Training Session on Compressors

Compressors &
Compressed Air
Systems
PRESENTATION

Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
Troubleshooting

Introduction
Significant Inefficiencies
Compressors: 5 to > 50,000 hp
70 90% of compressed air is lost

Introduction
Benefits of managed system
Electricity savings: 20 50%
Maintenance reduced, downtime decreased,
production increased and product quality
improved

Introduction
Main Components in Compressed
Air Systems
Intake air filters
Inter-stage coolers
After coolers
Air dryers
Moisture drain traps
Receivers

Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
Troubleshooting

Types of Compressors
Two Basic Compressor Types
Type of
compressor

Positive
displacement

Reciprocating

Rotary

Dynamic

Centrifugal

Axial

Types of Compressors
Reciprocating Compressor

Used for air and refrigerant compression

Works like a bicycle pump: cylinder volume reduces

while pressure increases, with pulsating output

Many configurations available

Single acting when using one side of the piston, and

double acting when using both sides

Types of Compressors
Rotary Compressor
Rotors instead of pistons: continuous
discharge
Benefits: low cost, compact, low weight,
easy to maintain
Sizes between 30 200 hp
Types
Lobe compressor
Screw compressor
Rotary vane / Slide vane

Screw compressor

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Types of Compressors
Centrifugal Compressor
Rotating impeller
transfers energy
to move air
Continuous duty
Designed oil
free
High volume
applications
> 12,000 cfm

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Types of Compressors
Comparison of Compressors
Efficiency at full, partial and no load
Noise level
Size
Oil carry-over
Vibration
Maintenance
Capacity
Pressure

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Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
Troubleshooting

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Assessment of Compressors
Capacity of a Compressor
Capacity: full rated volume of flow of
compressed gas
Actual flow rate: free air delivery (FAD)
FAD reduced by ageing, poor maintenance,
fouled heat exchanger and altitude
Energy loss: percentage deviation of FAD
capacity
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Assessment of Compressors
Simple Capacity Assessment Method
Isolate compressor and receiver and close receiver
outlet
Empty the receiver and the pipeline from water
Start the compressor and activate the stopwatch
Note time taken to attain the normal operational
pressure P2 (in the receiver) from initial pressure P1
Calculate the capacity FAD:
P2 = Final pressure after filling (kg/cm2a)
P1 = Initial pressure (kg/cm2a) after bleeding)
P0 = Atmospheric pressure (kg/cm2a)
V = Storage volume in m3 which includes receiver,
after cooler and delivery piping
T = Time take to build up pressure to P2 in minutes

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Assessment of Compressors
Compressor Efficiency
Most practical: specific power
consumption (kW / volume flow rate)
Other methods
Isothermal
Volumetric
Adiabatic
Mechanical

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Assessment of Compressors
Compressor Efficiency
Isothermal efficiency
Isothermal efficiency =
Actual measured input power / Isothermal power

Isothermal power (kW) = P1 x Q1 x loge r / 36.7

P1 = Absolute intake pressure kg / cm2

Q1 = Free air delivered m3 / hr
r = Pressure ratio P2/P1

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Assessment of Compressors
Compressor Efficiency
Volumetric efficiency
Volumetric efficiency
= Free air delivered m3/min / Compressor displacement

Compressor displacement = x D2/4 x L x S x x n

D = Cylinder bore, meter

L = Cylinder stroke, meter
S = Compressor speed rpm
= 1 for single acting and 2 for double acting cylinders
n = No. of cylinders

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Assessment of Compressors
Leaks
Consequences
Energy waste: 20 30% of output
Drop in system pressure
Shorter equipment life

Common leakage areas

Couplings, hoses, tubes, fittings
Pressure regulators
Open condensate traps, shut-off valves
Pipe joints, disconnects, thread sealants 19

Assessment of Compressors
Leak Quantification Method
Total leakage calculation:
Leakage (%) = [(T x 100) / (T + t)]
T = on-load time (minutes)
t = off-load time (minutes)

Well maintained system: less than 10%

leakages
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Assessment of Compressors
Quantifying leaks on the shop floor
Shut off compressed air operated equipments
Run compressor to charge the system to set
pressure of operation
Note the time taken for Load and Unload
cycles
Calculate quantity of leakage (previous slide)
If Q is actual free air supplied during trial
(m3/min), then:

