Presentation Compressed Air PN111, En

DC-I/Levent Unan Presentation: Compressed air 18 December 2008

Modern industrial pneumatics (PN111)Training course

Compressed air generation and preparation


1 Compressor2 Cooler3 Condansate separator4 Receiver5 Condensate drain6 Pre-filter7 Dryer8 Electronic purgier9/10/11 Class filters12 Water and oil seperator

Compressed air generation and preparation

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Type of compressors

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Compressors

Positive displacement

Dynamic

Reciprocating

Rotary

Centrifugal

Axial


Reciprocating compressor (single stage)

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Reciprocating compressor (double stage)

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Roots compressor (blower)

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Vane compressor

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Helical screw compressor

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Lubrication free screw compressor

External gear mechanism

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Centrifugal compressor

Single stage

Multistage

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Receiver1 Check valve2 Pressure gauge3 Receiver4 Drain valve5 Safety valve

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Dryers remove water vapor from the air, which lowers its dew point, which is the temperature to which air can be cooled before water vapour begins to condense.

There are many types of air dryers, the most common ones are:

•Refrigerant •Dessicant•Membrane

Air drying

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Air drying

Drying methods according to Class requirement

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Class Residual Oilµm mg/m³ DTP [°C] g/m³ mg/m³

1 0,1 0,1 -70 0,003 0,012 1 1 -40 0,12 0,13 5 5 -20 0,88 14 15 8 +3 6,0 55 40 10 +7 7,8 256 - - +10 9,4 -7 - - n.d. n.d. -

Residual Dust Residual Water

Air drying

Classes

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Dew point diagram

Water content

g/m 3

Temperature in °C -10 0 +10 20 30 40 50 60 70 80

1000

500

100

50

20

10

1

0.1

5

0.5

Maximum saturation

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Refrigerant dryers

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1 Air outlet2 Air inlet3 Separator4 Drain valve5 Refrigiration6 Drain valve7 Cold serpantine8 Heat exchanger


Regenerative adsorption dessicant dryers

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Adsorbtion dessicant dryers consist of granules which is known asSilica Gel. These granules are made of Sodium Silicate and they have very high attraction to water rather than air .

Silica Gel captures the vapour in air in the cavities within the body. When these cavities are filled with water, than a silica gel granule has no attraction to water and needs to be regenerated.

There are Silica Gel types that have a colour indication of saturation. When they are dry, they are blue, when they are saturated with water, they turn to pink.

Air consisting of humidity Reduced humidity

Cross section of a silica gel granule


Regenerative adsorption dessicant dryers

Cold regenerated dessicant dryer

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Housing cover

Hollow fibres

Nozzles

Exhaust ports for purging air

Membrane dryers

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Compressed air preparation

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1 m3 of air contains

- up to 180 million dust particles- up to 50 g of water (at 50o C)- up to 0,03 mg oil- various chemicals such as lead, cadmium etc.


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The compressed air is most efficient when conditions below are realised:

The right pressure

Less particles

Less condensate

The right oil


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The wrong adjustment of pressure may result in:

•early wearing of equipment•vibration of machine and poor product quality•more air leakages•high operation cost

More particles in the system may result in:

•early wearing of equipment•pressure drops•blocked lines•malfunction of system

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More condensate in the system may result in:

•corrosion•lower velocity•sludge blocking lines

Wrong adjustment or type of oil may result in:

•early wearing of equipment•washing out the special oil•swelling of seals•staining the product

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Poor air preparation results in:

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Service unit

+ + =

filtering dust and condensation

lubricating the system

regulating the pressure

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Service unit

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Adjustment of pressure

Q: What is the right pressure for a system?

A: The minimum possible pressure to operate the system smoothly.

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It is also possible to adjust the pressureremotely

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Dust and condensate

automatic drain

manual drain

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Dust and condensate

The filter should be changed when there is a pressure drop between inlet and outlet of the service unit.

Changing the filter:

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Dust and condensate

The best way is to install an indicator for pressure drop to change the filter on time.

Changing the filter

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Lubricating

Refilling of oil

Q: Which type of oil should be used?A: The best is not to use oil. In systems where lubrication is a must, the oil to be used is : Hydraulic oil with viscosity 32mm2/s

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Lubricating

Adjusting the oiling of the system

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Service unit

On-off valve

Filter-regulator

Branching module

Lubricator

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On-off valve

On-off valve is actually a NC 3/2 valve to exhaust the system when necessary

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Soft start valve

In many systems it is not safe to pressurise the system instantly. To prevent this, a Soft start valve is used which allows slower increase in the pressure.

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Pressure amplifier (booster)

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A pressure amplifier is a valve and a twin cylinder combination to compress air and increase pressure up to two times of the supply pressure.

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Presentation Compressed Air PN111, En

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