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SECTION 9
AIR AND GAS COMPRESSORS
AND VACUUM SYSTEMS
Find the cost of compressed air leaking through a 0.125-in (0.3175-cm) diameter
hole in a pipe main of a typical industrial air piping system, Fig. 1, to the atmo-
sphere at sea level when the air pressure in the pipe is 10 lb / in2 (gage) (68.9 kPa),
the plant, Fig. 2, operates 7500 h / yr, air temperature is 70⬚F (21.1⬚C), and the cost
of compressed air is $1.25 per 1000 ft3 (28.3 m3). What is the cost of the leaking
air when the pipe pressure is 50 lb / in2 (gage) (344.5 kPa) and the other variables
are the same as given above?
Calculation Procedure:
1. Find the volume of air discharged to the atmosphere
Air flowing through an orifice or nozzle attains a critical pressure of 0.53 times the
inlet or initial pressure. This reduced pressure occurs at the throat or vena contracta,
which is the point of minimum stream diameter on the outlet side of the air flow.
If the outlet or back pressure exceeds the critical pressure then the vena contracta
9.1
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AIR AND GAS COMPRESSORS AND VACUUM SYSTEMS
FIGURE 1 Typical compressed-air system main and branch pipes (Factory Manage-
ment and Maintenance).
or throat pressure rises to equal the backpressure. Air flow through a hole in a pipe
or tank replicates the flow through an orifice or nozzle.
When an inlet air pressure of 10 lb / in2 (gage) ⫹ 14.7 ⫽ 24.7 lb / in2 (abs) (170.2
kPa), the critical pressure is 0.53 ⫻ 24.7 ⫽ 13.09 lb / in2 (abs) (90.2 kPa). Since
13.09 lb / in2 (abs) is less than the atmospheric backpressure of 14.7 lb / in2 (abs)
(101.3 kPa), the throat pressure equals the backpressure, or 14.7 lb / in2 (abs) (101.3
kPa). Knowing this, we can compute weight of the escaping air from W ⫽ 1.06
A(P1[P ⫺ P1] / T )0.5, where W ⫽ leakage rate, lb / s (kg / s); A ⫽ area of leakage
hole, in2 (cm2); P ⫽ pipeline or initial air pressure, lb / in2 (abs) (kPa); P1 ⫽ outlet
or backpressure, lb / in2 (abs); T ⫽ absolute temperature of the air before leakage
⫽ ⬚F ⫹ 460.
Substituting, using the values given above, W ⫽ 1.06 ⫻ 0.012272(14.7[24.7 ⫺
14.7] / 530)0.5 ⫽ 0.006851 lb / s (0.0031 kg / s). Converting this air leakage rate to
lb / h (kg / h), multiply by 3600 s / h, or 0.006851 ⫻ 3600 ⫽ 24.66 lb / h (11.19 kg /
h). Since the cost of compressed air is expressed in $ / ft3, the flow rate of the
leaking air must be converted. Since air at 14.7 lb / in2 (abs) (101.3 kPa) weighs
0.075 lb per ft3 (1.2 kg / m3), the rate of leakage is 24.66 / 0.075 ⫽ 328.8 ft3 / h (9.31
m3 / h).
FIGURE 2 Typical compressed-air plant showing compressor and its associated piping and accessories (Power).
9.3
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AIR AND GAS COMPRESSORS AND VACUUM SYSTEMS
Show how to select a suitable air motor for a reversible application requiring 2 hp
(1.5 kW) at 1000 rpm for an industrial crane. Determine the probable weight of
the motor, its torque output, and air consumption for this intermittent duty appli-
cation. An adequate supply of air at a wide pressure range is available at the
installation.
Calculation Procedure:
1. Assemble data on possible choices for the air motor
There are four basic types of air motors in use today: (1) radial-piston type; (2)
axial-piston type; (3) multi-vaned type; (4) turbine type. Each type of air motor has
advantages and disadvantages for various applications. Characteristics of these air
motors are as follows:
(1) Radial-piston air motors, Fig. 3, have four or five cylinders mounted around
a central crankshaft similar to a radial gasoline engine. Five cylinders are preferred
to supply more horsepower with evenly distributed power pulses. In such a unit
there are always two cylinders having a power stroke at the same time. The radial-
piston motor is usually a slow-speed unit, ranging from 85 to 1500 rpm. It is suited
for heavy-duty service up to 20 hp (15 kW) where good lugging characteristics are
needed. Normally they are not reversible, though reversible models are available at
extra cost.
(2) Axial-piston air motors, Fig. 4, are more compact in design and require less
space than a four- or five-cylinder radial-piston motor. Air drives the pistons in
translation; a diaphragm-type converter changes the translation into rotation. This
arrangement supplies high horsepower per unit weight. Axial-piston motors are
FIGURE 3 (a) Five-cylinder piston-type radial air motor used in sizes from about 2 hp (1.5
kW) to 22 hp (16.4 kW) and at speeds from 85 to 1500 rpm. (b) How five-cylinder air motor
distributes power. Two cylinders are always on power stroke at any instant (Gardner-Denver
Company).
available in sizes from 0.5 to 2.75 hp (0.37 to 2.1 kW). They run equally well in
either direction. To make the motor reversible, a four-way air valve is inserted in
the line.
(3) Multi-vaned motors, Fig. 5, are suitable for loads from fractional hp (kW)
to 10 hp (7.5 kW). They are relatively high-speed units which must be geared down
for usable speeds. The major advantages of multi-vaned motors is light weight and
small size. However, if used at slow speed, the gearing may add significantly to
the weight of the motor.
