BOGE IA Compressor

S 100-2
Belt Driven Screw Compressor

- Md. Halim Molla

O&M Engineer
Components of the IA System

 Belt driven screw type air compressor.

 Refrigerant compressed air dryer.
 Adsorption dryer.
 Cyclone Separator.
 Pre-filter.
 Micron-filter.
 IA Distribution System
 Rotary screw compressor

A rotary screw compressor is a type of gas compressor which uses a

rotary type positive displacement mechanism. Rotary screw compressors
use two meshing helical screws, known as rotors, to compress the gas. As
the rotors turn, the air moves along and travels to the other end of the
compression chamber. The area in which the air is contained gets
increasingly smaller as the air moves along, and the smaller space
increases the pressure.

Two types of rotary screw compressor

 Oil-free Type.
 Oil Injected Type.
Helical Screw(Male & Female)
5 Rotary screw compressor
(oil Injected Type)

 Rotary-screw compressors use two meshing helical screws, known

as rotors, to compress the air. In an oil-flooded rotary-screw
compressor, lubricating oil bridges the space between the rotors, both
providing a hydraulic seal and transferring mechanical energy
between the driving and driven rotor. Air enters at the suction side
and moves through the threads as the screws rotate. The meshing
rotors force the air through the compressor, and the compressed air
exits at the end of the screws.

 The main advantage of using this compressor is that it can supply

compresses air continuously with minimum fluctuation in delivery
pressure.
Compression Stages
 BOGE Screw type IA Compressor

Technical Data (S 100-2)

 When Pmax =10 bar then Volume flow=10.5 m3(Settable)
 Maximum final Compression Temperature =110°C
 Drive Motor =75 kw
 Rated Speed @ 50 Hz =3000 rpm
 Intake air Temperature , Min =+5°C,Max =+40°C
 Operating Pressure Sensor, Pmax =9.5 bar , Pmin =8.5 bar m3
 Maximum Sound pressure level(Silence/Super Silence)=79/72 dB
Function Description

Air Circuit
Function Description

Oil circuit
 Function of Oil Injection

 It dissipates the compression heat & acts as coolant.

 It seals the gaps between the screw and between the screws and
housing.
 It lubricates the bearing.
 Network pressure

 For the compressor, the pressure downstream of the check

valve is termed network pressure. The control system
switches the compressor on and off during mode of
operation depending on the network pressure.
 IA Compressor Mode of Operation

 Load Operation
Delivers maximum amount of compressed air consuming maximum
energy.
 Idling Operation
Compressor runs but does not deliver any compressed air.
It consumes 75 % less energy than In load operation.
 Standstill ready for Operation
Compressor is standing still but ready for operation
13 IA Compressor Mode of Operation

 IA Compressor running & idleness mode:

 Cut-in Pressure → 9.5 Bar ( on Load Mode)

 Cut-in Pressure → 8.5 Bar ( on Idle Mode )

 Safety Alarm condition:

When IA fall below →
 Low Alarm → 7.5 Bar
 Low Low Alarm → 6.5 Bar
Operating Pressure Transmitter

 Switch-On Pressure Pmin

If the network pressure drops to the set switch on pressure Pmin, the
compressor switch on.
Network Pressure Pmin =8.5 bar
 Switch-Off Pressure Pmax
If the network pressure increases to the switch-off pressure Pmax, the
compressor switches to idling operation
Network Pressure Pmax =9.5 bar
15 Operating Pressure Transmitter
 Proportional Controller

 The proportional controller is an additional control device

intervening in the sequences of the intake regulator.
 The intake regulator only opens as far as necessary to supply the
current compressed air requirement.
 A compressor with proportional controller is able to supply it’s
delivered quantity variable between 0% to 100%.The proportional
controller is factory set to a delivered quantity between 50% and
100% of the compressor capacity.
Review of regular maintenance work
18 Review of regular maintenance work

Fig: Changing Supply air Filter & Suction Cartridge Filter

19 Review of regular maintenance work

Fig: Changing the Oil Filter & Oil Separator

20 Review of regular maintenance work

Fig: Drain off old Lube Oil for changing

 Scheduled Maintenance & frequencies

Sl Consumables Frequencies
No
1 Compressor oil (Syprem 8000s) 9000 hrs
2 Supply Air filter 500 hrs

3 Suction filter cartridge 3000 hrs

4 Oil filter 3000 hrs
5 Oil Separator 3000 hrs
6 V-belt If damage is visible.
 Safety temperature limiting device

The safety temperature limiting device switches off the compressor once
the maximum admissible final compression temperature has been
reached.
The compressor does not switch on when dropping below the minimum
temperature.
 Switch off the compressor (OFF button). Fault is acknowledged.
 Rectify the fault.
 Switch on the compressor (ON button).
 Safety Valve

Safety valve on the compressed air/oil receiver prevents the maximum

admissible pressure being exceeded. When the maximum pressure is
exceeded (e.g. incorrect setting of the operating pressure switch), the entire
delivery volume of the compressor is ejected.
24

Dryer & Distribution

System
 Air Drying

There are two basic modes of removal of moisture (drying of air)

from compressed air-
 Refrigeration drying.
 Adsorption drying.
 Refrigerant compressed air dryer.

