Air compressor support package
United States Patent [1 1 Sturgill Apr. 8, 1975 AIR COMPRESSOR SUPPORT PACKAGE [57] ABSTRACT [76] Inventor: Richard A. Sturgill, 1721 S. Bluff A unitary component package for supporting an air Rd., Montebello, Calif. 90640 compressor is disclosed herein having a single pressure [22] Filed; 18, 1972 vessel serving as an air receiver and oil sump and being provided with at least three internal component PP 316,350 compartments for housing an oil filter, oil cooler combination; an air-oil separator; and an air aftercooler.  
  52 us. Cl 55/269; 55/481 The Compartments are arranged in fixed Spaced apart 51 Int. Cl Bold 27/08 Parallel relationship Permit air-Oil mixture from the [58] Field of Search 55/269 175 174, 176, compressor to circulate within the receivenabout the 55/177, 438 439, 481; 62/467 470 84; component compartments. The lower portion of the 84/616 (L24 receiver functions as an oil sump and is in fluid communication with the compartment housin the oil filg I I [56] References Cited ter and the oil cooler as a part of the oil recirculating UNITED STATES PATENTS system. A conduit interconnects the separator compartment with the aftercooler compartment whereby 3,285,123 6/1942 Phl&#39;lllPS 62/84 the air 0il mixturg within the receiver is processed through the separator and then through the after- 7H9 g l T z 55/269 cooler for discharge from the vessel. Removable 3:755:66) 5/1973 chambersliiijii Q: 55/481 hatches are carried OPPOSiIe ends of the receiver Primary E.\&#39;aminer-Bernard Nozick Attorney, Agent, or Firm-Roger A. Marrs Airz/ou. IN  
 for access to selected component compartments for service and repair purposes.  
 10 Claims, 10 Drawing Figures AIQ 001&#39; 4 39 35 sum 2 OF 3 3876&#39;4Ol PATENTEDA R 1975 PATENTEBAPR ems AlQ/OIL IN AIR/OIL. IN  
 sumap AIR COMPRESSOR SUPPORT PACKAGE BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to the field of air processing apparatus and, more particularly, to a novel accessory or support component package housing a variety of components for processing fluid entrained gases arranged in a unitary construction.  
 2. Background of the Invention It is the conventional practice to process a fluid such as air by drawing ambient air through an air filter into a compressor such as a rotary screw type and then mixing the compressed air with oil droplets for absorption of the heat of compression. Cooled, filtered oil is introduced to the compressor from a sump and separated from the compressed air by means of a variety of process components which are external to the compressor and independently arranged from each other. In other words, in addition to the compressor itself there is conventionally provided an oil recirculating system incorporating a separate oil filter, oil cooler, air receiver and sump, and air air circulating system having a separator, and an aftercooler. Each of these components is a separate structure generally encased in a pressurized vessel or shell and interconnected by a plurality of conduits for establishing proper air and oil flow. Obviously, such an arrangement of separate components is extremely expensive, requires a substantial area for mounting and interconnection, and represents a substantial duplication in pressure vessels and interconnecting conduits. Problems are encountered in performing repair and maintenance proceedures that stem from the requirement of having to open many pressure vessels and to disconnect many pipes or conduits to gain access to component parts.  
  Consequently, a long standing need has existed to provide-a single pressure vessel having suitable access to and for housing a variety of components or accessories supporting the operation and function of processing compressed gases with entrained liquid requiring separating and cooling so as to eliminate duplication and system redundancy.  
 SUMMARY OF THE INVENTION Accordingly, the above difficulties and problems encountered with conventional air processing equipment are obviated by the present invention which provides a basic pressure vessel functioning as an air receiver and oil sump and which is provided with a plurality of compartments for housing a variety of components such as a secondary oil separator, oil filter, oil cooler, aftercooler and a thermal valve. The basic receiver functions primarily as a primary oil separator, oil reservoir, and includes interconnecting conduits or passageways for selectively placing the component compartments in fluid communication with each other for processing of a gas entrained liquid such as an air-oil compressed mixture. r  
  In one form of the invention, a pressure vessel is provided having three compartments wherein one compartment houses an oil filter and an oil cooler and is interconnected to an air compressor via an oil recirculating system. A second compartment houses an air-oil separator and is connected to the third compartment housing an aftercooler. Means are provided for supplying the air-oil compressed mixture to the pressure vessel receiver and for circulating the mixture internally of the receiver followed by introducing the mixture to the separator and the aftercooler. Means are provided for discharging the separated and cooled compressed air from the pressure vessel after processing through the aftercooler wherein the discharged air is ready for use. A feature of the invention resides in providing removable hatches to each of the component compartments so that replacement or repair may be readily achieved without extensive disassembly of the system components.  
