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