How to maximize air compressor efficiency and reduce the total maintenance cost.docx
- 1. How to maximize air compressor efficiency and reduce the total maintenance cost Published On - December 7, 2022 Nouman Khan Compressor
- 2. The majority of industries rely on compressed air to power their most essential machines. Air compressors provide power to power impactors, drills, and other assembly-line equipment. One of the most effective strategies to lower the company’s air compressor maintenance costs is to guarantee that the air compressors are operating at optimum compressor efficiency. This article will show you a comprehensive guide to air compressor efficiency and how to lower your company’s total maintenance costs.
- 3. Air compressor Efficiency and factors affecting reciprocating compressor performance A reciprocating compressor is a positive displacement machine. Theoretically, you can rapidly determine its capacity and horsepower. However, several loss factors reduce capacity and raise the horsepower from the optimum expected values. Compressor design, speed, suction and outlet pressure and temperature, gas composition, suction and outlet pipe design, and valve design impact the amount of losses. Losses that are significant in specific applications may be minor in others. Therefore, while constructing a performance prediction model, you must study the wide range of compressor designs, valve designs, gas molecular weight, and operating circumstances. Factors that make air compressors less efficient Compressed air power is an ideal energy source for high-demand applications despite its inherent inefficiency. Most air compressors require four to eight times the amount of horsepower
- 4. to produce one horsepower of compressed air. Furthermore, several variables cause air compressors to become less effective over time and without regular maintenance. Poor quality air intake Dirt, dust, and other pollutants in the air may cause muck to collect within an air compressor. This accumulation wears out components and limits internal volume, raising the expense of recurring air compressor repair sessions. Humidity Water has a high specific heat, and changing its temperature requires more energy. Furthermore, it gathers within the air compressor as moisture and rusts out its internal parts. One of the most excellent methods to safeguard your investment and increase the effectiveness of your air compressor is to ensure that the incoming air is as cold and dry as possible.
- 5. Hot Air The density of hot air is lower than that of cold air. As a result, cold air is inherently more “compressed” than hot air, which implies that pumping cold air into your air compressor is significantly more efficient. And this contributes to increasing the air compressor efficiency, which leads to increased production. Inconsistent air pressure controls The air compressor controls produce erratic or persistent high pressure. When air compressors operate at or near-maximum pressure, they place additional strain on the system and degrade compressor efficiency. Design system flaws
- 6. Air compressors can become less efficient due to flaws in the system architecture. Typical design defects include improper sized distribution systems, a lack of a recovery system and increased heat waste, needless bends in the pipes, and unrepaired leaks. Inappropriate air compressor model An inappropriate air compressor model may poorly tune the compressed air needs in your project. It reduces the compressor efficiency and overall performance of the application. Therefore, we recommend you first study the type of compressed air required for your application. Finally, choose the appropriate air compressor for the projected case. Decreased pressure Pressure dips in your air compressor system can significantly influence the compressor efficiency of your air compressor. Inadequately sized pipes, high moisture, filthy filters, or extended air travel lengths can cause a pressure decrease.
- 7. Irregular maintenance Poor maintenance will cause the system to wear down prematurely, increasing repair costs. Because of the quantity of moving components and the high usage of these systems, failing to establish a regular maintenance program might render air compressors ineffective. The costs of an inefficient air compressor system Your organization may incur losses as a result of an inefficient air compressor. Every business requires both time and money. As a result, it is vital to consider purchasing an efficient air compressor among many options. Inefficient air compressor systems cost you money in a variety of ways: ● Money: Air compressors functioning properly are swift, dependable, and productive. When they perform inefficiently, an activity that formerly took 10 minutes may now take 20 minutes, resulting in additional labour and higher power expenditures to operate the equipment.
- 8. ● Time: Loss of time also impacts your financial line by delaying productivity and reducing profit possibilities. Keeping your air compressors efficient, functioning, and service ensures that you stay on schedule. How to maximize air compressor efficiency? The expenses of compressor power consumption and maintenance account for over 90% of the cost of producing compressed air. The good news is that you can minimize energy usage and improve performance by taking a few simple measures. While a consistent and dependable air supply is critical for effective and safe plant operation, it comes at a cost. Increasing air compressor efficiency generally begins with analyzing what variables are causing the system to wear out. To offer optimal compressor efficiency, energy efficient compressors rely on controls and design. The most efficient air compressor system will necessitate carefully tuned controls that operate closer to the lowest pressure and a well-maintained system design appropriate for the application.
- 9. Improve the quality of the air intake. The quality of the air processed by your compressor has a considerable impact on its overall air compressor efficiency. When the air quality in your facility is poor, your compressor will not perform as effectively as it would in a higher-quality atmosphere. In this case, consider paying particular attention to the following three air-quality components in your workplace and making the required adjustments: ● Temperature: Cool air uses less energy to compress while encouraging increased air density, making it easier to process using air compressors. ● Composition: The compressed air in your equipment will travel more smoothly through the system if your air supply is clean and free of pollutants. Air dirty or contaminated can cause wear and tear on your air compressors. ● Humidity: If your air compressor is in a humid climate, moisture can accumulate within the system and cause corrosion. Dry-air compressors are less prone to sustain system and component damage from their environment.
