Compressed Air System

MECHANICAL AND ELECTRICAL ENERGY MANAGEMENT
Compressed Air System

Group 2
Presenter: Nur Hazirah binti Che Ithnin
Group Member: Huda binti Suhaimi
Instructor:Prof Ir Dr Sharifah Rafidah Bt Wan Alwi

Introduction
1. FUNDAMENTALS OF AIR COMPRESSORS (Mechanism, Types)
2. COMPRESSED AIR SYSTEM AND PERFORMANCE ASSESSMENT
- Considerations in Performing Audit Assessment (Energy, Capacity, Specific Power

Requirement Assessment)
- Factors Affecting Compressor Performance
3. IMPROVEMENT MEASURES (Avoid misuse, Leak reduction, Fixing Piping Layout, Capacity Control)
4. CASE STUDIES: Energy savings and cost reduction
5. SAMPLE ENERGY AUDIT REPORT

1. FUNDAMENTALS OF AIR COMPRESSORS
1.1 Operational Mechanism
- An air compressor is a mechanical device that takes in air or any gas at a
low pressure and compresses it to a higher pressure (above atmospheric
pressure).
- Air compressors basically operate on a simple idea: when air gets

compressed, the volume goes down and the pressure goes up.
Single
Cylinder
(air-cooled)
1.2 Types of Air Compressors Reciprocating Non-

Lubricated
Lubricated
Multi cylinder
Positive (water-cooled)
Displacement
Roots Blower
Rotary
Compressor Screw
Compressor
Axial Multistage
Dynamic
(Centrifugal)
Radial Single Stage
Figure 1: Overview of available types of air compressors
1.2.1 Positive Displacement Compressor
Positive displacement compressors function such that a given quantity of air is
sucked in and trapped in the compression chamber. The volume it occupies is
mechanically reduced, causing a rise in pressure prior to discharge.
A. Reciprocating Compressor
Most widely used type of air compressor :
used in air and refrigerant compression.
Mechanism as of a bicycle pump: volume of

air in cylinder is reduced while the pressure
increases, with pulsating output.
Air compressed by a piston driven in a

reciprocating motion via the crankshaft.
Available in variations
Lubricated or non-lubricated; Single or multiple cylinder; Water or air-
cooled; Single or multi stage (depending on needs)
1.2 Rotary Compressors
Rotary compressors have rotors in place of pistons and give a continuous
pulsation free discharge air through the rotating action.
Require lower starting torque as compared to reciprocating machine.
Available variations: Screw (most common); Roots Blower (limited to a

pressure of 1 bar)
Consists of two intermeshing

screw rotors, trapping air, and
reducing the volume of air along
https://youtu.be/S08sj8pfJJs
the rotors to the air discharge
point resulting in increased
pressure.
2. Dynamic Compressors (Centrifugal Compressor)
Dynamic compressors are continuous flow
compressors, characterized by rotating impeller to
add velocity and thus increasing pressure.
Better suited for applications requiring very high

capacities, typically above 12,000 cfm.
Approx. one half of air pressure is developed by

the impeller and the other half is achieved by
converting the velocity energy to pressure.
A single-stage centrifugal machine can provide the

same capacity as a multi-stage reciprocating
compressor.
2.1 Axial Compressor 2.2 Radial Compressor
Consists of a rotor with multiple rows of Less energy efficient in comparison to axial
blades and a matching stator with rows of compressors.
stationary vanes.
Typically used in single-stage designs
The rotating blades impart velocity energy,
primarily in an axial plane.
The stationary vanes acts as a diffuser to

convert the residual velocity into pressure
energy.
Suitable for high

compression ratios
General Criteria Selection Guideline of Compressor
Excerpt from National

Bureau of Energy
Efficiency which provides
selection criterion for
choosing the suitable
compressor based on
demands
Relative efficiency of compressors
2. COMPRESSED AIR SYSTEM
Compressor - produces
compressed air at required
pressure.
Air receiver tank - reservoir to

store and cool compressed air.
Air cooler, filter, and dryer

treat air at different points in
systems. Remove impurities from
air taken into compressor and
those added by compressor.
Distribution system supplies

compressed air to various uses
on site
Audit Equipment
Air velocity meter Air leakage indicator Pressure meter
CONSIDERATIONS IN PERFORMING ENERGY AUDIT
Energy Performance Assessment
Capacity Assessment
Specific Power Consumption Assessment

ENERGY PERFORMANCE ASSESSMENT
A periodic performance assessment is essential to minimize the cost of
compressed air.
Main concerns in performance assessment:
a) Compressor Ratio
b) Capacity of compressor
c) Free Air Delivery (FAD)
d) Isothermal power required
e) Isothermal efficiency
f) Volumetric efficiency
g) Specific power consumption
a) Compression Ratio
Ratio of absolute discharge pressure at last stage, to the absolute intake
pressure
Compression Ratio
2
r=
1
where P1 = absolute intake pressure
P2 = absolute delivery pressure

b) Capacity of Compressor
Capacity: full rated volume of flow of compressed gas under standard
conditions
c) Free Air Delivery (FAD), Qf

Actual flow rate at atmospheric conditions
FAD reduced by ageing, poor maintenance,

fouled heat exchanger and altitude.
Energy loss: Percentage deviation of FAD

capacity
d) Isothermal Power
Least power required to compress air assuming isothermal (constant
temperature) compression conditions.
e) Isothermal Efficiency
Percentage ratio of isothermal power to shaft power supplied (power that
determines electric bill).
f) Volumetric Efficiency
Ratio of free air delivered to the compressor swept volume.
g) Specific Power Consumption
Input power (kW) per unit volume flow rate (m3/h)
CAPACITY ASSESSMENT
One of the ways to assess performance of compressor is by measuring
capacity of compressor
Cubic feet per minute (cfm) is the standard unit of measuring air flow rate
Two methods of capacity assessment : nozzle method and pump up

