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AiiA - A Project of Potohar Center for Entrepreneurship Development


WELCOME


Recitation of

Holy Quran

ASIAN INSTITUTE OF INDUSTRIAL AIR

Turning knowledge into practice

A project of Potohar Center for Entrepreneurship

Development

ABOUT US

POTOHAR CENTER FOR ENTREPRENEURSHIP

DEVELOPMENT

ASIAN INSTITUTE OF

INDUSTRIAL AIR

PAKISTAN AEROSPACE

COUNCIL

ABOUT US

Asian Institute of Industrial Air (AIIA) is a training institute in Pakistan offering

an advanced level of certified training courses

Industrial Air

Engineering (only

institute in Pakistan)

Production

Engineering

Automation

OUR DOMAIN

Compressed

Air

Vacuum

Waste

Management

& Recovery

Audit

(Leaks)

Automation

Intelligent

Maintenance

Smart

Procurement

Air Quality

INDUSTR

IAL

TRAININ

G

OUR SERVICES

Training of Industry

Professionals and mid-career

level individuals

Providing fresh graduates with

the opportunity to build skillsOffering need-based

customized training for existing

workforce

OUR TRAININGS

COMPRESSED AIR

❏ Introduction to

Compressed Air

Engineering

❏ Advanced

Management of

Compressed Air

Systems

❏ Compressed Air

System Technology

❏ Working Safely with

Compressed Air

PRODUCTION ENGINEERING

❏ Industrial Plant Reliability

Improvement & Maintenance Cost

Reduction

❏ Reliability Improvement of

Mechanical Seals

❏ Pumps & Pumping Systems

❏ Advanced Course on Centrifugal

Pumps

❏ Managing a Successful Condition

Monitoring Maintenance Program

❏ Root Cause Analysis: Effective

Problem Solving & Decision

Making

❏ Mechanical Ventilation & Heat

Recovery

AUTOMATION

❏ Industrial

Automation (PLC,

SCADA & HMI)

❏ Ansys Workbench

❏ MicroController &

its Applications

❏ MATLAB Training

We Handle

Your Training Needs


TRAINERS

INTRODUCTION


Dr. Arshad Ali

CEO AIIA

Recipient of Pride ofPerformance and Sitara-i-Imtiaz from Govt ofPakistan for his services inPakistan Air Force andNUST University. He alsoserved as Rector NTUFaisalabad and ExecutiveDirector HEC.

Served in Navy and joinedRASTGAR & CO. in 2003. Heis Compressed AirMaintenance Expert Trainedin Germany, UK & Korea.Specializes in CompressedAir, Blowers, Vacuum &Nitrogen Generationsystems.

Mr. Masood Ahmed Mr. Danyal Ahmad

Compressor room designerand piping layout expert.He is also experiencedcorporate trainer with abackground in MechanicalEngineering, has workedon various plants incountry regardingCompressed Air systems.

Mr. Muhammad Ali

Has been working atRastgar as mentor andtrainer, havingexperience related totraining in compressedair audit, costing andbusiness development.


PARTICIPANTS

INTRODUCTION


Certificate Course

on

Compressed Air Systems

with collaboration of

National Textile University, Faisalabad


TRAINING PROGRAM

Time Subjects Trainers

Session I:Introduction to Compressor Engineering0940-1020

• Introduction• What is a Compressor• Compressor Types• Basic Compressed Air Terms

Dr. Arshad Ali

Session II: Selection & Maintenance of Compressor1020-1120

• How to Size & Select a Compressor• Compressor Room Organization• How to Select a Compressor Service Provider

Masood Ahmed

1120 - 1140 : Tea Break

Session II (Continue.): Selection & Maintenance of Compressor1140-1300

• Rotary Screw Air compressor Basics • Basic Component of Screw Air Compressor• How Screw Compressor Works• Compressor Installation and ventilation• Compressor Maintenance• Downstream Equipment

Masood Ahmed

1300 - 1400 : Lunch Break & Namaz + Group Photo


TRAINING PROGRAM

Time Subjects Trainers

1300 - 1400 : Lunch Break & Namaz + Group Photo

Session III :Transmission of Compressed Air1400-1500

• Principles Of Compressed Air Piping• Distribution Headers and Drops• Type of Piping Offered for Compressed Air• Typical Compressed Air Pipe Comparison

Danyal Ahmed

1500 - 1520 : Tea Break

Session IV:Air Quality & Cost1520-1600

• Impurities in Compressed Air• Automation, Instrumentation & Cost Accounting• The Value of 3rd Party Audits• Heat Recovery System• Compressed Air Safety Practices

