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2-3.1
(1) (Dynamic)
(2) (Displacement)
2-3.2 (Type of Compressor)
(1) (Dynamic Compressor)
(2) (Displacement Compressor)
(3) (Booster)
(4)
2-3.3
(1)
(2)
(3)
(4) (Treatment of Compressed air)
2-3.4 ?
(1)
(2)
(3)
(4)
(5) ()
(6)
(7)
(8)
(9)
(10)
2-3.5 ?
(1) ?
(2) ?
86
2-3.1
(1) (Dynamic)
(Casing)
Centrifugal, Ejector, Radial, Axial
Centrifugal
(2) (Displacement)
(Rotary)
(Reciprocating Piston Compressor)
2-3.2 (Type of Compressor)
2-3.1
2-3.1
(1) (Dynamic Compressor)
Centrifugal Compressors
1. 1 4.4 (CFM)
2. ( 400 HP 1,500 HP)
3. 24
1.
2.
( Unload )
(2) (Displacement Compressors)
- (Reciprocating)
2-3.3
0-20 bar
1. 1 3.4
2.
3.
4. 24 Overhaul
- (Rotary)
2.1 (Rotary Vane)
2-3.4
2-3.5
1. 1 4.4
88
2.
3. 24
4.
0-13 bar
2 (Rotary Van)
(Rotary Screw) 2-3.1
2-3.1 Rotary Vane Rotary Screw
Rotary Vane
1. 1450 RPM
Motor
1450 RPM
Rotary Screw
1. 3000
RPM
Motor
Compressor
1450 RPM
1450 RPM
Motor
2.
3. (Rotor)
Coupling
4. (Hydrovane)
(Bearing) Bearing Bush Shaft
Bearing Bush
Rotor
5.
6. SAE40
()
7.
Gear - Box
Compressor
3000 RPM
Pulley
Compressor
1450 RPM
3000 RPM
2.
3. 2 1)
2)
4. (Bearing) 6 Ball Bearing 4
Thrust Bearing 2
i
0.008
5.
6. Screw
7.
(3) (Booster)
1) (Pressure Booster)
89
2-3.8
2-3.3
(1)
2-3.9
90
2-3.9
1kg/m2 0.1 kg/m2
700 kPa (7 )
3 Rotary Van Rotary Screw
91
(2)
92
Water
Water
Oil Free
Oil Free
Water
Oil Free
Air
Oil injected
Air/Water
Oil Free
Air
Air
Oil Free
Oil injected
Air
Oil Free
Air/Water
Oil injected
Air/Water
Oil Free
Air
Air/Water
Oil Free
Oil injected
Air
Oil Free
Air
Air/Water
Lubricated
Oil injected
Air/Water
Lubricated
Air
Lubricated
2,000
1,000-2,000
250-1,000
25-250
2-25
1,000-,2000
250-1,000
25-250
250-1,000
25-250
2-25
250-1,000
25-250
2-25
250-1,000
25-250
2-25
I/s
0.36
0.39
0.45
0.45
0.52
0.38
0.38
0.43
0..41
0.45
0.52
0.41
0.47
0.56
0.36
0.43
0.52
7
kW/I/s
( VSD)
2-3.2
1)
2) Peak
Load 3) 4)
2
2-3.1
VR
VR
Co
Po
Pg
A
A x Co x Po
Pg + Po
m3
(m3)
m3/min (FAD)
(1.013 bar)
(bar)
(min) 1.5
3
2-3.2
v=
h( D 2 d 2 )
4
7-10 h 2 = h 3
2
r 2h
3
Ao = r ( 4h + s )
2
v=
2-3.3
(3)
1)
93
2) 3)
2
1.
2-3.10
2.
2-3.11
.
1 bar 7 - 11% 2 psi
1 %
2-3.4
Delta P
Delta P
f
L
Q
Pm
D
f L Q1.85
Pm D 5
= , bar
= ( f = 450 )
= (m)
= (L/s (FAD))
= , (bar)
= , (mm)
94
2-3.3
5% 30 6 /
10% 15%
0.1-0.2 bar .
