2.

8 Pressurization of Pneumatics
System
(Compressors)

By Tadele Libay

1
INTRODUCTION
Pneumatic systems use pressurized gases to transmit
and control power. Typically air is used as the fluid
medium from safety, availability and low-cost point
of view.

Generally, pneumatic systems are less expensive.

But because of compressibility, precise controlled
actuator velocities is impossible.

2
Pneumatics are limited to low pressure systems for
safety reasons (<250 psi [17 bar], tank explosions ).
2.9 PROPERTIES OF AIR
Composition of air 21% oxygen, 78% nitrogen and 1%
other gases such as argon and carbon dioxide on a
volume basis. Also contains up to 4% water vapor
depending on the humidity.
The reference (standard) atmospheric pressure is
101.325 kPa and changes with altitude.
Since volumes change with pressure pneumatic circuit
calculations use standard atmospheric pressure of
1 atm=101.325 kPa at 20oC and RH of 36%.
3
Two scales of pressure measurement: absolute
(reference is complete vacuum) and gage (reference
is standard atmospheric pressure for this topic).
PERFECT GAS LAWS
Boyle’s Law: T = Constant. P and V are related by
V1 P2

V2 P1
Charles’ law: p = constant. V and T are related by
V1/V2 = T1/T2

4
Gay-Lussac’s law: V is constant. P and T are related
by p1/p2 = T1/T2
General gas law
p1V1 p2V2

T1 T2

2.10. COMPRESSORS
A compressor compresses air or another gas from a
low inlet pressure to a higher discharge pressure as
required. This is achieved by forcing the fluid into a
region of reduced volume. Generally of the positive
displacement type and are either of the
reciprocating (piston) and rotary (screw and vane).
5
2.10.1. Piston Compressors
A single-piston compressor can provide pressure up to
10 bars. Above that pressure it will need staging as
the compression process becomes less efficient.
The compressor is fully automatic: switches on at a set
low pressure and switches off at the higher set
pressure.

6
 Effect of number of stages on discharge pressure
NUMBER OF STAGES PRESSURE CAPACITY (Psi)
1 80- 150
2 100-250
3 400-2500
4 2000-5000

2.10.2. Screw Compressors

A cutaway view is shown in Fig below. The air is
trapped and finally squeezed into a low volume
region. There is a carefully controlled clearance
between both rotors and the housing, protected by a
film of oil which also acts as a sealant.
7
Fig. Operation of screw compressor 8
2.10.3. Vane Compressors
Similar to the one seen in hydraulic pumps and
motors. Single stage up to 50 psi and up to 150 psi
in a two stage design.

2.11. Air Capacity Rating of Compressors

Compressors are rated in terms of m 3/min free air,
defined as air at actual atmospheric conditions. The
general gas equation can be modified to relate the
incoming and out going air(general Gas Law).
V1 = V2(p2/p1)T1/T2) → Q1 = Q2(p2/p1)T1/T2)

9
Sizing of Air Receivers
Air receiver is basically air reservoir and to size it will
require the system pressure and flow-rate
requirements, compressor output capability, and the
type of duty.
This can be estimated by
101t (Qr  Qc )
Vr 
pmax  pmin
t = time that receiver can supply required amount of
air (min)
Qr = Consumption rate of pneumatic system (m3/min)
10
Qc= Output flow-rate of compressor (m3/min)
pmax = Maximum pressure level in receiver (kPa)
pmin = Minimum pressure level in receiver (kPa)
Vr = receiver size (m3)

Power Required to Drive Compressors

The theoretical

p Q p 
power
0.286 required
 is given by
Pt  in
 out   1 (kW )
17.1  p in  


pin = inlet atmospheric pressure (kPa, abs)

pout = outlet pressure (kPa, abs)
Q = flow rate (m3/min) 11
To determine the actual power, the overall efficiency
need to be used.
FLUID CONDITIONERS
Purpose is to make air a more acceptable fluid
medium for the pneumatic system as well as
operating personnel. Included are regulators ,filters,
lubricators, mufflers, and air dryers.

12
Air Pressure Regulators
These are used to maintain a constant pressure air
supply. A diaphragm type regulator is shown in
fig below . Pressure is set by the compression of
spring C. Exit pressure acts on diaphragm D
(displaced downward) and action of the top spring
on stem J reduces the flow area of valve E. High
pressure reduces the flow area so that the outlet
pressure is reduced. Excess pressure is relieved to
the atmosphere through knob B (detachment of J
from diaphragm). ANSI symbol is also shown in
the same figure.
13
Fig. Use of gas-loaded accumulator in hydraulic
system for crushing car bodies. 14
Fig. Operation of gas-cooled piston accumulator 15