COMPRESSORS & COMPRESSED

AIR SYSTEM

Presented By
NAUSHAD AHMAD
Department: Mechanical Maint.
 What are compressors?

Compressors are mechanical devices that

compresses gases. It is widely used in
industries and has various applications

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 How they are different from pumps?

Major difference is that compressors handles the gases and pumps handles
the liquids.

As gases are compressible, the compressor also reduces the volume of gas.

Liquids are relatively incompressible; while some can be compressed

Centrifugal pump
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 What are its applications?
Compressors have many everyday uses, such as in :

 Air conditioners, (car, home)

 Home and industrial refrigeration

 Hydraulic compressors for industrial machines

 Air compressors for industrial manufacturing

Refrigeration compressor

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 What are its various types?
Compressor classification can be described by following flow chart:

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 What are positive displacement compressors?

Positive displacement compressors causes movement by trapping a fixed

amount of air then forcing (displacing) that trapped volume into the discharge
pipe.

It can be further classified according to the mechanism used to move air.

 Rotary Compressor
 Reciprocating compressor

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 Reciprocating compressor

It is a positive-displacement compressor that

 Uses pistons driven by a crankshaft to deliver

gases at high pressure.

The intake gas enters the suction manifold, then

flows into the compression cylinder

It gets compressed by a piston driven in a

reciprocating motion via a crankshaft,

Discharged at higher pressure

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 How to select a
particular type
of compressor ?

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 Selection criteria for compressor

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 Table showing operating conditions of various compressors

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 Advantages and disadvantages of positive displacement
type compressor
Advantages Disadvantages
Positive displacement
compressor
Reciprocating •Wide pressure ratios •Heavy foundation required
•High efficiency •Flow pulsation
•High maintenance

Diaphragm •Very high pressure •Limited capacity range

•Low flow •Periodic replacement of
•No moving seal diaphragm

Screw •Wide application •Expensive

•High efficiency •Unsuitable for corrosive or dirty
•High pressure ratio gases

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 RECIPROCATING COMPRESSORS

Detailed Analysis

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 Block diagram of reciprocating compressor

It is a piston and cylinder

device with (automatic)
spring controlled inlet and
exhaust valves

There is a clearance
between the piston crown
and the top of the
cylinder.

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 Construction of Reciprocating Compressors

 Reciprocating compressors can be divided into two main

groups.

1. Gas end.
2. Power end.

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 Different Parts Of Gas End

Various parts of gas end are:

 Cylinder & liner
 Piston
 Piston rod
 Piston rod packing
 Piston rings
 Valves

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 Different Parts of Power End

Various parts of power end are

 Crank and Crankshaft

 Connecting rod

 crosshead

Crank and crankshaft

Connecting rod crosshead

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 Cycle Analysis
process
1->2 compression
2->3 discharge
3->4 expansion
4->1 induction

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Compressor Performance

1. Capacity of a Compressor- Capacity of a compressor is the full rated volume of flow

of gas compressed and delivered at conditions of total temperature, total pressure, and
composition prevailing at the compressor inlet.

 Free Air Delivery (FAD) i.e. air at atmospheric conditions at any specific location.

The altitude, barometer, and temperature may vary at different localities and at different
times, it follows that this term does not mean air under identical or standard conditions.

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 Simple Capacity Assessment Method
 Isolate compressor and receiver and close receiver outlet
 Empty the receiver and the pipeline from water
 Start the compressor and activate the stopwatch
 Note time taken to attain the normal operational pressure P2 (in the receiver)
from initial pressure P1
 Calculate the capacity FAD:

P2 = Final pressure after filling (kg/cm2a)

P1 = Initial pressure (kg/cm2a) after bleeding)
P0 = Atmospheric pressure (kg/cm2a)
V = Storage volume in m3 which includes receiver, after cooler and delivery piping
T = Time take to build up pressure to P2 in minutes

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 2. Compressor Efficiency
1. Isothermal efficiency

P1 = Absolute intake pressure kg / cm2

Q1 = Free air delivered m3 / hr
r = Pressure ratio P2/P1

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 2. Volumetric efficiency

 Volumetric efficiency = Free air delivered m3/min / Compressor displacement

 Compressor displacement = Π x D2/4 x L x S x χ x n

D = Cylinder bore, meter

L = Cylinder stroke, meter
S = Compressor speed rpm
χ = 1 for single acting and 2 for double acting cylinders
n = No. of cylinders

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COMPRESSED AIR SYSTEM

.
 Introduction
Significant Inefficiencies
 Compressors: 1. 5 to > 50,000 hp
70 – 90% of compressed air is lost

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 Benefits of managed system
 Electricity savings: 20 – 50%
 Maintenance reduced, downtime decreased, production increased and product
quality improved

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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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 Efficient Operation of Compressed Air Systems
1. Location of compressors

Higher altitude = lower volumetric efficiency

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 2. Air Intake
 Keep intake air free from contaminants, dust or moist

Every 250 mm WC pressure drop =2% higher energy consumption

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  Keep intake air temperature low.

