Module COMPRESSED AIR

M 15 General

CONTENTS

15.1 Types of Air Compressor

15.2 Compressed Air System Components

15.3 Uses of Compressed Air

15.4 Compressed Air Distribution System

15.5 Compressed Air System Operation

Types of Compressor
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Objectives:
15.1 Identify the types of air compressor in general use; single stage reciprocating, rotary and
axial flow.

1. Compressed air
Compressed air is used for three main purposes in industry:
1. Producing power
2. Process control
3. Instrumentation

The main reasons for using compressed air are as follows:

1. Air is readily available and free.
2. Air is non-toxic and therefore can be exhausted to atmosphere after use.
3. Air can be stored in air receivers. Therefore large amounts can be made available for instant use.
4. Air flow can be easily controlled.
5. Air can be used for linear and rotary functions over a wide range of power and speed.
6. Air can be used for actuating and monitoring functions in process control.
7. Distribution network for a compressed air system is easy to design and inexpensive to produce
and maintain.
8. A compressed air pressure release system prevents the equipment being damaged due to overload.
9. Air leaks in the compressed air system, although undesirable, present no hazard to personnel.
10. Air does not require return piping because it is exhausted to atmosphere.

2. Types of Compressor

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AIR COMPRESSORS

POSITIVE DISPLACEMENT DYNAMIC

DISPLACEMENT

RECIPROCATING ROTARY
1) RADIAL FLOW
1) PISTON 1) SLIDING VANE 2) AXIAL FLOW
2) DIAPHRAGM 2) ROOTES BLOWER 3) MIXED FLOW
3) SCREW

Figure-1 Types of Air Compressors

There are many different types of compressor, but all fall into two main groups:
(1) Positive Displacement compressors.
(2) Dynamic or Centrifugal compressors.

2.1 Positive Displacement Compressors

A positive displacement compressor takes in a certain quantity of air every stroke and compresses it
by reducing its volume (hence increasing the pressure) and then discharges the air at a higher pressure.

There are two groups of positive displacement compressors:

(1) Reciprocating
(2) Rotary

2.1.1 Reciprocating Compressors

(1) Piston type compressor
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(1) Inlet or Suction

(2) Piston
(3) Coolant inlet
(4) LP inlet one way valve
(5) LP outlet one way valve
(6) HP inlet one-way valve
(7) Coolant outlet
(8) Inter-cooler
(9) HP outlet valve
(10) Outlet or discharge
(11) Cylinder or casing
(12) piston rod or connecting rod
(13) Crank shaft

Figure-2 Piston type compressor

The rotating crank causes the piston to reciprocate i.e. move up and down within the cylinder. On the
suction stroke (downward stroke) air is drawn into the cylinder through the inlet non-return valve i.e.
one-way valve. On the delivery stroke (upward stroke) the air is compressed and at a specified
pressure it is released through the outlet non-return valve.
These are simple, relatively cheap, machines suitable for duties such as the inflating of pneumatic
tyres. Their delivery pressure is limited to about 5 bar maximum, and they are usually driven by a
small electric motor. In most reciprocating compressors, the one way valves are generally in the form
of flat discs, and are operated by the pressure of the air (not mechanically as in a reciprocating
engine).

(2) Diaphragm type compressor

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Figure-3 Diaphragm type compressor

The pull rod moves the diaphragm up and down. When the diaphragm is pulled down air is drawn in
through the non-return valve. On return the pull rod pushes the diaphragm and expels the air through
the outlet non-return valve at a higher pressure. This type of compressor is capable of giving oil free
air at pressures up to about 7 bar.

2.1.2 Rotary Compressors

(1) Rotary sliding vane compressor

Figure-3 Rotary sliding vane compressor

This machine is made in a wide range of sizes. It consists of a rotor mounted eccentrically, which
carries sliding vanes or blades in slots. As the rotor rotates, the volume of air trapped at the inlet
between the adjacent blades is progressively compressed and delivered to the outlet at higher pressure.
Oil is injected into the machine to form a seal between the sides and the tips of the sliding vanes and
the casing inner walls. This type of compressor is generally used for delivery pressures not greater
then 5 bar. It is fairly expensive and sometimes referred to as an oil-flooded unit because quite large
quantities of oil are injected into the incoming air and reclaimed later in the system.

