Professional Documents
Culture Documents
AIR REQUIREMENTS
PISTON DISPLACEMENT:
Is the volume swept by the piston, generally expressed in cubic feet per A relatively simple procedure to see if additional compressor capacity
minute (CFM). For multi-stage compressors, the piston displacement (CFM) is required can be performed in any plant or compressed
of the first stage only is commonly stated as that of the entire machine. air-using operation.
Most general compressor air operations supply 100 PSIG at the
ACTUAL CAPACITY: compressor and deliver a minimum of 90 PSIG to the using air tool. For
Is the quantity of gas actually compressed and delivered to the lowest possible power cost, this means compressor has a cut out
discharge system by the compressor at rated speed and under rated pressure or unloads at 100 PSIG and cut-in or loads at 90 PSIG
receiver or system pressure. With these known figures (or whatever
pressure conditions. Actual capacity is expressed in cubic feet per unload and load figures a particular system utilizes), we can determine
minute at the temperature and pressure conditions existing at the inlet the following:
to the first stage.
If the receiver is below the normal cut-in point (90 PSIG) or does not
gradually rise to the cut-out point (100 PSIG), more air is probably
VOLUMETRIC EFFICIENCY: needed. Always check, of course, that there are no significant leaks
Is the ratio of actual capacity to piston displacement, generally stated and that the unloading and control system on the compressor are
as percentage. functioning correctly.
NOTE: If the compressor must operate at more than 100 PSIG to get
FREE AIR: 90 PSIG at the tools, check the distribution system for piping size or
Generally describes air at room or ambient temperatures and pressures, check points. The pipe may be too small or a single choke point too
that is, normal atmospheric conditions. In other words, the term free air small for the systems total demand (flow) or length.
describes the air actually taken into the suction of a compressor which
takes air from the surrounding atmosphere. CHECKING EXISTING
COMPRESSOR CAPACITY
STANDARD CONDITIONS:
Are not universally defined; therefore, since compressor capacities are
Running a timed pump-up test is a relatively accurate way to check
sometimes expressed in standard cubic feet per minute (SCFM), it is your existing air compressors capacity or output. This will confirm that
necessary to identify, before the compressor can be sized, (1) the your shortage of compressed air is not due to a worn unit or a
standard pressure condition; (2) the standard temperature condition; malfunction.
(3) the compressor suction pressure condition, and; (4) the Check the receiver volume in cubic feet. Check the pipe volume
compressor suction temperature condition. The most popular between the compressor and receiver in cubic feet. Operate the
identification for standard pressure and temperature conditions is 14.5 compressor at load. Close the air valve between the receiver and plant
PSIA or 60 F.
air system. Drain the receiver down to 70 PSIG. Close the drain valve
quickly. Record in seconds the required time to pump to 100 PSIG.
BRAKE HORSEPOWER (bhp): Now work the following equation:
Is the measured horsepower input at the compressor shaft. The If this is close to the rated capacity of your air compressor, then you can
horsepower output of the driver must equal or exceed the compressor be relatively sure the demand on your air system is too high and you
bhp plus any drive losses. need additional air.
C = COMPRESSOR CAPACITY IN CFM
LOAD FACTOR:
Is the ratio of the available demand for compressed air during a certain V = RECEIVER & PIPING VOLUME IN CU. FT.
period of time to the maximum rated output capacity of the compressor.
P2 = FINAL CUT OUT PRESSURE PSIA
= 100 PSIG + 14.7 = 114.7 PSIA
NOTES:
P1 = INITIAL PRESSURE PSIA
= 70 PSIG + 14.7 = 84.7 PSIA
144,000
C = 220.5
28 1
TERMINOLOGY CONTINUED COMMON LEAK PROBLEM AREAS
UNLOAD (No Load): COUPLINGS, HOSES, TUBES AND FITTINGS
Air compressor continues to run (usually at FULL RPM), but NO air is Tubes and push-to-lock fittings are common problems.
delivered because intake is either closed off or modified, NOT allow-
ing inlet air to be trapped. DISCONNECTS
O-rings required to complete the seal may be missing.
MODULATING UNLOAD: FILTERS, REGULATORS AND LUBRICATORS (FRLs)
Air compressor continues to run and air supply is matched to demand Low first-cost improperly installed FRLs often leak.
by partial unloading. This is usually accomplished by a regulator
controlled floating inlet. OPEN CONDENSATE TRAPS
Improperly operating solenoids and dirty seals are often problem
START-STOP CONTROL: areas.
Air supply is matched to demand by actual starting and stopping of the
unit. PIPE JOINTS
Missed welds are a common problem.
CUT-IN/CUT-OUT PRESSURE: CONTROL AND SHUT-OFF VALVES
The settings on a pressure switch used to either load or unload the air Worn packing through the stem can cause leaks.
compressor on constant speed application. The cut-out pressure is
also referred to as maximum pressure, the point at which there is NO POINT OF USE DEVICES
AIR DELIVERED. The cut-in pressure is also referred as Old or poorly maintained tools can have internal leaks.
minimum pressure - the pressure that the system is allowed to fall to
FLANGES
before additional air volume is called for. The compressor runs at full
Missed welds are a common problem.
load between cut-in and cut-out.
CYLINDER ROD PACKING
VARIABLE DISPLACEMENT CONTROLS: Worn packing materials can cause leaks.
Also called Rotor Length Adjustment in oil cooled Rotary Screw
controls. Particularly efficient in holding constant speed from 60% to THREAD SEALANTS
100% capacity variable speed control. Below this usually goes to blow Incorrect and/or improperly applied thread sealants cause leaks.
down and idle.
