JJ618 PLANT ENGINEERING TECHNOLOGY

COMPRESSED AIR PLANT

COMPRESSED AIR PLANT

1.0 COMPRESSED AIR PLANT SYSTEM
1.1 The function of compressed air plant
Compressed air plant used widely in many industries. It is can be assume as a heart of industry.
Some of the usage of compressed air plate is:
1.
2.
3.
4.
5.
6.

Handling reciprocating tools such as rivet gun, hammer and others

Handling rotating tools such as air motor, grinder, drill, reamer, air pump and others
Use as spraying mechanism; paint, oil, pesticide, and others
Handling air piston to energize tools such as pressing, lifting and clamping.
Air spray for cleaning purpose.
Pneumatic system

1.2 Typical compressed air plant layout.

First of all, air will suck to the system by an air compressor. But, before it, a filter is attach in
compressor inlet to avoid dust and bad particle from enter the system. Usually, compressed air
plant have two compressor. Between both compressor, an intercooler was installed to increase
system efficiency. After second compressor, an aftercooler was attach to clarify between true air
and vapor. The fluid then enter water separator. As it's name, water separator remove water from
the system. The dryer then use to purify the air. A clean air then store on receiver tank. From
receiver tank, a clean air will supply to end user. But, once again the air must through the dryer.
After that, it must through pass an oil separator (oil removal). This is important to to remove
lubricant that use to lubricate compressor. Lastly, the clean air supply to local end user through
pressure regulator and gauge.

Figure: Typical air compressor plant

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1.3 Compressed Air Plant Equipment and Component

1.3.1

Air Filter

A particulate air filter is a device composed of fibrous materials which removes solid particulates
such as dust, pollen, mold, moisture, and bacteria from the air.
1.3.2

Driver

Usually, the compressor in compressed air plant drives by either electric motor or internal
combustion engine.

Picture: Typical motor electric driver

1.3.3

Compressor

Compresses air to a small volume, increasing the air pressure.

1.3.4

Air Inter Coolers

In a multi-stage unit compressor, the air is compressed in succeeding cylinders, getting hotter and
hotter along the way. An intercooler will be installed between the cylinders to help cool the air
before it is ingested into the next cylinder for further compression. This aids in the compressor's
efficiency. Intercoolers in multi-stage units may function through air cooling or water cooling.
In air cooling the compressed air will pass through a chamber, on the outside of which, is
substantially increased surface area - sometimes called fins - exposed to the ambient
environment. The increased surface area will allow the heat inside the compressed air line to
move more readily to the surface and to escape into an area of lower temperature.

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Figure: Two stage compressor with intercooler

1.3.5

Aftercoolers

Compressed air discharged from an air compressor is hot (refer figure below). Compressed air at
these temperatures contains large quantities of water in vapor form. As the compressed air cools
this water vapor condenses into a liquid form. As an example if an aftercooler is not used, a 200
scfm compressor operating at 100 psig introduces 45 gallons of water into the compressed air
system each day.

Figure: Aftercooler system

1.3.6

Water Separator

During the process of compressing air, atmospheric air along with water vapor and atmospheric
contaminants (hydrocarbon or chemical vapors), are drawn into the compressor intake.
Additionally, the compression chambers of most compressors require oil for lubrication, sealing
and cooling. Once compressed, the air flows into an aftercooler to remove the heat of
compression. As the air cools in the aftercooler, water and hydrocarbon vapors will condense.
Additional condensation takes place as the air is further cooled in the piping and air dryers. This
condensed moisture must be removed from the compressed air system to prevent damage to
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COMPRESSED AIR PLANT

downstream components and processes. Drain valves are installed on moisture separators,
coalescing filters, air receivers, air dryers and drip legs to remove this condensate from the
compressed air system. The condensate should be piped from automatic drain valves to oil/water
separators to remove the oil from the condensate prior to discharge to a drain.
(By referring figure below) Compressed air enters at point A (air in) and first is made to rotate
within an outer chamber at high speed removing moisture, small particulate and oil. The removed
material is drained into the bottom bowl via holes B at the bottom of the outer chamber to collect
and be removed from the system utilizing the automatic drain C. The compressed air in the
outer chamber is then directed into an inner chamber D for a second rotation and a lower speed
preventing any back suction of particulate, oil or moisture. The 99.9% dry, clean compressed air
is then directed out and back into the system at point E. This patent pending two stage rotation
allows for the high level of clean, dry air with only one unit.