(2) Rootes Blower or Straight Lobe Compressor

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Figure-4 Rootes Blower or Lobe Compressor

These are also called multi-lobe compressors. They consist of two specially shaped rotors contained
within a simple casing. The rotors turn in opposite directions, and a small clearance is maintained
between the mating surfaces of the rotors and casing. This is achieved by gearing the rotors together
externally.
Air is drawn through the suction and is trapped between the adjacent rotor lobes and the casing. It is
carried around to the discharge at a higher pressure. These machines are made in a wide range of
sizes. Small Rootes blowers are used for super charging excess combustion air in diesel reciprocating
engines. Large Rootes blowers are used for pressurizing air for process work.
The maximum pressure achieved is about 1 bar, and multi-lobe compressors are used where large
quantities of air required at low pressure. Roote blowers are expensive because it is necessary to
machine the complex rotor form to close tolerances.

(3) Screw or Helical Lobe Compressor

In this compressor the air is displaced by
helically lobed rotors. It is often called a screw
compressor because the rotors resemble as a set
of screws. The air enters through the suction
port and is displaced by the rotating screws
towards the discharge port.

Figure-5 Screw Compressor

A screw compressor may be used when the discharge air must be absolutely free of oil.

2.1.3 Dynamic Compressors

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Figure-6 Dynamic compressor

These are commonly known as fans or turbo-blowers. These machines achieve compression of air by
drawing it into the centre of the rotating impeller that accelerates the air to high speed.
All fans work by aerodynamic action. This refers to the force produced by the action of the impeller
blades on the air. There are three types of air flow:
(1) Axial flow
(2) Radial or centrifugal flow
(3) Mixed flow

(1) Axial flow

Figure-6 (a) Axial flow

In a pure axial flow fan the effective progress of the air is straight through the impeller blades at a
constant distance from the axis. Impeller blade action is the main cause of pressure rise.

(2) Radial or Centrifugal flow

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Figure-6 (b) Radial flow

In a pure radial or centrifugal flow the air enters the impeller axially and progresses radially onwards
through the impeller blades. The centrifugal force resulting from the revolving impeller blades is the
main cause of pressure rise.
In a radial flow fan or centrifugal compressor air leaves the impeller at right angles, passing into the
diffuser casing where it is converted to high pressure. These centrifugal compressors can supply large
volumes of air. Small versions are driven by electric motors or reciprocating engines. Larger
machines may be turbine driven.
A single stage machine cannot achieve a discharge pressure of more than about 2.5 bar.
(3) Mixed flow

Figure-6 (c) Mixed flow

In a mixed flow fan the air enters the fan axially and turns outward through an angle from 30 ° to 90°.
The pressure rise is developed partly by the impeller blades and partly by the centrifugal force.

15.2 Compressed Air System Components

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Objective:
15.2 Describe the function of an air receiver, and air dryer.

1. A typical compressed air system

Figure-7 Compressed Air System

A typical compressed air system consists of the following components:

(1) Air filter
(2) Inter-cooler or dryer
(3) After-cooler or dryer
(4) Air receiver
(5) Automatic drain traps

1.1 Air intake filter

The function of the air intake filter is to remove dust particles from the air prior to suction.

1.2 Inter-cooler
An inter cooler is placed between the low pressure and high pressure stages of a compressor. Its
function is to cool the air between successive stages of compression. thus reducing the temperature
and the moisture (độ ẩm) level.

1.3 After-cooler

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An after-cooler is located between the compressor and the receiver. It further lowers the temperature
of air leaveing the compressor, and removes more moisture. On large plants a moisture separator is
also sometimes fitted.

1.4 Air receiver

Figure-8 Air receiver

The air receiver is a pressure vessel which has the following functions:
(1) to store compressed air at a desired pressure.
(2) to increase cooling of the compressed air.
(3) to remove moisture and to collect residual condensate.
(4) to equalize the pressure variations in the supply due to variations in demand
(5) to damp out pressure pulsation, giving more uniform air flow to tools connected to the air supply.
(6) to support the supply for a short time in the event of a compressor stoppage.

1.5 Automatic drain traps

Automatic drain traps are needed to prevent build-up of condensate in the moisture separator and the
air receiver. They remove the need for manual operation.

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2. Air filtration
To prevent foreign matter in the compressed air causing blockages, and abrasion damage to connected
devices, it is necessary to install filters throughout the system.
The filter should be capable of filtering:
(a) pipe scale
(b) pieces of gasket material
(c) joining compound introduced at assembly or during maintenance
(d) burnt compressor oil that would otherwise form of gums in pneumatic equipment.
Pneumatic equipment often requires a pressure which is lower than that of the air main. Pressure
regulating valves are therefore installed to provide the correct pressure required in a circuit. A
pressure reduction cum filter device is shown in figure-9.

