Compressors Basic Principles1

Compressors: Basic principles
l Compressors: Basic principles
Help Page
Basic product training
Previous Slide – Click on this button to access the previous page of the course
Go to last viewed slide – Click on this button to access the last viewed slide
Table of content – Click on this button to access the Table of Contents page the course
Course information – Click on this button to access the course information page of the course
Help – Click on this button for the help on navigation and command options available
l Industrial Air Academy 2

Course information page
 Course description
This course gives an overview of :
– Why and where do customers need compressed air, what are their specific requirements and what is the
customer value of compressed air for them.
– Ho do we make compressed air, by different compressors and their working principle.
 Course objectives: after the training participants should be able to:

– Explain the value of compressed air for the customer
– Analyse and define the customers needs
– Explain the working principle of different compressor types.
 Course developer / trainer

Walter Schroven
 Course duration
½ day
 Course update information

Last opdated: July 2007

1. Why do customers need compressed air?

Menu Page
1. Why do customers need 2. How do we make
compressed air? compressed air?
1.2. Applications of 1.3. Requirements of the 2.1. Basic principles for the
1.1. What is compressed air? compressed air customers compression of air
1.2.1. Where do customers use 1.3.1. Different requirements:

1.1.1. What is air? compressed air? pressure 2.2. Screw compressors
1.2.2. Applications of 1.3.2. Different requirements: 2.3. Oil injected

1.1.2. Compressed air compressed air flow screw compressor
1.2.3. Why using compressed 1.3.2. Different requirements

1.1.3. Absolute pressure air? flow: FAD 2.4. Oil free screw compressor
1.3.3. Different requirements: 2.5. Water injected

1.1.4. Effective pressure oil(free) screw compressor
1.3.3. Different requirements

1.1.5. Overview pressure oil(free): Class 0 2.6. Oil free tooth compressor
1.3.4. Different requirements:

1.1.6. Force of pressure quality air 2.7. Oil free scroll compressor

noise 2.8. Piston compressor

1.1 What is compressed air?

1.1.1. What is air

1. Why do customers need compressed air? > 1.1 What is compressed air?
 Air is a colorless, odorless and tasteless gaseous.

It contains:
– 78% nitrogen
– 21% oxigen
– 1% others
 Air press on the earth = Atmospheric pressure

– The air pressure depends on the relative location from the sea level.
 At sea level: 1 bar
 Above sea level: <1 bar
 Below sea level: >1 bar
 Height ↑ 1000m => pressure ↓0,1 bar (psi)

1.1.1. What is air

 Standard air:
Standard air is the air at

– 1 bar (14.5 psi)
– 20°C (68°F)
– Dry (relative humidity of 0%)

1.1.2. compressed air

Air in a balloon is initially at

atmospheric pressure
Balloon
As the air is gets filled in a

balloon, the balloon expands
Air in a balloon is initially at

Balloon
COMPRESSED
AIR
 The energy contained in the When the balloon can no
longer expand, the air in the
balloon gets compressed
compressed air within the balloon As the air gets filled in a
balloon, the balloon expands
is equal to the energy required to Air in a balloon is initially at
inflate it. Balloon


Energy required to fill the balloon

= Energy dissipated by the balloon
= Work done in moving the pencile
 When controlled, compressed air can be used to perform work.
Remark: there are always some losses during energy transformation.


 If the volume of a given amount of

air decreases, the pressure will
increase.
Volume ↓ => Pressure ↑

Final volume
of the balloon
Initial Volume
of the balloon
 The pressure in the balloon is
increased due to decrease in the
volume.