Figure: Water separator system

1.3.7

Dryer

Helps to eliminate any remaining moisture in the compressed air by using either a refrigerated
condenser or a desiccant. Refrigerated condensers cool the air to condense water vapors into a
liquid that is then drained from the system.
Desiccants are powders or gels that remove water by absorbing it. A compressed air dryer is a
device for removing water vapor from compressed air. Compressed air dryers are commonly
found in a wide range of industrial and commercial facilities.
The process of air compression concentrates atmospheric contaminants, including water vapor.
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This raises the dew point of the compressed air relative to free atmospheric air and leads to
condensation within pipes as the compressed air cools downstream of the compressor.
Excessive water in compressed air, in either the liquid or vapor phase, can cause a variety of
operational problems for users of compressed air. These include freezing of outdoor air lines,
corrosion in piping and equipment, malfunctioning of pneumatic process control instruments,
fouling of processes and products, and more.

Figure: One from various type of air dryer

1.3.8

Air receiver tanks

Air receiver tanks are designed to provide a supply buffer to meet short-term demand spikes that
can exceed the compressor capacity. They also serve to dampen reciprocating compressor
pulsations, separate out particles and liquids, and make the compressed air system easier to
control. In some cases, installing a larger air receiver tank to meet occasional peak demands can
even allow for the use of a smaller compressor.
Air receivers in compressed air systems serve the important purposes of:
1. Equalizing the pressure variation from the start/stop and modulating sequence of the
compressor
2. Storage of air volume equalizing the variation in consumption and demand from the system
3. Collecting condensate and water in the air after the compressor

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Picture: Air receiver tank

1.3.9

Pressure regulator

Pressure regulator use to controls air pressure and flow at individual points of use. Furthermore,
the regulator will attempt to maintain and control the outlet pressure within limits as other
conditions vary but the regulator will not control flow, only the delivery pressure. A regulator is also
not to be used as a shut-off device as there is always a small amount of leakage across the seat.
A shut-off valve must be used downstream of the regulator if isolation is required
1.3.10 Pressure gauge
Usually the pressure gauge was attached to pressure regulator. The pressure gauge help the
user to know the pressure that through out the pressure regulator.

Figure: Pressure regulator and pressure gauge unit

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1.3.11

Distribution Piping

Links the components. It distributes the air from a main header to branch lines and sub headers
to drop points connected to individual tools.
1.3.12

Lubricant

Most factories and manufacturing facilities use compressed air systems for a variety of
applications, and keeping these air compressors running is critical to keeping the entire operation
running. Nearly all air compressors require a form of lubricant to cool, seal or lubricate internal
components. Proper lubrication will ensure that your equipment will continue operating, and the
plant will avoid costly downtime and repairs.
Proper lubrication also will help air compressors run cooler and consume less electrical energy. It
is simple: reduced friction = reduced heat = reduced energy consumption. Compressed air
systems in most manufacturing plants consume a majority of the daily power requirements, so if
you are looking for a continuous improvement project, reducing energy costs through better
lubricant practices is a sure winner.
1.4 Advantages of compressed air plant as working agent
1.
2.
3.
4.
5.
6.
7.
8.

Air can't explode. Therefore, an expensive explosive prevention equipment is not require
Air system can be control at high velocity, up to 10m/s
Delivery system of air is simple and can be deliver at long distance
Air is clean
Recycle system is not required
The system is flexible
Air pressure and velocity can be adjust easily without considering the system capacity
Air compressed system relatively cheap.

2.0 COMPRESSOR TYPE

Compressors are broadly classified as: Positive displacement compressor and Dynamic
Compressor.
Positive displacement compressors increase the pressure of the gas by reducing the volume.
Positive displacement compressors are further classified as reciprocating and rotary
Compressors.
Dynamic compressors increase the air velocity, which is then converted to increased pressure
at the outlet. Dynamic compressors are basically centrifugal compressors and are further
classified as radial and axial flow types.
The flow and pressure requirements of a given application determine the suitability of a
particulars
type of compressor.

