 1 HP power.
Compressed air leakage of 30 40 percent is not uncommon. Carry out periodic
leak tests to estimate the quantity of leakage. Detection and repair can reduce
leaks to less than 10 percent of compressor volume. Leak repair, when combined
with adjustments to compressor controls, can reduce compressor run time,
increase equipment life and reduce maintenance
.
Keep the minimum possible range between load and unload pressure settings.
The compressor with the highest part-load efficiency is placed in trim service to
handle variations in load.
Retrofit with variable speed drives in big compressors, say over 100 kW,
to eliminate the unloaded' running condition altogether.
Reduce compressor delivery pressure, wherever possible, to save energy.
Reducing and controlling system pressure downstream of the primary receiver
can reduce energy consumption, leakage, demand for new capacity, as well as
cause less stress on components and operating equipment.
Use blowers instead of compressed air to provide cooling, aspirating, blow guns,
air lances, agitating, mixing, or to inflate packaging
Provide extra air receivers at points of high cyclic-air demand which permits
operation without extra compressor capacity.
Pressure drop is the reduction in air pressure from the compressor to the actual

point of use. A properly designed system should have a pressure drop of below
10 percent of the compressor's discharge pressure.
Eliminate inappropriate air users-Use brushes, blowers, or vacuum systems
instead of compressed air to clean parts or remove debris
Cooler air is denser and provides more mass for each compression cycle with no
additional power use. Lower inlet air temperature will result in less compressor
work. Use outside air for cooling reciprocating and lubricant-free screw
compressors when it is cooler than indoor air.
A smaller dedicated compressor can be installed at load point, located far off
from the central compressor house, instead of supplying air through lengthy
pipelines.
Automatic timer controlled drain traps wastes compressed air every time the
valve opens. So frequency of drainage should be optimized.
Use blowers, electric actuators, or hydraulics instead of compressed air blasts to
move parts
Properly designed heat recovery can recover 50 to 90 percent of the waste heat
and use it to heat air or water. Common applications include supplemental space
heating, industrial process heating, water heating, makeup air heating and boiler
makeup water preheating.
Install equipment interlocked solenoid cut-off valves in the air system so that air
supply to a machine can be switched off when not in use.
Carrying out pump up test, leakage test, specific power consumption
determination regularly
Compressed air piping layout should be made preferably as a ring main to
provide desired pressures for all users.
Present energy prices justify liberal designs of pipeline sizes to reduce pressure
drops.
Benefits of energy conservation measures in compressed air system
Increased Profits
Improved Quality
Minimum Energy Input & Maximum Output
Reduced Energy bills
Increased Profits
Increased Competitiveness
Increased Productivity

Improved Quality
Reduced consumptions
Increased Competitiveness
Leakage @ dia hole in Compressed Air line @ 7 Kg/cm2 can drain
almost waste Rs.2500/- per day
Power consumption increases 1% for every 2 psi increase in compressor
pressure
Every 100mm (water) pressure drop reduces the compressor capacity
1%
For every 12 degree C increase in water temperature, the power
consumption will increase by 5%.

Compressor tutorials-part-6
Compressor tutorials
Specific power consumption of Air compressor
Specific Power Consumption
Specific power consumption is the ratio of the power consumed by an engine to a certain force
such as the amount of output the engine (equipment) produces. It allows engines (equipments) of
all different sizes to be compared to see which is the most power efficient. It allows
manufacturers to see which engine (equipment) will use the least power while still producing a
high amount of output.
Specific power consumption of Air compressor
The ratio of power consumption (in KW) to the volume delivered at ambient conditions.

Specific power consumption=

Actual power consumed by the compressor/Measured free air delivery

Specific power consumption of Air

compressor
Specific Power Consumption

Specific power consumption is the ratio of the power consumed by an engine to a certain
force such as the amount of output the engine (equipment) produces. It allows engines
(equipments) of all different sizes to be compared to see which is the most power efficient. It
allows manufacturers to see which engine (equipment) will use the least power while still
producing a high amount of output.

Specific power consumption of Air compressor

The ratio of power consumption (in KW) to the volume delivered at ambient conditions.
Specific power consumption=
Actual power consumed by the compressor/Measured free air delivery
If the measured flow is 250 m3/hr and actual power consumption is 30KW.
Then Specific power requirement = 20 KW/250 m3/hr
=0.08 KW/M3/hr
For find out Air compressors Specific power requirement following procedure is carried out:
1) Find out actual power consumed with the help of electric power analyzer
2)

Find out free air delivery by measuring compressor FAD with the help of pump up method
or nozzle method.

Compressor tutorials-part-7
Compressor tutorials
Energy saving calculation for air compressor
Every 4 degree C reduction in inlet air temperature, the compressor can deliver the same
flow output at 1.5% less power.
Example:A 50 KW rotary air compressor is located in a room with an average temperature 33 degree C.
The inlet air is pulled from this room. If the air is ducted in from an outside shaded area, then the
inlet temperature average 21 degree C. The compressor can, with this cooler air intake, produce
the same air flow using approx. 4% less power.
If the compressor motor efficiency 95% runs 4500 hrs annually, and the cost of electricity is Rs.
7/Kwh, calculate the operating cost savings.
Compressor Energy = 50 Kw x 4500 R. hrs/Yr / 0.95
= 236842.1 Kwh/Yr
4% of Compressor energy = 0.04 x 236842.1 Kwh/Yr
= 9473.68 Kwh/Yr
Operating Cost savings = Rs. 7/Kwh x 9473.68 Kwh/Yr
= Rs. 66315.78/Yr