1

Compressed Dry Air System

Deo R. Ybarrita
Technical & Training Manager
 Program Agenda
 Air Requirements

 Understanding Air Compression, Distribution & Control

 Performance of compressed air system – Compressor efficiency

 Operation and control of air compressor, auxiliaries &

Accessories

 Operator care of air compressor, piping & control systems

 Monitoring & inspection of air system – Failure modes & their

effects

 Evaluation of risk of failure and fitness – for – service

 Control techniques

 Compressed air system audit

3
 Feed mill compressed air requirements

 Instrumentation
 Production pneumatic cylinders & valves
 Conveyors
 Blowers for Waste Water Treatment Plant

4
 Understanding Air Compressor
 Basic Parameters
 Pressure
 Atmospheric Pressure
 Gauge Pressure
 Absolute Pressure
 Psi or Bar
 Temperature
 Ambient temperature
 Room temperature
 Discharge temperature
 °C or °F
 Flow rate
 Volume per unit time
 l/s or cfm
 Power
 Package power
 Shaft input power
 HP or KW

5
 Understanding Air Compression
 Basic Compression
 Characteristics of compression
 Displacement
 Enclosing a volume of air and
then increasing the pressure by
reducing the area of the enclosed
volume
 Reciprocating
 Rotary
 Dynamic
 The flowing gas accelerates to a
high velocity by means of the
rotating blades, after which the
velocity of the gas is transformed
to pressure

6
 Understanding Air Compression
 Types of Compressor
 Displacement
 Reciprocating
 Piston Compressor
 Rotary
 Screw Compressor
 Other types
 Dynamic

7
 Distribution

Air Receiver Final filter

End User
Pre-filter

Compressor Refrigerated Air Dryer

8
 Control
Pg = working % RH = 14 to 26%
pressure
T out = Cooling air
+ 10 °C

Oil removal = 1 ppm Oil removal = .01 ppm

Part removal = 1 µm Part removal = 0.01 µm

T inlet < 40 °C PDP = 3 to 10 °C

Pg = 0 psi
9
 Compressor Efficiency

 % Efficiency = Output / input X 100

 CFM / shaft input power
 l/s / shaft input power

 The higher the cfm / shaft input power the more

efficient is the compressor

 The higher the motor efficiency the more

efficient is the compressor package

Power

cfm
10
 Operational and Control of Air Compressor,
Auxiliaries & Accessories

11
 Working Principle

Airflow
Oil Flow
Regulation
 Operating Principle : Air Flow
Air Intake
Air Filter Minimum Pressure Valve

Inlet Valve Air Cooler

Assembly

Compressor
Element Cooling Fan

Moisture Trap
Check Valve

Delivery Line

Float Valve
Oil/Air separator
tank

Oil Separator Element

13
 Air Flow Control
Tin < 40 °C Toutelement < Tin + 60 °C
Pin = 0 (g) Pout = WP (g)

Toutcomp = T cool air +

10 °C
Pout = WP (g)

Tout < Tin + 60 °C

Pout = WP (g)

14
 Working Principle

- Airflow

- Oil Flow
- Regulation
 Operating Principle: Oil Flow

Compressor Oil Cooler

Element
Cooling Fan
Check Valve
Thermostatic
bypass valve
Oil stop Valve

Scavenging Line

Oil/Air separator
tank Oil
Filter
Oil Line

Oil Separator Element

18
 Oil Flow Control - Loading
T = Tin + 60 °C
P = (WP – 1 to 2 bar) (g)

Tout = (Tin + 60 °C) - 25

P = (WP – 1 to 2 bar)
(g)

Tout = (Tin + 60 °C) - 25

P = (WP – 1 to 2 bar)
(g)

22
 Air Flow & Oil Flow During Loading
Tair = Tcooling air + 10 °C
P = WP (g)

Tair = Tin + 60 °C
P = WP (g)

100% in
inlet, cfm
cap
Tout = Tin + 60 °C Toil = (Tin + 60 °C) - 25
P = WP (g) P = WP (g)

23
 Oil Flow Control - Unloading
10% air
inlet, cfm T = Depends on TBV (60 to 75 °C
capacity
P = (< 1 bar) (g)

Tout = (Tin + 60 °C) - 25

P = (< 1 bar) (g)

Tout = (Tin + 60 °C) - 25

P = (< 1 bar) (g)

24
 Air flow and Oil Flow During Unloading
Tout = (Tin + 60 °C) -
25
P = (< 1 bar) (g)

10%
air
inlet,
cfm
cap
25
 Regulating System – Load / Unload

 Pressure Transducer
 Feedbacks signal to elektronikon for
data processing
 Electrical signal is 0 to 5 Vdc
 0.5 to 4.5 Vdc for 0 bar and max
pressure (bar) respectively

 Solenoid Valve
 Supplies control air into the unloader
valve during loading
 Vent the control air trap in the
unloader valve into the atmosphere
during unloading.
 Supply voltage is controlled by
elektronikon.

