COMPRESSED AIR SYSTEM

PRESENTED BY : SAMUEL. A (PT. KARYA INTERTEK KENCANA)

TRAINING MATERIAL

A. COMPRESSED AIR SCHEMATIC

B. MAIN EQUIPMENT

C. PIPE SIZING

D. AIR DISTRIBUTION

E. AIR CLEANLINESS
A. COMPRESSED AIR SCHEMATIC
 A. COMPRESSED AIR SCHEMATIC
Compressed Air System consist of 3 major sub systems :
1. Compressor 2. Conditioning Equipment 3. Air Distribution
Drives & Controls After coolers Main trunk lines
Inter-cooling Receivers Drops to usage
Compressor cooling Separators Valving
Waste heat Traps Additional filters
recovery Filters Additional traps
Air inlet filtration Air dryers Air hoses
Connectors
Pressure regulators
Etc
 A. COMPRESSED AIR SCHEMATIC
The important components of the system :
1. Inlet filter : removes particle from the air entering the compressor
2. Compressor : compresses air to a smaller volume, increasing the pressure
3. Motor : drives the compressor
4. Compressor controller : direct the compressor’s output
It may be microprocessor, electromechanical or pneumatically based
5. After cooler : lowers the temperature of the air, thus condensing & removing the water
6. Separator : removes liquids from the compressed air. Installed after the aftercooler
7. Receiver : stores a large reserve of compressed air to maintain a smooth flow to the plant
8. Air filter : removes solids & liquids from the compressed air stream
9. Dryer : eliminate remaining moisture in the compressed air
10. Condensate trap : collects & discharges liquid that condenses out of the air stream
11. Distribution piping : distributes the compressed air
Main header – Branch lines – Sub headers – Drop points – Individual tools/ machines
12. Pressure regulator : controls air pressure & flow at individual point of use
 B. MAIN EQUIPMENT

1. COMPRESSOR
2. AIR FILTER
3. AIR RECEIVER
4. AIR DRYER
5. DISTRIBUTION PIPING
6. DRAIN/ CONDENSATE
 B. MAIN EQUIPMENT
1. COMPRESSOR
A compressor is a device that compresses a gas or air to a
pressure higher than atmospheric pressure
If the pressure is lower than the atmospheric pressure,
the instrument is called a vacuum pump.
If the compression ratio is 1.25 or lower, then it is called
a fan
If the compression ratio is 1.25-2, then the equipment is
known as a blower
Above 2.0 compression ratio equipment is called
a compressor
 B. MAIN EQUIPMENT
1. COMPRESSOR
A compressor is a device that compresses a gas or air to a
pressure higher than atmospheric pressure

P xV
T
 B. MAIN EQUIPMENT
1. COMPRESSOR
 B. MAIN EQUIPMENT
1. COMPRESSOR
Positive Displacement Compressor
a. Work at a constant flow regardless of
outlet pressure
b. Inlet pressure, volume flow and pressure
ratio influence the power consumption
c. Inlet air temperature and mass flow
(density) have no effect to power

Dynamic Compressor
a. Work at a constant pressure
b. Inlet temperature and mass flow
(density) have a direct effect to power
B. MAIN EQUIPMENT
 B. MAIN EQUIPMENT
TYPES OF COMPRESSOR
1. Compression stages 4. Lubricant
a. Single stages a. Dry/ oil free/ non-lubricated
b. Multiple stages (Rotary screw, lobe,
2. Type of cooling reciprocating, centrifugal)
a. Air-cooled b. Lubricated
b. Water-cooled (Rotary screw, lobe,
c. Oil-cooled reciprocating)
3. Type of drive 5. Operating pressure
a. Electric motor a. Low (0 – 150 Psi)
b. Engine (Diesel) b. Medium (151 – 1.000 Psi)
c. Steam/ turbine c. High (> 1.000 Psi)
 B. MAIN EQUIPMENT
WORKING PRINCIPLES OF GENERAL COMPRESSOR
 B. MAIN EQUIPMENT
2. AIR FILTER
Selected based on air flow rates & pressure drop
Air filter can be devided into two
categories :
1. Pre-filters
Operate prior to compression
and/ or drying
2. After-filters
Put in place after the air is dried
 B. MAIN EQUIPMENT
3. AIR RECEIVER
An air receiver is a storage vessel for compressed air that acts as a
buffer reservoir so that short-term demand spikes can be met.
Function :
a. Create more stable pressure conditions
b. Work to dampen compressor pulsation
c. Separate out particles and liquids
d. Prevent frequent compressor start or a standby start events
e. Accommodate large intermittent system air demand
f. Meet sudden high rate-of-flow requirement of critical pressure
users
g. Act as secondary cooling device
h. Act as a condensate collector
 B. MAIN EQUIPMENT
3. AIR RECEIVER

