Air

Compressors
 4.0Compressed Air Plant
 4.1Demonstrate the compresses air plant system and construct
types of compressor.
 4.1.1Demonstrate the compresses air plant system;
 4.1.1.1Demonstrate the main equipment in compressed air plant and
list its functions.
 4.1.1.2Draw the layout of compressed air plant
 4.1.1.3Demonstrate equipment and usage of compressed air plant
 4.1.1.4Construct the advantages of using compressed airplant as
working agent and list examples of its usage.
 4.1.2Construct types of compressor;
 4.1.2.1Demonstrate the various types of compressors.
 4.1.2.2Construct Positive displacement Compressor
 4.1.2.3Demonstrate the main parts of positive displacement
compressor and its functions.
 4.1.2.4Construct the Rotor Dynamic Compressor
 4.1.2.5Demonstrate the main parts of rotor dynamic air compressor and its
functions.
 4.2Demonstrate extra equipment in compressed air system and apply the new
technology used in compressed air plant system;
 4.2.1Demonstrate extraequipment in compressed air system;
 4.2.1.1Demonstrate Free Air Delivery (FAD).
 4.2.1.2Construct the purpose of using the following auxiliary equipment’s in
compressed air system:a. Lubricantb. Filterc. Pressure regulatord. Water trapper
 4.2.1.3Demonstrate factors to be considered in the arrangement of
compressed air factory.
 4.2.2Apply the new technology used in compresses air plant system;
 4.2.2.1Allocate the industries that used new technology in this system
 4.2.2.2Demonstrate the concepts applied by the industries above
 An air compressor is a mechanical device that
increases the pressure of air by reducing volume.
 Air is compressible, the compressor reduces the
volume of air and induces pressure in the air
 An air compressor converts electrical energy into
kinetic energy in the form of the air
 The compressed air is stored in the air receiver and
can be used for cleaning under pressure, generating
torque and develop force using actuators
 This source is free of cost, safe, flexible and
convenient
 Air compressor has very few parts hence
maintenance is very low
Applications of compressed air

1) For spray painting in automobile industry.

2) To operate air brakes in automobiles,
pneumatic conveyers.
3) Air condition applications.
4) In blast furnaces.
5)In aeroplane application (Axial air compressors).
6) To supercharge IC engines.
7) Filling tyres in automobile tyres.
8) For driving mining tools.
9) For convey materials like concrete, sand along
pipelines.
 Pneumatics: A system which uses
compressed air is called pneumatics.
 It deals with the study of behaviour &
application of compressed air
 A basic pneumatic system consist of a
source of compressed air, control valves,
pipelines & pipe fittings and pneumatic
accessories like filter, regulator and
lubricator
 For drive of CNC machine tools
 For pneumatic conveying of materials
 For pneumatic gauging, inspection and low cost
automation systems
 An air compressor is a mechanical device that
increases the pressure of air by reducing volume.
 Air is compressible, the compressor reduces the
volume of air and induces pressure in the air
 An air compressor converts electrical energy into
kinetic energy in the form of the air
 The compressed air is stored in the air receiver
and can be used for cleaning under pressure,
generating torque and develop force using
actuators
 This source is free of cost, safe, flexible and
convenient
 Air compressor has very few parts hence
maintenance is very low
1. Air Compressor Coolers
 Intercoolers. Many older multiple stage compressors have intercoolers to remove the
heat of compression between the stages of compression.
 Aftercoolers. These units remove the heat of compression from both the compressor
lubricant and the discharge air. The air cooler can be either air or water cooled and is
installed after the last stage of compression.

2. Air Dryer
 Compressed air leaving the compressor aftercooler and moisture separator is normally
warmer than the ambient air and fully saturated with moisture. As the air cools the
moisture will condense in the compressed air lines. Excessive entrained moisture can
result in undesired effects like pipe corrosion and contamination at point of end use.

3. Filters
 Compressor Air Inlet Filter. An air inlet filter protects the compressor from atmospheric
airborne particles, insects and plant material.
 Compressed Air Filters. Compressed air filters downstream of the air compressor are
generally required to remove contaminants, such as particulates, condensate, and
lubricant. Numerous choices for filtering exist depending on the cleanliness of the air
required.
4. Receivers and Air Storage
The presence of adequate storage receiver capacity helps to maintain air quality, air

system stability and air system efficiency. Adequate air storage is extremely important
in systems using screw compressors.

Damping pulsations caused by reciprocating compressors.

a)Providing a location for free water and lubricant to settle from the compressed air
stream.
b)Supplying peak demands from stored air without needing to run an extra compressor.

c)Reducing load/unload or start/stop cycle frequencies to help screw compressors run

more efficiently and reduce motor starts. Most screw compressors have internal
protection that prevents more than 4 to 6 starts per hour.
d)Slowing system pressure changes to allow better compressor control and more stable
system pressures.

