AiiA - A Project of Potohar Center for Entrepreneurship Development
AiiA - A Project of Potohar Center for Entrepreneurship Development
WELCOME
AiiA - A Project of Potohar Center for Entrepreneurship Development
Recitation of
Holy Quran
ASIAN INSTITUTE OF INDUSTRIAL AIR
Turning knowledge into practice
A project of Potohar Center for Entrepreneurship
Development
ABOUT US
POTOHAR CENTER FOR ENTREPRENEURSHIP
DEVELOPMENT
ASIAN INSTITUTE OF
INDUSTRIAL AIR
PAKISTAN AEROSPACE
COUNCIL
ABOUT US
Asian Institute of Industrial Air (AIIA) is a training institute in Pakistan offering
an advanced level of certified training courses
Industrial Air
Engineering (only
institute in Pakistan)
Production
Engineering
Automation
OUR DOMAIN
Compressed
Air
Vacuum
Waste
Management
& Recovery
Audit
(Leaks)
Automation
Intelligent
Maintenance
Smart
Procurement
Air Quality
INDUSTR
IAL
TRAININ
G
OUR SERVICES
Training of Industry
Professionals and mid-career
level individuals
Providing fresh graduates with
the opportunity to build skillsOffering need-based
customized training for existing
workforce
OUR TRAININGS
COMPRESSED AIR
❏ Introduction to
Compressed Air
Engineering
❏ Advanced
Management of
Compressed Air
Systems
❏ Compressed Air
System Technology
❏ Working Safely with
Compressed Air
PRODUCTION ENGINEERING
❏ Industrial Plant Reliability
Improvement & Maintenance Cost
Reduction
❏ Reliability Improvement of
Mechanical Seals
❏ Pumps & Pumping Systems
❏ Advanced Course on Centrifugal
Pumps
❏ Managing a Successful Condition
Monitoring Maintenance Program
❏ Root Cause Analysis: Effective
Problem Solving & Decision
Making
❏ Mechanical Ventilation & Heat
Recovery
AUTOMATION
❏ Industrial
Automation (PLC,
SCADA & HMI)
❏ Ansys Workbench
❏ MicroController &
its Applications
❏ MATLAB Training
We Handle
Your Training Needs
AiiA - A Project of Potohar Center for Entrepreneurship Development
TRAINERS
INTRODUCTION
AiiA - A Project of Potohar Center for Entrepreneurship Development
Dr. Arshad Ali
CEO AIIA
Recipient of Pride ofPerformance and Sitara-i-Imtiaz from Govt ofPakistan for his services inPakistan Air Force andNUST University. He alsoserved as Rector NTUFaisalabad and ExecutiveDirector HEC.
Served in Navy and joinedRASTGAR & CO. in 2003. Heis Compressed AirMaintenance Expert Trainedin Germany, UK & Korea.Specializes in CompressedAir, Blowers, Vacuum &Nitrogen Generationsystems.
Mr. Masood Ahmed Mr. Danyal Ahmad
Compressor room designerand piping layout expert.He is also experiencedcorporate trainer with abackground in MechanicalEngineering, has workedon various plants incountry regardingCompressed Air systems.
Mr. Muhammad Ali
Has been working atRastgar as mentor andtrainer, havingexperience related totraining in compressedair audit, costing andbusiness development.
AiiA - A Project of Potohar Center for Entrepreneurship Development
PARTICIPANTS
INTRODUCTION
AiiA - A Project of Potohar Center for Entrepreneurship Development
Certificate Course
on
Compressed Air Systems
with collaboration of
National Textile University, Faisalabad
AiiA - A Project of Potohar Center for Entrepreneurship Development
TRAINING PROGRAM
Time Subjects Trainers
Session I:Introduction to Compressor Engineering0940-1020
• Introduction• What is a Compressor• Compressor Types• Basic Compressed Air Terms
Dr. Arshad Ali
Session II: Selection & Maintenance of Compressor1020-1120
• How to Size & Select a Compressor• Compressor Room Organization• How to Select a Compressor Service Provider
Masood Ahmed
1120 - 1140 : Tea Break
Session II (Continue.): Selection & Maintenance of Compressor1140-1300
• Rotary Screw Air compressor Basics • Basic Component of Screw Air Compressor• How Screw Compressor Works• Compressor Installation and ventilation• Compressor Maintenance• Downstream Equipment
Masood Ahmed
1300 - 1400 : Lunch Break & Namaz + Group Photo
AiiA - A Project of Potohar Center for Entrepreneurship Development
TRAINING PROGRAM
Time Subjects Trainers
1300 - 1400 : Lunch Break & Namaz + Group Photo
Session III :Transmission of Compressed Air1400-1500
• Principles Of Compressed Air Piping• Distribution Headers and Drops• Type of Piping Offered for Compressed Air• Typical Compressed Air Pipe Comparison
Danyal Ahmed
1500 - 1520 : Tea Break
Session IV:Air Quality & Cost1520-1600
• Impurities in Compressed Air• Automation, Instrumentation & Cost Accounting• The Value of 3rd Party Audits• Heat Recovery System• Compressed Air Safety Practices
Muhammad Ali
1600-1620 Question / Answer All Trainers
1620-1630 Certificate Distribution & Concluding Remarks Imtiaz Rastgar
AiiA - A Project of Potohar Center for Entrepreneurship Development
Session I:Introduction to Compressor Engineering
Dr. Arshad Ali
AiiA - A Project of Potohar Center for Entrepreneurship Development
• Compressed Air
• Compressor Types
• Selection of Compressors
• Compressed Air Piping
• Compressor Installation & Ventilation
• Controls, Instrumentation & Cost Accounting
• Air Compressor Maintenance & Trouble Shooting
• Compressed Air Safety Practices
• Understanding of Relevant ISO Standards
• The Value of Third Party Audits
• Heat Recovery System
LEARNING SUBJECTS
AiiA - A Project of Potohar Center for Entrepreneurship Development
INTRODUCTION
TO
COMPRESSOR AIR SYSTEMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
• What is a Compressor
• What is Compressed Air
• Type of Compressors
• Basic Compressors Terms
• Compressed Air Applications
IN THIS SESSION, WE SHALL COVER
AiiA - A Project of Potohar Center for Entrepreneurship Development
WHAT IS AIR?
