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Sudnya Industrial Services Pvt.Ltd., Pune
Energy Conservation in Fans,Blowers and Compressors
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Vacuum Pump, Fan, Blower or
Compressor?
How can we distinguish between thesemachines?
Vacuum Pump:Draws gases/ vapours from a system to make itspressure lower than its surroundings
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Moves gases/ vapours such that the difference in totalpressure is a few hundred mm WG
Blower:When the ∆∆∆∆P is > few hundred mm WG but < 2 kg f /cm 2
Compressor:When the ∆∆∆∆P is > 2 kg f /cm 2
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Types of Fans and BlowersCentrifugal
Forward Curved BladesBackward Curved BladesRadial Blades
Aerofoil Blades
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Tube Axial
Vane AxialPropeller
Lobe Type (Roots Blowers)Single-StageMulti-Stage
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Fan (& Pump) Equation
Rotation
u2
Volute (Discharge)
2 n H
d Q nQ
∝∝∝∝
∝∝∝∝
∝∝∝∝
u H uQ
∝∝∝∝
∝∝∝∝
2
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u1
Eye (Inlet)
3
3
2
d P
n P
H Q P d H
∝∝∝∝
∝∝∝∝
××××∝∝∝∝
∝∝∝∝
nu ∝∝∝∝
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System Flow Rate
35.00
40.00
45.00
50.00
1460 rpm 1095 rpm 730 rpm No Static Head 10 m Static Head 15 m Static Head
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0.00
5.00
10.00
15.00
20.00
25.00
.
0 20 40 60 80 100 120 140
Flow Rate m3/h
H e a d m
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Friction LossesFanning equation forPressure drop inStraight PipesLoss in Fittings
Values of K are
c
2
p g2
u
D
Lf 4P =∆
2u⋅
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tabulated inHandbooks
Since ∆∆∆∆P ∝∝∝∝ u 2 , therelationship betweenthese quantities is aparabolic curve
cf
g2
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Fan Efficiencies at different
Speeds
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Static Head vs Fan Efficiency in
Variable Speed Control
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Reading the Curves
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Flow Control Methods
Throttling by a valve
By-passing by a valve
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Parallel running of Pumps
Variable speed control of the pump
On-off control of the pump
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Throttle Control
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Throttling Increases Resistance
in the System
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By-Passing
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On-Off Control
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Variable Speed Control
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Fans in Parallel
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Pumps1 and 2
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Fans in Series
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Pumps1 and 2
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Variable Speed Control of Fans
Pays
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Consider Variable Speed Control
when...the fan is a part of the control system. the fan output varies.
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Power Consumption of a Fan
η ρ g H QP ***=
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H Qk P **=when η is constant
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Relative Power Consumption
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Energy Consumption of a Fanis the Power multiplied by the Time
P
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t
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Duty Cycle Curve
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QQQ min50maxm 61
32
61
FlowMedian Q ++=
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Energy Use Calculated by the
Median Flow Method
Qmax = 300 l/sQ50 = 250 l/sQmin = 81 l/s
∗
(= Energy Consumption in Variable Speed Control)
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l/s204l/s636m
=++=
and the equivalent power is 42 kW.
The total energy isW = 42 kW*5000 h = 210 MWh
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Reading the Power Consumed
by a Fan
Duty point of a fan:
Nominalx Throttle controlx Variable speed control
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Power consumption ofthe fan in variable speedcontrol
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Segmented Duty Cycle
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Comparison based on Energy
ConsumptionTime Flow Throttle
ControlVariable Speed
Control
1480 rpm
% h % l/s kW MWh rpm kW MWh
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40 2000 90 270 75 150 1400 64 128
30 1500 62 186 71 107 1180 35 53
30 1500 32 96 65 98 920 24 36
Compared to throttle control variable speed controlsaves energy 355 - 217 MWh = 138 MWh
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Variable Speed Control Saves
Energy
Cost saving =
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saved energy*energy price137 MWh * Rs.3700/MWh = Rs. 5.07 lakhs/year
For Variable Speed AC Drives
the Payback Period would beless than Two Years
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Types of CompressorsPositive Displacement
ReciprocatingLobe typeScrewScroll
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KinematicCentrifugal
Axial Flow
LubricatedNon-Lubricated
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Screw Compressor
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Volumetric Efficiency Volumetric Efficiency is the ratio of Volume of Gas delivered to the displacedvolume
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Power Drawn dp
p dW Power
P
P∫ ∫ ∆
==2
1 ρ k pV n =
−
−⋅⋅⋅⋅=
−
11
1
1
21
0
0
0γ
γ
γ
γ
η p p
T q
T p
K Power A
Adiabatic Compression
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Isothermal Compression
⋅=
1
20
0
1 ln p p
qT RT
K Power Aη
−
−<
=
−
11
ln
1
1
2
2
2γ
γ
γ
γ
p p
p p
X For n > 1 and p 2 > p1
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K A
K A = 0.004363 0.001 98066.5
p 0 , p 1 , p 2 lb f /in 2 Pa = N/m 2 kg f /cm 2
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T1 , T 2 °R °K °K
q 0 ft 3 / min m 3 /secm 3 /sec
P h. p. kW kW
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Factors affecting Energy UseTackle each of the factors in the equation
Factor Units Change by Energy usechanged by
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p 2 /p 1 kg f /cm 2 1 6 – 10%T1 °K 4 1%
q 0 m 3 /sec 1% 1%
X °K 5 2.1%
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Measures: Compression RatioClean filters regularlyReduce Process Operating PressureConsider two sets of numbers
1,2,4,8: AM = 3.75 GM = 2.821,3,9,27,81: AM = 24.2 GM = 9
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s suggests t at a ser es o compressors av ngCompression ratios < p 2 /p 1 of one largecompressor will have a lower energy usageHence, multi-stage compression
Implicit assumption: each stage startscompression at the same temperatureCompression Ratios for each stage are equal
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MeasuresCool intake from outside compressor room
Reduce leakagesMaintain compressor
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ModulationBlow off
By-passi.e. re-circulate from exhaust to suction “Unload” individual cylinders
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Inlet Guide Vane Control for CentrifugalCompressorsBlade angle control for Axial flow
Compressors Variable Speed Drives
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Reduce VolumeReduce Leakages
Reduce UsageFlow nozzles
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TestingCapacity
Time to pump up the pressure of a receiver of known
volume to a given pressureUse of flow nozzles
Leakages
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Close all valves at the points of usePump up the receiver to a desired pressureNote the time/s taken for the pressure to drop to a lowerpressure/s
U L
L
T T T LeakRate+
=
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Drying and FiltrationFilter air only if the application demands it
DryersRefrigerant DryersLimitation on the Dew Point temperatures that can
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Dessicant DryingPurge dryer using compressed air
Highest operating costs though capital costs are lowWaste a lot of compressed air
Heat of Compression DryersMost expensive, but most efficient
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GeneralReceiver
Volume: about 1 min. generation capacityLocate near large loads
Install drains and traps at intervals
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Avoid misuseUse only where necessaryCheck periodically for leakages
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Contact Us
Sudnya Industrial Services Pvt. Ltd.5 Raj Apartments,28 Pushpak, Park, Aundh,
27-Feb-14 Sudnya Industrial Services Pvt. Ltd., Pune 43
Pune – 411 007Tel: +91 20 3291 2316
Mobile: +91 98224 07214E-mail: [email protected]
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