Muhammad Ali

1600-1620 Question / Answer All Trainers

1620-1630 Certificate Distribution & Concluding Remarks Imtiaz Rastgar


Session I:Introduction to Compressor Engineering

Dr. Arshad Ali


• Compressed Air

• Compressor Types

• Selection of Compressors

• Compressed Air Piping

• Compressor Installation & Ventilation

• Controls, Instrumentation & Cost Accounting

• Air Compressor Maintenance & Trouble Shooting

• Compressed Air Safety Practices

• Understanding of Relevant ISO Standards

• The Value of Third Party Audits

• Heat Recovery System

LEARNING SUBJECTS


INTRODUCTION

TO

COMPRESSOR AIR SYSTEMS


• What is a Compressor

• What is Compressed Air

• Type of Compressors

• Basic Compressors Terms

• Compressed Air Applications

IN THIS SESSION, WE SHALL COVER


WHAT IS AIR?

The invisible gaseous substance surrounding the

earth, a mixture mainly of oxygen and nitrogen


WHAT IS FREE AIR?

Air at atmospheric conditions is generally called

"free air."


Pressure - Amount of force pushing against a given area.

WHAT IS PRESSURE?


WHAT IS PRESSURE?

How much pressure a gas exerts depends on the amount of

gas. The more gas particles there are, the greater the

pressure.


THERMODYNAMIC LAW

The state of A gas is specified by

• Pressure

• Volume

• Temperature


According to Boyle’s law,

if the temperature of a gas

is held constant,

increasing the volume of

the gas decreases its

pressure

BOYLE'S LAW


BOYLE'S LAW


According to Charles’s

law, if the pressure of a

gas is held constant,

increasing the

temperature of the gas

increases its volume.

CHARLES'S LAW


CHARLES'S LAW


AMONTON'S LAW

According to Amonton’s

law, if the volume of a gas is

held constant, increasing the

temperature of the gas

increases its pressure


AMONTON'S LAW


WHAT IS A COMPRESSOR

A compressor is a mechanical device that increases

the pressure of a gas by reducing its volume


WORLD’S FIRST COMPRESSOR

In 1650, German scientist Otto von Guericke devised

an air pump consisting of a single piston and

cylinder. With it he was able to experiment with

compressed air and vacuums.

In 1799, George Medhurst of England designed the

first motorized air compressor and used it in mining


Compressed air is free air that has been forced into a

smaller volume and is now at a pressure greater than

atmospheric.

WHAT IS COMPRESSED AIR?


• 7- 12 bar Pressure for Industrial applications

• Compressed Air is measure in m3/min, Liter/min,

CFM

• Capacity of an air compressor



A 11 kW Compressor can

deliver approximately

100 m3h of air at 7 Bar.

A 75 kW Compressor can

deliver approximately 800 to

850 m3/h of air at 7 Bar



TYPES OF COMPRESSORS

COMPRESSOR TYPES

POSITIVE

DISPLACEMENTDYNAMIC

Successive volumes of

air are confined within a

closed space where

pressure is increased as

the volume of the closed

space is decreased.

Air is compressed by

the dynamic action of

rotating impellers or

vanes imparting velocity

and pressure to the gas.


POSITIVE DISPLACEMENT

RECIPROCATING ROTARY


A Reciprocating

Compressor that uses a up-and-

down or back-and-forth linear type

positive-displacement mechanism.

In A Reciprocating Compressor, a volume of gas is drawn into a cylinder, it is trapped, and compressed by piston and then discharged into the discharge line.

RECIPROCATING


A Rotary-Screw

Compressor that uses a rotary-

type positive-displacement

mechanism.

Once air enters a rotary screw

compressor, it is trapped

between mating male and

female rotors, and compressed

to the required discharge

pressure.

ROTARY


TYPES OF COMPRESSORS


• Units of Measurement

• Actual Site Conditions

• Inlet Air Pressure & Temperature

• Actual CFM (ACFM)

• Standard CFM (SCFM)

COMPARING COMPRESSOR PERFORMANCE


PERFORMANCE VERIFICATION

OF

COMPRESSORS

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COMPARISON

OF

COMPRESSORS

Please see your Folder


• Air tools run cooler

• Air tools have a higher power-to-weight ratio

• Air tools have no shock risk

• Air tools have fewer parts and require less

maintenance

COMPRESSED AIR POWER

VS

ELECTRICITY


COMPRESSED AIR POWER

VS

HYDRAULIC

• Air systems generally have fewer parts

• Air systems generally cost less

• Air systems are less of a fire hazard

• Air systems are more dirt-tolerant

• Air systems are more tolerant to leakage


COST OF PLANT TASK WITH AIR POWER


DO YOU KNOW

COMPRESSED AIR IS 8 TO 10 TIME MORE EXPENSIVE

THAN ELECTRICITY?