HOW DO YOU FIND LEAKS?
VARIABLE SPEED CONTROL:
Most commonly applied in oil cooled Rotary Screws. Very efficient from Since air leaks are almost impossible to see, other methods must be
about 50% to 100% capacity. Below 50% usually defaults to modula- used to locate them. The best way to detect leaks is to use an
tion of Blow Down and idle. ultrasonic acoustic detector, which can recognize the high frequency
hissing sounds associated with air leaks. These portable units consist
RATED PRESSURE: of directional microphones, amplifiers, and audio filters, and usually
The operating pressure at which the air compressors performance (CFM have either visual indicators or earphones to detect leaks. A simpler
and BHP - Horsepower required) is measured. method is to apply soapy water with a paint brush to suspect areas.
Although reliable, this method can be time consuming. Other methods
SPECIFIC POWER: include: smoke sticks, candles, foam, manometers and stethoscopes.
Used to compare air compressor efficiency unless otherwise stated. Ultrasonic detectors can find mid to large sized leaks. The advantages
Usually in form of BHP/100 ACFM or CFM/HP. of ultrasonic leak detection include: versatility, speed, ease of use, the
ability to perform tests while equipment is running and the ability to find
a wide variety of leaks.
GENERAL TERMS
HOLE DIA. AIR LEAKAGE AT 100 PSI COST PER YEAR
COMPRESSORS: IN. CFM $.06 KWH
Are machines which compress air or gases from atmospheric pressure 1
/32 1.62 $158
to a higher discharge pressure. 1
/16 6.5 $633
BOOSTER COMPRESSORS:
1
/8 26 $2,532
Are machines which compress air or gases from a pressure higher
1
/4 104 $10,130
than atmospheric to a still higher discharge pressure.
WHAT DO SYSTEM LEAKS COST?
VACUUM PUMPS:
Are machines designed for compressing air or gases from an initial Determine size of leak either through calculation or actual size of
pressure which is below atmospheric to a pressure which is at or close orifice.
to atmospheric pressure.
1
/4 inch orifice can pass 104 CFM @ 100 PSIG.
RECIPROCATING COMPRESSORS: A typical 25 horsepower oil flooded Rotary Screw Air Compressor.
Are positive displacement machines used to increase the pressure of a
definite volume of gas by volume reduction. The compressing element At 6 cents a kW and 8,000 hours of operation, this can equal
is a simple piston which reciprocates back and forth in a cylinder. $9,946.00.
26 3
USEFUL FORMULAS * ORIFICES ARE REQUIRED
ANTICIPATING YOUR
1. COMP. RPM =
motor pulley p.d. x motor RPM FUTURE AIR REQUIREMENTS
comp. pulley p.d.
The following charts will be helpful to anyone planning a future air system or
requirement. Remember, these are averages for various types of tools and you
comp. pulley p.d. x comp. RPM should always consult the manufacturer for exact air requirements and analyze
2. MOTOR PULLEY p.d. =
motor RPM your own operation to evaluate normal.
24 5
FRICTION OF AIR IN HOSE
SYSTEM
SYSTEM
1/0 3/0 4/0 300 500 2-4/0 2-300 2-500 MOTOR
(240V)
100 110 125 175 200 250 300 400 600 600 800 200V
110 150 200 225 250 350 450 600 800 230V
S
S
GAUGE CU. FT. OF AIR PER MINUTE AT 80 PSIG
HOSE
100 100 150 200 200 300 350 400 500 600
104 130 154 192 248 312 360 480
414 552
200
PRESSURE 20 30 40 50 60 70 80 90 100 110 120 130
--
SIZE
OF LINE LOSS OF PRESSURE (PSI) IN 50 FT. LENGTHS OF HOSE
110 0.6 2.0 4.3 7.6 12.0 17.6 24.6 33.3 44.5
177
60
50 0.4 0.8 1.5 2.4 3.5 4.4 6.5 8.5 11.4 14.2
60 0.3 0.6 1.2 1.9 2.8 3.8 5.2 6.8 8.6 11.2
120 150
50
70 0.2 0.5 0.9 1.5 2.3 3.2 4.2 5.5 7.0 8.8 11.0
3
/4 80 0.2 0.5 0.8 1.3 1.9 2.8 3.6 4.7 5.8 7.2 8.8 10.6
40
90 0.2 0.4 0.7 1.1 1.6 2.2 3.1 4.0 5.0 6.2 7.5 9.0
100 0.2 0.4 0.6 1.0 1.4 2.0 2.7 3.5 4.4 5.4 6.6 7.9
30
80
92
110 0.1 0.3 0.5 0.9 1.3 1.8 2.4 3.1 0.9 4.9 5.9 7.1
THREE PHASE MOTOR DATA - For 60 Hz 1800 RPM Standard Motor
50 0.1 0.2 0.3 0.5 0.8 1.1 1.5 2.0 2.6 3.5 4.8 7.0