1.1.3. Absolute pressure

Pressure in the ball Pressure in the ball Pressure in the ball

= 0 bar = Atmospheric pressure > Atmospheric pressure
= 1 bar = 2 bar
i.e. Absolute pressure
= 0 bar (perfect vacuum) i.e. Absolute pressure i.e. Absolute pressure
= 1 bar = 2 bar
Atmospheric Atmospheric Atmospheric

Atmospheric
Plastic ball pressure 1 bar Plastic ball pressure 1 bar Pump Plastic ball pressure
pressure 11 bar
bar
 Absolute pressure is the total pressure measured from zero (perfect vacuum)

1.1.4. Effective pressure

Pressure in the ball = 2 bar

Pressure in the ball
> Atmospheric pressure
= 2 bar
Pressure ( in bar)
Atmospheric
Plastic ball pressure 1 bar
 Absolute pressure is the total pressure measured from zero (perfect vacuum)
 Effective pressure is the total pressure measured from the atmosheric
pressure.
 The effective pressure is the difference between absolute pressure and
 Effective pressure = Absolute pressure – Atmospheric pressure


 The pressure in the ball is equal to

Absolute pressure = 1 bar the atmospheric pressure
0 bar  The effective pressure is 0.
Effective pressure  The fan does not rotate
Atmospheric
Plastic ball pressure 1 bar


 The absolute pressure in the ball is 2 bar

 The effective pressure is 1 bar.
Absolute pressure = 1 bar
1 bar  The fan is rotating
Effective pressure
Pump Plastic ball

Atmospheric
pressure 1 bar
 The absolute pressure in the ball is 3 bar
 The effective pressure is 2 bar.
 The fan is rotating even faster
Absolute pressure = 2 bar
2 bar
Effective pressure
 The effective pressure is the pressure
available to deliver work.
Atmospheric
Pump Plastic ball pressure 1 bar

1.1.5. Overview pressure

Actual pressure
Effective pressure
(guage pressure)
{bar} (g) = {bar} (e)
Variable level
Vacuum {bar} Absolute

(u) pressure {bar}
(a)
Local
atmospheric
Normal pressure
atmospheric (barometric
pressure) {bar} Absolute
pressure (a) pressure {bar}
(a)
(a)

1.1.6. Force of pressure

 Example:
The force on the air receiver cover (0,08 m²) of XRVS476Cd during unload (27 bar) is:
 P= 27 bar 1 Pa = 10,13 N/cm2 = 10,13 x 104 N/m2

=> P= 27 x 10,13 x 104 N/m2
 P= F/A => F= P x A F= 27 x 10,13 x 104 N/m2 x 0,08 m2 F= 218808N

 F= m x g => m= F/g m= 218808 / 9,81 = 22304 kg
Atmospheric
pressure
XRVS 476 Cd
receiver
Forces on air receiver cover
Receiver pressure (0,08 m²) is more than 22000 kg
during unload = 27 bar

Menu Page








1.2. Applications of compressed air

1.2.1. Where do customers use compressed air?

1. Why do customers need compressed air? > 1.2 Applications of compressed air
Food & Beverage Food conservation and production
Medical and dental applications


Chemical and Petrochemical plants Gas separation and nitrogen production
Construction and other industries Water treatment and fish farming


Automobile and other manufacturing
Transport


Textile Mining
And many other applications

1.2.2. Applications of compressed air

Blowing Vacum
Air Motors Pumps Tools Sensing
Pneumatically operated machinery

1.2.3. Why using compressed air?

 Because it is the only solution in some applications.

Examples:
– Blowing, respirator, cleaning, paint spraying,…
 Because it is the easiest solution in some applications.

Examples:
– Automatisation:
 By using pistons: No need of motors and mechanical parts to make linear
movements to pless, clasp, throw out, positioning,…
 By using vacuum: No need of complex installations to pick and place parts.
– Transport
 No need of electrical motors and complex transmissions for converyer belts.
– …


 Because it is the safest solution in some applications.

Examples:
– No explosion risk by using pneumatic tools.
– Easy to notice when pneumatic tool is overloaded.
– No damage of tool and sourrounding by overloaded tool.
– …
 Because it is the most compact solution in some applications.

Examples:
– Compressed air tools are compacter than electic tools. This makes them
lighter and more ergonomic.
– Pneumatic parts takes less place in pneumatically operated machinery.
– …


 Because it is the chapes solution in many applications.

– All the previous benefits makes the use of compressed air the chapes
solution for many application.

