Fundamentals of compressed air power
• HOW CAN AIR GENERATE POWER?
• The normal state of air, barometric, is called atmospheric
pressure. When air is compressed, it is under pressure greater
than that of the atmosphere and it characteristically attempts to
return to its normal state.
• Since energy is required to compress the air, that energy is
released as the air expands and returns to atmospheric pressure.
• Air compressors were designed to compress air to higher
pressures and harness that energy. Unlike other sources of
power, no conversion from another form of energy such as heat is
involved at the point of application.
◦ A mechanical device that increases the pressure of a gas by
reducing its volume. Similar to a pump – Increases the pressure
on a fluid and transport it through a pipe.
•
Glossary of terms
• Compression, Adiabatic – Compression in which no heat is
transferred to or from the gas during the compression process.
• Compression, Isothermal – Compression is which the
temperature of the gas remains constant.
• Compression, polytropic – Compression in which the
relationship between the pressure and the volume is expressed by
the equation PVn is a constant.
• Compression Ratio – The ratio of the absolute discharge
pressure to the absolute inlet pressure.
• Capacity, Actual – The actual volume flow rate of air or gas
compressed and delivered from a compressor running at its rated
operating conditions of speed, pressures, and temperatures. Actual
capacity is generally expressed in actual cubic feet per minute
(acfm) at conditions prevailing at the compressor inlet.
• Capacity Gauge –A gauge that measures air flow as a
percentage of capacity, used in rotary screw compressors.
• Cut-In/Cut-Out Pressure – Respectively, the minimum and
maximum discharge pressures at which the compressor will
switch from unload to load operation (cut in) or from load to
unload (cut out).
• Cycle – The series of steps that a compressor with
unloading performs; 1) fully loaded, 2) modulating (for
compressors with modulating control), 3) unloaded, 4) idle.
• Cycle Time – Amount of time for a compressor to
complete one cycle.
• Degree of Intercooling – The difference in air or gas
temperature between the outlet of the intercooler and the inlet
of the compressor.
• Intercooling – The removal of heat from air or gas
between compressor stages.
• Types of Compressors:
• 1. Positive Displacement :A compressor that
confines successive volumes of gas within a
closed space in which the pressure of the gas is
increased as the volume of the closed space is
decreased.
• Intermittent Flow
2. Roto-Dynamic Compressors:A compressor using a
rotating mechanism to add velocity and pressure to gas.
• Continuous Flow
Positive displacement compressors can be further
divided into Reciprocating and rotary compressors.
Under the classification of reciprocating compressors, we
have
• Single-acting compressors,
• Double-acting compressors,
• Diaphragm compressors.
The rotary compressors are divided into
• Screw compressors,
• Vane type compressors,
• Lobe and scroll compressors
Under the Roto-dynamic compressors, we have
• Centrifugal compressors,
• Axial flow compressors
• The compressors are also classified based on
other aspects like
• Number of stages (single-stage, 2-stage and
multi-stage),
• Cooling method and medium (Air cooled, water
cooled and oil-cooled),
• Drive types ( Engine driven, Motor driven,
Turbine driven, Belt, chain, gear or direct
coupling drives)
• Service Pressure (Low, Medium, High)
Reciprocating Air Compressors
• Reciprocating air compressors are positive displacement
machines, meaning that they increase the pressure of the air
by reducing its volume.
• This means they are taking in successive volumes of air which
is confined within a closed space and elevating this air to a
higher pressure.
• The reciprocating air compressor accomplishes this by a piston
within a cylinder as the compressing and displacing element.
• Single-stage and two-stage reciprocating compressors are
commercially available.
• Single-stage compressors are generally used for pressures in
the range of 70 psig to 100 psig.
• Two-stage compressors are generally used for higher
pressures in the range of 100 psig to 250 psig.
Principle of Reciprocating Compressors
• Piston movement in a
cylinder connected to a
rod and crankshaft
• Downward piston motion,
low pressure gas enters
the chamber
• Upward piston motion,
gas is compressed and
exits the chamber
RECIPROCATING SINGLE ACTING
COMPRESSORS
• The reciprocating air compressor is single acting when the
compressing is accomplished using only one side of the
piston. A compressor using both sides of the piston is
considered double acting.