11.0 17.5 25.3 32.2 48.3 62.1 78.2
100
25
68
3
60 1.1 0.2 0.3 0.4 0.6 0.8 1.2 1.5 2.0 2.6 3.3 4.2
70 -- 0.1 0.2 0.4 0.5 0.7 1.0 1.3 1.6 2.0 2.5 3.1
20
90
54
80
90
4
1 80 -- 0.1 0.2 0.3 0.5 0.7 0.8 1.1 1.4 1.7 2.0 2.4
90 -- 1.1 0.2 0.3 0.4 0.6 0.7 0.9 1.2 1.4 1.7 2.0
15
90
80
60
42
60
6
100 -- 1.1 0.2 0.2 0.4 0.5 0.6 0.8 1.0 1.2 1.5 1.8
10
60
60
40
28
50
10
110 -- 0.1 0.2 0.2 0.3 0.4 0.6 0.7 0.9 1.1 1.3 1.5
8
50
45
10
30
40
30
12
25
25
14
5
few are to be used at one time, the compressor should have a capacity
at least equal to the total consumption of all those tools used
17.5
20
14
14
15
3
15
15
14
14
10
10
2
15
15
14
14
10
10
CAPACITY
(NEC) - AMPS MINIMUM 2.2 3.2 4.2
(NEC) - AMPS MINIMUM 2.5 3.7 4.8
Thermal-Magnetic Breaker 15 15 15
Thermal-Magnetic Breaker 15 15 15
14
14
1
8
4 6.25 8
14
14
DIMENSION
3
14
14
CIRCUIT BREAKER
FUSIBLE SWITCH
FUSIBLE SWITCH
22 7
DISCHARGE OF AIR
5.86
2.88
4.75
.94
8.45
.53
.24
3.76
1.47
.14
2.11
THROUGH AN ORIFICE
350
11.5
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
4.35
3.34
5.50
6.80
.28
2.45
9.78
1.70
1.09
.61
.16
13.4
300
GAUGE
PRESSURE
DIAMETER OF ORIFICE
BEFORE 1
ORIFICE /64 /32 /16 /8 1/4 3/8 1/2 5/8 3/4 7/8 1
1 1 1
2.02
.73
.33
3.96
6.55
1.30
8.07
2.91
.19
5.16
IN LBS.
15.9
11.6
250
PER
SQ.IN. Discharge in cubic feet of free air per minute
1 .028 .112 .450 1.80 7.18 16.2 28.7 45.0 64.7 88.1 115
2 .040 .158 .633 2.53 10.1 22.8 40.5 63.3 91.2 124 162
2.50
.23
.90
3.58
6.36
4.89
9.95
8.06
1.60
.41
.11
19.5
14.3
200
3 .048 .194 .775 3.10 12.4 27.8 49.5 77.5 111 152 198
4 .056 .223 .892 3.56 14.3 32.1 57.0 89.2 128 175 228
5 .062 .248 .993 3.97 15.9 35.7 63.5 99.3 143 195 254
2.08
3.26
4.68
.30
.53
6.37
8.31
.14
1.17
13.0
150
10.5
6 .068 .272 1.09 4.34 17.4 39.1 69.5 109 156 213 278
7 .073 .293 1.17 4.68 18.7 42.2 75.0 117 168 230 300
9 .083 .331 1.32 5.30 21.2 47.7 84.7 132 191 260 339
12 .095 .379 1.52 6.07 24.3 54.6 97.0 152 218 297 388
.36
3.83
9.80
.62
1.38
2.47
5.51
7.50
.17
125
12.4
15.3
15 .105 .420 1.68 6.72 26.9 60.5 108 168 242 329 430
LINE PRESSURE - PSIG
20 .123 .491 1.96 7.86 31.4 70.7 126 196 283 385 503
25 .140 .562 2.25 8.98 35.9 80.9 144 225 323 440 575
.44
2.99
4.67
.20
1.68
.76
6.71
9.15
11.9
100
30 .158 .633 2.53 10.1 40.5 91.1 162 253 365 496 648
35 .176 .703 2.81 11.3 45.0 101 180 281 405 551 720
40 .194 .774 3.10 12.4 49.6 112 198 310 446 607 793
.56
8.58
.26
5.96
3.81
.97
2.15
.10
45 .211 .845 3.38 13.5 54.1 122 216 338 487 662 865
75
50 .229 .916 3.66 14.7 58.6 132 235 366 528 718 938
60 .264 1.06 4.23 16.9 67.6 152 271 423 609 828 1082
70 .300 1.20 4.79 19.2 76.7 173 307 479 690 939 1227
2.98
5.29
.78
.36
1.34
.13
50
80 .335 1.34 5.36 21.4 85.7 193 343 536 771 1050 1371
90 .370 1.48 5.92 23.7 94.8 213 379 592 853 1161 1516
100 .406 1.62 6.49 26.0 104 234 415 649 934 1272 1661
.92
3.52
.43
1.59
.16
110 .441 1.76 7.05 28.2 113 254 452 705 1016 1383 1806
40
120 .476 1.91 7.62 30.5 122 274 488 762 1097 1494 1951
125 .494 1.98 7.90 31.6 126 284 506 790 1138 1549 2023
.52
4.30
.20
1.94
1.12
150 .582 2.37 9.45 37.5 150 338 600 910 1315 1789 2338
30
200 .761 3.10 12.35 49.0 196 441 784 1225 1764 2401 3136
250 .935 3.80 15.18 60.3 241 542 964 1508 2169 2952 3856
300 .995 4.88 18.08 71.8 287 646 1148 1795 2583 3515 4592
.67
2.50
.26
1.44
20
400 1.220 5.98 23.81 94.5 378 851 1512 2360 3402 4630 6048
500 1.519 7.41 29.55 117.3 469 1055 1876 2930 4221 5745 7504
750 2.240 10.98 43.85 174.0 696 1566 2784 4350 6264 8525 11136
.78
.30
1.69
1000 2.985 14.60 58.21 231.0 924 2079 3696 5790 8316 11318 14784
15
Table is based on 100% coefficient of flow. For well rounded entrance, multiply values
by 0.97. For sharp edged orifices a multiplier of 0.61 may be used for approximate
results. Values for pressures from 1 to 15 lbs. gauge calculated by standard adiabatic
.36
.94
formula. Values for pressures above 15 lbs. gauge calculated by approximate formula
10
proposed by S.A.
