Compressed Air

‘Open University’ Project Slide 1

 Pressure Measurement
(x + 1) (x)
bar a bar g
Absolute Pressure Gauge Pressure

Atmospheric Pressure
1 bar a 0 bar g
(1.013 bar)

Perfect Vacuum
0 bar a -1 bar g

‘Open University’ Project Slide 2

 Relationship Between Altitude and
Atmospheric Pressure

Altitude Atmospheric Pressure

(m) (bar)
Sea Level 1.013
500 0.945
1000 0.894
1500 0.84
2000 0.789
2500 0.737

‘Open University’ Project Slide 3

 Equipment and Ancillaries for
Compressed Air Generation
Temperature Vent to
Cooling atmosphere Moisture Separator
control system water out
Safety relief

Aftercooler

Air
Receiver
Cooling water in

Air Inlet
Filter Drain system

Compressed Air
Condensate
Compressor
Cooling Water

‘Open University’ Project Slide 4

 Compressor Types

Com pressors

Positive displacem ent Dynam ic

Reciprocating Rotary Centrifugal flow Axial flow

Piston S crew

Disphragm V ane

‘Open University’ Project Slide 5

 Compressor Stage Efficiencies
Po Atmospheric Pressure
P1 Intermediate Pressure
P2 Final Pressure
P2
D G C
Energy Saved

P1 F E

Po A B
Volume

Single Stage - ABCD Two Stage - ABEFGD

‘Open University’ Project Slide 6

 Piston Compressor

Air inlet Air outlet

Piston

‘Open University’ Project Slide 7

 Power Required to Compress Air

Gauge Pressure Theoretical Adiabatic Power kW/100 dm 3/s Free Air

bar g Single Stage Two Stage Three Stage

0.5 4 - -
1 7.5 - -
2.5 15 14 -
5 23 20 19
7 28 24 22
10 34 28 27
14 40 32 30

‘Open University’ Project Slide 8

 Diaphragm Compressor
Air Inlet Compressed Air

Diaphragm Connecting Rod

‘Open University’ Project Slide 9

 Diaphragm Compressor
Air Inlet Compressed Air

Diaphragm Connecting Rod

‘Open University’ Project Slide 10

 Rotary Vane Compressor
Inlet Port
Blades

Compression
Phase

Stator

Suction
Phase
Outlet Port

Rotor
‘Open University’ Project Slide 11
 Screw Compressor

Female rotor Male rotor

‘Open University’ Project Slide 12

 Centrifugal Compressor

Discharge Diaphragm Inlet

Shaft

Inlet shaft seal

‘Open University’ Project Slide 13

 Axial Compressor
Rotor vanes Shaft
support

Shaft
rotation

Shaft
support
Stator
vanes

Air in Air out

‘Open University’ Project Slide 14

 Types of Compressor for Different
Processes

1000
Reciprocating
Discharge pressure bar

500

100
50 Centrifugal
Rotary
10
Axial
5

1
0.5
Fans

0.1
5 10 50 100 500 1000 5000 10 000 100 000

Output in dm³/s

‘Open University’ Project Slide 15

 Temperature Control - Cooling Water
Bypass if necessary

Sensor
Sight check

Compressor
Mains Water
Out
Supply In
Reverse Acting
Temperature Control

‘Open University’ Project Slide 16

 Compressor Cooling
Temperature
Control System Cooling
Water Out
Safety Relief

Air Sight
Eliminator Check
Air Out
Aftercooler

Cooling
Water In Drain Point

Air Inlet
Filter Compressed Air
CA Air Trap
Draining Condensate
Intercooler Cooling Water

Compressor
‘Open University’ Project Slide 17
 The Saturation Curve
Temperature ºC

kg of water per 10m3 of air

‘Open University’ Project Slide 18
 Changes in Temperature, Pressure, Air Volume
and Moisture Content for a Typical Installation
A B C
Compressor Aftercooler/ Distribution
Separator System
Air
Intake

Trap to handle Traps to handle

2 stage 28.5 - 13.85 = 14.65 - 9.38 =
14.65 kg/h water 5.27 kg/h water

1 m3/s at 6 bar 6 bar Cools towards

20 ºC / 45 % RH 116 ºC 28 ºC / 100 % RH 20 ºC ambient
contains contains 9.38 kg/h water
28.5 kg/h 14.65 kg/h
of water of water