COST OF COMPRESSED AIR

76%

12%

12%

Electricity

Maintenance

Equipment


BUYING A COMPRESSOR

What needs to be considered in buying an air compressor?

• Application

• Flow

• Pressure

• Air Quality

• Dryer & Filters

• Operating Hours

• Daily Shift

• Flow Demand Fluctuations (VSD)

• Heat Recovery

• Future Expansion


Absolute Pressure

BASIC COMPRESSOR TERMS


Atmospheric Pressure



Air Receiver



Aftercooler



Compression



Compression Efficiency


Ratio Of

Theoretical To Actual Work Required

to Compress Air.

Takes Into Account Slip Leakage and Frictional Losses.


Compression Ratio


Ratio of the Absolute Discharge Pressure to the

Absolute Inlet Pressure


Design Pressure



Design Speed



Discharge Pressure



Discharge Temperature



Free Air


Air at Atmospheric Conditions


Inlet Pressure



Inlet Temperature



Moisture Separator



COMPRESSED AIR ADVANTAGES

Air compressors have been used in industry about over 100 years,

because air as a resource is safe, flexible, clean and convenient.

Easily Transported


Easily Stored



Clean & Dry



Lightweight



Safe To Use



Accident-Proof



Rational & Economical



Fast Work Medium



Fully Adjustable



COMPRESSED AIR APPLICATIONS

Textile



Vehicle Services



Food & Beverage Processing



Metals



Pharmaceutical



Plastics



Power Generation



Wood Products



Electronics



Cement



Spray Paint



Pneumatic-Operated Tools


DOWNLOAD

99Examples

Of Pneumatic Application

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SUBSCRIBE

OUR FUTURE TRAININGS

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SELECTION & MAINTENANCE

OF

AIR COMPRESSORS



• How to Size & Select a Compressor

• Compressor Room Organization

• How to Select a Compressor Service Provider

• Basic Component of Screw Air Compressor

• How Screw Compressor Works

• Compressor Installation and ventilation

• Compressor Maintenance

• Downstream Equipment


SIZING & SELECTING AN AIR COMPRESSOR

• How much Air Volume (FAD) required

• Pressure required at machine

• Actual site conditions

• What is the voltage?

• Any future expansion Plan


COMPRESSOR ROOM ORGANIZATION

Compressor Room

• Ventilation

• Room Dimension

• Drain Channels

• Distance Between Machines

• Machines to Wall Distance

• Foundation

• Exhaust Air Ducts

• Scheme of Machines Placement


COMPRESSOR ROOM ORGANIZATION

• Air Receivers

• Piping System

• Piping Material

• Main Header

• Inclination in Piping

• Installation of Downstream Equipment

• Electrical Power Required

• Health & Safety Checklist

IDEAL COMPRESSOR ROOM AND

INSTALLATION


CROSS VENTILATION

• Compressor Oil Life decrease

half for every 20 degree rise

above normal operating temp.

• Poorly ventilated, fluffy & dusty

environment can pass six times

more water in air system

• Hot compressed air will

experience pressure losses as

it passes through air treatment

system.


• Air End running at high temp it is

slowly opening up its clearances

and premature wear.

• The compressor must be installed

next to the air inlet aperture so that

it draws fresh air for compression

and cooling air for ventilation.

• The compressor must be positioned

right place so that it can not re-

induct its own heated exhaust air.

CROSS VENTILATION


Eight Basic Elements

• Demand, (Total free air delivery requirement with losses)

• Compressed Air Quality

• Supply, (Maximum and minimum pressure requirement

with pressure drop)

• Storage, (Air Vessel wet & dry)

• Distribution, (Straight & Ring-man system)

• Installation, (MS, SS, Aluminum, GI, Polymer etc)

• Maintenance, (Schedule & Corrective , minor & major etc )

• Condensate management

COMPRESSED AIR SYSTEM DESIGN


SELECTING A SERVICE PROVIDER

• Familiarity with the Systems Approach

• Availability of Compressed Air System

Assessment Services

• Compressor Knowledge and Expertise

• System Components and Controls Knowledge

and Expertise

• Company Capabilities

• Emergency service response

• Parts shipments

• Service Facilities

SALES SERVICES SPARES SOLUTIONS

Rotary Screw Compressors work on the principle ofair filling the void between two helical mated screwsand their housing. As the two helical screws areturned, the volume is reduced resulting in anincrease of air pressure.

