COMPRESSION PROCESS
• ISENTROP
This is a process taking place without
any heat exchange with the
surrounding.
• ISOTHERM
The isotherm is based on complete heat
exchange with the surrounding.
• In reality all compressor processes
will fall between these two.
This generalized process is called
POLYTROP.
COMPRESSION PROCESS
• ISOTHERM
P1.V1 = P2.V2
ie. p2/p1 = v1/v2.
• ISENTROP
p2/p1 = (v1/v2)K
• POLYTROP
(pv)N = constant
n =1 isotherm
n = k isentrop
COMPRESSOR STAGING
• STAGING
Compressor processes are
polytropic which means temp.
inceases with the pressure
ratio.The compression work
increases with temp. rises.
To limit the temp. rise & to
improve compression
efficiency,compression is
carried out in stages &air being
cooled between each stage.
TYPE OF COMPRESSORS
OBJECTIVE OF NEW GA II REDESIGN
• TO INCREASE SALES AND MARKET SHARE BY
BOOSTING BUYING BENEFITS
– IMPROVE PERFORMANCE
– DEVELOP THE FULL FEATURE UNITS
– PROVIDE MORE STANDARD OPTIONS
MOTOR RATING VS CAPACITY
1100
1000
900
800
700
600
500
400
90 110 132 160
ACI 487 600 735 838
CP 551 685 955
IR 581 684 981
ELGI SINGLE STAGE 535 664 809 900
TANDEM 570 700 825 930
ACI REDESIGN 587 708 850 1000
ACI CP IR ELGI SINGLE STAGE TANDEM ACI REDESIGN
GA 90 - 160 REDESIGN
• SCREW ELEMENT
– SIZE 2 SHORT SIZE 2 LONG.
(ACTIVE ROTOR LENGTH FROM 320 MM TO 410 MM)
• ALL COMPRESSORS ARE WITH SERVICE FACTOR MOTORS 1.15
• AVAILABLE IN PRESSURE VARIANTS - 7.5 BAR, 10 BAR, 13 BAR.
• AVAILABLE IN AIR COOLED AND WATER COOLED VERSIONS
• FULL FEATURE WITH INTEGRATD DRYERS & OIL REMOVAL
FILTERS.
• ALL COMPRESSORS WITH ELEKTRONIKON REGULATOR
• STANDARD OPTIONS
– COM 1 FOR ES CONTROL SYSTEM
– HEAVY DUTY FILTER FOR DUSTY ATMOSPHERE
TYPICAL RECIPROCATING
COMPRESSOR
TYPICAL RECIP INSTALLATION
WEAR ITEMS
A COMPARISON
PISTON SCREW
VEE BELTS (6) 2 GEARS
CRANKSHAFTS 6 BEARINGS
MAIN BEARINGS (4) 2 ROTORS
BIG END BEARINGS (4)
CONNECTING RODS (4)
SMALL END BEARINGS (4)
CROSS HEADS (4)
WIPER RINGS (4 SETS)
PISTONS (4)
PISTON RINGS (16)
CYLINDERS (4)
40 VALVES (SUCTION/DELIVERY)
TOTAL 99 WEAR ITEMS TOTAL 10 WEAR ITEMS
WEAR ALONG WITH OVALITY CAUSES A CAPACITY DERATION OF 5-6% PER YEAR.
HIGH NUMBER OF PARTS INCREASES DOWN TIME AND MANPOWER OUTLAY
“BALANCED” OPPOSED PISTONS
FORCE BALANCE
F2
F1
F1
F2
1. HORIZONTAL FORCES F1 BALANCE OUT
2. UNBALANCED VERTICAL FORCES CAUSE CYLINDER OVALITY,ACTING ALONG WITH
THE PISTON WEIGHT AND ALSO AN UNBALANCED COUPLE NECESSITATING HEAVY
FOUNDATIONS.
PISTON COMPRESSORS
EFFECTS OF CYLINDER OVALITY
CYLINDER
PISTON
CYLINDER OVALITY PREVENTS RESUMPTION OF CAPACITY TO ORIGINAL
LEVEL LEADING TO CONTINUED AI LEAKAGE
P-V DIAGRAM
EFFECT OF VALVE FLUTTER
. EFFECT OF VALVE
FLUTTER
P
w
VALVE FLUTTER CAUSES THE AREA OF THE P-V DIAGRAM TO INCREASE WHICH RESULTS
IN HIGHER THAN INDICATED POWER CONSUMPTION. FLUTTER OCCURS AFTER A SHORT
SPAN OF USAGE.