  Therefore, it is among the primary objects of the present invention to provide a novel unitary apparatus for processing compressed gases with entrained liquid that requires separation and cooling.  
  Another object of the present invention is to provide a novel air receiver in an air processing system having internal components functioning in a recirculating oil subsystem and an air/oil separation and cooling circulating subsystem.  
  Another object of the present invention is to provide a novel basic air receiver that functions in an oil recirculating subsystem having a primary oil separator, oil reservoir, an oil filter, oil cooler, and a thermal valve, and that functions in an air-oil circulating subsystem having an air-oil separator and an aftercooler.  
  Another object of the present invention is to provide a unitary pressure vessel with separate access to each of several internal compartments housing a variety of components used in the processing of compressed air.  
  Still another object of the present invention is to provide a novel pressure vessel in combination with a rotary screw type air compressor that houses a plurality of components in a unitary structure normally used in the process of compressed air wherein such components are normally separate and individually connectable together externally of the pressure vessel.  
  A further object of the present invention is to provide a novel support component package for a rotary screw compressor involving a single pressure vessel acting as &#39;a receiver functioning as a primary oil separator and an oil sump and which further includes a plurality of selectable interconnecting compartments housing standard air and oil processing components.  
 BRIEF DESCRIPTION OF THE DRAWINGS The features of the present invention which are believed to be novel are set forth with particularly in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages. thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, in which:  
  FIG. 1 is a diagrammatic drawing of a conventional air processing system incorporating standard components arranged separately and individually externally of the air receiver;  
  FIG. 2 is a diagrammatic drawing of the novel air compressor support package of the present invention illustrating the housing of air processing components in a single air receiver package;  
  FIG. 3 is a perspective view of the support package of the present invention incorporating the components as shown in FIG. 2;  
  FIG. 4 is a perspective view of the air receiver package illustrating the removable housing of the aftercooler and oil cooler components;  
  FIG. 5 is an end elevational view of the compressor support package shown in FIGS. 3 and 4 taken at the air exit end thereof;  
  FIG. 6 is an end elevational view of the compressor support package taken from the air inlet end opposite to the end shown in FIG. 5;  
  FIG. 7 is a longitudinal cross sectional view of the compressor support package as taken in the direction of arrows 7-7 of FIG. 5;  
  FIG. 8 is a longitudinal cross sectional view of the compressor support package shown in FIG. 6 as taken in the direction of arrows 8-8 thereof;  
  FIGS. 9 and 10 are diagrammatic illustrations of the novel compressor support package of the present invention illustrating submersion of the oil filter and cooler in the oil sump of the air receiver.  
 DESCRIPTION OF THE PREFERRED EMBODIMENT The prior art air processing system shown in FIG. 1 diagrammatically illustrates a conventional air compressor of the-rotary screw type indicated by numeral 10 which is supplied with ambient air through an air filter 11. The compressor in general comprises two matched rotors which draw air in through the filter and squeeze the air followed by discharging the air through a conduit 12. The matched rotors are operated by a motor 13. In order to absorb the heat of compression, the compressed air is mixed with oil supplied via a conduit 14. The temperature rise across the compressor is approximately 100 F. The air-oil mixture is not vaporized due to thermal control which prevents carbon formation and sludge build-up in the compressor or the air system. The oil mixed with the compressed air is in the form of droplets and is carried by the compressed air throughconduit 12 to an air receiver 15. The air-oil mixture within the chamber of the air receiver is circulated therein so that the oil droplet components of the mixture drop into an oil sump 16 located at the bottom of the air receiver. As the air is circulated within the receiver, it is introduced to an air-oil separator or demister which removes the remainder of the oil in the air. The remaining oil collected by the separator will drip into the oil sump and be returned to the compressor 10 by a thermal valve 17, an oil cooler 18 and an oil filter 20. The oil cooler takes the form of a heat exchanger having water introduced thereto for absorbing heat from the oil and exiting from the cooler for recirculation. The cleaned compressed air from the separator 21 is introduced to an aftercooler 22 and then is discharged through an outlet 23 for use. The aftercooler comprises a heat exchanger having water introduced for effecting heat exchange and return to the water system.  