(4) Air-turbine motors deliver fractional horsepowers at exceptionally high
speeds, from 10,000 to 150,000 rpm, and are an economical source of power. They
are tiny impulse-reaction turbines in which air at 100 psi (689 kPa) impinges on
buckets for the driving force. Force-feed automatic lubrication sprays a fine film of
oil on to bearings continuously, minimizing maintenance.
Based on the load requirements, 2 hp (1.5 kW) at 1000 rpm, a reversible radial-
piston air motor, Table 1, would be a suitable choice because it delivers up to 2.8
Diaphragm converts
piston translation
to rotation
Output
shaft
Pistons
(four or five)
FIGURE 4 Axial-piston air motor available in various output sizes (Keller Tool Com-
pany).
FIGURE 5 Typical multi-vane type air motor, available in fractional hp sizes and up to
some 10 hp (7.5 kW) (Gast Manufacturing Company).
Air consumption
Rated hp* Speed at rated Free speed Weight Stall torque at rated hp ft3
(kW) hp—rpm rpm lb (kg) ft—lbs free air/min
Radial piston motors (non-reversible)*
2.9 (2.2) 1,500 3,200 130 (59) .......... ..............
3.3 (2.5) 1,300 3.000 130 (59) .......... ..............
3.8 (2.8) 1,200 2,700 130 (59) .......... ..............
Radial piston motors (reversible)*
2.5 (1.7) 1,200 2,200 135 (61.3) .......... ..............
2.8 (2.1) 1,000 1,950 135 (61.3) .......... ..............
3.2 (2.4) 900 1,600 135 (61.3) .......... ..............
5.2 (3.9) 750 1,600 200 (90.8) .......... ..............
*at 90 lb / in2 (620 kPa).
Ingersoll-Rand.
hp (2.1 kW) at 1000 rpm with air delivered to the motor at 90 lb / in2 (620 kPa).
The weight of this motor, Table 1, is 135 lb (61.3 kg).
3. Check the motor duty cycle and load against the unit’s characteristics
When selecting an air motor, the first factor to be considered is the type of duty
cycle, intermittent or continuous. A crane, for which this motor will be used, does
have an intermittent duty cycle because it is not normally used continuously. There
is a rest period while the crane load is being put on the crane and again while
being off-loaded from the crane.
The great majority of air-motor applications have a low-load cycle; the air mo-
tors are used for only a few seconds continuously and have long off-duty periods.
The duty cycle will usually determine the type of motor and the size of compressor
that must be used.
5. Determine the effect of air pressure and quantity on the air motor output
Table 2 shows how the air pressure available at the motor inlet affects both the
power output and rpm of typical air motors. For the motor being considered here,
the output would be sufficient at the lowest air pressure listed. Thus, the motor
choice is acceptable.
Torque
Horsepower
Governor
controlled
curves
Horsepower
Torque
Rated performance
0 1
Stall speed Speed RPM Free speed
FIGURE 6 Performance curve of a typical air motor. Note how a built-in governor can change
the shape of the curve by limiting the maximum speed of the air motor (Product Engineering).
1,600
5
1,900
4
Free speed—rpm
2,030
3
2,250
2
2,650
1
900
5
800
4
rpm at rated hp
850
3
1,100
2
1,200
1
(0.29)
0.4
5
TABLE 2 Effect of Air Pressure on Motor Performance
(4.8)
6.4
4
Rated hp (kW)
(2.4)
3.2
3
(1.9)
2.5
2
Gardner-Denver Company.
(1.4)
1.9
1
At 60 psi lb
Motor style
(413 kPa)
no.
/ in2
9.9
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AIR AND GAS COMPRESSORS AND VACUUM SYSTEMS
Calculation Procedure:
1. Assess the types of cooling systems that might be used
Several types of cooling systems can be used for air compressors such as this.
Because the air compressor is used in an arid area subject to water shortages, a
recirculating system of some type is immediately indicated. Since both the engine
and air-compressor cooling water require temperature reduction in such an instal-
lation, the two requirements are usually combined in one cooling system.
The first arrangement that might be chosen, Fig. 8, combines a heat exchanger
for engine power-cylinder cooling and a cooling tower for raw-water cooling for
the compressor. Either a natural-draft cooling tower, such as that shown, or a me-
chanical-draft cooling tower might be used. The cooling-tower choice depends on
a number of factors. In an arid area, however, natural-draft towers are known to
perform well in dry climates. Further, they require much less piping and electric
wiring than mechanical-draft towers.
Another possible cooling-system arrangement uses a closed coil in the cooling
tower for both the power and air cylinders, Fig. 9. This totally closed system does
not allow contact between the compressor and engine cooling water with the at-
mosphere. This means that the compressor and engine cooling water can be treated
to reduce scale formation. Raw water recirculated through the cooling tower does
not contact the compressor coolant.
Where installation costs are critical, raw water can be used to cool the air-
compressor cylinders, Fig. 10. The engine power cylinders, which usually operate
FIGURE 7 Gas-engine driven compressor has oil-cooled power pistons. Compressor, left, uses metallic piston-rod packing (Cooper-
Bessemer Corp.).
9.11
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AIR AND GAS COMPRESSORS AND VACUUM SYSTEMS
FIGURE 8 Heat exchanger, center, for power-cylinder cooling and raw-water cooling
for the compressor (Ingersoll-Rand Co.).
FIGURE 9 Closed cooling system for power and air cylinders utilizing pipe coil in
the cooling tower (Ingersoll-Rand Co.).
FIGURE 10 Raw water cools the air cylinders; power cylinders use
closed system protected by thermostatic valve (Ingersoll-Rand Co.).
higher flow rate of 2.8 gal / min (364.3 L / s) per 100 ft3 / min (100 m3 / s), the cooling-
water flow required for this 25,000 ft3 / min (708 m3 / s) air compressor is (25,000 /
100)(2.8) ⫽ 700 gal / min (44.2 L / s).