GA90-160
New design
GA-Drive system
To improve performance
What’s new
GA90-110
– Screw element
• SIZE 2 short SIZE 2 long
(active rotor length from 320 mm to 410 mm)
Lower running cost
To improve performance
What’s new
SIZE 2 long element
– Higher built-in pressure ratio at the discharge
port
• 7.5 bar Same SER
• 10 bar 3% better SER
• 13 bar
Lower running 5% better SER
cost at higher
pressure
To improve performance
What’s new
The main motor
Service factor(50Hz)
More capacity
1.1 1.15
Service factor(60Hz)
1.2
To improve performance
What’s new
The main motor
Both the motor options are available ie.
TEFC &SPDP
Make : Crompton/Siemens/ as per customer
Service factor : 1.15
To improve performance
What’s new
The cooling fan arrangement
Pushing fan Sucking fan
More efficient cooling
Longer cooler cleaning interval
Cooler block Cooler block
To improve performance
What’s new
The cooling fan arrangement
Hinges for easier
cooler cleaning
To improve performance
What’s new
Fan motor
• Motor protection class : IP55
• Greased for life
• 1 fan motor for GA 90-110
Reliable
• 2 fan /motors
less maintenance
for GA 132-160
Fan motor
To improve performance
What’s new
Noise level(Preliminary) acc. to PN8NTC2
GA90-110 : 72 dB(A)
GA132-160 : installation
More choices on 74.5 dB(A)
and less installation cost
What’s new
Female connection
foreseen
Full feature
ID dryer
Full feature
Refrigerant liquid Insulation Intake air
Refrigerant gas / liquid Water Air / Oil mixture
Refrigerant gas Oil Wet air
Compressed refrigerant gas Dry air
Full feature
Air-cooled
• ID340 for GA90 - 110
• ID340W for GA90W - 110W
• ID470 for GA132 - 160
Water-cooled
• ID470W for GA132W - 160W
Full feature
ID dryer performance 50 Hz (Preliminary)
Dewpoint (°C) at 7 bar(e)
Ambient
Relative
temperature
humidity (%) ID340 ID470
(°C)
GA90-7.5 GA110-7.5 GA132-7.5 GA160-7.5
277 l/s 334 l/s 401 l/s 472 l/s
20 80 3 3 4 4
25 80 4 5 6 6
30 80 4 5 6 7
35 80 5 7 9 11
40 70 6 10 10 15
Full feature
ID dryer
By-pass system as standard
ID dryer
Full feature
Efficient and reliable aluminum
cooler block
Full feature
ID dryer
Dew point is displayed on Electronikon
together with dew point warning function
!
l e
Full feature
r sa
ID + Integrated DD filter Fo
Air quality to ISO8573-1 : Class 2.4.2
DD390 for ID340 (1,+3°C,1mg
DD520 for ID470
Dry Quality Air
oil/m drop
Pressure
3
) is monitored by
Electronikon
Integrated DD filter is foreseen
only with ID dryer.
.
Option : Phase sequence relay
• Avoid reverse rotation of driving motor
Option : OSD90 for ID dryer
Intake filter
Located at the back side
of the cubicle
Efficiency SAE fine :
1 µm : 98%
2 µm : 99.5%
3 µm : 99.9%
Throttle valve
Throttle valve
Air intake hose
New blowing off
system
Screw element
Size 2 long element
Stress free
coupling
Steel pipe in
stead of flexible
Oil separator tank
New cast vessel
Oil content : 3mg oil/m3
The hinge for easier
replacement of the
separator element
Coolers / moisture trap
Oil cooler
Aftercooler
New WSD
(Even with ID dryer)
Moisture trap
•WSD used
•WSD 250 for GA 90-110
•WSD 750 for GA 132-315
Oil filter
Easier
replacement
without oil
leakage
Throttle valve
• New design
• Integrated unloading and regulation valve
• Simple design
• Easy maintenance
New blowing off system
F
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o
w
d
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a
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Throttle valve
Throttle valve - Unload condition
Unloader - Load condition
Lifetimes
• Main shaft seal : 24.000 hrs
• Coupling element : 24.000 hrs
• Flexibles : 24.000 hrs
• Oil separator : 8.000 hrs
Lifetimes
• Oil (Roto inject fluid) : 4.000 hrs
• Oil filter : 4.000 hrs
• Air filter : 4.000 hrs
• Main motor regreasing : 4.000 hrs
MARKET & COMPETITION
GA II - RANGE : 587 CFM - 1050 CFM
TOTAL MARKET : 450 - 600 NOS.
(RECIP + SCREW)
DOMINANT PLAYER : ATLAS COPCO
ELGI EQPT.
