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Compressed air Generation

Compressed air is generated by compressors.

Air Reservoir is required as a buffer.

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Efficiency of compressor

Volumetric efficiency = FAD/ Inlet volume

Specific FAD = FAD/ power input (kW)

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Compressor Classification
Dynamic

Displacement
Reciprocating

Trunk

Crosshead Free-piston Labyrinth

Diaphragm

Rotary
Ejector

Centrifugal- Axial-turbo
turbo

Two
rotors

One
rotor

Helical

Vane

Liquid ring

Screw

Rotary blower

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Comparison of compressors
Reciprocating
Screw
Vane

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Piston compressor
Inlet valve

Cylinder

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Outlet valve
Piston
Connecting rod

Piston compressor

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Piston compressor

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Crosshead type

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Diaphragm compressor

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Vane compressor

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Screw compressor

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Screw compressor

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Rotary blower

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Axial flow compressor

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Radial flow compressor

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Reciprocating compressors

Simple design
Low initial cost
Easy to install
High efficiency in two stage compressors
Large range of motor power
Extremely high pressure from special
machines

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Reciprocating compressors

Higher maintenance cost

Many moving parts
Vibration problem
Not designed to run at full capacity 100%
time
Low specific FAD

Screw compressors

Simple design
Low to medium initial cost
Low to medium maintenance cost
Good efficiency in two stage models
Easy to install
Few moving parts
High specific FAD

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Screw compressors

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Limited airend (screw) life

Airends are not field serviceable
High rotational speeds
Single stage designs have lower efficiency
Two stage/oil free designs=> higher initial
cost
Difficulty with dirty environment

Vane compressors

Simple design
Easy to install
Low to medium cost
Low maintenance cost
field serviceable airend
Long life airend
Forgiving to dirty environments
Very low moving parts

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Vane compressors

Nikini

Oil injected designs have oil carryover

Single stage designs have lower efficiency
Difficulty with high pressures (over 200psi)
Oil free designs are unavailable
Relatively low FAD

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Rotary screw

Reciprocating compressor comparison

Low Outlet air temp. (40 or below C)

Less water carry over

High Outlet air temp. (60 C) or above

More water carry over

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Less wearing parts

More wearing parts

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Compressed air Preparation

36

Composition of Air
Oxygen
21%

Other Gases
1%

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Humidity
Dust
Industrial pollutants
Nytrogen
78%

Nikini

The Necessity of Compressed Air

Preparation

up to 180 million dirt particles

up to 80 g of water(at 50C)
up to 0.03mg of oil
Various chemical contaminations
(lead, cadmium, mercury etc.)

Nikini

Why Compressed Air Preparation?

If Compressed air contains
Water
Corrosion damages
Seizing of valves and cylinders
Dust
Wear valves/ cylinders
Blocking of flow control valves
Oil
React with seals
Not suitable for food industry. Not suitable for
Lubrication of drives

Nikini

Possible Consequences for System

Operation and Environment

Rust due to condensate

Residue and Condensate

Containing
Contaminates

Corroded components

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Criteria for Compressed Air

Preparation
Quality
-Water content
-Size of Airborne Particles
-Permissible / Maximum Oil Content

Quantity
-Minimum and Maximum Volume for the Required Flow
Pressure
-Minimum / Maximum Pressure
-Pressure Level Consistency

Nikini

Definition of Compressed Air

Quality to DIN ISO 8573 -1
Compressed air to quality class 5. 4. 2.
Class 5 for Solid Contamination
Class 4 for Water Content
Class 2 for the Total Oil Content

Nikini

Air Quality Classification

ISO 8573-1
Solids
Class

Water Content

Max. Particle
Max.Particle
Density(mg/m3)
size(m)

Oil content

density
(mg/ m3)

Max. dew
point (0C)

Max. oil density

(mg/m3)

0.1

0.1

0.003

-70

0.01

0.12

-40

0.1

0.88

-20

15

+3

40

10

7.8

+7

25

9.4

+10

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Allocation of quality classes

Solids
Application

Water dew
point

Max.oil content

Class

[pm]

Class

[0C]

Class

[mg,m3
]

Mining

40

25

Cleaning

40

+10

Welding machines

40

+10

25

Machine tools

40

+3

25

Compressed air cylinders

40

+3

0.1

35

5..40

+3

0.1

Compressed air valves

Cont..