A plant designer has the option of locating an air-compressor inlet pipe either inside
the compressor building or outside the structure. The prevailing average indoor
temperature is 90⬚F (32.2⬚C) while the average outdoor temperature is 50⬚F (10⬚C).
Air requirements for this plant from the compressor are: 1000 ft3 / min (28.3 m3 /
min) of free air at 70⬚F (21.1⬚C) at 100 lb / in2 (gage) (689 kPa) for 7500 h / yr; the
200-hp (149.1 kW) compressor drive motor operates at full load throughout the
7500 hr load year. Determine which is the best location for the compressor intake
based on power savings with an electric power cost of $0.04 / kWh.
Calculation Procedure:
1. Determine the power savings possible with cooler intake air
Compute the intake volume, I, required to deliver 1000 ft3 / min of free air at each
of the possible intake temperatures from I ⫽ 1000(density of air at 70 ⬚F, lb / ft3 /
density of air at inlet temperature, lb / ft3), where I ⫽ intake volume, ft3 (m3), re-
quired at the air inlet temperature.
For inlet air at 50⬚F (21.1⬚C), the outside intake air temperature, using a table
of air properties, I ⫽ 1000(0.07493 / 0.7785) ⫽ 962.49 ft3 (27.2 m3). With an inlet
temperature of 90⬚F (32.2⬚C), using the inside-of-the-building air intake, I ⫽
1000(0.07493 / 0.07219) ⫽ 1037.95 ft3 (29.37 m3), say 1038 ft3 (29.37) cu m).
The power saving from using lower-temperature intake air is then hp saving ⫽
100(intake volume required at the higher intake temperature ⫺ intake volume re-
quired at the lower intake temperature) / intake volume required at the higher intake
temperature. Substituting, hp saving ⫽ 100(1038 ⫺ 962) / 1038 ⫽ 7.32 percent.
2. Find the annual power saving with the lower intake temperature
The annual power saving, P kWh, can be found from: P ⫽ (hp saving / 100)(motor
hp)(0.746 kW / hp)(annual operating hours). Since the compressor operates at full
load 7500 h / yr using 200 hp, the annual power saving is P ⫽ (7.32 / 100)(200
hp)(0.746)(7500) ⫽ 81,910.8 kWh.
The annual cost saving, A ⫽ (kWh / h per yr saved)(power cost, $ / kWh). With
a power cost of $0.04 / kWh, the annual cost saving, A ⫽ (81,910.8)(0.04) ⫽
$3276.43. If an outside inlet were more expensive than an indoor inlet, this saving
could be used to offset the increased cost.
Related Calculations. As a general rule, an outside air intake, Fig. 12, is more
economical than an inside air intake when the air in the building is at a higher
temperature than the outside air. The only time an outside air intake might be less
desirable than an indoor air intake is when the outside air is polluted with corrosive
vapors, excessive dust, abrasive sand, etc., which would be injurious to people or
machines. Under these circumstances the designer might elect an indoor air intake.
However, before choosing an indoor intake, review the efficacy of outdoor air filters
of various types, Fig. 13.
Air in industrial districts may contain from 1 to 4 grains of dirt per 1000 ft3
(28.3 m3). If the intake air for a compressor contains only 1 gram per 1000 ft3
(28.3 m3), 7200 grains of dirt will pass into the air compressor in 1 week’s oper-
ation. With the higher level of 4 grains per 1000 ft3 (28.3 m3), 28,800 grains, or
over 4 lb (1.8 kg) will be carried into the compressor during 1 week’s operation.
Frequently, much of the dirt carried in the air is abrasive. If this dirt is allowed to
get into the compressor cylinders it will mix with the lubricating oil and cause rapid
wear of piston rings, cylinder walls, valves, and other parts.
Intake-air filters, Fig. 13, can reduce much of the danger of abrasive particles
in the supply air. Each type has its favorable features. Viscous coated wire filters,
Fig. 13a, are often used for small- and medium-size compressors. Centrifugal air-
flow units, Fig. 13b, and traveling-curtain oil-bath filters, Fig. 13c, are popular for
larger air compressors. The final choice of an intake filter is a function of com-
pressor capacity, intake-air quality, annual operating hours, and expected life of the
compressor installation. Filter manufacturers can be most helpful to the plant de-
signer in evaluating these factors.
The general procedure given here is valid for air compressors of all types: cen-
trifugal, reciprocating, vane, rotary, etc., and the procedure can be used for air
compressors in plants of all types—chemical, petroleum, manufacturing, marine,
industrial, etc. This procedure has universal application because it is based on the
properties of air, the compressor power input, the annual operating hours, and the
cost of power. These values can be found in any application of air compressors in
industry today.
10-ft (3-m)
(a)
(b)
FIGURE 12 (a) Outside intake-air filter for air compressor should have intake pipe as
short as possible and be fitted with long-radius elbows (Ingersoll-Rand Co.). (b) Glazed-
tile tunnel for outdoor-air intake.
(a)
(b) (c)
FIGURE 13 (a) Viscous coated-wire intake-air filter (Air-Maze Corp.). (b) Centrifugal
air-flow oil-bath intake-air filter also acts as a silencer. (c) Traveling-curtain oil-bath intake-
air filter cleans itself in the oil (American Air Filter Co., Inc.).