  In the conventional air processing system as shown in FIG. 1, the receiver acts as a primary oil separator and also serves as an oil reservoir. The air pressure in the receiver is used to push a controlled amount of oil through the oil cooler 18 externally of the receiver. The thermal valve 17, positioned upstream of the oil cooler bypasses oil around the cooler to maintain thermal balance across the compressor. The oil is filtered and returned for injection again into the compressor 10 via conduit 14. The compressed air, after separation by separator 21, is cooled by the aftercooler 22 and passed through outlet 23 for use. It is to be particularly noted that the aftercooler 22, oil cooler 18, thermal valve 17, and oil filter 20 are all external of the receiver and all include their own housing, inlets, outlets and interconnecting piping.  
  Referring now to FIG. 2, an air processing system is illustrated incorporating the support package of the present invention wherein all of the components required in processing of the air are contained within the confines of a pressure vessel 25 in the direction of arrow 25. The rotary screw compressor 10 is operated by motor 13 and draws ambient air through air filter 11 and, after mixing with oil from line or conduit 14, the mixture is discharged through conduit 12. Conduit l2 empties into the pressure vessel forming an air receiver and oil reservoir indicated by numeral 26. The air receiver includes an oil sump 27 at the bottom of the internal chamber and further includes separate component compartments which are arranged in fixed spaced parallel relationship within the chamber of the receiver. As illustrated diagrammatically, a first compartment is employed for holding an air-oil separator 28, a second compartment holds an aftercooler 30 and a third compartment houses an air filter 31 and an oil cooler 32 in end-to-end relationship. Furthermore, a thermal valve 33 is internally incorporated into the receiver in operating relationship with respect to the chamber housing the oil cooler and the oil sump 27 at the bottom of the receiver chamber. For flow purposes, the pressure vessel includes an air inlet 34 for introducing the compressed air-oil mixture into the chamber of the receiver and includes an outlet 35 for discharging cleansed compressed air from the receiver after processing. The receiver vessel further includes an inlet 36 for introducing water to the heat exchangers within compartments 30 and 32 and an outlet 37 for conducting water out of the vessel back to the recirculating water system. Also, it is to be noted that only a single oil return conduit 14 is employed for returning oil from the thermal valve- 33 to the compressor 10.  
  By packaging the processing components within the pressure vessel of the air receiver itself, the separate function described with respect to the conventional air processing system in FIG. 1 are combined into a single unitary receiver. It is to be particularly noted that the oil separator 23, oil filter 31 and aftercooler 30 compartments are provided with separate access openings for maintenance of the components housed therein. At the air discharge or exit end of the receiver, the vessel head 38 is formed with conduits for carrying a coolant such as water in common to the aftercooler and then to the oil cooler. Also, integral with the vessel is the thermal valve 33 which functions to bypass oil around the&#39;oil cooler as required. A feature of the invention resides in the fact that separate tubular heat exchanger bundles, which are removable, cool the air in the aftercooler 30 and cool the oil in the oil cooler 32 respectively.  
  Referring now to FIG. 3, the compressor component package 25 of the present invention takes the form of a pressure vessel having a cylindrical shell 40 closed at one end by an inlet manifold 41 and an exit manifold 39. The inlet manifold includes the inlet port 34 which is connectable to the output of the compressor 10. Exit port 35 is carried by the outlet manifold 39. Inlet manifold 41 includes a pair of access ports leading into integral compartments of the pressure vessel so that inter nal components can be readily repaired or replaced as needed. For example, oil filter 31 may be readily changed by removing cover44, and a separator 28, taking the form of a de-mist pad, may be changed by removing of hatch or cover 45. The respective hatches or covers 44 and 45 are held in place by respective snap rings 58 and 59 in FIGS. 7 and 8 which expand .into mating grooves formed on the inside of the accessports of the manifold.  
