Energy Compressors

8/6/2019 Energy Compressors

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8. ENERGY PERFORMANCE ASSESSMENT OFCOMPRESSORS

8.1

8.2

Introduction

The compressed air system is not only an energy intensive utility but also one of theleast energy efficient. Over a period of time, both performance of compressors andcompressed air system reduces drastically. The causes are many such as poor

maintenance, wear and tear etc. All these lead to additional compressors installations

leading to more inefficiencies. A periodic performance assessment is essential tominimize the cost of compressed air.

Purpose of the Performance Test

To find out:

y

y

yy

Actual Free Air Delivery (FAD) of the compressor

Isothermal power required

Volumetric efficiency

Specific power requirement

The actual performance of the plant is to be compared with design / standard values

for assessing the plant energy efficiency.

8.3 Performance Terms and Definitions

Compression ratio

Isothermal Power

Isothermal Efficiency

Volumetric efficiency

: Absolute discharge pressure of last stageAbsolute intake pressure

: It is the least power required to compress the airassuming isothermal conditions.

: The ratio of Isothermal power to shaft power

: The ratio of Free air delivered to compressor sweptvolume

Specific power requirement: The ratio of power consumption (in kW ) to thevolume delivered at ambient conditions.

8.4

8.4.1

Field Testing

Measurement of Free Air Delivery (FAD) by Nozzle method

Principle: If specially shaped nozzle discharge air to the atmosphere from a receivergetting its supply from a compressor, sonic flow conditions sets in at the nozzle throat


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Nozzle size (mm) 3Capacity (m /hr)6

1016

2233

50

80

125

165

39

9 3027 90

60 170130 375

300 450

750 2000

1800 5500

3500 - 10000

8. Energy Performance Assessment of Compressors

for a particular ratio of upstream pressure (receiver) to the downstream pressure(atmospheric) i.e. Mach number equals one.

When the pressure in the receiver is kept constant for a reasonable intervals of time,the airflow output of the compressor is equal to that of the nozzle and can be

calculated from the known characteristic of the nozzle.

8.4.2

8.4.3

Arrangement of test equipment

The arrangement of test equipment and measuring device shall confirm to Figure 8.1.

Nozzle Sizes

The following sizes of nozzles are recommended for the range of capacities indicated below:

Flow Nozzle: Flow nozzle with profile as desired in IS 10431:1994 and dimensions

Measurements and duration of the test.

The compressor is started with the air from the receiver discharging to the atmospherethrough the flow nozzle. It should be ensured that the pressure drop through the throttle

valve should be equal to or twice the pressure beyond the throttle. After the system is

stabilized the following measurements are carried out:

yyyyy

Receiver pressure

Pressure and temperature before the nozzle

Pressure drop across the nozzle

Speed of the compressor

kW, kWh and amps drawn by the compressor

The above readings are taken for the 40%, 60%, 100% and 110% of discharge pressure

values.

yyyy

Measuring instruments required for test

Thermometers or Thermocouple

Pressure gauges or Manometers

Differential pressure gauges or Manometers

Standard Nozzle


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Free air delivered, Q f (m / sec)! k x2(P3P4 )(P3 x Ra )

d x 1 x1


yyy

Psychrometer

Tachometer/stroboscope

Electrical demand analyser

FILTER

P1 T1

AIR COMPRESSOR

P2

RECEIVER

P4 P3 T3

THROTTLEVALVE

Nozzle

DISCHARGE TOATMOSPHERE

P3 P4 FLOWSTRAIGHTENER BY-PASS

Figure 8.1: Test Arrangement for Measurement of Compressed Air Flow

Calculation Procedure for Nozzle Method

I. s

4

2T

1 / 2

P T3

k

d

T1

P1

P3T3

RaP3-P4

:

::

:

:

:

:

:

Flow coefficient as per IS

Nozzle diameter MAbsolute inlet temperatureoKAbsolute inlet pressure kg/cm2

Absolute Pressure before nozzle kg/cm2

Absolute temperature before nozzleoK

Gas constant for air 287.1 J/kg k

Differential pressure across the nozzle kg/cm2


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Free air delivered, Q f (m / sec)! k x2(P3P4 )(P3 x Ra )

d x 1 x1

3032 x 0.036 x1.08 x 287


II. Isothermal Efficiency = Isothermal power / Input power

Isothermal power(kW)!

P1 x Q f x loge r

36.7

P1Qfr

==

=

Absolute intake pressure kg/ cm2

Free air delivered m3/hr.

Pressure ratio P2/P1

III. Specific power consumption atrated disch arg e pressure!

Power consumption, kW

Free air delivered, m3 /hr

IV. Volumetric efficiency!

Free air delivered in m3 / min

Compressor displacementinm3 / minx 100

Compressor displacement!

