Compressed Air

Systems
Engr. Rey P. Dumalaba, RMP, ME
Outline
• Introduction
• Classifications
• Displacement Types
• Cooling
• Applications
• Maintenance
• Reference
• Savings Tips
INTRODUCTION
• An air compressor is a device that converts power (using an electric motor,
diesel or gasoline engine, etc.) into potential energy stored in pressurized air
(i.e., compressed air).
• By one of several methods, an air compressor forces more and more air into a
storage tank, increasing the pressure. When tank pressure reaches its
engineered upper limit, the air compressor shuts off.
• The compressed air, then, is held in the tank until called into use. The energy
contained in the compressed air can be used for a variety of applications,
utilizing the kinetic energy of the air as it is released and the tank
depressurizes.
• When tank pressure reaches its lower limit, the air compressor turns on again
and re-pressurizes the tank. An air compressor must be differentiated from a
pump because it works for any gas/air, while pumps work on a liquid.
CLASSIFICATIONS
Compressors can be classified according to the pressure delivered:
• Low-pressure air compressors (LPACs), which have a discharge pressure of 150 psi or less
• Medium-pressure compressors which have a discharge pressure of 151 psi to 1,000 psi
• High-pressure air compressors (HPACs), which have a discharge pressure above 1,000 psi
They can also be classified according to the design and principle of operation:
• Single-Stage Reciprocating Compressor
• Two-Stage Reciprocating Compressor
• Compound Compressor
• Rotary-screw compressor
• Rotary Vane Compressor
• Scroll Compressor
• Centrifugal compressor
Displacement Types

Positive Displacement Dynamic Displacement

• Reciprocating Piston • Axial Compressors
Compressors • Centrifugal Compressors
• Rotary Screw Compressors • Scroll Compressors
• Rotary Vane Compressors
Displacement Types
• Positive Displacement
• Positive-displacement compressors work by
forcing air in a chamber whose volume is
decreased to compress the air. Once the maximum
pressure is reached, a port or valve opens and air
is discharged into the outlet system from the
compression chamber.
 Displacement Types
Types of Positive Displacement Air Compressor
Reciprocating Piston Compressors
1. Single Acting means that air is drawn in and
compressed on one side of the piston. The
other side is exposed to the crankcase of
the compressor. In this case, the
downward stroke of the piston draws in the
air, and the upward stroke compresses it.
2. Uses where the air is used for hand-
tools,cleaning dust,small paint jobs,commercial
uses,etc
1. Double Acting reciprocating
compressors have compression chambers
on both sides of the piston. On the down
stroke, air is drawn in on the top of the piston
while air is compressed on the bottom side. On
the upstroke, air is drawn into the bottom side
while air is compressed on the top side. Double
acting machines require sealing of the piston
rod, so a crosshead is used to eliminate the
angular movement of the rod.
• Rotary Screw
Compressors
• Rotary screw compressors are presently the industry
standard in plant air compressors from about 25 to 300
horsepower. They are rapidly expanding into both smaller and
larger markets, with many manufacturers offering size
ranges as low as 3HP on the low end, and over 600HP on the
high end.
• Rotary screw compressors draw air and lubricant into a void
created as two helical rotors mesh together. Once the rotors
pass by the inlet port of the pump (called an airend), the cavity
decreases in size for the remainder of the rotation,
compressing the air-oil mixture.
Rotary Vane
Compressors
Rotary sliding vane compressors
operate similar to an air motor, with
an off-center rotor turning sliding
vanes. As the vanes near the area
where the distance between the rotor
and casing is small, the air is
compressed.
• Axial Compressors
• An axial compressor is a gas compressor that can
continuously pressurize gases. It is a rotating, airfoil-
based compressor in which the gas or working fluid
principally flows parallel to the axis of rotation, or
axially. This differs from other rotating compressors
such as centrifugal compressors, axi-centrifugal
compressors and mixed-flow compressors where the
fluid flow will include a "radial component" through the
compressor.
Centrifugal Compressors
Centrifugal compressors, sometimes
called radial compressors, are a sub-class of
dynamic axisymmetric work-
absorbing turbomachinery
They achieve a pressure rise by adding kinetic
energy/velocity to a continuous flow
of fluid through the rotor or impeller. This
kinetic energy is then converted to an increase
in potential energy/static pressure by slowing
the flow through a diffuser. The pressure rise in
the impeller is in most cases almost equal to
the rise in the diffuser.
SCROLL TYPE
COMPRESSOR
(also called spiral compressor, scroll
pump and scroll vacuum pump) is a
device for compressing air or refrigerant. It is
used in air conditioningequipment, as an
automobile supercharger (where it is known
as a scroll-type supercharger) and as
a vacuum pump. Many residential central
heat pump and air conditioning systems and
a few automotive air conditioning systems
employ a scroll compressor instead of the
more traditional rotary, reciprocating, and
wobble-plate compressors.
Cooling
• Due to adiabatic heating, air compressors require some method of
disposing of waste heat. Generally this is some form of air- or water-
cooling, although some (particularly rotary type) compressors may be
cooled by oil (that is then in turn air- or water-cooled). The
atmospheric changes are also considered during cooling of
compressors. The type of cooling is determined by considering the
factors such as inlet temperature, ambient temperature, power of the
compressor and area of application. There is no single type of
compressor that could be used for any application.
 Lowering Your
Compressed Air
Energy Costs
Why Care About Compressed Air?

