Chapter 15

Source of Pneumatic Power

Compressed-Air Unit and Compressor

Objectives
Describe the function of a compressed-air unit. Name and explain the function of each of the components in a compressed-air unit. Identify the basic designs used in air compressor construction. Compare the operating characteristics of positive- and non-positive-displacement air compressors.
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Objectives
Compare the operating characteristics of rotary and reciprocating air compressors. Describe the general construction characteristics of the various compressor types. Explain the operation of the various systems used to control the maximum air pressure available from the compressed-air unit.

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Objectives
Identify the factors that must be considered to estimate the required output of a compressor to meet the air demands of a pneumatic system. Interpret performance data supplied by a compressor manufacturer.

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Compressed-Air Unit
The source of compressed air for a pneumatic system is the compressed-air unit
Prime mover Compressor Other components to condition and store the pressurized air used by the system workstations

Compressed air units vary in size

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Compressed-Air Unit
Very small packages may produce only a fraction of a cubic foot of air per minute (cfm)

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Compressed-Air Unit
Large, industrial units may produce thousands of cfm

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Compressed-Air Unit
Compressed-air units can be classified as portable units or central air supplies
Physical size is not the only factor in placing a unit in one of these classes Easy transport of a unit from one location to another is a more important factor Many portable units have a larger capacity than many stationary central air supplies

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Compressed-Air Unit
A portable unit may be large or small

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Compressed-Air Unit
Portable units allow the compressor to be moved to the work site

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Compressed-Air Unit
A compressed-air unit consists of:
Prime mover Compressor Coupling Receiver Capacity-limiting system Safety valve Air filter May have a cooler and dryer
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Compressed-Air Unit
The prime mover in a compressed-air unit may be:
Electric motor Internal combustion engine Steam or gas turbine

A coupling connects the prime mover to the compressor

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Compressed-Air Unit
Belt coupling

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Compressed-Air Unit
Mechanical coupling

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Basic Compressor Design

A variety of designs are used for air compressors in the compressed-air unit
Reciprocating piston Rotary, sliding vane Rotary screw Dynamic

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Basic Compressor Design

Reciprocating-piston compressors are the most common Rotary screw compressors are popular in new installations

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Basic Compressor Design

Inline, reciprocating compressor

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Basic Compressor Design

The basic operation of any compressor includes three phases
Air intake Air compression Air discharge

Component parts and physical operation varies between compressor designs

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Basic Compressor Classifications

Compressors are classified as:
Positive or non-positive displacement Reciprocating or rotary

Positive-displacement compressors mechanically reduce the compression chamber size to achieved compression Non-positive-displacement compressors use air velocity to increase pressure
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Basic Compressor Classifications

A reciprocating compressor has a positive displacement

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Compressor Design and Operation

Reciprocating compressors use a cylinder and a reciprocating piston to achieve compression Rotary compressors use continuously rotating vanes, screws, or lobed impellers to move and compress the air

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Compressor Design and Operation

Reciprocating compressors are commonly used in pneumatic systems
Very small, single-cylinder, portable compressors for consumer use Large, industrial, stationary units may produce thousands of cubic feet of compressed air per minute

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Compressor Design and Operation

Large, industrial, reciprocating compressor

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Compressor Design and Operation

Reciprocating compressors are available in single- or multiple-cylinder designs Multiple cylinders may be arranged as:
Inline Opposed V type W type Other cylinder configuration
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Compressor Design and Operation

Inline reciprocating compressor

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Compressor Design and Operation

V-type reciprocating compressor

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Compressor Design and Operation

Reciprocating compressors use a single-acting or double-acting compression arrangement
Single-acting compressors compress air during one direction of piston travel Double-acting compressors have two compression chambers, allowing compression on both extension and retraction of the piston

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Compressor Design and Operation

Double-acting compressor

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Compressor Design and Operation

Rotary, sliding-vane compressors use a slotted rotor containing movable vanes to compress air
Rotor is placed off center in a circular compression chamber, allowing the chamber volume to change during rotation These volume changes allow the intake, compression, and discharge of air during compressor rotation

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Compressor Design and Operation

Centrifugal force keeps the vanes in contact with the walls

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Compressor Design and Operation

Rotary screw compressors use intermeshing, helical screws to form chambers that move air from the atmosphere into the system on a continuous basis This produces a nonpulsating flow of air at the desired pressure level

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Compressor Design and Operation

Rotary screw compressors have intermeshing, helical screws

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Compressor Design and Operation

Rotary screw compressors have become popular for larger industrial installations
Lower initial cost Lower maintenance cost Adaptable to sophisticated electronic control systems

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Compressor Design and Operation

Sliding vane and screw compressor designs often inject oil into the airstream moving through the compressors
Reduces wear on vane and screw contact surfaces Improves the seal between the surfaces

Oil is removed by a separator to provide nearoilless compressed air for the pneumatic system

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Compressor Design and Operation

The basic operating theory of dynamic compressors is converting the kinetic energy of high-speed air into pressure Dynamic compressor designs are either:
Centrifugal Axial

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Compressor Design and Operation