Moss. Where:
0.5303 ACp1 W = discharge in lbs. per sec.
W =
FREE AIR
300
500
750
1000
1500
2000
2500
3000
3500
4000
4500
5000
6000
7000
C = Coefficient of flow
P1 = Upstream total pressure in lbs. per sq. in absolute
T1 = Upstream temperature in F abs.
CONTINUED
T1 = 530 F abs.
Weights (W) were converted to volumes using density factor of 0.07494 lbs./cu. ft. This is
correct for dry air 14.7 lbs. per sq. in. absolute pressure and 70 F. Formula cannot be used
20 9
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
CONTINUED
NOMINAL CFM LINE PRESSURE - PSIG
PIPE SIZE FREE AIR 10 15 20 30 40 50 75 100 125 150 200 250 300 350
75 .19 .16 .13 .10
100 .28 .24 .20 .16 .13 .11
150 .69 .57 .49 .38 .31 .26 .19 .15 .12 .10
200 1.20 1.00 .85 .66 .54 .46 .33 .26 .21 .18 .14 .11
250 1.53 1.31 1.02 .83 .70 .51 .40 .33 .28 .21 .17 .15 .13
300 1.89 1.47 1.20 1.01 .73 .57 .47 .40 .31 .26 .21 .18
400 2.50 2.04 1.73 1.25 .98 .80 .68 .52 .42 .36 .31
18
2 500 3.87 3.16 2.67 1.93 1.51 1.24 1.05 .81 .65 .55 .48
SCHEDULE 600 4.50 3.81 2.75 2.15 1.77 1.50 1.05 .93 .79 .68
40 800 4.87 3.82 3.13 2.66 2.04 1.65 1.39 1.20
1000 7.55 5.90 4.85 4.12 3.16 2.56 2.16 1.86
1250 9.12 7.49 6.35 4.87 3.96 3.32 2.87
1500 10.8 9.17 7.02 5.70 4.80 4.14
1750 12.5 9.54 7.74 6.50 5.62
2000 16.3 12.5 10.1 8.50 7.35
2250 15.8 12.8 10.8 9.30
2500 19.4 15.8 13.3 11.4
11
50 0.4 0.8 1.5 2.4 3.5 4.4 6.5 8.5 11.4 14.2
60 0.3 0.6 1.2 1.9 2.8 3.8 5.2 6.8 8.6 11.2
70 0.2 0.5 0.9 1.5 2.3 3.2 4.2 5.5 7.0 8.8 11.0
3 80 0.2 0.5 0.8 1.3 1.9 2.8 3.6 4.7 5.8 7.2 8.8 10.6
/ 4
90 0.2 0.4 0.7 1.1 1.6 2.3 3.1 4.0 5.0 6.2 7.5 9.0
100 0.2 0.4 0.6 1.0 1.4 2.0 2.7 3.5 4.4 5.4 6.6 7.9 9.4 11.1
110 0.1 0.3 0.5 0.9 1.3 1.8 2.4 3.1 3.9 4.9 5.9 7.1 8.4 9.9
50 0.1 0.2 0.3 0.5 0.8 1.1 1.5 2.0 2.6 3.5 4.8 7.0
60 1.1 0.2 0.3 0.4 0.6 0.8 1.2 1.5 2.0 2.6 3.3 4.2 5.5 7.2
70 -- 0.1 0.2 0.4 0.5 0.7 1.0 1.3 1.6 2.0 2.5 3.1 3.8 4.7
1 80 -- 0.1 0.2 0.3 0.5 0.7 0.8 1.1 1.4 1.7 2.0 2.4 2.7 3.5
90 -- 1.1 0.2 0.3 0.4 0.6 0.7 0.9 1.2 1.4 1.7 2.0 2.4 2.8
100 -- 1.1 0.2 0.2 0.4 0.5 0.6 0.8 1.0 1.2 1.5 1.8 2.1 2.4
110 -- 0.1 0.2 0.2 0.3 0.4 0.6 0.7 0.9 1.1 1.3 1.5 1.8 2.1
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
CONTINUED
NOMINAL CFM LINE PRESSURE - PSIG
PIPE SIZE FREE AIR 10 15 20 30 40 50 75 100 125 150 200 250 300 350
20 .45 .38 .32 .25 .20 .17 .13 .10
35 1.29 1.07 .92 .71 .58 .49 .35 .28 .23 .19 .15 .12 .10
50 1.81 1.40 1.15 .97 .70 .55 .45 .38 .29 .24 .20 .17
75 3.10 2.53 2.14 1.54 1.21 .99 .84 .65 .52 .44 .38
1 100 4.39 3.70 2.68 2.09 1.72 1.46 1.12 .91 .76 .66
SCHEDULE 125 5.70 4.10 3.22 2.64 2.24 1.72 1.39 1.17 1.01
40 150 5.88 4.60 3.78 3.20 2.46 1.99 1.68 1.45
16
200 8.05 6.61 5.61 4.30 3.49 2.94 2.53
250 10.3 8.87 6.72 5.45 4.59 3.96
300 12.6 9.66 7.85 6.60 5.70
400 17.2 14.0 11.7 10.1
500 21.8 18.3 15.8
Table 1. Refrigerated Air Dryer Performance (11 data per 100 CFM @ 100 PSIG)
50 F Dew-Point Unit
Inlet temperature 125 120 115 110 105 100 95 90
Inlet water vapor - lbs./hr. 4.7168 4.1008 3.5552 3.0756 2.6532 2.2836 1.9580 1.6764
Lbs. water removed/hr. 4.2900 3.6740 3.1284 2.6588 2.2264 1.8565 1.5312 1.2496
Water removed, percent 90.95 89.59 87.99 86.12 83.91 81.31 78.20 74.54
Percent of design point 280.2 239.9 204.3 172.9 145.4 121.1 100.0 81.6
Sensible load - btu./hr. 3181 2969 2757 2545 2333 2121 1908 1697
Latent load - btu./hr. 4595 3935 3351 2837 2425 1989 1640 1338
Total load - btu./hr. 7676 6894 6108 5382 4758 4110 3548 3035
Percent of design 216.3 194.3 172.2 181.7 134.1 115.8 100 85.5
Operation kw./hr. .67 .60 .53 .47 .41 .36 .31 .27
13
35 F Dew-Point Unit
Inlet temperature 125 120 115 110 105 100 95 90
Inlet water vapor - lbs./hr. 4.7168 4.1008 3.5552 3.0756 2.6532 2.2836 1.9580 1.6764
Lbs. water removed/hr. 4.4792 3.8632 3.3176 2.8380 2.4156 2.0460 1.7204 1.4388
