Compressed Air Plant (Engineering Plant Technology) 2014

UNGKU OMAR POLYTHECNIC DEPARTMENT OF MECHANICAL ENGINEERING DIPLOMA IN MECHANICAL ENGINEERING

JJ 618  – ENGINEERING PLANT TECHNOLOGY

COMPRESSED AIR PLANT

NO 1 2 3 4 5 6

NAME

ID NO

MUHAMMAD FAKHRUDDIN BIN ABDUL MOEN

01DKM11F2028 01DKM11F2028

MUHAMAD FAREEZ BIN BAHARUDDIN

01DKM11F2033 01DKM11F2033

FATEEN FAEZAH BINTI MANSOR

01DKM11F2031 01DKM11F2031

RAJMOGEN A/L RAMAKRISHNAN

01DKM11F2032 01DKM11F2032

MUHAMAD FAIZ BIN AJID

01DKM11F2034 01DKM11F2034

SHANKAR A/L BALAIZAM

01DKM11F2030 01DKM11F2030

GROUP MEMBERS No 1

Name

Name :MUHAMMAD FAKHRUDDIN BIN ABDUL MOEN Id No :01DKM11F2028 2

Name :MUHAMAD FAREEZ BIN BAHARUDDIN Id No :01DKM11F2033 3

Name :FATEEN FAEZAH BINTI MANSOR Id No :01DKM11F2031 4

Name : RAJMOGEN A/L RAMAKRISHNAN Id No :01DKM11F2032 5

Name : MUHAMAD FAIZ BIN AJID Id No : 01DKM11F2034 6

Name : SHANKAR A/L BALAIZAM Id No : 01DKM11F2030

4.1

Explain Compressed Air Plant System 

Compressed Air => air kept under a pressure greater than atmospheric pressure.

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Serve many domestic and industrial purposes.

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Use in Pneumatic System.

4.1.1 State the Main Equipment in Compressed Air Plant and Clarify Its Function 

Intake Air Filter ◦

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Inter-stage Coolers ◦

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Prevent dust from entering compressor

Reduce the temperature of the air before enter the next stage.

After Coolers ◦

To remove the moisture in the air by reducing the temperature in water-cooled heat exchanger.

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Air-dryers ◦

Removes the remaining traces of moisture after after-cooler using absorbent like silica gel or refrigerant dryers.

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Moisture Drain Traps ◦

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Remove moisture in compressed air.

Receivers ◦

Provide storage and smoothening pulsating air output.

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Reducing pressure variation from compressor.

4.1.2 Sketch Layout Of Compressed Air Plant

4.1.3 Explain Equipment and Usage of Compressed Air Plant 

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Mining ◦

Rock drilling and carriage systems

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Pneumatic hammer and chisels

Plastic Industry ◦

Transport of granulate in pipes

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Ejecting work piece from production

Textile Industry ◦

Thread detector

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Sewing needle and system cooling

4.1.4 Explain The Advantages of Using Compressed Air Plant As Working Agent By Including Example of Usage 

Easily Transported ◦

Air is available everywhere

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Compressed air can be transported over great distance in pipeline

Easily Stored ◦

Easy to store compressed air in purpose-built tank

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Compressed air bottles can be used at location with no pipe lines (underwater)

Lightweight ◦

Pneumatic device lighter than equipment with electrical power units.

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Pneumatic screw drivers and hammers

Safe To Use ◦

Work perfectly when there are great temperature fluctuation and the temperatures are extreme

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For operating forge presses and blast furnace doors

Accident Proof ◦

Even in areas with risk of fire, explosion and extreme weather, pneumatic element c an be used.

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Fast Work Medium ◦

The very high flows speeds allow rapid completion of work cycles.

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Provide short cut in time and fast conversion ene rgy to work

4.2

Identify Types Of Compressor

4.2.2 Explain Positive Shifted Compressor 

compressor a cylinder bore encloses a moving piston.

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As the crankshaft of the compressor rotate, the piston moves within the cylinder, similar to the piston in a car engine

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the piston is pulled down, the volume increases, creating a lower atmospheric pressure in the piston chamber.

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This difference in pressure causes air to e nter via the inlet valve

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This difference in pressure causes air to e nter via the inlet valve

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. As the piston is forced upwards the volume of air reduces

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The air pressure therefore increases. Eventually the pressure forces the outlet valve to o pen.

