Installing a Variable Frequency Drive (VFD) on Air Compressors

#1

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Usman Amjad Mir

03-26- 09:47 PM

Start by03-26- 09:47 PM

VFD Installation on Air Compressors

All,

I seek your comprehensive assistance regarding one of my projects. I kindly ask all of you to address my inquiries to ensure I receive proper support throughout this undertaking.

My project involves the installation of a VFD on an air compressor. The site has the following types of air compressors in operation:

a) Screw Air Compressor.
b) Piston Air Compressor.

As I'm unfamiliar with this technology, I have several questions:

1. Is it feasible to install a VFD on a piston air compressor, or is it predominantly beneficial for screw compressors?
2. What key parameters should I analyze for the air compressor prior to VFD installation?
3. What potential issues might arise from implementing a VFD, and how can these be proactively mitigated?

Can anyone assist me with insights?

As stated, my current endeavor involves the installation of a VFD on an air compressor. The intention is to regulate the speed of the compressor according to the desired pressure at the header. At present, the compressor's operation is based on a loading and unloading cycle depending on the pressure requirements at the shared header. The air compressors present on-site include:
a) Screw Air Compressor.
b) Piston Air Compressor.
I am new to this technology; hence I require guidance on:
1. Can I install a VFD on a piston air compressor? It is often noted that VFDs are primarily effective with screw compressors.
2. What parameters must be reviewed before I proceed with VFD installation?
3. What possible challenges could result from installing a VFD that can be addressed through proactive measures?
Any assistance would be greatly appreciated.

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#2

Steven Paul Richardson

03-27- 12:32 AM

03-27- 12:32 AM

Both reciprocating and screw compressors necessitate a minimum speed for adequate bearing lubrication. Each type has its maximum speed thresholds. Therefore, it is crucial to incorporate high and low-frequency settings, along with rate-of-change tuning to avoid surging. Enhanced pressure control, reduced vibration, and extended compressor lifespan should be achieved along with reasonable electrical savings. The screw compressor generally performs well, provided it doesn't require excessive turn-down while reciprocating compressors can accommodate greater turn-down.

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#3

Usman Amjad Mir

03-27- 03:20 AM

03-27- 03:20 AM

Hi Steven,

Thank you for your insights.

I am now interested in identifying the considerations necessary before VFD installation on the compressor:

a) Motor - consider replacing it with an inverter duty motor.
b) Air Compressor - this is where my concern lies presently. Is there any internal mechanism of the compressor that requires analysis or consideration? Specifically, any component of the compressor unit or its configuration that might pose operational challenges when integrated with a VFD?

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#4

Fawaz Ahmed

03-27- 05:21 AM

03-27- 05:21 AM

You may opt for a screw compressor for higher flow rate and volume while connecting one or two piston compressors to increase pressure, depending on signals from a pressure transmitter or switch.

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#5

Bob McClung

03-27- 08:12 AM

03-27- 08:12 AM

I suggest discussing your concerns with your supervisor and expressing your need for a skilled consultant to assist with the project.

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#6

Ashutosh Sharma

03-27- 10:16 AM

03-27- 10:16 AM

If you seek further information, please visit Mandiwi.

Ensure the motor is compatible with the VFD and verify the air demand in relation to the consumption rate per hour. It is advisable to utilize a screw compressor equipped with a pressure sensor switch.

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#7

Tom Graham

03-27- 01:01 PM

03-27- 01:01 PM

Operating the compressors in an unloaded state allows the VFD to function as a soft starter, minimizing the inrush current and heat generated in the motor windings. This enhances the motor's longevity and facilitates more frequent starts without compromising insulation integrity. An inverter-rated motor is essential.

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#8

Gaurav Tripathi

03-27- 03:35 PM

03-27- 03:35 PM

It's vital to monitor the motor's temperature settings when starting with a VFD frequently, as current surges can lead to temperature fluctuations, resulting in motor tripping.

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#9

Usman Amjad Mir

03-27- 05:42 PM

03-27- 05:42 PM

2. What key parameters should I focus on regarding the air compressor before proceeding with
3. What potential issues may arise from VFD installation that could be proactively addressed?

In addition, I illustrated my inquiry in the succeeding paragraph relevant to points 2 and 3 specified above:

b) Air Compressor - I am particularly concerned about this aspect. Are there internal components within the compressor unit that demand examination? In essence, are there parts or assemblies related to its design and operation that must be considered to prevent operational complications post-VFD installation?

All, I value your contributions, but I am seeking answers to the following: 2. What parameters should be studied for the air compressor prior to VFD installation? 3. What issues might occur due to the VFD installation that could be addressed proactively? The inquiry continues to focus on: b) Air Compressor - which remains my area of concern. Must any internal aspects of the compressor be reviewed before VFD integration to avert operational challenges?

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#10

Alexey Sheinkman

03-27- 08:11 PM

03-27- 08:11 PM

Usman, does your organization lack the necessary funds to hire a qualified consultant? If so, the considerations would be:
2. Basic operations of air compressors.
3. The User Manual associated with your Air Compressor.

Topics:on Variable Frequency Drive

Energy costs constitute over 70% of the total expenditure related to owning and operating a compressor. Luckily, Variable Speed Drive (VSD) technology is accessible and can tremendously minimize your energy consumption. The outcome: reduced operating expenses and a diminished emission footprint.

 

This is how VSD functions. Conventional rotary screw compressors are defined as fixed-speed. Typically, they are either off or on. If you operate in a production environment where the compressed air demand remains constant, a fixed-speed compressor could suffice. Conversely, if your air consumption fluctuates, operating a compressor at full capacity continuously can waste significant amounts of energy. Variable Speed Drive compressors modulate their motor speed to align with your air demands, yielding energy savings of up to 35%. iPM VSD compressors achieve even greater efficiency. They can save up to 45% on energy consumption and costs, partially due to their Interior Permanent Magnet motor.

 

VSD and iPM compressors entail a higher initial investment. Nonetheless, the energy savings generated quickly recover this investment. Your Ceccato representative can assist you in calculating whether a VSD or iPM compressor is the most suitable option for your needs. Their simulations based on your current compressed air requirements will display the timeframe for recouping your investment in VSD or iPM technology.

 

If you require additional information, kindly visit pm vsd screw air compressor.