COMPRESSED AIR SYSTEMS
PHILIPPINE SOCIETY OF MECHANICAL
ENGINEERS
PROFESSIONAL DEVELOPMENT COURSE
PSME NATIONAL H.Q.,
19 SCOUT BAYORAN ST., QUEZON CITY
RESOURCE SPEAKER:
ERNESTO J. CASIS, PME
PSME NATIONAL PRESIDENT – Year 2001
COMPRESSED AIR APPLICATIONS
ELECTRONICS/SEMICONDUCTOR
GLASS AND PACKAGING PLANTS
SHIPYARDS
STEEL MILLS
BREWERY
MINING
INSULATION PLANTS
CHEMICAL PLANTS
SUGAR MILLS
POWER PLANTS
SNOW MAKING
AIRLINES
TIRE MANUFACTURING
FOOD PLANTS
FLOUR MILLS
PETROCHEMICAL PLANTS
CONSTRUCTION
CAR MANUFACTURERS
CEMENT PLANTS
PAPER MILLS
TEXTILE MILLS
OIL REFINERIES
PHARMACEUTICAL PLANTS
PLASTIC MANUFACTURING
PRINTING PLANTS
GAS SERVICE STATIONS
OTHERS
COMPRESSED AIR
DISTRIBUTION SYSTEMS
AIR COMPRESSOR
AIR INLET FILTER-SILENCER
AFTERCOOLER
AIR RECEIVER
AIR DRYER
DRAIN TRAPS
CLOSED LOOP PIPING
ELECTRICS
Compressed Air must be treated as a
system
Compressed Air Distribution
Compressed Air Distribution
Closed Loop System
Typical Compnents of Demand
Typical Components of Air Demand
Artificial
Demand
10-15%
Production
Leaks 25 -30%
Poor Practices
5-10%
AIR COMPRESSOR
TYPE – RECIPROCATING, ROTARY SCREW,
CENTRIFUGAL, ROTARY DRY LOBE, ROTARY VANE
LUBRICATED OR NON-LUBRICATED/OIL-FREE
AIRCOOLED, WATERCOOLED, OR OIL-COOLED
STANDARD OR PACKAGE
STATIONARY OR PORTABLE
ENCLOSED OR UNENCLOSED
FOUNDATION MOUNTED OR NO FOUNDATION
MOTOR DRIVEN, ENGINE DRIVEN,OR TURBINE
DRIVEN
POSITIVE DISPLACEMENT
MACHINES
UNITS WHERE SUCCESSIVE
VOLUMES OF AIR ARE CONFINED
WITHIN A CLOSED SPACE AND
ELEVATED TO A HIGHER PRESSURE
COVERS RECIPROCATING, ROTARY
SCREW, ROTARY VANES, AND LOBE
UNITS
RECIPROCATING OR PISTON
TYPE
POSITIVE DISPACEMENT MACHINES IN WHICH
COMPRESSION AND DISPLACING ELEMENT IS A
PISTON HAVING A RECIPROCATING MOTION
WITHIN A CYLINDER.
STAGES – SINGLE, TWO STAGE, OR
MULTISTAGES
INTERCOOLED FOR TWO OR MULTISTAGE UNIT
SINGLE ACTING OR DOUBLE ACTING
LUBRICATED OR NON-LUBRICATED/OIL-FREE
CYLINDER
VERTICAL OR HORIZONTAL CONSTRUCTION
STANDARD OR PACKAGE UNIT
AIRCOOLED OR WATERCOOLED
Compressed Air Distribution
Single Main (Grid system)
ROTARY SCREW TYPE
POSITIVE DISPLACEMENT MACHINES
IN WHICH COMPRESSION AND DISPLACEMENT IS
EFFECTED BY THE POSITIVE ACTION OF THE ROTATING
ELEMENT
TWO INTERMESHING ROTORS EACH WITH HELICAL FORM
COMPRESS AND DISPLACE THE AIR.
