|
Useful Data
|
Compressor
Control Comparison
% Of Full Load
BHP Versus % Of Full Load Capacity |
|
% of
Compressor
Capacity |
Modulation
(Inlet Valve)
% FL BHP |
Variable
Displacement
(Geometry)
% FL BHP |
On-Line / Off-Line |
Variable Speed Drive (Switched
Reluctance) |
|
1 Gal/CFM |
3 Gal/CFM |
5 Gal/CFM |
|
% FL BHP |
% FL BHP |
% FL BHP |
% FL BHP |
|
100 |
100.00 |
100.00 |
100.00 |
100.00 |
100.00 |
100.00 |
|
95 |
98.50 |
96.00 |
101.51 |
100.49 |
99.95 |
95.20 |
|
90 |
97.00 |
92.00 |
100.44 |
98.36 |
97.28 |
90.40 |
|
85 |
95.50 |
88.20 |
99.28 |
96.11 |
94.51 |
85.60 |
|
80 |
94.00 |
84.70 |
98.02 |
93.71 |
91.61 |
80.80 |
|
75 |
92.50 |
81.50 |
96.64 |
91.17 |
88.59 |
76.00 |
|
70 |
91.00 |
78.30 |
95.12 |
88.46 |
85.43 |
71.20 |
|
65 |
89.50 |
75.40 |
93.45 |
85.57 |
82.10 |
66.40 |
|
60 |
88.00 |
73.00 |
91.58 |
82.49 |
78.63 |
61.60 |
|
55 |
86.50 |
70.80 |
89.49 |
79.19 |
75.02 |
56.80 |
|
50 |
85.00 |
69.00 |
87.13 |
75.67 |
71.25 |
52.00 |
|
45 |
83.50 |
64.60 |
84.44 |
71.89 |
67.34 |
47.20 |
|
40 |
82.00 |
60.20 |
81.35 |
67.80 |
63.28 |
42.40 |
|
35 |
80.50 |
55.80 |
77.76 |
63.41 |
59.06 |
37.60 |
|
30 |
79.00 |
51.40 |
73.53 |
58.76 |
54.69 |
32.80 |
|
25 |
77.50 |
47.00 |
68.51 |
53.84 |
50.15 |
28.00 |
|
20 |
76.00 |
42.60 |
62.48 |
48.65 |
45.46 |
23.20 |
|
15 |
74.50 |
38.20 |
55.19 |
43.17 |
40.60 |
18.40 |
|
10 |
73.00 |
33.80 |
46.26 |
37.41 |
35.57 |
13.60 |
|
5 |
71.50 |
29.40 |
36.19 |
31.36 |
30.37 |
8.80 |
|
0 |
70.00 |
25.00 |
27.33 |
26.30 |
26.09 |
4.00 |
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|
Sample power cost numbers |
|
Single shift operation / 10 hours per day / 5 days per
week / $0.05 per kw |
|
|
HP |
Full load power cost |
70% load |
70% load |
70% load |
50% load |
50% load |
50% load |
|
|
|
modulation |
On-Line / Off-Line |
Econotrol |
modulation |
On-Line / Off-Line |
Econotrol |
|
50 |
5,759.00 |
5,241.00 |
5,478.00 |
N/A
|
4,895.00 |
5,018.00 |
N/A
|
|
75 |
8,013.00 |
7,291.83 |
7,628.38 |
6,274.18 |
6,811.05 |
6,981.73 |
5,528.97 |
|
100 |
10,776.00 |
9,806.16 |
10,258.75 |
8,437.61 |
9,159.60 |
9,389.13 |
7,435.44 |
|
125 |
13,619.00 |
12,393.29 |
12,965.29 |
10,663.68 |
11,576.15 |
11,866.23 |
9,397.11 |
|
150 |
17,242.00 |
15,690.22 |
16,414.38 |
13,500.49 |
14,655.70 |
15,022.95 |
11,896.98 |
|
200 |
21,758.00 |
19,799.78 |
20,713.62 |
17,036.51 |
18,494.30 |
18,957.75 |
15,013.02 |
|
250 |
27,390.00 |
24,924.90 |
26,075.28 |
21,446.37 |
23,281.50 |
23,864.91 |
18,899.10 |
|
300 |
33,249.00 |
30,256.59 |
31,653.05 |
26,033.97 |
28,261.65 |
28,969.85 |
22,941.81 |
| CompAir SR
variable speed units |
|
|
70% Power Cost |
50% Power Cost |
|
|
|
|
|
|
L120SR - 160HP |
11,754.60 |
8,139.30 |
|
|
|
|
|
|
L75SR - 100HP |
7,362.00 |
5,265.00 |
|
|
|
|
|
|
LL45SR - 67HP |
4,978.00 |
3,528.00 |
|
|
|
|
|
|
Sample power cost numbers |
|
Three shift operation / 24 hours per day / 7 days per
week / $0.05 per kw |
|
HP |
Full load power cost |
70% load |
70% load |
70% load |
50% load |
50% load |
50% load |
|
|
|
modulation |
On-Line / Off-Line |
Econotrol |
modulation |
On-Line / Off-Line |
Econotrol |
|
50 |
19,404.00 |
17,658.00 |
18,457.00 |
N/A
|
16,493.00 |
16,907.00 |
N/A
|
|
75 |
26,997.00 |
24,567.27 |
25,701.14 |
21,138.65 |
22,947.45 |
23,522.49 |
18,627.93 |
|
100 |
36,306.00 |
33,038.46 |
34,563.31 |
28,427.60 |
30,860.10 |
31,633.42 |
25,051.14 |
|
125 |
47,740.00 |
43,443.40 |
45,448.48 |
37,380.42 |
40,579.00 |
41,595.86 |
32,940.60 |
|
150 |
58,093.00 |
52,864.63 |
55,304.54 |
45,486.82 |
49,379.05 |
50,616.43 |
40,084.17 |
|
200 |
73,307.00 |
66,709.37 |
69,788.26 |
57,399.38 |
62,310.95 |
63,872.39 |
50,581.83 |
|
250 |
92,283.00 |
83,977.53 |
87,853.42 |
72,257.59 |
78,440.55 |
80,406.18 |
63,675.27 |
|
300 |
112,025.00 |
101,942.75 |
106,647.80 |
87,715.58 |
95,221.25 |
97,607.38 |
77,297.25 |
| CompAir SR
variable speed units |
|
|
70% Power Cost |
50% Power Cost |
|
|
|
|
|
|
L120SR - 160HP |
39,495.46 |
27,348.05 |
|
|
|
|
|
|
L75SR - 100HP |
24,886.00 |
17,740.00 |
|
|
|
|
|
|
L45SR - 67HP |
16,771.00 |
11,887.00 |
|
|
|
|
|
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|
Cost of Air
Leaks
Single shift operation / 10 hours per day / 5 days per
week / $0.05 per kw |
|
1/4" air leak at 100PSI consumes approximately 104CFM
- which comes to a yearly power cost of $2,235.00 |
|
1/2" air leak at 100PSI consumes approximately 415CFM
- which comes to a yearly power cost of $8,483.00 |
|
Cost of Air Leaks
Three shift operation / 24 hours per day / 7 days per week
/ $0.05 per kw |
|
1/4" air leak at 100PSI consumes approximately 104CFM
- which comes to a yearly power cost of $7,530.00 |
|
1/2" air leak at 100PSI consumes approximately 415CFM
- which comes to a yearly power cost of $28,580.00. |
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Breakdown of Typical Plant Air Consumption
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Breakdown of Compressed Air Costs over 10 Years
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|
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