Menu Page








1.3 Requirements of the customers.

1.3 Requirements of the customers

 Compressed air is used in different applications in different industies.

They all have their proper demands and requirements on:
– Pressure
– Flow
– Quality of the air
 Oil
 Water
 Solid particles
– Noise
– …

1.3 Requirements of the customers

 On the next pages, you find some examples of customers

requirements concerning pressure, flow, quality air, noise,…
 Exercise: Merge the customers requirements with the right solution:

1.3.1. Different requirements: pressure

1. Why do customers need compressed air? > 1.3 Requirements of the customers
Demand: Sollution
 Compressed air that gets the main  A compressor who delivers air at
engines and generators of a ship 30 bar
sets going.
 A compressor who delivers air at 7
 Compressed air to use in a snow bar
blower.
 A compressor who delivers air at 2
 Compressed air to be used for bar
driving pneumatic tools.

1.3.2. Different requirements: flow

Demand Sollution
 Compressed air to be used for  A compressor who delivers 1 litre
driving a dentical tool. air per second
 Compressed air to be used for  A compressor who delivers more
driving all tools of a assembly line. than 100 litre air per second

1.3.2. Different requirements flow:

Ho do we measure flow?
 Delivered air / time unit = FAD

 FAD = volume of delivered air,
converted to the same pressure
and temperature prevailing at the PER
UNIT
inlet. TIME
 Internal leakages: Convert

Convert to
inlet
INLET
to
conditions
FAD < displaced air of element CONDITIONS
 FAD: independent from the

ambient conditions
PER
UNIT
TIME

1.3.2. Different requirements flow:

Where do we measure flow?
Inlet Inlet Compressor Oil After Water

filter valve element separator cooler trap
OUTLET
INLET
Gearbox
Measure point of Fan Measure point of

Engine
FAD acoording to FAD acoording to
ISO 1217 ed.3 ISO 1217 ed.3
without appendix C appendix C

1.3.3. Different requirements: oil(free)

Demand Sollution
 Compressed air to be used in the  A compressor who delivers air with
production process of food. some ppm of oil
 Compressed air to blow up tyres.  A compressor who delivers oil free
air

1.3.3. Different requirements oil(free):

What is oil-free air?
 Atlas Copco is the first

manufacturer to be certificated
ISO8573-1 CLASS 0 for its oil-free
screw and tooth compressors.
 This ISO standard defines the
maximum concentration of oil in
the compressed air.
 Find more information on
www.classzero.com

1.3.4. Different requirements: quality air

Demand Sollution
 Compressed air to be used in the  A compressor installation who
operating room of a hospital. provide absolute clean air.
 Compressed air to blow away the  A compressor who delivers
chips of a lathe. untreated air

1.3.4. Different requirements quality air:

What is the quality of the air?
 Compressed air purity ISO 8573-1:

– Compressed air calssification for 3 main contaminants:
 Dirt
 Water
 Oil

1.3.5. Different requirements: noise

Demand Sollution
 Compressed air to be used for the  A compressor with a noice level of
assembly of medicines. The 55 dB(A)
compressor will stay near to the
 A compressor with a noice level of
work place.
75 dB(A)
 Compressed air to be used on a
ship.

1.3.5. Different requirements noise:

Noise range


Demand Sollution
 Compressed air to be used in a factory with 85 employees  A compressor who delivers air at 30 bar
 A compressor who delivers air at 2 bar
 A compressor who delivers air at 7 bar
 A compressor who delivers 1 litre air per second
 A compressor who delivers more than 100 litre air per second
 A compressor who delivers air with some ppm of oil
 A compressor who delivers oil free air
 A compressor installation who provide absolute clean air.
 A compressor who delivers untreated air
 A compressor with a noice level of 55 dB(A)
 A compressor with a noice level of 75 dB(A)
 A compressor who adjust the delivered air depending on the
demand, to save energy.
 A very compact compressor
 A compressor with integrated dryer and electronic drain
 A compressor who can work in the toughest conditions.
 A compressor with an integrated control and monitoring system


Demand Sollution
 Compressed air to be used in a  You don’t have enough information
factory with 85 employees to provide your customer with the
best sollution.
Atlas Copco has a whole range of
sollutions (products), but you must
first know the specifications of your
customers application.
Before you can create customer
value, you must know his needs.

