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Operation of Screw Compressors Operation of Valves Operation Of Dessicant Dryer Sigma Controller Introduction of Microfilters

2/25/2012

MUHAMMAD SAJID

Construction 1 Airend
2 Energy-saving electric motor 3 Motor grease nipples 4 Inlet valve 5 Minimum pressure/check valve 6 Combined Auxiliary Vent Valve 7 Fluid cooler with mounted thermostatic valve and fluidmicro filter 8 Compressed air after cooler 9 Two-stage air inlet filter 10 Fluid separator tank with separator cartridge 11 Safety Valve 12 Anti Vibration Dampers 13 Sigma Control

2/25/2012

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2/25/2012

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Fluid Separation

2nd stage, fluid separator element


a) coarse filter layer b) fine filter layer

98-99%

1st stage, centrifugal


2/25/2012 MUHAMMAD SAJID

2/25/2012

MUHAMMAD SAJID

2/25/2012

MUHAMMAD SAJID

2/25/2012

MUHAMMAD SAJID

Tasks of Fluid
First task:
Heat transfer, discharge temp. approximately 75 - 80 oC

Second task: Third task: Fourth task

Lubrication of Airend Bearings Sealing gap between rotors and casing, prevention of metallic contact absorbing dust, sulphur, etc.

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Inlet Valve

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Min Pressure Check Valve


Off Load Position

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Full Load Position

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Air Oil Separation

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Thermostatic Element Function

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Thermostatic valve The purpose of the thermostatic valve is to bring the cooling fluid up to operating temperature as quickly as possible and to keep it at this level under all operating conditions (idle running, winter operation, etc.). This keeps the compressed air/fluid mixture above the pressure dew point**, preventing condensation in the fluid separator tank. Water in the fluid circuit leads to corrosion in metal parts and reduces the cooling and lubricating qualities of the fluid. Operating temperature, determined by the choice of working element within the thermostatic valve, is dependent on the pressure range and the climatic zone in which the compressor is used. ** Pressure dew point is the temperature at which the air is saturated with moisture. If the air picks up any more moisture it is precipitated out as water (condensate). II Fluid filter The valve also serves as a filter head to which a spin-on element is attached. The element is mounted directly on the valve outlet so that 100% of the fluid flow is filtered before returning to the airend. Direct mounting avoids the need for connecting pipes.

2/25/2012

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2/25/2012

A Cold fluid Fluid flows from the separator tank to the valve inlet(1). When the fluid is cold, the working element (2) and the actuating piston (3) remain in their initial positions. The fluid flows past the cooler through the bypass (4) (as the cooler presents a higher resistance to the fluid than the bypass, the fluid takes the path of least resistance). The fluid flows through the fluid filter (5) directly to the airend (6). In this way, it reaches operating temperature in the shortest possible time. B Warm fluid The fluid flows from the separator tank to the valve inlet (1). The heated fluid flows around the thermostatic working element (2). The working element forces the actuating piston (3) downwards. The passage to the bypass (4) narrows continuously and some of the fluid flows through the cooler. When the fluid reaches operating temperature, the actuating piston (3) is forced down completely by the working element (2). The bypass (4) is closed. All the fluid is routed through the cooler. The fluid flowing out of the cooler is fed to the filter (5). Cooled and filtered fluid is now routed directly to the airend (6).
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Sigma Control

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Traffic light function


Plain text display

Basic function: ON/OFF

Traffic light functions

Preselect functions

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Menu-functions UP key Scrolls the display text downard line for line DOWN key scrolls the display text upward line for line

Quick and simple operation thanks to menu guidance

Escape key returns to next higher level Return key initiates jump to next sub-menu or accepts value

Acknowledge key acknowledges alarms andwhen permitted - resets the alarm memory Info key access to additional information or to the event information memory.

2/25/2012

MUHAMMAD SAJID

Untreated air dirt oil aerosols moisture

Problems in the air main corrosion pressure loss contamination Maintenance

Problems with equipment contamination tool wear scrap downtime

COSTS COSTS

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Condensate separation
To ensure sufficient separation, liquids and heavy particles are subjected to centrifugal forces at high rates of flow. The degree of separation is around 95% at 6 bar, 20 C and the nominal volumetric flow rate. The pressure drop is approximately 0.05 bar .

air inlet

air outlet

deflector

cyclonic air movement

condensate collection 2/25/2012 MUHAMMAD SAJID

Desiccant Dryer
1 2 3 4 Microfilter FE (0.01 m, 0.01 ppm) Flow Distributor Stainless Steel Flow diffuser Desiccant bed: moisture adsorption 5 Upper Part of Dessicant chamber 6 Security Reserve 7 Flow distributor 8 Particulate filter FD 1 m 9 Purge (regeneration ) air valve 10 Desiccant bed: regeneration 11 Purge air exhaust silencer

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Drying cycle
The incoming compressed air from the receiver tank is filtered by the inlet filter FE (1) from liquid and dust particles (particle size 0,01 m). The air passes through inlet air valve via stainless steel flow distributor (3) where the air is distributed to the whole cross section of the chamber. In the mass transfer zone (4) most of the moisture is transferred to the desiccant granules.The second part of the chamber (5) takes away the remaining moisture to reach the needed dew point. The last part is a security reserve (6). The dried compressed air then flows through the flow distributor (7) and the shuttle valve to the compressed air outlet. Then the air is filtered from dust particles (particle size 1 m) in the dust filter FD (8).

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Regeneration of desiccant The regeneration is done by a part of the air flow of the dried air of the first chamber. The part air flow is passing through the shuttle valve (9) and going from top down through the second chamber. As expanding air is able to take up moisture, the dry air is regenerating the desiccant (10). The amount of needed regenerating air is a physical size and can be optimised by an adjustable regeneration nozzle (9). The wet purge air is passed through top flow distributor (2), purge air valve and purge air muffler (11) into the atmosphere.
2/25/2012 MUHAMMAD SAJID

How large are the impurities in the air?


Description: Perception: vapour / mist / smoke Description:
Sec.

dust microscopic

fog:

spray visual

rain

Falling time at 1 m height

Min.

Influence of the Brownian Molecular movement

water mist carbon dust traffic dust cement dust pollen plant spores bacteria metallurgical dust paint spray mist

foundry sand heavy industrial smog

Viruses gas molecules

oil vapours tobacco smoke

oil mist

centrifugal separation and filtration performance normal bag-type heavy air filter

pore dia, activ. carbon, silica-gel, etc.

Particle size in microns

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Prefilter (FB, FC Type)


used as a coarse filter for 100% saturated compressed air (or for water vapour components in the liquid phase)
Streamed from the inside to the outside.

FB is used to remove particles > 3 um FC is used to remove particles > 1 um

2/25/2012

MUHAMMAD SAJID

Microfilter (FE, FF Type)


0.01 micron for liquids (aerosols) and particles oil aerosol content: 0,01 ppm to 0,001 ppm

2/25/2012

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How does the microfilter work?


contaminated air filter medium (deep-bed filter) technically oil-free clean air

Direct interception Impact

Diffusion /Coalescence

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THANK YOU

2/25/2012

MUHAMMAD SAJID