‘Open University’ Project Slide 19

 The Compressor System
Temperature
control system
Output signal Control Input signal
system
Air Air out to
Safety
eliminator Cooling distribution
relief system
out

Aftercooler Dryer Air

Receiver
Air
inlet
filter Cooling
in Compressed Air
Compressor
Condensate
Cooling water

‘Open University’ Project Slide 20

 Multi-Stage Compressor -
‘Cascading’ System

Compressor 4
Normal Working Day
Night shift Twilight shift
Demand

(on stand by) Compressor 3

Compressor 2

System
Leakage Compressor 1

0 6 12 18 24

Shut Down Time Shut Down

‘Open University’ Project Slide 21

 Aftercooler
Temperature
control system Cooling
water out Safety
relief
Sight check
Air
eliminator Aftercooler Air out

Cooling
water in

Air
Inlet Drain point
Filter
CA Air Trap
Draining Compressed
Intercooler Air
Condensate
Cooling
water
Compressor
‘Open University’ Project Slide 22
 Refrigeration Dryer

15 ºC

Wet air

18 ºC
2 ºC
Saturated

Refrigeration unit

‘Open University’ Project Slide 23

 Adsorption Dryer

- 70 ºC Pressure
Dew Point

Pure Air 10%

Heatless
Adsorption
Dryer

Air 100%
Saturated

‘Open University’ Project Slide 24

 Air Receiver
Moisture
Separator
To the Process
Safety Valve

From Aftercooler

Air Receiver

Drain System

‘Open University’ Project Slide 25

 Air Compressor Cooling

‘Open University’ Project Slide 26

 Ideal Layout for Compressed Air
Systems
Primary Line
Secondary Line

Compressor

Consumption Point

‘Open University’ Project Slide 27

 Pressure Drop in Steel Pipes
(15mm to 100 mm) Pressure Drop
Internal Dia Flow of Free Through pipe Air Pressure
of pipe in mm Air in dm3/s in mbar/m In bar
5000
100
100
2000 Reference
90
80 Line
80 30
1000 2
70
65 20
60 500 3
50
50 4
200 10
40 5
40
32 100 6
35
7
30 5.0 8
50 4.0 9
25
3.0
25 10
20 20
20 X 2.0
15 10
15
1.0

Medium Weight Steel Pipe to BS 1387

‘Open University’ Project Slide 28
 Compressed Air Filter with Nylon Element

1
Air inlet Air outlet

2
3

4
5

‘Open University’ Project Slide 29

 Ultra Fine Coalescent Filter

 Automatic Drain
 Saturation indicator
 100 % water removal

‘Open University’ Project Slide 30

 Activated Carbon Filter

 Colour indicator of oil

carryover
 removal of odours and
vapours

‘Open University’ Project Slide 31

 IR1/IRN1 International Range
Regulator

‘Open University’ Project Slide 32

 IR International Range Regulator
Benefits
• Good flow characteristics
• Good regulation characteristics
• Fast response
• Dead tight shut off on no flow
• For line, bracket or panel mounting
• High quality black epoxy finish

‘Open University’ Project Slide 33

 IP2, IP2A and IP2D International
Range Filter/Regulator

‘Open University’ Project Slide 34

 IP International Range
Filter/Regulator Benefits
• Compact combined filter regulator
• Pilot operated automatic drain
• Semi-auto dump valve with quick action manual
override
• High quality black epoxy finish
• Shrouded whirl disc for efficient separation
• Easy clean nylon mesh
• Good flow and regulation characteristics
• Flexible mounting - line, bracket or panel
• Easy fit bowl guard available

‘Open University’ Project Slide 35

 SR3 Standard Range Compressed Air
Regulator

‘Open University’ Project Slide 36

 SR3 Benefits

• Good flow and regulation characteristics

• Fast response
• Dead tight shut off on no flow
• For line, panel or bracket mounting
• Black epoxy finish
• Tamper resistant control

‘Open University’ Project Slide 37

 MR1, MR2, MR3 Miniature Compressed Air
Regulator
2

5
6

4 3
‘Open University’ Project Slide 38
 MR1, MR2 & MR3 Benefits

• Good flow characteristics

• Good regulation characteristics
• Fast response
• Dead tight shut off on no flow
• Tamperproof
• For line, bracket or panel mounting