Centrifugal dynamic compressor:
An impeller increases airspeed Prime mover energy is converted into kinetic energy as airspeed rapidly increases through the impeller Kinetic energy is converted to air pressure as air movement slows in the volute collector

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Compressor Design and Operation

Centrifugal dynamic compressor

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Compressor Design and Operation

Impeller assembly of a centrifugal dynamic compressor

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Compressor Design and Operation

Axial-flow dynamic compressor:
Rotating rotor blades increase airspeed Fixed stator blades decrease airspeed Kinetic energy is converted to air pressure Series of rotor and stator sections are staged to form the axial-flow compressor

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Compressor Design and Operation

Axial-flow dynamic compressor

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Compressor Design and Operation

Pressure is created when high-speed air is slowed by the fixed stator blades

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Compressor Design and Operation

Dynamic compressor designs are used to compress air and other gases for large, industrial applications
Oil refineries Chemical plants Steel mills

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Compressor Design and Operation

Lobe-type compressors consist of two impellers with two or three lobes that operate in an elongated chamber in the compressor body
Spinning impellers trap air in chambers that form between the lobes As the impellers turn, this trapped air is swept from the inlet port to the outlet port to increase system pressure

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Compressor Design and Operation

Impellers from a lobe-type compressor

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Compressor Design and Operation

Lobe-type compressors are often called blowers They are typically used in applications requiring air pressure of only 10 to 20 psi

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Compressor Design and Operation

Compressor staging involves connecting a number of basic compressor units in series to raise air pressure in small increments This method permits easier control of air temperature, which results in more-efficient compressor package operation

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Compressor Design and Operation

Inline, staged, reciprocating compressor

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Compressor-Capacity Control
Compressor-capacity control refers to the system that matches the compressed-air output to the system-air demand The better the air output of the compressor matches system consumption, the more cost effective the operation of the system

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Compressor-Capacity Control
Compressor-capacity control systems include:
Bypass Start-stop Inlet valve unloading Speed variation Inlet size variation

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Compressor-Capacity Control
Bypass control uses a relief-type valve to exhaust excess air Air is continuously delivered to the system at the compressors maximum flow rate This type of control is not considered desirable as it is inefficient

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Compressor-Capacity Control
Start-stop capacity control is commonly used with small, electric motor-driven compressor packages that operate pneumatic systems consuming air on an intermittent basis

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Compressor-Capacity Control
Start-stop control uses a pressure-sensitive switch to start and stop the compressor to maintain a preselected pressure range

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Compressor-Capacity Control
Start-stop control: compressor start

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Compressor-Capacity Control
Start-stop control: compressor stop

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Compressor-Capacity Control
Inlet valve unloading controls compressor output by holding the inlet valve open whenever maximum system pressure is achieved
Allows the prime mover to operate continuously Can be used in systems having internal combustion engines or electric motors as the prime mover

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Compressor-Capacity Control
Varying compressor speed can control compressor capacity
Can be used with reciprocating and rotary compressor designs Primarily used on large, industrial installations Sensors monitor pressure and send a signal to control compressor speed

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Compressor-Capacity Control
Varying the size of the compressor inlet can control compressor capacity
Compressor operates at a constant speed The volume of air that can enter the compressor is restricted Output varies with the size of the inlet Primarily used on dynamic compressors

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Selecting a Compressor Package

Establishing the level of system air consumption is a key factor when selecting a compressor This can be accomplished by identifying:
Actuators used in the system Compressed-air needs of each item Percentage of time each functions

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Selecting a Compressor Package

Other factors must be considered during system compressor selection
Compressor and prime mover type Method of compressor-capacity control Auxiliary controls such as coolers, separators, and driers

System instrumentation

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Review Question
Compressed-air units may be classified as a(n) _____ or _____.

portable unit; central air supply

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Review Question
List the components found in a typical compressed-air unit and describe their function.
A. Prime mover to supply system energy; B. coupling to mechanically connect prime mover and compressor; C. compressor to pressurize atmospheric air; D. receiver to store conditioned air; E. capacity-limiting switch to limit the maximum pressure produced by the compressor; F. safety valve to vent pressure if the capacity-limiting switch fails; and G. may also include filters, coolers, and dryers.
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Review Question
The simplest compressor in both design and operating theory is the single-acting, _____ compressor. reciprocating

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Review Question
Dynamic compressors can also be classified as _____-displacement compressors.

non-positive

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Review Question
The continuous rotating motion of the compression elements identifies a(n) _____ compressor design. rotary

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Review Question
Describe the double-acting compressor design.
A connecting rod and crosshead are used to convert the rotary motion of the crankshaft to the reciprocating motion. Compression chambers on either side of the piston allow compression and intake during each piston stroke.

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Review Question
In a two-stage, reciprocating compressor, the outlet port of the first compression chamber is connected to the _____ port of a second compression chamber. inlet

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Review Question
Compressor-air output and system-air demand are matched by using some type of _____ system. compressor-capacity control

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Review Question
Name four factors that make selecting a compressor difficult.
A. The variety of compressor designs, B. load variations in a pneumatic system, C. the variety of auxiliary equipment available, and D. demands of future growth of the system.

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