10 /
2-3.5 6 m/sec
Dmm =
Po =
Pg =
Dmm =
Qcmm =
3536 QCMM Po
Pg + Po
(1.013 bar)
(bar)
(mm)
(FAD m3/min)
95
2-3.4
ASTM STANDARD PIPE Volume lite/sec at Pressure and Pipe Diameters (Velocity 6 m/s)
Pipe (in)
P(bar) /Dia (mm)
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
1/2
15.76
5.9
6.5
7.0
7.6
8.2
8.8
9.4
10.0
10.6
11.1
11.7
12.3
12.9
3/4
50.96
10.4
11.4
12.5
13.5
14.5
15.6
16.6
17.6
18.7
19.7
20.7
21.8
22.8
1.0
26.64
16.8
18.4
20.1
21.8
23.5
25.1
26.8
28.5
30.1
31.8
33.5
35.2
36.8
1,1/4
35.08
29.1
32.0
34.9
37.8
40.7
43.6
46.5
49.4
52.3
55.2
58.1
61.0
63.9
1,1/2
40.94
39.6
43.6
47.5
51.5
55.4
59.4
63.3
67.3
71.2
75.2
79.1
83.1
87.0
2.0
52.48
65.1
71.6
78.1
84.5
91.0
97.5
104.0
110.5
117.0
123.5
130.0
136.5
143.0
2,1/2
62.68
92.8
102.1
111.3
120.6
129.9
139.1
148.4
157.6
166.9
176.2
185.4
194.7
203.9
3.0
77.92
143.5
157.8
172.1
186.4
200.7
215.0
229.3
243.6
257.9
272.2
286.5
300.9
315.2
3,1/2
90.12
191.9
211.0
230.2
249.3
268.5
287.6
306.7
325.9
345.0
364.2
383.3
402.4
421.6
4.0
102.26
247.1
271.7
296.4
321.0
345.7
370.3
395.0
419.6
444.2
468.9
493.5
518.2
542.8
5.0
128.2
388.3
427.1
465.8
504.5
543.3
582.0
620.7
659.5
698.2
736.9
775.7
814.4
853.1
6.0
154.08
561.0
616.9
672.9
728.8
784.8
840.7
896.7
952.6
1008.6
1064.5
1120.5
1176.4
1232.4
2-3.12
96
1 2%
2-3.13
2-3.13 2-3.14
90 90
2-3.14
30 2-3.15
30
2-3.16 2-3.17 2-3.18 2-3.19
2-3.15
2-3.16
2-3.17 90
2-3.18 2-3.19 90
97
Class
1
2
3
4
5
6
Solid materials
Particle Size Particle density
m
mg/m3
0.1
0.1
1
1
5
5
15
8
40
10
-
Oil
Max. Oil content
mg/m3
0.01
0.1
1
5
25
-
Water
Residual water
Pressure dew point
3
g/m
C
0.003
- 70
0.117
- 40
0.880
- 20
5.953
+3
7.732
+7
9.356
+10
,
- After Cooler
70%
- Main Air Filter
- Refrigerant Air dryer 96%
- Desiceant Air dryer
15%-20% After cooler
2-3.4 ?
()
(kW)
Eff t
3.
x
Eff m
98
4.
Eff c
5.
(hr) 5
1.
3
4
5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
1.
2.
3.
1.
1.
2.
1.
2.
3.
(1)
1. 3C 1%
2-3.6
Wisen
ikRwT1 T2 P2
=
k 1
P
1
k 1
i *k
Da
LDU
i
K
T
T1
RW
P1
=
=
=
=
=
=
(Stage Compressor)
1.4 Isentropic of Air Constant
288 K (273 K + 15C)
T2
=
0.2871 (kJ / kg.K) 15C
1 (1.013 bar)
P2
=
2-3.20
2-3.21
2-3.22
3
1. Load + Unload
2. On + Off (
5 )
P
Load
Unload
Tn
Tload2
Tload1
T1
T2
Tunload1
Tunload2
Time
% LDU =
T load x 100
(T load + T unload )
T load 1 x 100
T1
LDU
=
Duty Cycle (1 )
3. Modulating ( Rotary Vane, Screw, Turbo)
Modulating
Air Flow Meter
Load+Unload On-Off Load
100
Modulating 100%
ECON 75 Load+Unload
216.67 / 7.5 6.5
100 20 12 / 300 /
40C 35C
Model/Type Air Compressor Screw Type 75 kW FAD = 216.67 at 7.5 Load +
Unload (LDU = (100/(100+20)) x 100 = 83.33%)
1
Air Inlet Temperature Before Improving
2
Air Inlet Temperature After Improving
3
Air Compressed Pressure Level
4
Air Inlet Absolute Pressure
5
Stage
6
Isentropic of Air
7
Gas Constant at T1
8
Fraction of Onload status
9
Densities of Air
10 Free Air Delivery
11 Energy Saving
12 Power Saving
13 Operating Days per year
14 Operating Times per day
15 Energy Saving per year
16 Energy Cost Saving per year
* Energy charge = 3.13 Baht/kWh
T1
T2
P2
P1
I
k
RW
LDU
Da
FAD
DW
P
d
hr
ES
EC
50 HP
40
35
7
1.013
1
1.4
0.2871
87.50
1.225E-03
98.83
4.048
0.43
300
24
2,701.29
8,455.03
C
C
bar
bar
o
kJ / kg.K
%
kg / litre
l /sec
kJ / kg
kW
d/y
hr/d
kWh/y
B/y
2-3.4 (1)
(LDU) (
3,600 7 2.50 )
101
()
7.5
11
15
22
30
37
55
75
110
(oC)
3oC
5oC
7oC
10oC
( .)
