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Po - Atmospheric Pressure P1 - Initial Pressure of the receiver (Kg/cm2) P2 - Final Pressure of the receiver (Kg/cm2) T - Average Time taken (min) Specific Power (KW / 100 CFM) = Actual Power x 100 / FAD (CFM) Where KW - Actual Power drawn by compressor Compare this value this design value of FAD. If the difference is more than 20%, it is high time to look at piston rings, cylinder bores etc. Leakage Test To conduct this test, close all the valves at the equipments where compressed air is in use. Drain the air receiver completely and start the compressor. Note down the time taken by the compressor to maintain the system pressure i.e. up to compressor unloads. This is compressor on load time in seconds. Due to the leakages in the systems (if present), the pressure in the receiver drops to the cut off pressure and again compressor starts. Note down the time taken by system pressure to drop up to cut off pressure. This is compressor off load time in seconds. The readings should be taken minimum three times and the average values are to be used to determine leakages in the lines. Feed these two values in seconds in the formula to determine leakages and its potential. Leakages (m3/min) = FAD x T1 / (T1 + T2) Where FAD - Actual free air delivery of compressor (m3/min) T1 = Average on load time of compressor (min) T2 = Average off load time of compressor (min) Power wasted in Rs. / Annum = 5.54 x L x Operasting hours per annum x Rs./KWhr Where L - Leakages in m3/min
Conversion Factors : M3/hr = NM3/hr x 1.17 Scfm (Standard Cubic foot per minute) = M3/hr x 31.81 M3/min = cfm x 35.3 While large leakages can be detected easily due to hissing sound produced, there are large number of small leakages that are difficult to detect. Small leakages can be detected by applying soap solution on pipelines, joints etc. or with the help of the ultrasonic testing equipments available in the market. Some of the most susceptible points are: Underground pipelines Threaded pipe joints Flange connections Valve steam Traps and drains Filters Hoses Connectors Operating valves on pneumatic devices Check valves Relief valves End use machines or tools
sizing of the pipelines and hoses and selection of appropriate type of valves and couplings are essential to ensure efficient operations. The pressure in a pipeline can be calculated using following formula: Pressure Drop, Kg/cm2 = 7.57 x (Q^1.85) x L x (10^4) / (d^5) x p Where Q = Air flow in cu.m/min (FAD) L = Length of pipeline (m) d = inside diameter of pipe (mm) P = Initial pressure, kg/cm2 ^- indicates 'to the power of' The points to be kept in mind while designing a distribution system are :
Low pressure drop between the compressor plant and the end use point. Minimum leakage Minimum number of joints, bends, fillings in the pipeline. Proper design and layout of the pipeline
A general guide for selection of pipe size as recommended in IS:6202 is that the pressure drop should not exceed 3 kg/sq.cm at the farthest end of the line. For plants, covering large area, the pressure drop up to 0.5 Kg/sq.cm may be acceptable. The required pipe diameter and length of the pipe line are given in report if the pressure drop exceeds the allowed pressure drop. The pressure drop can be reduced either with the increase in diameter or with reducing the effective length of the pipe but not with both.