The invisible gaseous substance surrounding the
earth, a mixture mainly of oxygen and nitrogen
AiiA - A Project of Potohar Center for Entrepreneurship Development
WHAT IS FREE AIR?
Air at atmospheric conditions is generally called
"free air."
AiiA - A Project of Potohar Center for Entrepreneurship Development
Pressure - Amount of force pushing against a given area.
WHAT IS PRESSURE?
AiiA - A Project of Potohar Center for Entrepreneurship Development
WHAT IS PRESSURE?
How much pressure a gas exerts depends on the amount of
gas. The more gas particles there are, the greater the
pressure.
AiiA - A Project of Potohar Center for Entrepreneurship Development
THERMODYNAMIC LAW
The state of A gas is specified by
• Pressure
• Volume
• Temperature
AiiA - A Project of Potohar Center for Entrepreneurship Development
According to Boyle’s law,
if the temperature of a gas
is held constant,
increasing the volume of
the gas decreases its
pressure
BOYLE'S LAW
AiiA - A Project of Potohar Center for Entrepreneurship Development
BOYLE'S LAW
AiiA - A Project of Potohar Center for Entrepreneurship Development
According to Charles’s
law, if the pressure of a
gas is held constant,
increasing the
temperature of the gas
increases its volume.
CHARLES'S LAW
AiiA - A Project of Potohar Center for Entrepreneurship Development
CHARLES'S LAW
AiiA - A Project of Potohar Center for Entrepreneurship Development
AMONTON'S LAW
According to Amonton’s
law, if the volume of a gas is
held constant, increasing the
temperature of the gas
increases its pressure
AiiA - A Project of Potohar Center for Entrepreneurship Development
AMONTON'S LAW
AiiA - A Project of Potohar Center for Entrepreneurship Development
WHAT IS A COMPRESSOR
A compressor is a mechanical device that increases
the pressure of a gas by reducing its volume
AiiA - A Project of Potohar Center for Entrepreneurship Development
WORLD’S FIRST COMPRESSOR
In 1650, German scientist Otto von Guericke devised
an air pump consisting of a single piston and
cylinder. With it he was able to experiment with
compressed air and vacuums.
In 1799, George Medhurst of England designed the
first motorized air compressor and used it in mining
AiiA - A Project of Potohar Center for Entrepreneurship Development
Compressed air is free air that has been forced into a
smaller volume and is now at a pressure greater than
atmospheric.
WHAT IS COMPRESSED AIR?
AiiA - A Project of Potohar Center for Entrepreneurship Development
• 7- 12 bar Pressure for Industrial applications
• Compressed Air is measure in m3/min, Liter/min,
CFM
• Capacity of an air compressor
WHAT IS COMPRESSED AIR?
AiiA - A Project of Potohar Center for Entrepreneurship Development
A 11 kW Compressor can
deliver approximately
100 m3h of air at 7 Bar.
A 75 kW Compressor can
deliver approximately 800 to
850 m3/h of air at 7 Bar
WHAT IS COMPRESSED AIR?
AiiA - A Project of Potohar Center for Entrepreneurship Development
TYPES OF COMPRESSORS
COMPRESSOR TYPES
POSITIVE
DISPLACEMENTDYNAMIC
Successive volumes of
air are confined within a
closed space where
pressure is increased as
the volume of the closed
space is decreased.
Air is compressed by
the dynamic action of
rotating impellers or
vanes imparting velocity
and pressure to the gas.
AiiA - A Project of Potohar Center for Entrepreneurship Development
POSITIVE DISPLACEMENT
RECIPROCATING ROTARY
AiiA - A Project of Potohar Center for Entrepreneurship Development
A Reciprocating
Compressor that uses a up-and-
down or back-and-forth linear type
positive-displacement mechanism.
In A Reciprocating Compressor, a volume of gas is drawn into a cylinder, it is trapped, and compressed by piston and then discharged into the discharge line.
RECIPROCATING
AiiA - A Project of Potohar Center for Entrepreneurship Development
A Rotary-Screw
Compressor that uses a rotary-
type positive-displacement
mechanism.
Once air enters a rotary screw
compressor, it is trapped
between mating male and
female rotors, and compressed
to the required discharge
pressure.
