Adjustable Speed

Control of Rotary Screw

Ai C Air Compressors
The Need for Air Control
10% of the electrical energy used by
industry is used to drive air compressors
Compressedair istentimesthecost of Compressed air is ten times the cost of
electricity
i f l fi Focus is often on lowest first cost
Typical loading: 70 80%of ratedcapacity Typical loading: 70 80% of rated capacity
Imprecise or inefficient pressure control
Benefits of Air Control
Stabilizedplant pressure Stabilized plant pressure
Reduced process variables p
Reduced system cycling y y g
Reduced maintenance
Benefits of Air Control
Reduced energy and
demand charges
1%additional 1 % additional
cost per 1 PSI of
pressure increase p essu e c ease
Air Demand Profiles
Base load
100%
5 day work week
Fixedair
40%
60%
80%
L
o
a
d
Fixed air
consumption
~8%of themarket
0%
20%
40%
L
~8% of the market
Potential for 14%
i
1
2
:
0
0
3
:
0
0
6
:
0
0
9
:
0
0
1
2
:
0
0
1
5
:
0
0
1
8
:
0
0
2
1
:
0
0
0
:
0
0
Time
energy savings
Time
Data provided by Atlas Copco
Air Demand Profiles
100%
16 hr / 5 day week
40%
60%
80%
L
o
a
d
No consumption
during nights &
0%
20%
40%
L
g g
weekends
Widefluctuations
1
2
:
0
0
3
:
0
0
6
:
0
0
9
:
0
0
1
2
:
0
0
1
5
:
0
0
1
8
:
0
0
2
1
:
0
0
0
:
0
0
Time
Wide fluctuations
~28% of the market
P t ti l f 29%
Time
Potential for 29%
energy savings
Data provided by Atlas Copco
Air Demand Profiles
100%
24 hr / 5 day week
Hi h ti
40%
60%
80%
L
o
a
d
High consumption
during day shifts
Lower consumption
0%
20%
40%
L
Lower consumption
during night shifts
Fixed consumption
1
2
:
0
0
3
:
0
0
6
:
0
0
9
:
0
0
1
2
:
0
0
1
5
:
0
0
1
8
:
0
0
2
1
:
0
0
0
:
0
0
Time
during the weekends
~65% of the market
P i l f 39%
Time
Potential for 39% energy
savings
Data provided by Atlas Copco
Air Compressor Types
Centrifugal
Refrigeration/heavy
chemical
100 20,000 HP
to200000CFM / to 200,000 CFM /
5,000 PSI
L t t f l Lowest cost for large
consumers
Air Compressor Types
Reciprocating
Plant and process air
- 500 HP
25-2,000 CFM / 50,000
PSI
High installation cost,
maintenance
Higher efficiency at part
load
Air Compressor Types
Rotary screw
Plant and process air
20 500HP 20 500 HP
20-13,000 CFM / 250
PSI PSI
Lower installed and
maintenance cost
Elementsof RotaryScrew Elements of Rotary Screw
Compressors Compressors
Rotary screw
Si l /d l t Single/dual stage
Positive displacement
Load characteristics
Low starting torque
Constant torque load
Elementsof RotaryScrew Elements of Rotary Screw
Compressors Compressors
Modulation control
Slid l Slide valve
Higher efficiency
Higher maintenance g
More common in
refrigeration
Throttle al e Throttle valve
Lower efficiency
Lower maintenance
More common in air
supplies
Regulation Methods
On-off control
Load-No Load [L-NL] control
Modulation Modulation
Throttle valve
Slide valve
HybridL-NL / Modulation Hybrid L NL / Modulation
Variable speed
On-Off Control
Power proportional
60
80
100
w
e
r
to total flow
Least precisecontrol
0
20
40
60
0 50 100
%

P
o
Least precise control
Suitable only for
l d l
% Capacity
very low duty cycles
Inrush current
Motor heating
Load-No Load
100
50% capacity
40
60
80
P
o
w
e
r
= 60 % power
0%capacity
0
20
0 50 100
%

0% capacity
= 20 - 25% power
d
0 50 100
% Capacity
60 - 90 seconds to
stabilize
ThrottleValve/SlideValve Throttle Valve/Slide Valve
Modulation
60
80
100
w
e
r
50% capacity
Modulation
0
20
40
60
%

P
o
w
= 85 % power
Pressuredropacross
0 50 100
% Capacity
Pressure drop across
throttle valve
b id h l l /
Throttle valve
Hybrid throttle valve /
L-NL control
60
80
100
w
e
r
0
20
40
0 50 100
%

P
o
0 50 100
% Capacity
Slide valve
Variable Speed Operation
100
50% capacity
40
60
80
P
o
w
e
r
= 55% power
35%energysavings
0
20
40
0 50 100
%

35% energy savings
0 50 100
% Capacity
Throttle valve On-Off
L-NL Variable Speed
Slide valve
Energy Savings Potential
LCC Conventional Control
Maintenance
5%
Purchase Price
11%
11% Purchase
5%Maintenance
5%
5% Maintenance
84% Energy
Energy
84%
Data provided by Ingersoll Rand
Energy Savings Potential
LCC Variable Speed Control
Maintenance
Purchase Price
12%
AFD Savings
30%
12% Purchase
7%Maintenance Maintenance
7%
30%
7% Maintenance
51% Energy
30%S i 30% Savings
Energy
51%
Data provided by Ingersoll Rand
Investment Payback
7
8
Dependent upon
3
4
5
6
7
load characteristics
Average1year
0
1
2
0 1 2 3 4 5
Average 1 year
payback on
incremental VFD
Total cost Incremental cost
24 hr / 5 day week Average
16 hr / 5 day week Base load
incremental VFD
cost
16 hr / 5 day week Base load
VariableSpeedControl Variable Speed Control
Limitations Limitations
2:1 turn down typical
Lubrication reduction
Dynamicsealinglosses Dynamic sealing losses
Efficiency loss
Friction Friction
Blow by
VLT 5000 Selection
Constant Torque characteristic
Normal Overload Mode
Additional loads Additional loads
Service Factor (NEMA motors)
110% - 120%
Auxiliary cooling fan
Closed Loop Regulation
Precise regulation
L NL 10PSI L-NL 10 PSI
Modulation 5 PSI
VFD 3PSI VFD 3 PSI
Built-in PID controller
P typically 3 yp y
I typically 1 - 3
Dependent upon
pressuretank size
80
100
120
pressure tank size
D term not used
20
40
60
80
0