Nikini

Allocation of quality classes

Solids
Application

Water dew
point

Max.oil content
Class [mg,m3
]

Class

[pm]

Class

[0C]

Packaging

40

+3

Micro-pressure regulators

+3

Measurement air

+3

Storage atmosphere

-20

Sensors

2..3

-40..-20

0.1

Foodstuffs

+3

0.01

Photographic processing

0.01..0.1

-40

0.01

Air Humidity

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Dew point

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Atmospheric dew point:

[C]

Lowest temperature to which atmospheric air can be

cooled without the precipitation of water

Pressure dew point:

Lowest temperature to which compressed air can be

cooled without the precipitation of water

[C]

Example Max Water

Atmospheric D.P. at 80 F 1 oz /Cubic M
8 bar D.P. at 80 F 1/10 oz /Cubic M

Nikini
Temperature, at which water is not yet condensed
Water Vapor
g/m 3
3.5 oz

Dew point
1/3 oz

50 F

150 F

Drying

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Super Compression
Air humidity is dependent on volume

Air is compressiblewater is not.

For this reason air can be squeezed like a lemon.

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Refrigerant dryers

PDP + 3 oC

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Refrigerant dryers

A
B

Compressed air with a

temperature of about 30C
Heat-exchanger

Cooling unit

Condensate drain

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Membrane dryers
1

Air flows through a Micro-Filter

Membrane Fibers

Vapor Passes through the

Membrane Wall

4,5 Dry air (purge)

6

Wet air
(A Entry / B , C Bypass / D Silencer )
PDP

-20 oC

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Adsorption dryers

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Hot air regenerated

PDP -70 oC

Adsorption dryers

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Cold regenerated

compressed air with a

temperature of about 30C

switching valve

purge

drying chamber

regeneration chamber
Desiccant (Drying agent):
Silicon dioxide
Activated carbon

Absorption Drying

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Chemical process
Drying Agents
Dehydrated calcium (s)
Magnesium salt (s)
Lithium chloride (liquidizing)
Calcium chloride (liquidizing)
Sulphuric acid (l)
Glycerin (l)

PDP

-20 oC

Oil vapor and oil particles separated

Simple installation
Low mechanical wear
No External energy requirement
Operating cost too high
Efficiency too low

Dryers - comparison
Refrigerant
dryers
Pressure
Dew point
Flow rates

+2C (35F)
high
(500->20000 l/min)

Clean air
categories

size

big

where ?

Compressor Room

Adsorption
dryers
-70C (-94F)
medium/high
(55-1820 l/min)

Nikini

Membrane
dryers
-20C (-4F)
low
(50-340 /min)

medium

small

Point of Use

Point of Use

Filtering

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Filter Types

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Basic Particulate Filter Principle

General Purpose Standard Filters:

Removal of solid particle

contaminants down to 40
microns or 5 microns and
for the separation of bulk
liquids.
This type of filter is
generally used in industrial
applications where liquid
water and oil, and harmful
dirt particles must be
removed from the
d i
t

Air Out

Baffle
Air In

Bowl
Guard

Filter
Element

Accumulated
liquid
Drain

Nikini

Basic Coalescing Filter Principle

Fine and Micro Filters (Oil Removal):

Two filter element grades (1 micron and

0.01 micron) are offered to meet air
quality requirements.

These filter elements are specifically

designed for the removal of solid
particles, water and oil aerosols down to
0.01 micron.

With a micro filter maximum remaining

oil content of air leaving the filter down
to 0.01 ppm at 70F (21C) at a pressure
of 100 psi (7 bar) using a typical
compressor lubricant.

Pressure
Differential
Indicator

Coalescing
Element
Transparent
Bowl

Bowl
Guard

Auto
Drain

Nikini

Basic Adsorption Filter Principle

Active Carbon Filters:

Differential
Indicator

The active carbon filter element is used for the

removal of oil vapor and oil associated odors.

Maximum remaining oil content of air leaving the

filter is 0.003 ppm/wt at 70F (21C) at a
pressure of 100 psi (7 bar).

Where the application requires very high air

quality, an active carbon filter is used, in
conjunction with a micro filter element.

Typical applications are food processing and

Bowl
packaging, pharmaceutical, fermentation,
electronics and semi-conductor, and critical air Guard
control.