ROTARY
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TYPES OF COMPRESSORS
AiiA - A Project of Potohar Center for Entrepreneurship Development
• Units of Measurement
• Actual Site Conditions
• Inlet Air Pressure & Temperature
• Actual CFM (ACFM)
• Standard CFM (SCFM)
COMPARING COMPRESSOR PERFORMANCE
AiiA - A Project of Potohar Center for Entrepreneurship Development
PERFORMANCE VERIFICATION
OF
COMPRESSORS
www.aiia.com.pk
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPARISON
OF
COMPRESSORS
Please see your Folder
AiiA - A Project of Potohar Center for Entrepreneurship Development
• Air tools run cooler
• Air tools have a higher power-to-weight ratio
• Air tools have no shock risk
• Air tools have fewer parts and require less
maintenance
COMPRESSED AIR POWER
VS
ELECTRICITY
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR POWER
VS
HYDRAULIC
• Air systems generally have fewer parts
• Air systems generally cost less
• Air systems are less of a fire hazard
• Air systems are more dirt-tolerant
• Air systems are more tolerant to leakage
AiiA - A Project of Potohar Center for Entrepreneurship Development
COST OF PLANT TASK WITH AIR POWER
AiiA - A Project of Potohar Center for Entrepreneurship Development
DO YOU KNOW
COMPRESSED AIR IS 8 TO 10 TIME MORE EXPENSIVE
THAN ELECTRICITY?
AiiA - A Project of Potohar Center for Entrepreneurship Development
COST OF COMPRESSED AIR
76%
12%
12%
Electricity
Maintenance
Equipment
AiiA - A Project of Potohar Center for Entrepreneurship Development
BUYING A COMPRESSOR
What needs to be considered in buying an air compressor?
• Application
• Flow
• Pressure
• Air Quality
• Dryer & Filters
• Operating Hours
• Daily Shift
• Flow Demand Fluctuations (VSD)
• Heat Recovery
• Future Expansion
AiiA - A Project of Potohar Center for Entrepreneurship Development
Absolute Pressure
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Atmospheric Pressure
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Air Receiver
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Aftercooler
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Compression
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Compression Efficiency
BASIC COMPRESSOR TERMS
Ratio Of
Theoretical To Actual Work Required
to Compress Air.
Takes Into Account Slip Leakage and Frictional Losses.
AiiA - A Project of Potohar Center for Entrepreneurship Development
Compression Ratio
BASIC COMPRESSOR TERMS
Ratio of the Absolute Discharge Pressure to the
Absolute Inlet Pressure
AiiA - A Project of Potohar Center for Entrepreneurship Development
Design Pressure
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Design Speed
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Discharge Pressure
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Discharge Temperature
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Free Air
BASIC COMPRESSOR TERMS
Air at Atmospheric Conditions
AiiA - A Project of Potohar Center for Entrepreneurship Development
Inlet Pressure
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Inlet Temperature
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Moisture Separator
BASIC COMPRESSOR TERMS
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR ADVANTAGES
Air compressors have been used in industry about over 100 years,
because air as a resource is safe, flexible, clean and convenient.
Easily Transported
AiiA - A Project of Potohar Center for Entrepreneurship Development
Easily Stored
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
Clean & Dry
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
Lightweight
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
Safe To Use
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
Accident-Proof
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
Rational & Economical
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
Fast Work Medium
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
Fully Adjustable
COMPRESSED AIR ADVANTAGES
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Textile
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Vehicle Services
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Food & Beverage Processing
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Metals
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Pharmaceutical
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Plastics
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Power Generation
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Wood Products
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Electronics
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Cement
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR APPLICATIONS
Spray Paint
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COMPRESSED AIR APPLICATIONS
Pneumatic-Operated Tools
AiiA - A Project of Potohar Center for Entrepreneurship Development
DOWNLOAD
99Examples
Of Pneumatic Application
www.aiia.com.pk
AiiA - A Project of Potohar Center for Entrepreneurship Development
SUBSCRIBE
OUR FUTURE TRAININGS
www.aiia.com.pk
AiiA - A Project of Potohar Center for Entrepreneurship Development
SELECTION & MAINTENANCE
OF
AIR COMPRESSORS
AiiA - A Project of Potohar Center for Entrepreneurship Development
IN THIS SESSION, WE SHALL COVER
• How to Size & Select a Compressor
• Compressor Room Organization
• How to Select a Compressor Service Provider
• Basic Component of Screw Air Compressor
• How Screw Compressor Works
• Compressor Installation and ventilation
• Compressor Maintenance
• Downstream Equipment
AiiA - A Project of Potohar Center for Entrepreneurship Development
SIZING & SELECTING AN AIR COMPRESSOR
• How much Air Volume (FAD) required
• Pressure required at machine
• Actual site conditions
• What is the voltage?
• Any future expansion Plan
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR ROOM ORGANIZATION
Compressor Room
• Ventilation
• Room Dimension
• Drain Channels
• Distance Between Machines
• Machines to Wall Distance
• Foundation
• Exhaust Air Ducts
• Scheme of Machines Placement
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR ROOM ORGANIZATION
• Air Receivers
• Piping System
• Piping Material
• Main Header
• Inclination in Piping
• Installation of Downstream Equipment
• Electrical Power Required
• Health & Safety Checklist
IDEAL COMPRESSOR ROOM AND
INSTALLATION
AiiA - A Project of Potohar Center for Entrepreneurship Development
CROSS VENTILATION
• Compressor Oil Life decrease
half for every 20 degree rise
above normal operating temp.
• Poorly ventilated, fluffy & dusty
environment can pass six times
more water in air system
• Hot compressed air will
experience pressure losses as
it passes through air treatment
system.
AiiA - A Project of Potohar Center for Entrepreneurship Development
• Air End running at high temp it is
slowly opening up its clearances
and premature wear.
• The compressor must be installed
next to the air inlet aperture so that
it draws fresh air for compression
and cooling air for ventilation.
• The compressor must be positioned
right place so that it can not re-
induct its own heated exhaust air.
