Faculty of Mechanical Engineering
Air compressors, air treatment and
pressure regulation
Lec.: Lưu Thanh Tùng
Pneumatic system
A pneumatic system is 'open'; the fluid is obtained free, used
and then vented back to atmosphere.
Pneumatic systems use a compressible gas. Hydraulic systems
an incompressible liquid, and this leads to some significant
differences.
The pressure of a liquid may be raised to a high level almost
instantaneously, whereas pressure rise in a gas can be distinctly
leisurely.
Pneumatic system
Pressure in a hydraulic system can be quickly and easily controlled
by devices such as unloading and pressure regulating valves
Fluid is thus stored at atmospheric pressure and compressed to the
required pressure as needed.
A pneumatic system and necessitates storage of compressed air at
the required pressure in a receiver vessel.
The volume of this vessel is chosen so there are minimal deviations
in pressure arising from flow changes in loads and the compressor
is then employed to replace the air used
Compressor
Compressor
- Dry cool air is stored in the receiver, with a pressure switch
used to start and stop the compressor motor.
- Air in a system has a light oil mist to reduce chances of
corrosion and to lubricate moving parts in valves, cylinders
and so on.
- Air in the receiver is held at a slightly higher pressure than
needed to allow for pressure drops in the pipe lines.
- A local pressure regulation unit is then employed with the
secondary air treatment close to the device using air
Compressor
Composite devices called service units comprising water
separation, lubricator and pressure regulation are available
for direct line monitoring close to the valves and actuators of
a pneumatic system.
Compressor
Piston compressors
The valves are similar to valves in an internal combustion engine. In
practice, spring-loaded valves are used, which open and close under
the action of air pressure across them. One common type uses a
'feather' of spring steel which moves above the inlet or output port.
Compressor
Rotary compressors
The vane compressor operates on similar principles to the hydraulic
vane pump
Compressor
Dynamic compressors
A large volume of air (up to 5000 m3/min) is often required for applications
such as pneumatic conveying (where powder is carried in an air stream),
ventilation or where air itself is one component of a process (e.g.
combustion air for gas/oil burners). Pressure in these applications is low
(at most a few bar) and there is no need for a positive displacement
compressor.
Compressor
Air receivers and compressor control
An air receiver is used to store high pressure air from the compressor. Its
volume reduces pressure fluctuations arising from changes in load and
from compressor switching
Compressor
Air receivers and compressor control
Control of the compressor is necessary to maintain pressure in the
receiver. The simplest method of achieving this is to start the compressor
when receiver pressure falls to some minimum pressure, and stop the
compressor when pressure rises to a satisfactory level again.
Compressor
Air treatment
Atmospheric air contains moisture in the form of water vapour. One cubic
metre at 200 can hold 17 grams of water vapour.
Compressor
Air treatment
It follows that relative humidity rises quickly with increasing pressure, and
even low atmospheric relative humidity leads to saturated air and
condensation at the pressures used in pneumatic systems (8-10 bar).
When the pressure is 1 bar gauge (or 2 bar absolute) its volume is 0.5
cubic metres, which can hold 8.6 grams of water vapour, giving us 68%
relative humidity. At 2 bar gauge (3 bar absolute) the volume is 0.33 cubic
metres, which can hold 5.77 grams of water vapour.
Compressor
Air treatment
It follows that relative humidity rises quickly with increasing pressure, and
even low atmospheric relative humidity leads to saturated air and
condensation at the pressures used in pneumatic systems (8-10 bar).
When the pressure is 1 bar gauge (or 2 bar absolute) its volume is 0.5
cubic metres, which can hold 8.6 grams of water vapour, giving us 68%
relative humidity. At 2 bar gauge (3 bar absolute) the volume is 0.33 cubic
metres, which can hold 5.77 grams of water vapour.
Compressor
Stages of air treatment
Air in a pneumatic system must be clean and dry to reduce wear and
extend maintenance periods and needs treatment before it can be used.
