UNITED CEMENTS PVT. LTD.

NAUBISE-4, DHADING, NEAPL

DATE: 28-08-16

PERFORMANCE REPORT FOR RAW MIL COMPRESSORS (300CP-1&2)

A site measurement conducted for observing the performance of Raw Mill Compressors.
Some important basic information for the Raw Mill Compressor 300CP-1 &2, which is taken from
the equipment details --
Max. Final Pressure = 7.50 Bar
Max. Final Pressure = 7.64 Kgs/cm2
Free Air Delivery = 80.00 Ltr/Sec
i.e. 288.00 M3/Hr.
Recommended Capacity = 290.00 M3/Hr.

We have collected following measurements in three different situations for better

SR. STOP-WATCH READING (SEC) ON-LOAD TIME OFF-LOAD TIME COMPRESSOR COMPRESSOR
REMARKS
NO. START STOP INTERVAL (SEC) INTERVAL (SEC) ON-LOAD (%) OFF-LOAD (%)

(A) WHEN ONLY L/S CRUSHER IS IN OPERATION (i.e. 100DC1 & 2)

1 0 28 28 --- --- ---
2 65 98 33 37 47.14 52.86
3 135 167 32 37 46.38 53.62
4 205 236 31 38 44.93 55.07
5 270 303 33 34 49.25 50.75
6 338 366 28 35 44.44 55.56
7 404 435 31 38 44.93 55.07
8 468 501 33 33 50.00 50.00
9 536 565 29 35 45.31 54.69
10 596 630 34 31 52.31 47.69
Average Value = 31 32 42 48
 (B) WHEN ONLY RAW MILL IS IN OPERATION (i.e. 200DC1&2, 300DC1&2, Girth Gear GS-System & 400DC1)
1 0 35 35 --- --- ---
2 56 93 37 21 63.79 36.21
3 114 151 37 21 63.79 36.21
4 170 205 35 19 64.81 35.19
5 224 258 34 19 64.15 35.85
6 279 313 34 21 61.82 38.18
7 331 365 34 18 65.38 34.62
8 385 420 35 20 63.64 36.36
9 440 474 34 20 62.96 37.04
10 493 528 35 19 64.81 35.19
Average Value = 35 18 58 32
(C) WHEN COMPLETRE RAW MILL SECTION IS IN OPERATION
1 0 40 40 --- --- ---
2 63 109 46 23 66.67 33.33
3 131 172 41 22 65.08 34.92
4 197 233 36 25 59.02 40.98
5 258 300 42 25 62.69 37.31
6 320 354 34 20 62.96 37.04
7 379 425 46 25 64.79 35.21
8 448 489 41 23 64.06 35.94
9 513 545 32 24 57.14 42.86
10 569 615 46 24 65.71 34.29
Average Value = 40 21 57 33

The above list of measurement gives following result as per its application in different situations.
(A) Per day (i.e. 24 Hrs) compressor in operation Hrs. = 10 Hrs. & 14 Hrs. idle.
(B) Per day (i.e. 24 Hrs) compressor in operation Hrs. = 14 Hrs. & 10 Hrs. idle.
(C) Per day (i.e. 24 Hrs) compressor in operation Hrs. = 14 Hrs. & 10 Hrs. idle

The above result shows satisfactory operation of compressor.

 PERFORMANCE REPORT FOR RAW MIL COMPRESSORS (300CP-1&2)
We have following data as observed on name plate or as recommended by M/s. CPW
design data for the raw mill circuit compressor system.
Max. Final Pressure = 7.50 Bar
Max. Final Pressure = 7.64 Kgs/cm2
Free Air Delivery = 80.00 Ltr/Sec
i.e. 288.00 M3/Hr.
Recommended Capacity = 290.00 M3/Hr.

(A) LEAKAGE ANALYSIS FOR 300CP-1 & 2: We found following data during no use of compressed air from
the receiver tank.
On-load time, T = 21 Seconds
Off-load time, t = 16 Min + 26 Sec.
= 986 Seconds

Now, % Air Leakage in the complete line system = T x 100 / (T+t)

= (21 x 100)/(21+986)%
= 2.08% which is quite higher i.e. not desirable.

(B) COMPRESSOR CAPACITY EVALUATION FOR 300CP-1 & 2:

Time taken for test duration,T = 13 Seconds
Initial Pressure,P1 = 6.30 Kg/cm2 and Final Pressure,P2 = 7.40 Kg/cm2 and Atmospheric Pressure,P0 = 1.03 Kg/cm2
Volume of Receiver (as given in drg.) i.e. dia =0.8 Mtr. And Height = 1.80 Mtr. i.e.
Volume = 3.14*0.8*0.8*1.8/4 = 0.904 M3

Now Capacity (M3/Min) = (P2-P1)xV/P0xT = 4.44 M3/Min = 266 Kg/cm2.

This shows the existing compressor is satisfactory.