presentation compressed air pn111, en
TRANSCRIPT
DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Modern industrial pneumatics (PN111)Training course
Compressed air generation and preparation
DC-I/Levent Unan Presentation: Compressed air 18 December 2008
1 Compressor2 Cooler3 Condansate separator4 Receiver5 Condensate drain6 Pre-filter7 Dryer8 Electronic purgier9/10/11 Class filters12 Water and oil seperator
Compressed air generation and preparation
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Type of compressors
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Compressors
Positive displacement
Dynamic
Reciprocating
Rotary
Centrifugal
Axial
DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Reciprocating compressor (single stage)
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Reciprocating compressor (double stage)
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Lubrication free screw compressor
External gear mechanism
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Centrifugal compressor
Single stage
Multistage
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Receiver1 Check valve2 Pressure gauge3 Receiver4 Drain valve5 Safety valve
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Dryers remove water vapor from the air, which lowers its dew point, which is the temperature to which air can be cooled before water vapour begins to condense.
There are many types of air dryers, the most common ones are:
•Refrigerant •Dessicant•Membrane
Air drying
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Air drying
Drying methods according to Class requirement
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Class Residual Oilµm mg/m³ DTP [°C] g/m³ mg/m³
1 0,1 0,1 -70 0,003 0,012 1 1 -40 0,12 0,13 5 5 -20 0,88 14 15 8 +3 6,0 55 40 10 +7 7,8 256 - - +10 9,4 -7 - - n.d. n.d. -
Residual Dust Residual Water
Air drying
Classes
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Dew point diagram
Water content
g/m 3
Temperature in °C -10 0 +10 20 30 40 50 60 70 80
1000
500
100
50
20
10
1
0.1
5
0.5
Maximum saturation
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Refrigerant dryers
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1 Air outlet2 Air inlet3 Separator4 Drain valve5 Refrigiration6 Drain valve7 Cold serpantine8 Heat exchanger
DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Regenerative adsorption dessicant dryers
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Adsorbtion dessicant dryers consist of granules which is known asSilica Gel. These granules are made of Sodium Silicate and they have very high attraction to water rather than air .
Silica Gel captures the vapour in air in the cavities within the body. When these cavities are filled with water, than a silica gel granule has no attraction to water and needs to be regenerated.
There are Silica Gel types that have a colour indication of saturation. When they are dry, they are blue, when they are saturated with water, they turn to pink.
Air consisting of humidity Reduced humidity
Cross section of a silica gel granule
DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Regenerative adsorption dessicant dryers
Cold regenerated dessicant dryer
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Housing cover
Hollow fibres
Nozzles
Exhaust ports for purging air
Membrane dryers
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
1 m3 of air contains
- up to 180 million dust particles- up to 50 g of water (at 50o C)- up to 0,03 mg oil- various chemicals such as lead, cadmium etc.
Compressed air preparation
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
The compressed air is most efficient when conditions below are realised:
The right pressure
Less particles
Less condensate
The right oil
Compressed air preparation
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
The wrong adjustment of pressure may result in:
•early wearing of equipment•vibration of machine and poor product quality•more air leakages•high operation cost
More particles in the system may result in:
•early wearing of equipment•pressure drops•blocked lines•malfunction of system
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
More condensate in the system may result in:
•corrosion•lower velocity•sludge blocking lines
Wrong adjustment or type of oil may result in:
•early wearing of equipment•washing out the special oil•swelling of seals•staining the product
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Service unit
+ + =
filtering dust and condensation
lubricating the system
regulating the pressure
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Adjustment of pressure
Q: What is the right pressure for a system?
A: The minimum possible pressure to operate the system smoothly.
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Adjustment of pressure
It is also possible to adjust the pressureremotely
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Dust and condensate
automatic drain
manual drain
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Dust and condensate
The filter should be changed when there is a pressure drop between inlet and outlet of the service unit.
Changing the filter:
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Dust and condensate
The best way is to install an indicator for pressure drop to change the filter on time.
Changing the filter
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Lubricating
Refilling of oil
Q: Which type of oil should be used?A: The best is not to use oil. In systems where lubrication is a must, the oil to be used is : Hydraulic oil with viscosity 32mm2/s
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Lubricating
Adjusting the oiling of the system
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Service unit
On-off valve
Filter-regulator
Branching module
Lubricator
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
On-off valve
On-off valve is actually a NC 3/2 valve to exhaust the system when necessary
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Soft start valve
In many systems it is not safe to pressurise the system instantly. To prevent this, a Soft start valve is used which allows slower increase in the pressure.
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DC-I/Levent Unan Presentation: Compressed air 18 December 2008
Pressure amplifier (booster)
A pressure amplifier is a valve and a twin cylinder combination to compress air and increase pressure up to two times of the supply pressure.
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