A lightly loaded compressor would consume about 55% of rated power at about 30% load, much better efficiency.Ī much more efficient way to run compressors is to have them start and stop, which is the way reciprocating compressors operate. With load/unload control, the compressor alternates between loaded (producing air) and unloaded (no output) condition, all the while keeping the compressor motor running, still consuming power. For example, for lightly loaded compressors such as in service shops, this would cause the compressor to run constantly while consuming about 80% of its rated power even though it might be only 30% loaded, consuming more than 2.5 times the required energy. This is nice and simple-and gives good pressure control, but is very inefficient in terms of energy consumption. With modulation, a control valve chokes off the inlet of the compressor to control the flow and pressure. The two most common are called “modulation” and “load/unload” control. Screw compressors have a few different ways to control the output to match the actual system flow. But running constantly usually means the units are not very efficient. If you have multiple compressors, your system should be set up so as not to allow constant operation.įor screw compressors, the cooling systems are much better, so the compressors can run constantly with no issues. If your reciprocating compressors are never turning off, you should investigate. When damage occurs, the compressor can experience valve failures, causing the compressors to run constantly. Reciprocating units need time to stop and cool off, or the internals will become damaged. But this simple system is problematic in that the compressor will usually overheat if the it runs more than about 50% duty cycle. The system is simple in order to keep the manufacturing costs down. These units generate lots of heat, but usually have quite basic cooling systems, typically consisting of a simple fan on a pulley blowing on cooling fins. If you have reciprocating compressors, then these definitely should not be running all the time without regularly shutting off. These compressor types have different characteristics, so depending on what type you have, the answer varies. There are two basic types of compressors commonly found in shops and manufacturing plants: reciprocating and screw type. The most obvious thing you should check for is leaks or a system machine malfunction that could be consuming excess air, but failing that here are some things to consider. It is very rare to see system compressors exactly match the facility demand, requiring the need for constant full-load operation. If your air compressor is constantly running without shutting off, this could be a sign of a problem-and it is probably costing you a bundle.
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