Training Session on Energy
Equipment
Compressors &
Electrical Equipment/
Compressed Air
Compressors
Systems
Presentation from the
“Energy Efficiency Guide for Industry in Asia”
www.energyefficiencyasia.org
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© UNEP 2006
Training Agenda: Compressor
Introduction
Electrical Equipment/
Types of compressors
Compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
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© UNEP 2006
Introduction
Significant Inefficiencies
• Compressors: 5 to > 50,000 hp
Electrical Equipment/
• 70 – 90% of compressed air is lost
Compressors
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(McKane and Medaris, 2003)
© UNEP 2006
Introduction
Benefits of managed system
Electrical Equipment/
• Electricity savings: 20 – 50%
Compressors
• Maintenance reduced, downtime decreased,
production increased and product quality
improved
(eCompressedAir) 4
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Introduction
Main Components in Compressed
Electrical Equipment/
Air Systems
Compressors
• Intake air filters
• Inter-stage coolers
• After coolers
• Air dryers
• Moisture drain traps
• Receivers 5
© UNEP 2006
Training Agenda: Compressor
Introduction
Electrical Equipment/
Types of compressors
Compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
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© UNEP 2006
Types of Compressors
Two Basic Compressor Types
Electrical Equipment/
Compressors
Type of
compressor
Positive
Dynamic
displacement
Reciprocating Rotary Centrifugal Axial
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Types of Compressors
Reciprocating Compressor
Electrical Equipment/
• 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
(King, Julie) 8
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Types of Compressors
Rotary Compressor
Electrical Equipment/
• 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
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Types of Compressors
Centrifugal Compressor
Electrical Equipment/
• Rotating impeller
Compressors
transfers energy
to move air
• Continuous duty
• Designed oil
free
• High volume
applications
> 12,000 cfm
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(King, Julie)
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Types of Compressors
Comparison of Compressors
Electrical Equipment/
• Efficiency at full, partial and no load
Compressors
• Noise level
• Size
• Oil carry-over
• Vibration
• Maintenance
• Capacity
• Pressure 11
© UNEP 2006
Training Agenda: Compressor
Introduction
Electrical Equipment/
Types of compressors
Compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
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Assessment of Compressors
Capacity of a Compressor
Electrical Equipment/
• 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
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Assessment of Compressors
Simple Capacity Assessment Method
Electrical Equipment/
• 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
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Assessment of Compressors
Compressor Efficiency
Electrical Equipment/
• Most practical: specific power
Compressors
consumption (kW / volume flow rate)
• Other methods
• Isothermal
• Volumetric
• Adiabatic
• Mechanical 15
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Assessment of Compressors
Compressor Efficiency
Electrical Equipment/
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
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Assessment of Compressors
Compressor Efficiency
Electrical Equipment/
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
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n = No. of cylinders
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Assessment of Compressors
Leaks
Electrical Equipment/
• 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
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Assessment of Compressors
Leak Quantification Method
Electrical Equipment/
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
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Assessment of Compressors
Quantifying leaks on the shop floor
Electrical Equipment/
• 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
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Assessment of Compressors
Example
Electrical Equipment/
• 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
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© UNEP 2006
Training Agenda: Compressor
Introduction
Electrical Equipment/
Types of compressors
Compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
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© UNEP 2006
Energy Efficiency Opportunities
1. Location
Electrical Equipment/
• Significant influence on energy use
Compressors
2. Elevation
• Higher altitude = lower volumetric
efficiency
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Energy Efficiency Opportunities
3. Air Intake
Electrical Equipment/
• 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 24
© UNEP 2006
Energy Efficiency Opportunities
4. Pressure Drops in Air Filter
Electrical Equipment/
• 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
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© UNEP 2006
Energy Efficiency Opportunities
5. Use Inter and After Coolers
Electrical Equipment/
• 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
© UNEP 2006
Energy Efficiency Opportunities
6. Pressure Settings
Electrical Equipment/
• Higher pressure
Compressors
• More power by compressors
• Lower volumetric efficiency
• Operating above operating pressures
• Waste of energy
• Excessive wear
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© UNEP 2006
Energy Efficiency Opportunities
6. Pressure Settings
Electrical Equipment/
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
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Pressure reducing valves no longer needed © UNEP 2006
Energy Efficiency Opportunities
6. Pressure Settings
Electrical Equipment/
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
© UNEP 2006
Energy Efficiency Opportunities
6. Pressure Settings
Electrical Equipment/
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
© UNEP 2006
Energy Efficiency Opportunities
7. Minimizing Leakage
Electrical Equipment/
• 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
© UNEP 2006
Energy Efficiency Opportunities
9. Controlled usage
Electrical Equipment/
• 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
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© UNEP 2006
Energy Efficiency Opportunities
9. Maintenance Practices
Electrical Equipment/
• Lubrication: Checked regularly
Compressors
• Air filters: Replaced regularly
• Condensate traps: Ensure drainage
• Air dryers: Inspect and replace filters
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© UNEP 2006
Training Session on Energy
Equipment
Electrical Equipment/
Compressors &
Compressors
Compressed Air
Systems
THANK YOU FOR YOUR ATTENTION
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© UNEP GERIAP
Disclaimer and References
• This PowerPoint training session was prepared as part of
the project “Greenhouse Gas Emission Reduction from
Electrical Equipment/
Industry in Asia and the Pacific” (GERIAP). While
reasonable efforts have been made to ensure that the
Compressors
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
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available on www.energyefficiencyasia.org
© UNEP 2006
