Air Compressors

Work Done

Lost
Volume

Clearance
TDC

BDC

Adiabatic PV = C

Polytropic PV = C
Isothermal PV = C
Lost
Volume

Clearance
TDC

BDC

VOLUMETRIC EFFICIENCY
= VOLUME OF AIR DISCHARGED (F.A.C SWEPT
VOLUME FIRST STAGE
AFFECTED BY:
Excessive piston end clearance (bump)
Defective valves
Piston / ring leakage
Restriction of intercooler
Restriction of air intake filter
Abnormally high inlet temperature
Restriction in discharge lines

Excessive Bump Clearance

P

Lost
Volume

Clearance
TDC

BDC

2-Stage, Two Crank

Relief Valve
Inter-Cooler
Compressor
After-Cooler

Air Filter

LP
Cylinder

HP

Drain /
Unloader
Water
Space
Relief
Valve

Air To
Bottle

Cooling Water Out

Cooling Water In

2-Stage, Single Crank

Compressor

Multi-Stage Compression
P

TDC

BDC

Multi-Stage Compression
P
Saving in Work Done

Intercooler Effect

TDC

BDC

Multi-Stage Compression
Lower Compression Ratio Per Stage
Lower Air Temperatures
Reduced Carbon Build Up
Increased Valve Life
Less Valve /Ring Leakage

Use Of Intercoolers To Reduce The Amount

Of Work Required For A Given Quantity Of
Air

Relief
Valve

Intercooler
Baffles /
Fixed
Valve
Plate

Supports

Air
Inlet
Air
Outlet

Drain
Valve

Cooling
Water

Bursting
Disc

Typical Auto-Ignition Temperature

400
300

1st Stage Compression Ratio

50

Typical Flashpoint

200

40
100
30
20
10
0

0.5

1.0

Pressure Across Filter - bar

1st Stage Outlet Temperature C

Effect of Choked Inlet

500 Filter

Suction
Delivery Valve
Lock
Nut
Spring
Plates

Lift
Washer
Valve
Plate

Leaking Delivery Valve

P

Lost
Volume

Clearance

Induction
TDC

BDC

Safety Devices
Relief valve fitted to every stage
Fusible plug (melts at 120C)
Bursting disc or relief valve for cooling
jacket
Alarms and cut outs for:
High air temperature
High cooling temperature
Low lubricating oil pressure

Water Space Relief Valve

Compressor
Casing

Water
Pressure
O Ring Seal

Safety Devices
Spindle
Spring

Setting Collar
Vent
Valve
Pressure

Fusible Plug
120C
Low Melting
Point Alloy

2-Stage Unloader

Exhaust

1st Stage
Ball

Diaphragm

2 Stage
Ball
nd

Control Air

Spring

2nd Stage Inlet

1st Stage Inlet

Carry-Over of Oil
Oxidation forming carbon deposits
Reducing sealing ability of valves
Blocking passages in valves
Increasing wear on valve

Reducing heat transfer at hot end of coolers

Oil deposits on cooler surfaces reduce heat
transfer

Oil in air stream will coat all lines and

receivers causing risk of explosion

Air Receivers - Sizing

At least TWO receivers
Reversing Engine
12 Starts (Alternating AHD / AST)

Non-Reversing Engine
6 Starts

Capacity
= Vol Air per Start x No. of Starts
x No. of
Engines
Max Press Min Press

Receiver Mountings

Safety Valve
No More Than 10% Rise For Full Inlet Flow
Fusible Plug
Drain Valve
Pressure Gauge
Main Outlet Valve
Auxiliary Outlet Valve
Whistle Valve
Filling Valve
Manhole
Service Air
Automation

Air Receiver
Service Whistle
Relief Air to Pressure
Air
Air
Valve Engine Gauge

Longitudinal Seam

Fusible
Plug

Circumferential
Seam

Manhole

Inlet from
Compressor

Drain Valve

Receiver Inspection
Permit To Work
Treat As Enclosed Space Personnel Outside
When Internal Work In Progress
Drain
Blank All Possible Means Of Compressed Air Entry
Inspect Shell
Inspect Fittings
Fit Of Manhole
Recoat Internally