AIR COMPRESSORS 101:

HOW AIR COMPRESSOR

COMPONENTS,
SYSTEMS AND PARTS
COME TOGETHER TO
MAKE COMPRESSED AIR
A comprehensive review of how design engineers integrate
various components, controls and parts into high-performance
compressed air systems.
TABLE OF CONTENTS

How Air Compressor Components, Systems and Parts Come Together To Make Compressed Air................................. 3
Compressed Air: The Short Version................................................................................................................................................... 3
Air Enters Through the Inlet Air Filter............................................................................................................................................... 4
Air Enters the Airend and Is Compressed........................................................................................................................................ 5
Two-Stage Compressors................................................................................................................................................................. 5
Lifetime Airend Warranty............................................................................................................................................................... 6
Why Is Oil Injected into the Air?..................................................................................................................................................... 7
Oil-Free Compressors..................................................................................................................................................................... 8
An Air-Oil Separator Removes Oil...................................................................................................................................................... 8
The Air Is Cooled.................................................................................................................................................................................... 9
Heat Recovery................................................................................................................................................................................ 11
Water Cooling................................................................................................................................................................................. 11
Supporting Components and Systems........................................................................................................................................... 11
Control Panel................................................................................................................................................................................. 11
Sensors, Transmitters, Switches and Valves............................................................................................................................. 12
The Motor(s)................................................................................................................................................................................... 12
The Oil Cooler................................................................................................................................................................................ 14
Filters.............................................................................................................................................................................................. 14
Downstream Equipment.................................................................................................................................................................... 14
The Air Is Dried.............................................................................................................................................................................. 14
The Air Is Stored............................................................................................................................................................................ 15
Expert Help........................................................................................................................................................................................... 16
Key Takeaways..................................................................................................................................................................................... 17
Let Us Help............................................................................................................................................................................................ 17
 Semiconductor fabrication requires a steady
flow of compressed air that is clean and free
of oil and moisture.

AIR COMPRESSORS 101: HOW AIR COMPRESSOR

COMPONENTS, SYSTEMS AND PARTS
COME TOGETHER TO MAKE COMPRESSED AIR

Many facilities rely on compressed air systems to provide a fourth utility. As with the other three
(water, electricity and natural gas), too many people take this vital service for granted, missing
the opportunity to save money and energy and improve the efficiency of their operations.

This white paper explains how an air compressor works and shows how its components,
controls and parts are integrated into high-performance systems that deliver the compressed air
so many businesses and organizations rely on.

The first section follows the air as it moves through your rotary screw air compressor. Then, we’ll
discuss the supporting elements, including the controls, motors and cooling systems. Finally,
we’ll talk about the downstream equipment that enhances the operation of the entire system,
including dryers that condition and tanks that store the air.

COMPRESSED AIR: THE SHORT VERSION

To set the stage for this account explaining how a rotary screw air compressor works, here’s a summary:
• Air enters through the inlet filter.
• Air enters the airend and is compressed.
• An air-oil separator removes oil (from oil-flooded units only).
• The air is cooled.

That’s the short version. There are many supplemental details—processes, devices and parts—that support the entire
enterprise, of course. The devil, as they say, is in the details.

Let’s start at the beginning when the air enters the system.

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AIR ENTERS THROUGH THE INLET AIR FILTER
Atmospheric air enters a rotary screw air compressor through an inlet air filter and an inlet valve that controls how
much air is drawn into the unit.

The process starts, however, even before the air enters the inlet air filter. It’s crucial that the air coming into your
compressor comes from a cool, clean and dry source.

Using air from inside many factories may not be the best approach. It may add airborne dust and dirt, and the
equipment room may be too small and not have adequate ventilation. Plus, it might have other equipment, like chillers
or boilers, that put heat into the air.

For anything above a 25-HP compressor, it’s probably wise to supply your compressor with clean, fresh, outside air
drawn in through a forced-air and duct system. You’ll want to avoid placing that intake at the truck parking near your
loading dock, to avoid sucking that exhaust into your compressor.

The inlet valve is open when your compressor has demand (or is loaded) and is closed when there is no demand (or in a
no-load state).

Determining the amount of air entering your compressor is not as straightforward as it may seem. Atmospheric air
pressure varies greatly depending on elevation. For example, a compressor in New Orleans might produce 1,000 CFM of
air while the same unit in Colorado, with the same settings, would deliver only 600 CFM.

