8.

Energy Performance Assessment of Compressors

8. 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 To find out the isothermal power required and volumetric efficiency To find out the specific power consumption

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 Flow nozzle with profile as desired in IS 10431:1994 and Dimensions The efficiency in present content means polytropic efficiency for centrifugal and isothermal efficiency for reciprocating compressors.

Flow Nozzle

Efficiency

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 for a particular ratio of upstream pressure (receiver) to the downstream pressure (atmospheric) ie Mach number equals one. 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.

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8.4.2

Arrangement of test equipment The arrangement of test equipment and measuring device shall confirm to figure 8.1 and figure 8.2.

8.4.3 Nozzle Sizes The following sizes of nozzles are recommended for the range of capacities indicated below: Nozzle size 6 10 16 22 33 50 80 125 165 8.4.4 Measurements and duration of the test. The compressor is started with the air from the receiver discharging to the atmosphere through the flow nozzle. It should be ensured that the pressure drop through the throttle valve should be equal to or twice the pressure beyond the throttle. 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, kWh and amps drawn by the compressor Capacity (m3/hr) 39 9 30 27 90 60 170 130 375 300 450 750 2000 1800 5500 3500 - 10000

The above readings are taken for the 40%, 60%, 100% and 110% of discharge pressure values. Measuring instruments required for test Thermometers or Thermocouple Pressure gauges or Manometers Differential pressure gauges or Manometers Standard Nozzle Psycho meter Tachometer/stroboscope Electrical demand analyser 106

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P
1

T1 P

FILTER

COMPRESSOR

HEAT EXCHANGER (AFTER COOLER)

RESERVOIR-2 Bo To o

T
RESERVOIR-1

HEAT EXCHANGER (INTER STAGE)

Figure 8.1: With After Cooler

P
3

T3

P3 P4 FLOW STRAIGHTENER RESERVOIR P

1

BY-PASS

P3

T1

THROTTLE VALVE

P
3

T3

P3 P4

T
COMPRESSOR BY-PASS

FLOW STRAIGHTENER

Figure 8.2: Without After Cooler

Bo To o

FILTER

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8. Energy Performance Assessment of Compressors

8.5
I.

Calculation Procedure for Nozzle Method

Free Air delivered Q1 = k x x d2 x T1 x 2 (P3-P4) (P3 x Ra) in m3/sec 4 P1 T3 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 287.1 J/kg k Differential pressure across the nozzle kg/cm2 = Isothermal power/Input power P1 x Q1 x loger/36.7 Absolute intake pressure kg/ cm2 Free air delivered m3/hr. Pressure ratio P2/P1 Power consumption ,kWh Free Air Delivered, m3/hr Free air delivered m3/min Compressor displacement = = = = = = x D2 x L x S x x n 4 Cylinder bore, metre Cylinder stroke, metre Compressor speed rpm 1 for single acting and 2 for double acting cylinders No. of cylinders

II.

Efficiency

Isothermal power(kW) = P1 Q1 r III. = = =

Specific power consumption = at rated discharge pressure Volumetric efficiency =

IV.

Compressor Displacement D L S n

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8.6 Example
Isothermal Efficiency Calculation for a Reciprocating Air Compressor. Step 1 : Calculate Volumetric Flow Rate k d P2 P1 T1 P3 T3 P3 P4 Ra : : : : : : : : : Flow coefficient (Assumed as 1) Nozzle diameter : 0.08 metre Receiver Pressure - 3.5 kg / cm2 (a) Inlet Pressure - 1.04 kg / cm2(a) Inlet air temperature 30oC or 303oK Pressure before nozzle 1.08 kg / cm2 Temperature before the nozzle 40oC or 313oK Pressure drop across the nozzle = 0.036 kg / cm2 Gas constant : 287 Joules / kg K

Free air delivered QF = k x x d2 x T1 x 2 (P3-P4) (P3 x Ra) 4 P1 T3 = 1 x x (0.08)2 x 303 x 4 1.04 3 = 0.391 m /sec = 1407.6 m3 / h. 2 x 0.036 x 1.08 x 287 313

Step 2 : Calculate Isothermal Power Requirement Isothermal Power (kW) P1 - Absolute intake pressure Q1 -Free Air Delivered Compression ratio Isothermal Power = P1 x Q1 x loger 36.7 = 1.04 kg / cm2 (a) = 1407.6 m3 / h. r = 3.5 1.04 = 3.36

= 1.04 x 1407.6 x loge3.36 = 48.34 kW 36.7

Step 3 : Calculate Isothermal Efficiency Motor input power Motor and drive efficiency Compressor input power Isothermal efficiency = 100 kW = 86 % = 86 kW

= Isothermal Power Actual Power = 48.34 86.0 109 = 56%

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8. Energy Performance Assessment of Compressors

8.7 Assessment of Specific Power Consumption

Specific power consumption = Actual power consumed by the compressor Measured Free Air Delivery In the above example the measured flow is 1407.6 m3/hr and actual power consumption is 100 kW. Specific power consumption = 100 1407.6 = 0.071 kW/m3/hr

8.8 Measurement of FAD by Pump Up Method

Another way of determining the Free Air Delivery of the compressor is by receiver filling method. Though this is less accurate, this can be adopted where the elaborate nozzle method is difficult to be deployed. Steps: Determine the volume of the connected receiver in m3. Determine the volume of the piping between the compressors and receiver in m3, if significant. Record the load/unload pressure settings of the compressors Kg/cm2. Wait for the compressor to turn on, pressurize the receiver, and turn off or unload. When the compressor turns off or unloads, start timing (it is assumed that the compressor unloads completely). Note the receiver pressure. Note the time it takes for the receiver pressure to drop and for the compressor to turn on or load up. Repeat these steps over a reasonable period of time.

The Free Air delivery is calculated as follows: FAD = Q x (PF PI) (Pa x t) Where FAD - Free Air Delivery (m3/min) Q - Total volume of the receiver and pipeline connected from compressor to air receiver (m3) PI - Initial Pressure of the receiver (Kg/cm2) PF - Final Pressure of the receiver (Kg/cm2) Pa - Atmospheric Pressure t - Average filling time (min)

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8. 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 Describe the method of estimating flow by pump up method Define the term isothermal efficiency and explain its significance Define the term volumetric efficiency and explain its significance How is specific power consumption calculated REFERENCES 1. 2. 3. IS 10431:1994: Measurement of air flow of compressors and exhausters by nozzles. IS 5456:1985 code of practice for testing of positive displacement type air compressors and exhausters Compressor performance Aerodynamics for the user by M Theodore GreshButterworth Heinemann.

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