Dls04e 0102

4.
Economic Appraisal
energy
energy
performance
Kaeser Kompressoren 2000
performance
http://www.kaeser.com
4. Economic Appraisal
Make-up of compressed air costs

for 1, 2 and 3-shift working
90 80 70 60 50 40 30 20 10 0
84 % 73 %
65-73 % 76-84 %
87 %
78-87 %
25-33% 13.5-21% 2% 2000 h/a 10.3-18% 2.5 % 4000 h/a 2.7 %
2%
power service of capital maintenance
7500 h/a
Basis
power costs: depreciation period: interest:
0.08-0.12 /kWh 5 years 8%

2
Air delivery and standards

motor efficiency total power consumption
FAD
????
DIN .... kWh
ISO ...
Standards
Free air delivery at the airend to ISO 1217 : 1996 Annex B - without air filter - without transmission losses (gearing/V-belts) - without power consumption of fan - without internal unit losses (fluid separator, cooler)
Free air delivery (FAD) of the overall package at max. gauge pressure at the air outlet to ISO 1217 : 1996 Annex C - all internal losses accounted for - FAD calculated with reference to inlet conditions
ISO 1217 : 1996

Air flow related to ambient conditions m3/min
below 0.5 0.5 - 1.5 1.5 - 15 Air flow Specific power consumption +/- 8 % +/- 7 % +/- 6 % Power consumption in idle *) +/- 20 % +/- 20 % +/- 20 %
+/- 7 % +/- 6 % +/- 5 %
over +/- 4 % +/- 5 % +/- 20 % 15 The above tolerances include the manufacturers tolerances for the compressor including measurement tolerances. *) if given by the manufacturer
ISO 1217 (old) / DIN 1945

Compressor power input under normal loading Usable capacity Specific power input Idling power
below 10 kW
10 to 100 kW above 100 kW
+/- 6 %
+/- 5 % +/- 4 %
+/- 7 %
+/- 6 % +/- 5 %
+/- 20 %
+/- 20 % +/- 20 %
Measurement of free air delivery

Power consumption in kW
Package
discharge pressure p2 discharge volume V2
inlet temperatureT1 inlet pressure p1 inlet humidity Frel1
discharge temperature T2
Flow of force and power

Electrical power consumption of fan motor, if separate fan is fitted kWh Overall electrical 0 0 0 power consumption Compressor shaft power: required mechanical force in kW at the Rated motor power: drive shaft mechanical shaft power in kW that the motor can supply at 100% load. Quoted on the nameplate
internal motor losses, accounted for in the motor efficiency Motor shaft output power: mechanical force in kW that the motor transmits into the shaft Drive losses of the cooling fan
Transmission losses of belts/gearing

http://www.kaeser.com 8
Calculation of power costs

INPUT
Drive motor
output power
at max. gauge pressure
FORMULA
kW
CALCULATION
kW 0.
drive motor output power drive motor efficiency
kW 0.
efficiency
0.
Separate fans (if fitted)

quantity: fan output power: efficiency: 0. kW
+
sum of output power of separate fans fan motor efficiency
overall electrical power consumption
kW
overall electrical powerconsumption
Required power per m3/min

INPUT
What is the known air delivery?
Effective air delivery of the airend to ISO 1217 app. B / DIN 1945 / PN2 CPT C1 Theoretical m3/min kW
FORMULA
CALCULATION
overall electrical power consumption free air delivery of overall package
m3/min
Effective free air delivery of the overall package

to DIN 1945, part 1, appendix F; ISO 1217 appendix C (1996) ;CAGI-PNEUROP PN2 CPT C2 at max. gauge pressure Practice m3/min
specific power
specific power at 3 m /min max. gauge pressure

kW
10
Power costs per year
INPUT
air consumption service hours per year: (1, 2 or 3 shift operation) kWh price incl. provision
m3/min
FORMULA
CALCULATION
x
kW/(m3/min) m3/min
h/year
specific power
airservice conx hours sumption per year
kWh price
x
h/year /kWh
/ kWh
power costs per year
per year
power costs
11
insulation class F
insulation class B
105 EPACT 80 Energy Policy Conservation Act 60 D temperature (K)
Temperatur (K) D power

spec. power kW/min m
Specific power of a screw compressor airend

at 7 bar related to speed and free air delivery (FAD)
7,0
airend 1
6,5
6,0
5,5
point of optimal utilisation
0
500
1000
9
1500
14
2000
19
2500
24
3000 min
-1
speed FAD in m/min