()
( .)
()
( .)
()
( .)
()
196
303
428
651
910
1,118
1,748
2,325
3,353
491
758
1,070
1,628
2,274
2,795
4,370
5,812
8,384
327
505
713
1,085
1,516
1,863
2,913
3,875
5,589
818
1,263
1,784
2,713
3,790
4,658
7,284
9,687
13,973
458
708
999
1,519
2,123
2,608
4,079
5,425
7,825
1,145
1,769
2,497
3,798
5,307
6,521
10,197
13,561
19,562
654
1,011
1,427
2,170
3,032
3,726
5,827
7,749
11,178
1,635
2,527
3,567
5,426
7,581
9,315
14,567
19,373
27,945
(2)
1) 2) 3)
1 bar 7 - 11 % 2 psi 1%
2-3.23
102
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
(in)
(mm) (ASTM)
(m)
(QFAD = l/s)
(Pg bar)
(bar (e))
[450 x L x Q1.85] / [D5x (Pm)]
(Pg bar)
(%)
(%)
(kW)
(hr/y)
(%)
(kWh/y)
(kWh/y)
(/)
1,1/2
40.94
100
217
7.0
1.03
2.0
52.48
100
217
7.0
0.30
5.97
14.71
7.57
75
7200
80
432,000
32,705
81,761
6.70
4.29
2.21
75
7200
80
432,000
9,526
23,814
2,1/2
3.0
62.68
77.92
100
100
217
217
7.0
7.0
0.12
0.04
6.88
1.71
0.88
75
7200
80
432,000
3,810
9,526
6.96
0.57
0.29
75
7200
80
432,000
1,270
3,175
3,1/2
90.12
100
217
7.0
0.02
6.98
0.29
0.15
75
7200
80
432,000
635
1,588
(3)
4-5
(Pressure Booter)
1. 1 bar 7.25%
2 psi 1%
2.
3.
4.
1.
2.
3.
103
4. 7.5 7
0.5
2-3.7
k 1
k 1
i k R T P i * k P i * k
W 21
22
k 1
k 1
1 i* k
( )
isen
Wisen
()
i k R T P
W 2
=
k 1 P
1
P = W
Da
LDU
i
K
T
T1
RW
P1
P21
=
=
=
=
=
=
=
=
=
( )
kJ/kg
k 1
i * k
* Da
kg/lite
* FAD
lite/sec
* %L DU
P22
=
ECON 60 HP 104.44 /
9 90% 300 (24 )
5 9 5 6
1
2
3
4
5
6
7
P11
P12
P2
I
k
T
RW
104
8.5
0
1.013
1
1.4
313.15
0.2871
0
7.5
1.013
1
1.4
313.15
0.2871
8.5
7.5
1.013
1
1.4
313.15
0.2871
bar
bar
bar
K
kJ / kg.K
8
9
10
11
12
13
14
16
LDU
Da
FAD
DW
OWork
EC : ES
EC
90.24
90.24
90.24
%
1.225E-03 1.225E-03 1.225E-03 kg / litre
91.51
91.51
91.51
l /sec
282.05
263.41
18.64
kJ / kg
28.53
26.65
1.89
kW
300
300
300
d/yy
12
12
12
hr/d
102,715
95,927
6,788
kWh/y
23,756 B/y
(4)
5%
1) 2) 3)
4)
, , , ,
2
(No-Load Testing)
2
1 ON/OFF Load
2-3.8 (Qleak)
Qleak = Q
Tav
Tav + t av
QLeak = (l/sec)
Q
= (l/sec : FAD)
Tav = (sec) tav = (sec)
1. ()
2. (Ton)
(toff)
3. 3-5
4. ( 2-3.4 (2))
105
ECON 15/11 HP/kW 20.48 L/sec ( 10 bar)
Tav = 45
tav = 120 (
(11kW/20.48l/s = 0.537 kW/l/sec) 3,600 /
2-3.8
Qleak = 20.48
45
45 + 120
kW
[P1 P2 ]
V
P1
Tav
Qleak
Tav
=
=
=
=
(liter)
(bar) P2 = (bar)
P1 P2 (sec)
(l/sec)
1.
