Compressor Basics

How do we make compressed air?
Compressors: Basic principles

DISTRIBUTOR TRAINING HAGBES 2011
l Compressors: Basic principles
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Basic product training
1. Why do customers need 2. How do we make
compressed air? compressed air?
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
l Industrial Air Academy 2

2.1. Basic principles for the compression of air
2. How do we make compressed air?

2.1.1 Two basic principles

2. How do we make compressed air? > 2.1 Basic principles for the compression of air
Dynamic compression Displacement principal

 Kinetic energy is converted to  Reducing the volume of the gas
pressure increases its pressure
– In dynamic compression air is drawn – In displacement compressors air is
into a rapid rotating compression drawn into a compression chamber.
impeller and accelerates to a high By reducing the volume of this
speed. The gas is then discharged chamber, the pressure of the air will
through a diffuser, where the kinetic increase.
energy is transformed to static Inlet valve
pressure. Outlet valve

Piston
Inlet valve
Suction Compressing
Outlet valve
Piston
Inlet valve
Compressing
Outlet valve
Piston
Diffusor

2.1.2 Dynamic compressors

Dynamic compressors are available in:

 Axial design: centrifugal compressors
 Radial design: torbo compressors
 A dynamic compressor works with a constant pressure.

The performance of a dynamic compressor is affected by external
conditions.
– Example: A small change in the inlet pressure results in a large change in
the capacity.

2.1.2 Dynamic compressors

 Working principle of centrifugal

compressors:
– Air is transferred at high speeds, translated
into kinetic energy
– This energy is then transformed into
pressure as the air is successfully slowed
down by the use of diffuser chambers
– Impellers have blades which operate at
very high speeds

2.1.3 Displacement compressors

 Compression principle:
– At point 1, the inlet valve and

the outlet valve are closed.
Inlet valve
Outlet valve
Piston
Pressure
Volume


 Compression principle: Inlet valve
Outlet valve
Piston
Inlet valve
Compressing
– As te piston moves from point 1 Outlet valve
Piston
to point 2, the volume reduces Inlet valve
and the pressure increases.

Compressing
Outlet valve
Piston
= compressing
Pressure
– During compressing the inlet As the piston moves forward
the air gets compressed and
valve and the outlet valve are reaches point 2
closed.
Volume of the air reduces and

the pressure increases
Volume


Inlet valve
– At point 2 the outlet valve gets

Compressing
Outlet valve
Piston
open
Inlet valve
– The piston moves from point 2 Discharging

Outlet valve Piston
to point 3.
Pressure
Discharging
– During this movement, the air
gets discharged at constant
pressure.
Compressing
Volume


Inlet valve
Discharging
– At point 3 the outlet valve gets Outlet valve
Piston
closed
Inlet valve
– The piston moves back from Outlet valve
Pressure reduction
Piston
point 3 to point 4.
Pressure
Discharging
– During this movement, the
volume gets increased and the
pressure gets reduced Pressure
Compressing
reduction
Volume


Inlet valve
– At point 4 the inlet valve gets Outlet valve
Pressure reduction
Piston
open
– The piston moves back from Inlet valve
Outlet valve
Suction
point 4 to point 1.
Piston
Pressure
– During this movement, the Discharging
volume increase and gets filled

with air at atmospheric
pressure. Pressure
Compressing
reduction
– At point 1 the inlet valve gets
closed and the process will
continuously repeate. Suction
Volume


Types of displacement compressors:

 Single rotor:
Vane Liquid ring Scroll
 Double rotor:
Screw Tooth Blower


Types of displacement compressors:
 Piston compressors:
Single acting Double acting Diaphragm Labyrinth saled

2.1.4 Comparison
 A centrifugall compressor is a
machine with:
– variable capacity
Pressure
– constant pressure.
 A displacement compressor is Centrifugal

compressor
a machine with:
– constant capacity
– variable pressure.
Displacement
Compressor
Flow

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2.1.3. Displacement

2.5. Water injected



compressor

2.2. Screw compressor

2.2 Screw compressors

Oil Injected screw compressor Oil Injected screw compressor GN
Water Injected screw compressor Oil-free screw compressor