Water removed, percent 94.96 94.20 93.31 92.27 91.10 89.60 87.00 84.80
Percent of design point 260.4 224.15 192.8 164.9 140.4 118.9 100.0 83.6
Sensible load - btu./hr. 3818 3605 3393 3181 2969 2757 2544 2332
Latent load - btu./hr. 4797 4134 3545 3042 2581 2191 1842 1540
Total load - btu./hr. 8615 7739 6938 6223 5540 4948 4386 3872
Percent of design 196.4 176.4 159.2 141.9 126.3 112.8 100.0 88.3
Operation kw./hr. 1.10 .99 .89 .78 .71 .63 .56 .49
DETERMINING ADDITIONAL GENERAL TERMS CONTINUED
COMPRESSED AIR REQUIRED TO
SINGLE-ACTING COMPRESSORS:
BRING YOUR AIR SYSTEM Are machines which compress on only one side of the piston.
BACK TO 100 PSIG Compression takes place on only one stroke per revolution of the
compressing element.
Once the actual existing compressed air capacity is known, it is DOUBLE-ACTING COMPRESSORS:
relatively easy to mathematically determine the air required to bring the Are machines which compress on both sides of the piston. The
air system up to 100 PSIG: running gear consists of a crank and crosshead mechanism with the
piston rod attached to the crosshead, and extending into the
CFM (REQUIRED) = CFM P2 compressor cylinder through a packing box. Compression takes place
P1 on both strokes in each revolution.
* Add 15% to adjust for the higher leakage rate at the 120 PSIG to 90 (Note that in compressors, ratio of compression is a ratio of pressures.
PSIG (30 PSIG x .5) It should not be confused with the similar term used by internal
combustion engine manufacturers. In engines, ratio of compression is
* Any leakage rate beyond 5% of the total system should be corrected. a ratio of volumes)
2 27
WHAT IS ELECTRIC ENERGY COST? TERMINOLOGY
HP x .746 x HRS. x RATE CFM DISPLACEMENT:
ELECTRIC ENERGY COST (DOLLARS) =
MOTOR EFFICIENCY CUBIC FEET PER MINUTE measures the volume displaced by the
air compressor at full RPM - but not Delivered Air or Usable Air.
This is the formula for electric energy cost in dollars, and you can see it
is a function of: CFM DELIVERED CUBIC FEET PER MINUTE:
Volume of air delivered to the system by the air compressor at rated
The number of hours of operation pressure.
The power used to drive the Compressor (HP)
The power rate (cents per kW) ICFM:
The motor efficiency INLET CFM is rated volume of Inlet air (at Inlet conditions i.e.:
temperature and pressure 14.7 PSIG at sea level) taken in to the
This formula is acceptable as accurate for estimating and comparison compressor.
purposes. (Your actual power bill can be further affected positively or
negatively by such things as Power Factor - Demand Charges, etc.). ACFM:
Is the actual cubic feet per minute of inlet compressed air delivered to
the system at a specified point at the final discharge pressure. i.e.: the
THE MAGNITUDE OF compressor delivers 625 ACFM of compressed air at 100 PSIG at the
ENERGY COST (ELECTRIC)! discharge end of the aftercooler.
To see the magnitude of your potential expenditure in power cost, FOR EXAMPLE
calculate the power cost of a 100 HP Air Compressor:
A 100 HP Air Compressor would have a $34,800 per year power cost.
In short, the ELECTRIC ENERGY COST OF OPERATION in a Heavy rating using equipment. To size for other than standard conditions, i.e.:
Duty Cycle-Full Load 6,000 Hours (2 Shifts Plus)) CAN EQUAL OR altitude or hot weather corrections must be made.
EXCEED THE INITIAL COST OF THE UNIT EVERY YEAR. Perhaps
PSI:
we should pay attention to this often overlooked continuing cost. A
Pounds Per Square Inch - A rating of air pressure in the system.
POSITIVE VARIANCE OF 15% - 25% in energy cost can be a
significant savings in any operation, and this is obtainable. PSIA ABSOLUTE:
Pressure. i.e.: Sea level - 14.7 PSIA or 0 PSIG (gauge pressure).
