![]() Over time, these movements weaken joints and can result in leaks. In addition, compressed air lines are dynamic in that they are constantly vibrating owing to the passage of compressed air. Compressed air contains trace amounts of oil and water, which can cause line corrosion and, in turn, results in pressure drops and affects efficiency. While steel is more accessible than aluminum, aluminum offers lower weight and corrosion resistance. Plastic, aluminum and steel are the most common materials for compressed air piping. Minimizing bends en route to the application reduces pressure drops and improves the efficiency of the system.Ĭhoosing the material for the distribution system is as important. When designing a compressed air piping system, the shorter the distance from the compressor to the application, the better. Both the design of the distribution and material used for piping affect energy efficiency. The biggest area for improvement could be the facility’s distribution system-how the compressed air is transported and used in the end application. When looking to improve energy efficiency, customers have to look further than the air compressor and evaluate the compressed air system as a whole. Image 2 illustrates the power savings with a VFD. ![]() By reducing the motor’s speed, the compressor consumes less energy than a fixed speed compressor versus inlet modulation control or load/no load (at 3 gallons per CFM storage). Fluctuating Air DemandsĪ VFD works by reducing the compressor motor’s speed to lower flow to match the actual air demand of the customer. Screw compressors are inefficient in the unload condition and, thus, a larger compressor will use more energy and consumables than a right-sized compressor for a given air requirement.Īs a general rule of thumb, a compressor that is only running at 50 percent capacity will consume 20 percent or more power than a compressor that is running at or close to full capacity. For example, if a compressor produces 500 cubic feet per minute (CFM) but the air requirement is only 300 CFM, then the compressor will be in unload condition for a significant portion of the time. (Loaded, means the compressor is producing air while unloaded means the compressor remains idle.) A compressor will continuously load when its air production capacity matches the air requirement. A rotary screw compressor is most efficient when running in a 100 percent loaded condition. Compressor Sizeīigger is not better when it comes to air compressors. Here are three main points to evaluate to transform utility cost into an energy-saving opportunity. IMAGE 1: Compressor life cycle cost breakdown (Images courtesy of ELGi North America)
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