8.

ENERGY PERFORMANCE ASSESSMENT OF COMPRESSORS

8.1 Introduction
The compressed air system is not only an energy intensive utility but also one of the least energy efficient. Over a period of time, both performance of compressors and compressed 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 to minimize the cost of compressed air.

8.2

Purpose of the Performance Test

To find out:
y Actual Free Air Delivery (FAD) of the compressor y Isothermal power required y Volumetric efficiency y 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 : Absolute discharge pressure of last stage Absolute intake pressure : It is the least power required to compress the air assuming isothermal conditions. : The ratio of Isothermal power to shaft power : The ratio of Free air delivered to compressor swept volume

Isothermal Power

Isothermal Efficiency Volumetric efficiency

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

8.4

Field Testing

8.4.1 Measurement of Free Air Delivery (FAD) by Nozzle method Principle: If specially shaped nozzle discharge air to the atmosphere from a receiver getting its supply from a compressor, sonic flow conditions sets in at the nozzle throat

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 Arrangement of test equipment The arrangement of test equipment and measuring device shall confirm to Figure 8.1. 8.4.3 Nozzle Sizes The following sizes of nozzles are recommended for the range of capacities indicated below: Nozzle size (mm) 6 10 16 22 33 50 80 125 165 Capacity (m /hr) 39 9 30 27 90 60 170 130 375 300 450 750 2000 1800 5500 3500 - 10000
3

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 atmosphere through 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:
y y y y y

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.
y y y y

Measuring instruments required for test Thermometers or Thermocouple Pressure gauges or Manometers Differential pressure gauges or Manometers Standard Nozzle

8. Energy Performance Assessment of Compressors

y Psychrometer y Tachometer/stroboscope y Electrical demand analyser

P1 FILTER

T1

P2

AIR COMPRESSOR

RECEIVER

P4

P3

T3
THROTTLE VALVE

Nozzle P3 P4
FLOW STRAIGHTENER

DISCHARGE TO ATMOSPHERE

BY-PASS

Figure 8.1: Test Arrangement for Measurement of Compressed Air Flow

Calculation Procedure for Nozzle Method

I.
T 2(P3 P4 )(P3 x Ra )  Free air delivered , Q f (m / sec)! k x 4 x d x 1 x1  T3  P
s 2

1/2

k d T1 P1 P3 T3 Ra P3-P4

: : :
:

: : : :

Flow coefficient as per IS Nozzle diameter M Absolute inlet temperature o K Absolute inlet pressure kg/cm2 Absolute Pressure before nozzle kg/cm2 Absolute temperature before nozzle o K Gas constant for air 287.1 J/kg k Differential pressure across the nozzle kg/cm2

8. Energy Performance Assessment of Compressors

II.

Isothermal Efficiency Isothermal power (kW )! P1 Qf r = = =

Isothermal power / Input power

P1 x Q f x loge r 36.7 Absolute intake pressure kg/ cm2 Free air delivered m3/hr. Pressure ratio P2/P1 Power consumption, kW Free air delivered , m3 / hr

III. Specific power consumption at rated disch arg e pressure!

IV. Volumetric efficiency!

Free air delivered in m3 / min Compressor displacement in m3 / min

 x D 2 x L x S x x n 4

x 100

Compressor displacement! D L S  n

= = = = =

Cylinder bore, metre Cylinder stroke, metre Compressor speed rpm 1 for single acting and 2 for double acting cylinders No. of cylinders

8.6 Example
Calculation of Isothermal Efficiency for a Reciprocating Air Compressor. Step 1 : Calculate Volumetric Flow Rate k : Flow coefficient (Assumed as 1) d : Nozzle diameter : 0.08 metre : Receiver Pressure - 3.5 kg / cm2 (a) P2 : Inlet Pressure - 1.04 kg / cm2 (a) P1 : Inlet air temperature 30o C or 303o K T1 : Pressure before nozzle 1.08 kg / cm2 P3 : Temperature before the nozzle 40o C or 313o K T3 P3 P4 : Pressure drop across the nozzle = 0.036 kg / cm2 : Gas constant : 287 Joules / kg K Ra
s

Free air delivered , Q f (m / sec)! k x

4 x d x 1 x1  P

2 T

2(P3 P4 )(P3 x Ra )  T3 

1/2

Free air delivered, Q f (ms / sec)!1 x = 0.391 m3/sec = 1407.6 m3 / h.

 303 2 x 0.036 x1.08 x 287  x   x (0.08)2 x 4 1.04 313 

1/2

8. Energy Performance Assessment of Compressors

Step 2 : Calculate Isothermal Power Requirement Isothermal power (kW )! P1 x Q f x loge r 36.7 = 1.04 kg / cm2 (a) = 1407.6 m3 / h. 3.51 ! 3.36 1.04
! 48.34 kW

P1 - Absolute intake pressure Qf -Free Air Delivered Compression ratio, r!

