WILKERSON
®
C O R P O R A T I O N
Training For Growth
Into the
21st Century
A Marketing Services Presentation ©1998 Wilkerson Corporation
Having trouble seeing your customer’s problem?
To Be Continued…………...
Basic Air Preparation
•A Look At:
•The Air System
•The Components
•The Mechanisms
You are what you breathe...
…or,Life at the Compressor Inlet
Each Cubic
Foot
of Atmospheric
Air Contains....
Dirt
Water
Vapors
ACME
CORPO
NO WHE
Intake Filter
25 - 50m
Acme
Compressor
Atmospheric Contamination
Compressor Intake
ACME
CORPO
Each Cubic Foot
of Atmospheric
Air Contains....
4,000,000 solid particles
5 ppm / wt. various vapors
NO WHE
Intake Filter
25 - 50 m
Acme
Compressor
A Closer Look at the Discharge
Look at all those molecules !!!
1,2,3,4,5.…yadda yadda yadda...
x
7.8 =
One Cubic Foot
Ambient Air
The Problem is Magnified!
Compression Ratio @ 100 psig
A Closer Look at Discharge
Contamination
Look at all those solids !!!
1,2,3,4,5....4,000,000
x
One Cubic Foot
Ambient Air has
UP TO
4,000,000 Solids
7.8 =
One Cubic Foot
Compressed Air
31,200,000 Solids
The Problem is Magnified!
Compression Ratio @ 100 psig
A Typical Compressed Air Supply System
Mainline Filtration
Compressor
Point of Use FRL
Dryer
Drains
Aftercooler here (heat removal)
Take drops off top of main header
Clean, properly-sized piping
Minimum of turns and bends
(Heat removal)
Mainline Filtration
Compressor
Point of Use FRL
Be a
plumber’s
friend!
Dryer
Drains
Drains at all low points
Aftercooler here (heat removal)
A Typical Compressed Air Supply System
Compressed Air Preparation:
•
•
•
•
•
Temperature Conditioning
Drying
Filtering
Regulating
Lubricating (when appropriate)
WHY DO WE NEED TO
PREPARE THE AIR ?
Compressed Air System
Problems
•Sources of trouble:
•Oil
•Particulates - (Dirt,pipe scale, rust)
•Water
•Pressure Drop
Heat
3 Sources of Compressed Air
Contamination
Atmospheric
Contamination
Piping Contamination
Compressor
Contamination
Compressor Contamination
Discharge Air
Compressor
38,600,000 Solid Particles (intake air)
&
Compressor Wear
Particles
&
Carryover Oil
(per year)
47 Gallons
.5
Discharge Contamination
continued
Oil, Oil Everywhere.
Where’s it all coming from ??
Acme
Compressor
J
E
F
F
Acme
Compressor
Acme
Compressor
Acme
Compressor
Bypass Oil Per Yr
Oilless
12 oz - 60 oz.
Flooded Screw
3.8 gal - 47 gal
Rotary Vane
5.6 gal - 188 gal
Reciprocal
47 gal - 188 gal
Piping Contamination
PIPE SCALE
YUK!!
AIR
AIR
BOB
WATER
OIL
PIPE RUST
The Ugly Truth
• Dirt - 4 Million particles/cubic ft. @ ambient
• Oil - 5 ppm carryover = several gallons / year
• Water - @70°F@70% RH, 100scfm system =
114 Gallons H2O / day
• Pressure Drop - Each 2 psid = about 1% BHP
The Problems
Premature valve failure, sticky valves
Swelling of O-Rings in valves and cylinders
Loss of lubrication in pre-lubricated valves
and cylinders
Equipment failure and down time
Problems to numerous to mention
How do we clean up this mess ?
• Properly design an air treatment system
• Properly install an air treatment system
• Properly maintain an air treatment system
The cost of p
“The bitterness of poor performance and
value lingers on long after the
sweetness of low price is forgotten.”
-Author Unknown
The savings of a few dollars on
component size can cost hundreds or
even thousands in lost efficiency and
wasted energy!