2. ()
3. (P1)
P2 3-5
( Unload 3-5 )
4.
106
1
2
3
4
5
P1
P1 =
T11 ..
T21 ..
T31 ..
T41 ..
T51 ..
P2
P2 =
T12 ..
T22 ..
T32 ..
T42 ..
T52 ..
T ()
T1 = T12 - T11 ..
T2 = T22 - T21 ..
T3 = T32 - T31 ..
T4 = T42 - T41 ..
T5 = T52 - T51 ..
Tavg = T1+ T5
l/sec
= 9.3 kW
= 9.3 x 7200
= 66,960 kWh/y
9 12.4%
24
2-3.10
0.158 x d2 x (Pg + Po) l/sec
Qleak =
0.158 =
( ISO 1217-1986 Annex
E ) ( Discharge Coefficient 0.97)
d
=
(mm)
Pg
=
. (bar) Po = (1.013 bar)
(d) . (Pg)
(2-3.4 (3))
107
Pressure
(bar)
3.0
4.0
4.5
5.0
6.0
7.0
7.5
8.0
9.0
0.3
0.5
l/ses kW l/ses kW
0.06 0.01 0.16 0.03
0.07 0.01 0.20 0.04
0.08 0.02 0.22 0.05
0.09 0.02 0.24 0.06
0.10 0.03 0.28 0.07
0.11 0.03 0.32 0.09
0.12 0.04 0.34 0.10
0.13 0.04 0.36 0.11
0.14 0.05 0.40 0.13
0.7
l/ses kW
0.31 0.05
0.39 0.08
0.43 0.09
0.47 0.11
0.54 0.14
0.62 0.18
0.66 0.20
0.70 0.21
0.78 0.25
7.0
l/ses
31.07
38.81
42.68
46.55
54.29
62.04
65.91
69.78
77.52
kW
5.31
7.97
9.42
10.95
14.21
17.71
19.56
21.45
25.40
2-3.24
108
10.0
l/ses
kW
63.41 10.83
79.21 16.26
87.11 19.22
95.01 22.34
110.81 28.99
126.61 36.15
134.51 39.91
142.41 43.78
158.21 51.83
2-3.25 () ()
2-3.26
(5) ()
1)
2) Peak Load 3)
4)
1 ECON 100 HP 13
/ 7
( 2-3.1)
VR
=
3 x 13 x 1.013 m3
=
5
m3
7 + 1.013
2-3.11
VR
=
Po x (Vd - Co) x t
(P1 - P2)
t
=
VR x (P1 P2)
min
Po x (Vd - Co)
Vd
=
m3/min
t
=
(min)
P1
=
(Unload) bar P2 = (Load) bar
109
2 1 16 /
6
VR
=
5
m3
Po
=
1.013 bar
P1
=
7
bar
Co
=
13
m3/min
P2
=
6
bar
Vd
=
16
m3/min
t
=
5 x (7 6)
=
1.65 99
1.013 x (16 13)
* 3 m3/min 1.65
3 2 10 /
6 Load Unload
tUnload
= 5 x (7 6) x 60
= 29.62 sec (23.08%)
1.013 x (10 0)
tload
= 5 x (6 7) x 60
= 98.72 sec (76.92 %)
1.013 x (10 13)
Unload (23.08%)
Unload
Unload 10-15
4 55
8.47 / 7 6
6 / 24x300 /
3 (
2.5 B/kWh 30% )
= (- )
min 29 sec
= ( - )
( - )
72/101x100 = 71.29
29/101x100 = 28.71
= x / x /
kWh/y
= 55 x 24 x 300 = 396,000
kWh/y
= x / x / kWh/y
110
(6)
1)
2) 3)
4)
-
-
-
-
2-3.27
2-3.27
()
2-3.28
111
2-3.28
0.7 2-3.4 (8)
ECON 2 15 HP () 60 HP ()
60 HP ()
15 HP (
)
19.30 / 9 17.81%
60 HP
60 HP
15 HP 60 HP
15 HP 28.33 / 9
68.11% 15 HP
69,322 / 187,115 /
15 HP
112
1
2
3
4
5
6
7
8
9
10
11
12
13
Load (Power)
Unload (Power)
