NOVEL THINKING

I arrived early the next morning, and the compressor setting was at 115 psig discharge pressure, just where it was supposed to be. But if the system was properly sized and maintained, this should be easily factored into what to set the discharge pressure of the compressor. However, if your application requires that you keep the block constantly moving over a span of many hours then you’ll need a larger compressor with more continuous flow. I instructed the owner to have those two valves closed. In this simple example, I would recommend adding a 7.5-hp compressor to the system to add volume, which will stabilize the discharge pressure to the desired level.

How much more compressor hp does the plant need to maintain the required 100 psig in the plant header? Pressure determines the compressor’s ability to perform a specified amount of work at any given point in time. block across the table. A needle valve is used to a. adjust the flow rate in a circuit. When we arrived back at the compressor, the machine was at full pressure. While 100 psi of air pressure may not be enough force to move the block, 115 psi will, which is why it’s important to know the minimum pressure needed for your process.

My philosophy to sales has always been to be a consultant and to educate the end user, not to merely be a salesman. For more information, please contact Chris Downs, Tel. Funny but true! To understand the relationship between the pressure drop across a pipeline and the flow rate through that pipeline, we need to go back to one of the most important fundamental laws that governs the flow of fluid in a pipe: the Conservation of Energy, which for incompressible liquids, can be expressed using the Bernoulli Equation. Remember, compressed air is “stupid” (i.e.

In addition, an educated customer is a quality customer. With a focus on Supply-Side Optimization, air compressor technologies and compressor control systems are profiled. A rule of thumb to remember is that for every 2-psi increase in discharge pressure, the energy (measured at the compressor) goes up by 1 percent. block across a long table.

Understanding pressure and flow will help you size your compressor based on process demands while reducing energy requirements, improving productivity and lowering lifecycle costs. Now that we know what these terms mean, let’s take a look at the relationship between pressure and flow. Solution: The following steps are illustrated by the broken line on Chart CG-25 and Chart CG-24. Why you ask? hbspt.cta._relativeUrls=true;hbspt.cta.load(2510332, '3ebc5d9d-1b33-4f65-bd50-bc94602a53f7', {}); Personalize your experience on the Compressed Air Blog. The artificial demand in this case is 25 psig. Say we need to move a 10 lb. Where P1 is the initial pressure, V1 is the initial volume, P2 is the final pressure, and V2 is the final volume.

When it comes to compressed air systems, pressure and flow are two of the most common terms you’ll encounter. Flow is the compressor’s ability to continue performing a certain task. Now that we know what these terms mean, let’s take a look at the relationship between pressure and flow. After several minutes of investigation I found the culprit, a quarry worker had opened two 1/8-inch ball valves to direct some of the compressed air on his face in an effort to cool himself in this sweltering environment. Your personalized homepage experience is available here. While 100 psi of air pressure may not be enough force to move the block, 115 psi will, which is why it’s important to know the minimum pressure needed for your process. In fact, we know from Boyle’s Law that: Where P1 is the initial pressure, V1 is the initial volume, P2 is the final pressure, and V2 is the final volume. Pressure and flow help facilities size their compressors to power applications with the proper air volume and flow rate so that no energy is wasted. 200-hp compressor operating at 125 psig (220 BHP), $0.10 per kWh (the energy cost can be calculated in most cases by obtaining a copy of the end user’s power bill. Below is a graph and table of this relationship. To calculate the energy savings, use the energy equation below: Note that compressors are rated in hp, not kW. For this exercise we can calculate the “blended” rate by dividing the total dollar amount of the bill by the total kW usage). The boiler uses 147l/hr of fuel, the water inlet temperature is 25degrees Celsius and its maximum steam output is 2tonnes/hr. b. adjust pressure downstream from the valve. c. control the direction of fluid flow.

A couple of weeks after the compressor was installed, I received a call from the owner, who was complaining that the compressor wouldn’t hold the desired pressure as the ambient temperature increased throughout the day. The compressor must provide the right amount of pressure, or force, needed to complete the process. Too little pressure means the job won’t get done, whereas too much pressure can damage the equipment and cause unexpected malfunctions. 1.