Isothermal power (kW )! 1.04 x1407.6 x loge 3.36 36.7 Step 3 : Calculate Isothermal Efficiency Motor input power Motor and drive efficiency Compressor input power Isothermal efficiency

= 100 kW = 86 % = 86 kW = Isothermal Power x 100 Compressor input Power = 48.34 x 100 = 56% 86.0

8.7 Assessment of Specific Power requirement

Specific power consumption = Actual power consumed by the compressor Measured 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 = 100 1407.6 = 0.071 kW/m3/hr

8.8 Measurement of FAD by Pump Up Method

(Note: The following section is a repeat of material provided in the chapter-3 on Compressed Air 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.

8. Energy Performance Assessment of Compressors

Simple method of Capacity Assessment in Shop floor Isolate the compressor along with its individual receiver being taken for test from main 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 the pipeline. 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! 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 P2 P1 P0


V Nm3 / Minute T

The above equation is relevant where the compressed air temperature is same as the ambient air temperature, i.e., perfect isothermal compression. In case the actual compressed air temperature at discharge, say t20C is higher than ambient air temperature say t10 C (as is usual case), the FAD is to be corrected by a factor (273 + t1) / (273 + t 2).
EXAMPLE

An instrument air compressor capacity test gave the following results (assume the final compressed air temperature is same as the ambient temperature) Comment? 16.88 m3/minute : Piston displacement 14.75 m3/minute @ 7 kg/cm2 : Theoretical compressor capacity Motor rated rpm : 1445 : Compressor rated rpm 750 7.79 m3 : Receiver Volume Additional hold up volume, 0.4974 m3 i.e., pipe / water cooler, etc., is : 8.322 m3 : Total volume 0.5 kg/cm2 : Initial pressure P1 7.03 kg/cm2 : Final pressure P2

8. Energy Performance Assessment of Compressors

Atmospheric pressure P0 Compressor output m3/minute

: : :

1.026 kg/cm2,a

P2 P1  Total Volume Atm. Pressure Pumpup time 7.03

0.5  8.322 = 13.17 m3/minute 1.026 4.021 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 compressors offer good energy efficiency performance as system head pressure floats to achieve efficient system operation. Variable volume ratio machines will deliver improved energy performance over a wide operating envelope but a price is paid for that benefit. Variable volume ratio compressors have slightly .higher capital costs, increased maintenance cost, and reduce reliability when compared to their fixed Vi counterparts. The increased maintenance costs and reduced reliability are attributed to the additional components needed for volume ratio control. If you have an opportunity, perform a life-cycle analysis for alternative compressor selections. The life-cycle cost should include capital, operating, maintenance, and replacement costs over a specified time period. Keep in mind that, based on evidence from the field, some ancillary equipment alternatives (such as liquid injection oil cooling) will lead to shortened compressor lifetimes when compared to others (such as 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 inlet 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 disposalcost. 3: the minimum air compressor work is achieved with isothermal compression. In practical way, we try to achieve that 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

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:

. 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 n man 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)

. Change to Synthetic Lubricants f you are using petroleum based lubricants, you could experience up to an 8% energy savings by switching to Compressor Synth etic ubricants. Plus extend equipment life and save on oil changes and disposal cost.

. Reduce Plant Operating Pressure f possible - reduce overall plant pressure. Less pressure > Less CFM used > less energy consumed. IP: Reduce plant pressure 2 pounds at a time, then test run for minimum 24 hours. If any equipment has issues...then increas e ressure 2 pounds until running smoothly again. For every 2 pound pressure reduction -you save 1% of the electrical cost to run the ir compressor. . Check Differential Pressure on Air Compressor Filters. tart at the compressor cabinet filter then check the compressor inlet filter. ote: A dirty inlet filter can cost you 1% to 3 % in additional electrical costs. Why? Because decreased air flow to the compressor let valve increases the compression ratios resulting in more run time. ext check the air/oil separator differential pressure under a full load. A new separator causes a differential pressure drop of pproximately 2-3 psig. When your pressure drop reaches 8-10 psig, then it is time to change your separator elements. A dirty eparator element can cost you up to 5% in additional electrical cost. ext change the control air filter element. This often over looked, but still important filter where the controls receive their air signal. pressure drop here causes the controls to receive the lower pressure signal loading the compresso more and using more r lectricity.

. Reduce the Compressor Inlet Temperature y reducing inlet air temperature 10F below 70F, you save 2% on electrical usage. Your benefit increases up to 8% on a 30F egree day. But increasing the inlet temperature 10F above 70F will cost you 2% in additional electrical usage for every 10F up to 0% at 120F. (Inlet temperature has very little affect on Lubricated screw compressors)

. Check Differential Pressure on Compressed Air Line Filters. ize Compressed Air Filters to be twice (2x) your compressor CFM flow rate. This will lower your pressure drop approximately 2-3 sig and save 1% on energy costs. Elements will last twice (2x) as long and you will save on maintenance costs.

. Know what quality of compressed air your plant needs. he cleaner & dryer the compressed air the more energy used. heck with the manufacturer of your equipment to determine the quality of air needed

y P e 8 . E n e r g