System leakage (m3/minute) = Q T / (T + t)

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Assessment of Compressors
Example
Compressor capacity (m3/minute) = 35
Cut in pressure, kg/cm2

= 6.8

Cut out pressure, kg/cm2

= 7.5

Load kW drawn

= 188 kW

Unload kW drawn

= 54 kW

Average Load time

=1.5 min

Average Unload time

= 10.5 min

Leakage = [(1.5)/(1.5+10.5)] x 35 = 4.375 m3/minute

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Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
Troubleshooting

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Energy Efficiency Opportunities

1. Location
Significant influence on energy use

2. Elevation
Higher altitude = lower volumetric
efficiency

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Energy Efficiency Opportunities

3. Air Intake
Keep intake air free from
contaminants, dust or moist
Keep intake air temperature low
Every 4 oC rise in inlet air temperature = 1%
higher energy consumption

Keep ambient temperature low when

an intake air filter is located at the
compressor
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Energy Efficiency Opportunities

4. Pressure Drops in Air Filter
Install filter in cool location or draw
air from cool location
Keep pressure drop across intake air
filter to a minimum
Every 250 mm WC pressure drop =
2% higher energy consumption
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Energy Efficiency Opportunities

5. Use Inter and After Coolers
Inlet air temperature rises at each
stage of multi-stage machine
Inter coolers: heat exchangers that
remove heat between stages
After coolers: reduce air temperature
after final stage
Use water at lower temperature:
reduce power

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Energy Efficiency Opportunities

6. Pressure Settings
Higher pressure
More power by compressors
Lower volumetric efficiency
Operating above operating pressures
Waste of energy
Excessive wear
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Energy Efficiency Opportunities

6. Pressure Settings
a. Reducing delivery pressure
Operating a compressor at 120 PSIG instead of 100
PSIG: 10% less energy and reduced leakage rate

b. Compressor modulation by optimum

pressure settings
Applicable when different compressors connected

c. Segregating high/low pressure

requirements
Pressure reducing valves no longer needed

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Energy Efficiency Opportunities

6. Pressure Settings
d. Design for minimum pressure drop in
the distribution line

Pressure drop: reduction in air pressure from

the compressor discharge to the point of use

Pressure drop < 10%

Pressure drops caused by

corrosion
inadequate sized piping, couplings hoses
choked filter elements

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Energy Efficiency Opportunities

6. Pressure Settings
d. Design for minimum pressure drop in
the distribution line

Typical pressure drop in compressed air line for

different pipe size (Confederation of Indian Industries)

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Energy Efficiency Opportunities

7. Minimizing Leakage

Use ultrasonic acoustic detector

Tighten joints and connections

Replace faulty equipment

8. Condensate Removal

Condensate formed as after-cooler reduces

discharge air temperature

Install condensate separator trap to remove

condensate

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Energy Efficiency Opportunities

9. Controlled usage
Do not use for low-pressure
applications: agitation, combustion air,
pneumatic conveying
Use blowers instead

10. Compressor controls

Automatically turns off compressor
when not needed
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Energy Efficiency Opportunities

9. Maintenance Practices
Lubrication: Checked regularly
Air filters: Replaced regularly
Condensate traps: Ensure drainage
Air dryers: Inspect and replace filters

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Training Agenda: Compressor

Introduction
Types of compressors
Assessment of compressors and
compressed air systems
Energy efficiency opportunities
Troubleshooting

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TROUBLESHOOTING
Problem
Compressor unit will not
start

Motor overheating

Over heating of
Compressor
Parts

Possible Cause

Remedy

No power to motor.

Turn on power.
Repair Unloaders.

Unloaders not operating.

Repair or readjust
controls.

Obstruction to rotation.

Remove obstruction.

Discharge pressure above

rating.

Readjust control.

Unloader setting incorrect.

Readjust Unloaders.

Inlet filter clogged.

Clean or replace filter.

Discharge Pressure above

rating

Lower Discharge
Pressure

Intake filter clogged.

Clean.

Worn or broken valves.

Replace.

Leaking gaskets.

Replace.

Unloader or control defective.

Replace.

Unloader setting wrong.

