Compressors

&
Compressed Air Systems

Introduction

Types of compressors

Compressed air systems

Introduction

Air compressor

An air compressor is a device that converts power

(usually from an electric motor, a diesel engine or a
gasoline engine) into kinetic energy by compressing and
pressurizing air, which, on command, can be released in
quick bursts.

Pneumatic Power Supply consists of a Prime mover, a

compressor, and a receiver tank
Prime mover driven by Electric motor
Gas or diesel engine also used
Receiver Tank store energy, provides smooth supply of air
required to the system operation.
Incorporated with Pressure Switch

Significant Inefficiencies associated with compressor

Compressors Range : 5 to 50,000 hp
70 90% of compressed air is lost

Types of compressors

Types of Compressors

Types of Compressors
Reciprocating Compressor
Works like a bicycle pump: cylinder volume reduces
while pressure increases, with pulsating output
Single acting when using one side of the piston, and
double acting when using both sides
Many configurations available

Single stage

Two Stage

Multi stage

Reciprocating Compressor

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Reciprocating Compressor

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Reciprocating Compressor Diagram

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Types of Compressors
Rotary Compressor
Rotors instead of pistons: continuous discharge
Benefits: low cost, compact, low weight, easy to maintain
Sizes between 30 200 hp
Types
Lobe compressor
Screw compressor
Rotary vane / Slide vane

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Rotary screw air compressor internal view

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Diagram of a rotary screw compressor

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Types of Compressors
Centrifugal Compressor
Rotating impeller
transfers energy
to move air
Continuous duty
Designed oil free
High volume
applications
> 12,000 cfm
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Main Components in Compressed Air Systems

Intake air filters
Inter-stage coolers
After coolers
Air dryers
Moisture drain traps
Receivers

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Components in Three stage Compressed Air Systems

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Important Terminologies:

Compressor Cycling 50% on,50% off

Cut-in pressure minimum pressure compressor turns on
Cut-out pressure - maximum pressure compressor turns off

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Comparison of Compressors
Efficiency at full, partial and no load
Noise level
Size
Oil carry-over
Vibration
Maintenance
Capacity
Pressure

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Compressors
Leakages
Consequences
Energy waste: 20 30% of output
Drop in system pressure
Shorter equipment life

Common leakage areas

Couplings, hoses, tubes, fittings
Pressure regulators
Open condensate traps, shut-off valves
Pipe joints, disconnects, thread sealants
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Leak Quantification Method

Total leakage calculation:
Leakage (%) = [(T x 100) / (T + t)]
T = on-load time (minutes)
t = off-load time (minutes)

Well maintained system: less than 10%

leakages

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Assessment of Compressor
Example
Compressor capacity (m3/minute) = 35
Cut in pressure, kg/cm2

= 6.8

Cut out pressure, kg/cm2

= 7.5

Load kW drawn

= 188 kW

Unload kW drawn

= 54 kW

Average Load time

=1.5 min

Average Unload time

= 10.5 min

Leakage = [(1.5)/(1.5+10.5)] x 35 = 4.375 m3/minute

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Portable Air Tank

Campbell Hausfeld
KT0700 - $20
7G
Pressure Gauge
125 PSI Max *
* - Incorporate a safety valve!!!

Portable Air Tank

Campbell Hausfeld
KT0500
5G
Pressure Gauge
125 PSI Max *
* - Incorporate a safety valve!!!

Oil-Free
Craftsman 16734 - $279
Noisy
33 G Storage Tank
6 HP, 110 VAC
150 PSI Max

Oil-Lubricated
Husky VT6314 - $429 *
Quieter
60 G Storage Tank
7 HP, 220 VAC
135 PSI Max
* - No Pressure Regulator

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