An air compressor is a device

that converts power (using an

electric motor, diesel or gasoline
engine, etc.) into potential
energy stored in pressurized air
(i.e., compressed air). It is a
simple piece of machinery, with
many important components
which are vital for its proper
operation and functioning. It is a
rotating machinery which can be
found from huge power plants to
a small mechanic shop.
 In the case of an air compressor, the compressing mechanism
is compressing the atmospheric air. The air compressor works in the
following way:
Air enters the piston or vane, and it is compressed by increasing
its pressure and at the same time decreasing its volume. As soon as
the pressure reaches a maximum set by the operator or the
manufacturer, a switch mechanism prevents any further air intake
in the compressor. The compressed air is used and pressure levels
decrease. As soon as the pressure reaches a minimum, also set by
the operator or the manufacturer, the switch allows air to enter the
compressor. This procedure is repeated as long as the compressor
is being used.
By one of several methods, an air compressor forces more and
more air into a storage tank, increasing the pressure. When tank
pressure reaches its upper limit the air compressor shuts off. The
compressed air, then, is held in the tank until called into use. The
energy contained in the compressed air can be used for a variety
of applications, utilizing the kinetic energy of the air as it is released
and the tank depressurizes. When tank pressure reaches its lower
limit, the air compressor turns on again and re-pressurizes the tank.
Parts
of
an
Air
Com
pre
ssor
 Motor
An air compressor needs an electric motor to power up
the machine. The motor basically drives two belts and a pulley
which allows the transfer of power from the motor to the
pump pistons and this is done through a flywheel and a
crankshaft. One important thing you need to install, to avoid
motor damage in the event of an overload, is a magnetic
starter.

 Compressor Pump
The pump is the instrument that allows air to be
compressed and discharged into the receiver. It is very
common to have two-stage air compressors and these require
two cylinder pumps to work. These compressors can produce
from 145-175 PSI by compressing the air twice. This is done by
first compressing the air in the larger, low pressure cylinder,
then onto the smaller, high pressure cylinder.
 Tank
This is the compressor part that stores the air being
compressed. It is the biggest part of the air compressor and it
can range from 1-10 gallons or even more for bigger
construction needs.
 Pressure Switch
The pressure switch automatically shuts down the motor
when the receiver reaches the factory-set limit. Once the
pressure level drops to a pre-set level then the pressure switch
restarts the motor therefore resuming the pumping of air by the
compressor. You can call this as an emergency switch that
regulates how much pressure your tank can take.
 Drain Valve
The main purpose of the drain valve is exactly what its
name implies. It drains the oil, dirt, moisture, and other debris
that might be trapped inside the tank. Simple maintenance of
air compressors entail draining a tank from impurities and
debris from use. Moisture and oil are the most common
reasons for rust to develop inside the tank when not drained.
 Pressure Gauge
This gauge measures compressed air pressure in the tank of the
air compressor. It lets the user know that there is a problem if the
measurement is higher than the regulated normal limit and serves as
a warning to inspect the air compressor or stop the compression
before the gauge reaches even higher measurements. On the
contrary, if the reading is very low from the normal allowed
measurement, it also indicates a problem with the compressor such
as a leak in the tank. This should also be checked right away to avoid
any more complications and accidents.

These and many more parts of an air compressor need to also be

looked at if you want to maintain it and keep it away from rust and wear
and tear from usage. A simple task as reading the manual is a good way
of making sure you take care of your component. You will find very useful
information inside the manual and it will indicate the actual usage of the
different parts of the compressor and how to effectively use them.
Compressors can be classified according to
the pressure delivered:
› Low-pressure air compressors (LPACs), which
have a discharge pressure of 150 psi or less;
› Medium-pressure compressors, which have a
discharge pressure of 151 psi to 1,000 psi; and
› High-pressure air compressors (HPACs), which
have a discharge pressure above 1,000 psi.
1. Reciprocating Air Compressors
A reciprocating air compressor is one which reciprocates
inside a cylinder (liner) unit. The piston moves up and down
continuously to pump the air after compression into the air
receiver. These are positive displacement machines,
meaning that they increase the pressure of the air by
reducing its volume. This means they are taking in successive
volumes of air which is confined within a closed space and
elevating this air to a higher pressure. The reciprocating air
compressor accomplishes this by a piston within a cylinder as
the compressing and displacing element.
The reciprocating air compressor is single acting when
the compressing is accomplished using only one side of the
piston. A compressor using both sides of the piston is
considered double acting. 1 to 50 HP are typically for
reciprocating units. Compressors 100 hp and above are
typically Rotary Screw or Centrifugal Compressors.
2. Rotary Screw Air Compressors
These compressors are not of reciprocating nature,
therefore does not have any pistons and crankshaft. Instead,
these compressors have screws, vanes, scrolls, and other
devices which rotate and thus compress air. The rotary
compressors are classified into screw type, vane type-lobe
type, scroll type and other types.
These type of air compressors are positive
displacement compressors. The most common rotary air
compressor is the single stage helical or spiral lobe oil flooded
screw air compressor. These compressors consist of two rotors
within a casing where the rotors compress the air internally.
There are no valves. These units are basically oil cooled (with air
cooled or water cooled oil coolers) where the oil seals the
internal clearances.
Since the cooling takes place right inside the compressor,
the working parts never experience extreme operating
temperatures. The rotary compressor, therefore, is a continuous
duty, air cooled or water cooled compressor package.
3. Centrifugal Air Compressors
Centrifugal air compressors use a rotating disk or
impeller in a shaped housing to force the gas to the rim of
the impeller, increasing the velocity of the gas. It is
a dynamic compressor which depends on transfer of
energy from a rotating impeller to the air. Centrifugal
compressors produce high-pressure discharge by
converting angular momentum imparted by the rotating
impeller (dynamic displacement). In order to do this
efficiently, centrifugal compressors rotate at higher
speeds than the other types of compressors. These types
of compressors are also designed for higher capacity
because flow through the compressor is continuous.
The centrifugal air compressor is an oil free compressor
by design. The oil lubricated running gear is separated
from the air by shaft seals and atmospheric vents.
 The compressed air system is not only an
energy intensive utility but also one of the least
energy efficient. Over a period of time, both
performance of compressors and compressed
air system reduces drastically. The causes are
many such as poor maintenance, wear and tear
etc. All these lead to additional compressors
installations leading to more inefficiencies. A
periodic performance assessment is “essential”
to minimize the cost of compressed air.
To find out:
 Actual Free Air Delivery (FAD) of the
compressor;
 Isothermal power required;
 Volumetric efficiency; and
 Specific power requirement.

