Fixed speed or variable speed?

The error in
generalizing capacity controls
Juan Jimenez

When sizing an efficient system, our job as compressor based on that capacity and
compressed air consultants is to ensure the pressure. But the challenge is plant production
compressors that are installed in the supply area demand varies throughout the day, or week,
deliver the exact amount of air required by the or year. That means compressors must adapt
plant’s demand area. to those variations, and that’s where capacity
Easy, isn’t it? We simply see how much air controls come in.
we consume on one side and choose the
A problem we typically encounter in the the valve to partially open or close depending
manufacturing industry is looking at only on demand. This control has several benefits;
two capacity control systems: Fixed Speed because the inlet valve modulates a little
Control and Variable Speed Control. This way at a time, the axial loads generated in the
of generalizing limits the conversation and compressor unit are lower compared to the load
deprives the user of finding a suitable system discharge control, which increases the life of the
for installation. There are actually four capacity compressor. A disadvantage of the modulation
control systems in the industry, each with system, however, is the gradual closure of
advantages and disadvantages. the intake valve generates a pressure drop,
which affects the energy consumption of the
equipment.
System One: Load/Unload
Load/unload control works by means of an Considering these two systems are so similar,
intake valve that determines how much air the question may be what system is better
enters the compressor. The valve in these suited for a given operation, modulation, or load/
systems opens at 100% when the compressor unload?
needs to deliver air to the plant and fully closes
the valve when it is no longer required, i.e., the
pressure is at the proper level, the latter state is Simply put, it depends. Based on the
called idle work as the electric motor continues operating curves of both systems [1], if the air
to rotate, but without compressing air. This consumption in the plant is very regular and the
might become a disadvantage since this system compressor works above 70% capacity all the
continues consuming energy from the electric time, then modulation is the best option in terms
motor, even though air is not being compressed. of energy efficiency. But if the system varies
often and the compressor operates at 50% or
60% capacity load/unload can be a good option,
Load/unload is the simplest control system and but only if you have a well-sized storage tank.
therefore, to generate greater energy efficiency The rule in the industry for sizing storage is to
in the compressor, it is necessary to include an have at least 3 gallons per cubic foot produced
air storage tank, which will function as a battery by the compressor. For example, if your
- supplying air when the system demands it. compressor produces 500 cubic feet per minute,
times 3 you would need a 1500-gallon buffer
System Two: Modulation tank, the equivalent of 6,000 liters. Something
else to strongly consider: if your air demand
Modulation capacity control is very similar to
varies greatly, you might want to consider one of
load/unload systems. The main difference is
the next two capacity controls.
instead of the intake valve being 100% open
or closed, it “modulates” the air and allows

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Operation curves of lubricated screw compressors with capacity control load/unload as a function of
charge percentage and installed storage tank capacity [2]

Operating curve of lubricated screw compressors with modulation capacity control. [3]

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System Three: Variable Displacement expensive than the other three systems and they
are the most difficult and expensive to maintain
In Variable displacement technology, the
and repair. Another disadvantage is operating
capacity control is not performed by the
this control at 100% capacity will consume more
intake valve, but by an additional valve that is
energy than any of the other three controls.
pre-installed in the compression block. Also
known as spiral valve, it opens and closes its
ports gradually depending on the demand, Comparing the variable frequency drive and
recirculating the air that is not required to variable displacement control, the latter is
compress in order to deliver only the necessary not susceptible to energy or pollution issues,
air, generating energy savings. This system does and maintenance costs are lower. Also, this
not have the pressure drop disadvantage that equipment can run at 100% without wasting
modulating capacity controls have, making the energy. Although this capacity system is not
variable displacement system very efficient. as energy efficient at low loads as the variable
frequency drive, it is the most versatile and
can work in a wide operating range with high
System Four: Variable Frequency reliability and low operating costs.
Drive
Frequency variable capacity control uses an
The four capacity controls in the compressed
inverter or variable frequency drive to reduce
air industry provide various advantages
the revolutions of the electric motor and the
and disadvantages and require a number of
compressor block delivering only the air that
questions to be analyzed and answered to
is needed. This method of control is the most
correctly to size the compressor to the operating
efficient if the compressor is working at 50% or
system. To lump these systems into only fixed
60% of capacity. However, if you are working at
speed and variable speed limits the analysis. In
these percentages most of the time, you should
the end, the important thing to know is which
consider right sizing your operations with a
capacity control will send the necessary amount
smaller compressor.
of compressed air to the plant in the most
efficient way possible.
With variable capacity controllers and variable
frequency drive controllers, the question
If you have any doubts which capacity control
of which system is better, depends on the
your compressed air equipment uses or how
application. Both systems work well working
to choose the best system for your current
under the operating ranges of 50% or 60%.
installation, contact your knowledgeable Sullair
However, systems that utilize a variable
sales representative.
frequency drive are the most efficient but
are also more susceptible to break down if
problems of power supply or contamination in [1] [2] [3] Improving Compressed Air System
the environment exist. These are also the most Performance, Compressed Air Challenge & U.S.
expensive controls, almost 25% or 30% more Department of Energy, 3rd edition.

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