Natural Gas Engine Drive Air Compressor Training

Industrial Center, Inc. Chicago, Illinois April 9, 1997

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Air Compressor Basics Presented By:

Allen L. Humphrey
Industrial Marketing Manager
Ingersoll-Rand Company Portable Compressor Division Air Compressor Group Mocksville, North Carolina
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Hi !, Im an expert in Natural Gas !

Isnt all gas natural!!!

Gas Company Guy

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Air Compressor Guy

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Im an expert in compressed air,! Hot air, cooled, and dried

I'm in trouble now, another guy full of hot air!!!

Air Compressor Guy

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Gas Company Guy

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Outline:
I. Compressed Air Facts

II.
III.

Compressed Air Technologies

Regulation & Controls

IV.
V.

System Location and Arrangement

Compressor System Components The Basics
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Compressed Air Facts

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Compressed Air Facts

Most facilities consider compressed air a utility on par with electricity, gas, and water However, few operating people know the real operating cost of their compressed air system

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What is cost per CFM ?

A Good Approximation Typical Compressor produces 4 CFM per 1 Hp 1 Hp = 0.746/0.9 = 0.829kW Therefore, 1 CFM = 0.207kW @ 0.06 $/kw-hr, 1 cfm = $0.0124/hr 10 CFM over 8000 hours costs 10 x 8000 x 0.124 = $ 992.00
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Where are NORMAL savings ?

Fix System Leaks !! Standard plant air system

8000 hrs per year operation Electrical costs = $ 0.06/kWhr Plant line pressure = 100 PSIG

(1) 1/8th inch air leak = 26 CFM 26 x 8000 x $.0124/hr = $ 2,579.00 A typical plant can have air leaks = to 20% of total air usage.
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Air Basics

Three Main Parameters

1. Pressure 2.Capacity 3. Horsepower

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Pressure(PSI) = Pounds per Square inch

Completely dependent on system, controls and safety valves An unregulated compressor will make ever increasing pressure until a failure occurs When plant capacity demand exceeds system capacity(CFM), compressor discharge pressure will drop
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Pressure - Capacity Relationship P1 x V1 = P2 x V2

P1= Initial pressure V1= Initial capacity P2= Final pressure V2= Final capacity If a system needs more capacity(CFM) than available, plant pressure drops in an unsuccessful trade of pressure for capacity
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The Cost of Pressure

Good Rule of Thumb Each # (PSI) of system pressure = 0.5% of system horsepower

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Pressure Cost Example

100Hp compressor set to discharge at 125 psig to plant system Plant system only requires 110 psig User resets compressor discharge pressure to 110 psig ( a 15 psi reduction) 15 PSI = 7.5 % of Hp = 7.5 Hp 7.5 x .746/.85 = 6.6kW x 8000 hrs x $.06/kWhr = $ 3,168.00 (Savings)
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Capacity(Flow) = CFM(ft3per minute)

Basic measure of true compressor output A fixed value in most designs, for a given model Most all capacity measurements are referred back to inlet conditions. Capacity varies only slightly with a change in discharge pressure, for a given model

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Capacity Measurement

In the pneumatics industry, ALL capacities are measured referring back to inlet conditions Various formulae are used to define capacity(CFM): SCFM; ACFM; ICFM; FAD, etc. Require your vendor to define which and where ASME and CAGI-Pneurop have generally accepted testing standards Capacity tolerances may vary from vendor to vendor. Request definition
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Horsepower

Typically, electric motor nameplate HP or NG engine MCHP(Max Continous Hp) The work it takes to compress X CFM up to Y PSI Driver HP is usually fixed. If either CFM or PSI is increased, the driver may overload, unless regulation, a speed reduction, or a change in either CFM or PSI takes place. Horsepower tolerances may vary from vendor to vendor. Request definition
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Air Basics Translations

Capacity(CFM) does the work; Pressure effects the rate at which the work is done A trending decrease in plant air pressure typically indicates a requirement for more capacity(CFM), not pressure Increasing or decreasing the existing compressor discharge pressure will normally have negligble effect on the compressor capacity