The air is delivered from the compressor at a pressure of 70 lb / in2 (abs) (482.4
kPa) and a temperature of 164⬚F (73.3⬚C). Suction-pipe flow area is 2.1 ft2 (0.195
m2); area of discharge pipe is 0.4 ft2 (0.037 m2) and the discharge pipe is located
20 ft (6.1 m) above the suction pipe. The weight of the jacket water, which enters
at 60⬚F (15.6⬚C) and leaves at 110⬚F (43.3⬚C), is 677 lb / min (307.4 kg / min). What
is the horsepower required to drive this compressor, assuming no loss from radia-
tion?
Calculation Procedure:
1. Determine the variables for the compressor horsepower equation
The equation for centrifugal compressor horsepower input is,
hp ⫽
w
0.707冋 V 2 ⫺ V12 Z2 ⫺ Z1
cp(t2 ⫺ t1) ⫹ 2
50,000
⫹
778
⫹ 册 冋
wj(t0 ⫺ ti) ⫹ Rc
0.707 册
In this equation we have the following variables: w ⫽ weight, lb (kg) of unit flow
rate, ft3 / s (m3 / s) through the compressor, lb (kg), where w ⫽ (P1)(V1) / R(T1), where
P1 ⫽ inlet pressure, lb / in2 (abs) (kPa); V1 ⫽ inlet volume flow rate, ft3 / s (m3 / s);
R ⫽ gas constant for air ⫽ 53.3; T1 ⫽ inlet air temperature, degree Rankine.
The inlet flow rate of 12,000 ft3 / min ⫽ 12,000 / 60 ⫽ 200 ft3 / s (5.66 m3 / s); P1
⫽ 14.0 lb / in2 (abs) (93.46 kPa); T1 ⫽ 60 ⫹ 460 ⫽ 520 ⬚R. Substituting, w ⫽
14.0(144)(200) / 53.3(520) ⫽ 14.55 lb (6.6 kg).
The other variables in the equation are: cp ⫽ specific heat of air at inlet tem-
perature ⫽ 0.24 Btu / lb ⬚F (1004.2 J / kg ⬚K); t2 ⫽ outlet temperature, R ⫽ 624 ⬚R;
t1 ⫽ inlet temperature, R ⫽ 520⬚R; V1 ⫽ air velocity at compressor entrance, ft /
min (m / min); V2 ⫽ velocity at discharge, fpm (kg / min); Z1 ⫽ elevation of inlet
pipe, ft (m); V2 ⫽ elevation of outlet pipe, ft (m); wj ⫽ weight of jacket water
flowing through the compressor, lb / min (kg / min); ti ⫽ jacket-water inlet temper-
ature, ⬚F (⬚C); t0 ⫽ jacket outlet water temperature, ⬚F (⬚C).
The air velocity at the compressor entrance ⫽ (flow rate, ft3 / s) / (inlet area, ft2)
⫽ 200 / 2.1 ⫽ 95.3 ft / s (29 m / s); outlet velocity at the discharge opening ⫽ 200 /
0.4 ⫽ 500 ft / s (152.4 m / s).
2. Compute the input horsepower for the centrifugal compressor
Substituting in the above equation, with radiation losses, Rc ⫽ 0,
hp ⫽
14.55
0.707 冋0.24(624 ⫺ 520) ⫹
5002 ⫺ 95.32
50,000
⫹
20
778 册
⫹ [677 / 60 ⫻ (110 ⫺ 60)] / 0.707
⫽ 20.6(24.95 ⫹ 4.8 ⫹ 0.0256) ⫹ 797 ⫽ 1,409 hp (1051 kW)
Related Calculations. This equation can be used for any centrifugal compres-
sor. Since the variables are numerous, it is a wise procedure to assemble them
before attempting to solve the equation, as was done here.
Determine the required capacity, discharge pressure, and type of compressor for an
industrial-plant compressed-air system fitted with the tools listed in Table 3. The
plant is located at sea level and operates 16 h / day.
Calculation Procedure:
1. Compute the required airflow rate
List all the tools and devices in the compressed-air system that will consume air,
Table 3. Then obtain from Table 4 the probable air consumption, ft3 / min, of each
tool. Enter this value in column 1, Table 3. Next list the number of each type of
tool that will be used in the system in column 2. Find the maximum probable air
consumption of each tool by taking the product, line by line, of columns 1 and 2.
Enter the result in column 3, Table 3, for each tool.
The air consumption values shown in column 3 represent the airflow rate re-
quired for continuous operation of each type and number of tools listed. However,
few air tools operate continually. To provide for this situation, a load factor is
generally used when an air compressor is selected.
FIGURE 14 Central system for compressed- FIGURE 15 Unit system for compressed-air
air supply. supply.
SIZING COMPRESSED-AIR-SYSTEM
COMPONENTS
What is the minimum capacity air receiver that should be used in a compressed-
air system having a compressor displacing 800 ft3 / min (0.38 m3 / s) when the intake
pressure is 14.7 lb / in2 (abs) (101.4 kPa) and the discharge pressure is 120 lb / in2
(abs) (827.4 kPa)? How long will it take for this compressor to pump up a 300-ft3
(8.5-m3) receiver from 80 to 120-lb / in2 (551.6 to 827.4 kPa) if the average volu-
metric efficiency of the compressor is 68 percent? For how long can an 80-lb / in2
(abs) (551.6-kPa) tool be operated from a 120-lb / in2 (abs) (827.4-kPa), 300-ft3 (8.5-
m3) receiver if the tool uses 10 ft3 / min (0.005 m3 / s) of free air and the receiver
pressure is allowed to fall to 85 lb / in2 (abs) (586.1 kPa) when the atmospheric
pressure is 14.7 lb / in2 (abs) (101.4 kPa)? What diameter air piston is required to
produce a 1000-lb (4448.2-N) force if the pressure of the air is 150 lb / in2 (abs)
(1034.3 kPa)?