CROSS VENTILATION
AiiA - A Project of Potohar Center for Entrepreneurship Development
Eight Basic Elements
• Demand, (Total free air delivery requirement with losses)
• Compressed Air Quality
• Supply, (Maximum and minimum pressure requirement
with pressure drop)
• Storage, (Air Vessel wet & dry)
• Distribution, (Straight & Ring-man system)
• Installation, (MS, SS, Aluminum, GI, Polymer etc)
• Maintenance, (Schedule & Corrective , minor & major etc )
• Condensate management
COMPRESSED AIR SYSTEM DESIGN
AiiA - A Project of Potohar Center for Entrepreneurship Development
SELECTING A SERVICE PROVIDER
• Familiarity with the Systems Approach
• Availability of Compressed Air System
Assessment Services
• Compressor Knowledge and Expertise
• System Components and Controls Knowledge
and Expertise
• Company Capabilities
• Emergency service response
• Parts shipments
• Service Facilities
SALES SERVICES SPARES SOLUTIONS
Rotary Screw Compressors work on the principle ofair filling the void between two helical mated screwsand their housing. As the two helical screws areturned, the volume is reduced resulting in anincrease of air pressure.
Most rotary screw compressors inject oil into thebearing and compression area. The reasons are forcooling, lubrication and creating a seal betweenscrews and the housing wall to reduce internalleakage. After the compression cycle, the oil and airmust be separated before the air can be used by theair system.
TYPE OF COMPRESSORS
ROTARY SCREW
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HOW SCREW COMPRESSOR WORKS
AiiA - A Project of Potohar Center for Entrepreneurship Development
MAIN COMPONENTS
Suction Regulator
Low Pressure Loss
Air End
High Performance
Suction Filter
Class 3 Micron
Bell housing, flexible direct coupling
Perfect Alignment of drive shafts
Cooling Air
Suction
filter
Silencer
Base Frame with fork lift, 6 openings Easy Transport
SALES SERVICES SPARES SOLUTIONS
ROTARY SCREW AIR COMPRESSOR BASICS
• V-belt
• Direct drives
• Gear-driven
Drives
SALES SERVICES SPARES SOLUTIONS
• Electronic Control
Panel
• Display Content
• System adjustments
Control Panel
ROTARY SCREW AIR COMPRESSOR BASICS
AiiA - A Project of Potohar Center for Entrepreneurship Development
DELCOS XL - BENEFITS
• Easy to use thanks to “Touch Screen” and
intuitive MMI (Man-Machine-Interface)
• Instant overview of compressor status
• All functions are intuitively visual
• Easy to check having correct compressor
settings
• Compressed air system can be easily
optimized thanks to trends information
AiiA - A Project of Potohar Center for Entrepreneurship Development
• Controlling and monitoring thanks to 6/5 programmable
inputs/outputs
• Data logging and software update via optional SD card
• Service diagnostic feature
• Modbus as standard
• Optional Profibus interface
• RS485 interface for Smart Air Master Sequencer
• Outstanding Optional Base Load Sequencing (BLS)
DELCOS XL - BENEFITS
SALES SERVICES SPARES SOLUTIONS
There are generally five areas of the compressor that
require maintenance:
• Airend
• Motor
• Drive Train
• Lubricants
• Filters.
ROTARY SCREW AIR COMPRESSOR
MAINTENANCE
SALES SERVICES SPARES SOLUTIONS
Airends and their
bearings are damaged
by contamination in the
air and lubricants and
by excessive heat.
Inspect for unusual
noises and vibrations.
AIREND MAINTENANCE
SALES SERVICES SPARES SOLUTIONS
Motor
• Bearings Lubrication
• Bearing Replacement
• Periodically check ampere
• Providing proper ventilation and
ambient temperature
MOTOR MAINTENANCE
SALES SERVICES SPARES SOLUTIONS
• Systems Alignment
• Gear drives Lubrication
• Inspect and adjust the
tension Replace Worn or
frayed belts
DRIVE TRAIN MAINTENANCE
SALES SERVICES SPARES SOLUTIONS
• Cool, Seal, Protect and Remove
Contaminants
• Drain All Existing Lubricant
• Change Oil On A Schedule
• Regular Oil Sampling
• Non-genuine
LUBRICANTS
SALES SERVICES SPARES SOLUTIONS
Filters
• Schedule air filters change
• Inlet filter with an increase of
pressure drop of 1% reduces
compressor capacity by 1%.
• Schedule Oil filters change
AIR FILTERS MAINTENANCE
SALES SERVICES SPARES SOLUTIONS
ROTARY SCREW AIR COMPRESSOR -
SIMULATOR
SALES SERVICES SPARES SOLUTIONS
• Preventive Maintenance is the
systematic inspection, detection,
and correction of potential
equipment failures before they
develop into major defects.
• The purpose of Preventive
Maintenance is to keep
equipment in safe and reliable
condition in operational state and
minimum cost of maintenance.
COMPRESSOR MAINTENANCEPREVENTIVE MAINTENANCE
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR MAINTENANCEDAILY CHECKS
• General operation of machine.
• Oil System: Drain condensate from
separator vessel.
• Oil System: Check oil level. Top up if
necessary
• As defined in the User Manual.
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR MAINTENANCEWEEKLY CHECKS
• Normally Undertaken by the End User
• Delcos Controller: Check for any indicated service
requirements.
• Delcos Controller: Check fault history
• Oil System: Drain condensate from separator vessel.
• Oil System: Check oil level. Top up if necessary
• Separator Element: Check element differential pressure
(Max 0.7 bar).
