CECCATO AIR GUIDE
Compressed PARTNETECHNOLOGYYOU CANTRUSTSIMP LI CIT Y
IntroductionThe Air GuideThe aim of the Air Guide is to get abetter understanding about air, and moreimportant of our business compressed air.In the Air Guide you will find everythingyou need to know about compressed airand most of the applications that comewith it. This can range from designing asystem to seeking information on how thecompressor works.The Air Guide is designed so that you, thecustomer, can feel confident with yourpurchase and know that all information isavailable in order to optimize you system.Another purpose of the Air Guide is that itcan serve as training/study material. TheAir Guide is written in a educating andentertaining way, and is suitable to usefor both company owners, sales crew,support functions and service crew, it hassomething for everyone.Enjoy The Air Guide
Table of contents1 Compressing air 4About air 5About compressed air 5What does compressed air contain? 6Units 6What happens when air is compressed? 7Compressed air as an energy medium 72 Choosing the system Choosing the compressor system Compressor system 822Compressed air dryer 236 Filteringcompressed air 24Compressed air filter 257 Technical Information 26910Compressed air budget 27Examples of compressed air consumptionRecommendations - the choice ofcompressor system 5 Drying compressed air 12by some common machines 27How much condensation is produced by the3 Reciprocatingcompressors The reciprocating compressor 4 Screw compressors 141516The screw compressor 17Frequency driven compressors 18Examples of potential savings 19Savings summary 20Heat recovery system 22Airborne heat recovery 21compressor system 28Classification of compressed air quality 28Air humidity 29Compressed air flow through pipes and nozzles 32Ventilation requirements / Heat recovery 34Electric motors, general information 36Conversion factors 38FAQ sheet pistons 39FAQ sheet screw compressors 40FAQ sheet quality air solutions 42Table of contents3
1.CompressingairWhat exactly happens when we compressair? How does a compressor work? What typeof compressor do I need? The CompressedAir Guide contains answers to such questions.It also explains terms and expressions thatoccur in connection with the compressionof air, and you will gain an insight into howthe different parts of a compressor systemcombine to supply your machines and toolswith compressed air.4Compressing air
About airLife on earth depends on a gas bubble, theatmosphere, that surrounds our globe. This protectivebubble extends approx. 1000 km into space. Whatwe commonly call air is a gas mixture consistingmainly of nitrogen, oxygen and a larger or smalleramount of water vapor. The air also contains smallamounts of inert gas and, unfortunately, a lot ofpollution in the form of hydrocarbons producedby man.The air composition remains largely the same, upto about two miles altitude.Other Gases 1%Oxygen (O)21%Nitrogen (N)78%About atmosphericpressureOn the earth’s surface the air has a weight of approx.1.2 kg/m³. This means that the earth’s surface, and anyobjects upon it, are subjected to a pressure that we callair pressure or atmospheric pressure.This pressure corresponds to the weight of an air columnwith a base of 1 cm² and a height of 1000 km; i.e. fromthe earth’s surface to the atmosphere’s upper limit.The air pressure decreases with increasing altitude; it ishalved approximately every 5 km upwards, and we saythat ”the air gets thinner.”About compressed airUnlike liquids, air can be compressed; i.e. a given volumeof air can be reduced with increased pressure within thenew volume as a result.Compression is carried out in a machine with a powersource, a compressor. In its simplest form, a compressorcan be a football pump with a human as the power source.Air is drawn into the pump and compressed to about 1/4of its original volume. The air pressure inside the footballtherefore rises to four times atmospheric pressure. We’veput air into the ball.Compressing air5
The absolute atmospheric pressure is about 100 kPa (1 bar).The air pressure in a football can be specified in different ways: as four times the absolute atmospheric pressure, 400 kPa (a) (4 bar), as excess pressure, 300 kPa(e) (3 bar), or as 300 kPa (3 bar) (understood as excess pressure).(See the fact box below)UnitsAtmospheric pressureCompressed airIn the international unit system, Pa (Pascal) is theaccepted basic unit of pressure.Compressed air pressure is typically specified asoverpressure; i.e. pressure above normal atmosphericpressure. This is usually implicit but is sometimesclarified with an (e), kPa(e).As 1 pascal in compressed air is a very small amountof pressure we typically use the unit:kPa (1 kilopascal 1000 Pa)orMPa (1 megapascal 1000 kPa)The general air pressure on the earth’s surface canbe specified in different ways, with more or lessthe same meaning:1 atm (atmosphere) 1 kp/cm² (kilopond/cm²)100 kPa (kilopascal) 1 barA compressor’s operating pressure is generallyspecified as overpressure.The compressor’s capacityA compressor’s capacity; i.e. the amount ofcompressed air that can be supplied per unit oftime; specified in:l/min (liters/min), l/sec (liters/second) or m³/min(cubic meters/minute).Capacity refers to atmospheric pressure expanded air.An (N) before the device; e.g. (N) l/sec stands for”normal” and means that the volume specificationapplies to a specific ambient pressure and a specifictemperature. In most practical cases, (N) l/sec isequivalent to l/sec.What does compressed air contain?The compressed air the compressor produces naturally contains the same elements as the sucked-upambient air. The water vapor in the air is also compressed and thus the compressed air is humid.Compressed air from an oil-lubricated compressor also contains small amounts of oil from the compressor’slubrication system.Depending on what the compressed air is to be used for, there are different requirements for what is acceptablein terms of pollution. The compressed air’s quality often needs to be improved by drying (humidity is reduced)and filtering (oil and other particles are removed).Compressed air quality can be defined in different classes according to an international system (see theTechnical Information page 31).6Compressing air