This treatment falls into three distinct stages, First, inlet filtering removes
particles which can damage the air compressor. Next, there is the need to
dry the air to reduce humidity and lower the dew point.
Compressor
Stages of air treatment
final treatment is performed local to the duties to be performed, and
consists of further steps to remove moisture and dirt and the introduction
of a fine oil mist to aid lubrication.
Compressor
Air dryers
A typical water trap and separator. Air flow through the unit undergoes a
sudden reversal of direction and a deflector cone swirls the air. Heavier
water particles to be flung out to the walls of the separator and to collect
in the trap bottom from where they can be drained.
Compressor
Lubricators
The operation is similar to the principle of the
petrol air mixing in a motor car carburettor as
air enters the lubricator its velocity is
increased by a venturi ring causing a local
reduction in pressure in the upper chamber.
The needle valve adjusts the pressure
differential across the oil jet and hence the oil
flow rate.
Compressor
Pressure regulation
Three methods of local pressure control:
Load A vents continuously to atmosphere. Air pressure is controlled
by a pressure regulator which simply restricts air flow to the load.
Load B is a dead-end load, and uses a pressure regulator which
vents air to atmosphere to reduce pressure.
Load C is a large capacity load whose air volume requirements are
beyond the capacity of a simple in-line regulator.
Compressor
Relief valves
This is not, in fact, normally used to control pressure but is employed
as a backup device should the main pressure control device fail
Compressor
Relief valves
A relief valve has a flow/pressure relationship and self-seals itself
once the pressure falls below the cracking pressure. Once a safety
valve cracks, it opens fully to discharge all the pressure in the line or
receiver, and it does not automatically reclose, needing manual
resetting before the system can be used again.
Compressor
Non-relieving pressure regulators
If outlet pressure is too low, the spring forces the
diaphragm and poppet down, opening the valve to
admit more air and raise outlet pressure.
If the outlet pressure is too high, air pressure forces
the diaphragm up, reducing air flow and causing a
reduction in air pressure as air vents away through
the load.
In a steady state the valve will balance with the
force on the diaphragm from the outlet pressure just
balancing the preset force on the spring.
Compressor
Relieving pressure regulators
Outlet pressure is sensed by a diaphragm
preloaded with an adjustable pressure setting
spring. The diaphragm rises if the outlet pressure
is too high, and falls if the pressure is too low.
If outlet pressure falls, the inlet poppet valve is
pushed open admitting more air to raise pressure.
If the outlet pressure rises, the diaphragm moves
down closing the inlet valve and opening the
central vent valve to allow excess air to escape
from the load thereby reducing pressure.
Problems
This is the figure of relief valve, let explain the
operation principle.
Problems
This is the figure of reducing pressure valve, let
explain the operation principle.
Problems
This is the figure of proportional control valve, let
explain the operation principle.
Problems
This is the figure of Accumulators, let explain the
operation principle.
Problems
Multiple choice question
1) Which of the following systems generate more energy when used in industrial
applications?
a. hydraulic systems
b. pneumatic systems
c. both systems generate same energy
d. cannot say
2) Which of the following factors is/are considered while selecting a compressor?
a. type of oil filter required
b. volumetric efficiency
c. viscosity of the liquids used
d. all of the above
3) Which of the following is a component used in air generation system?
a. pressure switch
b. pressure gauge
c. drier
d. intercooler
Problems
Multiple choice question
4) Where is an intercooler connected in a two stage compressor?
a. intercooler is connected after the two stage compressor
b. intercooler is connected between the two stages of the compressor
c. intercooler is connected before the two stage compressor
d. none of the above
5) What is a pressure sequence valve?
a. it is a combination of adjustable pressure relief valve and directional control valve
b. it is a combination of nonadjustable pressure relief valve and directional control valve
c. it is a combination of adjustable pressure reducing valve and check valve
d. it is a combination of adjustable pressure reducing valve and flow control valve
6) What is the part, shown in below diagram of 3/2 valve, called?
a. manually operated valve
b. pilot operated valve
c. pressure electric converter
d. none of the above
Problems
Multiple choice question