Sizing air receiver tank

One Gallon of receiver volume per SCFM of air
Receiver inlet & outlet
Inlet should be located at lower portion of the vessel and the
discharge in the upper portion to assist the settling of moisture

Receiver location
Avoid placing any receiver upstream of dryers or filters
Always be installed downstream of air treatment to avoid surges
across this equipment that could result in carry-over to the system
 B. MAIN EQUIPMENT
4. AIR DRYER
Atmospheric air has humidity or contains some water vapor
The most noticeable and easily removable forms of moisture are
water and aerosol (vapor)
The table below provides a comparison guideline for air dryness :
 B. MAIN EQUIPMENT
4. AIR DRYER
 B. MAIN EQUIPMENT
4. AIR DRYER
 B. MAIN EQUIPMENT
4. AIR DRYER
The factor to be considered for selecting a dryer :
a. The required dewpoint temperature
b. Initial cost
c. Ongoing maintenance requirements

There are 5 main types of dryer :

a. Refrigerant Dryer (35oF to 50oF Dew Point)
b. Desiccant Dryer (-40oF to -100oF Dew Point)
c. Deliquescent Dryer (50oF to 52oF Dew Point)
d. Membrane Dryer (40oF to -40oF Dew Point)
e. Sorption Dryer (5oF to -40oF Dew Point)
 B. MAIN EQUIPMENT
4. AIR DRYER
REFRIGERANT DRYER
 B. MAIN EQUIPMENT
4. AIR DRYER
DESICCANT DRYER
 B. MAIN EQUIPMENT
4. AIR DRYER
DESICCANT DRYER
 B. MAIN EQUIPMENT
4. AIR DRYER
DELIQUESCENT DRYER
 B. MAIN EQUIPMENT
4. AIR DRYER
MEMBRANE DRYER
 B. MAIN EQUIPMENT
4. AIR DRYER
SORPTION DRYER
 B. MAIN EQUIPMENT
5. DISTRIBUTION PIPING (MATERIAL)
Table 1: Piping Material Features and Characteristics

Extruded Aluminum
Piping Features Stainless Steel Black Iron Copper Alloy

Schedule 10 Schedule 40
Light Light
Weight Lighter Heavy

Corrosion Resistant Yes No Yes Yes

Vulnerable to Friction-
No Yes No No
generated Pressure Loss

Mechanical Strength Very Strong Very Strong Strong Strong

High Temperature Rating Yes Yes Yes Yes

Installation Ease Less Difficult Difficult Less Difficult Easy

Installation Cost
30% / 70% 25% / 75% 40% / 60% 80% / 20%
Material%/Labor%

Special Tools Required

Some
(welder, threader, groove Yes Yes No
(solder)
cutter)
 B. MAIN EQUIPMENT
5. DISTRIBUTION PIPING (LAYOUT)
a. SINGLE MAIN
 B. MAIN EQUIPMENT
5. DISTRIBUTION PIPING (LAYOUT)
b. RING MAIN
 B. MAIN EQUIPMENT
6. DRAIN/ CONDENSATE
In order to remove the water, drain traps
(preferably an automatic drain) should be
fitted to the drip legs
A drip leg is an extension of pipe below the
airline that is used to collect condensation in
the pipe
Drip legs should be installed at all low points
in the system
The recommended distance between drain
points is approximately 100 feet
The main header pipe in the system should
be sloped downward in the direction of the
compressed air flow. A general rule of thumb
is 1 cm per 1 m of pipe
C. PIPE SIZING
C. PIPE SIZING
D. AIR DISTRIBUTION
D. AIR DISTRIBUTION
 E. AIR CLEANLINESS
ISO 8573 : 2010 Compressed Air

Part 1 : Contaminant and Purity Classes

Part 2 : Test method for oil aerosol content
Part 3 : Test method for measurement of humidity
Part 4 : Test method for solid particle content
Part 5 : Test method for oil vapor and organic solvent content
Part 6 : Test method for gaseous contaminant content
Part 7 : Test method for viable microbiological contaminant content
Part 8 : Test method for solid particle content by mass concentration
Part 9 : Test method for liquid water content
 E. AIR CLEANLINESS

ISO 8573 : 2010 Compressed Air

Part 1 : Contaminant and Purity Classes
E. AIR CLEANLINESS

Dirt Oil

Dirt Dirt

Water/moisture
 E. AIR CLEANLINESS
BEWARE !!!
PIPE LEAKAGE WATER/ MOISTURE DIFUSES TO SYSTEM
UNIT CONVERSION