• After-Cooler / Oil Cooler: Check condition clean as
necessary.
• Cabinet Pre-Filters & VSD Filters: Check condition clean
as necessary.
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR MAINTENANCEMONTHLY CHECKS
• Regular equipment performance
analysis
• Cleaning of components
• Tightening of electrical
connections
• Oil check
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR MAINTENANCESCHEDULE SERVICE (2000 HRS)
• Oil system: Check oil level / top up oil sample if required.
• Air filter: Renew air filter.
• Oil filter: Renew oil filter.
• Electrical wiring: Check connections and condition.
Controller: Check connection and plugs.
• Cabinet filters / VSD filters: clean / Renew.
• After-cooler, oil cooler & fan.
• Clean externally.
• Control system: Checks for correct operation and control.
• Blow down system: Check for correct operation.
• Relief valve: Functionally test.
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR MAINTENANCESCHEDULE SERVICE (4000 HRS)
• Starter contactors: Checks contacts,
connections and condition.
• Oil system: Change oil.
• Separator filter: Renew filter
elements.
• Oil Scavenge system: Renew motor
lubricant cartridges
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSOR MAINTENANCESCHEDULE SERVICE (8000 HRS)
• Carryout 2000Hr and 4000Hr Service.
Plus…
• Minimum pressure valve: renew
• Suction regulator: Overhaul the suction
regulator.
• Control solenoid: Renew.
• Drive coupling inserts: Checks/Renew.
AiiA - A Project of Potohar Center for Entrepreneurship Development
DRYER MAINTENANCE
• Dryer external condenser
cleaning.
• Replacement of pre and after
filter.
• Auto drains kit replacement.
• Preventive service as per
manual. Other all service are
chargeable – (gas charges etc)
AiiA - A Project of Potohar Center for Entrepreneurship Development
DOWN STREAM EQUIPMENT
• Air Receiver
• Water Separators
• General Purpose Filter
• Dryer
• High Efficiency Coalescing Filter
• Activated Carbon Filter• Sterilize Filter• Auto Drains
SALES SERVICES SPARES SOLUTIONS
Water separators provide
bulk condensed water and
liquid oil removal and are
used to protect coalescing
filters against bulk liquid
contamination
DOWN STREAM EQUIPMENTWATER SEPARATORS
SALES SERVICES SPARES SOLUTIONS
• General Purpose
• High Efficiency Coalescing Filters
• Activated Carbon Filters
• Vapor Removal Filters
DOWN STREAM EQUIPMENTFILTERS
AiiA - A Project of Potohar Center for Entrepreneurship Development
Refrigerated air dryer works by cooling down
the air (like a refrigerator).
The warm wet air enters the dryer, where it is
cooled down to about 3 degrees Celsius. All
water vapor that was in the air condenses
into water
The liquid water is then removed from the
compressed air by a water-trap.
DOWN STREAM EQUIPMENTREFRIGERANT DRYER
AiiA - A Project of Potohar Center for Entrepreneurship Development
REFRIGERANT DRYER OPERATION
SALES SERVICES SPARES SOLUTIONS
• Absorbent chemicals used in air
dryers are known as "desiccants".
They attract moisture by the
chemical reaction known as
absorption.
• Adsorbents remove the moisture
from the air by attracting and
holding the water to the surface of
their particles.
DOWN STREAM EQUIPMENTDESICCANT DRYER
SALES SERVICES SPARES SOLUTIONS
ADSORPTION DRYER OPERATION
AiiA - A Project of Potohar Center for Entrepreneurship Development
DESICCANTS
There are three basic types
• Silica gel
• Molecular sieves
• Activated alumina
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SILICA GEL
AiiA - A Project of Potohar Center for Entrepreneurship Development
MOLECULAR SIEVES
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ACTIVATED ALUMINA
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DOWN STREAM EQUIPMENTAIR RECEIVERS
The Primary Role of a
Compressed Air Storage Tank
• Compressed air storage
• Provides a steady air signal to
the compressor controls
• To act as a second heat
exchanger
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ELECTRIC MOTOR
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MOTOR INSPECTION
• Ensure the windings are maintained in a
clean condition.
• Carefully remove the shaft / rotor assembly
from the stator frame.
• Check Bearings condition.
• Clean all components and inspect for wear
or damage.
• Use low pressure air to blow away dust and
dirt from the rotor and stator
AiiA - A Project of Potohar Center for Entrepreneurship Development
• When re-packing the bearings with grease, use
lithium complex grease, and avoid overfilling.
• Don’t use high-pressure air to clean the motor.
• Don’t use force when fitting the end shields on to
the bearings and spigots.
• Ensure electrical connection is correct and the
terminals nuts are tight.
• Check the air gap between the rotor and the stator
windings using long feeler gauge.
• Before attempting to run the motor, check that the
rotor rotates freely.
MOTOR INSPECTION
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TRANSMISSION
OF
COMPRESSED AIR
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IN THIS SESSION, WE WILL COVER
• Principles Of Compressed Air Piping
• General Guidelines For Compressed Air Distribution
System
• Distribution Headers and Drops
• Type of Piping Offered for Compressed Air
• Comparison of Compressed Air Pipes
Compressed Air
Systems: The
Secret is in the
Pipe
AiiA - A Project of Potohar Center for Entrepreneurship DevelopmentAsian Institute of Industrial Air
• Identify workstation using compressed air.
• Volume of air used at each location
• Pressure range required at each location.
• Establish the maximum used on each main and branch
line .
• Establish any allowance for future expansion.