Calculation Procedure:
1. Compute the required volume of the air receiver
Use the relation Vm ⫽ dp1 / p2, where Vm ⫽ minimum receiver volume needed, ft3;
d ⫽ compressor displacement, ft3 / min (use only the first-stage displacement for
two-stage compressors); p1 ⫽ compressor intake pressure, lb / in2 (abs); p2 ⫽ com-
pressor discharge pressure, lb / in2 (abs). Thus, for this compressor, Vm ⫽ 800(14.7
/ 120) ⫽ 97 ft3 (2.7 m3). To provide a reserve capacity, a receiver having a volume
of 150 or 200 ft3 (4.2 or 5.7 m3) would probably be chosen.
What is the minimum size receiver that can be used in a compressed-air system
having a compressor rated at 800 ft3 / min (0.4 m3 / s) of free air if the intake pressure
is 14.7 lb / in2 (abs) (101.4 kPa) and the discharge pressure is 120 lb / in2 (abs) (827.4
kPa)? How long will it take the compressor to pump up the receiver from 60 lb /
in2 (abs) (413.7 kPa) to 120 lb / in2 (abs) (827.4 kPa)? The compressor is a two-
stage water-cooled unit. How much cooling water is required for the intercooler
and jacket if they are piped in series and for the aftercooler?
Calculation Procedure:
1. Compute the required minimum receiver volume
For any air compressor, the minimum receiver volume vm ft3 ⫽ Dpi / pd, where
D ⫽ compressor displacement, ft3 / min free air (use only the first-stage displacement
for multistage compressors); pi ⫽ compressor inlet pressure, lb / in2 (abs); pd ⫽
compressor discharge pressure, lb / in2 (abs). For this compressor, vm ⫽
(800)(14.7) / (120) ⫽ 98 ft3 (2.8 m3). To provide a reserve supply of air, a receiver
having a volume of 150 or 200 ft3 (4.2 or 5.7 m3) would probably be chosen. Be
certain that the receiver chosen is a standard unit; otherwise, its cost may be ex-
cessive.
3. Determine the quantity of cooling water required Use the Compressed Air
and Gas Institute (CAGI) cooling-water recommendations given in the Compressed
Air and Gas Handbook, or Baumeister and Marks—Standard Handbook for Me-
chanical Engineers. For 80 to 125 lb / in2 (gage) (551.6 to 861.9 kPa) discharge
pressure with the intercooler and jacket in series, CAGI recommends a flow of 2.5
to 2.8 gal / min per 100 ft3 / min (334.2 to 374.3 L / s per 100 m3 / s) of free air. Using
2.5 gal / min (334.2 L / s), we see that the cooling water required for the intercooler
and jackets ⫽ (2.5)(800 / 100) ⫽ 20.0 gal / min (2673.9 L / s). CAGI recommends
1.25 gal / min per 100 ft3 / min (167.1 L / s per 100 m3 / s) of free air for an aftercooler
serving a two-stage 80 to 125 lb / in2 (gage) (551.6- to 861.9-kPa) compressor, or
(1.25)(800 / 100) ⫽ 10.0 gal / min (1377.3 L / s) for this compressor. Thus, the total
quantity of cooling water required for this compressor is 20 ⫹ 10 ⫽ 30 gal / min
(4010.9 L / s).
Related Calculations. Use this procedure for any type of air compressor serv-
ing an industrial, commercial, utility, or residential load of any capacity. Follow
CAGI or the manufacturer’s recommendations for cooling-water flow rate. When a
compressor is located above or below sea level, multiply its rated free-air capacity
by the appropriate altitude correction factor obtained from the CAGI—Compressed
Air and Gas Handbook or Baumeister and Marks—Standard Handbook for Me-
chanical Engineers.
An industrial vacuum system with a 200-ft3 (5.7-m3) receiver serving cleaning out-
lets is to operate to within 2.5 inHg (9.7 kPa) absolute of the barometer when the
barometer is 29.8 inHg (115.1 kPa). How long will it take to evacuate the receiver
to this pressure when a single-stage vacuum pump with a displacement of 60 ft3 /
min (0.03 m3 / s) is used? The pump is rated to dead end at a 29.0-inHg (112.1-
kPa) vacuum when the barometer is 30.0 inHg (115.9 kPa). The pump volumetric
efficiency is shown in Fig. 16.
Calculation Procedure:
1. Compute the pump operating vacuum
The pump must operate to within 2.5 inHg (9.7 kPa) of the barometer, or a vacuum
of 29.8 ⫺ 2.5 ⫽ 27.3 inHg (105.5 kPa).
Enter in the second column of Table 9 the ratio of the absolute pressure in the
receiver to the atmospheric pressure, or P / r / Pa, both expressed in inHg. Thus, for
the second step, Pr / Pa ⫽ 26.8 / 29.8 ⫽ 0.899.
The amount of air remaining in the receiver, measured at atmospheric conditions,
is then the product of the receiver volume, 200 ft3 (5.7 m3), and the ratio of the
pressures. Or, for the second pressure reduction, 200(0.899) ⫽ 179.8 ft3 (5.1 m3).
Enter the result in the third column of Table 9. This computation is a simple ap-
plication of the gas laws with the receiver temperature assumed constant. Assump-
tion of a constant air temperature is valid because, although the air temperature
varies during pumping down, the overall effect is that of a constant temperature.
Find the quantity of air removed from the receiver by successive subtraction of
the values in the third column. Thus, for the second pressure step, the air removed
from the receiver ⫽ 200.0 ⫺ 179.8 ⫽ 20.2 ft3 (0.6 m3) and so on for the remaining
steps. Enter the result of each subtraction in the fourth column of Table 9.
time required to remove air from the receiver is (ft3 removed) / (cylinder capacity,
ft3 / min), the time required to remove 20.2 ft3 (0.6 m3) is 20.2 / 54.6 ft3 ⫽ 0.370
min.