As a result, the inlet valve is one of the most important and complicated parts of a rotary screw air compressor. No part
of the compressor so uniquely differentiates the various manufacturers. It regulates two significant functions:
• The air entering the compression cycle. If the volume of air entering the chamber is not sufficient, your
compressor will struggle to provide enough air pressure. If the inlet valve brings too much air into the
chamber, on the other hand, it could cause over-pressurization, damaging the compressor and nearby
equipment.
• The oil lubricating the airend. When your unit compresses air, we use air pressure as a fluid-motion device,
creating oil pressure. Even when your compressor is in the unload state, you need to keep the oil flowing to
the airend. That, of course, is not required for oil-free compressors, which are discussed in greater detail
below.

Because of the inlet valve’s importance, you should change the intake filters regularly (at least every 2,000 hours)
and change them every 4,000 hours or per manufacturer’s recommendation or service indicators. Air filters remove
particulates that enter your compressor’s intake, regardless of the air source. Dirty filters increase the pressure drop,
making your system less efficient. Even a two-PSIG pressure drop caused by blocked filters will raise your energy
consumption by an average of 1%. Fortunately, a Kaishan compressor’s control system will monitor the pressure
differential in your compressor’s intake air filter.

In addition, you may have to rebuild an inlet valve after 16,000 hours under normal conditions or 8,000 hours in bad
environments. You should only have to replace an inlet valve if it begins failing too often.

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For more detail on the air inlet valve, read our blog post, “What Is the Air Compressor Inlet Valve, and How Does It
Work?”

The air moves through a suction filter to remove particles. Then it goes through the inlet valve and into the airend for
compression.

AIR ENTERS THE AIREND AND IS COMPRESSED

The air at atmospheric pressure enters a compression chamber, where two interlocking helical rotors or screws turn in
opposite directions. That movement traps the air and reduces the space between the rotors and the stator or housing,
compressing it.

The airend is the heart of the machine, where a rotary screw machine does the main work of pressurizing the air.

The airend’s efficiency and integrity determines the performance of the compressor. The more efficient the airend,
the more efficient the compressor, with the most efficient airend producing more air and using less energy. The design
engineer’s goal: to get the most air flow with the least amount of energy.

Each manufacturer combines the airend with the air inlet valve in unique ways, thus differentiating the various rotary
screw air compressor designs on the market.

We cut our own rotors in our 65,000-square-foot (soon to be 130,000) state-of-the-art facility in Loxley, AL. Advanced
CNC equipment machines them to extremely tight tolerances.

We cast the stator, sizing the housing uniquely for each product category and size. We test the entire airend of our oil-
flooded and oil-free units.

The rotors are powered by an electric motor directly or connected with a traditional coupling. Belt-drive units are also
available. We’ll discuss motors further below.

For more on the role of this critical component, read our blog post, “Your Rotary Screw Compressor Airend: Where the
Magic Happens.”

A compressor can also have several stages.

TWO-STAGE COMPRESSORS
A single-stage compressor like Kaishan’s KRSP premium rotary screw air compressor generates a compression ratio of
7.8 to 1 to create 100 PSIG of pressure. It is one of the most cost-effective compressors on the market.

Kaishan’s KRSP single-stage rotary screw

air compressors are among the most cost-
effective options on the market.

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A two-stage compressor, like Kaishan’s KRSP2 premium rotary screw air compressor splits the workload, building on the
pressure generated in the first stage.

As a result, the KRSP2 generates up to 15% to 20% more flow than a single-stage compressor of the same size or
horsepower. Payback on energy costs alone may be less than two to three years. Two-stage compressors, however,
cannot be used in applications with a discharge pressure that is too low (under 50 PSIG for an oil-flooded compressor or
under 80 PSIG for an oil-free unit). Oil carryover can result in oil-flooded compressors at lower discharge pressures.

Kaishan’s KRSP2 two-stage rotary screw

air compressor is one of the most energy-
efficient machines on the market.

For more on the benefits of two-stage compressors, read our blog post, “Five Critical Differences Between a Single-
Stage and a Two-Stage Air Compressor.”

Both Kaishan’s KRSP and KRSP2 premium rotary screw air compressors are backed by a lifetime warranty on the airend.

LIFETIME AIREND WARRANTY

Because of their reliability, efficiency and long life, Kaishan rotary screw air compressors have the best warranties in
the industry.

