Compressed Air System Maintenance: Achieving Maximum Performance with Minimal Investment
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1 Compressed Air System Maintenance: Achieving Maximum Performance with Minimal Investment Ultrasound World III Clearwater Beach, Florida November 5-8, 2006
2 COMPARISON OF COSTS ELECTRIC vs. AIR MOTOR Approx. $200/year Power Cost Approx. $1,500/year Power Cost * Air motors require about 7hp of compressor capacity or 27-30cfm per hp output. Based on 5,000 hours/year at $0.05/kWh
3 Why is Compressed Air so Inefficient? Less than 20% of input energy available for work Pressure drops and regulators reduce useable energy Typical air tool has typical 12-15% overall efficiency
4 A How Much?!?! A Question of Initial $0.06/kwh, a single stage rotary screw compressor costs about $10,000/year per 100 cfm to operate!
5 A How Much?!?! A Question of Initial Cost When selecting a compressor, the following should be taken into consideration: What is the total cost of ownership? What type of controls will best suit my operation? Two stage compressors will likely save money in the long run.
6 Plant Air Compressor Deliveries Design vs. Actual 5.0 to 5.3 cfm/hp H/D 2 Stage Water Cooled Recips. 4.5 to 5.0 cfm/hp Multistage Centrifs. 2 Stage Rotary Screw Higher Speed 2 Stage Recips to 4.5 cfm/hp Low Rotor Speed Single Stage Oil Flooded Screw 4.0 to 4.25 cfm/hp Most Single Stage Oil Flooded Screw 3.5 to 3.8 cfm/hp 80% of compressors at 230 BC Hydro and Ontario Hydro Customers had delivery I this range on compressors with modulating air inlet controls.
7 Plant Air Compressor Deliveries Design vs. Actual What Price is Efficiency? 5.25 cfm/hp $40,000 per year Difference 3.5 cfm/hp * Based on 8500 hours per year and $0.05/kWh and $7 / kw
8
9 Matching Compressors to Production Demands How does your facility stack up? Operating multiple rotary screw or centrifugal compressors, ALL featuring some form of inlet throttle modulating control. When production ends and maintenance takes over, are compressors just left running? No means of compressor performance testing. Output is assumed based on power draw or referencing OEM curves. Addressing air leaks is not a priority because of lack of manpower, lack of education, or attitude that leaks are not a high concern. Mentality is evident that air is free, it is used for menial applications such as blowing dust or water off of product, machine bearing cooling, optical scanning equipment cleaning, cooling personnel, etc.
10 Matching Compressors to Production Demands How does your facility stack up? THIS IS WHERE YOU WANT TO BE! Multiple compressor installation under control of a programmed PLC sequencer or equivalent. Air Leak monitoring is part of PM (Preventive Maintenance) program and maintenance and planning departments see that leaks get monthly attention and the process has ACCOUNTABILITY. Performance under load tests are utilized to measure actual compressor performance to confirm compressors are producing rated air and controls are allowing proper delivery of air into the system. Heatless desiccant air dryer purging is under full control of a RELIABLE dew point monitoring system.
11 An Example of Multiple Compressor Sequencing A 400 hp A 400 hp A 400 hp A 400 hp B 250 hp 125 hp C B 250 hp 125 hpc B 250 hp 125 hpc B 250 hp 125 hp C Current Operation: Time Days/Week Required Flow Leak Volume Compressors On 1st Shift 5 2,500-2, A & B & C 2nd Shift 5 2,000-2, A & B 3rd Shift B Weekends 53% of the 2time there is little 400or no air use400 in the system C Leak costs: 400cfm is roughly equivalent to 100hp which over a year will cost: 100hp *.746kW/hp * 8760 hrs/yr * $.06/kWh = $39,200 per year
12 An Example of Multiple Compressor Sequencing A 400 hp A 400 hp A 400 hp A 400 hp B 250 hp 125 hp C B 250 hp 125 hpc B 250 hp 125 hpc B 250 hp 125 hp C Current Operation: Time Days/Week Required Flow Leak Volume Compressors On 1st Shift 5 2,500-2, A & B & C 2nd Shift 5 2,000-2, A & B 3rd Shift B Weekends C Annual Electric Energy Cost: $109,781
13 An Example of Multiple Compressor Sequencing A 400 hp A 400 hp A 400 hp A 400 hp B 250 hp 125 hp C B 250 hp 125 hpc B 250 hp 125 hpc B 250 hp 125 hp C Recommendations: Repair Half of the System Leaks Install Dedicated compressor (5hp) for Sprinkler System Install PLC Multi-compressor Sequencer ~ $3,500
14 An Example of Multiple Compressor Sequencing A 400 hp A 400 hp A 400 hp A 400 hp B 250 hp 125 hp C B 250 hp 125 hp C B 250 hp 125 hp C B 250 hp 125 hp C Proposed Operation: Time Days/Week Required Flow Leak Volume Compressors On 1st Shift 5 2,300-2, A & B 2nd Shift 5 1,800-2, A & C 3rd Shift C Weekends None Annual Electric Energy Cost: $80,687
15 An Example of Multiple Compressor Sequencing Current Operation: $109,781 Time Days/Week Required Flow Leak Volume Compressors On 1st Shift 5 2,500-2, A & B & C 2nd Shift 5 2,000-2, A & B 3rd Shift B Weekends C Proposed Operation: $80,687 Time Days/Week Required Flow Leak Volume Compressors On 1st Shift 5 2,300-2, A & B 2nd Shift 5 1,800-2, A & C 3rd Shift C Weekends None Energy Savings = $ 29,094
16 Compressed Air Flow Volumes for Various Sized Orifices In reality, you will probably never come across a perfect, round, sharp edged orifice leak anywhere in your plant facility. Leaks occur in joints, couplings, slits or gashes in pipes and lines, and other types of fittings. Thus, the tables presented here can only be used as a guideline.