You may edit your selections at any time. $131,924 x 12.5% = $17,276.00 per year every year in energy savings! It’s common to see pressure regulators installed on production equipment — sometimes set for pressures well below the system/header pressure. You guessed it: He or she “jacks” up the pressure on the compressor, not realizing that he or she made the problem worse. After more than 25 years in the compressed air industry, it still amazes me that many plant personnel and even those who sell compressed air products for a living don’t fully understand the relationship between flow, or volume (cfm), and pressure (psig). a. d. align the needle in an industrial pneumatic sewing operation. Leave us a comment below or send us an email on our contact page.

One way granite is mined is by using a high-temperature torch that melts the rock to enable a slab to be removed.

For this example, I use $0.01/kWh. An industry term that has been used in recent years to describe supplying more pressure to the system than is necessary is “artificial demand.” For example, if the production floor only needs 75 psig to maintain steady production, why maintain the compressed air header at 100 psig? After thoroughly reviewing a compressed air system, I sold a 200-hp rotary screw compressor to a granite mining facility in east Georgia. Visualizing KPI’s: Specific Power, Flow, Pressure, Dewpoint - Webinar  Recording, Air Compressor Technology Monthly e-Newsletter, www.airbestpractices.com/system-assessments/pressure, Lontra Signs Agreement with IAC to Begin U.S. Distribution, Schulz Opens New Office in the United States, Atlas Copco Specialty Rental's Compressors Comply with EPA and Save on Stack Testing, Emerson Introduces AVENTICS Series AF2 Flow Sensor Monitor, How to measure and visualize key performance indicators within a compressed air system, How measurements can be properly benchmarked against the plant’s specification and demand, Opportunities for improved compressed air quality, energy management and compressed air system reliability, How to keep KPI’s relevant for stakeholders over time, How to maintain a focus on the right KPI’s.

Also note that rotary screw air compressors pull more hp than the motor’s nameplate rating. If you help an end user solve a problem, that person is much more apt to buy something from you in the future. There have been many articles written on this subject over the years, but many of them have been so technical that it was difficult to follow for a person outside of the industry.

System Assessment articles detail what compressor controls allow kWh consumption to match system demand. Your personalized homepage experience is available here. Another way to reduce leaks is to have a leak audit performed and implemented. Pressure Drop vs Flow Relationship 2-27 REVIEW QUESTIONS 1. Keep doing this over a period of time, and you will eventually have someone scream at you. Which components are combined within a pneumatic flow control valve? Another little known fact about compressed air from an end user’s point of view is that discharge pressure has a direct impact on flow.

A little hint on determining the critical pressure if it isn’t readily known — simply turn down the pressure switch on the compressor(s) by 2 psig, then wait to see if anyone complains about inadequate plant air pressure. An air compressor is needed in this process to project the flame. Given a flow rate of 6,700 lb/hr, an initial steam pressure of 100 psig, and a pressure drop of 11 psi/100 ft, find the size of Schedule 40 pipe required and the velocity of steam in the pipe. I knew that this had to be a “system” problem and not a “compressor” problem, so I began to walk around the quarry to see what I could find. Being a degreed engineer, I knew that what he was describing wasn’t possible. In this article, I try to address the subject in a way that non-engineering types can understand. A plant has a 25-hp rotary screw compressor rated at 100 acfm at 100 psig. To read more articles about Pressure please visit www.airbestpractices.com/system-assessments/pressure. Chris Downs, Regional Manager, Kaishan Compressor USA. Simply increasing pressure by 2 psi causes a 1 percent increase in the energy needed to maintain the same airflow. To determine the “critical pressure” in a production process, you have to leave the comforts of the compressor room and venture out onto the production floor. However, remember that you can effectively reduce leaks, but you can never completely eliminate them. Another major benefit to dialing down the system/header pressure is that any leaks in the distribution of the compressed air will be reduced. Because production workers typically blow off their workstations between shift changes. A comical fact when conducting a full plant air audit (both supply side and demand side) is that in many cases the largest event that spikes the system is a shift change. A handy rule of thumb to remember is that a 1/4-inch opening/orifice will leak approximately 100 cfm at 100 psig. Thank you for your submission. In fact, we know from Boyle’s Law that: P1 x V1 = P2 x V2.

Therefore, a 200-hp rotary screw air compressor actually pulls on average 220 BHP at full load, depending on the manufacturer. Dialing the pressure down by 25 psig, the plant could save 12.5 percent energy on an annual basis. To calculate kW, multiply BHP by the constant (.746). However, as the day got hotter I witnessed just what the owner had said — the discharge pressure began to fall. Airflow takes into consideration how often you need to move the 10 lb.

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