An unmatched lifetime airend warranty backs

Kaishan’s KRSP and KRSP2 screw compressors.

Our standard warranty covers the complete compressor package for 12 months from the date of startup (or 18 months
after it’s shipped, whichever comes first), with an airend warranty of 24 months.

With our extended warranties (provided at no additional cost), Kaishan’s KRSP and KRSP2 screw compressors are
backed by a lifetime warranty on the airend.

For more information on warranty protection, read our blog post, “How to Maintain Your Air Compressor with Genuine
Spare Parts.”

All oil-lubricated rotary screw compressors inject oil into the compression chamber.

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WHY IS OIL INJECTED INTO THE AIR?
Oil is so critical we often say it is the lifeblood of an oil-lubricated compressor. It performs the following essential tasks:
• Cooling. It removes the heat of compression and lowers the operating temperature. Thus, oil-lubricated
compressors can handle hotter environments and operate more efficiently (and cooler).
• Removing impurities. Oil removes contaminants and protects your unit’s components from oxidation and
corrosion.
• Sealing. It acts as a sealant between the male and female rotors, making the compressor more efficient.
• Prolonging compressor life. Oil reduces friction and wear and lubricates components, thus lengthening a
compressor’s service life.

For more on the role oil plays in compressor longevity, read our blog post, “Four Key Steps to Extend the Lifespan of
Your Rotary Screw Compressor with Proper Lubrication.”

Unfortunately, some traces of that oil are carried over in the compressed air as it leaves the compression chamber. That
oil must be removed to maintain air quality and prevent damage to downstream applications.

Oil removal is essential in industries such as food processing, semiconductor fabrication and electronics manufacturing.

Oil-free compressed air is essential in

food and beverage processing.

To comply with FDA regulations, most food manufacturers use oil-free compressors in applications where the air comes
in direct contact with food. However, some companies use oil-lubricated compressors in applications like packaging,
where direct contact is less of a concern. In instances where oil-flooded compressors are used, proper filtration and
maintenance of the filtration helps remove any oil, dirt or dust particles from the air stream.

For example, the oil carryover in a Kaishan KRSP-100 premium rotary screw air compressor is less than 3 ppm. As a
result, some companies needing high-quality air can use oil-flooded compressors with proper filtration—located before
the dryer or even right before the point of use—to remove oil and other impurities. They may also use food-grade oil.

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OIL-FREE COMPRESSORS
Oil-free machines, such as our KROF two-stage, oil-free rotary screw air compressor, do not inject oil into the airend.
As mentioned earlier, oil-free technology is used in sensitive applications—such as food processing, semiconductor
fabrication and electronics manufacturing —to avoid introducing oil into the pressurized air flow.

Our KROF two-stage, oil-free rotary screw air

compressor has special seals inside the airend to
keep oil out of the compression chamber.

Our oil-free compressors have special adaptations to accommodate oil-free operation:

• Micron precision. We carefully machine the rotors of our KROF to micron precision to keep the working gap—
the space the oil seals between the rotors in an oil-flooded machine—as small as possible. The rotors still
must spin without touching.
• Special seals. We have developed seals inside the airend to keep oil out of the compression chamber. In
addition, the KROF has hydraulic inlet valves to increase reliability in contaminated environments. Closed-
system hydraulics ensure positive sealing and control valve actuation through all operating pressures.
• Coating. The rotors have a special coating to protect and reduce the clearance between them, making the
working gap as small as possible. The coating also seals the rotors, prevents friction and reduces corrosion
and wear.
• Cooling. Oil-free machines need extra cooling because they do not use oil to cool the airend. As a result, our
KROF oil-free machine has oversized stainless-steel precoolers on each stage that lower temperatures for
both intercoolers and aftercoolers. More on this topic in the cooler section below.

Although oil is not injected into an oil-free compressor’s airend, there can still be carryover if the ambient air entering
the compressor contains oil. Proper filtration can remove that oil.

AN AIR-OIL SEPARATOR REMOVES OIL

After leaving the compression chamber, the air in an oil-flooded compressor enters the separator tank or sump, which
forces the air into a circular movement. That cyclonic effect forces out most of the oil.

The air is then drawn into the separator element—a mesh filter similar to an oil filter in your car—which removes all but
a tiny fraction of the oil—3 parts per million, to be exact.