17 Common Air Leaks and Misapplication Optical scanning equipment clean off use small blower Air hoses loose or frayed clamps Air lances and fittings Pressurized computer and electrical rooms/panels Belt cleaning use a small blower Cooling machinery bearings- use a fan Worn cylinder packing, O rings, faulty PR valves or broken diaphragms, bleed off vent holes in valves.
18 Tracking Compressed Air Leakage Target Leak Volume CompressedAir Leakage (cfm) Rolling Average Even with consistent program leaks will reoccur
19 Summary Table of Testing Results Compressor Compressor Expected flow(cfm) Actual peak flow(cfm) Location hp and pressure and pressure Main Mill Comp. Room 350 Main Mill Comp. Room 300 psig Stacker/Sorter 150 psig Planer 100 psig Totals 900 3,600 3,105 Note: Compressorsare underperforming by1600cfm-equiv. to 400hp compressor Summary Table of Air Leak Test Results Leak Volume %of Equivalent LeakLocations (cfm) Peak Flow Compressor hp Main Mill % 191 Reman Operation % 128 Sorter 0 0% 0 Stacker % 45 Planer % 65 Totals 1,485 48% 430 Note: Half of the compressed air produced is being lost directly to atmosphere with no useful work being done!
20 Sawmill Example. Cost of CompressedAir Annual Loaded Unloaded Hours of %of Time Annual Cost of energy Cost of Demand Total Cost Compressor kw kw Operation $5.43/kW of electricity Sorter/Stacker % 786,250 $ 30,349 $ 6,516 $ 36,865 Planer % 618,694 $ 23,882 $ 4,806 $ 28,687 Main Mill 300hp % 1,797,750 $ 69,393 $ 14,140 $ 83,533 Main Mill 350hp % 2,256,750 $ 87,111 $ 17,789 $ 104,899 Totals 5,459,444 $ 210,735 $ 43,250 $ 253,984 Sawmill Example. Leak Analysis and Achievable Savings Current kwh to kwh Cost Acceptable kwh Savings kwh Cost Savings Compressor %of Leaks Leaks of Leaks %of Leaks Achievable Achievable Sorter/Stacker 30% 255,000 $ 9,843 10% 170,000 $ 6,562 Planer 65% 407,469 $ 15,728 10% 344,781 $ 13,309 Main Mill 300hp 49% 903,805 $ 34,887 15% 627,130 $ 24,207 Main Mill 350hp 49% 1,137,045 $ 43,890 15% 788,970 $ 30,454 Totals 2,703,319 $ 104,348 1,930,881 $ 74,532
21 Performance Testing an Air Compressor Using the LP Load Flow Meter, to determine compressor performance: Isolate compressor from system Open meter orifices until compressor can just keep up at test pressure Open and close valves to test at other pressure/flow combinations
22 Leak Testing an Air System 1. Perform a compressor capacity test at system pressure 2. Pressurize the System without plant operating 3. Perform a second flow test at the same system pressure 4. The difference in measured flow volumes is the leak volume in the system Provides very accurate leak quantities which can be converted into annual costs. Any equipment or segemnt of the system thhat can be isolaed can be tested Focus maintenance efforts to areas of high leaks Other Applications: Check leaking block valves, leak test underground pipe, and check complex piping or process for total leak volume.
23 Testing Purge Volume on a Desiccant Dryer Purge cycle on a desiccant dryer can be tested just as if it were a leak. Procedure: 1. Perform standard performance test with dryer isolated (or bypassed) 2. Put dryer into purge mode and perform a second test 3. The difference in measured flow volume at the meter is the purge volume Any piece of equipment or process which can be isolated can be tested Typical purge volumes: 15-17% for heatless dryers 4-8% for heated regenerative dryers.