Compressed Air System
Problems
•Sources of trouble:
•Oil
•Particulates - (Dirt,pipe scale, rust)
•Water
•Pressure Drop
Compressed Air Preparation:
•
•
•
•
•
Temperature Conditioning
Drying
Filtering
Regulating
Lubricating (when appropriate)
Air-cooled
aftercooler
Air-cooled aftercooler
Water-cooled aftercooler and separator
Separator
Warm water out
Shell and tube heat exchanger
Hot air in
Cool water in
Condensate out
Cool
air out
Shell and tube water-cooled heat exchanger
Compressed Air Preparation:
•
•
•
•
•
Temperature Conditioning
Drying
Filtering
Regulating
Lubricating (when appropriate)
Compressed Air Drying
• Deliquescent
• Refrigerated
• Desiccant
• Membrane
Water Ingested by
Compressor
Compressed Air Drying
• Deliquescent
• Refrigerated
• Desiccant
• Membrane
Deliquescent Dryer
Salt tablets
Compressed Air Drying
• Deliquescent
• Refrigerated
• Desiccant
• Membrane
Refrigerated air dryer
Refrigerated Air Dryer
Large capacity refrigerated air dryer / chiller
Compressed Air Drying
• Deliquescent
• Refrigerated
• Desiccant
• Membrane
Heatless Regenerative
Twin Tower
Pressure Swing Cycle
Desiccant Dryer
Heatless Regenerative
Pressure Swing Dryer
(Twin tower dryer)
Compressed Air Drying
• Deliquescent
• Refrigerated
• Desiccant
• Membrane
Membrane Dryers
•No moving parts
•No electricity
•No CFC’s
•Simple to install and maintain
Membrane pore size allows water to pass,
but Nitrogen and Oxygen molecules bond
in pairs and are too large to pass.
Nitrogen molecules
N2
Oxygen molecules
O2
Water molecules
H 2O
Membrane
Membrane Dryer Cutaway
In
Out
Body casting w/ cover
Purge air exhaust
Membrane
Module
Bowl
Purge orifice
(Not a true cross-sectional drawing)
Membrane Dryer
with
Coalescing Filter
Compressed Air Preparation:
•
•
•
•
•
Temperature Conditioning
Drying
Filtering
Regulating
Lubricating (when appropriate)
Filtration Locations
Compressor Room
Acme
Compressor
Point - of - Use
Acme
M
a
T
c
o
h
o
i
l
n
e
Particulate filters
TWO-STAGE ACTION
SEPARATION
FILTRATION
Courtesy of Wilkerson
Filtration is
outside-toinside on
particulate
elements
5-micron
element
Quiet Zone Baffle
Courtesy of Wilkerson
Oil Carryover
Used compressor oil
is a POOR lubricant!
It is a sticky,
gummy mess!
Coalescing Filters
DP indicator
Flow path is inside to
outside element
Anti-reentrainment
foam sock
Oil drips off bottom of
element in wetted state
Courtesy of Wilkerson
Compressed Air Preparation:
•
•
•
•
•
Temperature Conditioning
Drying
Filtering
Regulating
Lubricating (when appropriate)
Regulators
3
2
• To Regulate Downstream Pressure
1. Main spring pushes up on diaphragm,
opening Valve
2. As downstream pressure rises,
air pushes on diaphragm on side
opposite from spring
3. When air pressure equals spring
force, diaphragm moves to neutral
position, and spring under valve
closes valve.
Courtesy of Wilkerson
1
Regulators
Bottom Plug
Body
Valve
Main Spring
Panel nut
Adjusting
stem assy.
Bonnet
Knob
Courtesy of Wilkerson
Valve spring
Diaphragm
If I had only known what a regulator does…..
Demand side control devices
Demand side control devices
Demand side control devices
Compressed Air Basics
D EW PO IN T C O N V ER S IO N C H A R T
100psig
140
Dew Point °F at Elev ated Pres s ure
120
Atmospheric
100
80
60
40
20
0
-20
-40
-60
-80
-100
-100
-80
-60
-40
-20
0
20
40
D e w Po in t ° F a t A tm o s p h e r ic Pr e s s u r e
60
80
100
Compressed Air Preparation:
•
•
•
•
•
Temperature Conditioning
Drying
Filtering
Regulating
Lubricating (when appropriate)
Lubricator Operation
•Adjustable oil feed &
sight dome combined
•Fill under pressure
•Filter in oil pick-up
•Manual drain to
remove water
Courtesy of Wilkerson
Proper Air Preparation
is Your KEY
to pneumatic system success!
Thank you for your time!
(spare slide section follows)