WHAT IS A COMPRESSOR?
A compressor is a mechanical device that increases the pressure of a gas by reducing its volume. The
most common use is to compress air (hence “air compressor”), but it also applies to other gases in
industries like refrigeration, oil & gas, and HVAC.
⚙️BASIC WORKING PRINCIPLE
Suction stroke: Gas enters the compressor at low pressure.
Compression: Volume is reduced, increasing pressure.
Discharge stroke: Compressed gas is expelled at high pressure.
Based on how this is achieved, compressors are classified into positive displacement and dynamic
types.
🧩 TYPES OF COMPRESSORS
1. Positive Displacement Compressors
These compress gas by trapping a volume and mechanically reducing its size.
a. Reciprocating (Piston) Compressor
Works like an engine piston.
Can be single-stage or multi-stage.
Used for high-pressure, low flow.
b. Rotary Screw Compressor
Uses helical screws to compress air.
Continuous operation, low vibration.
Best for medium to high flow, medium pressure.
c. Rotary Vane Compressor
Uses vanes on a rotor inside a cavity.
Compact and good for light-duty work.
d. Scroll Compressor
Two spiral-shaped scrolls compress air.
Quiet and efficient—common in HVAC and refrigeration.
2. Dynamic Compressors
These use high-speed rotating impellers to add velocity to the gas, then convert that into pressure.
a. Centrifugal Compressor
Impeller throws gas outward into a diffuser.
Suitable for high flow, moderate pressure.
b. Axial Compressor
Gas flows parallel to shaft; high flow and pressure.
Used in jet engines, gas turbines.
🔩 MAJOR COMPONENTS
Component Function
Air inlet filter Cleans incoming air
Compression element Piston, screw, vane, or impeller
Cooling system Cools air and parts (air-cooled or water-cooled)
Drive system Motor (electric/diesel)
Lubrication system Reduces friction, removes heat
Receiver tank Stores compressed air
Control system Manages operation & safety (pressure switch, VFD, etc.)
🧮 PERFORMANCE PARAMETERS
Parameter Description
Pressure Final pressure output (e.g., 8 bar, 100 psi)
Flow rate Amount of air delivered (e.g., CFM, m³/min)
Power Motor rating (kW or HP)
Duty cyclePercentage of time the compressor runs
Discharge temperature Temperature of air leaving compressor
Noise level Typically in dB(A)
Efficiency Energy consumed per unit air produced
COOLING METHODS
Air-cooled – Uses fans and fins to remove heat
Water-cooled – Circulates water; used in high-power compressors
🧽 LUBRICATION TYPES
Oil-lubricated – Requires regular oil checks
Oil-free – Cleaner output; used in food, pharma, electronics
🧰 COMMON APPLICATIONS
Industry Use
Manufacturing Pneumatic tools, automation
Construction Jackhammers, paint spraying
Oil & Gas Gas compression, flare recovery
Automotive Tire inflation, air tools
HVAC Refrigerant compression
Healthcare Dental tools, ventilators
Food & Pharma Oil-free compressed air
🧠 COMPRESSOR CONTROL METHODS
Start/Stop – Basic on/off control
Load/Unload – Maintains pressure by loading/unloading
Variable Speed Drive (VSD) – Adjusts motor speed to demand
Modulating Control – Adjusts inlet valve to control capacity
⚠️COMMON PROBLEMS & SOLUTIONS
Problem Likely Cause Solution
Overheating Poor ventilation or dirty filters Improve cooling or clean filters
Low pressure Leak, worn piston rings Leak test, replace parts
Excessive noise Bearing failure or loose parts Inspect and repair
Water in air lines No moisture trap Install aftercooler or dryer
Oil carryover Seal failure Check and replace seals
MAINTENANCE CHECKLIST
✅ Check oil level and quality
✅ Clean/replace air intake filter
✅ Inspect belts and couplings
✅ Drain moisture from air receiver tank
✅ Clean coolers
✅ Test safety valves
✅ Inspect for leaks and vibrations
🏭 POPULAR BRANDS
Atlas Copco
Ingersoll Rand
Kaeser
Sullair
ELGI
Gardner Denver
FS-Curtis
Boge
📐 HOW TO SELECT A COMPRESSOR
Know your pressure and flow requirements
Check power source (electric/diesel)
Consider duty cycle (intermittent or continuous?)
Decide on oil-lubricated vs oil-free
Check noise level if working indoors
Plan for air treatment (dryers, filters)
Think about future scalability
📘 RELATED TERMS
CFM (Cubic Feet per Minute) – Flow rate
PSI (Pounds per Square Inch) – Pressure unit
Bar – Metric pressure unit
Aftercooler – Cools compressed air before use
Air dryer – Removes moisture from air
Receiver tank – Air storage tank
Check valve – Prevents backflow
Drain valve – Removes condensed water