CONVERSION FACTORS
PSIG:
TO CONVERT FROM TO MULTIPLY BY Gauge pressure shows amount of air pressure above ambient; i.e.:
Sea level = 0 PSIG = 14.7 PSIA.
Kilowatt Hours (kW h) Horsepower Hours (hp h) 1.341 0
CONSTANT SPEED CONTROL:
Unit runs continuously but matches air supply to demand by loading
Watts (W) Horsepower (hp) 0.001341 0 or unloading the compressor.
4 25
AUTOMOTIVE SERVICE
SYSTEM
SYSTEM
2/0 3/0 4/0 350 MOTOR
(600V)
110 125 200 225 250 350 460V
S
EQUIPMENT
150
RANGE CFM
70- 100 *Air Filter Cleaner 3.0
125
70- 100 *Body Polisher 2.0
70- 100 *Body Sander (Orbital) 5.0
100 150
100
99
1
70- 100 *Brake Tester 3.5
70- 100 *Carbon Remover 3.0
96
77
70- 100 *Carwasher 8.5
3
90- 100 Dusting Gun (Blow Gun) 2.5
100
120-150 *Grease Gun 3.0
60
77
62
90
3
4
THREE PHASE MOTOR DATA - For 60 Hz 1800 RPM Standard Motor CONTINUED
70- 100 *Panel Cutter 4.0
100
70- 90 Drill, 1/16 to 3/8 4.0
50
90
65
52
80
4
6
125-150 *Impact Wrench, 3/8 sq.dr. 2.0
40
90
80
52
80
60
41
6
6
125-150 *Impact Wrench, 1/2 sq.dr. 3.5
125-150 *Impact Wrench, 5/8 sq.dr. 5.0
30
80
40
60
32
60
50
125-150 *Impact Wrench, 3/4 sq.dr. 7.5
8
125-150 *Impact Wrench, 1 sq.dr. 10.0
25
10
34
70
60
27
50
40
8
70- 90 *Die Grinder 5.0
90- 100 *Vertical Disc Sanders 10.0
20
60
22
45
10
10
27
40
30
90- 100 *Filing & Sawing Machine, small 3.0
90- 100 *Filing & Sawing Machine, large 5.0
12
15
10
40
35
21
30
25
17
90- 100 *Burring Tool 5.0
145- 175 Hydraulic Lift 6.0
10
25
14
14
20
14
20
20
11
125-150 Hydraulic Floor Jack 6.0
120-150 Pneumatic Garage Door 3.0
71/2
9.0
14
14
15
11
15
20
20
90- 100 Radiator Tester 1.0
90- 100 Spark Plug Cleaner 5.0
6.1
7.6
15
15
14
14
15
10
5
6.25
4.8
3.9
14
14
15
15
HAMMERS
3
8
5.6 6.25
90- 100 *Air Hammer 4.0
3.4
2.7
15
15
14
14
2
5
90- 100 *Tire Hammer 12.0
125-150 *Bead Breaker 12.0
11/2
3.0
2.4
14
14
15
15
4
SPRAY GUNS
1.7
2.1
3.2
15
15
14
14
1
1.3
3.2
2.5
/4
14
14
15
15
90- 100 *Paint Spray Gun (Production) 8.5
3
1.8
/2
Thermal-Magnetic Breaker 15
14
14
2
1
FUSIBLE SWITCH
FUSIBLE SWITCH
125-150 Rim Stripper 6.0
125-150 Tire Changer 1.0
125-150 Tire Inflation Line 1.5
125-150 Tire Spreader 1.0
6 23
BLASTING DATA
SYSTEM
SYSTEM
MOTOR
MOTOR
(120V)
(240V)
230V
115V
S
S
APPROXIMATE AIR CONSUMPTION
(CFM) PER BLAST NOZZLE
10
50
90
60
--
--
--
--
6
NOZZLE PRESSURE
NOZZLE
SIZE 80 PSI 90 PSI 100 PSI 120 PSI
71/2
100
110
60
80
40
80
3
8
1
/8 18 20 22 26
3
/16 (*3) 41 45 49 58
40
90
80
56
28
60
10
5
4
1
/4 (*4) 72 80 90 105
5
/16 (*5) 113 125 140 160
12
25
50
34
70
35
17
3
8
3
/8 (*6) 163 182 200 235
7
/16 (*7) 215 240 270 315
20
12
30
50
10
14
24
25
2
1
/2 (*8) 290 320 350 410
5
/8 (*10) 454 500 550 640
11/2
15
12
30
20
40
14
10
20
3
/4 (*12) 652 720 790 925
APPROXIMATE ABRASIVE
12
25
30
14
14
16
15
1
8
CONSUMPTION (LBS./HR.)
PER BLAST NOZZLE
13.8
6.9
/4
20
25
15
14
14
10
NOZZLE PRESSURE 3
NOZZLE
SIZE 80 PSI 90 PSI 100 PSI 120 PSI
4.9
9.8
/2
15
15
20
14
14
7
1
1
/8 115 130 140 165
10
15
3.6
5.6
7.2
15
14
14
1
SINGLE PHASE MOTOR DATA (60 Hz)
1
/4 (*4) 460 500 560 660
2.9
4.5
5.8
15
15
14
14
9
1
3
/8 (*6) 1050 1155 1260 1475
6.25
2.2
3.2
4.4
15
14
14
15
1
1
/2 (*8) 1850 2000 2250 2650 SIZE - (75 C) THW, THHN- THWN,
SIZE - (75 C) THW, THHN- THWN,
5
/8 (*10) 2900 3125 3520 4100
Thermal-Magnetic Breaker Trip
Thermal-Magnetic Breaker Trip
3
/4 (*12) 4180 4500 5060 5950
MOTOR X
Air volume and pressure are very important. The blasting production
CIRCUIT BREAKER
CIRCUIT BREAKER
FUSIBLE SWITCH
FUSIBLE SWITCH
rate will increase with higher blasting pressures and decrease with lower
Rating - AMPS
Rating - AMPS
Fuse - AMPS
Fuse - AMPS
data suggests that 1.5% of production is lost for each 1 PSI reduction in
blast nozzle pressure. Pressure drop through the blast unit itself is
normally less than 1 PSI. Air pressure loss can be avoided by using the
shortest possible hose of adequate size.
