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4 7 bar
Service air
Whistle air
Pneumatic tools
Life boat, pilot ladder
1.5 2 bar
Installation Requirements
Compressors
Minimum 2 or more compressors
Sufficient capacity to charge air receivers within 1 hour from atm. to max.
pressure to provide
Air Receivers
At least 2 air receivers with sufficient capacity without replenishment and
able to provide
Installation Requirements
Pressure Relief devices
Relief v/v to be fitted after each stage of compression
Relief v/v to be fitted on the air receiver
Relief v/v or bursting disc to be fitted on inter & after coolers
Air Temperature
Limited to 93OC to prevent explosion
Fusible plug or high temp cut out provided as safety measure
Pressure Test
Cylinders, cylinder covers, inter & after coolers are tested by hydraulic
pressure to twice their working pressure.
Casing of intercooler and after cooler is hydraulically tested to 1.5 times the
cooling water pressure
Air induction
1-2
Air compression
2-3
Air delivery
3-4
Expansion of
remaining air
Vc
Clearance vol.
Vs
VI
Volumetric Loss
Due to clearance Volume
Effect of increasing
Clearance Volume
Multistage Compression
As the pressure increases, more stages are required with intercooling due
to following disadvantages of single stage compression:
Low volumetric efficiency
Multistage Compression
Applied when delivery press.
is high
Compression is carried out
in stages
Ensures equal rise in temp in
each stages to prevent v/vs
& springs damage
Requires minimum work;
shaded area indicates the
wok saved
If stage pressures are P1, P2
& P3, P4
P2 = P1 . P3 & P3 = P2 . P4
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
Free air is air at atm. press and at 15 deg C
Vol.eff. always refer to low pressure piston
Components
Air Filter
Material felt or paper, metal gauze or nylon strands
Remove contaminant to prevent
abrasive wear of piston rings, valves
deposit on valves casing source of ignition
Components
Suction & Delivery Valves
Low inertia automatic valves which operate on low diff pressure
Material used for
Valve seat 0.4% carbon steel hardened & polished surface
Valve plate Nickel or stainless steel hardened & polished
Spring tempered hardened steel
Drain Trap
Provided to drain off water & oil automatically from
compressed air system
Water must be drained at each stage to prevent
Removal of oil film from cylinder wall, assisting wear of liner
and piston ring
Corrosion to form iron oxide, assisting degradation of oil
Air Receiver
Size depends on engine requirements
Should have sufficient capacity to give
12 consecutive starts for reversible engine
6 consecutive starts for non reversible engine
Fabricated from good quality mild steel with UTS 500 MN/m 2 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
Air Receiver
Air Receiver
Ambient condition
Ambient temp
Coolant temperature
Presence of dust or oil vapour
Operating system
Continuous or intermittent
maintenance
Lubrication 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
Low viscosity easy spreading, effective sealing,
hydrodynamic lubrication with low friction
Flash point above 220oC
Oil with minimum heavy ends
If oil has too broad distillation range, the more volatile portion may
tend to evaporate leaving behind heavier ends in the hot zone
Mechanics of Explosion
Oxidation of oil
Rate of oxidation depends on
Temperature
Air pressure
Presence of catalyst iron oxide
Exposure time
Explosion
Fire can initiate in unloaded compressor
Burning coke could act as ignition point for air-oil vapour mixture
Spontaneous ignition followed by weakening the metal wall can initiate
explosion
Prevention of Explosion
Design of compressor Installation
Air flow rates & exposure time
Prevent oil accumulation
Air flow rate of 8m/sec keeps the pipes clean by moving the large
oil droplets to cooler areas
Synthetic Oil
Product made of chemical synthesis
Raw materials or base stock may be mineral oil derived
The chemical structure is planned and controllable
The molecular structure is variable so that product
performance may be modified
Additive treated to produce lubricant with superior
properties to mineral oil
Synthetic Oil
Advantages
Superior to mineral oil & excellent protection against corrosion
Suitable for severe operation
Good thermal & oxidation stability
Operate over wide temperature range
Good viscosity vs temp. properties
Low pour point (-33OC to - 48OC)
Good wear resistance with low viscosity
Reduced maintenance
Cleaner compressor due to minimum deposits
Long service life
Enhanced safety due to high flash point (246 to 266 deg C)
Synthetic Oil
Disadvantages
Less compatible with seals & paint
Initial cost is high, but overall it may be
cost effective
Possible mineral oil incompatibility
Potential toxicity