COMPRESSED

AIR SYSTEM

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 Compressed Air System
• It consists of compressor used to generate high
pressure air as per requirement of a TPS.
• Two separate compressed air system namely
Instrument air system and Plant air system are
in use.
• Suitable dryer is provided for making the
delivered air free from moisture for specific
application purpose.

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 Necessity of Compressed Air

• Operating electro pneumatic controllers,

pneumatic valves, oil burner movement, Burner
tilt mechanism, pneumatic motors and devices
etc. in main plant

• Operating MGR & CHP equipments

• Pneumatic transportation of ash for DACS.

• Cleaning purpose.
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 Types of Air Compressors
Basically three types:
• Reciprocating
• Rotary screw
• Rotary Centrifugal
These types are further specified by:
 The number of compression stages
 Cooling method (air, water, oil)
 Drive method (motor, engine, steam, other)
 Lubrication (oil, Oil-Free where Oil Free means no
lubricating oil contacts the compressed air)
 Packaged or custom-built
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 Reciprocating Compressor
• Reciprocating air compressors are positive displacement
machines, meaning that they increase the pressure of the
air by reducing its volume.
• Made of pistons on an eccentric cam shaft that moves
forward and back inside cylinders.
• The fluid is admitted through an automatic inlet valve on the
back stroke and is compressed on the forward stroke.
• The pressurized fluid is then released by an automatic outlet
valve.
• Their characteristics suit them for applications that require a
high compression ratio.

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Reciprocating Compressor

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 Rotary Screw Compressor
• Rotary 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.
• It employs two intermeshed helical screws turning in opposite
directions to compress the gas.
• The fluid enters the compressor and moves up the threads of
the screws as they turn and the distance between the threads
becomes smaller toward the discharge side, compressing the
fluid.
• They are best suited for variable pressure applications with a
constant volume.
• The rotary compressor is a continuous duty, air cooled or
water cooled compressor package.
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 Rotary Screw Compressor
Oil Flooded Rotary Screw Compressor
It contains two rotating screws which mesh together, producing suction
through the air intake while forcing the air through progressively smaller
cavities, compressing it. This is done in an internal cavity within the
compressor which is flooded with oil. The oil acts as a coolant and a
sealant, preventing air from escaping as the screws turn. Both gas and oil
are pulled into a separation chamber, where the gas rises to the top and
the oil drains to the bottom. The gas is siphoned out of the chamber and
sent to a storage tank, while the oil drains out of the chamber into a
radiator, where it cools before flowing back into the compressor.
Oil-Free Rotary Screw Compressor
Both the suction and the compression are created by two interlocking
screws, which is then sent to a storage tank. This process creates more
heat and is less energy-efficient as the oil is not present to act as a sealant,
though it still is more efficient than many electrically powered gas
compressors. The oil-free rotary screw compressor is used in industries
where the possibility of oil contamination is not acceptable.
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Rotary Screw Compressor

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 Centrifugal Compressor
• The centrifugal air compressor is a dynamic compressor which
depends on transfer of energy from a rotating impeller to the air.
• A centrifugal compressor increases the pressure of a fluid by means
of an impeller which accelerates the flow and a diffuser which
restricts its flow. This increased flow into a restricted space
produces the pressure.
• Centrifugal compressors provide more flow than reciprocating
compressors.
• 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.
• Best suited for continuous operation applications requiring a
relatively low compression ratio.
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Centrifugal Compressor

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 Instrument Air Compressor
• An instrument air compressor controls the application of air
for operating valves in pneumatic instruments.
• An instrument air compressor has components and a
control system put together as an integrated unit and
housed in an enclosure to reduce the noise made by the
compressor.
• The components of the compressor unit include the
compressor, oil filter, drive motor, lubrication system, oil
separator, after coolers, a control system and a control
panel.
• The types of instrument oil compressors are the
reciprocating piston type that comes in oiled and oil less
versions, the rotary vane types, the rotary liquid ring type,
the centrifugal diaphragm type and the rotary screw type.
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 Instrument Air Compressor & Service-
Air Compressor - Comparison
• The compressors are named depending upon the application of air.
• Same type of compressor can be used for both the applications.
• Compressed air is generally passed through after cooler, moisture
trap, heater and alumina air dryer (adsorption type) so that its dew
point is controlled in the range of -500C, so that there is almost no
moisture present in air.
• Same air is distributed to instrument header and service air header.
• Since the control systems are very vital, separation of instrument air
and process air is essential.
• Due to any service air operation, instrument should not get
disturbed, so the separate lines are required.
• Service air is used for utility purposes. Pneumatic tools, pumps,
fans, blowing down hoses etc.
• Instrument air supply should be of the highest quality air that can be
obtained from compressors and air driers.
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 Air-Drying Unit
• Air contains moisture which tends to condense
and causes trouble in operation of various
devices by compressed air.
• Air drying unit consists of dual absorption towers
with embedded heaters for reactivation.
• The absorption towers are adequately filled with
specially selected silica gel and activated
alumina.
• While one tower is drying the air, the other tower
is under reactivation.
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Air-Drying Unit

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Components of Air Compressors

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Compressed Air Headers

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 Problem Encountered with
Compressed Air System

• System leakage.
• Loading – unloading cycle.
• Ambient temperature.
• Moisture in outlet (inefficiency in dryer).

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THANK YOU

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