2.2.1 Working principle screw element

2. How do we make compressed air? > 2.2 Screw compressors
 The screw element’s main parts

are the male and the female rotors,
wich move towards each other
while the volume between them
and the housing decreases. Suction Compression Compression Delivery
start
Compression Compression Compression Compression Compression
Suction Delivery

2.2.2 Pressure ratio

 The pressure ratio is the ratio Inlet

pressure
of the absolute discharge
pressure to the absolute inlet
pressure.
Discharge pressure
Pressure ratio =
Inlet pressure
Effective
pressure
 Example: Absolute
discharge
7 bar + 1 bar pressure
pressure ratio=
=8 1 bar

2.2.2 Pressure ratio

 Each screw element has a fixed integrated pressure ratio.

 The pressure ratio depends on:
– The lenght of the rotors
– The pitch of the screw
– The shape of the
discharge port Length of rotors Pitch of screw Shape of the disharge part
 Best efficiency is reached when the pressure ratio is adapted to the working pressure
Element A Element B

2.2.3 Element range

Oil injected screw compressors
 To increase the compressor output, there are 2 options:

– Make the compressor bigger
– Drive the compressor faster
C146 element
C111 element
C77 element
C55 element
C40 element
Power
GX 2-5 GA 5,5 - 11 GA 11+ - 30 GA 30+ - 75 GA 55+ - 90

range range range range range
Flow

2.3. Oil Injected Screw Compressor

2.3.1 Working principle

Oil injected screw compressor
2. How do we make compressed air? > 2.3 Oil Injected Screw Compressors
1. intake air filter .

2. Intake valve
3. compression element
4. oil separator vessel
5. minimum pressure valve
6. after-cooler
7. moisture separator
8. thermal bypass valve
9. oil cooler
10. oil filter


AIR
Intake air filter
Intake valve OIL
Compression
element
Oil separator
vessel 1. Intake air filter .
2. Intake valve
Minimum Thermostatic 3. Compression element
pressure valve bypass valve
4. Oil separator vessel
5. Minimum pressure valve
Aftercooler Oil cooler
6. After-cooler
Moisture Oil filter 7. Moisture separator
separator 8. Thermostatic bypass valve
9. Oil cooler
10. Oil filter


 Air enters the compressor through

the intake air filter (1) . The air
intake filter is there to protect the
compressor from airborne
contamination, its size and
filtration medium quality will affect
both the reliability and energy 1. Intake air filter .
2. Intake valve
efficiency of the compressor.
3. Compression element
6. After-cooler
7. Moisture separator
8. Thermostatic bypass valve
9. Oil cooler
10. Oil filter


 The Intake valve (2) allows air to

enter the compression element,
On load / off load control , the
valve is fully open or fully closed.
The vale is set to open at a
minimum pressure setting and
closes at a preset maximum 1. Intake air filter .
2. Intake valve
pressure setting Modulating
control system. The valve 4. Oil separator vessel
gradually opens and closes to 5. Minimum pressure valve
maintain a preset pressure within 6. After-cooler

the compressed air system
9. Oil cooler
10. Oil filter


 Air and oil are drawn into the

compression element (3)
simultaneously and gets
compressed.
1. Intake air filter .

2. Intake valve
6. After-cooler
9. Oil cooler
10. Oil filter


 The air oil mixture enters the oil

separator vessel (4) , and the air
is separated by mechanical
impact within the separator,
centrifugal action, by weight and
finally by the oil separator
cartridge. The quality of the filter 1. Intake air filter .
2. Intake valve
medium is essential to reducing oil
carryover into the compressed air 4. Oil separator vessel
network 5. Minimum pressure valve
6. After-cooler
9. Oil cooler
10. Oil filter


 When sufficient pressure is

generated within the separation
chamber, the minimum pressure
valve (5) opens and air is
delivered to the air net .