INGERSOLL - RAND
KGK / KPC
NEW ENTRANTS : COMPAIR- DEMAG
KAESER
INGERSOLL - RAND
• RANGE : UPTO 1216 CFM
• OPTIONS : -ONLY WATERCOOLED IN
SSR RANGE
- STD.OPEN VERSION &
PACK VERSION
- CONVENTIONAL
MODULATING CONTROL
- DUAL CONTROL
- INTELLISYS
IR - SCREW AIRCOOLED
PACK
IR - AIR COOLED SCREW
FLOW DIAGRAM - IR SCREW
IR- INTELLISYS PANEL
KPC/KGK
• RANGE : UPTO 1250 CFM
90 • OPTIONS :
80
70 - STD. OPEN
60
50
40
East -SILENCED PACK
West
30
20
North - > 300 CFM
10
0
1st 2nd 3rd 4th
Qtr Qtr Qtr Qtr
WATERCOOLED ONLY
- STEPLESS CAPACITY
CONTROL
ELGI EQPT
• RANGE : UPTO 1724 CFM
• OPTIONS : FOR ENTIRE
RAGE
- AIR COOLED
- WATER COOLED
-STD. & PACK VERSION
• LOGIC CONTROL -
MICROPROCESSOR
• COMPUTER COMPATIBLE
• VARIABLE SPEED DRIVE
• ODP/TEFC MOTOR
• HT MOTOR POSIBLE
ELGI EQPT - SINGLE STAGE COMPRESSOR
ELGI EQPT
TANDEM TWIN ELEMENT
ELGI EQPT - TANDEM TWIN ELEMENT
ELGI EQPT
OFFER BOTH SINGLE STAGE & TANDEM TWIN ELEMEN
AT THE SAME PRICE
10 -15 % ENERGY
SAVING
TANDEM TWIN ELEMENT SINGLE STAGE
MODULATING CONTROL
• Butterfly type of
valve is being used.
• Maximum
modulating possible
is 60 %. Below 60%
not posible.
• Power consumption
is higher than on/off
control.
Types of Regulation/Capacity
control Systems
• Load - No Load
• Suction modulation control
• Speed control - Variable Speed Drives
Load - No Load Regulation
100%
75%
50%
25%
0%
Power Capacity Power Capacity
Load No Load
ELGI - FLOW DIAGRAM
ELGI - FLOW DIAGRAM
DESIGNING A
COMPRESSED AIR
SYSTEM
DESIGNING A COMPRESSED
AIR SYSTEM
• Inefficiencies are built into the Compressed
Air System at the design stage itself.
– Oversizing of the Air Compressor.
– Improper piping design.
DESIGNING A COMPRESSED
AIR SYSTEM
• The Compressor Size.
• The type of Compressed Air Station.
• The type of Air Compressor- Reciprocating,
Screw or Centrifugal.
• The type of Regulating/Capacity control system
1 - Determining the Compressor
•
Size
The selection of a compressor has to be preceded by
a thorough examination of the required flow rate.
• Air consumption rates of the various equipment to
be collected from the manufacturer.
• Determination of the UTILIZATION FACTOR i.e.
the ratio the of time that the equipment is is in
operation to the total working time.
1 - Determining the Compressor
Size
• Determination of the LOAD FACTOR i.e. the
ratio in percentage of the actual flow to the full-
load flow during the operation time.
• Additional allowance to be made for leakage, for
any expected future plant growth, for peak loads
and for worn-out tools.
Compressor Sizing
• Total Air Flow
= { (No. of m/cs x Flow x Utilisation
Factor x Load Factor)
+ 5% for worn-out tools
+ 10%Energy loss compensation
+ 30% for future expansion.}
= { } Lit/sec.
Energy Losses
• Poorly dimensioned pipework and filters causing
excessive pressure drops; the compressor must
work harder.
• Badly assembled pipework and fittings causing air
leakage; the compressor must work longer. Each
additional 0.1 bar required to overcome pressure
drops increases the compressor’s power
requirement by 0.5%.
• Line leakage.
Air leakage
Hole diameter
MM 1 3 5 10
Air Leakage at
6 bar l/s 1 10 27 105
85psi cfm 2 21 57 220
Power required for compression
Hp 0 .4 4 .2 11.2 44
Kw 0 .3 3 .1 8 .3 33
2 - Types of Compressed Air
• Stations
Centralized compressor station.
– Lower Installation Cost.
– Lower power cost.
– Lower maintenance cost.
• De-centralized compressor station.
– Smaller air net and inherently less air leakage and
less pressure drops.
– Separate air nets can operate at different pressures.
– Flexibility in case of breakdown.
2 - Types of Compressed Air
• Stations
One Large compressor.
– Unit will be fully loaded for only a small percentage
of the time. Hence, will run at low efficiency.
– No back-up in the event of breakdown.
• Several small compressors.
– Some of the compressors will nearly always be fully
loaded i.e. they will be running at high efficiency.
– 50% 0r more back-up always available.
Compressor Sizing
• Total Air Flow
= { (No. of m/cs x Flow x Utilisation
Factor x Load Factor)
+ 5% for worn-out tools
+ 10% Energy loss compensation
+ 30% for future expansion.}
= { } Lit/sec.