Technical Data (DS-180)

 Flow Capacity=1080 m3/hr
 Pressure dew point (PDP)= +3°C
 Differential pressure at full load=0.230 bar
 Electrical Power Consumption=1.46 kw
 Min/Max Air Pressure=1 bar g/14 bar g
 Min/Max Ambient Temperature = 5°C/50°C
 PRESSURE DEW POINT

For a given pressure, the temperature at which water vapor will begin to
condense into liquid water
Class 4:
The lowest pressure dew point class for a refrigerated dryer is Class 4. Class 4
delivers a pressure dew point of +38°F. Refrigerated dryers should not operate
below the Class 4 range because the water vapor will freeze in the dryer.
Class 6:
The highest pressure dew point for a refrigerated dryer is Class 6. Class 6 delivers
a pressure dew point of +50°F.  The highest practical pressure dew point because
higher pressure dew point causes condensation in downstream piping.
Refrigeration drying.

Refrigerated air dryer circuit can be divided into two parts

 Air circuits
 Refrigerant circuit.
Air & Refrigerant circuit
Refrigerant R-407 C

Properties
 R-407 C is a non-ozone depleting bend of three refrigerant R-
32,R-125,R-134 A.(23/25/52 % by weight)
 Non flammable & safe to use.
 Environmentally Accepted.
 Commercially Available.
 Adsorption Drying

Adsorption drying works on basic principle of mass transfer i.e.

adsorption of moisture from compressed air by desiccant like
Silica Gel, Activated Alumina or Molecular Sieves. These types of
air dryers are economical when extremely dry air having
atmospheric dew point of -40oC or lower is required.
Adsorption Dryer

Technical Data (DAZ 126)

 Min/Max working pressure=1 bar/16 bar
 Min/Max working temperature= -10°C/50°C
 Volumetric flow= 750 m3/hr
 Volume =134 L
 Voltage=230 V
 Frequency= 50 Hz
 Running Principle

The adsorption drying principle is based on the ability of the

desiccant material to adsorb water vapor in the compressed air.
During the drying phase, water vapor is adsorbed into the surface
of the desiccant. At the same time, the other tower is purged by a
small quantity of dried air passing over the wet desiccant material.
The resulting moisture is vented in to the atmosphere. After the
pressurization the unit is then ready for a new drying phase.
Why Adsorption Dryer need?

 Water vapor contained in the air is corrosive and can affect your
compressed air network, solenoid valves, pneumatic equipment
etc.

 Dust and other contaminants can reduce the working life of your
pneumatic equipment, resulting in premature breakdowns and
higher maintenance costs.

 In addition, these contaminants can mix with your raw material

(paint, pneumatic handling, etc.),and increase the possibility of
product spoilage.
Product Description
Function Description
Operating Mode of Dryer

 Adsorption
 Regeneration
 Standby
Adsorption
Regeneration(Running in parallel to
adsorption)

At the same time the other vessel is prepared for a renewed take-up
of humidity. This is called regeneration.
With the dew point sensing control option, the regeneration phase is
followed by a standby phase.
The regeneration phase is sub divided into 3 phases:
 Expansion Phase
 Dehumidification Phase
 Pressure Build-up Phase
Expansion & Dehumidification Phase
Pressure Build-up Phase
Standby Phase & Switchover

Standby Phase
When in standby phase the fully regenerated vessel is ready for
adsorption operation. The system is switch to this vessel, as soon as
the measured dew point at the compressed air has reached the set dew
point value for switch over.

Switchover
When the drying agent in the adsorbing vessel has taken up a
sufficient level of
humidity ,then the switch over between the vessels will be effected
between the vessel.
 Display Panel

1. LED power
2. Flow diagram
3. Digital display
4. LED economy cycle
Flow Diagram
 Cyclone Separator Principle

The cyclone separator works according to

the mass-inertia principle. It consist of a
vortex cartridge and a reservoir. The vortex
cartridge induces the compressed air into
rotary movement. Solid & Liquid components
in the air are forced against the inside walls of
the separator by their own mass inertia. This
causes heavy particles of dirt & water to separate
and flow into the collection reservoir.
 Cyclone separator data & Application

Technical Data (Z 125 N)

 Flow capacity @ 10 bar=17.5 m3/min
 Maximum Operating pressure=16 bar
Application
Cyclone Separators take liquid , aerosol & solids from the
compressed air.
Based on physical law of inertia they operate with practically no
maintenance & ideally suited to compressed air systems without
an air receiver when installed directly downstream of the
compressor.
 Pre-filters BOGE V series

Technical Data (V-160)

• Capacity=960 m3/hr
• Max Design Pressure=16 bar
• Differential Pressure,ΔP=0.02 bar
• Min\Max Operating Temperature=1°C\80°C
• Volume=6 liter
Application
Pre-filters separate out coarse impurities
from the compressed air. Pre-filters remove
solids from compressed air with an efficiency
of 99.99% relative to 3 µm.
 Micro filters BOGE FP series

Technical Data (V-160)

• Capacity=940 m3/hr
• Max Design Pressure=16 bar
• Differential Pressure,ΔP=0.06 bar
• Min\Max Operating Temperature=1°C\80°C
• Volume=6 liter
Application
Micro filters separate out extremely fine impurities
in the compressed air. BOGE micro filters remove
solids from compressed air with an efficiency of
99.99999%relative to 0.01 μm and a residual oil
content up to 0.01 mg/m3.
Overall Flow Diagram of IA System
IA Distribution
51
Thanks to All