SIZING RECEIVER TANKS

Receiver tanks are found in most modern compressed air systems. Hence, one of the most common design tasks in sizing of a compressor system is the sizing of receiver tanks. To size the receiver tanks appropriately, we need to identify the key function of the receiver tank. In the modern compressed air plant, receiver tanks are mainly used for only 2 purposes: a) b) as a buffer to supply air during short demand peaks or power failure. as a protective element to prevent too frequent a cycling of the compressor/s. This can be to prevent mechanical failure of the inlet valve due to too frequent switching of onload/offload state or electrical failure of motors due to too frequent start/stop for small piston compressors.

A)

Sizing as a Buffer
The formula used to determine the appropriate size of the receiver tank when used as a buffer is:

VR =
where VR FAD T p -

FAD x t p
Size of receiver (m3) Free air delivery (m3/min) time (min.) the free air is required Pressure difference (bar)

For example, suppose a plant requires 5 m3/min of free air during any power failure to operate some pneumatic valves. The minimum pressure at the receiver tank during plant operations is 7 bar and the minimum pressure to operate the pneumatic valve is 5 bar. If the free air is required for 1 minute, then the appropriate size of the receiver tank is: VR = 5 m3/min x 1 min (7 bar 5 bar) 5/2 2.5 m3

= =

Hence the minimum size of the receiver tank required is 2.5 m3.

B)

Sizing as a Protective Element

The formula used to determine the appropriate size of the receiver tank when used as a protective element is:

VR =
where VR FAD A -

FAD x (A-A2) p x Z
Size of receiver (m3) Free air delivery (m3/min) Utility ratio i.e. utilized capacity / available capacity Utility factor Pressure difference (bar) Maximum cycling frequency (times/min)

A-A2 p Z -

In the above formula, it must be understood that, A, the utility ratio can vary through out the time the compressed air plant is in operation due to the varying consumption of compressed air. This will result in A-A2, the utility factor also varying. The graph below shows the possible values of the utility factor, A-A2 in the above equation when the Utility ratio, A varies from zero to full utilization.

Variation of Utility Factor, A-A A-A

0.3 0.25 0.2 0.15 0.1 0.05 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

0.9

Hence for conservative designs, the worst case value of 0.25 is used.

For example, suppose a compressor is operating in onload/off load mode with a free air delivery of 5 m3/min. The cut-in pressure is set at 7.0 bar and the cut-out pressure is set at 7.5 bar. If the maximum switching frequency allowed for onload/offload operation is 1 time/min., then the conservative size of the required receiver tank is: VR = 5 m3/min x 0.25 (7.5 bar 7.0 bar) x 1 time/min 5 x 0.25 0.5 x 1 2.5 m3

Hence the conservative minimum size of the appropriate receiver tank is 2.5 m3.

As receiver tanks are rather costly items, less conservative sizing using a less conservative utility factor, A-A2 (such as 0.16), a bigger pressure differential, p (such as 1 bar) and a higher maximum cycling frequency (such as 2 times/min) have been used. This can be rather dangerous and may cause unforeseen break down of the compressors. As such, for the optimum safety, the conservative design factors are always recommended.

Beyond the size issue, other requirements for receiver tanks to be used in Malaysia are: a) b) Design approval from the Factories and Machinery Department, Malaysia. Tested to the satisfaction of Factories and Machinery Department, Malaysia.

The receivers should also be equipped with Safety Valves of the appropriate flow and pressure ratings, Pressure Gauges of the appropriate size, accuracy and range and drain mechanism. For further details, please refer to the Factory and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970.