  With respect to FIG. 4, it can be seen that the outlet manifold 39 .is provided with similar access ports identified by numerals 46 and 47 that lead into internal compartments housing oil cooler 32 and aftercooler 30 respectively. The oil cooler and aftercooler take the form of separate tubular heat exchanger bundles which are carried by flanges indicated by numerals 48 and 49 for heat exchanger bundles 32 and 30 respectively. The flanges are provided with a plurality of holes or openings leading into the passageway of the tubes which comprise a length of tubing bent about itself so that the opposite ends of each tube correspond with openings in the flange carrying the bundle of tubing. The flanges and, thereby, the respective bundles are maintained in their respective compartments internally of the pressure vessels by a snap ring arrangement. The exit end of the pressure vessel is sealed with the head 38 that is bolted or otherwise secured to the outlet manifold 39. The manifold 39 includes an inlet port 50 for connection toa supply of water intended to be introduced to the heat exchangers and an outlet port 51 for returning the water to the recirculating water system.  
  In FIG. 5, it can be seen that the water inlet port 36 leads directly into the head 38 and that the water exit port is indicated by numeral 37. Also, it can be seen that the head 39 is detachably connected to one end of the cylindrical body via a plurality of bolts arranged around the peripheral edge marginal region of the head.  
  Referring now in detail to FIG. 6, it can be seen that the compressed air-oil mixture is introduced to the pressure vessel via inlet port 34 and that the air circulates internally of body 40 about a plurality of component compartments. A separator compartment 52 houses the de-mist pad 28 and the circulating compressed air-oil mixture flows into the compartment via an elongated opening 53 and through the pad 28. Separator compartment 52 is connected in fluid communication with an aftercooler compartment 54 by means of a conduit 55. Compartment 54 houses the heat exchanger bundle comprising the aftercooler. As a portion of the oil recirculating system, a filter and oil cooler compartment 56 is provided which houses oil filter 31 and heat exchanger bundle 32 in an end-to-end relationship. The airoil mixture introduced to the pressure vessel is separated from the oil filter and oil cooler by the walls of the compartment 56. However, it is to be particularly noted that the lower portion of body 40 provides a sump 57 for storing oil accumulated after separation of oil droplets from the compressed air while being circulated in the internal chamber of the pressure vessel.  
  In FIGS. 7 and 8 it can be seen that the internal chamber ofthe pressure vessel is divided by the compo nent compartments 52, 54 and 56 and that these compartments extend between the opposite ends of the cylindrical body 40 in fixed spaced apart parallel relationship. Air introduced through inlet 34 to the interior of the pressure vessel circulates about the component compartments and the oil content of the air forms droplets which accumulate in the sump 57. The circulating compressed air is then introduced to the separator compartment 52 through opening 53 into the demist pad 28. The oil content of the compressed air is extracted by the pad and accumulates in the bottom of the compartment where it is returned to the sump 57 via a passageway 60 formed in the manifold 41. A drain plug 61 may be removed for cleansing purposes and for draining oil from the separator compartment and the sump 57. Upon removal of the oil from the compressed air, the air is circulated through conduit 55 into the aftercooler compartment 54. The air travels about the plurality of tubes in the heat-exchanger 30 and exits through port 35 carried on the outlet manifold 39.  
  With respect to the recirculating oil system, oil from sump 57 is introduced to the filter 31 via passageway 63 formed in inlet manifold 41 and then through an openingin an internal partition 64 into the oil cooler 32. Note that the oil filter 31 and the oil cooler 32 are carried in the same compartment 56. The oil circulates about the heat exchanger tubes and exits from an outlet 65 adjacent the thermal valve 33. The thermal valve is of a conventional type and is temperature sensitive so as to provide a balanced oil return system whereby oil may be returned to the system directly from the sump via opening of gate valve 33 or, when temperatures are excessive, the oil in the sump will pass through the oil filter and the oil cooler for exit through outlet 65.  
  Water is introduced to the heat exchangers 30 and 32 through inlet 36 formed in head 38 and initially passes through the tubes of heat exchanger 30. Head 38 is formed with chamber 66 common to the outlet side of the tubes comprising heat exchanger 30 and to the inlet side of the tubes comprising heat exchanger 32. Upon exiting the tubes of the heat exchanger 32, the water is returned to its system via outlet 37. p  
  In FIG. 7, it can be seen that access to the aftercooler compartment 54 is had by removal of the head 38 and by removing the snap ring attachment of the heat exchanger to the outlet manifold 39. This will permit the heat exchanger 30 to be removed for repair or maintenance purposes. Likewise, the removal of head 38 permits access to the oil cooler taking the form of heat exchanger 32 within compartment 56. Oil filter 31 may be readily repaired or replaced by detachment of the snap ring holding cover 44 in place and by removing a compression spring 67, the oil filter may be readily removed from compartment 56. In FIG. 8, the de-mist pad 28 may be readily removed by detachment of the snap ring holding hatch or cover 45 in place so that after removal of the cover, pad 28 may be extracted from compartment 52.  
