Compressed Air Operations Manual

433 Pages·2006·4.85 MB·English

by  Brian Elliott

Compressed Air
Operations
Manual
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Compressed Air
Operations
Manual
An Illustrated Guide to
Selection,Installation,
Applications,and Maintenance
Brian S. Elliott
McGraw-Hill
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Copyright © 2006 by The McGraw-Hill Companies, All rights reserved. Except as permitted under the United
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ISBN: 978-0-07-149184-6
MHID: 0-07-149184-8
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Contents
List of Figures and Tables xi
Preface xxi
Acknowledgments xxiii
Chapter 1. The History of Compressed Air 1
Questions 8
Chapter 2. Compressed Air Applications 9
Blow-Off Guns 10
Tire Inflators 12
Portable Air Tanks 14
Fire Extinguishers 15
Air Cylinders 16
Pressure Amplifiers 25
Percussion Tools 27
Air Motors 29
Rotating Tools 33
Turbine Motors 37
Paint Sprayers 38
Siphon Guns 40
Sandblasters 42
Air Nailers 45
Air Staplers 46
Caulk Guns 48
Grease Guns 48
Pop Rivet Puller 49
Dual Diaphragm Pumps 50
Vacuum Generators 51
Air Bearings 52
Spray Misters 53
Vibrators 54
v
vi Contents
Automobile Lifts 55
Air-Over-Hydraulic Jacks 56
Air Bag Jacks 59
Pneumatic Suspension 60
Air Brakes 62
Self-Contained Underwater Breathing Apparatus (SCUBA) 66
Self-Contained Breathing Apparatus 68
Questions 70
Chapter 3. Compressor Types 71
Squirrel Cage Blowers 73
Centrifugal Blowers 74
Regenerative Blowers 75
Rotary Lobe Blowers (Roots) 77
Liquid Ring Compressors 77
Diaphragm Compressor 78
Piston Compressor 79
Double-Acting Compressors 80
Two-Stage Compressors 83
Screw Compressor 85
Rotary Vane Compressors 88
Turbo Compressors 90
Axial Compressors 91
Injector Compressors 91
Questions 93
Chapter 4. The Conservation of Mass and Energy as Applied to
Compressed Air 95
Questions 98
Chapter 5. The Compressed Air Supply 99
Screw Compressors 99
Duplex Compressors 101
Redundant Compressors 103
Duplex Controllers 103
After Coolers 104
Air-Cooled After Coolers 106
Water-Cooled After Coolers 107
Air Dryers 108
Instrument Air 110
Field Compressors 113
Questions 116
Chapter 6. Compressed Air Dryers 117
Traps 118
Contents vii
Plate Separators 124
Coalescing Filters 125
Water-Cooled Aftercoolers 128
CFC-Based Refrigerated Dryers 128
Elliott Cycle Refrigerated Dryers 135
Standard Installations 141
Duplex Installations 142
Applications Greater Than 120 SCFM 144
Instrumentation Air Systems 144
Saltwater Prepared Dryers 145
Ice Bath Dryers 146
Desiccant Dryers 150
Deliquescent Dryers 154
Membrane Dryers 154
Absorption Dryers 157
Dryer Performance,Types,and Applications 157
Oil/Water Separators 158
Questions 161
Chapter 7. Support Components 163
Filters 164
Pressure Regulators 165
Lubricators 166
Filter,Regulators,and Lubricators Guide 167
Safety Relief Valves 168
Pressure Relief Valves 169
Check Valves 170
Expansion Joints and Vibration Isolators 172
Hoses and Hose Connectors 173
Retractable Hoses 174
Hose Clamps 175
Hose Connectors 176
Drain Valves 178
Commercial Pipe Fittings 181
Compression Fittings 183
Pipe Hangers 184
Ball Valves 186
Gate Valves 186
Globe Valves 189
Butterfly Valves 189
Solenoid Valves 191
Pilot Valves 192
Needle Valves 193
Speed Control Valves 194
Tire Valve Fittings 195
Mufflers 195
Intake Air Filters 195
viii Contents
Pressure Gauges 196
Pressure Switches 198
Compressor Control Switches 198
Continuous-Run Unloader Valves 199
Vee Belts 200
Sound Dampening Enclosures 201
Compressor Mounts 202
Skid Mounting 203
Questions 209
Chapter 8. Pneumatic Controls 211
In-House Pneumatic Symbols 217
Questions 221
Chapter 9. Electrical Controls 223
Single-Pole Control 225
Double-Pole Control 226
Motor Starters 227
120-VAC Control Loops 228
Sensor Loops 229
On,Off,and Automatic Functions 231
Sensors 232
Delta/Wye Motor Starters 233
Soft Starters 235
Variable Frequency Drives 237
Programmable Logic Controllers 238
Microprocessor-Based Controllers 240
Emergency Stop Circuit 240
Power Disconnects 243
Service Outlets 243
Lockout/Tagout Programs 243
Duplex Controllers 246
Parallel Duplex Operation 249
Weekly and Daily Duplex Operation 250
Wire Types 251
Din Rails and Wire Guides 252
Questions 254
Chapter 10. Maintenance 255
Supply Side 256
Distribution 259
Applications 261
Maintenance Program 262
Replacement Parts Inventory 264
Questions 267
Contents ix
Chapter 11. Energy and Costs Associated with Compressed Air 269
Leaks 270
Misuse 272
The Compressed Air Supply 272
Heat 272
The Motor 273
Drive Belts 274
Master Regulator 274
Water 274
Water Damage 274
Air Versus Electricity 277
Questions 279
Chapter 12. System Models 281
Contractor Compressors 281
Automotive Repair 283
Small Manufacturing Plants 288
Dry-Cleaning Operations 291
Heating,Ventilation and Air Conditioning (HVAC) 293
Dental Systems 296
Home Shop 298
Medium to Large Manufacturing Facilities 298
Instrument Air 302
High Purity 305
Service Trucks 310
Field and Construction 312
SCUBA and SCBA Charging Systems 315
Questions 320
Chapter 13. Specifying a Compression System 321
Estimating Required SCFM 322
Selecting a Compressor 323
Master Regulator 324
Receiver Size 325
Pipe Sizing 326
Remote Receivers 327
Cost Savings 329
Miscellaneous 330
Distribution Layouts 331
Plumbing 333
Buried Pipe 334
Plumbing Tools 336
Questions 339