Every 4 Deg C rise in inlet air temperature = 1% higher energy consumption

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 3. Cooling Water Circuit
 The compressed air system performance depends upon the effectiveness of inter-
coolers & after coolers, which in turn are dependent on cooling water flow and
temperature.

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 4. Use Inter and After Coolers
 Inlet air temperature rises at each stage of multi-stage machine.
 Inter coolers: heat exchangers that remove heat between stages
 After coolers: reduce air temperature after final stage
 Use water at lower temperature: reduce power

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 5. Cooling Water Circuit
 The compressed air system performance depends upon the effectiveness of inter-
coolers & after coolers, which in turn are dependent on cooling water flow and
temperature.

Increase of 5.5 Deg C in the inlet air temperature to the second stage results in a 2 %
increase in the specific energy consumption.

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 6. Pressure Settings
 Higher pressure

• More power by compressors

• Lower volumetric efficiency

 Operating above operating pressures

• Waste of energy
• Excessive wear

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 1. Reducing delivery pressure

A reduction in the delivery pressure by 1 bar in a compressor would reduce the power
consumption by 6 – 10 %.

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 2. Segregating low and high pressure air requirements

If the low-pressure air requirement is considerable, it is advisable to generate low pressure and high-
pressure air separately, and feed to the respective sections instead of reducing the pressure through
pressure reducing valves, which invariably waste energy.

3. Use blowers in place of Compressed Air System

4. Minimizing Leakage

• Use ultrasonic acoustic detector

• Tighten joints and connections
• Replace faulty equipment

5. Condensate Removal

• Condensate formed as after-cooler reduces discharge air temperature

• Install condensate separator trap to remove condensate

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 Capacity Control of Compressors
1. Automatic On / Off Control:

• Efficient method of controlling

• Motor idle-running losses are eliminated,
• Suitable for small compressors

2. Load and Unload:

• Two-step control where compressor is loaded when there is air demand and unloaded when there is
no air demand.

• During unloading, a positive displacement compressor may consume up to 30 % of the full load
power.

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 3. Multi-step Control:
 Use in Large capacity reciprocating.
 In this type of control, unloading is accomplished in a series of steps, (0%, 25 %, 50 %, 75 % & 100
%) varying from full load down to no-load .

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 Avoid Air Leaks
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:

T = on-load time (minutes)

t = off-load time (minutes)

 Well maintained system: less than 10% leakages

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 Quantifying leaks on the shop floor
 Shut off compressed air operated equipments
 Run compressor to charge the system to set pressure of operation
 Note the time taken for “Load” and “Unload” cycles
 Calculate quantity of leakage

 If Q is actual free air supplied during trial (m3/min), then:

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 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

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 AIR DRYER
Why Do Compressed Air Systems Need Drying?

All atmospheric air contains some water vapor, which will begin to condense into liquid water in the
compressed air or gas system when the air or gas cools past the saturation point, i.e., the point where
it can hold no more water vapor. The temperature at which this happens is known as the dew point.

o Causes rust and increased wear of moving parts

o Can adversely affect the color, adherence, and finish of paint applied by compressed air
o Can jeopardize process industries where many operations are dependent upon the proper functioning
of pneumatic controls. The malfunctioning of these controls due to rust, scale, and clogged orifices
can result in damage to product or in costly shutdowns.
o Can freeze in control lines in cold weather, which may cause faulty operation of controls
o Causes corrosion of air or gas operated instruments, giving false readings, interrupting or shutting
down plant processes.

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Types of Compressed Air Dryer
 Refrigerant type:
 Cycling
 Non-cycling

 Regenerative desiccant type:

 Heatless (no internal or external heaters)
 Heated (internal or external heaters)
 Heat of Compression

 Single Tower
 Deliquescent
 Desiccant
 Membrane

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 Heat of Compression Type Dryers
 Heat of Compression Type Dryers are Regenerative Desiccant Dryers which use
the heat generated during compression to accomplish desiccant regeneration, so
they can be considered as Heat Reactivated. There are two types, the Single
Vessel Type and the Twin Tower Type.

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 Advantages
 Low electrical installation cost.
 Low power costs.
 Minimum floor space.
 No loss of purge air.

Disadvantages
 Applicable only to oil free compressors.
 Applicable only to compressors having a continuously high discharge temperature
 Inconsistent dew point.
 Susceptible to changing ambient and inlet air temperatures.
 Booster heater required for low load (heat) conditions.

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 Working Principle of Heat of Compression Type Dryers
 Consist two vessel “A” and “ B”.

 Vessel “A” will be in service for 4 hrs

Meanwhile vessel “B” is reactivated
which consist of heating 2 ½ hrs and
Cooling for 1 1/2hrs.

 After this vessel “B” is taken in service

and vessel “A” is reactivated.

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 Vessel “A” in service , Vessel “B” in heating

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 Vessel “A” in service , Vessel “B” in Cooling

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THANK YOU FOR YOUR
ATTENTION