Most rotary screw compressors inject oil into thebearing and compression area. The reasons are forcooling, lubrication and creating a seal betweenscrews and the housing wall to reduce internalleakage. After the compression cycle, the oil and airmust be separated before the air can be used by theair system.

TYPE OF COMPRESSORS

ROTARY SCREW


HOW SCREW COMPRESSOR WORKS

Session II/How_Screw_Airend_Works_Setup.exe

Session II/How_Screw_Airend_Works_Setup.exe


MAIN COMPONENTS

Suction Regulator

Low Pressure Loss

Air End

High Performance

Suction Filter

Class 3 Micron

Bell housing, flexible direct coupling

Perfect Alignment of drive shafts

Cooling Air

Suction

filter

Silencer

Base Frame with fork lift, 6 openings Easy Transport


ROTARY SCREW AIR COMPRESSOR BASICS

• V-belt

• Direct drives

• Gear-driven

Drives


• Electronic Control

Panel

• Display Content

• System adjustments

Control Panel

ROTARY SCREW AIR COMPRESSOR BASICS


DELCOS XL - BENEFITS

• Easy to use thanks to “Touch Screen” and

intuitive MMI (Man-Machine-Interface)

• Instant overview of compressor status

• All functions are intuitively visual

• Easy to check having correct compressor

settings

• Compressed air system can be easily

optimized thanks to trends information


• Controlling and monitoring thanks to 6/5 programmable

inputs/outputs

• Data logging and software update via optional SD card

• Service diagnostic feature

• Modbus as standard

• Optional Profibus interface

• RS485 interface for Smart Air Master Sequencer

• Outstanding Optional Base Load Sequencing (BLS)

DELCOS XL - BENEFITS


There are generally five areas of the compressor that

require maintenance:

• Airend

• Motor

• Drive Train

• Lubricants

• Filters.

ROTARY SCREW AIR COMPRESSOR

MAINTENANCE


Airends and their

bearings are damaged

by contamination in the

air and lubricants and

by excessive heat.

Inspect for unusual

noises and vibrations.

AIREND MAINTENANCE


Motor

• Bearings Lubrication

• Bearing Replacement

• Periodically check ampere

• Providing proper ventilation and

ambient temperature

MOTOR MAINTENANCE


• Systems Alignment

• Gear drives Lubrication

• Inspect and adjust the

tension Replace Worn or

frayed belts

DRIVE TRAIN MAINTENANCE


• Cool, Seal, Protect and Remove

Contaminants

• Drain All Existing Lubricant

• Change Oil On A Schedule

• Regular Oil Sampling

• Non-genuine

LUBRICANTS


Filters

• Schedule air filters change

• Inlet filter with an increase of

pressure drop of 1% reduces

compressor capacity by 1%.

• Schedule Oil filters change

AIR FILTERS MAINTENANCE


ROTARY SCREW AIR COMPRESSOR -

SIMULATOR

Session II/L-series_simulator_V1_1.exe

Session II/L-series_simulator_V1_1.exe


• Preventive Maintenance is the

systematic inspection, detection,

and correction of potential

equipment failures before they

develop into major defects.

• The purpose of Preventive

Maintenance is to keep

equipment in safe and reliable

condition in operational state and

minimum cost of maintenance.

COMPRESSOR MAINTENANCEPREVENTIVE MAINTENANCE


COMPRESSOR MAINTENANCEDAILY CHECKS

• General operation of machine.

• Oil System: Drain condensate from

separator vessel.

• Oil System: Check oil level. Top up if

necessary

• As defined in the User Manual.


COMPRESSOR MAINTENANCEWEEKLY CHECKS

• Normally Undertaken by the End User

• Delcos Controller: Check for any indicated service

requirements.

• Delcos Controller: Check fault history

• Oil System: Drain condensate from separator vessel.

• Oil System: Check oil level. Top up if necessary

• Separator Element: Check element differential pressure

(Max 0.7 bar).

• After-Cooler / Oil Cooler: Check condition clean as

necessary.

• Cabinet Pre-Filters & VSD Filters: Check condition clean

as necessary.


COMPRESSOR MAINTENANCEMONTHLY CHECKS

• Regular equipment performance

analysis

• Cleaning of components

• Tightening of electrical

connections

• Oil check


COMPRESSOR MAINTENANCESCHEDULE SERVICE (2000 HRS)

• Oil system: Check oil level / top up oil sample if required.

• Air filter: Renew air filter.