 Compressed air is expensive

 Compressed air is essential to plant
productivity
 Compressed air systems can be effectively
managed to improve plant operation
 Compressed air systems usually have
significant opportunities for efficiency
improvement
 Life Cycle Cost of an air compressor

Energy consumption

LCC comparison between an installation without energy recovery (left), and a system
with energy recovery (right).

 Life cycle cost (LCC) calculations are used as a tool to evaluate the different investment
options for equipment. Included in LCC calculations are the product’s combined costs during
a specific period – usually 10 years – which includes capital costs, operating costs, and service
and maintenance costs.
Different investment options affect the
following factors and are central issues to
consider during LCC calculations and
subsequent equipment recommendations:
 Production quality;
 Production safety;
 The potential for subsequent
investments;
 Maintenance of production machines and
the distribution network;
 Environment;
 Final product quality; and
 Risk assessment for downtime and
rejections.
A complete LCC analysis should include, but
is not limited to, the following:
 Load profile;
 Unloaded energy costs;
 Energy recovery;
 Pressure drops across equipment and
through the piping system;
 Demand charges;
 Dryer energy costs;
 Energy costs to operate auxiliary
equipment such as cooling towers,
chillers, air conditioners and duct fans;
 System pressure set-points;
 Load/unload cycle time;
 Bleed-down losses;
 Non-production operation;
 Artificial demand;
 Air leak losses; and
 Other factors the project engineer
recommends.
Benchmark Your System’s Efficiency

 To make an accurate
determination of energy
savings solutions, it is
important to measure
your system flow,
pressure and kW as well
as evaluate any plans
for future expansion
 This is accomplished by
a flow and kW survey
Benchmark Your System’s Efficiency

 Measure your compressed air

requirements
 Flow
 Pressure
 Dew point
 kW and kWh
 Benchmark your current
system’s efficiency kWh/MCF
 Receive a detailed report
outlining improvements
Energy Reduction Opportunities

 Use Efficient Compressor Controls

 Reduce Compressed Air Usage
 Lower Compressor Discharge Pressure
 Efficiently Sequence Air Compressors
 Operate and Maintain Compressed Air Equipment at Peak
Efficiency
 Use Efficient Compressor Controls
75 HP Lubricated screw compressor
w/ Modulation Control -vs.- 60 HP VSD

Average electrical cost = Php $0.06 / KWHR

A) 1st shift 250 CFM 2200 HRS/YR
B) 2nd shift 175 CFM 2200 HRS/YR
C) 3rd shift 100 CFM 2200 HRS/YR

75 HP unit @ 125 PSIG 60HP VSD @ 125 PSIG

82.5 Bhp full load power 66 Bhp full load power

320 CFM 290 CFM

91.5% Motor eff. 94%
Note: 2200 hrs/yr indicates assumed continuous operation of 3 months within the year since there are
maintenance schedule are followed and unexpected shutdown included.
Use Efficient Compressor Controls

75 Hp modulating 60 Hp VSD

250 CFM: 250/320 = 78% (93% Bhp) 250/290 = 86% (86% Input kW)

175 CFM: 175/320 = 55% (86.5% Bhp) 175/290 = 60% (61% Input kW)

100 CFM: 100/320 = 31% (79% Bhp) 100/290 = 34% (38% Input kW)
Use Efficient Compressor Controls
75 HP lubricated screw with modulation control
A) First shift 250 CFM:
82.5 Bhp X (.93 factor) X .746kW X $.06 X 2200Hrs = $8,257.11
.915 Mtr. eff. Hp kWh