5. Separators and Drains

Water separators are devices that remove entrained liquids from the air. They are

installed following aftercoolers to remove the condensed moisture. Water separators

should not be confused with oil separators which are used within lubricated rotary screw
compressors to recover lubricant from the compressed air discharge.
6. Piping
Piping delivers compressed air from the compressor room to end use equipment and

processes

7. Flow Controllers
These devices (sometimes called intermediate controllers or expanders) are typically

located near the air compressor room discharge. They stabilize system pressure with
more precision than compressor controls. These units can be pneumatically controlled
or have very accurate electronic PID control

8. Filter Regulator Lubricator Devices

Filter Regulator Lubricator. The pressure regulation for air systems can be located at

the end use. In many cases the regulator is part of an assembly called a filter, regulator,
lubricator (FRL). A lubricator may be situated near a point of end use to lubricate
pneumatic tools and other machinery. The lubricator is sometimes combined with a
filter and a pressure regulator in the form of a FRL.
9. Fittings
Fittings and couplings for air hoses need to be durable and airtight
 Air compressors are classified according to
method of energy transfer and pressure
generation i.e. positive displacement and
dynamic compressors
 Positive displacement compressors work
on the principle of increasing the pressure
of air by reducing the volume of air in an
enclosed chamber
 Dynamic compressors works on the
principle of imparting the energy by
rotating vanes of impeller on air flowing
through casing that increases pressure in
air
 According to number of stages
Single stage, double stage, three stage of
multiple stage
 According to action
Single acting or double acting
 According to position of cylinder w.r.t.
crankshaft
Cylinders inline, vertical, radial position, V-
type cylinder arrangement
 According to prime mover
Electric motor drive or IC engine drive, Gas
turbine drives
 According to cooling medium
Air cooled, water cooled air compressors
 Reciprocating air compressors are positive
displacement type of air compressors.
 These are piston & diaphragm type, vane

type, gear type, screw type compressors.

 The principle of operation is same but
according to stages the delivery pressure
is different in each compressor.
 A reciprocating air compressor consist of a
piston which is enclosed within a cylinder
and equipped with suction and discharge
valve
 The piston receives power from electric

motor or IC engine.
 The compression of air is done by first
drawing a volume of air into the cylinder
through suction valve during suction
stroke of piston and then compressed and
discharged through delivery valve during
delivery stroke
 In this type the entire compression is
carried out in a single cylinder
 When piston starts moving downwards,
the pressure inside the cylinder falls below
atmospheric pressure that opens suction
valve.
 The pressure of the air in the cylinder rises

during compression and at the end of

compression, delivery valve opens and
discharges the compressed air into the
receiver tank.
 Single stage air compressor develop
pressure upto 7 bar.
 For higher pressures multistage

compressors are suitable

 It consist of two cylinders – low pressure
cylinder and high pressure cylinder
 Piston, crankcase, piston rod, crank,

crankshaft, oil, fins etc.

 The fresh air is drawn inside the L.P. cylinder
through inlet suction filter.
 This air is compressed by piston
 As the piston moves towards the end of
cylinder, the air compression took place.
 The delivery valve opens and this
compressed air from L.P. cylinder is directed
to enter inside the high pressure cylinder.
 In high pressure cylinder this pressurised air
is further compressed to higher pressure.
 The high pressure air from H.P. cylinder is
then delivered to receiver through discharge
valves.
 In this compressor, a pressure of air delivered
is upto 13 bar.
Advantages of multistage compression.
1) Air can be cooled at intermediate
pressures.
2) Power required to run multistage compression is
less than single stage compression.
3) Multistage compressors have less fluctuations
4) Volumetric efficiency is more.
5) Improved lubrication due to low temperature.

Disadvantages of Multistage compression.

1) The initial cost is high as intercooler is likely to be

more expensive.
 Number of moving parts are more
 Higher maintenance cost
 Heavy foundation is required as it has

vibration problem
 Cannot run at full capacity
 LUBRICATION

 COOLING

 FILTERING
 MAIN FUNCTION IS TO REDUCE FRICTION
BETWEEN THE MOVING PARTS
 LUBRICATION HELPS COOLING THE

COMPRESSOR MOVING PARTS AND HELP

PREVENT THE LEAKING GAS OUT OF
COMPRESSOR.
 MAIN FUNCTION IS TO REDUCE FRICTION
BETWEEN THE MOVING PARTS
 LUBRICATION HELPS COOLING THE

