Basics of Compressed Air - Distance Learning

Basics of Compressed Air

Basics of Compressed Air - Distance Learning

What is compressed air ?

• Compressed air is compressed
atmospheric air.

• Compressed air is a carrier of heat

energy.
• Compressed air can be stored (in a
receiver), can travel distances (pipelines)
and perform work (when compressed air
at outlet ie:power tool, etc..).
• The 4th utility.
Basics of Compressed Air - Distance Learning

What is compressed air ?

Picture the familiar bicycle pump.
The bicycle pump, like all other
compressors, takes air in at an initial
intake pressure.
As the piston moves in a cylinder, the air
is compressed into a smaller space and
raises it to a higher discharge pressure.
Finally the compressed air is delivered
to a receiver be it a bicycle tire, a steel
tank, or a piping system.
Heat energy is generated - feel the
warmth from the output of the pump.
Basics of Compressed Air - Distance Learning

Uses of compressed air ?

Compressed air has a variety of uses in Industry and
elsewhere. These include :

• Clamping of parts.
• Operating pneumatic tools. THINK OF -
1) OTHER USES FOR COMPRESSED AIR ?
• Spray painting.
2) WHAT INDUSTRIES USE COMPRESSED AIR ?
• Conveyance by compressed air.

Very few industries do not use compressed air.

Basics of Compressed Air - Distance Learning

Light Industrial Up to 30kW

Medium Industrial 37 to 350kW
Heavy Industrial Above 350kW
Basics of Compressed Air - Distance Learning

There are two general groups of air compressors, positive

displacement and continuous flow. In the positive displacement
machines, the air is physically squeezed, by a piston, a lobe, or mating
screws.

We’ll look at these ‘Positive Displacement’ compressors.

Basics of Compressed Air - Distance Learning

Reciprocating: Intake Valve Outlet Valve

RECIPROCATING COMPRESSORS are those

in which the compressing element is a piston
moving back and forth in a cylinder.
Piston
The piston draws in air on the downstroke,
through the intake valve. This valve closes on
start of upstroke. Connecting
Rod
On the upstroke the piston compresses the
air, releasing it through pressure valves, when
correct pressure is reached.
The piston is driven by a crank drive with a Crankshaft

crankshaft and a connecting rod.

Basics of Compressed Air - Distance Learning

Reciprocating:

Types of Reciprocating :
Single stage - compression to final pressure in
one piston stroke.

Single action - one compression action with one

rotation of the crankshaft.
Double action - two compression actions with
one rotation of the crankshaft.

Single Stage
Basics of Compressed Air - Distance Learning

Reciprocating:

Types of Reciprocating :
Two stage - Air compressed in the cylinder in
the 1st stage (LP - Low pressure stage), is cooled 1st Stage
InterCooler
in the intermediate cooler and compressed to
final pressure in the 2nd stage (HP - High
pressure stage).

2nd Stage
Basics of Compressed Air - Distance Learning

Reciprocating: Aluminium Low

Pressure
Cast Iron High
Pressure

Two Stage :

Equalised Mass HP & LP pistons.

Sized and balanced for smooth running.
Basics of Compressed Air - Distance Learning

Two-Stage Design Simple multifinger valves

Reciprocating: Dependable and easy to maintain

Finned
Centrifugal Intercooler
Runs cool, even in
unloader the most demanding
saves motor life conditions

One piece
Overhung crankshaft
Precision balanced to run connecting Rod
smoothly and quietly for few wearing parts
Splash Lubrication
Simple and reliable, does not require an
oil pump, making the system
inexpensive and easy to maintain
Basics of Compressed Air - Distance Learning

Light Industrial -
Reciprocating Range :
MERLIN
EURO 20
TYPE 30
MERLIN

TYPE 30
EURO 20 (Silenced)
Basics of Compressed Air - Distance Learning

Rotary :

Compression and displacement are achieved by

the positive action of the rotating elements.
Air is compressed by the rotary motion of two
intermeshing helical rotors - one female, the
other male - with differing profiles, that work
in opposite directions.
The air is compressed in chambers, that
continuously decrease in size, due to the rotor
rotation, until the final pressure is reached
and forced out of the discharge outlet.
Basics of Compressed Air - Distance Learning

Rotary :

• Designed to provide pulsation-

free air 24 hours a day.
• 100% continuous duty.
• Quiet operation.
• Energy efficient at full load.
• Extended service intervals.
• Reliable long life.
• Improved air quality.
Basics of Compressed Air - Distance Learning

Light Industrial Rotary Range :

UNIGY
UP5 - 11 to 22kW
UP5 - 22E to 30kW

UP5 - 22E to 30kW

UP5 - 11 to 22kW
Basics of Compressed Air - Distance Learning

Medium Industrial Rotary Range :

M37 PE
NIRVANA
SIERRA
2 - STAGE
M37 PE

NIRVANA SIERRA
Basics of Compressed Air - Distance Learning

Contaminants in System :
In our air there are many particles invisible to the naked eye :
> Moisture.
> Dirt particles, etc…
> Oil. These contaminants can cause the following problems -
Moisture - Causes corrosion in system.
Can freeze in piping.
Wear in tools.

