Print this page Compressed Air Systems
A. Bhatia, B.E.
Course Outline
This 4-hour course
provides comprehensive information on the compressed air systems. Compressed
air is an essential utility in almost all mechanical, chemical and process industries.
It drive tools and machinery, powers pneumatic controls and is used in variety
of applications such as material handling, dust extraction, breathing air, laboratory
air, industrial and process air.
The course describes the practical overview of basics, types and selection considerations
of the air compressor systems. The course is intended for use primarily to the
students, end users, working professionals, consultants, contractors, facility
designers, O&M engineers and sales people.
This course includes
a multiple-choice quiz at the end, which is designed to enhance the understanding
of the course materials.
Learning Objective
At the conclusion of this course, the student will:
- Be knowledgeable about the type of compressors and systems
- Be aware of system design considerations in compressed air generation and distribution
- Be able to comprehend
the principle components, basic operation, and safety considerations associated
with air compressors and compressed air systems.
Air Compressors
deserve independent treatment due to many reasons. There is a wider choice of
different types of compressor designs each operating at different efficiencies
and suitable for specific application. The type of compressor decided upon has
direct implications on the lifetime energy costs. Also the decision as to a
single compressor of large capacity versus multi-compressor installation where
each compressor has a smaller capacity than the demand influences the possible
energy savings considerably.
Compressed air production is often one of the primary energy expenses in an
industrial plant. In a typical industrial plant, compressors consume 8 to 25%
of the total electricity.
Since compressed air users seldom see the amount or true cost of air use, it
is most often thought of only in terms of air delivery capacity and consequent
capital cost. However, air compressors can consume an equivalent of this capital
each year in operating cost! Therefore, selection should include careful consideration
of efficiency.
No two-air systems are alike and no two plants use air the same way. It is important
to take specific plant operations and requirements into consideration when analyzing
a system or proposing changes to an air system.
The ideal time to think about your compressed air system is before it is installed.
The course provides 30 sections that is comprehensive compilation of major aspects
related to compressed air systems.
Course Content
The the course content is in a PDF file Compressed Air Systems. You need to open or download this document to study this course.
Course
Summary
The compressed
air system must supply air of suitable quality, proper quantity, and proper
pressure to allow for all modes of plant operation. Air capacities are usually
expressed as standard cubic feet per minute (SCFM).
Air compressor equipment is sized for an application using standard load estimating
techniques found in any engineering handbook. Determining the actual load profile
of an installed and functioning compressed air system, even if it is a rough
estimate, is of considerable value. It offers an engineer an idea of how actual
compressed air usage relates to the theoretical load estimates used to size
equipment as well as provide evidence of how much reserve capacity a system
has for possible expansion. In addition, knowledge of one load profile can help
an engineer troubleshoot a system experiencing problems.
It is very important to evaluate whether the compressed air is the most cost-effective
for the job. To ensure the best compressed air system design and operation,
it is necessary to review the specific application, best fit-in type of compressor,
configuration, type of dryer, auxiliaries, the piping system that includes and
not limited to the pipe size, the layout, by-pass valves, tees, elbows, pipe
slope, configuration, number of drops or connection points to air-operated equipment,
in-line receivers and the number and type of condensate traps.
Typically atmospheric air passing through a compressor is one-eighth its previous
volume, yet still contains the same amount of contaminants (water and particulate).
It is therefore, imperative that the compressed air system considers the aftercoolers,
dryers, separators and high efficiency filters to ensure complete protection
to the downstream equipments. If there are concerns about near zero moisture
requirements, then desiccant quality air should be considered.
When using compressed air for any application, attempts should be made to minimize
the quantity and pressure of air used, as well as ensuring running times are
of the shortest possible duration. The need to use compressed air should be
constantly monitored and re-evaluated; for example, it is not uncommon to find
airflow still being supplied to unused equipment when plants reconfigure their
processes. Despite this information, well intended production personnel give
little thought to the use of compressed air and actually think that "more
is better". More pressure ...more volume ...more dryness ...more whatever
is good.
The main source of compressed air energy losses are leaks, equipment inefficiencies,
and production and distribution inefficiencies. Vigilant maintenance, more efficient
equipment and advanced control methods will all contribute to a less expensive
compressed air system.
Related
Reading
Energy Audit
and Management of Compressed Air Systems
Compressed air is one of the most expensive services that waste as much as 40%
of their total operating cost. One main reason is that compressed air is often
viewed as a "free" utility by the people that consume the air. An
effective maintenance program could contribute to saving good amount of dollars
on electrical energy. The concepts have been discussed exclusively in another
course 'Energy Audit and Management of Compressed Air
Systems'
Once
you finish studying the
above course content,
you need to
take a quiz
to obtain the PDH credits.
DISCLAIMER: The materials contained in the online course are not intended as a representation or warranty on the part of PDHonline.com or any other person/organization named herein. The materials are for general information only. They are not a substitute for competent professional advice. Application of this information to a specific project should be reviewed by a registered professional engineer. Anyone making use of the information set forth herein does so at their own risk and assumes any and all resulting liability arising therefrom.
