BBJ21105: Energy Efficiency

Optimization
Chapter 14
Electrical Energy-use Equipment -Air Compressors

Syed Mohd Zulfadhli bin Syed Adnan

Fakulti Pendidikan Teknikal dan Vokasional

Jabatan Teknologi
Bilik 30, Tingkat 5,
Universiti Tun Hussein Onn (UTHM)
Content Title

14. Electrical Energy-use Equipment -Air Compressors

14.1Identify the compressor types and selection
14.2Operation and monitoring of air compressors
14.3Inspection and maintenance of air compressor
14.4Comparison of centralized and de-centralized
systems
Objectives
In the end of course session, students able to:
1. Identify the compressor types and selection.
2. Understand the Inspection and maintenance of air compressor.
 Identify the compressor types and selection

 Compressed air is versatile tool used widely throughout

industry for a variety of purposes.
 Unfortunately, running air compressor often uses more
energy than any other equipment.
 Air Compressor is one part of the system followed by After
Cooler, Receivers, Air Dryers, Air Storage Tanks and Supply
Line.

Valve 1
Pneumatic crane

Valve 2
After cooler
Valve 3
Air Dryer
Filter
Utility
Compressed Air Supply Reservoir Tank
 Identify the compressor types and selection

 Instrumentation devices consumes large amounts of compressed air in industrial plant.

 Normally, it not operate at 100% condition due to air leakages.
 Most of leaks are:
1. At threaded connection points.
2. At valve
3. At regulators
4. At seals
5. In old pneumatic equipment
 More than 85% of electrical energy input to an air compressor is lost as waste heat,
leaving 15% of electrical energy consumed to be converted to pneumatic air energy.
 Identify the compressor types and selection

Type of Compressor

Positive Displacement
Dynamic Compressor Type
Compressor Type
Piston compressor

Reciprocating Rotary Screw Centrifugal

Single Acting Sliding vane

Double
Twin screw
Acting
Reciprocating

Diaphragm Lobe

Liquid Piston

Twin-screw compressor
 Identify the compressor types and selection
Difference between Rotary and
Reciprocating
Rotary Screw
No.
Compressor Type
1. Rotary screw air compressors use two meshing helical screws,
known as rotors or air-end, to compress the air.
2. As compressor has only two moving parts which are not in
contact with each other so no wear & tear, hence there is less
possibility of breakdown.
3. The internal air-end (screw component) operating
temperature is around 80 to 99 Deg C. This is possible
because of no friction between the screws and oil / lubricant
forms a non-wearing seal between rotors and casing thereby
removing heat through a thermostatically controlled fluid
circuit.
4.  These above reasons make the screw compressors suitable
for 24 hours (continuous operation).
5.  As there is only one piston type inlet valve Carbonation is less
hence shutdown for cleaning the valves is not required.
6.  Screw compressors are available in silenced version [noise
levels are within 75 dB(A)±3 which can be kept in a shop floor
near the point of application.
Reciprocating
Compressor Type
Reciprocating (Piston Type) air compressors use pistons driven
by a crankshaft to compress the ai
There are a lot of moving parts like piston, piston ring,
crankshaft, connecting rod, valves, etc. causing wear & tear.
Hence lesser reliability & more chances of breakdown
The internal temperature at which the pistons operate is around
150 to 200 Deg C. This is because of the friction generated by
the contact of piston rings against the cylinder walls.
These above reasons make the reciprocating compressors
suitable for intermittent use only.
This has around 8 or more valves in total & hence will require
frequent cleaning due to high Carbonation. High Maintenance.
These compressors require separate compressor room or a
sound isolating box as noise levels could go as high as 100-dB
(A).
 Identify the compressor types and selection
Difference between Rotary and
Reciprocating
Rotary Screw
No.
Compressor Type
1. Cooling system- As screw compressors can be
offered as AIR-COOLED, WATER cooling is not
required in most of the cases.
2. Energy Efficiency: More air flow at less power
consumed. The difference is more beneficial and
viable at 20HP and above machines.
3.  Initial cost is very High. Around twice the cost of
reciprocating piston compressors.
Reciprocating
Compressor Type
 Small compressors are air cooled but large machines
from 30HP and above are only Water Cooled Systems-
As these compressors are only water cooled, cooling
water is required which adds to operating /
maintenance / capital cost.
 Energy efficiency is less of 20HP models
 Half the initial cost compared to Screw Air
compressors.
 Identify the compressor types and selection

Type of Compressors
Operating
No. Compressor Type
Efficiency(kW/100cfm)
1. Single acting air cooled reciprocating air compressor 22 to 24
2. Double acting, water cooled reciprocating air 15 to 16
compressor
3. Single stage, lubricant injected rotary screw 18 to 19
compressor
4. Two stage, lubricant-injected rotary screw compressor 16 to 17
5. Lubricant-free rotary screw air compressor 18 to 22
6. Centrifugal air compressor 16 to 20

Scan me to watch video

 Operation and monitoring of air compressors

 Operation and monitor of air compressors can be carry on including:

1. Pressure gauges on each receiver or main branch line and different gauges across
dryers, filters etc.
2. Temperature gauges across the compressor and its cooling system to detect fouling
and blockages.
3. Flow meters to measure the quantity of air used.
4. Dew point temperature gauges to monitor the effectiveness of air dryers.
5. kWh meters and hours run meters on the compressor drive.
 Inspection and maintenance of air compressor

 Operation and monitor of air compressors can be carry on including

1. Repair and service Compressor Motor after 4 years of services.
2. Repair and service compressor side. Cleaning the part inside of compressor
periodically will increase the efficiency of compressor.
3. Inspect the clogging tube.
4. Make sure air ventilation and air flow inside the room in good condition.
 Comparison of centralized and de-centralized systems

 The centralized air compressor system consists of a central compressed air system
installation, where large air compressors and dryers located in one area provide
compressed air for the entire facility. This type of air compressor system installation is
facilitated through extensive pipe and ductwork, and distributes air to every department
where it is needed.
 Advantages of the centralized air compressor system include:
o Lower costs — In general, a centralized compressor system will require less
equipment, and the installation of distribution piping costs less than installing
smaller compressor units throughout the facility.
o Easier logistics — Only a single area must be addressed for issues such as noise
reduction. Having all the equipment in one area allows for better opportunities
for recovering energy.
o Easier monitoring — Only one system must be monitored, rather than several
smaller ones.
 Comparison of centralized and de-centralized systems

Other Energy Saving Methods

 Single Unit Controls

1. Start and stop. Turn compressor ON and OFF according to discharge pressure
2. Load and unload. Leaves motor running continuously. But unloads compressor
according to discharge pressure.
3. Modulating. Control inlet volume to satisfy flow need.
4. Multistep. For compressor designed to operate at multiple partially loaded condition.
 Comparison of centralized and de-centralized systems

Other Energy Saving Methods

 Strengthen the path

1. When designing a compressed
air piping system, the shorter the
distance from the compressor to the
application, the better.
2. Minimizing bends a route to the
application reduces pressure drops
and improves the efficiency of the
system.

Best practices for compressed air design

 Comparison of centralized and de-centralized systems

Other Energy Saving Methods

 Use cooler intake air.

1. The energy required to compress cool air is much less than required to compress
warmer air.
2. Reducing intake temperature by moving the compressor intake outside the building
and into a shaded area may drastically lower the energy required for compression.
Thank You