8 21
LOSS OF AIR PRESSURE
2.96
9.02
4.62
6.62
.20
.28
1.20
1.68
.49
.76
.13
DUE TO FRICTION - IN PSI 100 FT.
350
11.8
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
OF PIPE OR HOSE 100 PSI GAUGE
INITIAL PRESSURE
.23
.33
3.42
.88
5.36
1.39
1.95
.57
.15
7.70
10.5
13.7
300
CU. FT. EQUIVALENT TYPICAL
FREE CU. FT. Nominal Diameter, In. (I.D.)
2.32
.39
.68
1.66
6.39
1.05
AIR COMPRESSED 1
4.07
.27
.18
9.13
.10
12.5
16.3
PER MIN. AIR/MIN. /2 /4 1 1 /4 1 /2 2 2 /2 3 3 /2 4
3 1 1 1 1
250
10 1.28 2.6 .1 .03
2.04
.48
.22
.33
5.02
.83
20 2.56 6.9 .4 .11 .03 .01
1.30
2.87
.13
7.86
15.4
20.0
11.3
200
30 3.84 .59 .9 .25 .06 .07
40 5.12 1.6 .45 .10 .05
2.66
50 6.41 2.5 .69 .16 .07 .02
3.73
.44
6.55
.62
.28
1.69
1.09
.12
.16
10.3
14.7
150
60 7.68 3.6 1.00 .23 .10 .03
70 8.96 4.9 1.40 .32 .14 .04
80 10.24 6.5 1.80 .41 .18 .05 .02
.73
.33
4.40
1.99
1.28
.51
3.14
7.82
.19
.14
12.1
125
90 11.52 8.3 2.30 .52 .23 .06 .02
.89
2.43
3.83
.63
5.36
9.40
.23
1.56
.41
.11
.17
100
150 19.23 6.30 1.5 .64 .17 .07 .02
175 22.40 1.9 .87 .24 .09 .03
200 25.62 2.6 1.14 .31 .12 .04 .02
.52
2.00
4.89
.80
.30
6.85
.21
3.10
.14
1.14
75
250 31.64 4.0 1.79 .49 .19 .06 .03
300 38.44 5.8 2.58 .69 .27 .08 .04 .02
350 44.80 3.51 .94 .36 .11 .05 .03
.72
4.30
6.78
.29
1.58
2.76
.19
.41
.11
1.11
50
400 51.24 4.58 1.21 .48 .15 .07 .04
450 57.65 5.80 1.54 .59 .19 .09 .05
500 63.28 7.16 1.92 .74 .23 .11 .06
.85
.23
.35
.49
1.87
3.27
1.31
.13
5.17
40
600 76.88 2.76 1.07 .34 .16 .08
700 89.60 3.77 1.45 .46 .21 .11
800 102.50 4.90 1.90 .59 .28 .14
2.28
4.00
.28
.43
.60
1.04
1.60
.16
30
900 115.30 6.23 2.41 .76 .35 .18
1000 128.10 7.69 2.98 .93 .44 .22
1500 192.30 6.70 2.10 .98 .49
2.95
.36
.55
.22
1.34
.77
2.07
20
.90
.24
1.57
15
1.08
10
proportional to the length; i.e.: for 50 ft., one-half of the above; for 400 ft.,
four times the above, etc.
NOTES:
FREE AIR
1. These figures are for estimating - different types of pipe and hose
CFM
1250
200
250
300
400
500
600
800
1000
1500
150
2000
2500
3000
3500
4000
may have rougher linings and cause higher pressure drops.
40
1
Piping for a sample system of 3,000 CFM at 100 PSIG of central air, with
five 600 CFM uses figured according to the chart for loss of air pressure
due to friction.
10 19
FRICTION OF AIR IN HOSE - Pulsating Flow* CONTINUED
SIZE OF HOSE, GAUGE CU.FT. FREE AIR PER MIN. PASSING THROUGH 50 FT. LENGTHS OF HOSE
COUPLED PRESSURE 20 30 40 50 60 70 80 90 100 110 120 130 140 150
EACH END, IN. AT LINE, LB. LOSS OF PRESSURE (PSI) IN 50 FT. LENGTHS OF HOSE
50 -- -- 0.1 0.2 0.2 0.3 0.4 0.5 0.7 1.1
60 -- -- -- 0.1 0.2 0.3 0.3 0.5 0.6 0.8 1.0 1.2 1.5
70 -- -- -- 0.1 0.2 0.2 0.3 0.4 0.4 0.5 0.7 0.8 1.0 1.3
1
1 / 4 80 -- -- -- -- 0.1 0.2 0.2 0.3 0.4 0.5 0.6 0.7 0.8 1.0
90 -- -- -- -- 0.1 0.2 0.2 0.3 0.3 0.4 0.5 0.6 0.7 0.8
100 -- -- -- -- -- 0.1 0.2 0.2 0.3 0.4 0.4 0.5 0.6 0.7
110 -- -- -- -- -- 0.1 0.2 0.2 0.3 0.3 0.4 0.5 0.5 0.6
12
50 -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.3 0.4 0.5 0.6
60 -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.3 0.4 0.5
70 -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.3 0.4
11/2 80 -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3 0.4
90 -- -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2 0.3
100 -- -- -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2
110 -- -- -- -- -- -- -- -- -- -- 0.1 0.2 0.2 0.2
*For longer or shorter lengths of hose, the friction loss is proportional to the length, i.e.: for 25 ft. one-half of the above; for 150 ft., three times the above, etc.