‘Open University’ Project Slide 39

 1

2
MP2 Miniature
11 Compressed
10
12
Air
8
3 9 Filter/Regulator
13 4
5
7

‘Open University’ Project Slide 40

 MP2 Benefits

• Compact, combined miniature filter/regulator

• Long life 5 micron element
• Improved moisture separation with multi bladed
whirl disc
• Fast response
• Polycarbonate bowl to BS 6005
• For line, bracket or panel mounting
• Good flow and regulation characteristics
• Easy fit bowl guard available
• Black epoxy finish for improved protection

‘Open University’ Project Slide 41

 MPC2 Filter / Regulator Air Set

‘Open University’ Project Slide 42

 Lubricators

 Friction reduction
 Heat dissipation
 Corrosion protection
 Miniature, Standard
and International
versions all available

‘Open University’ Project Slide 43

 Moisture Separator

‘Open University’ Project Slide 44

 IFM Compressed Air Flow Meter

‘Open University’ Project Slide 45

 Condensate Drain Traps for Compressed
Air

Airodyn Compressed Air Trap EDT2 Electronic Drain Trap

Dri-line Compressed Air Trap CA14 Compressed Air Trap

‘Open University’ Project Slide 46
 Ball Valve

‘Open University’ Project Slide 47

 Self Acting Temperature Controls

‘Open University’ Project Slide 48

 Self Acting Temperature Controls:
Operation
Heating Cooling

Flow

Movement caused by Plug

temperature change at
Plug sensor

Thrust
pin Thrust pin
Temperature
sensor

Spring loaded piston

mechanism for
temperature adjustment
and overload

‘Open University’ Project Slide 49

 BRV71 and BRV73 Compact, Direct
Acting, Bellows Operated Pressure
Reducing Valve

‘Open University’ Project Slide 50

 BRV71 and BRV73 Operation
Anti-vibration adjustment Alloy spring housing with
handwheel 4 bolt removal for easy
in-line access to internals

Control spring

SG Iron body, electroless Control bellows

nickel plate finish,
with screwed or
flanged connections
Bellows and push rod
assembly

Stainless Steel valve head Valve seat

and seat assembly provides Valve head
high wear resistance Valve head return
under low load conditions spring

‘Open University’ Project Slide 51

 BRV2 Direct Acting Pressure
Reducing Valves

‘Open University’ Project Slide 52

 BRV2 Operation
Anti-vibration
adjustment handwheel

Alloy spring housing with

4 bolts removal

Stainless steel
bellows assembly Control spring

Bellows

Stainless steel valve and

seat assembly Push rod
Valve seat
PN25 SG iron body with Valve head
screwed or flanged
connections. Valve head return
spring

‘Open University’ Project Slide 53

 DRV Direct Acting Pressure Controls
for Water Mains Distribution

‘Open University’ Project Slide 54

 DRV Operation

Flow from
under seat
Double guided stem

Balancing bellows
Spanner operated
pressure setting plate

Chrome vanadium
springs, colour Bellows stem sealing
coded for setting
range and
interchangeability
Spring plate with
needle roller bearing
Range of
interchangeable
actuators combined Pressure chamber
with 6 spring ranges with reinforced
diaphragms
‘Open University’ Project Slide 55
 DP17 G and DP17 R Pilot Operated
Pressure Reducing Valves

‘Open University’ Project Slide 56

 How Pilot Operated Valves Work
Pressure adjustment

Pilot diaphragm Control spring

Downstream external
Pilot valve sensing pipe connection
Return spring
Main valve
Flow Control port

Main diaphragm

‘Open University’ Project Slide 57

 SDP143 Surplussing Valve

‘Open University’ Project Slide 58

 SV60 and SV61 Safety Valves

‘Open University’ Project Slide 59

 Gilflo Flow Meter
Precision heavy duty Adjuster used to set cone
nickel cobalt alloy spring during manufacture
Orifice chamfer on
upstream face
eliminates wear
and dirt build-up
Low DP
tapping
Stop prevents
any damage from
reverse flow
Stop
prevents
damage from
surges or
excessive
flows

Flow direction Precision cone

Drain hole
High DP tapping

‘Open University’ Project Slide 60

 Separator
Large internal volume
to reduce flow velocity,
providing efficient
moisture separation
and reducing the risk of
moisture re-entrainment

Baffle with large impact

area to capture all
moisture droplets

Full range of
separators in the
following materials:
Cast iron, SG Iron,
Cast Steel and
Austenitic stainless
steel to cover all
applications

‘Open University’ Project Slide 61

 DCV Wafer check valve

‘Open University’ Project Slide 62