hbspt.cta._relativeUrls=true;hbspt.cta.load(2510332, '3ebc5d9d-1b33-4f65-bd50-bc94602a53f7', {}); Personalize your experience on the Compressed Air Blog. As you can imagine, this is a hot environment for the employee who is working the torch. Furthermore, the majority of production personnel do not have a clue that compressed air isn’t free. 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. 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? Leave us a comment below or send us an email on our contact page. Use the Bernoulli equation to solve other types of fluid flow problems. Obviously, there are pressure drops across the clean-up equipment (dryers and filters), which could equate to 10 to 15 psig or more. (251) 510-2333. In this article, I try to address the subject in a way that non-engineering types can understand. If you help an end user solve a problem, that person is much more apt to buy something from you in the future. 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. block across the table. 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. 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. A needle valve is used to a. adjust the flow rate in a circuit. It’s common to see pressure regulators installed on production equipment — sometimes set for pressures well below the system/header pressure. For more information, please contact Chris Downs, Tel. Only see the articles on the blog you are interested in reading. 2. You guessed it: He or she “jacks” up the pressure on the compressor, not realizing that he or she made the problem worse. Pressure is measured in pounds per square inch (psi). To read more articles about Pressure please visit www.airbestpractices.com/system-assessments/pressure. You may personalize your experience at any time during your visit. 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. A handy rule of thumb to remember is that a 1/4-inch opening/orifice will leak approximately 100 cfm at 100 psig. However, they can only maintain 80 psig in the production area. Where P1 is the initial pressure, V1 is the initial volume, P2 is the final pressure, and V2 is the final volume. After thoroughly reviewing a compressed air system, I sold a 200-hp rotary screw compressor to a granite mining facility in east Georgia. Pressure Drop vs Flow Relationship 2-27 REVIEW QUESTIONS 1. 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. 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. Because production workers typically blow off their workstations between shift changes. a. Remember, compressed air is “stupid” (i.e. 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. 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. Solution: The following steps are illustrated by the broken line on Chart CG-25 and Chart CG-24. block across a long table. The exact BHP can be derived from the manufacturer’s technical datasheet, or by contacting a representative of that brand. When it comes to compressed air systems, pressure and flow are two of the most common terms you’ll encounter. Understanding pressure and flow will help you size your compressor based on process demands while reducing energy requirements, improving productivity and lowering lifecycle costs. Your personalized homepage experience is available here. When we arrived back at the compressor, the machine was at full pressure. Flow is the compressor’s ability to continue performing a certain task. However, remember that you can effectively reduce leaks, but you can never completely eliminate them. To calculate the energy savings, use the energy equation below: Note that compressors are rated in hp, not kW. Pressure determines the compressor’s ability to perform a specified amount of work at any given point in time. Visit atlascopco.us - Legal Notice & Cookies, Air Compressors Use in Agriculture and Farming, Buying Air Only - A New Way to Purchase Compressed Air, How to Correctly Size Your Compressed Air Piping System, Pressure Regulation Methods for Compressed Air Systems. Airflow takes into consideration how often you need to move the 10 lb. In addition, an educated customer is a quality customer. System Assessment articles detail what compressor controls allow kWh consumption to match system demand. Dialing the pressure down by 25 psig, the plant could save 12.5 percent energy on an annual basis. Say we need to move a 10 lb. I instructed the owner to have those two valves closed. However, as the day got hotter I witnessed just what the owner had said — the discharge pressure began to fall. Assuming that the clean-up equipment and piping distribution system were poorly sized and maintained, which equates to a 20-psig pressure drop, you could still cut the pressure on the compressor operating at 125 psig to 100 psig, and still maintain the desired 75 psig on the production floor. Walk into many body shops or small manufacturing plants, and you will find the compressor operating at an elevated pressure to satisfy the “demand.” If a plant has low air pressure on the production floor, what is the first thing that the maintenance professional does? Simply increasing pressure by 2 psi causes a 1 percent increase in the energy needed to maintain the same airflow. Keep in mind that this example is for a modulating or load/no load controlled compressor, possibly without adequate storage. To calculate kW, multiply BHP by the constant (.746). I’ve personally been in plants where the vast majority of the production equipment only needed 75 psig to function properly, but the plant air header was being maintained at 100 psig. Typically compressor manufacturers utilize a 1.15 service factor motor, meaning that the motor can safely operate 10 to 15 percent beyond its nameplate rating. With a focus on Supply-Side Optimization, air compressor technologies and compressor control systems are profiled. 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. The moral to the story is that the quarry worker didn’t know that by opening two 1/8-inch valves under 100 psig discharge pressure the system would lose approximately 100 cfm, which equates to a 25-hp rotary screw air compressor (rule of thumb is that a rotary screw compressor delivers 4 to 5 cfm per 1 hp). Let’s take a look at an example of how to use Boyle’s Law in a real-world scenario: 25/4.5 = 5.5 hp (I assumed 4.5 cfm per 1 hp). 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. Another way to reduce leaks is to have a leak audit performed and implemented. Feedwater Mass Flow = Steam Mass Flow / [ 1 - Blowdown Rate] [ Feedwater Mass Flow = 44.4 klb/hr = 40.4 klb/hr / ( 1 - 0.091 ) ] Using the Steam Property Calculator, properties are determined using Deaerator Pressure and Quality = 0 (Saturated Liquid). Thank you for your submission. You may edit your selections at any time. The artificial demand in this case is 25 psig. Personalize your experience by selecting the topics you are interested in below. I also knew that the only way for me to solve this phenomenon was to visit the site to gather data. Now that we know what these terms mean, let’s take a look at the relationship between pressure and flow. The amount of flow needed depends on the length of time required to complete the task. Then turn it up 2 psig, and leave it alone. Let’s go through a quick example: 220 BHP x .746 x 8000 hours x $0.1 kWh = $138,206.00. 1. Which components are combined within a pneumatic flow control valve? Funny but true! c. control the direction of fluid flow. I arrived early the next morning, and the compressor setting was at 115 psig discharge pressure, just where it was supposed to be. For this exercise we can calculate the “blended” rate by dividing the total dollar amount of the bill by the total kW usage). 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. Being a degreed engineer, I knew that what he was describing wasn’t possible. Steam Tables Steam and temperature posess a reliable realtionship whereby if the pressure of the steam is know its temperature can be predicted (and vice versa). Keep doing this over a period of time, and you will eventually have someone scream at you.

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