Air Compressor

An air compressor is a device that converts power (using an electric motor, diesel
or gasoline engine, etc.) into potential energy stored in pressurized air (i.e.,
compressed air). By one of several methods, an air compressor forces more and
more air into a storage tank, increasing the pressure. When tank pressure reaches
its engineered upper limit, the air compressor shuts off. The compressed air, then,
is held in the tank until called into use.The energy contained in the compressed air
can be used for a variety of applications, utilizing the kinetic energy of the air as it
is released and the tank depressurizes. When tank pressure reaches its lower limit,
the air compressor turns on again and re-pressurizes the tank. An air compressor
must be differentiated from a pump because it works for any gas/air, while pumps
work on a liquid.

Positive Displacement Compressors

An air compressor is a device that converts power (using an electric motor, diesel
or gasoline engine, etc.) into potential energy stored in pressurized air (i.e.,
compressed air). By one of several methods, an air compressor forces more and
more air into a storage tank, increasing the pressure. When tank pressure reaches
its engineered upper limit, the air compressor shuts off. The compressed air, then,
is held in the tank until called into use.The energy contained in the compressed air
can be used for a variety of applications, utilizing the kinetic energy of the air as it
is released and the tank depressurizes. When tank pressure reaches its lower limit,
the air compressor turns on again and re-pressurizes the tank. An air compressor
must be differentiated from a pump because it works for any gas/air, while pumps
work on a liquid.

Dynamic Compressor

In a dynamic compressor, the pressure increase takes place while the gas flows.
The flowing gas accelerates to a high velocity by means of the rotating blades on
an impeller. The velocity of the gas is subsequently transformed into static pressure
when it is forced to decelerate under expansion in a diffuser. Depending on the
main direction of the gas flow used, these compressors are called radial or axial
compressors. As compared to displacement compressors, dynamic compressors
have a characteristic whereby a small change in the working pressure results in a
large change in the flow rate.

Types of Air Compressor

1. Reciprocating Air Compressors

Reciprocating air compressors are positive displacement machines, meaning

that they increase the pressure of the air by reducing its volume. This means
they are taking in successive volumes of air which is confined within a
closed space and elevating this air to a higher pressure.

The reciprocating air compressor accomplishes this by a piston within a

cylinder as the compressing and displacing element.

1 HP ~ 4 CFM at 100 psi

and that 1 to 50 HP are typically for reciprocating units. Compressors 100 hp

and above are typically Rotary Screw or Centrifugal Compressors.

The reciprocating air compressor is single acting when the compressing is

accomplished using only one side of the piston. A compressor using both
sides of the piston is considered double acting
2. Rotary Screw Compressors

Rotary air compressors are positive displacement compressors. The most

common rotary air compressor is the single stage helical or spiral lobe oil
flooded screw air compressor. These compressors consist of two rotors
within a casing where the rotors compress the air internally. There are no
valves. These units are basically oil cooled (with air cooled or water cooled
oil coolers) where the oil seals the internal clearances.
Since the cooling takes place right inside the compressor, the working parts
never experience extreme operating temperatures. The rotary compressor,
therefore, is a continuous duty, air cooled or water cooled compressor
package.

Rotary screw air compressors are easy to maintain and operate. Capacity
control for these compressors is accomplished by variable speed and
variable compressor displacement. For the latter control technique, a slide
valve is positioned in the casing. As the compressor capacity is reduced, the
slide valve opens, bypassing a portion of the compressed air back to the
suction. Advantages of the rotary screw compressor include smooth, pulse-
free air output in a compact size with high output volume over a long life.
The oil free rotary screw air compressor utilizes specially designed air ends
to compress air without oil in the compression chamber yielding true oil free
air. Oil free rotary screw air compressors are available air cooled and water
cooled and provide the same flexibility as oil flooded rotaries when oil free
air is required.
3. Centrifugal Compressor
The centrifugal air compressor is a dynamic compressor which depends on
transfer of energy from a rotating impeller to the air.
The centrifugal air compressor is a dynamic compressor which depends on
transfer of energy from a rotating impeller to the air.
Centrifugal compressors produce high-pressure discharge by converting
angular momentum imparted by the rotating impeller (dynamic
displacement). In order to do this efficiently, centrifugal compressors rotate
at higher speeds than the other types of compressors. These types of
compressors are also designed for higher capacity because flow through the
compressor is continuous.