0.0003
ppm/wt
Active
Carbon
Element

Transparent
Bowl
Drain

Nikini

Pressure Regulator
LR / LRS / LRVS

On-off valve HE
Manual

Filter Regulator Particle Filter

LFR
LF 40 or 5 m

On-off valve
HEE / HEP
electrical / pneumatic

Soft start valve

HEL
(gradual start)

Fine Filter
LFMB
1 m

Micro Filter
LFMA
0.01 m

Branching Module
FRM

Lubricator
LOE

Installation
Components

Nikini
Sizes:

1/8 to 1
Range Sizes- Mini, Midi, Maxi

2 pressure ranges:

0.5 ... 7bar

0.5 ... 12bar

Flow rates:

Mini
Midi
Maxi

Grade of filtration:

0.01 / 1 / 5 / 40 m

Condensate drain:

Manual, Automatic

Metal bowl guard:

To Standard EN 983

Regulating knob :

Lockable

up to 1700 l/min
up to 3500 l/min
up to 11500 l/min

Nikini
Micro Filter
Sizes:

1/2 3/4 1

Pressure range:

max. 16 bar

Flow rates:

1100 l/min to 5200 l/min

Grade of filtration:

0.01 / 1 m

Filter:

Borosilicate glass fiber

Special characteristics :

-Vapor Removal
-Red/Green Differential Pressure Gauge
-High Flow Rates
-Automatic Condensate Drain

Nikini
Adsorption Dryer
Sizes:

1/4 1/2 as H1...H7

Drying agent:

Aluminum Oxide

Quality:

1.2.1 at nominal flow rate

1.1.1 at 70% nominal flow rate

Dew point:

-40C at nominal flow rate

-70C at 70% nominal flow rate

Flow rate:Up to 1800 l/min

Adsorption Dryer for

Decentralized Drying

Purging air:

20...22% of flow rate for decentralized drying

Voltage:

24 V DC / 110 or 230 V AC

Pure air System

Remote
monitoring/
auto-dialing

Nikini

Microfine filter
(filtration according
to required
air quality)

Flow
Control

Oil level
detector

Screw
compressor

Cyclone
separator

Oil Mist
Eliminator

Air receiver tank

with condensate
drain

Dryer for
high air quality
requirements

Oil-water
separator tank

Pure air System

Nikini

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Compressed air Service Unit

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Function of Service Unit

Basic Components

Pressure Regulator
Pressure gauge
Dust filter
Condensate Drain
Lubricator

Nikini

Compressed air Service Unit

Pressure Regulator
0.5-7 bar or 0.5-12 bar

Pressure gauge
0-16 bar

Dust filter
40 m or 5m

Condensate Drain
Manual or Automatic

Lubricator
Festo Special Oil
Shell Tellus Oil DO32
BP Energol HLP 32
ARAL Vitam GF32

Nikini

Water separator
& Air filter

Pressure regulator
& Pressure gauge

Air Lubricator

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Water Separator & Air Filter

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Pressure Regulator & Pressure

Gauge

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Lubricator

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Air preparation Components

Pressure Regulator

Pressure or Vacuum
gauges

Pressure Regulator
Condensate Separator & Water Separator

Lubricator

Nikini

Other equipments
Fine filter:
1 m
Micro Filter:
0.01 m

Fine & Micro Filters

Precision Pressure Regulator

Control Range:
0.05-0.7 bar
0.05-2.5 bar
0.05-4 bar
0.1-10 bar

Adsorption Dryer
Pressure dew point: -40 0C

Nikini

Additional options
Branching module
Pressure
Sensor

Lockable 3/2
way on-off
valve

Safety soft
start-up
Solenoid 3/2
way on-off
valve

Nikini

Symbols used in energy conversion

& preparation
Pressure source

Air service unit

Nikini

Symbols used in energy conversion

& preparation
Supply
Compressor

Air receiver and

T junction

Service equipment
Filter
Lubricator

Water separator
Pressure
regulator

Nikini

Compressed air Distribution

Compressor

Air receiver with

condensate drain

Machine

Machine

Nikini

Example of a compressed air pipe

system

Nikini

Different Types of pipes

STEEL
(black or galvanized)

GLUED PLASTIC
(ABS, Polyethylene,
PE or PVC)

Traditional
usage

Threaded or welded
Installation by
experienced fitters
Increased build-up of rust
and corrosion