• Select the air compressor type, with pressure and
temperature
PRINCIPLES OF COMPRESSED AIR PIPING
AiiA - A Project of Potohar Center for Entrepreneurship DevelopmentAsian Institute of Industrial Air
• Check max-min Ambient temperature
• Produce a final piping network
• Select the piping material
with min pressure drop
• Use minimum fittings,
connectors and elbows
• Piping Inclination should be 3 ~5° down to one side
• Install condensate drain at lower portion
KEEP IN MIND
AiiA - A Project of Potohar Center for Entrepreneurship DevelopmentAsian Institute of Industrial Air
• Selection of poor piping material
• Piping design and line sizes too small for the desired air flow.
• Undersized piping restricts the flow and reduces the discharge pressure.
• Poor piping practices by increasing velocity- and turbulence-induced backpressure
Common Mistakes
AiiA - A Project of Potohar Center for Entrepreneurship DevelopmentAsian Institute of Industrial Air
REDUCE POSSIBILITY OF VIBRATIONPoints to consider while dealing with compressed air
line.
• Vibration & Pulsations
AiiA - A Project of Potohar Center for Entrepreneurship DevelopmentAsian Institute of Industrial Air
PIPE CAN DEFORM WITH EXCEESIVE
TEMPERATURE
AiiA - A Project of Potohar Center for Entrepreneurship DevelopmentAsian Institute of Industrial Air
MOISTURE
Moisture is compressed air is unavoidable but that does
not mean it is acceptable.
AiiA - A Project of Potohar Center for Entrepreneurship Development
• Pressure drop between the compressor and point of use isirrecoverable.
• Pipe size should be large enough that pressure drop is held to a minimum.
• Design inlet and discharge piping for smooth flow with uniform translational velocity over the entire area of the piping.
AVOID PRESSURE DROP
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• Install safety valve • Never exceed the working pressure rating of an
ASME vessel in the system.• Consider bypass lines or valves on all items that
may require future maintenance.
SAFETYVALVES & BYE-PASS LINES
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• Use loop design system if possible, both around the plant and within each production zone
USE CLOSE LOOP OR RING MAIN
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SWAN NECKS TAKE CARE OF MOISTURE
• Use Swan Necks for branch Lines.
Incorrect Drop Correct Drop
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A. Poor installation/condensate in branch line flow to tool
B. Better installation/Condensate in branch line tends to flow past service line
C. Best installation/condensate in branch line cannot get into service line
GENERAL GUIDELINES
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DISTRIBUTION HEADERS AND DROPS
• Purpose of Header is to transport the maximum
anticipated flow to the production area.
• Provides an acceptable supply volume for drops.
Modern designs
consider an
acceptable
header and line
pressure loss to
be 0 bar.
AiiA - A Project of Potohar Center for Entrepreneurship Development
PIPE SLOPE
• All lines in the system main and branch lines should
slope or pitch downward at least 1" per 100 feet or less
in the direction of the air flow to a drain point – drop
leg, receiver, etc. This will allow condensation to
collect at the low points where it can be trapped and
removed.
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TYPES OF PIPING
Compressed air piping materials
can be divided into two basic
types:
• Metal
• Non-Metal.
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Metal pipe used in a compressed air system are:• Mild Steel• Stainless steel• Copper• Aluminum
TYPES OF PIPING
Metal Pipe
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Mild Steel or Steel Pipe — Traditional Material in
Compressed air piping.
Durable and Strong on the outside.
but from inside it corrodes when
exposed to condensate (H2O) and thus
become a major source of contamination
to the whole system.
•Connection: Threaded when it is 3" diameter and smaller
Welded if the diameter is larger than 3“•Heavier and harder to work with, but less expensive.
TYPES OF PIPINGMetal Pipe
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Stainless Steel — is often a good selection particularly
when exposed to oil-free wet air. Stainless Steel is most
widely used material in Food, Pharma and Chemical
Process industries.
•Connection: Welded or Pressed
•SS has excellent resistance to
corrosion
•High installation and labor cost.
TYPES OF PIPINGMetal Pipe
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Copper Pipe — is a common selection for sensitive air
systems.
• This metal is corrosion-free and easy to cut and weld and
it is lightweight but this is very costly piping.
• The working pressure of copper piping is from 17 bar to
28 bar. Further, solder melts at 216°C, it will be more
resistant to high temperatures. Even if it does fail, it will
do so in a predictable manner. The pipe ends
will separate. The working temperature limit
is about 204°C
TYPES OF PIPINGMetal Pipe
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Aluminum compressed air pipe as applied today has
become very popular. Aluminum has the same anti-
corrosive properties of stainless steel but without the
weight.
• Low pressure loss due to low friction.
• Smooth inner surface that eliminate "self
contamination.
• Enhanced flexibility to meet the ever-
changing compressed air distribution needs.
• The piping material usually has a melting
point of over 600°C.
TYPES OF PIPINGMetal Pipe
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• Non-Metal Pipe — commonly called "plastic" pipe
• Lighter than metal
• Easier to handle
• No special tools required
• Non-corrosive.
• Less Labor Cost
What has held back this material’s acceptance by many
compressed air people and organizations?
TYPES OF PIPINGNon-Metal Pipe
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limitations• Most of these are limited to an operating temperature of 60°C
to 90°C. The failure in an after-cooler can easily reach or
exceed these numbers. PVC, for instance, is limited to about
70°C at 8.5bar, but it actually starts to weaken at 30°C.
• Most of these materials are not compatible with compressor oils
in general and particularly many synthetics.
