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**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: • • • • Actual Free Air Delivery (FAD) of the compressor Isothermal power required Volumetric efficiency 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

8.4.1

Field Testing

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

Bureau of Energy Efficiency

107

Energy Performance Assessment of Compressors for a particular ratio of upstream pressure (receiver) to the downstream pressure (atmospheric) i.8.e. 8.4.2 Arrangement of test equipment The arrangement of test equipment and measuring device shall confirm to Figure 8. Mach number equals one.4. 8.1.10000 Flow Nozzle: Flow nozzle with profile as desired in IS 10431:1994 and dimensions 8. It should be ensured that the pressure drop through the throttle valve should be equal to or twice the pressure beyond the throttle. The compressor is started with the air from the receiver discharging to the atmosphere through the flow nozzle.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 (m3/hr) 3–9 9 –30 27 –90 60 – 170 130 – 375 300 – 450 750 – 2000 1800 – 5500 3500 . kWh and amps drawn by the compressor The above readings are taken for the 40%. 60%. • • • • Measuring instruments required for test Thermometers or Thermocouple Pressure gauges or Manometers Differential pressure gauges or Manometers Standard Nozzle Bureau of Energy Efficiency 108 . After the system is stabilized the following measurements are carried out: • • • • • Receiver pressure Pressure and temperature before the nozzle Pressure drop across the nozzle Speed of the compressor kW.4 Measurements and duration of the test. 100% and 110% of discharge pressure values. 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.

1 J/kg k Differential pressure across the nozzle kg/cm2 Bureau of Energy Efficiency 109 . T ⎛ 2( P3 − P4 )( P3 x Ra ) ⎞ ⎟ Free air delivered . Q f (m / sec) = k x x d x 1 x ⎜ ⎟ 4 P ⎜ T3 1 ⎝ ⎠ s π 1/ 2 2 k d T1 P1 P3 T3 Ra P3-P4 : : : : : : : : Flow coefficient – as per IS Nozzle diameter M Absolute inlet temperature oK Absolute inlet pressure kg/cm2 Absolute Pressure before nozzle kg/cm2 Absolute temperature before nozzle oK Gas constant for air 287.8.5 Calculation Procedure for Nozzle Method I. Energy Performance Assessment of Compressors • • • Psychrometer Tachometer/stroboscope Electrical demand analyser T1 P1 FILTER 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 8.

08 x 287 ⎞ x⎜ ⎟ 1.08 kg / cm2 P3 T3 : Temperature before the nozzle 40oC or 313oK P3 – P4 : Pressure drop across the nozzle = 0. Isothermal Efficiency Isothermal power (kW ) = P1 Qf r = = = = Isothermal power / Input power P x Q f x log e r 1 36.08) 2 x 303 ⎛ 2 x 0. m3 / hr IV. Step – 1 : Calculate Volumetric Flow Rate k : Flow coefficient (Assumed as 1) d : Nozzle diameter : 0. Pressure ratio P2/P1 III.391 m3/sec = 1407. kW Free air delivered .036 x1.8.036 kg / cm2 Ra : Gas constant : 287 Joules / kg K T ⎛ 2( P3 − P4 )( P3 x Ra ) ⎞ ⎟ Free air delivered .5 kg / cm2 (a) P2 : Inlet Pressure .04 ⎝ 313 ⎠ 1/ 2 Bureau of Energy Efficiency 110 .7 Absolute intake pressure kg/ cm2 Free air delivered m3/hr.3.6 m3 / h.1. π 4 x (0. Volumetric efficiency = Free air delivered in m3 / min x 100 Compressor displacement in m3 / min Compressor displacement = D L S χ n π 4 x D2 x L x S x χ x n = = = = = Cylinder bore.08 metre : Receiver Pressure . metre Cylinder stroke. Specific power consumption at rated disch arg e pressure = Power consumption. of cylinders 8.04 kg / cm2(a) P1 T1 : Inlet air temperature 30oC or 303oK : Pressure before nozzle – 1. metre Compressor speed rpm 1 for single acting and 2 for double acting cylinders No. Energy Performance Assessment of Compressors II. Q f (m / sec) = k x x d x 1 x ⎜ ⎟ 4 P ⎜ T3 1 ⎝ ⎠ s π 1/ 2 2 Free air delivered . Q f (m s / sec) =1 x = 0.6 Example Calculation of Isothermal Efficiency for a Reciprocating Air Compressor.