B) Second shift 175 CFM:

82.5 Bhp X (.865 factor) X .746kW X $.06 X 2200Hrs = $7680
.915 Mtr. eff. Hp kWh

C) Third shift 100 CFM:

82.5 Bhp X (.79 factor) X .746kW X $.06 X 2200Hrs = $7,014.11
.915 Mtr. eff. Hp kWh

Total = $22,951
Use Efficient Compressor Controls
60 Hp Variable Speed compressor

A) First shift 250 CFM:

66 Bhp x .746 kW x (.86 factor) x $.06 x 2200Hrs = $5,946
.94 ME. Hp kWh

B) Second shift 175 CFM:

66 Bhp x .746 kW x (.61 factor) x $.06 x 2200Hrs = $4,217
.94 ME Hp kWh
C) Third shift 100 CFM:
66 Bhp x .746 kW x (.38 factor) x $.06 x 2200Hrs = $2,627
.94 ME Hp kWh

Total = $12,790
Use Efficient Compressor Controls
Total Power Savings:
$22,951 - $12,790 = $10,161 per year

60 HP VSD costs $25,000 for a 2.46 year

payback!
Reduce Compressed Air Usage

 Eliminate inappropriate air users

• Use brushes, blowers, or vacuum systems instead of compressed air to
clean parts or remove debris;
• Use blowers, electric actuators, or hydraulics instead of compressed air
blasts to move parts;
• Use high efficiency nozzles instead of open orifices
• Use fans to cool electrical cabinets instead of compressed air vortex
tubes
• Apply a vacuum system instead of using compressed air venturi methods
• Use blowers instead of compressed air to provide cooling, aspirating,
blow guns, air lances, agitating, mixing, or to inflate packaging
Reduce Compressed Air Usage
 Shut off air to equipment
that is shutdown or
abandoned
 Install automatic solenoid valves
 Valve off idled sections of the plant

 Fix Leaks
 Leaks can account for
10-50% of the total
compressed air usage!
Reduce Compressed Air Usage
 Minimize Leaks
 Measure leak load to quantify the opportunity
 Find the leaks with an ultrasonic leak detector
 Tag the leaks
 Fix the leaks
 Re-measure the leak load to quantify the savings
 Develop and on-going leak reduction program
 Evaluate the pressure requirements of all compressed air users
 Put the small high pressure user on its’ own compressor
 Install good compressor sequencing controls
 Lower the system air pressure
Reduce System Air Pressure

 Measure system/component
pressure drops
 Minimize distribution and
component pressure drops
 Loop air header
 Upgrade, repair or eliminate
high delta P components
 Upsize piping/hoses
 Address large intermittent air
“gulpers” that draw the
system down with storage and
metering valves
 Decentralize compressors
Reduce Compressed Air Usage

 Reduce system air

pressure
 Use intermediate
controllers with
storage to regulate
system air pressure
 Effective when part of
the plant operates at
a lower pressure
 Lowers air
consumption
 Does not lower
compressor pressure
RULE OF THUMB

Power consumption
increases 1% for every 2
psi increase in
compressor pressure
Good Maintenance Saves Energy

Inlet Filters

Every 4 inches (water)

pressure drop reduces the
compressor capacity 1%
A dirty inlet filter can rob you
of 5% or more!
Good Maintenance Saves Energy

Dirty Coolers

For every 11oF deterioration in

the intercooler approach or
increase in water temperature,
the power consumption will
increase by 1%.
Good Maintenance Saves Energy

Dirty Coolers

For every 10oF deterioration

of the after cooler approach
temperature, the dryer load is
increased by as much as 46%.
Good Maintenance Saves Energy

Dirty Oil Separator

A dirty oil separator can

increase your HP 5%
REFERENCES:

http://cascousa.com/compressed-air-101/types-of-compressors
https://en.wikipedia.org/wiki/Air_compressor
https://www.cagi.org/working-with-compressed-air/benefits/10-steps-to-
savings.aspx
https://www.youtube.com/watch?v=czL0ZSscbsM
https://www.google.com/search?biw=1536&bih=706&tbm=isch&q=
https://www.airbestpractices.com/system-assessments/leaks/are-compressed-air-
leaks-worth-fixing