SINGLE OR TWO STAGE
INTERCOOLED FOR TWO STAGE
LUBRICATED OR OIL-FREE
AIR COOLED OR WATERCOOLED AFTERCOOLER
PACKAGE UNIT
ENCLOSED OR UNENCLOSED UNIT
FOUNDATION NOT NECESSARY
ROTARY VANE TYPE
ROTARY POSITIVE DISPLACEMENT
MACHINES IN WHICH AXIAL VANES
SLIDE RADIALLY IN A ROTOR
ECCENTRICALLY MOUNTED IN A
CYLINDRICAL CASING
INTERCOOLED FOR TWO STAGE
LUBRICATED UNITS
PACKAGE UNITS
DYNAMIC MACHINES
ROTARY CONTINOUS-FLOW
MACHINES IN WHICH THE RAPIDLY
ROTATING ELEMENT ACCELERATES
THE AIR AS IT PASSES THROUGH
THE ELEMENT CONVERTING THE
VELOCITY HEAT INTO PRESSURE,
PARTIALLY IN THE ROTATING
ELEMENT AND PARTIALLY IN THE
DIFFUSER
LOBE TYPE
ROTARY POSITIVE DISPLACEMENT
MACHINES IN WHICH TWO LOBES
TRAP THE AIR AND CARRY IT FROM
INTAKE TO DISCHARGE
LIMITED FROM SMALL TO MEDIUM
CAPACITIES
INTERCOOLED FOR TWO STAGE
OIL-FREE UNITS
PACKAGE UNITS
COATED OR STAINLESS ROTORS
CENTRIFUGAL TYPE
DYNAMIC MACHINES IN WHICH ONE OR MORE
IMPELLERS USUALLY SHROUDED ON THE SIDES
ACCELERATE THE AIR. MAIN FLOW IS RADIAL.
CONVERTS VELOCITY ENERGY INTO PRESSURE
ENERGY WITH THE AID OF DIFFUSER.
INTERCOOLED FOR TWO OR MULTISTAGE UNIT
OIL FREE UNITS.
PACKAGE UNITS.
ENCLOSED OR UNENCLOSED UNITS.
FOUNDATION NOT NECESSARY.
BEST FOR BASE LOAD OPERATION
AIR COMPRESSOR
REGULATION CONTROL
AUTOMATIC START AND STOP
CONTROL
CONSTANT SPEED CONTROL
MODULATION CONTROL
AUTO DUAL CONTROL
SEQUENCE CONTROLLER
LOAD FACTOR
THE RATIO OF ACTUAL COMPRESSED AIR
OUTPUT (UNIT OPERATING) TO THE
RATED FULL LOAD OUTPUT AT SAME
PERIOD
50% TO 80% IS RECOMMENDED
RESULT IN: MORE UNIFORM PERIOD EVEN
DURING PEAK DEMAND, COOLING OFF
PERIOD,LESS MAINTENANCE, AND
ABILITY TO INCREASE USE OF AIR
WITHOUT INCREASE IN PLANT SIZE
TECHNICAL INFORMATION
NEEDED TO SELECT AN AIR
COMPRESSOR
ANALYSIS – AIR OR GAS
QUANTITY
INLET CONDITION- BAROMETRIC PRESSURE, PRESSURE AT
COMPRESSOR FLANGE, TEMPERATURE AT COMPRESSOR
FLANGE,RELATIVE HUMIDITY
STANDARD CONDITONS- PLACE OF MANUFACTURE
DISCHARGE CONDITION- PRESSURE AT DISCHARGE FLANGE
REGULATION
COOLING WATER – TEMPERATURE, PRESSURE, WATER
CONDITION
HEAT EXCHANGERS- INTERCOOLERS, AFTERCOOLER
REQUIREMENT
DRIVER- ELECTRIC MOTOR, STEAM, OR GAS TURBINES
MOTOR OR DRIVER CONTROL
LUBRICANTS
PNEUMATIC TOOL USE FACTOR
PERCENT OF TIME THE TOOL
ACTUALLY IS USED – NEEDED IN
DETERMINING THE TOTAL CAPACITY
FORMULA: NO. OF TOOL X USE
FACTOR X VOLUME OF AIR
REQUIRED BY THE TOOL
UNITS OF MEASUREMENTS
CAPACITY OR VOLUME – CFM OR
M3/MIN
PRESSURE – PSIG, KGS/CM2, BARS,
PA, KPA
POWER – BHP, NOMINAL HP, KW
SPECIFIC POWER
CONSUMPTION
(BHP/100 CFM)
ACCESSORIES
INLET-FILTER SILENCER – DUST OR CHEMICAL TYPE, COMPRESSOR MOUNTED OR
PIPED OUTSIDE THE BUILDING
AFTERCOOLER – AIR OR WATERCOOLED TYPE
DRAIN TRAPS- AUTOMATIC MECHANICAL OR ELECTRONIC TYPE
AIR RECEIVER- ASME SYMBOL, VERTICAL, WITH PRESSURE GAGE, SAFETY VALVE
AND SERVICE VALVE
AIR DRYER- REFRIGERATED, CHEMICAL, DESSICANT TYPE ( HEATLESS OR HEAT
REACTIVATED)
CLOSED LOOP COOLING SYSTEM- COOLING TOWER, FRP
MOTOR CONTROL – MAGNETIC REDUCED VOLTAGE STARTER, AUTOTRANSFORMER,
REACTOR TYPE, SOFT START, DIRECT ON – LINE/FULL VOLTAGE
MOTORS- INDUCTION TYPE, 3-PHASE, 60 HZ, 1800 OR 3600 RPM
OR ENERGY EFFICIENCY PERMANENT MAGNET MOTOR ( 0
TO FULL RPM ) VARIABLE SPEED DRIVE, VARIABLE FREQUENCY DRIVE
NL MODULE
COMPRESSOR COOLANT/FLUID- SYNTHETIC OR MINERAL
MAIN AIR PIPING
COST REPRESENTS HIGH PROPORTION OF
THE INITAIL COST OF COMPRESSED AIR
INSTALLATION.
