COMPRESSED AIR PLANT

Disediakan Oleh:-
MOHD ZULHAIRI BIN ZULKIPLI
Pensyarah,
Politeknik Ungku Omar
JJ618-Engineering Plant Technology
COMPRESSED AIR SYSTEM
Compressed air systems are safe, reliable and versatile, but they are
usually taken for granted with scant regard to cost. An essential
resource for industry, business and the public sector, compressed air is
often referred to as the fourth utility after electricity, gas and water.
However, unlike the other three, compressed air is generated on-site,
and users therefore have much more control over usage and costs.
Plant air compressor systems can vary in size from a small unit of 5
horsepower (hp) to huge systems with more than 50,000 hp.
Compressed air systems consist of a SUPPLY SIDE, which includes
compressors and air treatment, and a DEMAND SIDE, which includes
distribution and storage systems and END-USE EQUIPMENT. A
properly managed supply side will result in clean, dry, stable air being
Layout Of Compressed Air Plant
Supply Side
Demand
Side
End-use Equipment
Main Components
of Compressed Air Systems
A modern industrial compressed air system is composed of several major sub-
systems and many sub-components.
Major sub-systems include the compressor, prime mover, controls,
treatment equipment and accessories, and the distribution system.
Compressor is the mechanical device that takes in ambient air and
increases its pressure.
Prime mover powers the compressor.
Controls serve to regulate the amount of compressed air being produced.
Treatment equipment removes contaminants from the compressed air,
and accessories keep the system operating properly.
Distribution systems are analogous to wiring in the electrical worldthey
transport compressed air to where it is needed.
Compressed air storage can also serve to improve system performance
and efficiency.
Air Distribution Systems
The air distribution system links the various components of the compressed
air system to deliver air to the points-of-use with minimal pressure loss. The
specific configuration of a distribution system depends on the needs of the
individual plant, but frequently consists of an extended network of main lines,
branch lines, valves, and air hoses. The length of the network should be kept
to a minimum to reduce pressure drop. Air distribution piping should be large
enough in diameter to minimize pressure drop.
There are two basic distribution systems for compressed air are:
1
Single main
2
Ring main
Air Distribution Systems
SINGLE MAIN
This is most suitable for simple installations where the points of use and the
supply are relatively close together. In a well designed system, the maximum
pressure drop should be no greater than 0.2 bar (20kPa). In practice, try to
make the main pipe as large as possible, especially if there may be future
expansion of the system.
Single main pipe with branch lines
Air Distribution Systems
RING MAIN
For larger systems with numerous
take-off points, a ring main is the
preferred layout. Because air is
supplied to any piece of equipment
from two directions the velocity is
halved and the pressure drop
reduced. Another advantage is that
isolation valves can be incorporated
to enable specific sections of the
system to be shut down for
servicing without interrupting the
air flow to other users. Such
systems are more energy efficient.
Ring main with take-off points
Type of Compressor
Positive Displacement Compressor
Reciprocating compressor
- In industry, reciprocating compressors are the most widely used type for
both air and refrigerant compression. They work on the principles of a bicycle
pump and 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.
Dynamic Compressor
Centrifugal Compressors
- Dynamic compressors impart velocity
energy to continuously flowing air or gas
by means of impellers rotating at very
high speeds. The velocity energy is
changed into pressure energy both by
the impellers and the discharge volutes
or diffusers. In the centrifugal-type
dynamic compressors, the shape of the
impeller blades determines the
relationship between air flow and the
pressure (or head) generated.
Accessories
Accessories are the various types of equipment used to treat compressed air
by removing contaminants such as dirt, lubricant, and water; to keep
compressed air systems running smoothly; and to deliver the proper pressure
and quantity of air throughout the system.
Compressor aftercoolers
Filters
Separators
Dryers
Heat recovery equipment
Lubricators
Pressure regulators
Air receivers
Traps
Automatic drains
Accessories
AIR INLET FILTERS
-An air inlet filter protects the compressor from atmospheric airborne
particles. Further filtration is typically needed to protect equipment
downstream of the compressor.
INTERCOOLING
Most multi-stage compressors use intercoolers, which are heat exchangers
that remove the heat of compression between the stages of
compression. Intercooling affects the overall efficiency of the machine.