• Single-stage compressors are generally used for pressures of
70 psi (pounds per square inch) to 135 psi.
• In the two-stage compressor, air is drawn in from the
atmosphere and compressed to an intermediate pressure in
the first stage. Most of the heat of compression is removed as
the compressed air then passes through the intercooler to the
second stage, where it is compressed to final pressure.
• Reciprocating air compressors are available either as air-
cooled or water-cooled in lubricated and non-lubricated
configurations and provide a wide range of pressure and
capacity selections.
RECIPROCATING SINGLE ACTING
COMPRESSORS
• They are used a LOT for
general-purpose
applications ('workshop-
air'), where the air is
used for hand-tools,
cleaning dust, small
paint jobs, etc. Together
with the rotary screw
compressor, it's one of
the most used
compressor types.
ROTARY SLIDING VANE TYPE
• The rotary sliding vane compressor consists of a
vane-type rotor mounted eccentrically in a housing .
• As the rotor turns, the vanes slide out against the
housing.
• Air compression occurs when the volume of the
spaces between the sliding vanes is reduced as the
rotor turns in the eccentric cylinder.
• Single or multi-stage versions are available. This
type of compressor may or may not be oil lubricated.
• Some of the advantages of rotary sliding vane
compressors are smooth and pulse-free air output,
compact size, low noise levels, and low vibration
levels.
ROTARY SLIDING VANE TYPE
ROTARY HELICAL SCREW TYPE
• Rotary helical screw compressors utilize two intermeshing helical rotors
in a twin-bore case.
• In a single-stage design, the air inlet is usually located at the top of the
cylinder near the drive shaft end.
• The discharge port is located at the bottom of the opposite end of the
cylinder. As the rotors unmesh at the air inlet end of the cylinder, air is
drawn into the cavity between the main rotor lobes and thesecondary
rotor grooves. As rotation continues, the rotor tips pass the edges of the
inlet ports, trapping air in a cell formed by the rotor cavities and the
cylinder wall.
• Compression begins as further rotation causes the main rotor lobes to roll
into the secondary rotor grooves, reducing the volume and raising cell
pressure.
• Oil is injected after cell closing to seal clearances and remove heat of
compression.
• Compression continues until the rotor tips pass the discharge porting and
release of the compressed air and oil mixture is obtained.
• Some advantages of the rotary helical screw compressors are smooth
and pulse-free air output, compact size, high output volume, low
vibrations, prolonged service intervals, and long life.
Rotary Screw Compressors
• Rotary air compressors are positive displacement
compressors.
• The most common rotary air compressor is the single stage
helical or spiral lobe 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. The rotors have a very special shape and turn in
opposite directions with very little clearance between them.
• Air sucked in at one end gets trapped between the rotors, and
get pushed to the other side of the rotors (the pressure-side).
• These units are basically oil cooled (with air cooled or water
cooled oil coolers) where the oil seals the internal clearances.
• Rotary screw air compressors
are easy to maintain and
operate. Capacity control for
these compressors is
accomplished by variable speed
and variable compressor
displacement.
• For the latter control technique,
a slide valve is positioned in the
casing. As the compressor
capacity is reduced, the slide
valve opens, bypassing a
portion of the compressed air
back to the suction.
• Advantages of the rotary screw
compressor include smooth,
pulse-free air output in a
compact size with high output
volume over a long life.
Scroll compressor
• They compress the air
using two spiral elements.
1 is stationary (it doesn't
move), and the other one
moves in small eccentric
circles inside the other
spiral. Air gets trapped and
because of the way the
spirals move, gets
transported in small air-
pockets to the center of
the spiral. It takes about
2.5 turn for the air to reach
the pressure output in the
center.
Centrifugal Compressors
• The centrifugal air compressor is a dynamic compressor which
depends on transfer of energy from a rotating impeller to the air.
• Centrifugal compressors produce high-pressure discharge by
converting angular momentum imparted by the rotating impeller
(dynamic displacement). In order to do this efficiently, centrifugal
compressors rotate at higher speeds than the other types of
compressors. These types of compressors are also designed for
higher capacity because flow through the compressor is
continuous.
