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COMPRESSOR
LEARNING OBJECTIVES
Uses of compressed air
Installation requirements
Air compression theory
Multistage compression
Volumetric efficiency
Constructional details
Operation and Maintenance
Compressor lubrication
Explosion hazard
Air receivers
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AIR COMPRESSOR TEORY
Nearly perfect gas, as air is composed of mainly 23% oxygen and 75.5%
nitrogen & rest other gases by mass
During compression
Volume reduces
Pressure & temperature increases
Mass remains constant
TYPES OF COMPRESSION
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IDEAL P-V DIAGRAM
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VOLUMETRIC LOSS
DUE TO CLEARANCE VOLUME
EFFECT OF INCREASING
CLEARANCE VOLUME
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MULTISTAGE COMPRESSION
AS THE PRESSURE INCREASES, MORE STAGES ARE REQUIRED WITH INTERCOOLING
DUE TO FOLLOWING DISADVANTAGES OF SINGLE STAGE COMPRESSION:
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MULTISTAGE COMPRESSION
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VOLUMETRIC EFFICIENCY
It is the relationship between the Qty of air discharged
and the swept volume.
vol of air discharged as free air
Vol efficiency = ____________________________
swept vol of L.P. piston
CLEARENCE VOLUME
To provide for thermal expansion and prevent the piston from striking
cylinder cover, a small clearance, called bumping clearance is
maintained between cylinder cover & piston
Bumping clearance must be as small as possible
High bumping clearance reduces volumetric efficiency of compressor
Reduces compressor capacity & increases discharge air temp.
Bumping clearance is effected by bearing wear & gasket thickness
Low bumping clearance can cause mechanical damage
Bumping clearance must be checked after overhauling
Clearance volume is about 6% of swept volume
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FACTORS AFFECTING VOLUMETRIC
EFFICIENCY
Clearance volume - gaskets , bearing wear down
Valves dirty, leaky, spring tension
Leakage past piston rings
Insufficient cooling water due to dirty coolers
High cooling water temp.
High air inlet temp.
Throttling of air intake due to
Dirty intake filter
Insufficient suction v/v lift
Strong suction v/v spring
END
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COMPRESSOR
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TWO STAGE AIR COMPRESOR IN LINE
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THREE STAGE AIR COMPRESSOR-IN-LINE
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PISTON
Trunk type piston is used in single acting compressor
BEARING/CRANKSHAFT
BEARINGS
Thin shell type in modern compressor
Requires L.O. pressure above 2 bar
Conventional thick shell can run even at 1.0 bar
CRANKSHAFT
Usually forged carbon steel integral with counter weight
Cast steel being fatigue prone is not us
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INTER-COOLER / AFTER-COOLER
MULTI TUBULAR
Copper tubes expanded in brass tube plates with
allowance for expansion of tube nest
INTER-COOLER / AFTER-COOLER
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DRAIN TRAP
Provided to drain off water & oil automatically from compressed air
system
UNLOADER
PREVENTS COMPRESSOR TO START ON LOAD
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UNLOADER
AIR RECIEVER
SIZE DEPENDS ON ENGINE REQUIREMENTS
Fabricated from good quality mild steel with UTS 500 MN/m2 with an
elongation of not less than 23% to 25%
having one longitudinal welded seam
welded hemispherical dish at the ends with elliptical manhole door
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AIR RECIEVER
AIR RECIEVER
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FUNCTION OF COMPRESSOR LUBRICANT
Compressor design
Type of cooling
Number of stages
Air flow rate
Oil retention time
Ambient condition
Ambient temp
Coolant temperature
Presence of dust or oil vapour
Operating system
Continuous or intermittent
maintenance
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LUBRICARION SELECTION
According to normal lubrication requirement and to minimise coke deposit
Plain mineral oil is not used as it oxidises easily at high temp. and pressure
Lube oil must have anti-oxidant additives for good oxidation resistance
If oil has too broad distillation range, the more volatile portion may tend to evaporate
leaving behind heavier ends in the hot zone
END
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