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
CONTINUED
NOMINAL CFM LINE PRESSURE - PSIG
PIPE SIZE FREE AIR 10 15 20 30 40 50 75 100 125 150 200 250 300 350
50 .31 .25 .22 .17 .14 .12
75 .65 .54 .46 .36 .29 .25 .18 .14 .12 .10
100 1.13 .94 .80 .62 .51 .43 .31 .24 .20 .17 .13 .11
125 1.44 1.24 .96 .78 .66 .48 .37 .31 .26 .20 .16 .14 .12
150 2.04 1.75 1.35 1.11 .94 .68 .53 .43 .37 .28 .23 .19 .17
200 3.04 2.36 1.93 1.63 1.18 .92 .76 .64 .49 .40 .34 .29
11/2 250 3.68 3.01 2.54 1.83 1.44 1.18 1.00 .77 .62 .52 .45
17
SCHEDULE 300 4.29 3.62 2.62 2.05 1.74 1.43 1.09 .89 .75 .64
40 400 6.35 4.58 3.59 2.94 2.50 1.92 1.55 1.31 1.13
500 7.12 5.59 4.59 3.89 2.98 2.42 2.03 1.76
600 8.00 6.55 5.55 4.26 3.46 2.91 2.51
700 10.8 8.89 7.55 5.78 4.70 3.95 3.40
800 11.6 9.80 7.50 6.10 5.12 4.42
1000 15.2 11.7 9.45 7.95 6.86
1200 16.4 13.3 11.2 9.61
1400 22.9 18.6 15.6 13.5
DECIMAL AND METRIC
.44
2.58
3.68
3.67
5.20
6.50
.25
.96
1.67
1.52
.61
2.37
.12
.31
1.01
350
9.14
.11
EQUIVALENTS OF COMMON
14.3
10.1
FRICTION LOSS OF AIR IN PIPE - PRESSURE LOSS IN POUNDS FOR EACH 100 FEET OF STRAIGHT PIPE
FRACTIONS OF AN INCH
.30
.35
2.99
4.25
6.03
1.94
4.27
.12
1.76
.51
.71
2.74
7.52
1.18
.14
1.11
300
10.6
16.6
11.7
FRACTION DECIMAL Mm
1/64 0.01562 0.397
1/32 0.03125 0.794
3.26
.35
.42
5.05
2.30
5.08
.84
3.55
8.95
1.32
1.40
.61
.15
2.10
.16
7.16
13.9
12.6
19.7
250
3/64 0.04688 1.191
1/16 0.06250 1.588
5/64 0.07812 1.984
3/32 0.09375 2.381
2.84
.43
4.02
6.22
.20
.52
6.25
8.85
2.58
1.63
.75
1.72
1.03
4.37
.18
15.6
200
11.0
7/64 0.10938 2.778
17.1
1/8 0.12500 3.175
9/64 0.14062 3.572
5/32 0.15625 3.969
2.25
.26
.68
5.25
5.70
3.70
150
.98
1.35
.57
.24
2.12
3.37
8.12
8.16
11/64 0.17188 4.366
14.4
11.5
3/16 0.18750 4.763
13/64 0.20312 5.159
7/32 0.21875 5.556
2.50
2.65
6.75
9.70
3.98
6.40
.67
.28
.80
125
1.59
9.61
4.37
.31
1.15
15/64 0.23438 5.953
12.6
1/4 0.25000 6.350
.38
3.05
.34
.98
3.23
8.20
1.93
.81
5.31
4.74
7.53
1.41
100
19/64 0.29688 7.541
11.7
11.7
5/16 0.31250 7.938
21/64 0.32812 8.334
11/32 0.34375 8.731
23/64 0.35938 9.128
.43
.48
3.90
6.80
9.60
1.04
1.25
1.80
2.47
4.12
.12
6.19
75
3/8 0.37500 9.525
25/64 0.39062 9.922
13/32 0.40625 10.319
3.42
.60
.67
2.48
5.40
1.72
1.43
5.71
27/64 0.42188 10.716
.16
50
7/16 0.43750 11.113
29/64 0.45312 11.509
15/32 0.46875 11.906
31/64 0.48438 12.303
2.04
4.05
.79
1.70
2.94
.71
.19
40
1/2 0.50000 12.700
33/64 0.51562 13.097
17/32 0.53125 13.494
35/64 0.54688 13.891
2.08
2.50
.96
3.60
.23
4.95
.87
30
3.22
.30
1.24
1.12
20
.35
1.45
1.31
15
100
100
150
200
250
125
10
15
10
20
30
40
50
60
80
20
35
50
65
80
27/32 0.84375 21.431
55/64 0.85938 21.828
7/8 0.87500 22.225
57/64 0.89062 22.622
29/32 0.90625 23.019
59/64 0.92188 23.416
SCHEDULE
SCHEDULE
PIPE SIZE
NOMINAL
/4
40
40
14 15