Original equipment manufacturers engineer their air-oil separators to match the specific requirements of each
compressor model. On ours, for instance, the control lines and fittings are stainless steel, ensuring equipment longevity
and air quality.

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OEMs also factor in the type of oil, the pressures you need and the ambient heat in your facility. So, it’s critical
that you follow those recommendations.

As we note in our blog post, “How to Maintain Your Air Compressor with Genuine Spare Parts,” inappropriate
replacement of an air-oil separator can result in fires, explosions and even injuries to workers.

While dramatic events like fires and explosions rarely happen, a problem with an air-oil separator can have
many other negative consequences, including:
• Oil pass-through, resulting in poor air quality
• Pressure drop
• Increased costs
• Damage to downstream equipment

As a result, maintaining an air-oil separator is critical to the operation of an oil-flooded machine.

Maintaining the air-oil separator is critical

to the operation of an oil-flooded machine.

For more on the importance of air-oil separators, read our blog post, “Everything You Need to Know About Air/
Oil Separators.”

THE AIR IS COOLED

During the compression process, your compressor generates heat as a part of normal operations. It’s called
the heat of compression, and it occurs naturally as the air molecules are jammed closer together. The higher
the ratio between the discharge and suction pressure, the more heat you generate.

The ambient air that enters your system, presumably at 70°F, will reach 175°F-200°F in an oil-lubricated screw
compressor or 300°-350°F in an oil-free rotary screw or single-stage piston compressor, according to the Air
Compressor Guide. The difference demonstrates how effectively oil removes the heat of compression from
the air.

You’ll need cooling and drying equipment to condition that air to a more manageable level. However, it will still
be 10°-20°F higher than when it came into your compressor.

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So, when the air comes from a compressor room that is 10°F-20°F hotter because it’s in a closed room that is
usually not adequately ventilated or from a super-heated parking lot baking in the hot summer sun, you’ll start
with a temperature deficit.

As a result, if your intake air is at 110°F, you will struggle to get the compressed air you send downstream
below 120°F-130°F.

Temperatures that high will:

• Shorten the life of the oil and the compressor itself. The oil’s lifespan is cut in half for every 10°F
you operate the compressor above its normal operating temperature.
• Increase all your costs, including electricity bills and maintenance expenses.
• Produce poor air quality, including oil and water pass-through.
• Impact drying, requiring dryers to work harder to remove moisture. As a result, dryers need to be
derated for higher temperatures.
• Damage end-use tools and equipment, degrading lubricants and seal materials.

That’s why it’s crucial to have the air coming into your compressor from a cool, clean and dry source. And then
there’s the humidity in hot air.

The water vapor in hot air will cause corrosion and scale buildup and may even result in freezing in colder
climates. Kaishan, by the way, offers cold-weather packaging, which adds heat tracing on critical lines and the
oil sump.

Water vapor-laden compressed air also causes quality problems in applications such as automotive painting,
semiconductor and healthcare and medical device manufacturing.

Compressed air that is hot and contains

moisture would cause quality problems for
a medical device manufacturer.

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That heat is removed in an aftercooler, a heat exchanger with a fan blowing ambient air over finned tubes. An air-cooled
machine can have as many as two fans to aid the cooling process. As the air cools, water condenses and is extracted
with a moisture separator. The moisture is removed from the separator through an automatic drain valve.

To manage the additional heat from its oil-free operation, our KROF has oversized stainless-steel precoolers on each
stage, as well as intercoolers and aftercoolers.

HEAT RECOVERY
The good news is that you can recover some of that heat and use it in other parts of your enterprise for space heating,
preheating boiler water, water heating or even process heating (like drying). In oil-free compressors, the heat can also
be captured and paired with a heat-of-compression dryer, using the heat to regenerate the desiccant beds in the dryer.
In this option, the KROF does not have an aftercooler.

In most cases, at least 70% to 80% of the energy used to compress the air becomes waste heat. Compressed Air Best
Practices even says you can recover up to 90% of that heat loss.

For more information on configuring your compressed air system to maximize heat recovery, see our blog post,
“Compressor Room Design.”

WATER COOLING
You can also use water as the cooling medium for the compressor airend. In a water-cooled compressor, the cooling
water flows through a shell and tube or brazed plate heat exchanger, which cools the oil and/or the air.