Dirt particles - Clog/wear out tools.

Contaminate finishes.

Oil - Poor finish quality.

Contaminate tools.
Contaminate environment.
Basics of Compressed Air - Distance Learning

Contaminants in System :
Compressing air concentrates these contaminants many times.

Correct treatment of compressed air gives the following benefits :

• Longer life of end tools.
• Airlines free of rust and condensate.
• Lower maintenance costs.
• Lower pressure losses - pipework cleaner, etc..
• Fewer malfunctions.
• Better, more consistent end product.
• Less production downtime.
Basics of Compressed Air - Distance Learning

System Components :

• Compressor
• Aftercooler
• Receiver Tank
• Drain Traps
• Dryers
• Filters
• Piping
Basics of Compressed Air - Distance Learning

Aftercooler:
If you compress air - it becomes hot.
Too hot for standard filtration.

An Aftercooler is required to bring

compressed air temperature down.

Through action of cooling the air, water

condenses and drains away, along with
other contaminants.

Result is cleaner, cooler air that, with

further filtering and drying provides best
quality air, for better performance of
your air system.
Basics of Compressed Air - Distance Learning

Receiver Tank:

• Stores air for high demand periods.

• Reduce compressor cycling.
• Allows piston compressors to cool.
• Facilitates air/water separation.
• Available in various sizes -
depending on application.
• Minimises the loaded run time of
the compressor.
• Choice of vertical or horizontal.
Basics of Compressed Air - Distance Learning

Dryers: Air contains water in the form of moisture.

The higher the temperature, the more

moisture it can hold (ie: humidity).
Removes harmful moisture from your
system.
The air dryer removes water in compressed
air by mechanical refrigeration, or by
chemical means.

Dryers :
DryStar Refrigerated Air Dryers
ThermoStar Refrigerated Air Dryers
TMS - Thermal Mass Cycling Air Dryer
ThermoSorb Desiccant Dryers
Basics of Compressed Air - Distance Learning

Filters:
Compressed air contains contamination, and if not
removed, will damage the compressed air system and
components.

Correct selection and application of compressed air

filters will protect your air system and increase
production efficiency, and thus save energy.

Available in 4 grades :
GP - General Purpose Protection
HE - High Efficiency Oil Removal
AC - Activated Carbon
DP - Dust Protection
Basics of Compressed Air - Distance Learning

Piping: Join equipment together and distribute compressed air.

Simplair: Simplair is simplicity, versatility and

performance in one integrated piping system.
It is a modular piping system constructed of
anodised aluminium extrusion and is ideal for
compressed air systems of all sizes.

The system is quick

to assemble and easy
to install. Once
installed,
modification or
expansion to the
system is easy.
Basics of Compressed Air - Distance Learning

Selection Factors:

• How much air does the plant system require ?

• What is the optimum pressure level ?

• What quality of air is required ?

• Usage rates.

• Compressor location.

• Electrical/Voltage required.
Basics of Compressed Air - Distance Learning

Motors:
TEFV = Totally Enclosed Fan Ventilated
TEFC = Totally Enclosed Fan Cooled

Motors have a duty rating and a service factor.

There are three duty ratings :

S3 = Motor is designed for intermittent use.

S2 = Motor is designed for 50% full load use.
S1 = Motor is designed for constant full load use. A megger

Motors are given a service factor which indicates how much they can be overloaded.
If a motor is rated at 15kW and has a service factor of 1.15 it is actually a 17.25kW
motor (15 x 1.15).
Keep motors clean, avoid repeated jogs/starts & use a ‘megger’ to keep check on your
motor condition.
A ‘megger’ is an electronic device for motor condition monitoring
Basics of Compressed Air - Distance Learning

Motors:
IP stands for “Ingress Protection” and is used to rate a motors ability to resist the ingress of
foreign matter.
It is normally shown as IP55
The first number is the ability to resist solid object ingress.
The second number is the ability to resist liquid ingress.

IP FIRST NO. INDICATES PROTECTION AGAINST SOLID OBJECTS

0 NO PROTECTION

1 SOLID OBJECTS UPTO 50 mm eg ACCIDENTAL TOUCH BY HAND

2 SOLID OBJECTS UPTO 12 mm eg FINGERS

3 SOLID OBJECTS OVER 2.5 mm eg TOOLS AND WIRES

4 SOLID OBJECTS OVER 1mm eg TOOLS AND WIRES

5 PROTECTION AGAINST DUST LIMITED ENTRY ALLOWED

6 TOTALLY DUST TIGHT

Basics of Compressed Air - Distance Learning

Motors:
IP SECOND NO INDICATES PROTECTION AGAINST LIQUIDS

0 NO PROTECTION

1 VERTICALLY FALLING DROPS OF WATER eg CONDENSATION

2 DIRECT SPRAYS OF WATER UP TO 15 DEG FROM VERTICAL

3 SPRAYS TO 60 DEG FROM VERTICAL

4 WATER SPRAYED FROM ALL DIRECTIONS LIMITED ENTRY PERMITTED

5 LOW PRESSURE JETS OF WATER FROMALL DIRECTIONS LIMITED ENTRY

PERMITTED

6 STRONG JETS OF WATER eg SHIP DECKS

Basics of Compressed Air - Distance Learning

Regulation:

Automatic Stop/Start (ASS)

• At the maximum required pressure the pressure switch will stop the motor.
• When the pressure falls below the minimum set value, the motor is started.

