List of Tables

Table Practical Page

No Table Name
No No No
1 1.1 Air Consumption of machines / tools calculation 01 2
2 1.2 Compressed Air System Pressure Calculation 01 2
3 1.3 Sample spinning unit pneumatic machine data 01 3
4 1.4 Sample Problem FAD Calculation 01 4
5 1.5 Sample Problem Pressure Calculation 01 4

Type of Air Dryer against Pressure Dew Points and their

6 2.1 02 6
Energy Cost
7 2.2 Correction Factor against Operating Pressure 02 6
8 2.3 Correction Factor against maximum ambient temperature 02 6
9 2.4 Correction Factor against maximum inlet temperature 02 6
10 2.5 Correction Factor against Dew point 02 6

Type of Contaminant and Compressed Air Equipment Used to

11 3.1 03 9
Filter it
12 3.2 ISO 8573 Purity Class 03 10

13 4.1 Compressed Air Piping Material Comparison 04 14

14 4.2 Approximate Pressure Drop in a compressed air system 04 15
Compressed Air Piping components and their equivalent
15 4.3 04 15
lengths

16 5.1 Hole Size and Estimated Corresponding Leak and Power Losses 05 19

1
 Practical # 1 Important Tables

1.1 Air Consumption of machines / tools calculation:

Air Consumption of Tools and Machines Used

Air
Total air
Consumption No of Tools / Load / Duty Simultaneity
Tools / Machine consumption
/ Tool machine Cycle (%) Factor (%)
(m3/min) (m3/min)

Total air Consumption

Other Estimated Consumptions (cleaning purpose)
Compressed Air Network Leakages
Future Expansions
Total (Min) required Free Air Delivery from compressors (m3/min)

1.2 Compressed Air System Pressure Calculation:

Description Pressure (bar)

Pneumatic Machines Requirement 6
Sources of Pressure Drops Pressure (bar)
Dryer 0.20
Coalescing Filters 0.10
Particulate (Dust) Filters 0.10
Line and Fitting Losses 0.30
Required Compressor Pressure ≈ 7 bar

2
1.3 Sample spinning unit pneumatic machine data:

No of Machines Total Machines

Gauge
Machine (Including Consumption
Section (Currently Pressure
Particulars Future (m3/min)
Installed) [Bar]
Expansion)

Multimixer
8 9 3.6 6 bar
(MPM-6)
Blow Room Lop Tex 1 1 0.0006 6 bar

Damper 8 8 0.106 6 bar

Filter/Machine
- 0.2 --
Cleaning

Trutzschler Card
37 47 1.95 6 bar
Carding (DK-760)

Machine Cleaning - 0.2 --

Rieter Drawing
4 4 0.013 6 bar
(RSB-D30)

Rieter Drawing
1 1 0.003 6 bar
(RSB-D22)
Drawing Rieter Drawing
1 0.003 6 bar
(SB-D22)

Toyoda (DX-8LT) 3 3 0.1 6 bar

Machine Cleaning - - 0.2 --

Savio Espero /
20 22 26.4 7 bar
AutoCone Polar

Machine Cleaning - 0.2 --

Waste Roving Machine

3 3 1.99 6 bar
Area

Spray --
9 1.476 --
Nozzle

Doubling Savio Espero 3 3 3.6 7 bar

Total Consumption 40.04

Total Consumption ( adding 5% line losses) 42.04

3
Calculations and Observations:
1. What type of compressor is required for the spinning unit of textile industry?
------------------------------------------------------------------------------------------------------------

2. By using the table in theory section for calculating total required FAD (free air
delivery), fill the table below and calculate total FAD required for the example
problem:

Total air Consumption

Other Estimated Consumptions
Compressed Air Network Leakages
Future Expansions
Total (Min) required Free Air Delivery from compressors (m3/min)

Table 1.4 Sample Problem FAD Calculation

3. By using the table in theory section for calculating total required pressure fill the table
below and calculate total Pressure required for the example problem:

Description Pressure (bar)

Pneumatic Machines Requirement
Sources of Pressure Drops Pressure (bar)
Dryer
Coalescing Filters
Particulate (Dust) Filters
Line and Fitting Losses
Required Compressor Pressure ≈

Table 1.5 Sample Problem Pressure Calculation

4. Go to the link rastgar-co.com and find an appropriate compressor model which meets
your compressed air requirement. You could find out a single model or use
combination of models to fulfil your compressed air demand?
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