COMPRESSOR MOVING PARTS AND HELP

PREVENT THE LEAKING GAS OUT OF
COMPRESSOR.
 WHEN A GAS IS COMPRESSED HEAT IS
PRODUCED THIS HEAT CAN CAUSE TWO
PROBLEM
1. EXCESS HEAT CAN BREAK DOWN OIL
CAUSING IT TO BE LOOSE ITS
LUBRICATING CHARECTORSTIC
2. GASED EXPAND WHEN THEY ARE
HEATED SINCE COMPRESSOR IS
DESINGED TO COMPRESS GASES THE
EFFECT CREATE ADDITIONAL FORCE
WHICH COMPRESSOR MUST
OVERCOME.
 AIR COOLING AND WATER COOLING ARE
TWO TECHNIQUES
1. AN AIR COOLED COMPRESSOR
EASILY IDENTIFIED BY MEAL FINS
ON ITS CASING
THE FINS PROVIDE INCREASED
SURFACE AREA.
 2. ANOTHER WAY TO REMOVE THE
EXCESS HEAT IS TO COOL THE GAS
AFTER THE COMPRESSION IS
COMPLETE, THE DEVICE THAT
DOES THIS IS AN AFTERCOOLER OR
INTERCOOLER
 DEPENDING UPON ITS LOCATION THESE

EXCHANGERS ARE CLASSIFIED AS

INTERCOOLER OF AFTER COOLER.
 THE PROPER OPERATION OF COMP.
DEPENDS UPON INSTRUMENTAITON AND
CONTROL DEVICES
 THESE DEVICES ALLOWS THE COMPRESSOR
TO BE STARTED AND STOPPED.
 THEY PROVIDE INFORMATION ABOUT THE
COMPRESSOR OPERATING CONDITIONS
 THEY MAINTAIN THE VALUES OF PROCESS
VARIABLES
 THEY KEEP THE COMPRESSOR OPERATION

STABLE
 THEY CAN SHUT DOWN THE COMPRESSOR

IF UNSAFE CONDTITON OCCURED

 CONTROL PANEL MAY HAVE CONTROL TO

REGULATE THE SPEED

 FOR A GIVEN DISCHARGE PRESSURE A
COMPRESSOR HAS A CERTAIN MINIMUM
FLOW RATE. BELOW THIS FLOW RATE THE
COMPRESSOR BECOME UNSTABLE. A
DECREASE IN FLOW BELOW THE MINIMUM
FLOW CAN CAUSE A SERIES OF MOMENTARY
REVERSAL OF FLOW THROUGH THE
COMPRESSOR. THIS SITUATIION IS CALLED
SURGE
 SURGING RESULTS IN VIOLENT
FLUCTUATIONS IN DISCHARGE PRESSURE.
 WHEN AN ELECTRIC MOTOR IS USED AS

DRIVER SURGING CAN CAUSE EXTREME

VARIANTION IN MOTOR CURRENT.
 SYMPTOMS OF SURGING ARE LOW GAS

FLOW, EXCESSIVE VIBRATION AND

BANGING SOUND INSIDE COMPRESSOR
 TO PREVENT THE SURGING THE FLOW RATE
OF THE GAS THRU THE COMPRESSOR MUST
BE KEPT ABOVE THE MINIMUM STABLE
FLOW RATE OR SURGE POINT
 WHEN THE DEMAND IS LOW FLOW RATE IS

MAINTAINED BY RECIRCULATING THE

PORTION FROM DISCHARGE TO BACK TO
COMPRESSOR.
 It is positive displacement type compressor.
 It provides higher efficiency and flow rates over
a wide range of pressure
 Rotary vane compressor consist of rotor with a
number of vanes inserted in the radial slots cut
in rotor.
 The rotor is mounted eccentric in a casing.
 The vanes slides radially in and out of the rotor.
 As the rotor rotates at higher speed, centrifugal
force throws the vanes outward keeping the end
of vane in contact with the stator ring.
 As the rotor turns, compression is
achieved as the volume goes from a
maximum at intake port to minimum at
the exhaust port.
 An oil is injected into the air intake and

along the stator walls to cool the air and

lubricate bearing and vanes and to
provide a seal between the vane and
stator wall to reduce internal leakage.
 Simple design
 Compact in size Lower efficiency
 Light in weight Difficulty with higher pressure above 200
 Easy to install psi
 Low cost Oil injected designs have oil carryover
 Low maintenance cost
 Longer life
 Few moving parts
 Low rotational speed
 Expensive foundation not required
 It consist of two screws - one with convex
and the other with concave contour mostly
called male and female rotor respectively.
 These two screws gets rotating by means

of gear trips there by sucking the air

through an inlet port in chamber and then
compressing the same
 The helix of the male and female rotor
screw is designed to permit complete
charging of the inter lobe space before the
re-mesh.
 On completion of the filling operation the