26
 Regulating System – Load / Unload

 Elektronikon
 Monitor
 Compares feedback data
against setting
 Provides or cuts off electrical
supply to solenoid valve

 Unloading Assembly
 Opens or close the air intake
 Control air is coming through
solenoid valve

27
 Regulating System - Unloaded
Y1 – Solenoid Valve
is de-energized

28
 Regulating System - Loaded
Y1 – Solenoid Valve
is energized

29
 Proper Operation

 Before Starting:
 Check vacuum indicator, clean or replace air
filter element if necessary
 Check Oil level, top-up if necessary
 Check belt condition if belt driven, retighten or
replace if necessary
 Check external condition of coolers, schedule
servicing if necessary
 Close the manual drain valve.

30
 Proper Operation
 During Operation
 Check vacuum indicator, schedule replacement if necessary
 Check pressure of oil separator if supported by the elektronikon
 Check if automatic drain is working, schedule immediate
servicing if malfunctioning.
 Record the operating parameter data

 Stopping the compressor

 Push program stop button
 During emergency cases, push emergency stop for the
compressor to stop immediately
 Open the manual drain valve

31
Monitoring & Inspection
 Important Parameters
Pg = working % RH = 14 to 26%
pressure
T out = Cooling air
+ 10 °C

Oil removal = 1 ppm Oil removal = .01 ppm

Part removal = 1 µm Part removal = 0.01 µm

T inlet < 40 °C PDP = 3 to 10 °C

Pg = 0 psi
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 Protections

45
 Protection
 Overheating protection
 Element out temperature
sensor – PT 1000
 Trips at 110 °C (or 120 °C)

 Over pressure protection

 Delivery pressure sensor
(for the new units)
 Electrical protection
 Can be set at
Elektronikon module (1.5
bars above maximum
working pressure MWP)
 Safety Valve
 Mechanical protection
 Setting is 1.5 bars above
MWP

46
 Protection

 Overload Protection
 Located at load side, Phase
current
 OL Setting, Phase = (FLA/1.73)
x Service Factor
 Located at supply side, FLA
 OL Setting = FLA x Service
Factor

 Phase sequence relay

(Optional)
 Protect the motor against
reverse rotation
 Protect the motor against
single phasing supply side

47
 Protection

 Short circuit protection

 Circuit breaker

 Ground fault protection

 Circuit breaker

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Elektronikon

Control and Monitoring System

 Elektronikon®
 The hardware

– compact electronic controller,

microprocessor based, with a real time
operating system
– stabilized 24 V AC, wide voltage band
power supply
(-30% to + 40%)
– ergonomic user interface (3xLEDs,
easy to read alfa-numeric display, high
quality push buttons)

50
 Elektronikon®

 Reliability
– controls and monitors compressor
and integrated ancillaries
– protects compressor
and surroundings via automatic
shut-down
in case of a fault in a vital function
– gives warnings well before shut-
down, so proactive measurements
can be taken

51
 Elektronikon®

 Service friendliness

– monitors service intervals

– generates service
‘WARNING’ messages

– easy troubleshooting and

fault-diagnosis

52
Atlas Copco Compressors

Proper Care
 Proper Care
– Compressor Elements

 Air Filter
 Must be maintained/replaced regularly

 Oil
 Right Quality is of utmost importance
 Non Foaming Property
 Correct Viscosity Grade
 Oil affects the lifetime of the bearings
 Operating temperature

54
 Proper Care
- Main Drive Motor

 Greasing
 Frequency
 Every 4,000 running hours or
 Every 2,000 running hours

 Quality
 As specified in the manual and reflected in motor
data plate
 Do not mix different type of grease

 Quantity
 As specified in manual or data plate if re-greasing
is done every 4,000 running hrs
 ½ of specified quantity if re-greasing is done
every 2,000 running hours

