Why Air Compressor are NOT producing enough

Why Air Compressor are NOT producing enough ?

Almost all compressors in these region ( Tropical ) are not climatised or tropicalised for use here. 

They are standard equipment in country of manufactured.

Tropicalised = suitable for hot and high humidity weather conditions.

Therefore: 

they cannot operate at full load, if load to the rated pressure and flow for a longer period, it will trip due to high operating temperature.

And, it need to off-load or unload. the fan will cool the operating temperature. and not producing any discharge air or pressure.

When compressors go to off-load, it consume energy; varies from 30% to 60% of Full Load Amperes, and no work is done.

        $$$$$     Energy wasted      $$$$$

Air Compressor Sizing 

  3 Simple Ways on How to Select an Air Compressor 

  Two basic scenarios present to decide! 

1. New Plant, and 

2. Old Plant [to upgrade or downgrade] 

  1. New Plant 

Step 1, 

Group all equipment in loading or usage categories. If equipment is in use most or all the time into one group = 1. (100% loading) Example: Production machinery, SMT, Conveyor etc Another group or groups may be .6 [60% loading ], .3 [30% loading] in a day or working shift. 

 Step 2, 

Add up total usage and multiply with the usage factor, to arrive at the capacity usage. 

Step 3,

 add about 10% to 15% of losses, due to leakage and other losses. After listing all the air operated devices and equipment to be supplied by the air compressor, decide using charts, the pressure range and volume of air required by each and every devices and equipment. 

 These air compressor or compressors must maintain a minimum pressure at least equal the highest of these pressure ranges. 

  ----- For Example: 

 If the highest pressure range required by any one device in a given group is 90 psi - 110 psi, a compressor or compressor must be able to supply the required volume, then the cut-in at not less than 90 psi and cut=out at 110 psi should be considered. 

Exceptional: 

Speed Controlled Air Compressor are used! 

 Then You have a rough idea of your plant compressed air requirement! 

  2. Existing Plant 

2a. [Compressor always loading, that is cannot reach the required rated pressure] Formula used: 

P1V1 = P2V2 

 2b. [Compressor can off-load] Formula used: Air Consumption required = Vl/(u+l) 2c. 

 Using Instruments Energy Balance System

Energy Cost:

1.

Total Energy cost in operation of Air Compressors.

2.

Energy cost during Operation.

3.

Energy cost due to maintenance.

4.

Energy cost on operation.

Our Air Compressors & Equipment;

do not used reconditioned or seconded-hand ( pre-loved ) components & parts.