Compute the required time for each pressure step in the same manner. The total
pump-down time is then the sum of the individual times, or 9.019 min, column 7,
Table 9. This result is suitable for all usual design purposes because it closely
approximates the actual time required, and the errors involved are so slight as to
be negligible. Leakage into industrial-plant vacuum systems often equals the vol-
ume handled by the vacuum pump.
Choose a mechanical vacuum pump for use in a laboratory fitted with a vacuum
system having a total volume, including the piping, of 12,000 ft3 (339.8 m3). The
operating pressure of the system is 0.10 torr (0.02 kPa), and the optimum pump-
down time is 150 min. (Note: 1 torr ⫽ 1 mmHg ⫽ 0.2 kPa).
Calculation Procedure:
1. Make a tentative choice of pump type
Mechanical vacuum pumps of the reciprocating type are well suited for system
pressures in the 0.0001- to 760-torr (2 ⫻ 10⫺5 to 115.6-kPa) range. Hence, this
type of pump will be considered first to see whether it meets the desired pump-
down time.
FIGURE 17 (a) Pump-down factor for single-stage and compound vacuum pumps; (b) pump-
down factor for mechanical booster and backing pump. (After Kinney Vacuum Division, The New
York Air Brake Company, and Van Atta.)
ing pump can be used to assist the 130-ft3 / min (0.06-m3 / s) unit. This large-capacity
unit is operated until the transition pressure is reached and roughing down is fin-
ished. The pump is then shut off, and the balance of the pumping down is carried
on by the combination unit. This keeps the power consumption at a minimum.
Thus, if a 1200-ft3 / min (0.06-m3 / s) single-stage roughing pump were used to
reduce the pressure to 15 torr (2.3 kPa), its pump-down time would be t ⫽
12,000(4.0) / 1200 ⫽ 40 min. The total pump-down time for the combination would
then be 40 ⫹ 69 ⫽ 109 min, using the time computed above for the two pumps in
combination.
Van Atta1 gives the following typical examples of pumps chosen for vacuum
systems:
A laboratory vacuum system has a volume of 500 ft3 (14.2 m3). Leakage into the
system is expected at the rate of 0.00035 ft3 / min (0.00001 m3 / min). What backing
pump speed, i.e., displacement, should an oil-sealed vacuum pump serving this
system have if the pump blocking pressure is 0.150 mmHg and the desired oper-
ating pressure is 0.0002 mmHg? What should the speed of the diffusion pump be?
What pipe size is needed for the connecting pipe of the backing pump if it has a
displacement or pumping speed of 380 ft3 / min (10.8 m3 / min) at 0.150 mmHg and
a length of 15 ft (4.6 m)?
Calculation Procedure:
1. Compute the required backing pump speed
Use the relation db ⫽ G / Pb, where db ⫽ backing pump speed or pump displacement,
ft3 / min; G ⫽ gas leakage or flow rate, mm 䡠 min / ft3, multiply the ft3 / min by 760
mm, the standard atmospheric pressure, mmHg. Thus, db ⫽ 760(0.00035) / 0.150 ⫽
1.775 ft3 / min (0.05 m3 / min).
1
C. M. Van Atta—Vacuum Science and Engineering, McGraw-Hill, New York, 1965.
value, or 2(1.775) ⫽ 3.550 ft3 / min (0.1 m3 / min), say 4 ft3 / min (0.11 m3 / min),
would probably be used.
If this backing pump is to be used for pumping down the system, compute the
pump-down time as shown in the previous calculation procedure. Should the pump-
down time be excessive, increase the pump displacement until a suitable pump-
down time is obtained.
Calculation Procedure:
1. Determine how the actual air leakage might be found
Methods to determine the amount of air leakage into a vacuum system can be
categorized as operational or empirical. In operational methods, an actual field test
is performed to estimate the volume of air entering the vacuum system. One of the
most accurate methods in this category is termed the ‘‘rate of rise’’ [1] method.
However, performing this test is not always feasible for an existing plant, because
it requires a departure from normal production and operations.
In cases where operational methods cannot be used, empirical calculations may
be convenient. Although not as rigorous, empirical methods yield reasonable values
for a first approach in engineering calculations. The Heat Exchange Institute (Cleve-
land OH) publishes a set of air leakage curves for empirical calculations, as a
function of the volume of the system and the operational pressure. Such curves
give maximum air leakage values for commercially tight systems.
To speed up calculation of air leakage and avoid graphical interpretation of these
curves, an equation has been developed. This equation reproduces air-leakage val-
ues given by the Heat Exchange Institute’s curves and it will be used here to
compute the actual air leakage.
For this system, MAL ⫽ 0.1995 ⫻ 10,0000.6630 ⫽ 87.7 lb / h (39.86 kg / h). Using
the same data, the maximum air leakage read from the Heat Exchange Institute’s
curves is approximately 88 lb / h (40 kg / h).
Related Calculations. This approach can be used when designing a new vac-
uum system or evaluating an existing system. In such design or evaluation work, a
key factor to be determined is the load of noncondensable gas. In most cases the
noncondensable gas load can be taken as the mass flow of external air leaking into
the system. This gas eventually passes through and is exhausted. But while in the
system the gas displaces a certain volume, and alters the level of vacuum being
maintained.
It is always true that if no carrier gas is being introduced into the system, and
that no chemical reaction in the system is generating additional noncondensable
gas, then leakage is the sole source of these noncondensables [2].