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Figure: Compressor family

2.1 Positive Displacement Compressors
2.1.1

Reciprocating Compressors

Reciprocating compressors are the most widely used type for air compression. They are
characterized by a flow output that remains nearly constant over a range of discharge pressures.
Also, the compressor capacity is directly proportional to the speed. The output, however, is a
pulsating one.
Reciprocating compressors are available in many configurations, the four most widely used of
which are horizontal, vertical, horizontal balance-opposed and tandem.
Vertical type reciprocating compressors are used in the capacity range of 50 150 cfm.
Horizontal balance opposed compressors are used in the capacity range of 200 5000 cfm in
multi-stage design and upto 10,000 cfm in single stage designs.
Reciprocating compressors are also available in variety of types:
Lubricated and non-lubricated
Single or multiple cylinder
Water or air-cooled.
Single or multi stage
In the case of lubricated machines, oil has to be separated from the discharge air. Non-lubricated
compressors are especially useful for providing air for instrumentation and for processes
which require oil free discharge. However non-lubricated machines have higher specific power
consumption (kW/cfm) as compared to lubricated types.
Single cylinder machines are generally air-cooled, while multi-cylinder machines are generally
water cooled, although multi-stage air-cooled types are available for machines up to 100
kW. Water-cooled systems are more energy efficient than air-cooled systems.
Two stage machines are used for high pressures and are characterized by lower discharge
temperature (140 to 160C) compared to single-stage machines (205 to 240C). In some cases,
multi-stage machines may have a lower specific power consumption compared to single stage
machines operating over the same total pressure differential. Multi-stage machines generally
have higher investment costs, particularly for applications with high discharge pressure (above 7
bar) and low capacities (less than 25 cfm). Multi staging has other benefits, such as reduced
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pressure differential across cylinders, which reduces the load and stress on compressor
components such as valves and piston rings.
The main advantages of the reciprocating compressor are that it can achieve high pressure ratios
(but at comparatively low mass flow rates) and is relatively cheap.
It is a piston and cylinder device with (automatic) spring controlled inlet and exhaust valves.
Delivery is usually to a receiver. The receiver is effectively a store of energy used to drive (eg)
compressed air tools.
Reciprocating compressors usually compress air but are also used in refrigeration where they
compress a superheated vapour (to which the gas laws strictly do not apply).
In order to be practical there is a clearance between the piston crown and the top of the cylinder.
Air 'trapped' in this clearance volume is never delivered, it expands as the piston moves back and
limits the volume of fresh air which can be induced to a value less than the swept volume.

Figure: Reciprocating compressor system

2.1.2

Rotary Compressors

Rotary compressors have rotors in place of pistons and give a continuous, pulsation free
discharge air. They are directly coupled to the prime mover and require lower starting torque as
compared to reciprocating machine. They operate at high speed and generally provide higher
throughput than reciprocating compressors.
Also they require smaller foundations, vibrate less, and have a lower number of parts - which
means less failure rate. Among rotary compressor, the Roots blower (also called as lobe
compressor) and screw compressors are among the most widely used. The roots blower is
essentially a low-pressure blower and is limited to a discharge pressure of 1 bar in single-stage
design and up to 2.2 bar in two stage design.
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The most common rotary air compressor is the single stage helical or spiral lube oil flooded screw
air compressor. These compressors consist of two rotors, within a casing where the rotors
compress the air internally. There are no valves. These units are basically oil cooled (with air
cooled or water cooled oil coolers) where the oil seals the internal clearances. Since the cooling
takes place right inside the compressor, the working parts never experience extreme operating
temperatures.
The oil has to be separated from discharge air. Because of the simple design and few wearing
parts, rotary screw air compressors are easy to maintain, to operate and install. The oil free rotary
screw air compressor uses specially designed air ends to compress air without oil in the
compression chamber producing true oil free air.
These compressors are available as aircooled or water cooled types and provide the same
flexibility as oil flooded rotary compressors. There is a wide range of availability in configuration
and in pressure and capacity. Dry types deliver oil-free air and are available in sizes up to 20,000
cfm and pressure upto 15 bar. Lubricated types are available in sizes ranging from 100 to 1000
cfm, with discharge pressure up to 10 bar.

Figure: Root blower compressor

Figure: Root blower compressor operating system

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2.2 Dynamic Compressors

Dynamic compressors are mainly centrifugal compressors and operate on similar principles
to centrifugal pump. These compressors have appreciably different characteristics as compared
to reciprocating machines. A small change in compression ratio produces a marked change in
compressor output and efficiency.
Centrifugal machines are better suited for applications requiring very high capacities, typically
above 12,000 cfm. The centrifugal air compressor depends on transfer of energy from a rotating
impeller to the air. The rotor accomplishes this by changing the momentum and pressure of the
air. This momentum is converted to useful pressure by slowing the air down in a stationary
diffuser.
The centrifugal air compressor is an oil free compressor by design. The oil-lubricated running
gear is separated from the air by shaft seals and atmospheric vents. The centrifugal is a
continuous duty compressor, with few moving parts, and is particularly suited to high volume
applications, especially where oil free air is required.
A single-stage centrifugal machine can provide the same capacity as a multi-stage reciprocating
compressor. Machines with either axial or radial flow impellers are available.
Axial flow compressors are suitable for higher compression ratios and are generally more
efficient than radial compressors. Axial compressors typically are multi-stage machines, while
radial machines are usually single-stage designs.

Figure: Axial compressor

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Figure: Radial compressor

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. It sometimes means actual flow rate, rather than rated volume of flow. This also termed
as Free Air Delivery (FAD) i.e. air at atmospheric conditions at any specific location. Because
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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