Improving Energy Efficiency of Compressed Air Systems

Course Overview

In this workshop, you will learn the essentials of compressed air systems for improving their energy efficiency. It includes compressed air system design from compressor to end use, piping and fittings, materials, codes and standards, and waste heat recovery.


Learn how to optimize the system for performance, to create and maintain balance between system supply and end user demand, and to eliminate leakage and inappropriate use of compressed air. You will also gain an understanding of the maintenance issues, the cost of air leakage, the methods of detecting and correcting system faults to ensure smooth operation.


Course Duration

16


Total Training Duration (Hour)

16


Course Outline

Day 1


Session 1: General Introduction

  • Compressed Air System Components - Air compressors, air dryers, Filters, Aftercoolers, Drain Traps, Regulators
  • Definitions
  • Standard Rating Conditions
  • Uses of compressed air


Session 2 - Type of Compressors

  • Oil Lubricated vs. Dry Compressors
  • Reciprocating, Rotary Screw and Centrifugal Compressors
  • Air Compressor Drivers (motor, steam turbine, gas turbine and gas/diesel engine)
  • Performance Data Sheets
  • Specifying Compressors
  • Strategies for Improving Energy Efficiency of Air Compression
  • Cost of Compressed Air
  • Class Exercises


Session 3 - Storage & Dryers

  • Air Receiver Sizing
  • Estimation of Free Air Demand (FAD)
  • Dew Point Temperature
  • Types of Dryers (Chemical Deliquescent, Refrigerant, Heated/heatless, Heat of compression and Membrane types)
  • Advantages and Disadvantages of Dryers
  • Class Exercises


Session 4: Leaks, Inappropriate Usage and Air Audit

  • Estimation of Leaks; Artificial Demand; Inappropriate Usage
  • Importance of Air Measurements
  • Audit of Compressed Air Systems
  • Sensors & Data Analysis
  • Maintenance Aspects; Preventive Maintenance, Safety
  • Class Exercises



Day 2


Session 1 - Theory of Compression

  • Isothermal, Adiabatic and Polytropic Compression
  • Power Consumption
  • Single Stage vs. Multistage Compression
  • Effect of Intercooling
  • Air Intake Temperature
  • Case Studies and Exercises


Session 2A: Waste heat Recovery


  • Direct/Indirect Waste Heat Recovery from Air Compressor
  • Heat of Compression Dryer
  • Case Studies and Exercises


Session 2B: Compressor Controls

  • On/Off; Load/Unload Controls
  • Inlet Modulation Control
  • Variable Speed Drive (VSD) Control
  • Case Studies and Exercises


Session 3: Compressed Air System Design


  • Design Considerations
  • Air Demand
  • Selecting Type and Size of Compressor
  • Case Studies and Exercise


Session 4: Piping System Design

  • Pipe Losses; Fitting Losses; Pipe Sizing
  • Case Studies and Exercise



Certification Obtained and Conferred by

All participants will receive a Certificate of Attendance from SEAS upon completion.


SCEM: 14 PDU Points

GMAP: 6

PE PDU: 12


Medium of Instruction & Trainer

Prof. Gade Pandu Rangaiah has been with the National University of Singapore (NUS) since 1982, in the Department of Chemical & Biomolecular Engineering. He received his Bachelor, Masters & Doctoral Degrees in Chemical Engineering from Andhra University, IIT Kanpur and Monash University respectively. He worked in Engineers India Limited for 2 years before his Doctoral study. Prof. Rangaiah was recognized with Annual Teaching Excellence Awards by NUS for 4 consecutive years.


Dr. Chirla Chandra Sekhara Reddy is Technology & Optimization Manager at Singapore Refining Company Private Limited, where he leads a range of activities such as Technology, Optimization, Project Development, Process Engineering, Plant

Troubleshooting and Process Safety. He holds Bachelors and Doctoral Degrees in Chemical Engineering from Andhra University and Master Degree in Chemical Engineering from IIT Kanpur. He also holds MBA Degree from Murdoch University. He has 22 years of rich diverse experiences in Process Engineering, Project Management, Technical services, Operations Optimization and Process Safety in Refinery, Petrochemical, Chemical and Utility plants.


Price
Course Fee Payable
Original Fee Before GST With GST (9%)
Course Fee $1,100.00 $1,199.00

Standard Rate: $1,100 (Before GST)

SEAS Member: $990 (Before GST) [Apply SEASMEMBER10 promo code upon check out]

SCEM: $1,045 (Before GST) [Apply SCEM5 promo code upon check out]


Please apply respective promo codes upon check out if you are eligible for the above discount for SEAS Member or SCEM. For verification purposes, please provide your SCEM or SEAS Member registration number in the application form.

Please note that prices are subject to change.
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