The method given here is valid for a variety of vacuum systems used in industry,
including those for distillation columns, metallurgical applications: extraction, re-
fining, degassing, melting, brazing, diffusion bonding, deposition, metallic coatings,
etc. It is also applicable in other manufacturing and processing operations for phar-
maceuticals, foods, mineral oils, cosmetics, epoxy resins, natural flavor extracts,
etc. Likewise, the method can be used for wind tunnels and space simulation cham-
bers, and power-plant steam condensing systems of various types.
While the pressures given here are expressed in mmHg, some designers and
engineers use the torr. One torr ⫽ 1 mmHg; hence the terms are used interchange-
ably.
This procedure is the work of Jose Vicente Gomez, formerly Process Engineer
for Maraven S.A., an affiliate of Petroleos de Venezuela, as reported in Chemical
Engineering magazine.
Check the vacuum rating of a cylindrical flat-ended process tank which is 12.75 ft
(3.9 m) tall and 4 ft (1.22 m) in diameter. It contains fresh water at 190⬚F (87.8⬚C)
and is located where g ⫽ 32.0 ft / s2 (9.8 m / s2) and the atmospheric pressure is 14.7
lb / in2 (101.3 kPa). What is its maximum vacuum when the tank is gravity-drained?
Find both the final tank vacuum and final height of liquid above the tank bottom
when the tank is initially 75 percent full, first with gravity drain and then using a
pumped drain, each discharging to the atmosphere. The pumped-down piping sys-
tem consists of double extra-strong 2-in (5.1-cm) pipe with an equivalent length of
75 ft (22.9 m) and a pump which can discharge 40 gal / min (151 L / min) with its
suction centerline 2 ft (0.61 m) below the tank bottom and has a net positive suction
head of 4.5 ft (1.4 m).
Calculation Procedure:
1. Find the density of the fresh water
From a suitable source such as Baumeister, Mark’s Standard Handbook for Me-
chanical Engineers, freshwater density p ⫽ 60.33 lb / ft3 (966.7 kg / m3) at the given
conditions.
3. Compute the head space volume when the tank is 75 percent full
Airspace volume Vo ⫽ (1.00 ⫺ 0.75)(H ⫻ 0.7854 D2) ⫽ 0.25(12.75 ⫻ 0.7854 ⫻
42) ⫽ 40.1 ft3 (1.14 m3).
4. Compute the final height of liquid above the tank bottom created by gravity
drain
By trial and error, the final height of liquid can be computed by solving the equation
for hfg shown in Fig. 18 where the ambient atmospheric pressure Po ⫽ 14.7 lb / in2
(101.3 kPa); tank radius R ⫽ 2 ft (0.61 m); initial fluid height above tank bottom
ho ⫽ 0.75H ⫽ 0.75(12.75) ⫽ 9.56 ft (2.91 m); ratio of molar specific heats, Cp /
Cr, is ␥ ⫽ 1.4 for diatomic gases. Assuming a reasonable initial value of hfg on the
right-hand side of the equation and substituting appropriate other values, too, gives
hfg ⫽ 144(14.7)(1 ⫺ {40.1 / [40.1 ⫹ (22)(9.56 ⫺ hfg)]}1.4) / (60.33 ⫻ 32.0 / 32.174)
⫽ 7.18 ft (2.19 m), where the left-hand side value is used to repeat the interaction
process until the hfg values on either side of the equal sign are in close agreement.
a ⫽ 0.7854d2 ⫽ 0.7854(1.503 / 12)2 ⫽ 0.0123 ft2 (0.00114 m2). Thus, water mean
velocity v ⫽ q / a ⫽ 0.0891 / 0.0123 ⫽ 7.24 ft / s (2.2 m / s).
11. Compute the final height of liquid above the tank bottom created by the
pumped drain
In the equation for hfp shown in Fig. 18, the net positive suction head (NPSH) ⫽
4.5 ft (1.37 m); freshwater vapor pressure Vp ⫽ 22.29 ft (6.79 m) of water (Bau-
meister, Mark’s Standard Handbook for Mechanical Engineers); height between
tank bottom and centerline of pump suction hi ⫽ 2 ft (0.61 m). Substituting appro-
priate values gives hfp ⫽ 4 ⫹ 9.77 ⫹ 22.29 ⫺ 2 ⫺ 144(14.7){40.1 / [40.1 ⫹
(22)(9.56 ⫺ hfp)]}1.4 / (60.33 ⫻ 32.0 / 32.174) ⫽ 6.94 ft (2.12 m), by trial and
error, as was done for the gravity drain. From 4 to 10 trials should do it.
12. Compute the final tank vacuum for the pumped drain
Final tank vacuum is found by solving the equation for Pp shown in Fig. 32, thus
Pp ⫽ 2.036(14.7){1 ⫺ (40.1 / [40.1 ⫹ ( ⫻ 22)(9.56)])1.4} ⫽ 19.44 inHg (65.83
kPa).
Related Calculations. Specifying an appropriate vacuum rating could prevent
the collapse of a storage vessel as the contents are being drained while the vent is
inadvertently blocked. Vacuum ratings range from full vacuum to no vacuum. A
full vacuum rating is advisable for tanks such as those for steam-sterilized sanitary
service and those with pumped discharge. Tanks with vents that cannot be blocked
require no vacuum rating.
That the maximum gravity-drain vacuum rating occurs at 100 percent full ca-
pacity was borne out by the above calculations for Ps and Pg. However, the pumped-
drain vacuum rating Pp, under more favorable conditions, still turned out to be 3.19
times greater than Ps, the maximum for gravity drain. This varies with pump ca-
pacity and the drain system piping size. These calculations assume ideal gas be-
havior in the head space above the fluid surface and the process is considered
isothermal for drain times longer than 5 min. If the initial fluid height is set too
low, it is possible for the tank to be emptied by pump drain before maximum
vacuum occurs. The calculations presume a centrifugal pump will not deliver if the
NPSH requirements are not met and then backflow into the tank starts. Use the
equation for Pp to find the final tank vacuum if it is expected that the tank will be
emptied before backflow occurs.
