Training Session on Compressors

Compressors &
Compressed Air
Systems
PRESENTATION

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Training Agenda: Compressor

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

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Introduction

Significant Inefficiencies
• Compressors: 5 to > 50,000 hp
• 70 – 90% of compressed air is lost

3
Introduction

Benefits of managed system

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

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Introduction

Main Components in Compressed

Air Systems
• Intake air filters
• Inter-stage coolers
• After coolers
• Air dryers
• Moisture drain traps
• Receivers 5
6
Training Agenda: Compressor

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

7
Types of Compressors

Two Basic Compressor Types

Type of
compressor

Positive
Dynamic
displacement

Reciprocating Rotary Centrifugal Axial

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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

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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
Screw compressor
• Rotary vane / Slide vane 10
Types of Compressors

Centrifugal Compressor
• Rotating impeller
transfers energy
to move air
• Continuous duty

• Designed oil
free
• High volume
applications
> 12,000 cfm
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Types of Compressors

Comparison of Compressors
• Efficiency at full, partial and no load
• Noise level
• Size
• Oil carry-over
• Vibration
• Maintenance
• Capacity
• Pressure 12
Training Agenda: Compressor

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

13
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

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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
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Assessment of Compressors

Compressor Efficiency
• Most practical: specific power
consumption (kW / volume flow rate)
• Other methods
• Isothermal
• Volumetric
• Adiabatic
• Mechanical 16
Assessment of Compressors

Compressor Efficiency
Isothermal efficiency
Isothermal efficiency =
Actual measured input power / Isothermal power

Isothermal power (kW) = P1 x Q1 x loge r / 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
Volumetric efficiency
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
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 19
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
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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) 21

Assessment of Compressors

Example
• Compressor capacity (m3/minute) = 35
• 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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Training Agenda: Compressor

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

23
Energy Efficiency Opportunities

1. Location
• Significant influence on energy use

2. Elevation
• Higher altitude = lower volumetric
efficiency

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 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
compressor 25
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

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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 27
Energy Efficiency Opportunities

6. Pressure Settings
• Higher pressure
• More power by compressors
• Lower volumetric efficiency
• Operating above operating pressures
• Waste of energy
• Excessive wear
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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
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Pressure reducing valves no longer needed
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 30
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) 31
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 32
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
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Energy Efficiency Opportunities

9. Maintenance Practices
• Lubrication: Checked regularly
• Air filters: Replaced regularly
• Condensate traps: Ensure drainage
• Air dryers: Inspect and replace filters

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Training Agenda: Compressor

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

35
 TROUBLESHOOTING
Problem Possible Cause Remedy
No power to motor. Turn on power.
Repair Unloaders.
Compressor unit will not
Unloaders not operating. Repair or readjust
start
controls.
Obstruction to rotation. Remove obstruction.
Discharge pressure above
Readjust control.
rating.
Motor overheating  
Unloader setting incorrect. Readjust Unloaders.
Inlet filter clogged. Clean or replace filter.
Discharge Pressure above Lower Discharge
rating Pressure
Intake filter clogged. Clean.
Worn or broken valves. Replace.
Leaking gaskets. Replace.
Over heating of
Unloader or control defective. Replace.
Compressor
Parts Unloader setting wrong. Correct
Compressor components worn
or Replace. 36
broken.
 Problem Possible Cause
Insufficient cooling water.
V-belt or coupling
misalignment.
Bearings too tight.
Oil level too high.
Over heating of
Compressor Parts
Lubrication inadequate.
(Contd)
Ambient temperature too high
Valves dirty.
Belts too tight.
Packings too tight.
Moisture separator not
draining.
Air in receiver too moist Air coolers ineffective
Inadequate cooling water flow
rate
Remedy
Increase quantity of
cooling water.
Realign components.
Adjust bearings.
Correct oil level.
Correct Oil Level
Ensure correct oil
Ensure Correct Oil
viscosity being used
Lower ambient temperature.
Increase Ventilation
Clean valves.
Readjust belt tension.
Readjust packings.
Unclog or repair separator drain.
Check temperature of
cooler at discharge port.
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Check cooling water flow pressure.
 Problem Possible Cause Remedy
System leaks excessive. Stop leaks.

Clean or replace filter as

Intake filter clogged.
applicable.
Replace worn or broken
Valves worn or broken.
valves.
Belts slipping. Tighten.
Speed lower than rating. Increase speed.
Delivery of air of air less than
Compressor components worn
rated capacity
or Replace.
broken
Control device inoperative or Repair or adjust control
maladjusted device
Water quantity insufficient. Increase water quantity.
Check water quantity and
Inlet temperature too high. temperature at
intercooler.

Mounting bolts loose. Tighten mounting bolts.

Excessive vibration of Misalignment of belt pulleys Realign as necessary

compressor
Adjust or replace 38
Bearings out of adjustment
bearings.
 Problem Possible Cause Remedy
Cylinder, head, or intercooler Clean compressor system
Outlet water dirty. parts.
temperature Increase cooling water
Water quantity insufficient
above normal supply.
Compressor speed too high. Slow down compressor.
Discharge pressure above
Lower discharge pressure.
rating.
Belts slipping. Readjust belts.
V-belts or coupling
Realign.
misaligned.
Tighten pulley or flywheel
Compressor Pulley or flywheel loose.
mountings.
noisy or
knocks Drive motor or compressor
Tighten mounting bolts.
mounting bolts loose.
Increase oil level or
Lubrication inadequate. pressure.
Use correct oil viscosity.
Check for loose mounting
Intercooler vibrating.
hardware.

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 Problem Possible Cause
Discharge pressure above rating.
Operating cycle Worn or broken internal
lasts too long compressor parts.
Unloader or control device defective.
Unloader or control defective.
Air receiver pressure
above Unloader setting wrong.
normal Leaks in control air piping.
Control air line clogged.
Valves worn or broken.
Intercooler pressure Valves not seated
above Unloader setting wrong.
normal Intercooler passages clogged.
Insufficient water.
System demand exceeds rating.
Intercooler pressure System leakage excessive
below
Intake filter clogged
normal
Valves worn
Unloader setting wrong.
Remedy
Readjust control
Replace worn or broken, parts.
Replace defective device
Repair or replace defective
parts.
Correct unloader setting.
Stop leaks.
Unclog control air lines.
Replace valves.
Reseat or relocate valves
Correct unloader setting
Clean intercooler
Increase water supply.
Upgrade compressor
Stop leakage.
Clean or replace air
filter as applicable.
Replace worn valves.
Correct unloader setting 40
 Problem Possible Cause
Clogged air filter
Broken piston and/or rings.
Oil level too high.
Oil in air receiver
Oil viscosity incorrect
Oil wrong type.
Unloaded running time too long.
Surging of Operating at less than designed
distribution air
minimum flow.
Cavitation of water Feed water level too low.
in
cooling supply Air leaks into suction piping
Remedy
Clean or replace air filter element.
Replace broken parts
Correct oil level.
Change lubricant to proper viscosity.
Change lubricant to proper viscosity.
Use auto start/stop control.
Increase flow of compressor.
Install surge control
valve in discharge line.
Increase feed water level in reservoir.
Stop leaks.
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 Training Session


Compressors &
Compressed Air
Systems
THANK YOU FOR YOUR ATTENTION

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