55
 Proper Care
- Main Drive Motor

 Re-bearing
 Every after 24,000 hours < 100 hp

 Every after 40,000 hours > 100 hp

56
 Proper Care
- Operational Integrity

 Compressor Room
 Ambient should not exceed 40°C

 Timely implementation of PMS

 Minimizes or reduced possibility of
an expensive unscheduled
shutdown Oil Separator
Air Filter
 Use of OEM Parts only

 Electrical components must be

audited or inspected every two
years Oil Filter
 Contactors Air
Compressor Oil
 Overload Relay
 Transformers
 Wire & Cables including terminal
connections

57
Atlas Copco

Preventive Maintenance Schedule

 Types of Maintenance

 Reactive/Breakdown Maintenance

 Preventive Maintenance

 Predictive Maintenance

 Preventive + Predictive Maintenance

 Practiced by Atlas Copco and Introduced through Service Plan Program

59
 Compressor filtration system

Oil Separator
Air Filter

Oil Filter
Air
Compressor Oil

60
 PMS: Preventive Maintenance Schedule
 Every 2,000 hrs
 Change Oil
 Change oil filter
 Change air filter
 For GX units: Replace oil separator
 Change drive belt/s for GX units & GA5-
GA10 units
 Grease motor bearing (if not greased for
life)
 Servicing of moisture trap

 2,000 hrs PM kit is available

 Every 4,000 hrs

 Repeat 2,000 hrs PM
 Change Oil separator for units up to 22 kW
(30 hp)
 Clean the coolers externally if the condition
demands
61
 PMS: Preventive Maintenance Schedule
 Every 6,000 hrs
 Repeat 2,000 hrs PM
 Change Oil Separator for units bigger than
22 kW (30 hp) or Delta P of 1 bar across oil
separator element if available (GA 55 &
above)
Every 12,000 hrs
 Repeat 4,000/6,000 hrs PM
 Overhaul Oil Stop Valve
 Overhaul Unloading/inlet valve
 Overhaul Minimum Pressure Valve
 Overhaul Check Valve
 Overhaul Moisture Trap
 Clean the coolers externally
Replace thermostatic by pass valve
Replace rubber coupling for non direct drive
units
 12,000 hrs PM kit is available
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 PMS: Preventive Maintenance Schedule

 > 24,000 hrs

 Repeat 12,000 hrs PM
 Overhauling of compressor
elements ( depend on SPM Reading
for GA 30 up to 90C)
 Overhauling of the drive
arrangement
 Re-bearing of the electric motors
( SPM Reading)
 Re-conditioning of electric motors
Internal cleaning of oil cooler

63
 Troubleshooting

78
 Troubleshooting
 Overheating:
» Causes, Prevention & Solution

 Not Loading or Not Unloading:

» Systematic approach

 Water & Oil Mixture in air receiver

 Water in the Air System
 High Oil carry-over: oil in the air
system at receiver or end use
 Air/Oil mixtures back-flow in Air
intake filter element.
 Electrical Failure:
 Causes, Prevention & Solution

79
 Troubleshooting
 Compressor overheating
 High ambient/room temperature
 Very low oil level
 Clog air filter
 Clog oil separator element
 Clog cooling fins of oil cooler
 Oil cooler clog internally
 Clog oil filter – insufficient cooling during unloading
 Oil stop valve stuck up at close position
 Thermostatic by pass valve stuck up at by passed
position
 Malfunctioning cooling fan motor & damaged cooling fan

80
Overheating Problem
>40 °C Oil cooler, internally

 High ambient / room temperature

 Very low oil level
 Clog cooling fins Cooling fins

 Oil cooler clog internally

 Clog oil filter - OF

Low oil level

OF

81
 Overheating Problem Oil separator AF Motor & fan

 Malfunctioning cooling motor or

damaged cooling fan
 Clog air filter - AF
 Clog oil separator
 Oil stop valve stuck up at close
position – OSV OSV
 Stuck up thermostatic by pass
valve at by passed position – TBV

TBV

82
 Troubleshooting Scavenging Line

 Excessive oil carry over

 Wrong oil use
 Clog scavenging line
nozzle
 Clog oil separator OS
element, OS
 Damaged oil separator Tank
element, OS
 Leaking o – ring &
fittings inside oil/air
separator tank
 Internal condensation Oil