2. Intake valve
6. After-cooler
9. Oil cooler
10. Oil filter


 Air passes through the after-

cooler (6) and is cooled to 10 C
above ambient causing moisture
to condense into water droplets

2. Intake valve
6. After-cooler
9. Oil cooler
10. Oil filter


 The moisture droplets in the air

are separated by centrifugal
action within the moisture
separator (7) . Compressed air
now enters the customers

2. Intake valve
6. After-cooler
9. Oil cooler
10. Oil filter


 Oil that has collected in the

separator vessel is forced by the
pressure in the vessel to enter the
thermostatic bypass valve (8)
– Oil at low temperature is sent straight
to the oil filter
– Oil at high temperature is sent to the 1. Intake air filter .
2. Intake valve
oil cooler (9).
The oil is cooled by cold air being
forced (by fan) across the radiator , or 5. Minimum pressure valve
in the case of water cooled machines 6. After-cooler
by an oil/water heat exchanger 7. Moisture separator
9. Oil cooler
10. Oil filter


 Prior to re-injection to the rotary

screw element the oil is filtered in
the oil filter (10) to remove any
harmful contaminants

2. Intake valve
6. After-cooler
9. Oil cooler
10. Oil filter



2.3.2 Role of the oil

 The oil provides four vital tasks Element
in the oil injected screw

compressor:
– Cooling:
compression heat is absorbed by
the oil.
Element
– Lubrication:
Lubrication of gears, rotors and
bearings
Rotor housing
Element
– Sealing: Gear Rotor Bearing

Sealing between rotors and rotor
housing Rotor housing
Element
– Corrosion protection: Gear Rotor Bearing

Corrosion protection of the internal
metal parts
Gear Rotor Bearing

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2.1.3. Displacement

2.5. Water injected



compressor

2.4. Oil Free Screw Compressor


Oil free screw compressor
2. How do we make compressed air? > 2.4 Oil Free Screw Compressors
 The working principle of the oil free screw compressor is simular to the
working principle of the oil injected screw compressor.
 1 major difference: there is no oil injected in the compression chamber.
 This results in several differences between both types of screw compressors.

2.4.2 Consequences
of oil free screw element
 No oil is injected in the air

– Able to deliver completely oil-free air
– No need of oil-separator
Oil separator
Air Receiver
Oil Free Screw Oil Injected Screw

2.4.2 Consequences
 No oil is injected in the compression chamber:

no oil sealing between rotors and rotor housing.
– The rotors and housing are manufactured with great precision to minimise leakage
from the pressure side to the inlet.
– An external gear is used in dry screw compressors to synchronise the counter
rotating rotors.
– Special coating on het rotors to prevent metal-metal contact.
Synchronizing Gear
Special coated rotors

2.4.2 Consequences

no lubrication.
– As the rotors neither come into contact with each other nor with the compressor
housing, no particular lubrication is required in the compression chamber.
– Oil is used tor lubrication of bearings and gears: Compleate separation of
compression chamber and bearings / gears by using seal rings on the shafts.
 Separate oil system with oil pump is used to lubricate and to cool the bearings and gears.
Shafts Seal Ring

2.4.2 Consequences

no Cooling.
– A water jacket is used to cool the element
Element
Water Jacket
Water Jacket Water Jacket is used

to cool the element

2.4.2 Consequences

no Cooling.
– The integrated pressure ratio is limited by the temperature difference between the
intake and the discharge.
– This is why oil-free screw compressors are frequently built with several stages .
High Temperature

2.5. Water Injected Screw Compressor


Water injected screw compressor
2. How do we make compressed air? > 2.5 Water injected Screw Compressors
 The working principle of the water injected screw compressor is simular to the
working principle of the oil injected screw compressor.
 1 major difference: no oil but water is injected in the compression chamber.