4.2.3 Reciprocals Air Compressor 

Reciprocating ◦

Most widely used

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They are characterized by a flow output that remains nearly constant over a range of discharge pressures.

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The compressor capacity is directly proportional to the spee d. The output, however, is a pulsating one.

4.2.4 Rotor Dynamic Compressor 

Rotary Compressor ◦

Rotary compressors have rotors in place of pistons and give a continuous, pulsation free discharge air

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Require smaller foundations, vibrate less, and have a lower number of part s - which means less failure rate.

4.2.5 Identify The Main Parts of Rotor Dynamic Air Compressor

4.3.1 Define Free Air Delivery (FAD) 

Free air delivery refers to harmonized measure of the capacity of an air compressor. To determine the free air delivery of a compressor, the temperature and pressure at the inlet of the compressor are required in addition to the pressure and temperature of the outlet air along with the volume discharged.

4.3.2 Lubricant 

Lubrication helps reduce friction between sliding surfaces to not only improve e fficiency and increase cycling speed of a component, but reduces wear, which ultimately means longer component life and less maintenance.

4.3.2 Filter 

a device which removes contaminants from a compressed air stream.

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This can be done using a number of different techniques, from using a "media" type that traps particulates, but allows air to pass through to a venturi, to a membrane that only allows air to pass through.

4.3.2 Pressure Administrator 

Proper compressor control is essential to efficient operati on and high performance.

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System master controls coordinate all of the functions necessary to optimize compressed air as a utility

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the ability to monitor and control all components in the system, as well as trending data, to enhance maintenance functions and minimize costs of operation

4.3.2 Water Trapper 

allow the removal of condensate from the c ompressed air system.

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Automatic condensate traps are used to conserve energy by preventing the loss of air through open petcocks and valves.

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Poorly maintained traps can waste a lot of c ompressed air.

4.3.3 State Factor Should Be Considered In The Arrangement Of Compressed Air Factory 

Both a general purpose pre-filter and an o il filter and an oil removal filter should be installed just downstream of the compressor aftercooler to remove solid contaminants, water and oil.

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A dryer should be installed between the afte rcooler and receiver.

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Pressure drop between the receiver and the point of use should be kept at a minimum. The loss should be 3% or less of the line pressure.

4.4 Identify The New Technology Using In This System  

The electric generator is the motor that is used to compress air. At night, it uses electricity to create a mechanical force, and in the daytime mechanical power is applied to generate electricity.

4.4.1 List Of Industry Using This System Industry

Example Compressed Air Uses

Food

Dehydration, bottling, controls and actuators, conveying, spraying coatings, cleaning, vacuum packing

Textiles

Agitating liquids, clamping, conveying, automated equipment, controls and actuators, loom jet weaving, spinning, texturizing

Apparel

Conveying, clamping, tool powering, controls and actuators, automated equipment

Lumber and Wood

Sawing, hoisting, clamping, pressure treatment, controls and actuators

Furniture

Air piston powering, tool powering, clamping, spraying, controls and actuators

Pulp and Paper

Conveying, controls and actuators

Chemicals

Conveying, controls and actuators

Petroleum

Process gas compressing, controls and actuators

Rubber and Plastics

Tool powering, clamping, controls and actuators, forming, mold press powering, injection molding

Stone, Clay, and Glass

Conveying, blending, mixing, controls and actuators, glass blowing and molding, cooling

Primary Metals

Vacuum melting, controls and actuators, hoisting

Metals Fabrication

Assembly station powering, tool powering, controls and actuators, injection molding, spraying

4.4.2 Explain The Concept That Industry Apply  

Industrial facilities use compressed air for a multitude of operations. Almost every industrial facility has at least two compressors, and in a medium-sized plant there may be hundreds of different uses of compressed air.

4.4.3 Indentify New Technology Concept Using Now 

A variable-speed drive (VSD) air compressor is an air compressor that takes advantage of variable-speed drive technology. This type of compressor uses a special drive to control the speed (RPM) of the unit, which in turn saves ene rgy compared to a fixed speed equivalent

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The benefits of this technology included reducing power cost, reducing power surges (from starting AC motors), and delivering a more co nstant pressure. The down side of this technology is the heavy expense associated with the drive, and the sensitivity of these drives – specifically to heat and moisture.