4
5. When a fixed speed compressor goes off-load, it still consumes 15 – 35 % of total energy
without producing any output so in order to keep off-load hours to absolute minimum
by keeping fixed load (approx. 80%) of total load on fixed speed compressors and
(approx. 20%) of total load on variable speed (regulated speed) compressor. Design the
system in such a way to divide the load between fixed and variable speed compressor.
For Reference you can visit rastgar-co.com.
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

5
 Practical # 2

2.1 Type of Air Dryer against Pressure Dew Points and their Energy Cost:

Pressure Dew point Dryer Type Added Energy

Cost
+3 ℃ Refrigerant 5%
-20 ℃ Membrane 28%
-20 ℃ Heat Regenerative 3–5%
-40 ℃ Heatless type 10 – 15 %
-40 ℃ Blower Purge 8 – 12 %
Regeneration
-70 ℃ Heatless Type 21

2.2 Correction Factor against Operating Pressure:

bar 5 6 7 8 9 10
Correction
0.85 0.93 1 1.06 1.11 1.15
Factor

2.3 Correction Factor Against Maximum Ambient Temperature:

℃ 25 30 35 40 42 45
Correction
1.11 1.07 1 0.85 0.75 0.66
Factor

2.4 Correction Factor Against Maximum Inlet Temperature:

℃ 30 35 40 45 50 55
Correction
1.43 1.30 1.20 1 0.87 0.68
Factor

2.5 Correction Factor against Dew point:

℃ 3 5 7 9 10
Correction 6
1 1.09 1.18 1.30 1.33
Factor
Calculation and Observation:

1. Using the Data from Practical # 4, Select type of compressor you think could be used for
the application problem given in Practical #4?

--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------

2. Using the formulae stated above, calculate the size of air dryer using data from Practical #
4?

--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------
7
3. Go to https://rastgar-co.com/compressed-air-drying/ and find an appropriate model for
your calculated air dryer size.

--------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------

8
 Practical # 3

3.1 Type of Contaminant and Compressed Air Equipment Used to Filter it:

ISO
Contaminants Testing
Standards
Particles Water Oil
atmospheric
micro- vapor aerosol
pipe scale dirt and liquid aerosol liquid vapors
organisms s s
particles
ISO 8573-
2:2007
Coalescing ISO 8573-
x X x x
filters 4:2001
ISO 12500-
1:2007
ISO 8573-
5:2007
Adsorption ISO 8573-
x
filters 6:2007
ISO 12500-
2:2007
Dust ISO 8573-
Removal x X 4:2001
Filters ISO 8573-
Micro- 6:2003
biological x ISO 8573-
sterile filters 8:2004
ISO 12500-
3:2009

Water ISO 8573-

x x
separators 9:2004
ISO 12500-
4:2009
Adsorption
x
dryers
Refrigeration ISO 8573-
x
dryers 3:1999
Dual ISO
refrigerant/ 7183:2007
x
adsorption
dryers

9
3.2 ISO 8573 Purity Class:

Example: Understanding ISO 8573 Purity Class

Solid Particles Water Oil

Maximum no of particles per m 3 Particles Concentration Vapor Liquid Total Oil

0.1 - .05 0.5 – 1 1-5 Size mg Pressure g (aerosol

liquid and
micron micron micron micron m3 Dew Point m3 vapors)
0 As specified by the equipment user or supplier
1 100 1 0 -70 ℃
2 100,100 1,000 10 -40 ℃ 0.01
3 10,000 500 -20 ℃ 0.1
4 1,000 +3 ℃ 1
5 20,000 +7 ℃ 5
6 5 5 +10 ℃
7 40 10 0.5
8 5
9 10

10
 Calculations and Observations:
1. Use Data from previous practical(s) and mark with a cross sign of the purification
technology, you think is required for the compressed air system

ISO
Contaminants Testing
Standards
Particles Water Oil
atmospheric
micro- vapor aerosol
pipe scale dirt and liquid aerosol liquid vapors
organisms s s
particles
ISO 8573-
2:2007
Coalescing ISO 8573-
filters 4:2001
ISO 12500-
1:2007
ISO 8573-
5:2007
Adsorption ISO 8573-
filters 6:2007
ISO 12500-
2:2007
Dust ISO 8573-
Removal 4:2001
Filters ISO 8573-
Micro- 6:2003
biological ISO 8573-
sterile filters 8:2004
ISO 12500-
3:2009

Water ISO 8573-

separators 9:2004
ISO 12500-
4:2009
Adsorption
dryers
Refrigeration ISO 8573-
dryers 3:1999
Dual ISO
refrigerant/ 7183:2007
adsorption
dryers

11
2. For table given below mark ISO 8573-1:2010 Class 1.2.1:

Solid Particles Water Oil

Maximum no of particles per m 3 Particles Concentration Vapor Liquid Total Oil

0.1 - .05 0.5 – 1 1-5 Size mg Pressure g (aerosol

liquid and
micron micron micron micron m3 Dew Point m3 vapors)
0 As specified by the equipment user or supplier
1 100 1 0 -70 ℃
2 100,100 1,000 10 -40 ℃ 0.01
3 10,000 500 -20 ℃ 0.1
4 1,000 +3 ℃ 1
5 20,000 +7 ℃ 5
6 5 5 +10 ℃
7 40 10 0.5
8 5
9 10

12
 Experiment No. 3b

1. Use Data from the previous practical(s) to calculate air receiver size. You can also
assume data if any variable is not available:

---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

13
 Experiment No. 4

4.1 Compressed Air Piping Material Comparison:

Feature Stainless Black Iron Copper Thermoplasti Aluminium

Steel c
Lighter than
Weight Heavy Less Weight Light Weight Light Weight
Black Iron
Corrosion
Yes No Yes Yes Yes
Resistant
High Mechanical Less than Black Less than black
Yes Yes Low
Strength Iron but Strong iron but strong
High Temperature
Yes Yes Yes No Yes
Capability
Ease of Installation Less hard Hard Less hard Easy Easy
Installation Cost 30 % 25 % 40 % 50 % 80 %
(Material % /
Labor %) 70 % 75 % 60 % 50 % 20 %
Types of Flame welder Flange /
Flange / Cold Glue /
Connection (varies (threaded very Threaded / Sealed reusable
Soldered Sealed reusable
with size) hard to seal) Welded
Low “Friction –
Generated” Yes No Yes Yes Yes
Pressure Loss
Resistant to
Internal Deposit Yes No Yes Yes Yes
Buildup
Can be Electrostatic
Surface Treatment NA NA NA
Galvanized Painting
Solder Limit to 200 ℉ to 450
Melting Point Above 1000℉ Above 1000℉ Above 1000℉
400℉ ℉
Flexibility to Easily
Modify after Initial Yes No No Yes Yes
Installation
Special Tools No
Required (Welder,
Yes Yes Some (Solder) No
Pipe Threaded,
Groove Cutter)
Skilled Labor, Pipe
Fitter for Yes Yes Yes No No
installation

14
4.2 Approximate Pressure Drop in a compressed air system:

Pressure Drop in Main line (Header) 0.29 psi (0.02 bar)

Pressure Drop in Branch lines 0.725 psi (0.05 bar)
Pressure Drop in Drop legs 0.435 psi (0.03 bar)
Total Pressure Drop 1.45 psi (0.1 bar)

4.3 Compressed Air Piping components and their equivalent lengths:

Equivalent Pipe Length (ft)

Pipe Size (inches)
Fittings
0.5” 0.75” 1” 1.25” 1.5” 2” 2.5” 3” 4” 5”
o
90 bend 0.5 0.7 0.8 1.2 1.7 2 2.6 3.3 4 5
90 o elbow 0.8 1.3 1.7 2.1 2.6 3.3 4.6 5.9 7.9 10.6
Tee –
Horizontal 0.7 1 1.3 1.7 2.3 2.8 4.4 4.3 5.3 6.6
Outlet
Tee – Side
1.7 2.3 4.6 5.9 7.9 8.9 11.9 15.1 18.8 23.1
Outlet

15
Calculations and Observations:
1. Write five advantages of aluminium piping over other types of piping material for
compressed air.
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

2. Using the data from previous practical(s), calculate the size of compressed air pipe
main line and branch lines by allowing compressed air velocity to be 10 m/s in main
line and 15 m/s in branch lines.
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

16
3. Calculate approximate pressure drop in compressed air network installed in NTU
compressor room.
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

17
4. Using the namograph shown below, calculate the pressure drop in compressor room
of NTU or you could also use approximate data.

18
 Experiment No. 5

5.1 Hole Size and Estimated Corresponding Leak and Power Losses:

Power Required by
Hole Diameter (mm) Leakage rate (l/s)
Compressor (kW)
0.4 0.19 0.06
1 1.18 0.37
1.6 3.07 0.97
3 10.95 3.36
6 49.1 15.0
10 122 37

19
Calculations and Observations:
1. For the following data, Calculate approximate leakage rate using the first formulae
given above
V = 300 liters
P1 = 7 bar
P2 = 6 bar
t = 300 seconds

---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
2. Today there are many instruments available in the market for detecting and quantifying
compressed air leakage. Research and write names of such instruments and how these
instruments work?

---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

20
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------

21