• Adjusting the inlet guide vanes is the most common method to
control capacity of a centrifugal compressor. By closing the guide
vanes, volumetric flows and capacity are reduced.
• 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.
AIR POWER VERSUS ELECTRIC
POWER
• Cost: Air tools have fewer moving parts and are simpler in
design, providing lower cost maintenance and operation than
electric tools.
• Flexibility: Air tools can be operated in areas where other
power sources are unavailable, since engine-driven portable
compressors are their source of air power. Electric power
requires a stationary source.
• Safety: Air-powered equipment eliminates the dangers of
electric shock and fire hazard. Air tools also run cooler than
electric tools and have the advantage of not being damaged
from overload or stalling.
• Weight: Air tools are lighter in weight than electric tools,
allowing for a higher rate of production per man-hour with less
worker fatigue.
AIR POWER VERSUS HYDRAULIC
POWER
• Cost: An air system has fewer parts than a hydraulic system, lowering
service and maintenance costs. Also, the use of a single compressed air supply
permits operation of many separate systems at once. Hydraulic systems require
more complex and costly controls.
• Flexibility: Compressed air systems offer simpler installation than hydraulics,
particularly where tools are frequently interchanged. Compressed air systems
also offer better adaptability for automation and flexibility for changing or
expanding operations.
• Maintenance: Air systems have less downtime than hydraulic systems
because they have less complex controls. Less preventative maintenance is
required with air, whereas hydraulic fluids must be monitored and replaced
periodically.
• Safety: Hydraulic devices operating near open flame or high temperatures
present fire hazards, unless fire-resistant fluids are used. Leakage in hydraulic
systems can result in the presence of dangerous hydraulic fluids and even
complete system shutdown. In contrast, compressed air devices operate with
lower system pressures, and accidental air leaks release no contaminants.
Weight: High ratio of power-to-weight in air tools contributes to a lower
operator fatigue versus hydraulic tools.
AIR COMPRESSOR PERFORMANCE
• DELIVERY (ACFM/SCFM)
• The volume of compressed air delivered by an air
compressor at its discharge pressure, normally is stated
in terms of prevailing atmospheric inlet conditions (acfm).
The corresponding flow rate in Standard cubic feet per
minute (scfm) will depend upon both the Standard used
and the prevailing atmospheric inlet conditions.
• Displacement is the volume of the first stage cylinder(s)
of a compressor multiplied by the revolutions of the
compressor in one minute. Because displacement does
not take into account inefficiencies related to heat and
clearance volume, it is useful only as a general reference
value within the industry.
• Efficiency, Compression – Ratio of theoretical power
to power actually imparted to the air or gas delivered by
the compressor.
• Efficiency, Isothermal – Ratio of the theoretical work
(as calculated on a isothermal basis) to the actual work
transferred to a gas during compression.
• Efficiency, Mechanical – Ratio of power imparted to
the air or gas to brake horsepower (bhp).
• Efficiency, Polytropic – Ratio of the polytropic
compression energy transferred to the gas, to the actual
energy transferred to the gas.
• Efficiency, Volumetric – Ratio of actual capacity to
piston displacement.
ACCESSORIES
• AIR RECEIVER
• A receiver tank is used as a storage reservoir for compressed
air. It permits the compressor not to operate in a continuous
run cycle. In addition, the receiver allows the compressed air
an opportunity to cool.
• BELT GUARD
• A belt guard protects against contact with belts from both sides
of the drive and is a mandatory feature for all V-belt driven
compressor units where flywheel, motor pulley, and belts are
used.
• DIAGNOSTIC CONTROLS
• Protective devices designed to shut down a compressor in the
event of malfunction. Devices may include high air
temperature shut down, low oil level shut down and low oil
pressure shut down, preventative maintenance shut down, etc.
• INTAKE FILTER
• The intake filter eliminates foreign particulate
matter from the air at the intake suction of the
air compressor system. Dry (with consumable
replacement element) or oil bath types are
available.
• MANUAL AND MAGNETIC STARTERS
• Manual and magnetic starters provide thermal
overload protection for motors and are
recommended for integral horsepower and all
three-phase motors.