Correct

Compressor components
worn or
broken.

Replace.

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Problem

Over heating of
Compressor Parts
(Contd)

Air in receiver too moist

Possible Cause

Remedy

Insufficient cooling water.

Increase quantity of
cooling water.

V-belt or coupling
misalignment.

Realign components.

Bearings too tight.

Adjust bearings.

Oil level too high.

Correct oil level.

Lubrication inadequate.

Correct Oil Level

Ensure correct oil
Ensure Correct Oil
viscosity being used

Ambient temperature too high

Lower ambient temperature.

Increase Ventilation

Valves dirty.

Clean valves.

Belts too tight.

Readjust belt tension.

Packings too tight.

Readjust packings.

Moisture separator not

draining.

Unclog or repair separator drain.

Air coolers ineffective

Check temperature of
cooler at discharge port.

Inadequate cooling water flow

rate

Check cooling water flow pressure.

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Problem

Delivery of air of air less than

rated capacity

Excessive vibration of
compressor

Possible Cause

Remedy

System leaks excessive.

Stop leaks.

Intake filter clogged.

Clean or replace filter as

applicable.

Valves worn or broken.

Replace worn or broken

valves.

Belts slipping.

Tighten.

Speed lower than rating.

Increase speed.

Compressor components
worn or
broken

Replace.

Control device inoperative or

maladjusted

Repair or adjust control

device

Water quantity insufficient.

Increase water quantity.

Inlet temperature too high.

Check water quantity and

temperature at
intercooler.

Mounting bolts loose.

Tighten mounting bolts.

Misalignment of belt pulleys

Realign as necessary

Bearings out of adjustment

Adjust or replace
bearings.

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Problem
Outlet water
temperature
above normal

Compressor
noisy or
knocks

Possible Cause

Remedy

Cylinder, head, or intercooler

dirty.

Clean compressor system

parts.

Water quantity insufficient

Increase cooling water

supply.

Compressor speed too high.

Slow down compressor.

Discharge pressure above

rating.

Lower discharge pressure.

Belts slipping.

Readjust belts.

V-belts or coupling
misaligned.

Realign.

Pulley or flywheel loose.

Tighten pulley or flywheel

mountings.

Drive motor or compressor

mounting bolts loose.

Tighten mounting bolts.

Lubrication inadequate.

Increase oil level or

pressure.
Use correct oil viscosity.

Intercooler vibrating.

Check for loose mounting

hardware.

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Problem
Operating cycle
lasts too long

Air receiver pressure

above
normal

Intercooler pressure
above
normal

Intercooler pressure
below
normal

Possible Cause

Remedy

Discharge pressure above rating.

Readjust control

Worn or broken internal

compressor parts.

Replace worn or broken, parts.

Unloader or control device defective.

Replace defective device

Unloader or control defective.

Repair or replace defective

parts.

Unloader setting wrong.

Correct unloader setting.

Leaks in control air piping.

Stop leaks.

Control air line clogged.

Unclog control air lines.

Valves worn or broken.

Replace valves.

Valves not seated

Reseat or relocate valves

Unloader setting wrong.

Correct unloader setting

Intercooler passages clogged.

Clean intercooler

Insufficient water.

Increase water supply.

System demand exceeds rating.

Upgrade compressor

System leakage excessive

Stop leakage.

Intake filter clogged

Clean or replace air

filter as applicable.

Valves worn

Replace worn valves.

Unloader setting wrong.

Correct unloader setting

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Problem

Oil in air receiver

Possible Cause

Remedy

Clogged air filter

Clean or replace air filter element.

Broken piston and/or rings.

Replace broken parts

Oil level too high.

Correct oil level.

Oil viscosity incorrect

Change lubricant to proper viscosity.

Oil wrong type.

Change lubricant to proper viscosity.

Unloaded running time too long.

Use auto start/stop control.

Increase flow of compressor.

Surging of
distribution air

Operating at less than designed

minimum flow.

Cavitation of water
in
cooling supply

Feed water level too low.

Increase feed water level in reservoir.

Air leaks into suction piping

Stop leaks.

Install surge control

valve in discharge line.

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Training Session

Compressors &
Compressed Air
Systems

THANK YOU FOR YOUR ATTENTION

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