• Oil filter: Renew oil filter.

• Electrical wiring: Check connections and condition.

Controller: Check connection and plugs.

• Cabinet filters / VSD filters: clean / Renew.

• After-cooler, oil cooler & fan.

• Clean externally.

• Control system: Checks for correct operation and control.

• Blow down system: Check for correct operation.

• Relief valve: Functionally test.



• Starter contactors: Checks contacts,

connections and condition.

• Oil system: Change oil.

• Separator filter: Renew filter

elements.

• Oil Scavenge system: Renew motor

lubricant cartridges



• Carryout 2000Hr and 4000Hr Service.

Plus…

• Minimum pressure valve: renew

• Suction regulator: Overhaul the suction

regulator.

• Control solenoid: Renew.

• Drive coupling inserts: Checks/Renew.


DRYER MAINTENANCE

• Dryer external condenser

cleaning.

• Replacement of pre and after

filter.

• Auto drains kit replacement.

• Preventive service as per

manual. Other all service are

chargeable – (gas charges etc)


DOWN STREAM EQUIPMENT

• Air Receiver

• Water Separators

• General Purpose Filter

• Dryer

• High Efficiency Coalescing Filter

• Activated Carbon Filter• Sterilize Filter• Auto Drains


Water separators provide

bulk condensed water and

liquid oil removal and are

used to protect coalescing

filters against bulk liquid

contamination

DOWN STREAM EQUIPMENTWATER SEPARATORS


• General Purpose

• High Efficiency Coalescing Filters

• Activated Carbon Filters

• Vapor Removal Filters

DOWN STREAM EQUIPMENTFILTERS


Refrigerated air dryer works by cooling down

the air (like a refrigerator).

The warm wet air enters the dryer, where it is

cooled down to about 3 degrees Celsius. All

water vapor that was in the air condenses

into water

The liquid water is then removed from the

compressed air by a water-trap.

DOWN STREAM EQUIPMENTREFRIGERANT DRYER


REFRIGERANT DRYER OPERATION

Session II/Compair F0120HS.exe

Session II/Compair F0120HS.exe


• Absorbent chemicals used in air

dryers are known as "desiccants".

They attract moisture by the

chemical reaction known as

absorption.

• Adsorbents remove the moisture

from the air by attracting and

holding the water to the surface of

their particles.

DOWN STREAM EQUIPMENTDESICCANT DRYER


ADSORPTION DRYER OPERATION

Session II/CompAir-Compressed-Air-Dryers.exe

Session II/CompAir-Compressed-Air-Dryers.exe


DESICCANTS

There are three basic types

• Silica gel

• Molecular sieves

• Activated alumina


SILICA GEL


MOLECULAR SIEVES


ACTIVATED ALUMINA


DOWN STREAM EQUIPMENTAIR RECEIVERS

The Primary Role of a

Compressed Air Storage Tank

• Compressed air storage

• Provides a steady air signal to

the compressor controls

• To act as a second heat

exchanger


ELECTRIC MOTOR


MOTOR INSPECTION

• Ensure the windings are maintained in a

clean condition.

• Carefully remove the shaft / rotor assembly

from the stator frame.

• Check Bearings condition.

• Clean all components and inspect for wear

or damage.

• Use low pressure air to blow away dust and

dirt from the rotor and stator


• When re-packing the bearings with grease, use

lithium complex grease, and avoid overfilling.

• Don’t use high-pressure air to clean the motor.

• Don’t use force when fitting the end shields on to

the bearings and spigots.

• Ensure electrical connection is correct and the

terminals nuts are tight.

• Check the air gap between the rotor and the stator

windings using long feeler gauge.

• Before attempting to run the motor, check that the

rotor rotates freely.

MOTOR INSPECTION


TRANSMISSION

OF

COMPRESSED AIR


IN THIS SESSION, WE WILL COVER

• Principles Of Compressed Air Piping

• General Guidelines For Compressed Air Distribution

System

• Distribution Headers and Drops

• Type of Piping Offered for Compressed Air

• Comparison of Compressed Air Pipes

Compressed Air

Systems: The

Secret is in the

Pipe

AiiA - A Project of Potohar Center for Entrepreneurship DevelopmentAsian Institute of Industrial Air

• Identify workstation using compressed air.

• Volume of air used at each location

• Pressure range required at each location.

• Establish the maximum used on each main and branch

line .

• Establish any allowance for future expansion.

