Modernisation of screw compressors: how integrating a frequency converter saves up to 35% in energy and eliminates the need for a generator
Modern Ukrainian businesses operate in a challenging environment: an unstable energy supply, constantly rising electricity tariffs and the need for rigorous optimisation of operating costs (OPEX). In such circumstances, the efficiency of industrial equipment becomes a matter of the company’s survival. One of the main consumers of resources in any production facility is the compressed air system. If your site is equipped with a reliable compressor operating on the traditional ‘load/unload’ cycle, you are overpaying for excess capacity every day. Dalgakiran Compressor Ukraine offers a highly efficient engineering solution – retrofitting your compressor with variable-speed drive technology directly at your production site. This is a practical way to adapt your existing fleet of equipment to modern requirements without the need for capital investment in new units.
Why a compressor without variable-frequency drive leads to overspending and risks for the power grid
Most industrial screw compressors designed in previous years are fitted with fixed-speed electric motors. However, actual compressed air consumption in production is almost never linear: it varies depending on shifts, the connection of new lines or production downtime.
When the demand for air drops, a standard compressor will switch to idle mode. In this state, it continues to rotate the screw block whilst consuming between 30% and 40% of its rated power without producing any useful output. This represents a direct financial loss for the company.
The issue of compatibility with off-grid power sources
A separate and most critical challenge today is running the compressor from a generator. When the engine is started using a direct start or even a ‘star-delta’ start circuit, the screw compressor generates enormous starting currents, which are 5–7 times higher than the rated values.
To ensure such a start, the company is forced to purchase a diesel generator with a huge (and often excessive) power reserve. If, however, the autonomous power source lacks sufficient capacity, every compressor start-up leads to a voltage dip in the local network, an emergency shutdown of the generator, or the failure of sensitive control systems.
Retrofitting instead of buying new equipment: how the service works
Purchasing a new compressor with a factory-fitted frequency converter is a reliable but capital-intensive (CAPEX) solution, which is not always the most sensible option if your current compressor is in excellent technical condition.
Upgrading screw compressors from ‘Dalgakiran Compressor Ukraine’ is a cost-effective alternative. Our specialists integrate a variable frequency drive (VFD) for the compressor into the existing equipment control system.
Cost savings: The cost of the VFD and its installation is significantly lower than purchasing a new compressor of equivalent capacity.
Speed of implementation: All work is carried out on a turnkey basis directly at the customer’s site, minimising production line downtime.
Technical compatibility: Screw compressors from most well-known global brands are eligible for modernisation, regardless of their year of manufacture.
Key benefits of integrating a variable frequency drive
The introduction of variable frequency control radically changes the operating algorithm of the pneumatic system. Instead of ‘start-stop’ cycles, the VFD flexibly adjusts the electric motor’s speed to match the current air flow. This provides a number of strategic advantages:
Smooth compressor start-up (Soft Start): The variable frequency drive accelerates the motor smoothly, completely eliminating current surges in the mains supply. Start-up currents are reduced to nominal levels (1:1).
Stable pressure in the pneumatic network: The VFD maintains the set pressure with an accuracy of 0.1 bar. The elimination of pressure fluctuations removes the need to maintain ‘reserve’ high pressure in the receivers, which further reduces energy consumption.
High energy efficiency of compressor equipment: Electricity savings range from 30% to 35%. On the scale of an industrial enterprise, this allows the modernisation to pay for itself within a period ranging from several months to one year.
Fuel savings for diesel generator sets: Reduced energy consumption by the compressor and the elimination of start-up peaks allow the use of a lower-capacity generator and significantly (by up to 20–25 per cent) reduce the consumption of scarce diesel fuel.
Engine protection and extended service life: The absence of hydrodynamic and mechanical shocks during start-ups reduces wear on the screw block, bearings, drive belts and couplings, and extends the service interval.
Professional modernisation of compressor equipment by ‘Dalgakiran’
Successful integration of a variable frequency drive requires precise engineering calculations. It is not enough simply to purchase and connect the VFD — it is necessary to take into account the motor’s thermal conditions at low speeds (a forced cooling system is installed where required), and to configure the compressor controller and protective automation systems.
The specialists at ‘Dalgakiran Compressor Ukraine’ provide a full modernisation cycle:
Assessment of the technical condition and audit of the existing compressed air system.
Design of the solution and selection of the optimal VFD model.
Installation, integration into the control cabinet, programming and commissioning.
Ongoing compressor servicing and 24/7 technical support.
Direct import of frequency converters. Our own spare parts warehouse.
Are you ready to optimise your company’s costs?
Contact the experts at “Dalgakiran Compressor Ukraine” today. We will carry out a detailed technical audit of your compressed air network, calculate the exact payback period for your production facility, and ensure the stable operation of your equipment regardless of any energy challenges. Submit a request for a free consultation with an engineer!
0800 30 13 77
0800 30 13 77
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