) Another way of determining the Free Air Delivery of the compressor is by Pump Up Method .36 1.8 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-3.04 Isothermal power (kW ) = 1.34 x 100 = 56% 86.7 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 1407.04 x1407.Absolute intake pressure Qf -Free Air Delivered Compression ratio.04 kg / cm2 (a) = 1407. Although this is less accurate.071 kW/m3/hr 8.7 = 1.0 8.6 = 0. P1 . Specific power requirement = 100 1407.51 = 3.36 = 48.also known as receiver filling method.8.6 m3 / h. this can be adopted where the elaborate nozzle method is difficult to be deployed. Energy Performance Assessment of Compressors Step – 2 : Calculate Isothermal Power Requirement Isothermal power (kW ) = P x Q f x log e r 1 36. r = 3.6 x log e 3.34 kW 36. Bureau of Energy Efficiency 111 .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 = 48.6 m3/hr and actual power consumption is 100 kW.

and delivery piping Time take to build up pressure to P2 in minutes The above equation is relevant where the compressed air temperature is same as the ambient air temperature.88 m3/minute Theoretical compressor capacity : 14. Start the compressor and activate the stopwatch. In case the actual compressed air temperature at discharge.322 m3 Initial pressure P1 : 0.. i.. the FAD is to be corrected by a factor (273 + t1) / (273 + t2). after cooler.79 m3 Additional hold up volume.e.4974 m3 Total volume : 8. i.e. Note the time taken to attain the normal operational pressure P2 (in the receiver) from initial pressure P1. is : 0. EXAMPLE An instrument air compressor capacity test gave the following results (assume the final compressed air temperature is same as the ambient temperature) – Comment? Piston displacement : 16. Calculate the capacity as per the formulae given below: Actual Free air discharge Q = Where P2 P1 P0 V T = = = = = P2 − P1 V × Nm3 / Minute P0 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. thus closing the receiver outlet.8. Make sure that water trap line is tightly closed once again to start the test. perfect isothermal compression. etc. pipe / water cooler. 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. Open water drain valve and drain out water fully and empty the receiver and the pipeline.03 kg/cm2 Final pressure P2 Bureau of Energy Efficiency 112 . say t20C is higher than ambient air temperature say t10C (as is usual case).5 kg/cm2 : 7.75 m3/minute @ 7 kg/cm2 Compressor rated rpm 750 : Motor rated rpm : 1445 Receiver Volume : 7..

8.. Pressure × Pumpup time = 13. which indicates compressor performance needs to be investigated further.021 Capacity shortfall with respect to 14. Energy Performance Assessment of Compressors Atmospheric pressure P0 Compressor output m3/minute : : : 1.5) × 8.026 × 4.69 %.03 − 0. (7.a (P2 − P1 ) × Total Volume Atm.17 m3/minute 1. 10.e.322 Bureau of Energy Efficiency 113 .75 m3/minute rating is 1.026 kg/cm2.577 m3/minute i.

IS 10431:1994: Measurement of airflow of compressors and exhausters by nozzles. Define the term isothermal efficiency and explain its significance. Bureau of Energy Efficiency 114 . IS 5456:1985 code of practice for testing of positive displacement type air compressors and exhausters 3. Energy Performance Assessment of Compressors QUESTIONS 1) 2) 3) 4) 5) 6) What is meant by Free Air Delivery? Describe the method of estimating flow by nozzle method. Compressor performance – Aerodynamics for the user by M Theodore GreshButterworth Heinemann.8. How is specific power requirement calculated? REFERENCES 1. Define the term volumetric efficiency and explain its significance. 2. Describe the method of estimating flow by pump up method.

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