83
 Clog OS
Troubleshooting P < MWP
Inlet or discharge

 Compressor overloading
 Clog oil separator
element, OS
 High operating pressure
(should be less than the
CV
MWP)
 Bearing problem for the
compressor element –
Inlet or discharge side
 Bearing problem for the Drive end or N Drive end
motor – Drive End or N
Drive End
 Leaking check valve CV
– trip during starting

84
 Troubleshooting P
Loose
con. KO4 P set
to SV
 Compressor not sensor
loading
 Loading pressure
setting is below
operating pressure
(with other units)
 Malfunctioning
pressure sensor
 Upper solenoid Upper
valve plunger plunger
leaking
 No supply voltage
for solenoid valve
SV
 KO4 always open
 Loose
connection
loading circuit KO4
 Open solenoid Open Supply inside
coil voltage module
valve coil
85
 KO4
Troubleshooting inside
module
Seal ring
 Compressor not & o ring
loading
 Open contact from
KO4 relay
(Elektronikon
module)
 Leaking switching
valve & broken
spring for
unloading valve
assembly
 Inlet valve stuck
up at closed
position
 Leaking loading
piston seal ring Inlet valve
and o-ring
 Leaking pilot air
Switching Pilot air
line
valve &
Spring

86
 Troubleshooting Plant Pressur P
deman e sensor settin
d g
 Compressor not
unloading/partial loading
 High unloading
pressure setting
(with other units)
 High plant demand
 Air leak Leaking
plunger
 Malfunctioning
pressure sensor
 Leaking lower
solenoid valve
plunger
 Inlet valve stuck up
at open position
 Clog pressure sensor
- air side Inlet
IV valve
 Broken inlet valve Spring
spring
87
 Compressed Air Audit

 Air Leakages
 Moisture content & Relative humidity
 Room Lay out & Ventilation
 Restrictions on air filters, oil separator & line filters

92
 Control
Pg = working % RH = 14 to 26%
pressure
T out = Cooling air
+ 10 °C

Oil removal = 1 ppm Oil removal = .01 ppm

Part removal = 1 µm Part removal = 0.01 µm

T inlet < 40 °C PDP = 3 to 10 °C

Pg = 0 psi
93
 Air Leakage

94
 Air leakage and corresponding Power Consumption

EQUIVALENT AIR LEAKAGE COMPRESSOR POWER COST PER

HOLE DIAMETER @ 7 BAR REQUIREMENT YEAR
(mm) (L/sec) (cfm) ( Kw ) ( hp ) (PHP)

1 0.9 1.9 0.3 0.4 12,000

2 3.6 7.6 1.3 1.8 52,000
5 22.5 48 8.1 11 324,000
10 88 186 32 44 1,280,000

Power Rate = PHP/kw – hr = 5

95
 Water in Compressed Air System

96
 Compressed Air Quality Dry Air,
After AR Design
– Wet Air %RH = 15
Delivery
– Wet Air to 26

Air
Receiver
, AR –
Wet Air

Air Inlet –
Depends on
% RH at site

97
 Water entering the system = 39.286 g/m³ x 0.85 x
Water in the system 200 liters/s x 60 s/min x 60 min/hr x m³/1000 liters x
24 hrs/day = 577,032.768 g/day x liters/1000 g =
577.032768 liters/day ≈ 577 liters/day
 Compressor with a working
pressure of 7 bar (e),
compressed the air to 1/8 of the
7 bar (e)
volume.
 How much water enter the
system in liters/day?
 Answer: 577 liters/day

577 l/day
of water

Inlet: 35 °C, 85
% RH, 200 l/s

98
 Water in the system
 How much water separated at the air cooler °C
 Answer = 437 l/day of water or condensates

 How much water enter to the air net at a temperature of 45 °C?

 Answer = 140 l/day of water or condensates

At 45 °C (Tamb + 10) after air cooler, 64.848 g/m³

How much water goes to the air receiver = 64.8 g/m³ x 90
m³/hour x 24 hrs/day = 139,968 g/day x liter/1000 g =
Inlet: 35 °C, 139.968 liters/day ≈ 140 l/day

85 % RH, 200
577 l/day 140 l/day
l/s of water of water

How much water is separated = 39.286 g/m³ x 0.85 x 8 (P.R.) – Outlet: 45 °C, 100 %
64.8 g/m³ = 202.3448 g/m³ x 90 m³/hr x 24 hrs/day = RH, 200 l/s, 7 bar (e)
437,064.768 g/day x liter/1000 g = 437 liters/day
Or = 577 – 140 = 437 liters/day (at 35 °C, 85% RH, FAD of 200 437 l/day
l/s) of water