- 10. Organize the air compressor controls A single compressor or multiple compressors match the Air compressor and controls the compressor’s output to the compressor system’s needs. Such controls are critical for the compressor efficiency and performance of an air compressor system. Compressed air systems maintain a specific pressure range while delivering a volume of air that fluctuates with end-user needs. The control system reduces compressor output when the pressure hits a particular level, and when the pressure drops, the compressor output increases. The most accurate control systems can keep average pressures low while meeting system requirements. Failure to meet system criteria may result in equipment malfunction. This is why matching system controls with storage capacity is critical. The following adjustments can help single compressors run more efficiently:
- 11. ● Compressors on and off-state depend on pressure using start and stop controls. ● Load and unload features allow the compressor to be loaded and unloaded to discharge pressure. ● Modulating controls manage flow requirements, whereas multistep controls allow compressors to run at a partial load. ● Dual-Control and Auto-Dual controls allow you to choose between start/stop and load/unload. ● Variable displacement can function in two or more partially loaded states. ● Varied speed drives continually vary the speed of the drive motor to satisfy varying demand requirements. ● System master controls are used in systems with many compressors to coordinate all of the operations required to optimize compressed air. ● When the complexity of a compressed air system surpasses the capability of local and network controls, system master controls are appropriate to coordinate the system. Such controllers may monitor system components and trend data to improve maintenance functions. ● Pressure and flow controllers store more excellent pressure air that satisfies demand changes. Improve system design. Improving the system design raises the air compressor efficiency. You may enhance the architecture of your air compressor system in six ways.
- 12. ● Straighten out the pathway: Narrow or steep bends in delivery lines can increase friction and pressure decreases in the system, resulting in less pressure reaching the point of application. With fewer bends and loops, improved design should provide more pressure while consuming the same energy. ● When necessary, economize energy: A storage tank can cushion short-term demand fluctuations and decrease on/off cycling. A tank can help keep system pressure below the minimum pressure requirements when demand is strong. When there is a pressure decrease, the system pressure rises, resulting in lost air pressure. The power of the compressor determines the size of the tank. A 50-gallon air receiver tank, for example, is required for a 50-horsepower air compressor. ● Cool the intake air: The energy necessary to compress cold air is less than required to compress warmer air. You can lower the energy necessary for compression by placing the compressor intake outside into a shaded region. ● Use several small compressors: Oversized air compressors can be inefficient since they demand more energy per unit when operating at a partial load. Such systems may benefit from using numerous smaller compressors with sequencing controls, which allow sections of the system to be shut down simply by turning off some compressors. ● Recover waste heat: Waste heat may be suitable to boil water and heat water for space heating. A well-designed heat recovery machine may recover up to 90% of the electrical energy used in air compression. ● Locate near high-demand locations: It is simpler to satisfy demand with less total compressor capacity by placing air receivers near sources of high demand. Consider compressed air needs.
- 13. It is critical to understand the optimum air requirement for your project. Otherwise, you risk losing compressed air, resulting in a loss. ● Check the load profile: Consider the load profile when designing a compressed air system. If air demand varies widely, the system must be efficient even while only partially loaded. When there are huge swings in demand, several compressors will enable more economical energy utilization. ● Minimize artificial demand: The surplus air volume required for uncontrolled usage while employing greater pressure than needed for applications is the artificial demand. ● Determine the correct pressure needed: Artificial demand refers to the excess air volume required for uncontrolled utilization when using higher pressure than is necessary for applications. The system wastes air when an application requires 50 psi but only receives 90 psi. Pressure regulators installed at the point of use can reduce false demand. ● Examine proper supply and demand: Check that air compressors are not excessively big for their intended usage. Consider all end-use applications, measuring the amount of air required for each. A broad examination of your complete compressed air system should aid in the investigation of distribution system problems and reduce incorrect air utilization. ● Use block diagrams and pressure profiles: Block diagrams will aid in the identification of all components in an air compression system. A pressure profile indicates pressure dips in the system, which should give input for controlling the system. To complete a pressure profile, you must measure the compressor’s input, the difference across the air/lubricant separator, and the interstage for multi-stage compressors. You can detect system interruptions, intermittent loads, system changes, and general circumstances by data logging system pressures and airflow. System controls can handle variations in pressure and airflow to reduce their influence on the output. ● Use compressed air storage: Storage can limit demand events during demand peaks by slowing degradation and lowering pressure drop. It can also safeguard important activities from other system events by shutting down a compressor if necessary.