• Select the air compressor type, with pressure and

temperature

PRINCIPLES OF COMPRESSED AIR PIPING


• Check max-min Ambient temperature

• Produce a final piping network

• Select the piping material

with min pressure drop

• Use minimum fittings,

connectors and elbows

• Piping Inclination should be 3 ~5° down to one side

• Install condensate drain at lower portion

KEEP IN MIND


• Selection of poor piping material

• Piping design and line sizes too small for the desired air flow.

• Undersized piping restricts the flow and reduces the discharge pressure.

• Poor piping practices by increasing velocity- and turbulence-induced backpressure

Common Mistakes


REDUCE POSSIBILITY OF VIBRATIONPoints to consider while dealing with compressed air

line.

• Vibration & Pulsations


PIPE CAN DEFORM WITH EXCEESIVE

TEMPERATURE


MOISTURE

Moisture is compressed air is unavoidable but that does

not mean it is acceptable.


• Pressure drop between the compressor and point of use isirrecoverable.

• Pipe size should be large enough that pressure drop is held to a minimum.

• Design inlet and discharge piping for smooth flow with uniform translational velocity over the entire area of the piping.

AVOID PRESSURE DROP


• Install safety valve • Never exceed the working pressure rating of an

ASME vessel in the system.• Consider bypass lines or valves on all items that

may require future maintenance.

SAFETYVALVES & BYE-PASS LINES


• Use loop design system if possible, both around the plant and within each production zone

USE CLOSE LOOP OR RING MAIN


SWAN NECKS TAKE CARE OF MOISTURE

• Use Swan Necks for branch Lines.

Incorrect Drop Correct Drop


A. Poor installation/condensate in branch line flow to tool

B. Better installation/Condensate in branch line tends to flow past service line

C. Best installation/condensate in branch line cannot get into service line

GENERAL GUIDELINES


DISTRIBUTION HEADERS AND DROPS

• Purpose of Header is to transport the maximum

anticipated flow to the production area.

• Provides an acceptable supply volume for drops.

Modern designs

consider an

acceptable

header and line

pressure loss to

be 0 bar.


PIPE SLOPE

• All lines in the system main and branch lines should

slope or pitch downward at least 1" per 100 feet or less

in the direction of the air flow to a drain point – drop

leg, receiver, etc. This will allow condensation to

collect at the low points where it can be trapped and

removed.


TYPES OF PIPING

Compressed air piping materials

can be divided into two basic

types:

• Metal

• Non-Metal.


Metal pipe used in a compressed air system are:• Mild Steel• Stainless steel• Copper• Aluminum

TYPES OF PIPING

Metal Pipe


Mild Steel or Steel Pipe — Traditional Material in

Compressed air piping.

Durable and Strong on the outside.

but from inside it corrodes when

exposed to condensate (H2O) and thus

become a major source of contamination

to the whole system.

•Connection: Threaded when it is 3" diameter and smaller

Welded if the diameter is larger than 3“•Heavier and harder to work with, but less expensive.

TYPES OF PIPINGMetal Pipe


Stainless Steel — is often a good selection particularly

when exposed to oil-free wet air. Stainless Steel is most

widely used material in Food, Pharma and Chemical

Process industries.

•Connection: Welded or Pressed

•SS has excellent resistance to

corrosion

•High installation and labor cost.



Copper Pipe — is a common selection for sensitive air

systems.

• This metal is corrosion-free and easy to cut and weld and

it is lightweight but this is very costly piping.

• The working pressure of copper piping is from 17 bar to

28 bar. Further, solder melts at 216°C, it will be more

resistant to high temperatures. Even if it does fail, it will

do so in a predictable manner. The pipe ends

will separate. The working temperature limit

is about 204°C



Aluminum compressed air pipe as applied today has

become very popular. Aluminum has the same anti-

corrosive properties of stainless steel but without the

weight.

• Low pressure loss due to low friction.

• Smooth inner surface that eliminate "self

contamination.

• Enhanced flexibility to meet the ever-

changing compressed air distribution needs.

• The piping material usually has a melting

point of over 600°C.



• Non-Metal Pipe — commonly called "plastic" pipe

• Lighter than metal

• Easier to handle

• No special tools required

• Non-corrosive.

• Less Labor Cost

What has held back this material’s acceptance by many

compressed air people and organizations?

TYPES OF PIPINGNon-Metal Pipe


limitations• Most of these are limited to an operating temperature of 60°C

to 90°C. The failure in an after-cooler can easily reach or

exceed these numbers. PVC, for instance, is limited to about

70°C at 8.5bar, but it actually starts to weaken at 30°C.

• Most of these materials are not compatible with compressor oils

in general and particularly many synthetics.