  Therefore, it can be seen that the support component package of the present invention provides a unique construction in that the separate functions employed in the prior art as shown in FIG. 1 by individual and separate components are combined into a unitary basic air pressure receiver. A single pressure vessel is provided incorporating all of the components needed in the processing of compressed air for cooling and removal of oil mixed with the compressed air. The manifolds at opposite ends of the cylindrical body comprising the pressure vessel are provided with separate access openings and covers for maintenance and repair purposes of the oil separator and oil filter. A conventional commercial type oil separator keeps the air clean and virtually oil free. Also, a simple commercial oil filter may be employed for maintaining the oil clean. At the discharge end of the vessel, the head is provided with a coolant system common to the aftercooler and the oil cooler. Also, integral with the head is the thermal valve to bypass oil around the cooler as required. The separate tubular heat exchanger bundles are removably disposed within the internal compartments and are employed for cooling the air in the aftercooler and the oil in the oil cooler respectively.  
  The support equipment for an air compressor, particularly of the rotary screw type, is contained within a unitary air receiver. This receiver functions as a primary oil separator, oil reservoir and includes a secondary oil separator, oil filter, oil cooler, air aftercooler,  
 and a thermal valve. This construction features only one pressure vessel with access at each end to each of its separate components which are housed in individual compartments. The prior art includes at least five separate pressure vessels or components which are all external to one another and requires substantial piping and interconnecting conduits.  
  FIGS. 9 and 10 illustrate in diagrammatic form that the oil cooler compartment 56 may be submerged in the oil oil sump of the air receiver 40. Therefore, the level of oil in the sump is not critical and may substantially occupy the interior of the receiver. The orientation of the de-mister compartment and the air cooler places these compartments at the top of the receiver above the oil sump level.  
  While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention.  
 1 claim:  
  1. In an air processing system, a compressor component support package comprising the combination of:  
 a pressure vessel having an internal chamber defined by a cylindrical body closed at its opposite ends by an inlet manifold and an outlet manifold;  
 a plurality of compartments extending through said chamber between said manifolds and each of said compartments housing components utilized in support of an air compressor for processing air;  
 one of said manifolds having removably covered openings for access to associated ones of said compartments; and  
 means interconnecting selected ones of said compartments in fluid communication with said chamber and said inlet and outlet manifolds for conducting processing, compressed air flow therebetween.  
 2. The invention as defined in claim 1 wherein:  
 said selected compartments house components for processing compressed air-oil mixture from said,  
 chamber and wherein said other compartments house components for processing oil.  
 3. The invention as defined in claim 2 wherein said selected compartments house an air-oil separator and an air aftercooler respectively.  
 4. The invention as defined in claim 3 wherein:  
 said other compartment houses an oil filter and an oil cooler in coextensive relationship.  
 5. The invention as defined in claim 4 wherein:  
 said air aftercooler and said oil cooler comprise heat exchangers in the form of elongated tubular bundies.  
 6. The invention as defined in claim 5 wherein:  
 each of covers include snap-lock fasteners for removably securing said cover to said associated manifold.  
 7. The invention as defined in claim 6 wherein:  
 the lower portion of said internal chamber constitutes an oil sump and conduit means are provided in said body intercommunicating said other compartment with said oil sump.  
 8. The invention as defined in claim 7 including:  
 an oil pressure balancing means associated with said oil filter and said oil cooler and operable in response to temperature of oil in said oil sump to control oil supplied to an air compressor oil return line.  
 9. The invention as defined in claim 8 wherein:  
 at least three compartments are included that lie substantially parallel to each other in fixed spaced apart relationship.  
 10. The invention as defined in claim 9 wherein:  
 said air-oil separator compartment is in fluid communication with said oil sump via a discharge duct thereto.