USING REDUCED DIAMETER PIPE MIGHT
SAVE ON CAPITAL COST BUT GREATER
PRESSURE DROP IN THE SYSTEM
RESULTS I HIGHER OPERATING COSTS
WHICH WOULD SOON EXCEED THE PRICE
OF A LARGER DIAMETER PIPING.
BASIC SYSTEM FOR MAIN AIR PIPING
(REFER TO FLWG SLIDES)
MAIN AIR PIPING
DETERMINE DIAMETER OF PIPE BY RESTRICTING
FLOW TO 6.0M/SEC TO AVOID EXCESSIVE
ENERGY LOSS.
FORMULA: ACTUAL VELOCITY
1273Q
V =--------------
(P+1)D2
WHERE:
V= FLOW VELOCITY, M/SEC
Q= FREE AIR FLOW RATE, M/SEC
P= AIR PRESSURE, BAR(G)
D= PIPE INTERNAL BORE, MM
MAIN AIR PIPING
FORMULA:
212xQ
D(mm) =
(P+1)
D= MINIMUM INTERNAL DIAMETER
OF AIR MAIN PIPING IF FREE AIR
FLOW IS KNOWN TO ENSURE VELOCITIES
BELOW 6M/SEC.
MAIN AIR PIPING
D, mm SHOULD BE GREATER THAN
5 Q - FOR STANDARD INSTALLA-
TION WITH A LINE PRESSURE IN
THE REGION OF 7 bar(g)
MAIN AIR PIPING
D, mm should be greater than 5 Q
ABOVE IS FOR INSTALLATIONS WITH A
LINE PRESSURE IN THE REGION OF 7
BARS.
MAIN AIR PIPING
FORMULA:
212 x Q
D, mm=
(P + 1 )
IF FREE AIR FLOW IS KNOWN THE
MINIMUM INTERNAL DIAMETER OF THE
AIR MAIN TO ENSURE VELOCITIES BELOW 6
M/SEC CAN BE COMPUTED FROM THE ABOVE
FORMULA.
BRANCH AIR PIPING
FORMULA:
(P + 1) D2
Q=
85
D,mm = INTERNAL BORE OF PIPE
Q, l/s = FREE AIR FLOW RATE
P,bar(g)=AIR PRESSURE
MAIN LINE PIPING MATERIALS
MAIN LINE PIPESSYSTEMS CAN BE OF FLWG:
STEEL- BLACK OR GALVANIZED FORM( LESS ABLE TO
CORRODE).FOR OVER 65mm NOMINAL BORE, WELDED
FITTINGS ARE RECOMMENDED. BELOW 65mm- SCREW
FITTINGS ARE USED.
STAINLESS STEEL – FOR CLEAN AIR REQUIREMENT LIKE
ELECTRONICS AND PHARMACEUTICAL.
COPPER – TUBING MAY BE USED FOR MAIN PIPE WITH A
NOMINAL DIAMETER OF UP TO 40 mm.
THERMOPLASTICS-SHOULD NOT BE
USED AS SYNTHETIC OILS AND OTHER MINERAL OILS WILL
DEGRADE IT.