• Although pipeline fires are rare today, when there is one in
plastic pipe, there is a good chance that it will melt through the
plastic pipe and migrate into the plant.
TYPES OF PIPINGNon-Metal Pipe
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COMPRESSED AIR PIPE COMPARISON
Mild Steel Feature Aluminum
Schedule40 Heavy
Weight Lightweight
NoCorrosionResistance
Yes
YesHigh
MechanicalStrength
Less thanMild Steel,but strong
25% / 75%
InstallationCost
(Material % /
Labor %)
80% / 20%
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Mild Steel Feature Aluminum
Flange /Threaded /Welded /
Other
Type ofConnection (varies with
size)
Sealed /Reusable /
Other
NoLow "Friction generated“ Pr
essure LossYes
Yes
InstallationRequirements(Skilled Labor,
PipeFitters, etc.)
No
COMPRESSED AIR PIPE COMPARISON
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• Calibrated Aluminum Pipe: Qualicoat Painting
• Colors: Available in blue - grey – green
• Maximum Working Pressure
• 16 bar up to 100 mm
• 13 & 7 bar for all diameters
• Working Temperature: -20°C to 85°C
• Compatibility: Lubricated or oil-free compressed air,
industrial vacuum, nitrogen (99.99% purity), inert gas.
ALUMINIUM PIPE SYSTEMS FOR INDUSTRIAL FLUIDS
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EASY JOINING & INSTALLATION SYSTEMS FOR ALUMINIUM PIPE
Diameters (in mm)
16.5 - 25 - 40 - 50 - 63 - 76 - 100 - 168
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BENEFITS OF ALUMINUM PIPING
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BENEFITS OF ALUMINUM PIPING
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BENEFITS OF ALUMINUM PIPING
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The purpose of the compressed air piping system is to deliver
compressed air with enough volume, appropriate quality and pressure
to properly power the components
COMPRESSED AIR (RING MAIN SYSTEM)
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CONCLUSION
The objective of compressed air piping is to deliver compressed air to the end uses without pressure loss and the introduction of contaminants. Proper piping material selection and following guidelines for both distribution and compressor discharge piping can help system designers accomplish this goal. If Participant take one thing from this Presentation is that they remember larger diameter pipe sizes reduce air velocities (and therefore turbulence) resulting in minimized pressure losses.
AiiA - A Project of Potohar Center for Entrepreneurship Development
COMPRESSED AIR
QUALITY
&
COST
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• Impurities in Compressed Air
• Automation, Instrumentation & Cost Accounting
• The Value of 3rd Party Audits
• Heat Recovery System
• Compressed Air Safety Practices
IN THIS SESSION, WE SHALL COVER
AiiA - A Project of Potohar Center for Entrepreneurship Development
IMPURITIES IN COMPRESSED AIR
• Vapour: Water and oil in gas
form
• Aerosols: Suspension of any
particles of liquid, solid or
both within Compressed Air
• Solids: Dust, sand and
particles resulting from
corrosion and wear
• Liquid: Water, oil
Principal Impurities in Compressed Air
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IMPURITIES IN COMPRESSED AIR
Compressed Air Oil Carry Over is
0.01 to 0.03 mg/m³(Mineral Oil Aerosols and un-burnt Hydrocarbons)
Atmospheric Bacteria and Viruses
Traces of Heavy Metals such as
Lead, Mercury, Iron, etc.
(For Specific Industries)
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Compressed air at 7 bar (g) has
Eight Times more impurities than normal
ambient air.
IMPURITIES IN COMPRESSED AIR
ImpuritiesVolume
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IMPURITIES IN COMPRESSED AIR
1m3 of Atmospheric Air contains 180 Million Dirt Particles
Size: 0.01 to 100 m
At 10 Bar
Concentration of Impurities rises 11 times
1m3 of Compressed Air contains 2 Billion Dirt Particles
Size: 0.01 to 100 m
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Condensate:
Condensate comprises around 99% waterand around 1% impurities
1% Impurities Contain:
Oil in case of oil-lubricated compressors,Dirt from corroded particles in piping,Additional contaminants from the ambientair that has been drawn in.
IMPURITIES IN COMPRESSED AIR
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AUTOMATIONMultiple Compressors Controller
Multiple compressors controller
at your Plant site can save up to
35% Compressed Air energy
costs
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INSTRUMENTATIONFLOW METERS
Compressed Air Flow
Meters
Use compressed air flowmeters to for measurementof Compressed air, Nitrogenand Technical Gases.
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INSTRUMENTATIONFLOW METERS
Compressed Air
Flow Meters
a
b
e
dc
f
a = b + c + d + e + f
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Use Power Meter for
Permanent Power
Measurements.
Rated Power
vs
Actual Power
INSTRUMENTATIONPOWER / ENERGY METERS
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Importance:
If WET air is fed into the pipelines, it
results in a substantial amount of
condensation. This leads to problems in
valves, pneumatic components and
eventually results in loss of production.
Since pressure dew point is one of the
key parameters for quality compressed
air, it should be monitored constantly.
INSTRUMENTATIONDEW POINT MONITORING
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Increased quality control in
production processes forces
manufacturers to monitor
compressed air quality
permanently in accordance with
the standards applied (DIN ISO
8573-1) and principles for quality
audits compressed air has to be
evaluated whenever it gets in
touch with the product itself.
INSTRUMENTATIONQUALITY MONITORING
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INSTRUMENTATIONLEAKAGE DETECTION
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Human Audible
20 db – 120 db
INSTRUMENTATIONLEAKAGE DETECTION
< < Ultrasonic
Gun
Ultrasonic
Gun
Ultrasonic Gun for
this range too
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Why Pressure Measurement is
Important?