Figure-9 Filter, Regulator, & Lubricator Unit

For pressure regulation, a reduction unit is installed which is usually a combined with a filter,
regulator, lubricator and automatic drain trap to carry out the following functions:
2.1 Filter: removes foreign matter and moisture.
2.2 Regulator: maintains a constant downstream pressure at a level preset or adjusted for a
particular application.
2.3 Lubricator: generates a fine oil mist in the compressed air which is deposited onto the
moving components of the machine and lubricates them.
2.4 Automatic drain trap: discharges the condensate automatically.

3. Compressed Air Dryers

Compressed air has to be dry (i.e. free of moisture) for certain applications. The drying process
involves removing the moisture from the compressed air. In this process chemicals such as
dehydrated lime, magnesium per chlorate, and lithium chloride are used to absorb moisture. These
chemicals need to be changed regularly but are not expensive
A desiccant such as silica gel is used to absorb the water vapour in suspension in the compressed air.
After it has been used for a period of time the desiccant can be regenerated by passing a stream of dry
purge air back through it. Although this system is expensive to install, its maintenance cost is
relatively low.

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15.3 Uses of Compressed Air

Objective:
15.3 List the uses of compressed air, both in the workshop and in plant engineering

1. Uses of Compressed Air

Compressed air has three distinct uses:
1) Direct usage
2) Power provision
3) Control and measurement

1.1 Direct usage

The following are some examples of direct usage of compressed air:
1) Paint spraying
There is a wide range of systems for different applications. A system is selected according to the size
and scope of operation. The paint is fed under air pressure or by gravitational flow to a spray nozzle
where it is atomized by compressed air to the required spray. The velocity of the compressed air
carries the paint spray to the object being painted. To obtain the desired surface finish, the pressure
must be regulated as recommended and the air must be clean and dry.
2) Agitation
Compressed air introduced into tanks of liquids through pipes can cause considerable agitation.
3) Conveying
Various pneumatic conveying systems use compressed air, particularly where long distances and large
driving forces are required.
4) Shot blasting
This is a special way of cleaning the surfaces of objects. It is also known as sand blasting. It is
important that both pressure and speed are regulated

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1.2 Power provision

Compressed air can provide power through actuators that produce two types of motion:
(1) linear motion
(2) rotary motion

(1) Linear Actuator

Figure-10 Linear Actuator

If compressed air is induced through the valve (A) to the rear of the cylinder, the air will exert
pressure (P) on the crown of the piston and cause a thrust (T). This thrust can be converted to a wide
range of uses (to move, turn, bend, form, lift etc.), depending on the method of mounting the actuator.

(2) Rotary Actuator

The rotary actuator depends on a sliding vane motor driven by compressed air. It is similar to the
sliding vane compressor (see Figure-3 in Section 5.1). However, the rotary actuator uses compressed
air to produce rotary motion, whereas the compressor uses rotary motion to compress air. The motor
has to turn at very high speed in order to produce a high power output. Therefore the majority of
these units run at about 20,000 rpm. However, the final output speed is reduced by a small epicycle
gear-box, depending on the application.
Rotary actuators are mainly used to drive hand tools that drill, screw, sand, cut, polish, tighten, loosen
etc. They are also used for mixers and conveyors since variable speeds are achievable. Tools driven
by compressed air are safer than those driven by electric motors. They do not produce sparks and
therefore can be used in fire hazard areas. They are also more resistant to damage. Most of these
units are designed to be used with an air pressure of 5 to 6 bars, and the compressed must be clean and
moisture free.

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1.3 Control and Measurement

(1) Control
Compressed air is frequently used in pneumatic controllers. A flapper nozzle arrangement is a
frequent application to control the temperature of a fluid in the tank.

Figure-11 Fluid Temperature Controller

The purpose of this system is to control the temperature of the fluid in tank (A). As the temperature of
the fluid in tank rises, it causes an increase in vapour pressure in the vapour pressure bulb (B). The
pressure increase is transmitted to the bellows, which expand and activate the flapper (D) to close the
compressed air nozzle (E) resulting in an increased pressure signal to the pneumatically operated
valve (F). The closer the flapper approaches the end of the nozzle the greater the pressure in the
nozzle, and the stronger the signal to the control valve. This causes the control valve to reduce the
steam flow that heats the fluid in the tank (A).
If the temperature of the fluid in the tank decreases the reverse will occur. The pressure signal will
decrease in the nozzle, opening the valve to allow the steam to flow which heats the fluid in the tank
(A).

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(2) Measurement
To start a control sequence, a signal must be sent from one part of the system to another. A pneumatic
signal in the form of pressure change may be set off mechanically by means of a trip valve as shown
in Figure-12.