24 Performance Curves Modulating valve prematurely throttling
25 Performance Test - Theory Vs. Reality 325 cfm
26 Inlet Throttle Control
27 Modulating Air Inlet Controls
28 Modulating Control Valve Cutaway Dirt, oil, water, or other contaminants can foul the valve causing pre-mature modulation
29 Constant Speed Centrifugal Compressor Centrifugal Compressor Diagram Centrifugal Compressor Performance Curve Check Valve Air Flow Measurement 100% Surge Limit Constant Speed Drive Vent Valve to Atmosphere Air Inlet Discharge Pressure 0% Blow Off Range Capacity (ICFM) Throttle Range 100%
30 Centrifugal Instrumentation Inlet, outlet, and inter-stage temperatures and pressures are the quickest method to determine compressor health. Gauges or control points should be installed and monitored for : Air and water temperature Air and water pressure Power consumption (amps, kw, kwh) Flow Make sure gauges or control points: 1. Exist 2. Calibrated regularly 3. Accessible 4. Logged (maintenance sheets or datalog)
31 Commonly Found Centrifugal Compressor Problems Moisture Carryover - Improper moisture removal by trap - Leak in intercooler Electrical - Improper motor grounding - Residual magnetism (static) - Welding (improper ground) Improperly set clearances High Vibration - Unmatched rotor assemblies - Shaft Misalignment - Worn or damaged bearings Ingestion of particles - Surge induced - Poor filtration
32 Performance Diagnostics: Examples from the Field 1. Nuclear Power Plant Centrifugal compressor testing Surging problem blamed on compressor traced to stuck valve on dryer Saved critical equipment downtime and 2 man weeks of labor 2. Pet Food Company Previous air study recommended expensive modifications Testing revealed serious deficiencies in compressors performance After repairs (~$920), intermediate control project was cancelled ($15,000 cost) 3. Sawmill Operation 300hp Compressor tested at 60% of rated flow 4 hours of maintenance found coil spring problem Output increased 47% 4. Wood Products Plant 50 hp at 211 cfm, 75 hp at 160cfm 16kW in energy savings at a zero implementation cost Knowledge is power - be a TYRANT. The more you know about your compressor operation, the quicker you can solve the root problems!
33 Sample Project Savings Improvements do not need to be expensive. Operations and maintenance savings can amount to 50% or more of project savings. From experience, most facilities do not need expensive new equipment, they just need to make the equipment and system they have work correctly.
34 Desiccant Dryer Overview Prefilter - removes dirt, oil, and water Dryer Removes water vapor After Filter Removes fines to protect the system from contamination Oil contamination reduces the effectiveness of desiccant to adsorb water. Oil contamination increases chances of fire hazard
35 Drain Trap Types Timer Drains Open based on time and duration Waste energy by blowing air Float Traps Use float to open valve No air loss Maintenance concerns Inductive Traps Use inductive sensor No air loss Higher reliability Higher cost Can include alarms
36 Receiver Placement in Compressor Rooms Compressor - Receiver - Dryer? Compressor - Dryer - Receiver?
37 Locating and Sizing Air Receivers Receiver helps smooth out demand and allows compressors to react to changes in Demand. Essentially to give the system capacitance. One receiver should be located in or near the compressor room. As a Rule of Thumb, receiver volume should be at least 5% of total compressor(s) output in cu. ft. Locate receivers in the plant at high use locations. This will help resolve local pressure/velocity issues and help reduce the overall pressure setpoint. Receive r Receive r
38 Air Piping Considerations Pressure Drop Rule of Thumb - Max. 3 psig drop between supply point of use. High Air Velocities undersized piping = high velocity and high pressure drop. Rule of thumb = velocity should be under 10,000 /minute (5-7,000 better). Velocity = CFM*144/Pipe Area Corrective actions include: 1. Increase the section of undersized piping 2. Install an air receiver at the point of air usage. Pipe Diameter vs. Flow If you double the pipe diameter, the cross sectional area will increase by 4 times. *** Use long radius elbows and Y connections
39 Air Piping Considerations Maintenance Consideration Blow out scale periodically. Open a large valve and purge air system every 6 months for an hour. 1. Less particulate load on filters 2. Air dryer may be bypassed during flushing Loop Piping Where possible use loop piping layout instead of branch layout. The loop system will often result in a more stable system air pressure. Comp.
40 Air Piping Considerations Maintenance Consideration Blow out scale periodically. Open a large valve and purge air system every 6 months for an hour. 1. Less particulate load on filters 2. Air dryer may be bypassed during flushing Loop Piping Where possible use loop piping layout instead of branch layout. The loop system will often result in a more stable system air pressure. Note: Increasing the system setpoint pressure to compensate for other deficiencies is NOT the way to go.
41 Reasons for High Oil Carryover AIR PRESSURE : low pressure air holds more liquid (oil or water) 1. Demand exceeds compressor delivery output, 2. Compressors with load/no load control where unload pressure is too low 3. High air velocity due to dirty separator element. TEMPERATURE : 1. Over cooled compressor can have saturated air entering separator. 2. Can lead to water condensation with cooling affect through separator. 3. This condition can be accentuated with a dirty separator filter.
42 Energy Efficient Alternative Solutions to Common Air Uses Specialty Regulators Pilot regulators on a receiver for low pressure applications. Receiver charged at line pressure, flow controlled for low pressure applications. Blowers Low pressure, high volume: as little as 3 psig can be affective Dust/debris removal Drying Vortex Amplifiers blast or jet of air: entrain ambient air with compressed air. 20:1 amplification possible Spot cooling Dust removal Air assist Boosters Limited volume at higher pressure pressure Can use line pressure or ambient air Process Air assist Air jet
43 Thank You! Questions?
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