- 14. Avoid Over-pressurization As compressed air passes through the distribution system, pressure dips occur. Excessive pressure dips might impair performance and increase energy use. Pressure decreases upstream of the compressor signal, reducing the end-user operating pressure. Higher pressures are required to fulfil the compressor control parameters. Reduce pressure drops in the system before adding capacity or raising system pressure. In this situation, operate the compressed air equipment at the lowest efficient operating pressure possible to achieve the greatest results. You can decrease pressure drops by following the steps below. ● Follow the Actual Design: Inadequate pipe size between the distribution header and the producing equipment is the most prevalent cause of the high-pressure drop. It can happen if you pick pipework based on the projected average compressed air demand without considering the maximum flow rate. ● To reduce moisture, keep air filtration and drying equipment in good working order. ● Ensure that filters are clean and clear of debris, which inhibits airflow and causes pressure dips. It is necessary to maintain and replace filter components regularly to reduce pressure loss. ● Select the separators, dryers, filters, and after-coolers with the lowest pressure drop feasible. A pressure difference of 7 pounds per square inch is average for a filter, hose, and pressure regulator (psid). ● Choose the regulators, hoses, lubricators, and connectors that provide the highest performance at the smallest pressure differential.
- 15. ● Reduce the amount of air that goes via the compressed air system. Choose the right air filter and inlet location Lowering operating expenses begins at the intake – the colder the entering air, the less electricity required to create line pressure. Locate the air intake for the optimum benefits. We suggest a clean, dry, shady outdoor space at least 1.8 m above the ground. Reduced pressure drop via intake ducts while running at full capacity will also help to reduce operating expenses. Using an air filter with the appropriate capacity for the intake and compressor can extend the duration between filter replacements and reduce load, saving money. Optimize the operating temperature
- 16. Keep the cooling water temperature about 5.5oC above the inlet air temperature to guarantee optimal performance of reciprocating compressors. Moisture cannot condensate in the water- cooled cylinders as a result of this. The temperature at the output should be less than 49°C. Other best practices include ensuring that no cooling water flows when a compressor starts or shuts down and that water jackets are inspected and cleaned regularly. Regular maintenance and cleaning of air-cooled compressors can prevent debris from blocking fans’ fins and preventing them from running correctly. After all, drain the condensed water appropriately. Match lubricants to conditions Compressors work best when lubricated with appropriate materials for their operating circumstances. These lubricants must also be kept and administered in the proper proportions.
- 17. Maintaining the proper lubricant flow rate is critical for reciprocating air compressors; a feed rate that is too low or too high will increase wear on cylinders and rings and increase oil consumption and overheating. Some rotary screw compressors use dry screws that require oil to grease their bearings. Others use wet screws that are soaked with lubricant. Wet screws need cooled oil to absorb compression heat, lubricate rotors, and maintain a good seal. Heat exchangers that use oil-to- air or water-to-air can keep the air supply at the proper temperature and reduce carbon deposits. The Mobil SHC Rarus series is intended to save downtime for rotary screw air compressors used in severe industrial environments. Eliminate moisture and maintain compressor efficiency Repairing damage caused by undesired moisture in compressed air systems may account for up to 5% of plant maintenance expenses. Therefore keeping it to a minimum is critical. Using after-coolers and dryers to remove water from the air released by compressors is a good practice. Condensation in the air distribution system is reduced as a result.
- 18. Another strategy to cut expenses and boost compressor efficiency is to ensure no pressure loss between the compressor and the point of usage. As a general rule, keep the pressure at usage above 620.5 kPa. Airline lubricators may also improve the compressor efficiency of compressed air-powered machinery. It is best to use a lightweight oil that can be transported by air. Oilers should be refilled, and filthy or milky oil should be changed. Stop leaks and store air reserves safely Leaks in any section of the air system can raise operational costs by requiring compressors to compress more air than in a leak-free system. An ultrasonic leak detector is an excellent technique to identify and remove air leaks. Taking instrument readings throughout each shift is essential for checking for leaks or excessive restrictions in the suction line between the filter and compressor. Reserve air storage should be made safe and efficient. It is ideal for installing air receivers to entirely drain oil or condensed water from the compressor or after-cooler outlet. A spring-loaded safety valve installed at the receiver is a crucial safety element that should be examined regularly to ensure it is in excellent operating order.
- 19. Proper setup, frequent maintenance, and quality lubrication may enhance the energy efficiency and performance of air compressors while also lowering operating costs. Maintain your compressor The best method to ensure compressed air availability is to take good care of your compressed air equipment. It entails investing in frequent preventative maintenance to maintain the compressor efficiency achieved by acquiring a new compressor or increasing the performance of an existing unit. Sign up for a scheduled maintenance program at pre-determined intervals from the Confidence distribution centre if you wish to purchase replacement parts solely and execute maintenance in- house. Regular maintenance will increase the uptime and energy efficiency of your equipment. The inverse might result in additional downtime, more energy use, and, possibly, a breakdown. Confidence Efficient Air Compressor
- 20. Confidence Air Compressor can provide optimum performance while using less energy with its power-saving choices. Energy efficiency equates to financial savings for your company. Confidence Compressor has a long history of manufacturing high-quality most efficient compressors that combine compressor efficiency and durability. Contact us to learn more about how we can outfit your business with a compressor or compressor system that will help you save time and money. Summary Above all, the design and preventative maintenance procedures implemented to guarantee that the system functions smoothly always determine the air compressor efficiency. Your top goal should be to examine leaks, change filters regularly, utilize pressure regulators, and run the system at the lowest possible pressure. Working with an air compressor professional to identify energy-saving options will save you money while also improving the compressor efficiency of your system. Facebook
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