Objective
To demonstrate a 35% volumetric increase and 30% electrical energy saving in the operation of a large single stage and 2-stage reciprocating compressor plant in a glass works by cooling the intake air to the machines down to -25 deg. C and removing moisture.
Also, to prove that there are benefits in product quality through moisture free air.
The project will show the efficient water removal technique of the compressor pre-cooler unit and the optimum pressure balance/integration of a 2-pressure system.
This is the first time that this technology has been applied to a single and 2-stage reciprocating compressor plant with delivery pressures of 3 and 6 bar respectively and temperatures as high as + 85 deg. C.
The installation has not operated as intended, therefore, there is no operational experience or results. Work is continuing to resolve a vibration problem associated with the operational characteristics of the particular compressors. The single stage machines have three modes of operation; fully loaded, half-loaded and off-loaded. It is in the half-load position where excessive vibration is created.
Modifications are to be implemented to include the removal of this middle mode and the fitting of inlet mufflers to reduce the pressure pulses that go back down the intake lines. This work will be carried out during 1994; it is then expected that the pre-cooler installation can operate satisfactorily be reducing the intake air temperature to -25 deg. C and giving the volumetric increase and energy saving benefit as envisaged.
There are a total of 9 reciprocating compressors serving the glass works, 7 single stage and two 2-stage, all of which are of the oil lubricated design with externally mounted separators.
The present situation is that the low and high pressure systems operate indepedent of each other with 4-low pressure compressors fully loaded and one modulating 85%) and one high pressure machine modulating (53%). By cooling the compressor intake air down to - 25 deg. C, the total volumetric increase is 20% (18% through mass and 2% by moisture removal), such that only 4 compressors in total are required to operate. With the existing independent arrangement, this would mean that the high pressure compressor would continue to modulate (be it at a lower level) and 3 of the low pressure machines fully loaded and one continuing to modulate. This would not be the ideal method to operate the system and does not take full advantage of the potential electical savings from compressor pre-cooling due to theinefficiencies of part loaded machines.
The proposed arrangement utilises the 100 mm diameter interconnection between low and high pressure systems with the incorporation of a pressure control valve. By taking advantage of the 2-stage high pressure compressors and maintaining the single machine necessary at full load a much more efficient system is possible. The pressure control valve, through a pressure transmitter, will maintain the high pressure system at 6 bar allowing the surplus capacity into the 3 bar low pressure system. With a fall in pressure the control valve will drive towards the closed position and with a rise in pressure open. The requirement now for the low pressure system is a maximum of 3 compressors. With increasing pressure in the 3 bar system, the third L.P. compressor will modulate.
With this improved arrangement, a maximum of 4 compressors will operate; without the controlled interconnection between the two systems 5 machines would be continuously running with 2 modulating.
The Construction Phase of the project will take 7-months to complete including Commissioning. A 12 months Measurement period will follow where the installations operating conditions are to be closely monitored and the overall performance evaluated.
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Coordinator
4 Dublin
Ireland
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