CASE52 · Manufacturing · Compressor staging
Testing the required compressor count with loading and unloading data
Ten-second power, airflow, pressure and operating-state records distinguish useful air production from unloaded running. Stepwise dispatch tests seek efficient base/trim combinations while preserving production pressure.
01 · CASE ANALYSIS
Why running status is insufficient
A compressor can consume electricity while producing little useful air in an unloaded state. Counting running units alone can therefore hide avoidable power.
Large and smaller compressors were analyzed together to separate base-load supply from demand-following trim operation.
02 · CASE ANALYSIS
Align the core measurements
Collect compressor kW, CDA airflow, supply/header pressure, load factor, active units and loading/unloading on one time axis.
Compare system specific energy, electricity divided by delivered air volume. When using kW divided by Nm³/h, the resulting unit is kWh/Nm³; source shorthand must not obscure the time basis.
| State | Data to examine | Diagnostic meaning |
|---|---|---|
| Loading | kW, airflow, pressure and load factor | Useful production and specific energy |
| Unloading | Residual kW, duration and repeated events | Unloaded-energy loss |
| Stopped | Stop duration and next start | Required unit count and transitions |
03 · CASE ANALYSIS
Diagnose transitions and storage
Separate loading, unloading and stopped intervals. Identify additional starts, whether flow actually increased, and how long the added machine remained useful.
Receiver capacity, pressure deadband and sequencing may explain why short peaks trigger unnecessary starts. The lowest average unit count is not enough if terminal pressure becomes unstable.
04 · CASE ANALYSIS
Stepwise dispatch test
Record a baseline, change the running combination during a suitable demand interval, allow stabilization and remeasure total compressor power and service conditions.
Remaining machines may consume more power after one unit stops. Calculate savings from system measurements rather than the stopped unit’s nameplate kW.
| Indicator | Baseline | Changed dispatch |
|---|---|---|
| Active units | Record | Adjust and record |
| Airflow and header/terminal pressure | Measure | Measure |
| Total compressor power | Measure | Measure |
| Loading/unloading duration | Record | Record |
| System specific energy | Calculate | Calculate |
| Production conditions | Confirm normal | Confirm maintained |
05 · CASE ANALYSIS
Verification and transfer
Use comparable airflow, pressure and production conditions or an adjusted baseline where adequate data exist. Establish efficient base/trim roles from actual curves rather than machine size alone.
The source documents field analysis and Test & Adjust logic but does not publish an isolated final saving rate for this case.
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