Constant Speed Control (CSC)

• The compressor is set to run continuously venting air when in an unloaded condition.
• This type of control is required for continuous operation, or when most of the air
requirements are of a steady nature.
Basics of Compressed Air - Distance Learning

Regulation:

Dual Control

• Dual control provides for either auto start-stop or constant speed operation.

• Dual Control is accomplished by turning the 3 way valve.

• For constant speed operation, the valve is turned vertical until fully open.This will
allow the auxiliary valve to function.

This causes the compressor to run in a Constant Speed mode.

• When the valve is in the horizontal potion the air is then allowed to feed the
pressure switch

This allows for A.S.S to be achieved.

Basics of Compressed Air - Distance Learning

Starter Types:

Direct-on-line (DOL) :

• Advantage is simplicity.

• Disadvantages are many;

• In rush current is up to 7 times F.L.C.

• Contactor,fuses and cables need to be large to handle

current.

• Power supply authorities do not like power surges.

• Only used on very small motors or high voltage motors.

Basics of Compressed Air - Distance Learning

Starter Types:
Star/Delta (S/D) :

• Reduced voltage start means lower inrush current approximately 3.5 times F.L.C.

• Contactors and cables can therefore be smaller.

• Preferred by power supply authorities.

• Slightly complex timing circuit needed to control the 3 contactors.

• Generally accepted as industry norm.

• Reduced voltage in Star is 58% of full voltage.

This means lower inrush current but torque is reduced by 2 thirds.

• Once motor is up to speed (4 to 15 secs) delta transition allows full line voltage
connection and FL torque
Basics of Compressed Air - Distance Learning

Terminology:
Duty Cycle :
The Duty cycle is the amount of time that the compressor will need to run in order to deliver the
required amount of air to the customers system.

Continuous Duty does not mean Constant Duty

Light Duty - The compressor should not need to run for more than 50% of the working time and no
more than 1/2 of the working day.
This is the task for Aluminium Construction (Euro 20) Compressors.
Medium Duty - The compressor should not need to run for more than 50% of the working time but
can be run for the full working day. ( Continuous Duty )
This is the task for the larger BD Merlin Compressors.
Heavy Duty - The compressor should not need to run for more than 75% of the working time but
can be run for the full working day. ( Continuous Duty )
This is the task for T30 Cast iron Compressors
Constant Duty - The compressor needs to run all the time it is switched on and all of the working
day.
This is the task for Rotary Screw Compressors
Basics of Compressed Air - Distance Learning

Terminology:
Free Air - This is all around us. It varies from location to location dependant on temperature, altitude & relative
humidity. There is a blanket of air all around the world that presses down with almost equal force. At sea level this
mass of air exerts a force of 14.7 pounds on every square inch of surface. We call this atmospheric pressure.
Since this is a constant and continuous all pressure gauges are calibrated to register it as zero.

Gauge Pressure - The pressure everyone knows and commonly refers to.
(What we see on a gauge at atmospheric pressure).

PSIA - When we add atmospheric pressure to the

gauge pressure we have absolute pressure,
pounds per square inch absolute.

Cubic Foot - Is the common measure of air volume,

it is the amount of air that fills a cube,
one-foot by one-foot.

CFM - (Cubic Feet per Minute) is the number of cubic feet of air per minute flowing through a system.

Standard Cubic Feet per Minute (SCFM) - is the flow of air referred to a temperature of 60 deg. F., a pressure of
14.7 psia, and 0°/a relative humidity.

Relative Humidity - is the ratio of the actual water vapor content in air to the vapor content at the saturated
condition.

Dew Point - is the temperature at which water vapor in air starts to condense into water droplets.
Basics of Compressed Air - Distance Learning

Terminology:
Piston Displacement - is expressed in CFM, and represents the
volume of air swept through the cylinder by the piston with each
stroke.

Actual Delivery- is the piston displacement minus the losses in

the cylinder. It is the air available to do work, expressed in CFM
of free air, and is the real measure of flow.

The Power Efficiency - is the ratio between the amount of air

delivered by the compressor and its electrical requirements.
Usually, this is expressed in Kilowatts (kW) per 100 CFM of
delivered air.

Kilowatt Power - is the power required at the compressor input

shaft for a specific speed, capacity, and pressure condition.

Motor Kilowatt power - is the nominal rating of the motor.

Service Factor is the additional power built into an electric motor
above the nominal rating expressed as a percent. Within the
service factor the brake horsepower of the compressor can
operate above the nominal Kilowatt power of the motor
Basics of Compressed Air - Distance Learning

FOR ALL YOUR COMPRESSED AIR NEEDS -

BEFORE, DURING AND AFTER INSTALLATION.