inlet end of male and female lobes begins

to re-engage thus reduces the volume of
air continuously.
 Thus compression begins and air is
discharged at the end of other side.
 There is no contact between male and

female rotors and casing. Hence no

lubrication require but oil may injected for
the purpose of cooling.
 It is used in applications where higher flow
at comparatively low pressure is required.
 Here two lobes are placed in a casing
 The air is transferred from suction side to

the delivery side with continuous rotation

of two lobes
 The lobes are precisely maintained and

the casing also maintained to close

tolerances
 It has limited compression ratio @ 1.7
 Multi stage compressor is use to develop
pressures more than 35 kg/cm2.
 For preparation of mineral water bottle, air
pressure more than 40 kg/cm2 is required
to produce desired shape of bottle at
bottom side.
 Here two stage compressor is not used as
it produces pressure up to 35 kg/cm2 .
 Three stage compressor is use as it
produces pressure up to 85 kg/cm2 .
 Above four stage compressor is used.
 The working is same as that of double
stage compressor.
 In three stage compressor fresh air from

atmosphere enters first stage cylinder

through air cleaner.
 Here it is compressed by piston to 4

kg/cm2 and then delivered to second stage

cylinder through intercooler for further
compression.
 In second stage cylinder low pressure air
is compressed upto 14 kg/cm2 and
discharge to third stage cylinder through
second intercooler to increase air pressure
up to desired delivery pressure i.e. 35 to
85 kg/cm2
 It is dynamic compressor.
 It consist of a rotating impeller which

rotates at higher speed (upto 60000 rpm)

 An impeller fitted inside casing force the

air to the rim of impeller, increasing

velocity of air.
 Centrifugal
Compressor
 Centrifugal compressors accelerates the
velocity of the gases (increases kinetic
energy) which is then converted into
pressure as the air flow leaves the volute
and enters the discharge pipe.

 Usually operate at speeds > 3,000 rpm.

 Deliver much higher flow rates than

positive displacement compressors
Basic
Components
 Impellers, Vanes, Volutes, Suction
Eyes, Discharge lines, Diffuser Plates,
Seals, Shaft, Casing
 Suction Vane Tips = Part of the
impeller vane that comes into contact
with air first.
 Discharge Vane Tips = Part of the
impeller
vane that comes into contact with air
 These are also used in IC engine
superchargers and turbochargers.
 In gas turbine plants
 It can provide extremely high output

pressures greater than 10000psi.

Axial flow
compressor
Axial flow
compressor
 Composed of a rotor that has rows of fanlike
blades.
 In industry, axial compressors are used a lot
high flows and pressures are needed.
 Air flow is moves along the shaft.
 Rotating blades attached to a shaft push air
over
stationary blades called stators.
 Stator blades are attached to the casing.
 As the air velocity is increased by the rotating
blades, the stator blades slow it down. As the air
slows, kinetic energy is converted into pressure.
 air velocity increases as it moves from stage to
stage until it reaches the discharge.
 Multi-Stage axial compressors can generate very
high flow rates and discharge pressures.
 Axial compressors are usually limited to 16 stages
(due to
temperature/material limitations)
 Pound for pound, axial compressors are lighter,
more efficient, and smaller than centrifugal
 Selection of air compressor for given
application is governed by several factors
as below
 Pressure
 Flow rates or capacity
 Geometry of cylinder
 Speed of piston
 The layout of pipe line, system
requirement and the distance of user
machine from compressor plant
 Pressure :
 The discharge pressure from the

compressor should be decided first

considering the needs of the cylinder, air
motor & pressure drop in the circuit.
 Most of pneumatic systems and tools are

designed for pressure of 6 – 7 bar.

 A compressor used should meet the

requirement.
 Pressure :
 Pneumatic circuit requiring air at high

pressure can be supplied with air by a

separate high pressure compressor
 While any low pressure can be met by

availing a reducing valve.

 For huge air flow rates at pressures below

2 bar, a turbo-blower or low pressure

rotary compressor may be used.
 Flow rates or capacity:-
 Volume of air required per minute is also

an important factor for selection.

 The capacity should be adequate enough

to supply air to all devices operating

simultaneously.
 In many plants where pneumatic tools are

operated intermittently, in such cases

maximum instantaneous demand of the
compressed air has to be find first.
 Geometry of cylinder:-
 For single cylinder geometric fashion :-

vertical-single acting or double acting

horizontal- single or double acting
 For two cylinders geometric fashion:-

- vertical inline, single or double

acting
- V-type, single or double acting
- horizontal duplex, double acting
 Speed of piston:-
 The speed of piston inside the cylinder
must also be considered.
 For small capacity compressor, the piston
speed 300 m/min, whereas for large
capacity compressor piston speed 250
m/min.

 The layout of pipe line, system

requirement and the distance of user
machine from compressor plant