Menu Page








2. How do we make compressed air?
Menu Page
2.1. Basic principles for the 2.3. Oil injected screw

1.1. What is compressed air? compression of air compressor 2.6. Oil free tooth compressor
1.2. Applications of
compressed air 2.1.1. Two basic principles 2.3.1. Working principle 2.6.1. Compression process
1.3. Requirements of the

customers 2.1.2. Dynamic compressors 2.3.2. Role of the oil 2.6.2. Working principle
2.1.3. Displacement
1.1.3. Absolute pressure compressors 2.4. Oil free screw compressor 2.7. Oil free scroll compressor
2.1.4. Comparison 2.4.1. Working principle 2.7.1. Compression process
2.4.2. Consequences of oil free

2.2. Screw compressors screw element 2.7.2. Working principle
2.5. Water injected

2.2.1. Working principle screw compressor 2.8. Piston compressor
2.2.2. Pressure ratio 2.5.1. Working principle 2.8.1. Compression process
2.8.2. Features of piston

2.2.3. Element range compressor
2.8.3. Range of piston

compressor

Compressors Basic Principles1

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Compressors Basic Principles1

Uploaded by

Copyright:

Available Formats

Compressors: Basic principles

l Compressors: Basic principles

l Industrial Air Academy 2

Course information page

 Course objectives: after the training participants should be able to:

 Course developer / trainer

 Course update information

l Industrial Air Academy 3

Basic product training

1.2.1. Where do customers use 1.3.1. Different requirements:

1.2.2. Applications of 1.3.2. Different requirements: 2.3. Oil injected

1.2.3. Why using compressed 1.3.2. Different requirements

1.3.3. Different requirements: 2.5. Water injected

1.3.3. Different requirements

1.3.4. Different requirements:

1.3.5. Different requirements:

1.3.6. Different requirements

l Industrial Air Academy 5

1. Why do customers need compressed air?

1.1.1. What is air

 Air is a colorless, odorless and tasteless gaseous.

 Air press on the earth = Atmospheric pressure

 Height ↑ 1000m => pressure ↓0,1 bar (psi)

l Industrial Air Academy 7

1.1.1. What is air

Standard air is the air at

l Industrial Air Academy 8

1.1.2. compressed air

Air in a balloon is initially at

As the air is gets filled in a

Air in a balloon is initially at

l Industrial Air Academy 9

1.1.2. compressed air

Energy required to fill the balloon

Remark: there are always some losses during energy transformation.

l Industrial Air Academy 10

1.1.2. compressed air

 If the volume of a given amount of

Volume ↓ => Pressure ↑

l Industrial Air Academy 11

1.1.3. Absolute pressure

Pressure in the ball Pressure in the ball Pressure in the ball

Atmospheric Atmospheric Atmospheric

l Industrial Air Academy 12

1.1.4. Effective pressure

Pressure in the ball = 2 bar

l Industrial Air Academy 13

1.1.4. Effective pressure

 The pressure in the ball is equal to

l Industrial Air Academy 14

1.1.4. Effective pressure

 The absolute pressure in the ball is 2 bar

Pump Plastic ball

l Industrial Air Academy 15

1.1.5. Overview pressure

Vacuum {bar} Absolute

l Industrial Air Academy 16

1.1.6. Force of pressure

 P= 27 bar 1 Pa = 10,13 N/cm2 = 10,13 x 104 N/m2

 P= F/A => F= P x A F= 27 x 10,13 x 104 N/m2 x 0,08 m2 F= 218808N

l Industrial Air Academy 17

1.2.1. Where do customers use 1.3.1. Different requirements:

1.2.2. Applications of 1.3.2. Different requirements: 2.3. Oil injected