4

x D 2 x L x S x x n

DL

S

n

==

=

=

=

Cylinder bore, metreCylinder stroke, metre

Compressor speed rpm

1 for single acting and

2 for double acting cylindersNo. of cylinders

8.6 ExampleCalculation of Isothermal Efficiency for a Reciprocating Air Compressor.

Step 1 : Calculate Volumetric Flow Ratek : Flow coefficient (Assumed as 1)

d : Nozzle diameter : 0.08 metre

P2

P1T1

P3T3

P3 P4

Ra

: Receiver Pressure - 3.5 kg / cm2 (a)

: Inlet Pressure - 1.04 kg / cm2(a)

: Inlet air temperature 30oC or 303oK

: Pressure before nozzle 1.08 kg / cm2: Temperature before the nozzle 40oC or 313oK

: Pressure drop across the nozzle = 0.036 kg / cm2

: Gas constant : 287 Joules / kg K

s

4

2T

1 / 2

P T3

Free air delivered, Qf(ms / sec)!1 x

4x (0.08)2 x

1 / 2

x1.04 313

= 0.391 m3/sec

= 1407.6 m3 / h.


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Step 2 : Calculate Isothermal Power Requirement


P1 x Q f x loge r

36.7

P1 - Absolute intake pressure

Qf -Free Air Delivered

= 1.04 kg / cm2 (a)

= 1407.6 m3 / h.

Compression ratio, r!

3.51

1.04! 3.36


1.04 x1407.6x loge 3.36

36.7! 48.34 kW

Step 3 : Calculate Isothermal Efficiency

Motor input powerMotor and drive efficiencyCompressor input power

Isothermal efficiency

= 100 kW= 86 %= 86 kW

= Isothermal Power x 100Compressor input Power

= 48.34 x 100 = 56%86.0

8.7 Assessment of Specific Power requirement

Specific power consumption = Actual power consumed by the compressorMeasured Free Air Delivery

In the above example the measured flow is 1407.6 m3/hr and actual power consumption is

100 kW.

Specific power requirement = 1001407.6

= 0.071 kW/m3/hr

8.8 Measurement of FAD by Pump Up Method

(Note: The followingsection is a repeatof material provided inthe chapter-3 on CompressedAir System in Book-3.)

Another way of determining the Free Air Delivery of the compressor is by Pump Up Method- also known as receiver filling method. Although this is less accurate, this can be adopted

where the elaborate nozzle method is difficult to be deployed.


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Simple method of Capacity Assessment in Shop floor

Isolate the compressor along with its individual receiver being taken for test frommain compressed air system by tightly closing the isolation valve or blanking it,

thus closing the receiver outlet.

Open water drain valve and drain out water fully and empty the receiver and thepipeline. Make sure that water trap line is tightly closed once again to start the

test.

Start the compressor and activate the stopwatch.

Note the time taken to attain the normal operational pressure P2 (in the receiver)

from initial pressure P1.

Calculate the capacity as per the formulae given below:

Actual Free air discharge

Q!

P2P1

P0

V

T

Nm3

/ Minute

Where

P2

P1

P0

V

T

=

=

=

=

=

Final pressure after filling (kg/cm2 a)

Initial pressure (kg/cm2a) after bleeding

Atmospheric Pressure (kg/cm2 a)

Storage volume in m3 which includes receiver,

after cooler, and delivery piping

Time take to build up pressure to P2 in minutes

The above equation is relevant where the compressed air temperature is same as the ambientair temperature, i.e., perfect isothermal compression. In case the actual compressed air

temperature at discharge, say t20C is higher than ambient air temperature say t10C (as is usual

case), the FAD is to be corrected by a factor (273 + t1) / (273 + t2).

EXAMPLE

An instrument air compressor capacity test gave the following results (assume the finalcompressed air temperature is same as the ambient temperature) Comment?

Piston displacement

Theoretical compressor capacity

Compressor rated rpm 750

Receiver Volume

Additional hold up volume,

i.e., pipe / water cooler, etc., is

Total volume

Initial pressure P1

Final pressure P2

:

:

:

:

:

:

:

:

16.88 m3/minute

14.75 m3/minute @ 7 kg/cm2

Motor rated rpm : 1445

7.79 m3

0.4974 m3

8.322 m3

0.5 kg/cm2

7.03 kg/cm2


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Atmospheric pressure P0

Compressor output m3/minute

:

:

1.026 kg/cm2,a

P2P1Total VolumeAtm. Pressure Pumpup time

:7.030.5 8.322

1.026 4.021= 13.17 m3/minute

Capacity shortfall with respect to 14.75 m3/minute rating is 1.577 m3/minute i.e.,

10.69 %, which indicates compressor performance needs to be investigated further.