Adjusting the inlet guide vanes is the most common method to control
capacity of a centrifugal compressor. By closing the guide vanes, volumetric
flows and capacity are reduced.
The centrifugal air compressor is an oil free compressor by design. The oil
lubricated running gear is separated from the air by shaft seals and
atmospheric vents.
Main application of air compressor

Air compressors are found in a wide range of environments for an even wider
range of uses. You’ll see gas stations offering compressed air to inflate your
vehicle’s tires and your tire shop using compressed air with an air tool to remove
your tires. You may have seen small desktop air compressors used with an airbrush
or a trailer-style gas-powered air compressor at a construction site powering
jackhammers and concrete compactors.

In fact, you’ve likely been around many different kinds of air compressors and
didn’t even know it — they may be hidden away in your refrigerator or the HVAC
system at your local arena.

Air compressors have a multitude of uses for leisure and maintenance at home or
in businesses to get work done efficiently and safely. The pressure that comes from
compressed air has so many uses that we’re sure to leave out a few applications,
but we have compiled a lengthy list that will widen your knowledge about the
various ways that air compressors are used in a multitude of environments.

Different applications call for different types of air compressors and while there
are many types of compressors in size and power supply, you will find two main
designs for the majority of air compressors: reciprocating piston air compressors
and rotary screw air compressors.

In these two designs you’ll find several models offering a selection ranging from
the low pressure air in a small storage tank sufficient to pump up your bike or car
tires to the ultimate power of pressurized air that will supply a heavy
manufacturing facility with constant and reliable air for plant operations.

Unless you work in manufacturing or another industrial setting, you’re probably

most familiar with reciprocating piston air compressors, but you may not have seen
all the variations of this air compressor design. The tank can be vertical or
horizontal, can be a single cylinder tank or double cylinder and can be a portable
design with wheels to easily move around or a stationary model that stays in one
place.

Air compressors can be grouped into three classifications: consumer grade,

professional grade and industrial grade.

 Consumer grade air compressors can be described as a pancake or single-

stage model. They’re used for household tasks like inflating tires and
inflatable products and possibly some low-load air tools like staplers and
brad guns.
 Professional grade air compressors provide more power and higher
pressurized air. They could be two-stage reciprocating models or rotary
screw models and can provide more power to run several air tools at once
with intermittent use.
 Industrial grade air compressors will be the workhorse of a manufacturing
plant or the reliable power source on an oil rig. They are designed to provide
a steady flow of compressed air for long periods of time and can take
fluctuating surges in use typical in major manufacturing plants. These
compressors are built with high-quality components that allow for
customization to the specific environment to improve performance, energy
efficiency and reliability.
Components of Centrifugal Compressor

 Inlet The inlet to a centrifugal compressor is typically a simple pipe. It may

include features such as a valve, stationary vanes/airfoils (used to help swirl
the flow) and both pressure and temperature instrumentation. All of these
additional devices have important uses in the control of the centrifugal
compressor.