Accessories
COMPRESSOR COOLING
- Air or gas compression generates heat. As a result, industrial air compressors
that operate continuously generate substantial amounts of heat.
Compressor units are cooled with air, water, and/or lubricant.
Single-acting reciprocating compressors are typically air-cooled using a fan, which
is an integral part of the belt-drive flywheel.
Rotary compressors use the injected lubricant to remove most of the heat of
compression.
Double acting reciprocating air compressors have built-in cooling water jackets
around the cylinders and in the cylinder heads. (water-cooled)
Centrifugal compressors are generally water-cooled.
Accessories
AFTERCOOLERS.
As mechanical energy is applied to a gas for compression, the temperature of
the gas increases. Aftercoolers are installed after the final stage of
compression to reduce the air temperature. As the air temperature is
reduced, water vapor in the air is condensed, separated, collected, and
drained from the system. Most of the condensate from a compressor with
intercooling is removed in the intercooler(s), and the remainder in the
aftercooler.
Accessories
SEPARATORS
Separators are devices that separate liquids entrained in the air or gas. A
separator generally is installed following each intercooler or aftercooler to
remove the condensed moisture. This involves changes in direction and velocity
and may include impingement baffles.
DRYERS
When air leaves an aftercooler and moisture separator, it is typically
saturated. Any further radiant cooling as it passes through the distribution
piping, which may be exposed to colder temperatures, will cause further
condensation of moisture with detrimental effects, such as corrosion and
contamination of point of- use processes. This problem can be avoided by the
proper use of compressed air dryers.
Accessories
HEAT RECOVERY
As noted earlier, compressing air generates heat. In fact, industrial-sized air
compressors generate a substantial amount of heat that can be recovered
and put to useful work. More than 80 percent of the electrical energy going to
a compressor becomes available heat. Heat can be recovered and used for
producing hot water or hot air.
Accessories
LUBRICATION
In lubricant-injected rotary screw compressors, lubricants are designed to
cool, seal, and lubricate moving parts for enhanced performance and
longer wear. Important considerations for compressor lubricants include
proper application and compatibility with downstream equipment, including
piping, hoses, and seals. A lubricator may be installed near a point of- use to
lubricate items such as pneumatic tools. The lubricator may be combined
with a filter and a pressure regulator to make up what is commonly called
a FRL (filter-regulator-lubricator).
Accessories
PRESSURE/FLOW CONTROLLERS
Pressure/flow controllers are optional system pressure controls used in
conjunction with the individual compressor or system controls described
previously. Their primary function is to stabilize system pressure separate
from and more precisely than compressor controls. A pressure/flow controller
is a device that serves to separate the supply side of a compressor system
from the demand side.
AIR RECEIVERS
Receivers are used to provide compressed air storage capacity to meet peak
demand events and help control system pressure by controlling the rate of
pressure change in a system. Receivers are especially effective for systems
with widely varying compressed air flow requirements.
Accessories
TRAPS AND DRAINS
Traps (sometimes called drains) allow the removal of condensate from the
compressed air system. Automatic condensate traps are used to conserve
energy by preventing the loss of air through open petcocks and valves. Poorly
maintained traps can waste a lot of compressed air.
Accessories
LUBRICATION
In lubricant-injected rotary screw compressors, lubricants are designed to
cool, seal, and lubricate moving parts for enhanced performance and
longer wear. Important considerations for compressor lubricants include
proper application and compatibility with downstream equipment, including
piping, hoses, and seals. A lubricator may be installed near a point of- use to
lubricate items such as pneumatic tools. The lubricator may be combined
with a filter and a pressure regulator to make up what is commonly called
a FRL (filter-regulator-lubricator).
Accessories
LUBRICATION
In lubricant-injected rotary screw compressors, lubricants are designed to
cool, seal, and lubricate moving parts for enhanced performance and
longer wear. Important considerations for compressor lubricants include
proper application and compatibility with downstream equipment, including
piping, hoses, and seals. A lubricator may be installed near a point of- use to
lubricate items such as pneumatic tools. The lubricator may be combined
with a filter and a pressure regulator to make up what is commonly called
a FRL (filter-regulator-lubricator).
Components of a Typical Industrial Compressed Air System.
Uses Of Compressed Air
Table 1 : Industrial Sector Uses of Compressed Air
Uses Of Compressed Air
Table 2 : Non-Manufacturing Sector Uses of Compressed Air