13
spec. power
Use of power-optimised airend

(7 bar) at 1500 min-1
kW/min m 7.0
airend 1 6.5
6.0
airend 2
airend 3
airend 4
5.5 optimum points
14
18
23
30
FAD in m/min
14
spec. power kW min m
7,0
Screw compressor operating range
smaller airend airend 1 larger airend airend 2
6,5
6,0
often encountered operating ranges*

optimum performance
5,5
optimum operating range* *airend too small high speed bad specific power shorter life lower purchase price higher total cost of compressed air generation Kaeser Kompressoren 2000
power costs (%)
100 ca. 6%
Reducing compressor power costs

by optimising systems
1 bar reduction in pressure by means of a modern master control system Reduction in consumption by minimising leakages
Better utilisation by optimum matching of operating mode through industrial computer controller
ca. 4,5% 90
ca. 10%
80
Savings potential through the use of modern air generating plant
ca. 10%
Equipping the compressor with a modern airend, efficient power transmission and an EPACT motor
70
60
savings potential Kaeser Kompressoren 2000

Performance characteristics
Turbo compressor - screw compressor
Spec. Power, screw kW min/cbm Spec. Power, turbo, kW min/cbm
Normale volume cbm/min Mass air flow kg/min
160
Spez. Leistung Schraube kW min/cbm Spez. Leistung Turbo kW min/cbm 140 Normalvolumen cbm/min Massenstrom kg/min
Relationship: air delivery referred to normal volume or as mass air flow to specific power at changing inlet temperatures
7,5
8,5
120
7
kW min/cbm
100 8
80
kg/min cbm/min
6,5
7,5
60
40
Annual mean temperature in Europe < 10 0C
20
5,5
6,5
0 100 8 Ansaugtemperatur C 15 25 35
17
Performance characteristics
Oil-cooled - oil-free screw compressors at 7 bar (g)
oil-free compressor oil-cooled compressor
specific power in kW/(m3/min)
Motor output power in kW

4. Economic Appraisal Cooling: costs for air and water - cooled units
Cooling costs
12000 10000 8000 /a 6000 4000 2000 0 110
132
Basis: service hours 4000 h/a water costs 0.20 /cbm kWh price 0.09 /kWh
160
Water Air 200 250
Air Water
Motor output power(kW) main drive motor
19
Comparison of average maintenance costs for various compression systems