Pressure drop wastes millions of
Rupees.
To overcome pressure drop and
maintain system pressure, your
compressor must draw additional
electric power.
Every 2 psi of pressure adds 1% to
the cost of electric power supplied to
the compressor.
INSTRUMENTATIONPRESSURE MEASUREMENT
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DO YOU KNOW?
COMPRESSED AIR IS 8 TO 10 TIME MORE EXPENSIVE
THAN ELECTRICITY
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COST ACCOUNTING
76%
12%12%
Operating Costs for Compressed Air Systems over 10 Years
Electricity
Maintenance
Equipment
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COST ACCOUNTING
Do you know your Compressed Air Cost per unitof Product?
Do you know about Departmental Utilizationof Compressed Air?
Have you ever calculated Annual Cost ofCompressed Air System?
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Optimize your Energy Efficiency
with VP Vision
• Real Time Insights with Energy
Management Software.
• Monitoring of Compressed air and
all other utilities in your plant.
• Departmental Usage and Cost
Calculations.
COST ACCOUNTING
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ISO8573 - THE COMPRESSED AIR QUALITY STANDARD
ISO8573 is the group of international standards relating to the quality (or
purity) of compressed air.
The standard consists of nine separate parts,
• Part 1 specifying the Quality Requirements of the compressed air
• Parts 2 – 9 specifying the Methods of Testing for a range of
contaminants
Part 1
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ISO8573 - THE COMPRESSED AIR QUALITY STANDARD
PART 2 - 5
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ISO8573 - THE COMPRESSED AIR QUALITY STANDARD
PART 6 - 9
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Specifying air quality (purity) in accordance with ISO8573-1:2010, the international
standard for Compressed Air Quality
ISO8573 - THE COMPRESSED AIR QUALITY STANDARD
QUALITY CLASSES
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How Audit Helps You
• Waste Less Air / Energy
• Reduce Compressed Air System Load
• Identify Silent Leaking Machines
• Restore Plant to Peak Efficiency
• Leads to Air Quality
• Improve Manufacturing Productivity & Quality
• Supply & Demand Side Flow Analysis
THE VALUE OF PERIODICAL THIRD PARTY AUDITS
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THE VALUE OF PERIODICAL THIRD PARTY AUDITS
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THE VALUE OF PERIODICAL THIRD PARTY AUDITS
AiiA - A Project of Potohar Center for Entrepreneurship Development
10 – 20% of the savings are commonly found on the supply
side of a compressed air system by identifying areas of
improvement in:
• Equipment
• Technology
• Controls
• Monitoring
• Equipment maintenance
• Installation issues
THE VALUE OF PERIODICAL THIRD PARTY AUDITS
SAVINGS, SUPPLY SIDE:
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A further 20 to 30% of savings are commonly found on the
demand side of a compressed air system by identifying areas
of improvement in;
• Compressed air leaks
• Artificial demand
• Improper Usage
• System design
• Monitoring & sub-monitoring
THE VALUE OF PERIODICAL THIRD PARTY AUDITS
SAVINGS, DEMAND SIDE:
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THE VALUE OF PERIODICAL THIRD PARTY AUDITS
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HEAT RECOVERY FROM COMPRESSED AIR
T.B.
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T.B.
HEAT RECOVERY FROM COMPRESSED AIR
AiiA - A Project of Potohar Center for Entrepreneurship Development
T.B.
HEAT RECOVERY FROM COMPRESSED AIR
AiiA - A Project of Potohar Center for Entrepreneurship Development
T.B.
HEAT RECOVERY FROM COMPRESSED AIR
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COMPRESSED AIR SAFETY
1. Pneumatic Safety
2. Electrical Safety
3. Safety Attire
4. Safe Working Practice
5. Site Safety Rules
6. General Safety
7. Read and Understand All Warning Labels
8. Chemical Safety
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COMPRESSED AIR SAFETY
Isolate Compressor From System
It is advisable to use an Isolation Notice so people are aware that work is being carried out.
COMPRESSED AIR SAFETY
PNEUMATIC SAFETY
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Isolate from Main Supply
Isolate the compressor unit from the main power supply.
COMPRESSED AIR SAFETY
ELECTRICAL SAFETY
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Safety Footwear
Gloves
Hard Hat
Ear Defenders/ Plugs
Safety Glasses
Coveralls
Reflective Vest / Jacket
COMPRESSED AIR SAFETY
SAFETY CLOTHINGS:
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Always use correct tools for the job
Using incorrect tools can damage components and make further maintenance difficult and costly.
e.g.Always use correctly sized spanners, never use grips or adjustable spanners.
COMPRESSED AIR SAFETY
SAFE WORKING PRACTICES
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Observe All Posted Signs and Notices
COMPRESSED AIR SAFETY
SITE SAFETY RULES
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If testing is required with unit running:-
Ensure all guards are in place.
Be aware moving parts / machines
Don’t wear long hanging cloths, neck ties
Do not play with compressed air
Do not point air hoses at anyone
Do not use compressed air to blow dirt from clothing
COMPRESSED AIR SAFETY
GENERAL SAFETY
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Warning:
Don’t attempt any servicing / maintenance without reading the manual first.
COMPRESSED AIR SAFETY
UNDERSTAND ALL WARNING LABELS
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COMPRESSED AIR SAFETY
CHEMICAL SAFETY
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THANK YOU
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