OVERSIZED COMPRESSOR ???
WHY DO WE NEED
REGULATION ??????
Load - No Load Regulation
• The Load – No Load type of regulation is
incorporated in all Atlas Copco Compressors.
• The inlet valve is either fully open or fully closed.
• When the compressor has reached the maximum
pressure in the air net, it is not stopped but switched
to ‘No Load’. The inlet valve closes off completely
but the drive motor continues to run.
• Unfortunately a waste of power (25%) occurs in No
Load running condition.
Modulation Control
• The inlet valve is closed off partially (Throttling). This will vary
the capacity between 100% and 50%. The drive motor will run
continuously, avoiding too many motor starts per hour.
• Due to throttling, a considerable pressure drop occurs over the
inlet valve. As a result the pressure ratio over the compressor
element increases. Therefore, the power consumption will not
drop to 50% but remain above 85%, which means a 35% waste
of power
• Below 50% capacity, the compressor switches to No Load
condition and similar phenomena occur as on a purely Load –
No Load compressor.
Modulation Control Regulation
100%
75%
50%
25%
0%
Power Capacity Power Capacity
Full Load 50% Modulation
VARIABLE SPEED
DRIVE SCREW AIR
COMPRESSOR
Variable Speed Drive Regulation
• A VSD compressor runs continuously with a
completely open inlet valve. The air output is varied
according to air demand by increasing/decreasing the
speed of the drive motor.
• There is no limitation on the amount of motor starts.
Part Load or No load conditions and the related
waste of power do not exist. The VSD consumes
power according to the customer’s air demand.
• Out-performs both the traditional regulation systems.
Variable Speed Drive Regulation
100%
75%
50%
25%
0%
Power Capacity Power Capacity Power Capacity
100% capacity 75% capacity 50% capacity
Variable Speed Drive - System
Frequency convertor:
Simovert - GA 90 VSD COM 1- Elektronikon
Masterdrive - GA 50 VSD Module MK III HRRS
Pressure
sensor
Compressor
Drive motor screw
element
FAD
The system targets a constant delivery pressure (setpoint )
Customer air net
VSD-system
The Control Principle:
Once the VSD is started, the pressure sensor readout is continuously compared
with the programmed ‘SETPOINT’ pressure
(Pload and Punload don’t exist anymore)
If the net pressure is higher, the speed is decreased
If the net pressure is lower, the speed is increased
The implemented control algorithm is of the P&I-type (Proportional &
Integrating controller) which is most used in industrial applications.
The usable compressor speed is limited by a Maximum and Minimum
Frequency convertor
Siemens convertor:
Simovert for GA 90 VSD
Masterdrives for GA 50 VSD
High efficient PWM (Pulse Width Modulation)
frequency convertor using high speed, low loss
IGBT’s (Insulated Gate Bipolar Transistor) for low
harmonic distortion and minimal electrical losses
in the motor
Regulation
• Conventional compressors -
– Regulation system consists of solenoid valves, vent valves, pressure
switch and the unloader assembly.
– Regulation system is pressure based.
• LOADING PRESSURE (= 6.5 Bar)
• UN-LOADING PRESSURE (= 7.1 Bar)
• VSD compressors -
– No solenoid valves, vent valves and unloader valve. Pressure transducer
senses the net pressure.
– Regulation system is also pressure based.
• SETPOINT (= 6.0 Bar)
• IN-DIRECT STOP LEVEL (= 6.1 Bar)
• DIRECT STOP LEVEL (= 6.3 Bar)
Regulation
SETPOINT
Once the VSD is started, the pressure sensor
readout is continuously compared with the
programmed ‘SETPOINT’ pressure
(Pload and Punload don’t exist anymore)
If the net pressure is higher, the speed is decreased
If the net pressure is lower, the speed is increased
Regulation
MAXIMUM SPEED
Whenever the net-pressure is still below the setpoint and
the compressor is already running at maximum speed: the
compressor will continue to run at maximum speed.
Note:
- The maximum speed depends on the pressure setpoint
- On GA50VSD the max. speed can be limited down to
75%
Regulation
INDIRECT STOP LEVEL
If the netpressure continues to increase even when the
compressor is running at minimum speed, it will be stopped
as soon as the netpressure reaches a certain (programmable)
value.
This is called the Indirect stop level.
If the Indirect stop level is reached before the Compressor
reached its minimum speed, the compressor will slow down
first to minimum speed and then stop.
MARKET DISTRIBUTION
GA SIZE II
CHEM. & FERT. MISC.
5% 8%
RAIL. & AVI. CONSTR.
6% 13%
TEXTILES
CEMENT
11%
5%
MINING
4%
GEN. ENGG.
IRON & STEEL 16%
8%
FORG. & FOUND.
AUTO.
7% EXPORT
9%
8%