Clean air
Light weight
Good internal
quality

Glued/ cold welded

Installation by
experienced fitters
High dilatation
Not compatible with all
compressor oils

Nikini

Different Types of pipes

STAINLESS STEEL
(pressed or welded)

ALUMINIUM
Quick connection
technologies

Clean air
Low dilatation
Good internal
quality
Clean air
Light weight
Low dilatation
Good internal quality
Flexibility, evolutivity
Simple assembly
Quick modifications
Lateral dismantling
Reusable components

Heavy weight
Installation by experienced
fitters

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Controlling operating costs

Cost of pressure drops over a 10 years period

Nikini

Air distribution methods

Ring main
= air consumer

Dead end split-flow main

Ring Mains

Nikini

Nikini

Air mains without air dryer

Falling pipeline
Approximately 2%

Filter, water
separator,
Regulator,
lubricator

Filter,
Regulator

Condensate
drain
Compressor

Air receiver with

condensate drain

Nikini

Air mains without air dryer

Nikini

Air mains with air dryer

No falling pipeline
Vertical branch line possible

Regulator,
lubricator

Compressor

Air receiver with

condensate drain

Dryer, including
condensate drain

Regulator

Tubes

Polyurethane tubing
Nylon tubing
Polyethylene tubing
Braided PVC hose
Self-fastening hose
Recoil tubing
Anti-spark tubing
Fluropolymer tube

Nikini

Tube sizes
Sizes: (Outer Dia.)
[

3 mm

4 mm

6 mm

8 mm

10 mm

12 mm

[ 14 mm

[ 16 mm

Nikini

Polyurethane tubing

Nikini

Large range of working Temperature and

Pressure
High Flexibility

Polyurethane tubing
Type

Advantages

Polyester

Good chemical resistance

Good aging
Close tolerance, 3mm to 14 mm tube o.d.

Polyether

Good resistance to humidity and

bacteriological aggression
Close tolerance, 4mm to 14 mm tube o.d.

Twin tubing

Compact cabling
4mm to 8mm tube o.d.

Anti-Static

Prevents accumulation of electrostatic charges

Close tolerance, 4mm to 12 mm tube o.d.

Nikini
Applications
Pneumatic
systems

Electronic
environments

Nylon tubing
Type

Advantages

Nikini
Applications

Semi-rigid

Large range of working Temperature Pneumatic systems

and Pressure
Good chemical resistance
3mm to 16mm tube o.d.

Multitube
Semi-rigid/PVC
sheath

Small bend radius

Rigid

Close tolerance, 4mm to 10 mm tube Centralized lubrication

o.d.
circuits

Pneumatic circuits
submitted to external
aggression

Polyethylene tubing
Type

Advantages

Resistance to chemicals
Food quality
Economical solution
Close tolerance, from 1/8" to 1/2"
And 4 mm to 14 mm tube o.d.

Nikini
Applications

Food and industrial

applications

Braided PVC hose

Type

Advantages

Translucent for visual checking of fluid

Food quality
8 mm to 26 mm tube o.d.

Nikini
Applications

Suitable for use with

food and industrial
fluids

Self-fastening hose
Type

Advantages

Excellent resistance to hydracarbons, UV,

welding sparks and abrasion
Simplicity of installation

Nikini
Applications

Automotive
process
equipment
Cooling circuits
Pneumatic
installations

Recoil tubing
Type

Advantages

Nylon

The coil will continue to contract

after multiple use
Fitted with protection springs
6 mm and 8 mm o.d.

Polyurethane

The coil will continue to contract

after multiple use
High flexibility
Fitted with protection springs
Suitable for reduced space
4 mm and 12 mm o.d.

Nikini
Applications
Pneumatic equipment

Anti-spark tubing
Type

Advantages

Nylon

Excellent resistance to spark projections

Resistant to high pressure
From 6mm to 12mm tube o.d.

Polyurethane

Excellent resistance to spark projections

Resistant to high pressure
From 6mm to 12mm tube o.d.

Single layer
Polyurethane

Excellent resistance to spark projections

Excellent humidity resistance
From 6mm to 12mm tube o.d.

Nikini
Applications
Installations
submitted to
aggressive
environments and
spark projections

Fluropolymer tube
Type

Advantages

Excellent resistance to chemicals and high

temperature
Food quality
Close tolerance, 4 mm to 12 mm tube o.d.

Nikini
Applications

Food and
industrial
applications