Water injected screw compressor
2. How do we make compressed air? > 2.5 Water injected Screw Compressors

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2.1.3. Displacement

2.5. Water injected



compressor

2.6. Oil Free Tooth Compressor

2.6.1 Compression Process

Oil free tooth compressor
2. How do we make compressed air? > 2.6 Tooth compressor
 The compression element in a tooth compressor consists of two rotors that

rotate towards each other in a compression chamber.
 The compression process consists of intake, compression and outlet.
– intake : air is drawn into the compression chamber until the rotors block the inlet.
– compression : the drawn in air is in the compression chamber, which gets smaller
and smaller as the rotors move.
 Outlet = closed; intel = open.
– Outlet: (discharge) when one of the rotors opens the channel
 Compressed air is forced out of compressor chamber







2.7. Oil Free Scroll Compressor


Oil Free Scroll Compressor
2. How do we make compressed air? > 2.7 Scroll Compressor
 The compressor element consists of a fixed

spiral in an element housing and a motor powered
eccentric, moveable spiral.
 compression process:
– The moving spiral is driven by a short stroke
crankshaft and runs eccentrically around the centre
of the fixed spiral.
– Intake: at the top of the element housing.
– When the moving spiral runs clockwise, air is drawn
in, captured in one of the air pockets and
compressed variably in towards the centre
– where the outlet and a non-return valve are situated.




Oil free scroll compressor









2.8. Piston Compressor


Piston compressor
2. How do we make compressed air? > 2.8 Piston Compressor

2.8.2 Features of piston compressor

 Basic design
– Limited number of working parts
– Staight working principle
 Solution for harsh conditions
 Few service, easily accessible
= easy maintenance
 No direct contact air – oil

 No oil filter, no oil separator
 Low mass
– Less condensation formation
 Reliability and liftime
 Direct drive: no transmission losses

2.8.3 Range of piston compressor

Oil lubricated piston compressor Oil free piston compressor

2.8.3 Range of piston compressor

Oil free Oil lubricated

 LF x 0.7 – 2.0; 10 bar  LE 2 – 20; 10 bar
 LFx med  LT 2 – 20; 15/20/30 bar
 LF 2 – 10; 10 bar  Automan 15 – 100; 8/10/12 bar

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How do we make compressed air?

Compressors: Basic principles

2.1. Basic principles for the 2.3. Oil injected screw

1.3. Requirements of the

2.1.4. Comparison 2.4.1. Working principle 2.7.1. Compression process

2.4.2. Consequences of oil free

2.5. Water injected

2.2.2. Pressure ratio 2.5.1. Working principle 2.8.1. Compression process

2.8.2. Features of piston

2.8.3. Range of piston

l Industrial Air Academy 2

2. How do we make compressed air?

2.1.1 Two basic principles

Dynamic compression Displacement principal

pressure. Outlet valve

l Industrial Air Academy 4

2.1.2 Dynamic compressors

Dynamic compressors are available in:

 A dynamic compressor works with a constant pressure.

l Industrial Air Academy 5

2.1.2 Dynamic compressors

 Working principle of centrifugal

l Industrial Air Academy 6

2.1.3 Displacement compressors

– At point 1, the inlet valve and

l Industrial Air Academy 7

2.1.3 Displacement compressors

 Compression principle: Inlet valve

to point 2, the volume reduces Inlet valve

and the pressure increases.

Volume of the air reduces and

l Industrial Air Academy 8

2.1.3 Displacement compressors

– At point 2 the outlet valve gets

– The piston moves from point 2 Discharging

l Industrial Air Academy 9

2.1.3 Displacement compressors

l Industrial Air Academy 10

2.1.3 Displacement compressors

volume increase and gets filled

l Industrial Air Academy 11

2.1.3 Displacement compressors

Types of displacement compressors:

Vane Liquid ring Scroll

Screw Tooth Blower

l Industrial Air Academy 12

2.1.3 Displacement compressors

Types of displacement compressors:

Single acting Double acting Diaphragm Labyrinth saled

l Industrial Air Academy 13

 A displacement compressor is Centrifugal

l Industrial Air Academy 14

2.1. Basic principles for the 2.3. Oil injected screw

1.3. Requirements of the

2.1.4. Comparison 2.4.1. Working principle 2.7.1. Compression process

2.4.2. Consequences of oil free

2.5. Water injected

2.2.2. Pressure ratio 2.5.1. Working principle 2.8.1. Compression process

2.8.2. Features of piston