The procedure presented here allows the designer to choose a vacuum rating
appropriate to the tank. However, it is suggested that the designer perform appli-
cable code calculations before making a final decision of the vacuum rating for a
tank. This presentation is based upon an article by Barry Wintner of Life Sciences
International, and which appeared in Chemical Engineering magazine.
Calculation Procedure:
1. Determine the rupture disk diameter for the gas
For a gas, use the relation d ⫽ (W / 146P)0.5 (1 / Mw)0.25, where d ⫽ minimum
rupture-disk diameter, in; W ⫽ relieving capacity, lb / h; P ⫽ relieving pressure,
lb / in2 (abs); Mw ⫽ molecular weight of gas being relieved. By substituting,
d ⫽ [50,000 / 146(94.7)]0.5 (1 / 2)0.25 ⫽ 1.60 in (4.1 cm).
2. Find the rupture-disk diameter for the liquid
Use the relation d ⫽ 0.236(Q)0.5 (Sp)0.25 / P0.25, where the symbols are the same as
in step 1 except that Q ⫽ relieving capacity, gal / min; Sp ⫽ liquid specific gravity.
So d ⫽ 0.236(100)0.5(0.0)0.25 / (214.7)0.25 ⫽ 0.60 in (1.52 cm).
Related Calculations. Rupture disks are used in a variety of applications—
process, chemical, power, petrochemical, and marine plants. These disks protect
pressure vessels from pressure surges and are used to separate safety and relief
valves from process fluids of various types.
Pressure-vessel codes give precise rules for installing rupture disks. Most man-
ufacturers will guarantee rupture disks they size according to the capacities and
operating conditions set forth in a purchase requisition or specification.
Designers, however, often must know the needed size of a rupture disk long
before bids are received from a manufacturer so the designer can specify vessel
nozzles, plan piping, etc.
The equations given in this procedure are based on standard disk sizing com-
putations. They provide a quick way of making a preliminary estimate of rupture-
disk diameter for any gas or liquid whose properties are known. The procedure is
the work of V. Ganapathy, Bharat Heavy Electricals Ltd., as reported in Chemical
Engineering magazine.
Show suitable equations for computing airflow in compressed-air and vacuum sys-
tems, using data published by manufacturers.
Calculation Procedure:
1. List the equations
Manufacturers use, and publish, a variety of airflow equations for computing flow,
pressure drop, and other factors in system design. Given in this procedure, Table
13, are several such equations and their defining data and conversion factors. Any
of these equations, used consistently in engineering design, will give satisfactory
results.
Nomenclature
Q ⫽ airflow in standard units, scfm (14.7 psi, 68⬚F)
q ⫽ airflow at actual conditions, cfm. Q ⫽ q(P / 14.7)(528 / T)
V ⫽ velocity, ft / s (average through valve)
P ⫽ pressure in absolute units, psia (subscript D ⫽ downstream, U ⫽ upstream)
p ⫽ gauge pressure, psi
⌬P ⫽ pressure drop, psi
r ⫽ pressure ratio PD / PU
⫽ density, lb / ft3
G ⫽ specific gravity, gas / air
T ⫽ absolute temperature, ⬚R ⫽ ⬚F ⫹ 460
A ⫽ inlet pipe area, in2
冪⌬P ⫻ P
Hand valve CV ⫽ 1.26 Q ⫻ 60 GTU
CV ⫽
1360 U
冪33P
Do ⫽ 0.25 Q 1
Pressure reducer Do ⫽ ⫻
U 兹r(r 0.43 ⫺ r 0.71)
冪r(1 ⫺ r)(3 ⫺ r)
F ⫽ unknown Q 1
Control valve F⫽
PU 兹8 / 5
Air motor Q ⫽ 250 scfm; P ⫽ 600 psia (given)
K
Do CV F r ⫽ 1.0 r ⫽ 0.75 r ⫽ 0.5
兹A 兹A 兹A
Do ⫽ 0.236 兹CV ⫽ 0.316 兹F ⫽ 1.456 ⫽ 1.521 ⫽ 1.641
K1/4 K1/4 K1/4
A A A
CV ⫽ 18.0D2o ⫽ 1.8F ⫽ 38.2 ⫽ 41.5 ⫽ 48.3
兹K 兹K 兹K
A A A
F ⫽ 10D2o ⫽ 0.556CV ⫽ 21.2 ⫽ 23.1 ⫽ 26.9
兹K 兹K 兹K
9.41
A2 A2 A2
r ⫽ 1.0 ⫽ 4.5 ⫽ 1460 ⫽ 450
D4o C 2V F2
A2 A2 A2
K, r ⫽ 0.75 ⫽ 5.36 ⫽ 1725 ⫽ 534
D4o C 2V F2
A2 A2 A2
r ⫽ 0.5 ⫽ 7.29 ⫽ 2330 ⫽ 724
D4o C 2V F2
Note: The K factor varies with r and A and you must know which values the manufacturer used to derive its
AIR AND GAS COMPRESSORS AND VACUUM SYSTEMS
9.42
60 V 冪 MTU 5180 冪P U⫺ P 2D
REFERENCES
1. Standards for Jet Vacuum Systems, 4th Ed., Heat Exchange Institute, Cleveland OH 1988).
2. Myerson, E.B., ‘‘Calculate Saturated-gas Loads for Vacuum Systems,’’ Chemical Engi-
neering Progress, March 1991.