Unlike some competitors, Kaishan uses oil, not water, in the jackets cooling the airend, keeping them from becoming
contaminated with scale or rust buildup, which impedes the heat exchange and thus reduces the life of the airend and
results in elevated operating temperatures.

But water cooling is not a set-it-and-forget-it solution. Whether it’s a closed-loop (using a cooling tower) or an open-
loop system (drawing from an external water source like a river or pond), you need filters and even water treatment to
prevent clogging or fouling of the water. Water coolers also require a minimum pressure and flow. Inadequate water
treatment is often the reason why water-cooled heat exchangers fail prematurely.

SUPPORTING COMPONENTS AND SYSTEMS

CONTROL PANEL
Today’s rotary screw air compressors feature a control panel that displays all the information you need to know
regarding the status of your compressor. It’s the user interface for the control system that regulates the operation of
the compressor.

The control panel of a typical compressor can contain as many as five different voltages, so only a qualified electrician
or compressor repair person should open the cabinet. Those different levels are managed by our controls, of course, so
you will only need to supply your compressor with current at one voltage.

Every Kaishan compressor displays all relevant operational data on the screen of your compressor controls: pressure,
temperature and voltage. Unlike many competitors, we also display current (amps) on the screen.

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As a result, you don’t need to open the control panel to have the critical status information you need. More proof that
we do everything we can to help you operate our equipment with relative safety. For more on safety, see our blog post,
“Four (and a Half) Critical Compressed Air Safety Tips.”

If you want to keep an eye on key parameters and receive notifications via text, you can even monitor your compressor
remotely through the Internet of Things. We offer options like AirWatch, which digitally creates a twin online using
Modbus protocol to display pressure, temperature, faults, status and other key indicators.

To make compressor operation easier and safer,

Kaishan units display all relevant data on the screen
of your compressor controls: pressure, temperature,
voltage and any amps that are present.

SENSORS, TRANSMITTERS, SWITCHES AND VALVES

Compressors use a variety of sensors, transmitters, pressure switches and valves to monitor and control key
operational parameters, including pressures, temperatures and flow:
• Valves, including a minimum pressure valve, ensure that the pressure leaving the compressor meets the
system requirements.
• Pressure switches track the differential pressure (or ΔP—a comparison of pressures before and after a
device) to indicate a clogged filter. Most compressor manufacturers measure ΔP on oil filters. The critical inlet
air filter mentioned previously has a pressure switch to ensure it is not collapsed.
• Internal safety checks and valves measure temperature or pressure to ensure that your compressor is not
over-pressurized, preventing injuries to your staff and damage to your equipment.
• Temperature transmitters track temperatures at various stages.

For example, an oil-flooded screw compressor is monitored for temperature at two or three locations, while oil-free
rotary screw compressors monitor additional values for temperature and pressure to protect the oil-free package.

THE MOTOR(S)
A main motor powers a rotary screw air compressor. The motor’s horsepower rating tells us how much work the
compressor can perform—the higher the motor’s horsepower, the greater the compressor’s capacity.

You need that power to generate the energy to deliver compressed air at the required flow and pressure.

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Another key motor rating is the insulation class, which establishes the temperature that your motor can endure. Class F
is the most common rating used in motors above 5 HP, while Class H is less common and is used for heavy-duty, hot or
high-altitude conditions. Kaishan and many competitors use Class F insulation, although some use a lower classification.

The key thing to remember is that if you go too far beyond the rating, you’ll risk burning out the motor. The rule of
thumb is that every 10°C you operate a motor above the insulation rating cuts the insulation’s service life in half,
according to Machine Design magazine.

All our compressors are equipped with totally enclosed, fan-cooled motors, preventing debris and contaminants
from entering the unit. In addition to cooling the unit, the fan boosts the efficiency and equipment life of TEFC motors
compared with open drip-proof motors.

Induction and PM Motors

Currently, most motors used in rotary screw air compressors are induction motors, but the industry is moving toward
permanent magnet motors because of their efficiency, light weight and greater reliability.

Air compressor motors connect to the airend in several ways:

• Direct-drive motors like KRSD direct-drive rotary screw air compressor, are directly connected to the airend.
• Traditional couplings. A coupling usually connects the main motor to the airend (although some companies
use a gearbox or other device between the motor and the airend to eliminate the need for couplings).
• Belt-drive units, such as our KRSB belt-drive rotary screw air compressors, are driven by a belt-and-pulley
system.