• Although pipeline fires are rare today, when there is one in

plastic pipe, there is a good chance that it will melt through the

plastic pipe and migrate into the plant.

TYPES OF PIPINGNon-Metal Pipe


COMPRESSED AIR PIPE COMPARISON

Mild Steel Feature Aluminum

Schedule40 Heavy

Weight Lightweight

NoCorrosionResistance

Yes

YesHigh

MechanicalStrength

Less thanMild Steel,but strong

25% / 75%

InstallationCost

(Material % /

Labor %)

80% / 20%


Mild Steel Feature Aluminum

Flange /Threaded /Welded /

Other

Type ofConnection (varies with

size)

Sealed /Reusable /

Other

NoLow "Friction generated“ Pr

essure LossYes

Yes

InstallationRequirements(Skilled Labor,

PipeFitters, etc.)

No

COMPRESSED AIR PIPE COMPARISON


• Calibrated Aluminum Pipe: Qualicoat Painting

• Colors: Available in blue - grey – green

• Maximum Working Pressure

• 16 bar up to 100 mm

• 13 & 7 bar for all diameters

• Working Temperature: -20°C to 85°C

• Compatibility: Lubricated or oil-free compressed air,

industrial vacuum, nitrogen (99.99% purity), inert gas.

ALUMINIUM PIPE SYSTEMS FOR INDUSTRIAL FLUIDS


EASY JOINING & INSTALLATION SYSTEMS FOR ALUMINIUM PIPE

Diameters (in mm)

16.5 - 25 - 40 - 50 - 63 - 76 - 100 - 168


BENEFITS OF ALUMINUM PIPING






The purpose of the compressed air piping system is to deliver

compressed air with enough volume, appropriate quality and pressure

to properly power the components

COMPRESSED AIR (RING MAIN SYSTEM)


CONCLUSION

The objective of compressed air piping is to deliver compressed air to the end uses without pressure loss and the introduction of contaminants. Proper piping material selection and following guidelines for both distribution and compressor discharge piping can help system designers accomplish this goal. If Participant take one thing from this Presentation is that they remember larger diameter pipe sizes reduce air velocities (and therefore turbulence) resulting in minimized pressure losses.

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COMPRESSED AIR

QUALITY

&

COST


• Impurities in Compressed Air

• Automation, Instrumentation & Cost Accounting

• The Value of 3rd Party Audits

• Heat Recovery System

• Compressed Air Safety Practices



IMPURITIES IN COMPRESSED AIR

• Vapour: Water and oil in gas

form

• Aerosols: Suspension of any

particles of liquid, solid or

both within Compressed Air

• Solids: Dust, sand and

particles resulting from

corrosion and wear

• Liquid: Water, oil

Principal Impurities in Compressed Air



Compressed Air Oil Carry Over is

0.01 to 0.03 mg/m³(Mineral Oil Aerosols and un-burnt Hydrocarbons)

Atmospheric Bacteria and Viruses

Traces of Heavy Metals such as

Lead, Mercury, Iron, etc.

(For Specific Industries)


Compressed air at 7 bar (g) has

Eight Times more impurities than normal

ambient air.


ImpuritiesVolume



1m3 of Atmospheric Air contains 180 Million Dirt Particles

Size: 0.01 to 100 m

At 10 Bar

Concentration of Impurities rises 11 times

1m3 of Compressed Air contains 2 Billion Dirt Particles

Size: 0.01 to 100 m


Condensate:

Condensate comprises around 99% waterand around 1% impurities

1% Impurities Contain:

Oil in case of oil-lubricated compressors,Dirt from corroded particles in piping,Additional contaminants from the ambientair that has been drawn in.



AUTOMATIONMultiple Compressors Controller

Multiple compressors controller

at your Plant site can save up to

35% Compressed Air energy

costs


INSTRUMENTATIONFLOW METERS

Compressed Air Flow

Meters

Use compressed air flowmeters to for measurementof Compressed air, Nitrogenand Technical Gases.


INSTRUMENTATIONFLOW METERS

Compressed Air

Flow Meters

a

b

e

dc

f

a = b + c + d + e + f


Use Power Meter for

Permanent Power

Measurements.

Rated Power

vs

Actual Power

INSTRUMENTATIONPOWER / ENERGY METERS


Importance:

If WET air is fed into the pipelines, it

results in a substantial amount of

condensation. This leads to problems in

valves, pneumatic components and

eventually results in loss of production.

Since pressure dew point is one of the

key parameters for quality compressed

air, it should be monitored constantly.

