Calculation of moisture condensate in compressed air

Test was carried out on compressor-IRN75K-OF, serial no.-TE0465U09230

during night from 1:00 am to 3:00 am.
Moisture is condensed in 4 places, Stage-1, Stage-2, Receiver and Drier. Each
drain is collected individually at a frequency of 1 hr.
Two observations were noted from 1:00 -2:00 and 2:00-3:00.
Flow of air(V) in various stages is calculated using PV=RT.
Moisture condensed is calculated using V2*w2 V1*w1
where.. w= Absolute humidity in air in g/m3
V= Flow of air in m3/hr

Observations

There is huge difference between actual and theoretical

Major problem is drain in compressors.

Data used for calculations

Observation 1 from 1:00 am to 2:00 am

V1= 7560
m3/hr
T1= 25

T=186

P1= 1 bar

1 = 73%

V2= 2449
m3/hr

Compressor
Stage-1

T2= 36

P=3.2 bar
Press. Dew pt. =

P2= 3.2 bar

38

Condens
er

= 100%

Theoretical drain- 24.83

kg/hr
Actual drain- 2.73 kg/hr

V2= 2449
m3/hr
T2= 36

T= 207

P2= 3.2 bar

= 100%

V3= 794.12
m3/hr

Compressor
Stage-2

P= 9.9 bar
Press. Dew pt. =

Condens
er

= 100%

Theoretical drain- 66.65

kg/hr
Actual drain- 2.28 kg/hr

V2= 764.4
m3/hr

T2= 3

P2= 9.1 bar

P3= 9.9 bar

90

V2= 764.4
m3/hr
T2= 33

T3= 37

P2= 9.1 bar

= 100%

= 100%

Drier
V1= 7560
m3/hr
T1= 25

P1= 1 bar

Theoretical drain- 22.45

Compressor
Observation 2 from 2:00 am kg/hr
to 3:00 am
Actual drain- 1.72 kg/hr
Stage-1
T=187
P=3.1 bar
Press. Dew pt.

Condens

V2= 2561 m3/hr

T2= 40

P2= 3.1 bar

= 100%

w2= 50.672 g/m3

Theoretical- 0 kg/hr
Actual- 2.78 kg/hr

V2= 2561
m3/hr
T2= 40

T= 210

P2= 3.1 bar

= 100%

V3= 806.59
m3/hr

Compressor
Stage-2

P= 10 bar
Press. Dew pt. =

T2= 3

= 100%

Theoretical- 77.47
kg/hr
Actual- 2.4 kg/hr

P2= 9.1 bar

= 100%

w2= 33.490

V2= 764 m3/hr

P2= 9.1 bar

Condens
er

Drier

P3= 10 bar

100

V2= 764 m3/hr

T2= 32

T3= 45

= 100%

w2= 5.953
Theoretical- 21.05
kg/hr
Actual- 1.27 kg/hr