Load (Time)
Unload (Time)
Dutycycle (Time)
Load Fraction (Load/Dutycycle)
Unload Fraction (UnLoad/Dutycycle)
Power Average
Operating Days
Operating Times
Energy Consumption
Energy Cost
Energy Saving (EComp1 EComp2) ESave
PL
PUL
TL
TUL
TDu
LDu
ULDu
PAvg
OWork
ESum
EC
Comp.1
30.77
15.32
32
146
178
17.98
82.02
18.10
300
24
130,306
325,765
Comp.2
10.91
3.29
121
57
178
67.98
32.02
8.47
300
24
60,984
152,460
69,322
173,305
kW
kW
Sec
Sec
Sec
%
%
kW
d/y
hr/d
kWh/y
B/y
kWh/y
B/y
=
25,200 x 2.50
=
63,000 B/y
2-3.29
2.
(
1)
2-3.30
113
3.
( 1)
2-3.31
4.
3 2 mm ( 1)
2-3.32
5.
( 1)
2-3.33
2-3.34
6. ()
7.
114
(8)
1.
2-3.35
2-3.36
2. Nozzle
2-3.37 Nozzle
2-3.38 Nozzle
115
2-3.39 Nozzle
Nozzle
2-3.40 Nozzle
2-3.41 Nozzle
116
2-3.39
3. Booster
2
2
5-6
2-3.42
4.
5.
1) 2) 3)
4) (Load Unload) 5)
3075% 15
2-3.43
ECON 22
Load + Unload
- Load
=
18.61 kW (55%)
- Unload
=
9.89 kW (45%)
-
=
8.77 kW
-
=
7,200 hr/y
2-3.44
2-3.45
(9)
2-3.46 2-3.47
5 2-3.46
6.91 10
15% 10.79
2-3.46
Pressure Ratio = {(5.59 x 0.04 + 0.20) + 1.013} / (1.0 - 0.01) = 6.91 bar
2-3.47
118
Pressure Ratio = {(8.40 x 0.04 + 0.80) + 1.013} / (1.0 - 0.05) = 10.79 bar
1. Air Filter
2. Oil Separator
3. After Cooler
4. Main Filter
5. Air Dryer
6. Mist Filter
7. Main Pipe
8. (1-3)
9. (4-7)
(bar)
0.01
0.20
0.04
0.14
0.20
0.20
0.05
0.25
0.59
(bar)
0.05
0.80
0.04
0.70
0.20
0.70
0.70
0.89
2.30
2-3.48
2-3.49
(10)
94 %
2% 4%
2-3.50
119
1) 2)
3)
2-3.51
1.
2.
3.
2-3.12
Wheat = [(K1 x Q1)+(K2 x Q2)] x TR x
kWh/year
Wheat = (kWh/year)
K1 =
K2
Q1 = (kW LOAD)
Q1
= (kW UNLOAD)
TR = (hours)
(FAD)
90% 10%
INSTALL (HP)
50
60
90
110
150
175
190
230
280
350
120
2-8.5 ?
(1) ?
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
121
80%
auto drain
auto drain
0.5 Barg.
1 Barg.
12.
.................
13.
.... Barg. %
.... Barg. %
.... Barg. %
14.
15.
(Ring loop)
16.
17.
18.
122
(Booster air compressor)
0.5 Barg.
kW/m3/min
19. unload
load
unload
unload
20.
21.
5%
5%
22.
23.
24.
25.
26.
123
27.
...................
...................
kW/m3/min
......................
( 2 )
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
(Cooling tower)
/ (on/off)
(load/unload)
124
3
3
3
125