INSTRUMENTATIONDEW POINT MONITORING


Increased quality control in

production processes forces

manufacturers to monitor

compressed air quality

permanently in accordance with

the standards applied (DIN ISO

8573-1) and principles for quality

audits compressed air has to be

evaluated whenever it gets in

touch with the product itself.

INSTRUMENTATIONQUALITY MONITORING


INSTRUMENTATIONLEAKAGE DETECTION


Human Audible

20 db – 120 db

INSTRUMENTATIONLEAKAGE DETECTION

< < Ultrasonic

Gun

Ultrasonic

Gun

Ultrasonic Gun for

this range too


Why Pressure Measurement is

Important?

Pressure drop wastes millions of

Rupees.

To overcome pressure drop and

maintain system pressure, your

compressor must draw additional

electric power.

Every 2 psi of pressure adds 1% to

the cost of electric power supplied to

the compressor.

INSTRUMENTATIONPRESSURE MEASUREMENT


DO YOU KNOW?

COMPRESSED AIR IS 8 TO 10 TIME MORE EXPENSIVE

THAN ELECTRICITY


COST ACCOUNTING

76%

12%12%

Operating Costs for Compressed Air Systems over 10 Years

Electricity

Maintenance

Equipment


COST ACCOUNTING

Do you know your Compressed Air Cost per unitof Product?

Do you know about Departmental Utilizationof Compressed Air?

Have you ever calculated Annual Cost ofCompressed Air System?


Optimize your Energy Efficiency

with VP Vision

• Real Time Insights with Energy

Management Software.

• Monitoring of Compressed air and

all other utilities in your plant.

• Departmental Usage and Cost

Calculations.

COST ACCOUNTING


ISO8573 - THE COMPRESSED AIR QUALITY STANDARD

ISO8573 is the group of international standards relating to the quality (or

purity) of compressed air.

The standard consists of nine separate parts,

• Part 1 specifying the Quality Requirements of the compressed air

• Parts 2 – 9 specifying the Methods of Testing for a range of

contaminants

Part 1



PART 2 - 5



PART 6 - 9


Specifying air quality (purity) in accordance with ISO8573-1:2010, the international

standard for Compressed Air Quality


QUALITY CLASSES


How Audit Helps You

• Waste Less Air / Energy

• Reduce Compressed Air System Load

• Identify Silent Leaking Machines

• Restore Plant to Peak Efficiency

• Leads to Air Quality

• Improve Manufacturing Productivity & Quality

• Supply & Demand Side Flow Analysis

THE VALUE OF PERIODICAL THIRD PARTY AUDITS






10 – 20% of the savings are commonly found on the supply

side of a compressed air system by identifying areas of

improvement in:

• Equipment

• Technology

• Controls

• Monitoring

• Equipment maintenance

• Installation issues


SAVINGS, SUPPLY SIDE:


A further 20 to 30% of savings are commonly found on the

demand side of a compressed air system by identifying areas

of improvement in;

• Compressed air leaks

• Artificial demand

• Improper Usage

• System design

• Monitoring & sub-monitoring


SAVINGS, DEMAND SIDE:




HEAT RECOVERY FROM COMPRESSED AIR

T.B.


T.B.



T.B.



T.B.



COMPRESSED AIR SAFETY

1. Pneumatic Safety

2. Electrical Safety

3. Safety Attire

4. Safe Working Practice

5. Site Safety Rules

6. General Safety

7. Read and Understand All Warning Labels

8. Chemical Safety



Isolate Compressor From System

It is advisable to use an Isolation Notice so people are aware that work is being carried out.


PNEUMATIC SAFETY


Isolate from Main Supply

Isolate the compressor unit from the main power supply.


ELECTRICAL SAFETY


Safety Footwear

Gloves

Hard Hat

Ear Defenders/ Plugs

Safety Glasses

Coveralls

Reflective Vest / Jacket


SAFETY CLOTHINGS:


Always use correct tools for the job

Using incorrect tools can damage components and make further maintenance difficult and costly.

e.g.Always use correctly sized spanners, never use grips or adjustable spanners.


SAFE WORKING PRACTICES


Observe All Posted Signs and Notices


SITE SAFETY RULES


If testing is required with unit running:-

Ensure all guards are in place.

Be aware moving parts / machines

Don’t wear long hanging cloths, neck ties

Do not play with compressed air

Do not point air hoses at anyone

Do not use compressed air to blow dirt from clothing


GENERAL SAFETY


Warning:

Don’t attempt any servicing / maintenance without reading the manual first.


UNDERSTAND ALL WARNING LABELS



CHEMICAL SAFETY

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THANK YOU

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