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Sixth Edition
COMPRESSED AIR
A. J. Clark School of Engineering Department of Civil and Environmental Engineering
11
By
Dr. Ibrahim Assakkaf
ENCE 420 Construction Equipment and Methods
Spring 2003
Department of Civil and Environmental Engineering
University of Maryland, College Park
Slide No. 1
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COMPRESSED AIR
Slide No. 2
INTRODUCTION
Compressed air is used for:
9Drilling rock
9Driving piles
9Operating hand tools
9Pumping
9Cleaning
PUMP
INTRODUCTION
PAVING
BREAKER
Slide No. 3
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INTRODUCTION
Slide No. 4
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INTRODUCTION
Slide No. 5
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Things to consider:
9Effect of altitude on capacity.
9Loss of air pressure in pipe
and hose systems.
9Capacity factors.
Slide No. 6
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OVERVIEW
Selecting the right air
compressor depends on
many factors.
Compressor capacity and operating
pressure depend on the tools used.
Engine and compressor lose power
and capacity as altitude increases
and temperature rises.
OVERVIEW
Slide No. 7
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GLOSSARY OF GAS-LAW
TERMS
Slide No. 8
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GLOSSARY OF GAS-LAW
TERMS
Slide No. 9
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Slide No. 10
GLOSSARY OF GAS-LAW
TERMS
Slide No. 11
GLOSSARY OF GAS-LAW
TERMS
TF = 32 + 1.8TC
GLOSSARY OF GAS-LAW
TERMS
Slide No. 12
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GLOSSARY OF GAS-LAW
TERMS
Slide No. 13
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Slide No. 14
GLOSSARY
Gas-law equations are
based on absolute
temperature.
R Absolute temperature is
Fahrenheit plus 460.
Slide No. 15
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GLOSSARY
TAMPER
R Diversity factor is
the ratio of the actual
quantity of air required
for all uses to the sum of
the individual quantities
for each use.
TYPES OF COMPRESSION
Slide No. 16
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Isothermal Compression:
When a gas undergoes a
change in volume without
any change in temperature,
this is referred to as
isothermal expansion or
compression.
TYPES OF COMPRESSION
Slide No. 17
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Adiabatic Compression:
When a gas undergoes a
change in volume without
gaining or losing heat, this is
referred to as adiabatic
expansion or compression.
Slide No. 18
BOYLES LAW
P1V1 = P2V2 = K
(2)
Slide No. 19
Example 1
V2 =
P1V1 = P2V2 = K
P1V1 34.7(1000)
=
= 257.6 ft 3
P2
134.7
10
Slide No. 20
V1 V2
=
=C
T1 T2
(3)
V1 = initial volume
T1 = initial absolute temperature
V2 = final volume
T2 = final absolute temperature
C = a constant
Slide No. 21
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(4)
V1 = initial volume
T1 = initial absolute temperature
P1 = initial absolute pressure
V2 = final volume
T2 = final absolute temperature
P2 = final absolute pressure
C = a constant
11
Slide No. 22
Example 2
P2V2
= a constant
T1
T2
P1 = 40 + 14.7 = 54.7 psi
3
V1 = 1,000 ft
PV T
54.7(1000) 570
P2 = 1 1 2 =
= 304.7 psi
0
T1 V2
510
200
T1 = 460 + 50 = 510 F
V2 = 200 ft3
T2 = 460 + 110 = 5700F Final Gauge = 304.7 - 14.7 = 291 psi
Slide No. 23
ENERGY REQUIRED TO
COMPRESS AIR
P1V1 = P2V2 = K
(5)
P1V1n = P2V2n = K
(6)
12
Slide No. 24
ENERGY REQUIRED TO
COMPRESS AIR
Slide No. 25
ENERGY REQUIRED TO
COMPRESS AIR
dW = VdP
But
Hence
K n
V =
P
(7)
(8)
1
n
K
dW = dP
P
(9)
13
Slide No. 26
ENERGY REQUIRED TO
COMPRESS AIR
Integrating yields
1 2
W = Kn
1
dP
1
n
(10)
P
For isothermal compression, n = 1, therefore
2
W = K
1
P
dP
= K ln 2 + C
P
P1
(11)
ENERGY REQUIRED TO
COMPRESS AIR
Slide No. 27
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P
P
W = K ln 2 = (2.3026) K log 2
P1
P1
(12)
14
ENERGY REQUIRED TO
COMPRESS AIR
Slide No. 28
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P
P
W = ( 2.3026) K log 2 = ( 2.3026)(2116.8)V1 log 2
P1
P1
or
P
W = ( 4.873)V1 log 2
P1
ENERGY REQUIRED TO
COMPRESS AIR
(13)
Slide No. 29
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15
Slide No. 30
ENERGY REQUIRED TO
COMPRESS AIR
(14)
Slide No. 31
Example 3
P2
114.7
= 0.1477(100) log
P1
14.7
16
Slide No. 32
ENERGY REQUIRED TO
COMPRESS AIR
hp = (0.0642 )
nV P2
n 1 P1
Example 4
(15)
Slide No. 33
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nV P2 n
1
hp = (0.0642 )
n 1 P1
1.4 1
1.4 1 14.7
17
EFFECT OF ALTITUDE
Slide No. 34
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EFFECT OF ALTITUDE
Slide No. 35
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18
EFFECT OF ALTITUDE
Slide No. 36
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Because a compressor of a
specified capacity actually supplies
a smaller volume of air at a given
discharge pressure at a higher
altitude, it requires less power to
operate a compressor at a higher
altitude.