Comparison of average annual maintenance costs between screw compressors and compressors with oil free compression chamber, referred to 2000 h/a and a service period of one decade
Screw compressors with oil free compression chamber Turbo Oil-cooled screw compressors
600 300
Average annual maintenance costs per m3/min air delivery in
500 250
200 400 150 300 100 200
100
50
Air delivery m3/min
90
20
Comparison of specifications
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Technical specification Units Compressor model Number of compressors Power transmission B (belt), G (gear), D (direct) Constructional type Manufacturer of airend or block Airend or block speed min-1 Cooling air/water Working pressure bar (g) Free air delivery at max. gauge working pressure l/sec Free air delivery at max. gauge working pressure m3 /min Free air delivery at max. gauge working pressure m3 /h Motor output power kW Compressor motor efficiency % Number of separate fans Motor output power per fan motor kW Fan motor efficiency % A B C D
21
Comparison of specifications
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Technical specification Power consumption of compressor motor (12 x 100 /13) Power consumption of fan motors (14 x 15 x 100 /16) Overall power consumption under full load (17+18) Overall power consumption under off load running Compressor drive motor speed Cooling air volume Cooling water consumption (at Delta t cooling water = .... K) Required compressor unit floor space Total oil content Oil change interval Hourly compressed air demand Service hours Annual compressed air demand (27 x 28/ 1000 ) Full load hours (29 x 1000 /11) Off load running hours Units kW kW kW kW min-1 m3/h m3/h m2 l h m3/h h/year 1000 m3/year h/year h/year A B C D
22
Calculation of costs
36 Service of capital (package value/1000 x service of capital factor) 1) KA = / 1000 x KB = / 1000 x KC = / 1000 x KD = / 1000 x 37 Full load power costs (19 x 30 x 33) A= kW x B= kW x C= kW x D= kW x 38 Off load running power costs (20 x 31 x 33) 39 Water costs (23 x (30 + 31) x 34) 3 A= m /h x B= m3/h x C= m3/ h x D= m3/h x
Operational data 33 Electricity costs 34 Water costs 35 Oil costs

A = = = = B C
/kWh /m3 /l
D
h/year x h/year x h/year x h/year x
/ / / /
kWh = kWh = kWh = kWh =
h/year x h/year x h/year x h/year x
/ / / /
m3 = m3 = m3 = m3 =
1) See Formulas and tables for service of capital (transparency no. 25)
23
40 Oil costs (25 x ( 30 + 31 )/ 26 x 35 A= lx B= lx C= lx D= lx 41 42 43 44
A 1/year x 1/year x 1/year x 1/year x / / / / l= l= l= l=
Maintenance costs 2) Sum of all costs (36 bis 41) Compressed air index (42 / ( 29 x 1000 ) Extra costs for more efficient unit Remarks on the evaluation
/ year / m3 / year
2) Recommended values for maintenance costs in % related to power costs

Compressor type Percentage fluid-cooled screw 3 fluid-free screw 6 piston 10 turbo 5 sliding vane 6
24
Formulas and tables for service of capital
K a A n p = = = = = package value / 1000 x a A x [1/n + p/100 x (n+1)/(2 x n) ] / year package capital ( =1000 ) depreciation period in years interest in %
9 150 156 161 167 172 178 183 189 10 139 144 150 155 161 166 172 177 11 121 127 132 138 143 148 154 159 12 115 120 125 131 132 142 147 152
"Service of capital factor a per 1000 package value" Years 5 6 7 8 7% 242 208 183 164 8% 248 214 189 170 9% 254 219 194 176 10% 260 225 200 181 11% 266 231 206 187 12% 272 237 212 193 13% 278 243 217 198 14% 284 248 223 204 If n = years and p = % then a =
25
User: Air consumption Service hours Interest Depreciation period Power costs Cooling water costs Oil costs Maintenance cost calculation Oil cost calculation m /a*1000 h/a % a /kWh /m3 /litre Yes/No Yes/No 5601,6 8000 0 0 0,10 0,00 2,00 No Yes Package1
Motor output power at max. pressure kW (g) Motor efficiency % Fan power at max. ventilator thrust kW Motor efficiency % Power consumption at max. pressure kW (g)
2,00 2,00 0,00 0,00
75,00 94,10 0,00 0,0 79,70 6,830 17,80 91,00 19,56 90,00 0,00 70 4000 8000,00 0,00 0,00 0,00 0,00 0,00 280,00 0,00 0,00 63761,96 0,00 64041,96
74,40 93,90 2,15 82,00 81,86 7,537 20,00 90,90 24,62 90,00 0,00 26 1500 8000,00 596,69 740,33 6662,98 0,00 0,00 323,68 0,00 0,00 70368,32 1823,00 72515,01
75,30 94,50 2,60 82,00 82,85 7,478 18,20 91,40 23,08 90,00 0,00 80 4000 8000,00 425,99 757,40 6816,61 0,00 0,00 367,34 0,00 0,00 69812,11 1748,32 71927,77
0,00 0,00 0,00 0,00 0,00 0,000 0,00 0,00 0,00 0,00 0,00 0 0 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00
0,00 0,00 0,00 0,00 0,00 0,000 0,00 0,00 0,00 0,00 0,00 0 0 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00
Specific electrical power
kWmin/m
Package2
Package3
Package4
Package5
Package model CS 121 / 8 Manufacturer KAESER Block or airend manufacturer KAESER Block/airend model S 2c Construction " "=oillubsc;1=oilfrscr;2=recip;3=turb;4=rot vane No. of base load units No. off No. of peak load units No. off " "= air; 1= water Cooling Separate fan motor Yes/No NO Max. working pressure (g) Min. working pressure (g) bar bar
COMPETIT COMPETIT 1 2
Motor output power in off load running kW Motor efficiency % Power consumption in off load running kW Percentage standstill/off load running % Cooling water consumption Oil content Oil change interval m /h l h
0 1 0 0 YES
0 1 1 0 YES 8 6 10,86 3412 0
0 1 1 0
0 0 0 0
0 0 0 0
Full load hours under base load h Full load hours under peak load h Off load running hours h Hours at standstill h Purchase price Capital costs Oil costs Maintenance costs Cooling water costs Power costs under full load Power costs in off load running Overall costs /a
8 5,5 11,67 4714 0
8 7 11,08 6200 0
0 0 0,00 0 0
0 0 0,00 0 0
Air delivery at max. pressure (g) m /min Stage 1 block/airend speed Stage 2 block/airend speed min min
26

