Compressed Air

Operations
Manual
An Illustrated Guide to
Selection, Installation,
Applications, and Maintenance

Brian S. Elliott

McGraw-Hill
New York

Chicago San Francisco Lisbon London Madrid

Mexico City Milan New Delhi San Juan Seoul
Singapore Sydney Toronto

Contents

List of Figures and Tables

Preface
xxi
Acknowledgments
xxiii

xi

Chapter 1. The History of Compressed Air

Questions
Chapter 2. Compressed Air Applications
Blow-Off Guns
Tire Inflators
Portable Air Tanks
Fire Extinguishers
Air Cylinders
Pressure Amplifiers
Percussion Tools
Air Motors
Rotating Tools
Turbine Motors
Paint Sprayers
Siphon Guns
Sandblasters
Air Nailers
Air Staplers
Caulk Guns
Grease Guns
Pop Rivet Puller
Dual Diaphragm Pumps
Vacuum Generators
Air Bearings
Spray Misters
Vibrators

1
8
9
10
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14
15
16
25
27
29
33
37
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40
42
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48
48
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50
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52
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54

vi

Contents

Automobile Lifts
Air-Over-Hydraulic Jacks
Air Bag Jacks
Pneumatic Suspension
Air Brakes
Self-Contained Underwater Breathing Apparatus (SCUBA)
Self-Contained Breathing Apparatus
Questions

55
56
59
60
62
66
68
70

Chapter 3. Compressor Types

71

Squirrel Cage Blowers

Centrifugal Blowers
Regenerative Blowers
Rotary Lobe Blowers (Roots)
Liquid Ring Compressors
Diaphragm Compressor
Piston Compressor
Double-Acting Compressors
Two-Stage Compressors
Screw Compressor
Rotary Vane Compressors
Turbo Compressors
Axial Compressors
Injector Compressors
Questions

73
74
75
77
77
78
79
80
83
85
88
90
91
91
93

Chapter 4. The Conservation of Mass and Energy as Applied to

Compressed Air
Questions
Chapter 5. The Compressed Air Supply
Screw Compressors
Duplex Compressors
Redundant Compressors
Duplex Controllers
After Coolers
Air-Cooled After Coolers
Water-Cooled After Coolers
Air Dryers
Instrument Air
Field Compressors
Questions
Chapter 6. Compressed Air Dryers
Traps

95
98
99
99
101
103
103
104
106
107
108
110
113
116
117
118

Contents

Plate Separators
Coalescing Filters
Water-Cooled Aftercoolers
CFC-Based Refrigerated Dryers
Elliott Cycle Refrigerated Dryers
Standard Installations
Duplex Installations
Applications Greater Than 120 SCFM
Instrumentation Air Systems
Saltwater Prepared Dryers
Ice Bath Dryers
Desiccant Dryers
Deliquescent Dryers
Membrane Dryers
Absorption Dryers
Dryer Performance, Types, and Applications
Oil/Water Separators
Questions

Chapter 7. Support Components

Filters
Pressure Regulators
Lubricators
Filter, Regulators, and Lubricators Guide
Safety Relief Valves
Pressure Relief Valves
Check Valves
Expansion Joints and Vibration Isolators
Hoses and Hose Connectors
Retractable Hoses
Hose Clamps
Hose Connectors
Drain Valves
Commercial Pipe Fittings
Compression Fittings
Pipe Hangers
Ball Valves
Gate Valves
Globe Valves
Butterfly Valves
Solenoid Valves
Pilot Valves
Needle Valves
Speed Control Valves
Tire Valve Fittings
Mufflers
Intake Air Filters

vii

124
125
128
128
135
141
142
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144
145
146
150
154
154
157
157
158
161

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186
186
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189
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viii

Contents

Pressure Gauges
Pressure Switches
Compressor Control Switches
Continuous-Run Unloader Valves
Vee Belts
Sound Dampening Enclosures
Compressor Mounts
Skid Mounting
Questions

196
198
198
199
200
201
202
203
209

Chapter 8. Pneumatic Controls

211

In-House Pneumatic Symbols

Questions

217
221

Chapter 9. Electrical Controls

Single-Pole Control
Double-Pole Control
Motor Starters
120-VAC Control Loops
Sensor Loops
On, Off, and Automatic Functions
Sensors
Delta/Wye Motor Starters
Soft Starters
Variable Frequency Drives
Programmable Logic Controllers
Microprocessor-Based Controllers
Emergency Stop Circuit
Power Disconnects
Service Outlets
Lockout/Tagout Programs
Duplex Controllers
Parallel Duplex Operation
Weekly and Daily Duplex Operation
Wire Types
Din Rails and Wire Guides
Questions

Chapter 10. Maintenance

Supply Side
Distribution
Applications
Maintenance Program
Replacement Parts Inventory
Questions

223
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235
237
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Contents

Chapter 11. Energy and Costs Associated with Compressed Air

ix

269

Leaks
Misuse
The Compressed Air Supply
Heat
The Motor
Drive Belts
Master Regulator
Water
Water Damage
Air Versus Electricity
Questions

270
272
272
272
273
274
274
274
274
277
279

Chapter 12. System Models

281

Contractor Compressors
Automotive Repair
Small Manufacturing Plants
Dry-Cleaning Operations
Heating, Ventilation and Air Conditioning (HVAC)
Dental Systems
Home Shop
Medium to Large Manufacturing Facilities
Instrument Air
High Purity
Service Trucks
Field and Construction
SCUBA and SCBA Charging Systems
Questions

Chapter 13. Specifying a Compression System

Estimating Required SCFM
Selecting a Compressor
Master Regulator
Receiver Size
Pipe Sizing
Remote Receivers
Cost Savings
Miscellaneous
Distribution Layouts
Plumbing
Buried Pipe
Plumbing Tools
Questions

281
283
288
291
293
296
298
298
302
305
310
312
315
320

321
322
323
324
325
326
327
329
330
331
333
334
336
339

Contents

Chapter 14. Conducting an Air Audit

Distribution Map
SCFM Requirements
Leaks
Hoses
Filters
Regulators
Lubricators
Remote Receivers
Master Regulator
Primary Receiver
Dryers
Compressors
Routine Maintenance
Employee Training
Sample Outline for Conducting an Air Audit
Questions

Chapter 15. Single-Stage Home-Built Air Compressor

Engine Preparation Instructions
Selecting the Sheaves (Items 21 and 22)
Assembly Instructions
Some Notes and Comments

341
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343
345
345
345
346
346
347
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348
348
349
349
350
353

355
357
361
362
363

Chapter 16. Home-Built Compressed Air Drying System

365

Appendix A. Glossary of Terms and Abbreviations

369

Appendix B. Miscellaneous Technical Information

371

Appendix C. Occupational Safety & Health Administration (OSHA)

Laws and Regulations Concerning Compressed Air

397

Appendix D. Answers to Chapter Questions

401

Index

403