The actual performance of the plant is to

be compared with design / standard values
for assessing the plant energy efficiency.
 Compression ratio: It is the Absolute discharge pressure of last stage
divided by the Absolute intake pressure.

 Isothermal Power : It is the least power required to compress the air

assuming isothermal conditions.

 Isothermal Efficiency : The ratio of Isothermal power to shaft power

 Volumetric efficiency : The ratio of Free air delivered to compressor

swept volume

 Specific power requirement: The ratio of power consumption (in kW )

to the volume delivered at ambient
conditions.
  Measurement of Free Air Delivery (FAD) by Nozzle method

If specially shaped nozzle discharge air to the

atmosphere from a receiver getting its supply from a
compressor, sonic flow conditions sets in at the nozzle throat
for a particular ratio of upstream pressure (receiver) to the
downstream pressure (atmospheric) i.e. Mach number
equals one.
When the pressure in the receiver is kept constant for a
reasonable intervals of time, the airflow output of the
compressor is equal to that of the nozzle and can be
calculated from the known characteristic of the nozzle.
 Arrangement of test equipment
The arrangement of test equipment and measuring device shall confirm to Figure 8.1.
 Nozzle Sizes
The following sizes of nozzles are recommended for the
range of capacities indicated below:
Nozzle size (mm) Capacity (m3/hr)

6 3–9
10 9 –30
16 27 –90
22 60 – 170
33 130 – 375
50 300 – 450
80 750 – 2000
125 1800 – 5500
165 3500 - 10000
 Measurements and duration of the test
The compressor starts with the air from the receiver
discharging to the atmosphere through the flow nozzle.

It should be ensured that the pressure drop through the

throttle valve should be equal to or twice the pressure
beyond the throttle. After the system is stabilized the
following measurements are carried out:

• Receiver pressure
• Pressure and temperature before the nozzle
• Pressure drop across the nozzle
• Speed of the compressor
• kW, kWh and amps drawn by the compressor

The above readings are taken for the 40%, 60%, 100% and
110% of discharge pressure values.
 Measuring instruments required for test:
• Thermometers or Thermocouple
• Pressure gauges or Manometers
• Standard Nozzle
• Psychrometer
• Tachometer/stroboscope
• Electrical demand analyser
• Differential pressure gauges or Manometers
1. Free air delivered (FAD)
2. Isothermal Efficiency

3. Specific Power Consumption at rated discharge Pressure

P = Power consumption/Free air delivered

Power consumption, kW
Free air delivered, cu. m/hr
4. Volumetric Efficiency
 Calculation of Isothermal Efficiency for a
Reciprocating Air Compressor.
Step 1 : Calculate Volumetric Flow Rate
Step 2 : Calculate Isothermal Power
Requirement
Step 3 : Calculate Isothermal Efficiency

Motor input power = 100 kW

Motor and drive efficiency = 86%
Compressor input power = 86 kW

Isothermal efficiency = (Isothermal Power)(100)/Compressor input Power

(48.34)(100)/86 = 56%
Specific power consumption=Actual power consumed by
the compressor/Measured Free Air Delivery

In the above example the measured flow is 1407.6 cu. m/hr.

and actual power consumption 100 kW

Specific power requirements = 100kW/1407.6 cu. m/hr.

= 0.071 kW/cu. m per hr.