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II. Compressed Air Technologies

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Compressor Technology
Air Compressors

Positive Displacement

Dynamic Displacement

Reciprocating

Rotary Screw

Centrifugal

Single Acting

Double Acting

Oil Flooded

Oil Free

Single Stage

Two Stage

Lower Technology
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Higher Technology
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Dynamic Displacement
Performance Curve
180 160 140 120 100 80 60 40 20 0
0% FL 20% 40% 60% 80% 100% 120%

Discharge Pressure PSI

Percent of Full Load

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Centrifugal Compressors

Advantages

Only real option over 600+ Hp High air quality- 0 PPM oil carryover Moderate to high efficiency Longer design life than Rotaries Higher initial cost Fluid cooled only Power reduction down to 70% flow Constant speed operation
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Disadvantages

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Positive Displacement
180 160 140 120 100 80 60 40 20 0
0% FL

Performance Curve

Discharge Pressure PSI

20%

40%

60%

80%

100%

120%

Percent of Full Load

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Positive Displacement

Reciprocating or Rotary Screw Designs

Constant cfm; Variable pressure Adaptable to variable speed drive Variable speed and unloading provide close alignment with system demand

Oil Flooded Rotary Screws--The design of choice for NGEDACs

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Rotary Screw
Oil Flooded- Single Stage Advantages

Low 1st cost; Low maintenance $ Simple packaged design Adaptable to variable speed drive

Disadvantages

Somewhat lower efficiency Moderate durability - 10 15 years on average

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Rotary Screw

Oil Free Advantages

High air quality- 0 PPM oil carryover Moderate efficiency Packaged design

Disadvantages

Higher initial cost Higher maintenance cost

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Compressor Selection Criteria

Evaluated First Cost Efficiency Controls Maintenance Cooling Air Quality Durability
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General Guidelines- First Cost

Single-stage rotary screw

Typically lowest first cost Greatest market growth, largest population Typically lowest efficiency

Possible Alternatives
Two-stage rotary screw Oil free rotary screw* Centrifugal* *Dependent on air quality requirements

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General Guidelines- Maintenance

Capabilities of on site maintenance personnel ? Contract maintenance ? Oil flooded rotaries typically require lowest maintenance Air-in-the-box design enables on site overhauls of both compressor system and engine
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General Guidelines- Cooling

Fluid-Air cooled - less expensive Most designs have fluid or fluidair cooled design options available Closed evaporative cooling towers; open towers and external fluid to air coolers are viable cooling options
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III. Regulation & Controls

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Regulation/Controls Applications

Average number of compressors = 2.5 per facility Typical system controls: manual/ none Each incremental 1 PSIG of unnecessary pressure cost 0.5% of compressor horsepower Each electric motor driven compressor running unloaded = 35-50% of the full loaded electrical costs
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Regulation Basics

Do not run compressors unnecessarily Evaluate current regulation parameters Consider upgrading substandard controls The most efficient operating point is 100% full load.

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Basic Types of Regulation

This information will be covered in detail later in the seminar presentation

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IV. System Location and Arrangement

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Possible Locations
#1 FACILITY

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Outdoors

Advantages

Zero floor space Zero heat load Potential weather damage (Freezing, water, etc.) Potential lack of maintenance (Out of sight, out of mind)
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Disadvantages

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Possible Locations
#1
FACILITY

#2

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Indoors Centralized

Advantages

Protected from elements Potentially easier access

Greatest floor space Potentially long piping runs

Disadvantages

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Possible Locations
#1 FACILITY

#3
#3

#2

#3

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Indoors Decentralized

Advantages

Possible to install closest to large air users Least amount of pressure drop through air lines
Highest probability of incorrect regulation Potential to spread noise and heat complaints to broadest number of employees
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Disadvantages

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Environmental Factors

Temperature Ventilation Conditions

Atmosphere Personnel

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Temperature - Low

Below 350 F

Possible control freeze problem Possible condensate freeze problem Possible fluid misapplication Heaters Heat tracing key elements Relocate
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Recommendations

