Anatomy Of Multi-Compressor System: How to Get the Best Performance
Managing multiple compressor systems can be daunting, especially if you are doing it yourself. Manual management takes up a substantial amount of electricity and can cost you a fortune!
If your business relies on multiple air compressor systems to function, it's important to have a proper management plan. Taking a strategic approach and using the right tools ensures that your multiple air compressors are running at optimum levels without using unnecessary energy.
This blog post will discuss how you can manage multiple air compressor systems efficiently.
How Does Pressure Differential Affect the Performance of Multiple Compressor Systems?
The most important factor in a compressed air system is pressure. If the pressure released from the multiple air compressors isn’t maintained at certain levels, it could cause disruptions in functioning and can even bring the whole production process to a halt!
Managing pressure differential isn’t everyone’s cup of tea.
It is important to consider that the air released from a multiple air compressor system passes through several components, such as a filter, dryer and FRL, before it reaches the end user. The pressure drops as it passes through these components, and the pressure is significantly low by the time it reaches the end user.
Even though practical scenarios make it difficult to determine the accurate pressure output reaching the endpoint, you need to be as critical and precise as possible.
How To Stabilize Pressure To The Critical End User?
Unfortunately, the air compressor can only control the pressure of air when the air is released from the compressor itself. So, if you want to stabilize the air pressure to the end user using a compressor control, that can’t happen.
But the problem remains.
The large pressure drop can cause problems at the end of use. For example, it could lead to inconsistent output or even bring an operation entirely down until corrective action is taken!
To deal with this problem, operators artificially increase the end-use pressure to compensate for the lost pressure.
Is Artificial Pressure Discharge the Ideal Solution?
Even though artificial pressure seems a wise solution, as it increases the pressure discharge by 10 PSI, it comes with an increased operational cost.
According to a general rule, a 2% increase in the discharge pressure equals a 1% increase in the compressor’s power consumption.
Do Multi Locations Affect the Performance of Multiple Compressor Systems?
Multi locations adversely impact the performance of the multi-compressor systems.
When the compressors are placed in different rooms, technicians find it difficult to manage them as each compressor comes with varying loads and air pressure requirements.
To ensure that these multi-compressor systems function efficiently despite being in different rooms, a wide pressure band is used by operators. However, it only works if the load variation isn’t massive. It also comes with a restriction that all compressors share loads, with each unit functioning at partial loads.
What Are The Consequences Of Not Doing Partial Loading Properly?
Several operators set the same pressure level for every unit within the multiple compressor installation, so the load is divided amongst all units equally. While this sounds like a good solution, it comes with a substantial energy cost. This is because fixed-speed rotary screw compressors function efficiently when the load is full.
Imagine doing this to 10 or 20 air compressors; more energy would be consumed, resulting in incredibly high energy bills.
To avoid this, keeping all compressors within the multiple compressor system fully loaded except for one is recommended. The one with a partial load on itself will have the highest partial load efficiency. Hence, solving the partial inefficiency problem.
What Are Other Ways to Control Pressure Differential at The End-Use Application?
Until now, we have established that the air pressure can only be adjusted when they leave the air compressor itself. It is impossible to control the air pressure through the components, such as the dryer and compressor piping, all the way to the critical end user.
The only thing that can be done is to use high-quality and reliable components that stabilize the air pressure till the end of use.
Oftentimes, technicians overlook the components' quality and size, which results in high-pressure variations and leads to inefficient output. Several important components such as regulators, hoses, connectors and filters are chosen only because they fit the standard sizes used in the plants and not because they are ideal for end-use applications.
Another reason behind the high-pressure fluctuation is the poor installation and fitting of the air compressor components. For instance, if a big air-powered impact wrench is linked to a long quarter-inch hose, the pressure differential could be substantial.
You can reduce the pressure fluctuation significantly by upgrading the size of components so that they meet the end-use application requirements. A few examples of upgrading can be changing the filter styles, upsizing the air dryers and increasing the piping’s capacity.
The use of air storage tanks, or air receivers also help when they are positioned close to the point of use as they act like a capacitor with stored compressed air.
Following the above practices will help you provide the desired pressure levels to the critical end-use application.
Minimize Costs & Efficiently Manage Multiple Air Compressors With AIRScan
A comprehensive compressor audit can significantly control the discharge pressure and optimize energy consumption.
Here’s how a compressor audit report helps you identify the following and save unnecessary costs.
- Leakages: A compressor more than 5 years old produces an average air leakage of 20%.
- Unloaded time: Air compressors running with zero load takes up 25% of the total energy consumption.
- Reduced Pressure Band: A 1 bar net pressure decrease saves up 7% of energy consumption.
AIRScan is an effective compressor audit solution that comes with maximum customization and flexibility.
Whether your facility has a single compressor or multiple compressor installation, AIRScan can run an audit on both. The best thing about AIRScan is that it doesn’t stop the production process, and performs the audit while the air compressor systems are running.
Using 4.0 Central Controller To Manage Multiple Air Compressor
Installing a modern central controlling system, such as the 4.0 central controller, is another way to effectively manage multiple air compressor systems.
The advanced 4.0 central controller equally divides the workload between different air compressor systems ensuring increased availability, decreased risk of unexpected breakdowns and better planned maintenance.
Moreover, it comes with a smart program that allows users to automatically control pressure differentials in the entire system, and automatically shuts down machines during non productive hours during the night time, weekends and holidays. This decreases both operational hours and costs.
Optimizer 4.0 connects your multiple air compressors and dryers through Local Area Network (LAN) or via cloud-based monitoring system and provides you insightful real-time data which you can use to determine the condition of your air compressors and create energy efficient plans.
Click here to learn more about our different types of master controller.
Trust Atlas Copco To Manage Multiple Compressor Systems Efficiently
Atlas Copco is a premium air compressor supplier and manufacturer in the UAE. Our efficient air compressors allow users to monitor, manage and maintain multi-compressor systems remotely and help your air compressor system achieve operational efficiencies.
Contact our industrial air compressor experts at Atlas Copco for a free quotation and to determine which air compressor system and accessories work best for your facility.