EFFECT OF ALTITUDE
Slide No. 37
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19
Slide No. 38
EFFECT OF ALTITUDE
Table 1. Theoretical Horsepower Required to Compress 100 ft3 of Free Air per Minute
at Different Altitudes
Slide No. 39
EFFECT OF ALTITUDE
The capacity of an air
compressor is rated at a
barometric pressure of
20
Slide No. 40
BOYLES LAW
P1V1 = P2V2
P1 is the pressure of the free
air when we are considering
the use of a compressor.
Text p. 307
Slide No. 41
BOYLES LAW
14.7 14.2
13.7
13.2
12.7
12.2
21
Slide No. 42
EFFECT OF ALTITUDE
Consider 100 cu ft of free air
compressed to 100 psi gauge.
Applying Boyles law.
P1V1
V2 =
P2
V1 = 100 cfm
P1 = atmospheric
pressure
P2 = atmospheric
pressure
+ 100
Slide No. 43
EFFECT OF ALTITUDE
Change in V2 (cu ft) with
12.2
10.9
22
STATIONARY
COMPRESSORS
Slide No. 44
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STATIONARY
COMPRESSORS
Slide No. 45
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23
STATIONARY
COMPRESSORS
Slide No. 46
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TANK MOUNTED
COMPRESSORS
Slide No. 47
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24
RECIPROCATING
COMPRESSORS
Slide No. 48
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A reciprocating compressor
depends on a piston, which
moves back and forth in a
cylinder, for the compressing
action.
The piston may compress air
while moving in one or both
directions.
RECIPROCATING
COMPRESSORS
Slide No. 49
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25
RECIPROCATING
COMPRESSORS
ROTARY COMPRESSORS
Slide No. 50
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Slide No. 51
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26
ROTARY SCREW
COMPRESSORS
Slide No. 52
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ROTARY SCREW
COMPRESSORS
Slide No. 53
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27
ROTARY SCREW
COMPRESSORS
Slide No. 54
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Slide No. 55
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ADVANTAGES OF ROTARY
SCREW COMPRESSORS
28
Slide No. 56
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ADVANTAGES OF ROTARY
SCREW COMPRESSORS
Slide No. 57
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PORTABLE COMPRESSORS
29
COMPRESSOR CAPACITY
Slide No. 58
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COMPRESSOR CAPACITY
Slide No. 59
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30
Slide No. 60
COMPRESSOR CAPACITY
Slide No. 61
Example 5
Consider a 315
- cfm two stage portable compressor
with the following specifications as given by the
manufacturer:
No. of low-pressure cylinders = 4
Diameter of low-pressure cylinders = 7 in
Length of stroke = 5 in
Revolution per minute (rpm) = 870
7
2
Area of cylinder = = 0.267 ft 2
(144)
5
Displacement per cylinder per stroke = 0.267 = 0.111 ft 3
12
31
Example 5 (continued)
Slide No. 62
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ft 3
min
315
100 = 81.5%
386.3
Slide No. 63
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EFFECT OF ALTITUDE ON
CAPACITY OF COMPRESSORS
32
Slide No. 64
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EFFECT OF ALTITUDE ON
CAPACITY OF COMPRESSORS
If a compressor is operated at a
higher altitude, such as 5,000 ft
above sea level, the absolute
barometric pressure will be about
12.2 psi.
At the higher altitude, the density is
less and the weight of air in ft3 of
free volume is less than at sea
level.