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Temperature - High

Above 1000 F

Possible unit shutdown Increased engine maintenance Possible decreased lubricant life

Recommendations

Improved ventilation/relocate Higher performance lubricant More suitable equipment design

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Ventilation

Insufficient Ventilation

Possible unit shutdown Increased maintenance Possible decreased lubricant life

Air-cooled Water-cooled
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Requirements

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Ventilation - The High Air Temperature (HAT) Vicious Cycle

Compressor Generates Heat Insufficient Ventilation Causes Heat To Remain Around Unit

Unit Temperature Spirals Upward

This Heat is Ingested By Engine-Compressor Increasing Operating Temperatures Of Unit
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Miscellaneous Conditions

Atmosphere Personnel

These important subjects will be covered later in the Seminar

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V. Compressor System Components-The Basics

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Basic Selection Criteria

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Real World Systems

Design Criteria Air Quality required by User Moisture content ? Oil carryover ? Contaminants Pressure Drop Demand Characteristics Energy profile
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Ideal Components For a Compressed Air System

Compressor Aftercooler Wet Receiver Pre-Filter Dryer After Filter Dry Receiver
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Ideal Components Layout

Dry Receiver
Dryer

After-Cooler

Prefilter

Compressor Afterfilter WetReceiver

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Dryers - Moisture Content

Rule of Thumb
Aftercooler
Air Compressor
100F 80F 60F

100% RH

100% RH 100% RH

Effect of Compressed Air Temperature on sizing of drying equipment. A 20 F reduction in temperature condenses 50% of the water vapor in saturated air.(Collect it; trap it; dispose of it)

A 20 F. rise in temperature doubles (200%) the moisture holding capacity of the air.
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After Filter (Recommended)

Purpose Reduce oil carryover Benefit Improved air quality Improved product quality

Instrument air applications Painting

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Dry Receiver (Recommended)

Purpose Provide a reservoir of clean dry air to meet fluctuating system demands Benefit When sized and installed correctly can minimize airline pressure fluctuations Prevents short term capacity requirements from overloading cleanup equipment
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Real World Systems

Moisture Content Pressure Dewpoint - Temperature at which water vapor condenses into liquid in a compressed airline Rule of thumb: Select a dewpoint 10-200 F below the lowest temperature the compressed airlines will see

Real World Systems

WARNING:
This applies only to general industrial application. Specific applications have specific dewpoint requirements (i.e., paint booths, instruments, etc.)
Contact equipment OEMs

Real World Systems

Typical Real World System A 1000 CFM system with

lowest plant ambient temperature of 600 F sensitivity to lubricant fairly steady plant demand

Real World System

AfterCooler Wet Receiver
Dryer

Afterfilter

Compressor

Air Cooled 1000 CFM Compressor 1000 gallon receiver

oil coalescing filter

Refrigerated air dryer with a 400 F dewpoint

Real World Systems

Pressure Drop Pressure Drop is the cost of air quality

Every air clean up device will utilize 2-10 PSI to perform its function

Air dryers typically 3-5 PSI Air filters typically 2-10 PSI (dependent on how long the element has been in place)

Remember @ 1/2% energy for each PSI, additional filters may become needlessly expensive

Real World Systems

Demand Characteristics Receiver size and placement varies depending on plant demand cycle and receiver size Possible to supply a new intermittent large air user with a properly sized and installed receiver tank

Real World Systems

Typical Compressor Carryover Values:
Reciprocating Compressors Lubricated Non - Lubricated

50-100 PPM 0 PPM 3-10 PPM 0 PPM 0 PPM

Rotary Compressors Oil Flooded Oil Free

Centrifugal Compressors

Real World Systems

Oil Content Requirements Whether the oil is removed at the compressor, or at the point of use, should be determined by overall plant requirements

Real World Systems

WARNING:
Although some equipment may benefit from (or even require) lubricant in compressed air, many other applications (paint booths, instrumentation) cannot tolerate it Again overall system requirements should dictate system design

Air Compressor Basics

Thank you for your kind attention

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