RESERVE AIR CAPACITY
TO PROVIDE LARGE VOLUME OF AIR FOR A SHORT PERIOD AVOIDING LARGE PIPE INSTALLATION
WITH MINIMUM PRESSURE DROP, AN AUXLIARY AIR RECEIVER CAN BE INSTALLED CLOSE TO THE
EQUIPMENT.
REQUIRED AIR RECEIVER CAPACITY (lit)
DEMAND PER OPERATION ( lit. free air)
PRESSURE DROP (bar)
IMPT: CHECK THAT THE COMPRESSOR IS LARGE ENOUGH
TO RECHARGE THE AIR RECIVER UP TO THE ORIGINAL
PRESSURE BEFORE THE NEXT PERIOD OF HIGH DEMAND.
FORMULA:
∏ x D2 x L
RECEIVER CAPACITY(lit) =
4
LEAKAGE RATE IN PIPING
FORMULA:
V x (P1-P2)
LEAKAGE,lit/sec =
T
where: V= volume of main air piping
downstream of air receiver
including all branch and drop
pipes , liters
P1= system pressure without leak, bar
P2= system pressure with leak, bar
t= time,secs
P1-P2 = pressure drop
THE RECEIVER VALVE SHOULD BE CLOSED AND ISOLATE
ALL TOOLS AND EQUIPMENT. CHECK THE TIME FOR THE SYSTEM
TO LEAK DOWN TO A LOWER PRESSURE.
LEAKAGE RATE IN MAIN PIPING
FORMULA:
V x (P1-P2)
L.R. =
T
where: L.R. = LEAKAGE RATE, lit/sec
V = VOLUME OF AIR MAIN PIPING DOWNSTREAM
OF AIR RECEIVER ISOLATING VALVE AND ALL
BRANCH AND PIPE. WITH COMPRESSOR,
PUMP THE WHOLE SYSTEM TO NORMAL
OPERATING PRESSURE AND SHUTDOWN.
P1= NORMAL OPERATING PRESSURE,bar
P2= LOWER PRESSURE DUE TO LEAKAGE, bar
P1-P2 = PRESSURE DROP
T= TIME, secs –FOR SYSTEM TO LEAK DOWN TO
LOWER PRESSURE
Compressed air leaks
Pressure Psig 1/64 1/32 1/16 1/8
90 0.37 1.48 5.92 23.7
100 0.406 1.62 6.49 26
110 0.441 1.76 7.05 28.2
120 0.476 1.91 7.62 30.5
125 0.494 1.98 7.9 31.6
150 0.582 2.37 9.45 37.5
Discharge in CFM at the differential stated to atmospheric pressure,
for e.g. system pressure of 110psig will discharge 7.05 cfm through a 1/16” orifice
POWER COST FORMULA
ANNUAL POWER COST (APC )
(BHP/100 CFM) X O.746
________________________________ X HRS OPN/YEAR X COST OF POWER/KW.HR X TOTAL CFM
MOTOR EFFICIENCY X POWER FACTOR
WHERE: APC = ANNUAL POWER COST
BHP/100 CFM = SPECIFIC POWER CONSUMPTION
0.746 = BHP TO KW
MF = MOTOR EFFICIENCY
PF = POWER FACTOR OF MOTOR
NO. OF HOURS OPERATION PER YEAR = NET OF MAINTENANCE SHUTDOWN
COST OF POWER/KW HR = INDUSTRIAL POWER RATE BY MERALCO OR NPC OR
IN HOUSE POWER GENERATION UNIT
EFFECT OF ALTITUDE ON
COMPRESSOR CAPACITY AND
POWER
REDUCTION FOR EACH 1000 MTRS ABOVE SEA
LEVEL
FAD BHP
SCREW 0.8 4.0
2-STAGE AIRCOOLED 2.0 7.5
2-STAGE WATERCOOLED 1.8 6.0
SINGLE STAGE SINGLE
ACTING 5.0 6.0
AIRCOOLED 5.0 6.0
Computing Energy Costs
Hp BHP
Kw
HP = BHP
Motor Efficiency
COMPRESSOR
MANUFACTURERS SERVICES
SERVICE TRAINING- FACTORY AND
LOCAL
MAINTENANCE CONTRACT-
PREDICTIVE
OIL AND WATER ANALYSIS
ENERGY AUDIT
AIR SURVEY
END OF SESSION
THANK YOU!!!!