 Centrifugal impeller The key component that makes a compressor

centrifugal is the centrifugal impeller, Figure 0.1, which contains a rotating
set of vanes (or blades) that gradually raises the energy of the working gas.
This is identical to an axial compressor with the exception that the gases can
reach higher velocities and energy levels through the impeller's increasing
radius. In many modern high-efficiency centrifugal compressors the gas
exiting the impeller is traveling near the speed of sound.
 Impellers are designed in many configurations including "open" (visible
blades), "covered or shrouded", "with splitters" (every other inducer
removed) and "w/o splitters" (all full blades). Both Figures 0.1 and 3.1 show
open impellers with splitters. Most modern high efficiency impellers use
"backsweep" in the blade shape.[

 Diffuser The next key component to the simple centrifugal compressor is the
diffuser.[ Downstream of the impeller in the flow path, it is the diffuser's
responsibility to convert the kinetic energy (high velocity) of the gas into
pressure by gradually slowing (diffusing) the gas velocity. Diffusers can be
vaneless, vaned or an alternating combination. High efficiency vaned
diffusers are also designed over a wide range of solidities from less than 1 to
over 4. Hybrid versions of vaned diffusers include: wedge, channel, and pipe
diffusers. Some turbochargers have no diffuser.

Bernoulli's fluid dynamic principle plays an important role in understanding

diffuser performance.

 Collector The collector of a centrifugal compressor can take many shapes

and forms.When the diffuser discharges into a large empty chamber, the
collector may be termed a Plenum. When the diffuser discharges into a
device that looks somewhat like a snail shell, bull's horn or a French horn,
the collector is likely to be termed a volute or scroll. As the name implies, a
collector’s purpose is to gather the flow from the diffuser discharge annulus
and deliver this flow to a downstream pipe. Either the collector or the pipe
may also contain valves and instrumentation to control the compressor.
Components of Reciprocating Air Compressor

Pistons
piston reciprocating air compressor parts

Special Aluminum alloy pistons for non-lubricated air compressor and

graded cast iron pistons are used for lubricated models. Piston Rings are
used for sealing to a cylinder.

Connecting Rod
connecting rod reciprocating air compressor parts

Forged alloy steel connecting rod is duly normalized, are designed to

provide minimum thrust on cross head bearing surface.

Main Bearings & Big End Bearings

main bearing reciprocating air compressor

Copper lead alloy designed for long life. It gives perfect rigidity to running
gear.

Cross Slide & Cross Head

cross head reciprocating air compressor

Manufactured from high-grade S.G. Iron material. Its low inertia along with
low friction cross slide ensure the perfect running of the crosshead.

Suction & Discharge Valves

suction valve, discharge valve reciprocating air compressor

Stainless Steel plate type or spring type valves are arranged symmetrically in
suction & discharge provides longer life.

Oil Pump
oil pump reciprocating air compressor parts

It feeds oil to main bearings, connecting rod bearings & to cross slides. The
oil pump regulates the oil pressure by pressure regulating screw.

Along with above parts some other small parts as like oil seal ring, small end
bushing, Suction filter element, crosshead pin, heads, belts nut, and bolt,
gaskets etc. are used.

Besides this information, you are suggested to read something more from
below engineering books

Frame/Crankcase
crankcase reciprocating air compressorCrankcase which is also known as
Frame is a heavy, rugged housing containing all the rotating parts. A
cylinder and crosshead guide is also mounted on the crankcase.
Bearing housing is fitted on a crankcase with accurately bored to fit main
bearings. So, misalignment or eccentricity is avoided.

This is a totally enclosed rigid cast iron body in square or rectangle shape,
often work as oil sump.

Crank Shaft
crankshaft reciprocating air compressor parts

High-grade S.G. Iron crankshaft in one piece in design, dynamically

balanced with counterweights, avoid any twisting.

Crank pin & journals duly ground & polished ensure the long life of
bearings. A flywheel is fitted on the crankshaft.

Cylinders
cylinder reciprocating air compressor parts

Graded cast iron cylinders designed with a water jacket in water-cooled air
compressor to remove heat generated during compression.
 PNTC COLLEGES
MARINE ENGINEERING DEPARTMENT

GROUP 2
REPORT (HARD COPY)

BUSTAMANTE JOHN CARL V.

 PNTC COLLEGES
MARINE ENGINEERING DEPARTMENT

GROUP 1
REPORT (HARD COPY)

ALMAREZ KIM BRYAN M.