Conclusion

With a proper choice of volume ratio, fixed volume ratio compressorsoffer good energy efficiency performance as system head pressurefloats to achieve efficient system operation. Variable volume ratiomachines will deliver improved energy performance over a wideoperating envelope but a price is paid for that benefit. Variable volumeratio compressors have slightly.higher capital costs, increased maintenance cost, and reduce reliabilitywhen compared to their fixed Vi counterparts. The increasedmaintenance costs and reduced reliability are attributed to theadditionalcomponents needed for volume ratio control.If you have an opportunity, perform a life-cycle analysis for alternativcompressor selections. The life-cycle cost should include capital,operating, maintenance, and replacement costs over a specified timeperiod. Keep in mind that, based on evidence from the field, someancillary equipment alternatives (such as liquid injection oil cooling) willead to shortened compressor lifetimes when compared to others (sucas thermo siphon oil cooling)

1:The power consumed by a compressor is proportional to the specific volume, which is proportional to the absolute

temperature of the gas at a given pressure. It is also clear that the compressor work is directly proportional to the inle

temperature of air. Therefore, the lower the inlet temperature of the air, the smaller the compressor work.

2: If you are using petroleum based lubricants, you could experience up to an 8% energy savings by switching to

Compressor Synthetic Lubricants. Plus extend equipment life and save on oil changes and disposal cost.

3: the minimum air compressor work is achieved with isothermal compression. In practical way, we try to achieve tha

by involving some cooling during compression process that leads to Polytropic compression process.

4: Since the delivery pressure increases, the associated temperature also increases. Thus the temperature of the air

after compression is so high as to cause mechanical problems and the amount of heat is actually the energy loss


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Top 7 Compressed Air Energy Saving Tips

Would you like to reduce electrical costs related to your compressed air system?

More than likely - you can. Start by determining your annual compressed air electrical costs by using this formula:

Brake Horse Power X 0.746 X Annual Hours of Operation X KWH (Kilowatt-Hour) Cost (divided by) Motor Efficiency

NOTE: 1 CFM (Cubit Feet per Minute) @ 100 PSIG (pound-force per square inch gauge)

Next...follow these Top 7 Compressed Air Energy Saving Tips:

1 . Fix your Air Leaks

if you do nothing else - follow this one tip: Find and fix your compressed air leaks. Air leaks are industrys' "biggest

looser"!

The average plant loses 20% to 30% it its compressed air through multiple small air leaks. The money spent

an power and parts to find and fix these leaks is well worth it. Note (a 1/4 inch hole will flow 103 cfm @ 100 psig)

ange to Synthetic Lubricants

u are using petroleum based lubricants, you could experience up to an 8% energy savings by switching to Compressor Synthet

icants. Plus extend equipment life and save on oil changes and disposal cost.

educe Plant Operating Pressure

ssible - reduce overall plant pressure. Less pressure > Less CFM used > less energy consumed.

Reduce plant pressure 2 pounds at a time, then test run for minimum 24 hours. If any equipment has issues...then increase

sure 2 pounds until running smoothly again. For every 2 pound pressure reduction -you save 1% of the electrical cost to run th

ompressor.

eck Differential Pressure on Air Compressor Filters.

t at the compressor cabinet filter then check the compressor inlet filter.

e: A dirty inlet filter can cost you 1% to 3 % in additional electrical costs. Why? Because decreased air flow to the compressor

valve increases the compression ratios resulting in more run time.

t check the air/oil separator differential pressure under a full load. A new separator causes a differential pressure drop of

roximately 2-3 psig.When your pressure drop reaches 8-10 psig, then it is time to change your separator elements. A dirty

rator element can cost you up to 5% in additional electrical cost.

t change the control air filter element. This often over looked, but still important filter where the controls receive their air sign

essure drop here causes the controls to receive the lower pressure signal loading the compressor more and using more

tricity.


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educe the Compressor Inlet Temperature

educing inlet air temperature 10F below 70F, you save 2% on electrical usage. Your benefit increases up to 8% on a 30F

ee day. But increasing the inlet temperature 10F above 70F will cost you 2% in additional electrical usage for every 10F up t

at 120F. (Inlet temperature has very little affect on Lubricated screw compressors)

eck Differential Pressure on Compressed Air Line Filters.

Compressed Air Filters to be twice (2x) your compressor CFM flow rate. This will lower your pressure drop approximately 2-3

and save 1% on energy costs. Elements will last twice (2x) as long and you will save on maintenance costs.

now what quality of compressed air your plant needs.

cleaner & dryer the compressed air the more energy used.

ck with the manufacturer of your equipment to determine the quality of air needed

8.E

ne

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