99
 Water into the FD dryer = 50.672 g/m³ x 200 l/s x
Water in the system 3600 s/hour x 1/8 x m³/1000 l x l/1000 g x 24
hours/day = 109.45 l/day

 From the set up: Comp > Air 45 7 bar 109.45

Receiver > FD dryer 32 °C
°C (e) l/day
 How much water separated at
the moisture trap of the Air
Receiver in liters/day?
 Answer: 30.62 l/day
 How much water enter the FD
dryer in liters/day? 40 °C
 Answer: 109.45 l/day
30.62
l/day
Condition: Air temperature going to air receiver, 45 °C =
64.848 g/m³, for a dT of 5 °C, the temperature of
air leaving the air receiver is 40 °C = 50.672 g/m³
Solutions:
Water separated at air receiver = (64.848 g/m³ - 50.672 Inlet: 35 °C, 85
g/m³) x 200 l/s x 3600 s/hour x 1/8 x m³/1000 l x
l/1000g x 24 hours/day = 30.62 l/day % RH, 200 l/s

100
 Water in the system
7 bar Water into
 From the set up: Comp > Air 40 °C air net =
(e)
Receiver > FD dryer 12.86
l/day
 How much water separated at
the moisture trap of FD dryer 32
 Answer: 96.59 l/day
°C
 How much water enter the air net
(leaving the dryer) with a PDP or
LAT of 3 °C?
 Answer: 12.86 l/day

Water separated at moisture of FD dryer =

(50.672 g/m³ - 5.953 g/m³) x 200 l/s x 3600 Water
s/hour x 1/8 x m³/1000 l x l/1000g x 24 PDP = 3 sep =
hours/day = 96.59304 l/day ≈ 96.59 l/day °C 96.59
l/day
Water into the FD dryer = 5.953 g/m³ x 200 l/s x
3600 s/hour x 1/8 x m³/1000 l x l/1000 g x 24 Inlet: 35 °C, 85
hours/day = 12.85848 l/day ≈ 12.86 l/day % RH, 200 l/s
101
 %
Water in the system 32 RH ?
°C
 What is the relative humidity
of compressed air leaving the
dryer?
 Answer: % RH = 18

%
RH =
PDP = 3
°C
18

Condition: % RH = (Actual moisture content, g/m³) / possible moisture content

at given temperature, g/m³ x 100
Actual moisture at PDP of 3 °C = 5.953 g/m³
Possible moisture at given temperature of 32 °C = 33.490 g/m³
Solution: % RH = (5.953 g/m³) / (33.490 g/m³) x 100 = 17.17 ≈ 18
Note: Design Delta T between dryer inlet & outlet = 8 °C, 40°C – 8°C = 32°C

102
 Room Lay Out & Ventilation

103
 Compressor Room Layout

Wall

A A
Wall
Compressor Wall

A = 1000 mm, Minimum

104
 Compressor Room Layout

Wall

Comp 1
>A
>A
A

Comp 2

A = 1000 mm, Minimum

105
 Compressor Room Ventilation
dp max across ducting < 30 Pa
 Limit temperature rise to 5 °C
 Maximum pressure drop of 30 Pa for
ducting
 Maximum length of 6 meters
 Maximum bends of 2 dT < 5 ˚C
 Cross sectional area of ducting should be >
the area of the base.

 Ventilation air from coldest and Compressor

cleanliest location
 Ventilation requirements
 Where:
 Qv – Required ventilation capacity in
m³/s
 N – Shaft input of compressor in kw
 dT – Temperature increase in
compressor room in °C

106
 Compressor Room Ventilation

 Installation of Pre Filter for dusty

surroundings
 Ventilation with louvers and grid Max T < 40 ˚C
multiply area by 1.7
 Effective area is decreased to 60%
with installed louvers

 Ventilation Air Speed

Compressor
 Maximum air velocity through
unrestricted opening is 5 m/s
 For motor cooling

 Maximum air inlet temperature

 40 °C

High air intake temperature causes a decrease in mass flow

approx.3 % for each 10°C above normal ambient temperature, 0 % RH.

107
 Material Specification

108
 Committed to
sustainable productivity.

113
114