Figure-12 Pneumatic signal trip valve

A signal like this could be used to start up a production process by detecting the pressure reduction
when an object passes between the nozzle and the pressure sensitive receiver. The signal could also be
used to count objects on a conveyer belt. If two trip valves were located at different heights the signals
could be used to differentiate between short and tall components, so that automatic process could be
obtained.

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15.4 Compressed Air Distribution System

Objective:
15.4 To explain a compressed air system.

1. Compressed Air Distribution System

A typical compressed air distribution system is shown in Figure-13. Compressed air must be
transferred to the point of use in the best possible condition. Therefore the separation of all water and
oil should take place before the air leaves the main receiver and enters the distribution network. This
only happens if expensive dryers are included in the compressed air system. Normally, to assist the
drainage of moisture in the distribution network, the pipes are given a fall of about 1% (fitted at an
angle) in the direction of flow and automatic drain traps are fitted to drain the moisture that is
formed.

Figure-13 Compressed air distribution system

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Wherever possible the distribution network should be in the form of ring mains, because the ring will
reduce the air velocity. This prevents re-entrainment of moisture and also reduces the pressure drop
in the distribution network. In addition, installing a small receiver near the point of use,
accommodates sudden fluctuations in demand.
The branches from the main ring take the compressed air from both directions and therefore helps to
reduce the air velocity which otherwise cause the formation of moisture.
Drainage points should be provided using equal tees. A change in direction of air flow will enhance
the separation of moisture. Also the branch lines should be taken off the top of the main to prevent
moisture in the main ring entering into them.

Figure-14 Ring Circuit of a Compressed Air Installation

1. Air Intake Filter 8. Automatic Drain Trap 16. Precision Controller

2. Compressor 9. Drip Leg Drain 17. Filter
3A. Air Cooler 10. Dryer 18. Regulator
3B. Heat Exchanger 11. Dry Air After Filter 19. "Ultaire" Filter
4. Air Receiver 12. Regulator 20. Pneumatic Drill
5. Safety relief valve 13. Automatic Drain Filter 21. Receiver/Gauge Gun
6. Isolation Valve 14. Lubricator 22. Branch Line
7. Main Line Filter 15. "Ultaire" Filter 23. Pneumatic Grinders

Although large mains are expensive, undersize mains have high air velocities, producing excessive
pressure drop and re-entrainment of moisture
Therefore air mains are usually sized on velocity requirements and a design figure of 6 m/s to 9 m/s is
considered acceptable. In sub-mains higher figures for velocity might be acceptable if there is no
more than a few meters of pipe work. The following formula can be used to determine the size of the
pipe.
v = (1280 Q) / d2 v = velocity in m/s, Q = actual flow rate of air at the pressure of
use in dm3/s, d = inside pipe diameter in mm

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Steel, copper and nylon tubes are used for the construction of compressed air pipe work.
Pressure drop
When sizing both mains and sub-mains, it is important that at a chosen velocity and pipe size the
pressure drop for the system is estimated, and that it is not excessive.

15.5 Compressed Air System Operation

Objective:
15.5 To describe the operation of a compressed air system for a specified condition

1. Compressed Air System Operation

This schematic layout shows the main components of a two-stage reciprocating air compressor
feeding a workshop with a 7 bar supply system.
The atmospheric air is introduced through the intake air filter, which removes dust and dirt. It then
passes into the suction side through the auto-control intake shut off valve and enters the low pressure
cylinder (LP). This is the first stage of the reciprocating compressor.
After first stage compression to 2.5 bar, the compressed air leaves the low pressure (LP) cylinder and
enters the inter cooler. The inter cooler is a water cooled heat exchanger which has a pressure gauge
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scaled 0 to 10 bar and a temperature indicator scaled to 0°C to 120°C. The automatic drain trap drains
the water condensed in the cooler.
After cooling in the inter cooler, the compressed air enters the high-pressure cylinder (HP). This is
the second stage of the reciprocating compressor. After second stage compression to 7 bar, the air
passes to the main receiver through the isolation valve.
The two-stage reciprocating air compressor is driven by a 20 kW, 400 volt, 3 phase electric motor
which is started and stopped by a push button switch. The electrical circuit can be isolated by a circuit
breaker.
The main air receiver is equipped with a pressure gauge, a spring-loaded relief valve and a pressure
sensor, which controls the intake, shut off valve. A blow down valve is provided, together with an
automatic drain trap to drain the condensate.
The compressed air at 7 bar leaves the main receiver through the isolation valve and passes via an
automatic drain trap to the workshop ring main. The inlet pressure of the ring main is given by a
pressure gauge. The ring main carries branches to the point of use via isolation valves where
pneumatic tools are connected. The workshop ring main is also equipped with a pressure gauge and
automatic drain trap.