1. Nozzle Method - Measurements and working
The compressor is started
with the air from the receiver
discharging through the
throttle valve and flow nozzle.
Pressure drop through

throttle should be equal/twice
pressure beyond throttle
Following measurements are

carried out :
Test Equipment
Calculation Exercise
Calculation of Isothermal Efficiency for a Reciprocating Air Compressor with
the following data:
Steps:
1. Calculate Volumetric Flow Rate (hint find FAD)
2. Calculate Isothermal Power Requirement
3. Calculate Isothermal Efficiency

ANSWER
2. Simple Capacity Assessment/Pump Up Method
1. Isolate compressor and receiver and close receiver outlet
2. Empty receiver and the pipeline from water
3. Start the compressor and activate the stopwatch
4. Note the time taken to attain normal operational pressure, P2 in receiver

from initial pressure P1
5. Calculate capacity FAD
*good for isothermal condition of air

If t2 > t1, use multiplication factor of (273+t1/273+t2)
SPECIFIC POWER CONSUMPTION ASSESSMENT
Most effective guide in comparing compressor efficiencies.
Important from an energy conservation point of view.
Sample calculation:
Factors Affecting Compressor Performance
Inlet air temperature every 4C rise, 1% increase of energy
Dust inlet in air excessive wear; malfunction of valve check pressure drop
Dryness of inlet air Cooling air beyond dewpoint cause condensation-

cylinder damage
Altitude/elevation Consume more power at high altitudes
Pressure settings beyond optimum operating pressure, higher power use

IMPROVEMENT MEASURES
Avoiding misuse of compressed air
Reduction of delivery pressure
Leak reduction (Quantification of Leakage)
Leaks reduce effective capacity, waste energy
and reduce the performance of the equipment
Sources of leakage: failed auto drain valves,

leaking pressure regulators
Important to detect leakage and is easily

detected though hissing sound
Methods include through ultrasonic detection

Any expenditure on stopping leaks would be paid back through energy
saving.
Example in a case study in India:

Fixing Piping Layout
Loss of pressure due to piping caused by resistance in pipe fittings and
layout; dissipating energy through turbulence.
Can be minimized by :
- Arranging piping system as a closed loop to allow more uniform air

distribution to consumption points
- Separate services requiring heavy air consumption
- Pipes should be installed parallel with lines of building

Capacity Control
Automatic ON/OFF control
Load and unload control
Multi-step control
Speed control
CASE
STUDY 1:
CASE
STUDY 2
APPENDICES
Excel spreadsheets
SAMPLE ENERGY AUDIT REPORT
https://www.irjet.net/archives/V3/i5/IRJET-V3I5340.pdf
https://www.permaweld.com/images/reports/compressed_air_survey_and_s
ystem_energy_audit_report.pdf
References
https://www.slideshare.net/saurabhtholia/compressor-and-compressed-air-
systems
https://www.slideshare.net/kushal19/compressor-36409438
https://www.irjet.net/archives/V3/i5/IRJET-V3I5340.pdf
file:///C:/Users/USER/Desktop/3Ch3%20Compressed%20Air%20Systems.pdf
Bureau of Energy Efficiency

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MECHANICAL AND ELECTRICAL ENERGY MANAGEMENT

Compressed Air System

Instructor:Prof Ir Dr Sharifah Rafidah Bt Wan Alwi

2. COMPRESSED AIR SYSTEM AND PERFORMANCE ASSESSMENT

- Considerations in Performing Audit Assessment (Energy, Capacity, Specific Power

- Factors Affecting Compressor Performance

4. CASE STUDIES: Energy savings and cost reduction

5. SAMPLE ENERGY AUDIT REPORT

- Air compressors basically operate on a simple idea: when air gets

1.2 Types of Air Compressors Reciprocating Non-

Mechanism as of a bicycle pump: volume of

Air compressed by a piston driven in a

Require lower starting torque as compared to reciprocating machine.

Available variations: Screw (most common); Roots Blower (limited to a

Consists of two intermeshing

Better suited for applications requiring very high

Approx. one half of air pressure is developed by

A single-stage centrifugal machine can provide the

The stationary vanes acts as a diffuser to

Suitable for high

Excerpt from National

Air receiver tank - reservoir to

Air cooler, filter, and dryer

Distribution system supplies

Energy Performance Assessment

Specific Power Consumption Assessment

Main concerns in performance assessment:

P2 = absolute delivery pressure

c) Free Air Delivery (FAD), Qf

FAD reduced by ageing, poor maintenance,

Energy loss: Percentage deviation of FAD

Two methods of capacity assessment : nozzle method and pump up

Pressure drop through

Following measurements are

2. Calculate Isothermal Power Requirement

3. Calculate Isothermal Efficiency

2. Empty receiver and the pipeline from water

3. Start the compressor and activate the stopwatch

4. Note the time taken to attain normal operational pressure, P2 in receiver

5. Calculate capacity FAD

*good for isothermal condition of air

Important from an energy conservation point of view.

Dryness of inlet air Cooling air beyond dewpoint cause condensation-

Altitude/elevation Consume more power at high altitudes

Pressure settings beyond optimum operating pressure, higher power use

Sources of leakage: failed auto drain valves,

Important to detect leakage and is easily

Methods include through ultrasonic detection

Example in a case study in India:

- Arranging piping system as a closed loop to allow more uniform air

- Separate services requiring heavy air consumption

- Pipes should be installed parallel with lines of building

Load and unload control

Bureau of Energy Efficiency

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