Our KRSB belt-drive rotary screw air compressors

are driven by a belt-and-pulley system.

Other Motors
In addition to the motor driving the airend, rotary screw air compressors have secondary motors driving key
components like the cooling fans used in air-cooled units. Water-cooled machines also have very small motors to
circulate hot air out of the package.

The different uses of these motors are spelled out in the sheets developed by the Compressed Air & Gas Institute. For
more on reading and interpreting the information in these important documents, read our blog post, “A Beginner’s
Guide to Reading Rotary Screw Compressor Performance Curves.”

You’ll find more about motors in our blog post, “Ten Key Facts You Need to Know About Rotary Screw Air Compressor
Motors.”

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Variable-Speed Drives
A related issue is the drive function fulfilled by variable-frequency and variable-speed drives. VSDs and VFDs are
electronic components that adjust the frequency of the power supplied to your air compressor’s motor. Based on
input from sensors throughout your system, the VSD speeds up or slows down the motor to match the compressed air
demand, delivering several significant benefits.

Many companies have saved significant amounts of energy by using rotary screw air compressors equipped with VSD
technology. And energy savings are not the only benefit. VSD compressors can earn rebates, allow soft starts and offer
better control of your compressed air system. They are also an energy-efficient way to address rapid cycling.

For more information on the benefits of VSDs and VFDs, read our blog post, “How Variable-Frequency-Drive Air
Compressors Work.”

THE OIL COOLER

As mentioned, keeping your compressor cool is critical to operating your system successfully. As a result, there are
cooling circuits for the air (mentioned previously) and the oil.

Oil-flooded rotary screw air compressors have an oil lubrication system that seals the compression cycle, lubricates
components and removes the heat of compression, lowering your system’s operating temperature. That heat is
removed in the oil-cooling cycle.

Cool oil returns to the airend. Oil that is too hot goes through an oil cooler, typically a fin-and-tube heat exchanger
similar to a car radiator. It usually has a fan blowing ambient air across the fins to remove the heat.

The oil is then filtered to remove contaminants that could harm the compressor and returned to the airend, where the
cycle starts again.

While oil-free units do not rely as much on oil, they still use oil to lubricate components (such as gears not in
contact with the compressed air) and to lower operating temperatures in the stage cooling jackets (keeping casting
temperatures lower).

FILTERS
Maintaining filters is critical for coolers. Clogged filters will impede and eventually block air flow, causing energy loss
that is both unnecessary and avoidable. So, you’ll need to replace filter elements regularly.

DOWNSTREAM EQUIPMENT

THE AIR IS DRIED

Compressed air systems must remove moisture that inevitably enters your system. If not removed, water creates
downstream issues, from contamination of end products to damaging pneumatic machinery and other components.

A recent article by CAGI outlines the hazards of moisture in compressed air, including rust, corrosion, freezing and
increased wear in most applications. And problems with color, adherence and finish in painting applications.
Depending on the pressure, dewpoint and air quality a customer needs, a rotary screw air compressor system may
include a refrigerated air dryer or a desiccant air dryer to remove additional moisture. That’s especially important in
industries like automotive, semiconductor and electronics.

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As mentioned, heat-of-compression dryers are also available for high-temperature applications, especially oil-free units,
like our KROF.

Electronics manufacturers need high-quality

compressed air that is clean and dry.

Removing all that moisture requires drains in a variety of locations, including sumps, condensate traps, separators and
even filters. It’s important to Inspect the moisture trap drain and the drains in all your tanks, filters and dryers. You’ll
want to remove any scale, rust, dirt or other solids from condensate traps and drain points daily.

Dirt and debris often accumulate in drains, causing them to become stuck. Stuck in an open position, the drain will leak
air. And a closed drain will allow moisture and other impurities to pass through, contaminating your compressed air
and possibly damaging production equipment. It’s also important to separate drains from different locations so they do
discharge into each other.

And be aware that compressor condensate cannot simply be poured down the drain into a municipal sewer system.
While that fluid is mostly water, condensate can contain oil and other contaminants that are removed from the air and
concentrated in the condensate during the compression process. Most local municipalities require that you properly
dispose of that condensate.

THE AIR IS STORED

Storage plays an integral role in any compressed air system. Air compressor tanks help balance the supply of air from
the compressor with the system’s demand.