2 Compressed Air System Control

If the compressor is running and the compressed air is not in full use, the receiver pressure will
rise until the relief valve operates to prevent pressure build up. This is unnecessary and wasteful.
Therefore automatic control is fitted to trip the system as and when the demand falls. Compressed air
system control can take a number of forms:

2.1 Compressor Speed Control.

This method uses a pressure-sensing device to control the speed of the machine, (a) increasing the
speed to cope with increasing demand and (b) decreasing the speed as demand falls. This method is
most used with the dynamic type compressors.
2.2 "Stop & Start" Control
This is a convenient method of control when using small, electrically driven compressors. When the
receiver pressure reaches a certain pre-adjusted level, a pressure sensor provides a signal to stop the
machine. When the receiver pressure falls to a lower level, the pressure sensor signals the pressure
drop and the compressor restarts.
2.3 Intake Shut-off Valve Control
This method is used in Figure-13. An intake shut-off valve in the compressor air intake closes when
the receiver pressure reaches the pre-adjusted level and reopens when the pressure falls. In between
the closing and the opening, the compressor is idle (i.e. the compressor does not discharge any air).
2.4 Inlet valve lifting
In reciprocating compressors a method similar to that of the "intake shut-off valve" is achieved by
using the receiver high pressure signal to hold the inlet valve to the first stage off its seat (i.e. the inlet
valve of the low pressure cylinder remains open). Since the low pressure valve is not closed, no
compression can take place. When the receiver pressure falls, the inlet valve is allowed to close and
normal operation is resumed.

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3 Choice of Compressor System

Generally more than one type of compressor will meet a particular requirement and the choice will
then be made after consideration of following factors:
3.1 The working pressure
The general working pressure required is determined by the type of use of the compressed air.
3.2 The capacity
The capacity of the machine is be obtained by summing up the air requirements for all the tools and
equipment which will be using compressed air, and adding another 25% to cover future expansion.

3.3 The quality of the compressed air

The quality of the compressed air required, including permissible levels of moisture and oil content
must be determined. E.g. In the food industry oil can not be permitted.

3.4 The method of driving the compressor.

The compressor can be driven by electric motor, gas turbine, reciprocating engine etc.

3.5 The method of compressor control.

3.6 The capital & maintenance cost.

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15.6 Assessment Questions

1. Why does a piston compressor require non-return valves?

______________________________________________________________________________
_
2. In the diaphragm type of compressor, which component is most likely to fail?

______________________________________________________________________________
3. For safety purposes, what components are fitted on an air receiver?

______________________________________________________________________________
_
4. The stroke of a piston type compressor is 10 cm and the bore is 8 cm. What will be the intake of
air during the suction stroke?

______________________________________________________________________________
_
5. What would be the effect of varying the rotor speed on a rotary vane compressor?

______________________________________________________________________________
_
6. Name the three types of fan used in the production of compressed air. Explain briefly how each of
them increases air pressure.

______________________________________________________________________________
_

______________________________________________________________________________
_

______________________________________________________________________________
_
7. What are the two main groups of compressors? List examples of each type.

______________________________________________________________________________
_

______________________________________________________________________________
_
7. What are main functions of an air receiver?

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______________________________________________________________________________
_
8. What are the main uses of compressed air?

______________________________________________________________________________
_
9. List the main components of a compressed air system and explain their functions.

______________________________________________________________________________
_

______________________________________________________________________________
10. With aid of Figure-15 suggest a control system that would control the water level in the tank.

Figure-15

11.

a). Use a pencil and rule to draw and connect a workshop ring main with six points suitable for
a small workshop.

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b) Label the Figure-16 and state the functions of each unit.

Figure-16

12.

Sketch a compressed air system for a small factory, which is required to operate two paint sprayers,
two pneumatic tools, a hoist to operate at 5 bar. Also one blower to operate at 7 bar.

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GLOSSARY

1. actuate
2. aerodynamic
3. agitation
4. atmospheric
5. axial
6. bellows
7. capacity
8. centrifugal
9. component
10. compress
11. condensate
12. convey
13. desiccant
14. diaphragm
15. differentiate
16. discharge
17. dynamic
18. eccentric
19. enhance
20. entrain
21. epicyclic gear box
22. flapper
23. impeller
24. isolate
25. linear
26. lobe
27. moisture
28. monitor
29. nozzle
30. pneumatic
31. positive displacement
32. purge
33. reciprocating
34. ring mains
35. rotary
36. rotor
37. sand-blasting
38. sequence
39. silica gel

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40. suction
41. tee
42. tolerance
43. trip valve
44. vane

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