Slide No. 65
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EFFECT OF ALTITUDE ON
CAPACITY OF COMPRESSORS
33
Example 6
Slide No. 66
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Example 7
Slide No. 67
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34
INTERCOOLERS
Slide No. 68
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INTERCOOLERS
Slide No. 69
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An intercooler requires a
continuous supply of circulating
water to remove the heat from the
air. It will require 1.0 to 1.5 gal of
water per minute for each 100 cfm
of air compressed.
35
AFTERCOOLERS
Slide No. 70
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RECEIVERS
Slide No. 71
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36
RECEIVERS
Slide No. 72
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Slide No. 73
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37
Slide No. 74
Slide No. 75
PRACTICAL EXERCISE
What will be the pressure at the
end of a compressed air pipeline
used to transmit 3,000 cfm of
free air?
Hose
Pipe
38
Slide No. 76
Slide No. 77
CL Q 2
f =
5
r d
(16)
39
Slide No. 78
CL Q 2
f =
r d5
Where
f = pressure drop, psi
L = length of pipe, ft
Q = volume of free air, ft3, per second
r = ratio of compression, based on absolute press.
d = actual ID of pipe, in
C = experimental coefficient
Slide No. 79
0.1025 L Q 2
f =
5.31
r
d
(17)
40
Slide No. 80
Figure 2
Compressed-Air Flow Chart
Slide No. 81
Example 8
100 + 14.7
= 7.803
14.7
2
f =
0.1025 L Q 2
5.31
r
d
1000
0.1025(100) 60
=
= 0.232 psi
7.803
(4)5.31
41
Example 8 (continued)
Slide No. 82
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Slide No. 83
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42
Slide No. 84
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Slide No. 85
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43
Slide No. 86
Example 9
1450 ft of pipe,
4 gate valves,
Slide No. 87
Example 9 (continued)
The equivalent length of the pipe will be:
Pipe
Gate valves: 4 X 2.4 (Table 3)
onon-run tees: 6 X 7.7 (Table 3)
angle valves: 3 X 56.0 (Table 3)
Total
r=
= 1450 ft
= 9.6 ft
= 46.2 ft
= 168 ft
1673.8 ft
90 + 14.7
= 7.122
14.7
2
f =
0.1025L Q 2
5.31
r
d
1200
0.1025(1673.8) 60
=
= 7.86 psi
7.122
(4)5.31
44
Example 10
Slide No. 88
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Slide No. 89
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Table 4
(Table 11-7, Text).
Loss of Pressure (psi)
in 50 Feet of
Hose
45
Slide No. 90
Example 10 (continued)
Pdrop =
Slide No. 91
DIVERSITY OR CAPACITY
FACTOR
46
Slide No. 92
CAPACITY FACTORS
Slide No. 93
DIVERSITY OR CAPACITY
FACTOR
47
Slide No. 94
DIVERSITY OR CAPACITY
FACTOR
Slide No. 95
DIVERSITY OR CAPACITY
FACTOR
48
Slide No. 96
DIVERSITY OR CAPACITY
FACTOR
Slide No. 97
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49
Slide No. 98
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Slide No. 99
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50
51
Example 11
52
THE COST OF
COMPRESSED AIR
THE COST OF
COMPRESSED AIR
53
THE COST OF
COMPRESSED AIR
THE COST OF
COMPRESSED AIR
54
THE COST OF
COMPRESSED AIR
Example 12
55
Example 12 (continued)
Hourly Costs:
Fixed cost: 19,686 1,400 = $14.06
Fuel: 7.2 X 1.00
=
7.2
Lubricating oil: 0.125 X 3.20 =
0.4
Operator:
=
8.0
Total cost per hour = $29.66
Volume of compressed per 50
- m
in hr:
= 50X600 = 30,000 ft3
30,000
Cost per 1,000 ft 3 = $29.66
= $0.99
1,000
56
In a typical plant, air leaks account for 20% of the total air usage!
8000 hr per year operation
Electrical costs = 0.06 $/kwhr
Line pressure = 100 psi
Plant Demand (cfm) 400 cfm
Air leaks (cfm) 20% 80 cfm
Total Compressor Demand 480 cfm
57
$43,840
$ 8,768
$52,608
TOTAL
COMPRESSOR
SELECTION
1. Tools or equipment to be
used.
2. Air (cfm) requirement of
each.
3. Pressure (gpsi) requirement
of each
4. Piping and hose lengths
58
COMPRESSOR
SELECTION
5. Capacity factor.
6. Theoretical compressor size.
7. Economical compressor
available, that exceeds
theoretical requirement
and provides flexibility.
59