As a result, tanks can help accommodate surges in demand, acting as reservoirs during peak times. They also help
remove water from the compressed air system, minimize pulsations in the air flow and ensure smooth operation.

In addition, a well-sized storage tank can significantly impact energy efficiency. Properly sized tanks reduce the number
of compressor starts and stops, promoting energy conservation and extending the compressor’s life.

CAGI recommends up to 10 gallons per CFM and provides a formula to calculate the air receiver size based on time
allowed for the pressure drop. The main point is that the tank should be sized so the system does not cycle more than
10 times per hour.

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Since there are seven and a half gallons for every cubic foot, 50 CFM translates into 1,500 gallons of storage. That might
sound like a lot of storage. But, depending on the size of the peaks in demand, it may not be enough. Here’s why. Let’s
say you have a 100-gallon tank at 100 PSI, but your application uses 200 CFM. Should you have a surge in demand, you’ll
see the tank pressure drop by one atmosphere (14.7 PSIG) every 30 seconds. That doesn’t give you a lot of time.

As a result, if a peak event lasts more than 30 seconds, it’s probably too large to be managed by storage alone.

Another reality is that a receiver tank requires differential pressure to store air. If it has the same inlet and outlet
pressure, you don’t have any stored energy (or air). Without differential pressure in the tank, it’s just a big piece of pipe.

Wet and Dry Compressed Air Tanks

Compressed air can also be stored “wet” or “dry,” with wet storage tanks located before the air-drying system and dry
tanks located after the dryers.

The major advantage of dry storage is that compressed air is readily available for use directly from the tank. This
approach reduces the risk that high-demand events will exceed the air dryer’s capacity.

Wet storage, however, allows excess water and lubricant to condense out of the system before it hits the filter and dryer.
It thus increases your air dryer’s energy efficiency and prolongs the life of the pre-filter element. Plus, it adds a buffer
that avoids slamming the dryer, allowing it to cool more efficiently and eliminate the pressure drop on the air dryer side
of the system that occurs with dry storage. Wet tanks are essential for desiccant dryer systems due to the large amount
of air used when the towers switch.

Most facilities have a combination of wet and dry storage, with a third of storage capacity as wet storage and two-thirds
as dry.

As with so many aspects of compressed air technology and systems, it helps to have a knowledgeable partner to help
with these critical decisions.

EXPERT HELP
From choosing the right compressor and sizing and equipping it correctly to operating and maintaining it for optimal
efficiency and long-term reliability, most facilities will benefit from the advice of a trusted compressed air professional.

Our nationwide network of independent distributors, provides on-site help and consultation to customers throughout
the Americas. While Kaishan provides them with state-of-the-art equipment, our independent distributors are the
heroes who help their customers save money and improve air quality. Read just a few of their stories on our case
studies page.

We partner with these independent, local businesses because we know of no better way to ensure that you have
expert guidance, fast response times and personalized support tailored to your needs. They’re in business to build
relationships, ensuring you get the right system, reliable service and quick access to parts when you need them most.

They have factory-trained technicians with a deep understanding of industrial applications and can help you maximize
efficiency and minimize downtime throughout your compressed air system. When you buy through Kaishan, you’re
getting more than a product—you’re getting a local partner who cares about your business and seeing it succeed.

16
KEY TAKEAWAYS
• The air inlet is a gatekeeper to a rotary screw air compressor.

• The airend is the heart of an air compressor, combining with the inlet valve
to create differentiation among compressors.

• Oil is the lifeblood of an oil-lubricated compressor, removing contaminants

and the heat of compression and making it more efficient and reliable.

• Maintaining an air-oil separator is critical to the operation of an oil-flooded

rotary screw air compressor.

• It’s crucial that the air entering your compressor comes from a cool, clean
and dry source.

• High compressed air temperatures will shorten the life of the oil and the
compressor itself, increase costs, produce poor air quality and damage end-
use tools and equipment.

• If moisture is not removed from the compressed air, it will create

downstream issues, including contamination of end products and damage to
machinery and components.

• Storage plays an integral role in any compressed air system, helping balance
the supply of air from the compressor with the demand from the system.

LET US HELP
Understanding the basic components of a rotary screw air compressor and how they
work together is an essential step in operating your compressed air system and all the
processes that rely on that system. If you need help with any aspect of the process, get
in touch with the experts at Kaishan. Contact us today.