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4.

Make-up of compressed air costs

25-33% 13.5-21% 2% 2000 h/a 10.3-18% 2.5 % 4000 h/a 2.7 %

power service of capital maintenance

0.08-0.12 /kWh 5 years 8%

Air delivery and standards

DIN .... kWh

Kaeser Kompressoren 2000

Kaeser Kompressoren 2000

ISO 1217 : 1996

+/- 7 % +/- 6 % +/- 5 %

Kaeser Kompressoren 2000

ISO 1217 (old) / DIN 1945

Kaeser Kompressoren 2000

Measurement of free air delivery

inlet temperatureT1 inlet pressure p1 inlet humidity Frel1

Kaeser Kompressoren 2000

Flow of force and power

Transmission losses of belts/gearing

Calculation of power costs

drive motor output power drive motor efficiency

Separate fans (if fitted)

overall electrical power consumption

overall electrical powerconsumption

Kaeser Kompressoren 2000

Required power per m3/min

overall electrical power consumption free air delivery of overall package

Effective free air delivery of the overall package

specific power at 3 m /min max. gauge pressure

Kaeser Kompressoren 2000

Power costs per year

airservice conx hours sumption per year

power costs per year

Kaeser Kompressoren 2000

Temperatur (K) D power

Kaeser Kompressoren 2000

Specific power of a screw compressor airend

point of optimal utilisation

speed FAD in m/min

Use of power-optimised airend

5.5 optimum points

Screw compressor operating range

smaller airend airend 1 larger airend airend 2

often encountered operating ranges*

Reducing compressor power costs

Savings potential through the use of modern air generating plant

savings potential Kaeser Kompressoren 2000

Spec. Power, screw kW min/cbm Spec. Power, turbo, kW min/cbm

Normale volume cbm/min Mass air flow kg/min

Annual mean temperature in Europe < 10 0C

Kaeser Kompressoren 2000

oil-free compressor oil-cooled compressor

specific power in kW/(m3/min)

Motor output power in kW

12000 10000 8000 /a 6000 4000 2000 0 110

Water Air 200 250

Motor output power(kW) main drive motor

Kaeser Kompressoren 2000

Comparison of average maintenance costs for various compression systems

Air delivery m3/min

Kaeser Kompressoren 2000

Kaeser Kompressoren 2000