What happens when air is compressed?HeatWater vaporThe power supplied to the compressor is entirelyconverted during the compression process intoheat, regardless of the type of compressor. Thetotal heat production is therefore always equal tothe input power.Following compression and a certain amount ofcooling, the compressed air is saturated with watervapor and will have a relative humidity of 100%. Asthe compressed air passes through the compressedair system’s coolants, this steam condenses intowater. The temperature at which this occurs iscalled the dew point.A relatively small compressor with a motor powerof 3 kW thus generates as much heat as a saunaunit! To improve the overall budget of a compressorsystem, this heat can be recovered through localheating.To prevent overheating, the compressor’s coolingmust be properly designed. Cooling is generallyachieved using air, or in some cases with water.We then find condensate in the air and water tanksand piping. The amount of condensate dependson four factors, namely1) the amount of water vapor in the ambient air,2) the amount of air that is compressed,3) the compressed air’s drop in temperature aftercompression and4) the compressed air’s pressure.Compressed air as an energy mediumExtracting power from compressed air is advantageous in many aspects. Firstly, as a power source,compressed air is both clean and harmless, and secondly, it can also be used for such diverse tasks asoperating tools and pistons in order to move or cool material.An external power source is required to power a compressor; typically an electric or internal-combustionengine. The power that is theoretically required to compress air to a certain volume and a certain pressureis physically fixed and cannot be changed.There is a certain power loss during compression, which affects the system’s total power needs. We willtherefore discuss a compressor’s specific power needs; i.e. the actual power required to compress a givenvolume of air to a specific pressure, plus the power loss in the compressor.For compression to 700 kPa (7 bar) in a modern industrial compressor, normally requires approximately6.5 kW/m³/min of power. An increase or decrease in pressure of 100 kPa (1 bar), results in a correspondingincrease or decrease in power requirements of approximately 7%.Compressing air7
2.Choosingthe systemThe Compressed Air Guide has identified twomain types of compressors: reciprocatingcompressors and screw compressors. Acomprehensivecompressedairsystem,which meets modern budgetary, accessibilityand environmental demands, consists of thefollowing units.8Choosing the system
Choosing the compressor systemIn order to choose the right type of compressor and associated equipment, we need to know or determinecertain conditions. An accurate assessment of the actual requirements means the selected system is usedoptimally, with regard to capacity and budget.Basic requirementsThe following factors are essential when designing a compressor system: What amount of compressed air is needed to perform the proposed job? During which operational cycle is the compressed air used? What quality of water, oil and particulate content of the compressed air is required for the supportingequipment? Which operating pressure does the supporting equipment require?AmountOperational CycleCompressed air consumption can be estimatedfrom past experience. The method is uncertainand requires considerable experience on the partof the assessor.Is consumption continuous around the clock?Does consumption vary during the working day?Is there any special equipment that requires largeintermittent expulsion of compressed air?Another way is to measure an existing compressor’sload; a method that works well for the expansionof an existing system.A third method is to measure connected machinesand tools’ compressed air consumption. To getan accurate result, it is important to include theworking time and the consumption’s operationalcycle in the assessment.Working pressureThe compressor is adapted to the piece ofequipment that requires the maximum workingpressure. Compressed air tools within theindustry are often designed to be suppliedwith a working pressure of 600 kPa (6 bar).The compressor will normally produce a slightlyhigher pressure to compensate for pressure dropsin compressed air dryers, filters and ducts.QualityDepending on what the compressed air is to beused for, determines what is acceptable in termsof particles, oil residue and water.Estimating your air consumptionN ( V x p ) x 60tN air consumption in l/minV tank capacity in liters p max./min. pressure differential (min. advicedvalue 2 bar)t needed time (in sec.) to go down from max. tomin. pressure (while a plant is running)In the above example, a suitable working pressurefor the compressor would be 700 kPa (7 bar).Choosing the system9
Compressor systemThe Compressed Air Guide has identified two maintypes of compressors: reciprocating compressorsand screw compressors. A comprehensivecompressed air system, which meets modernbudgetary, accessibility and environmental demands,consists of the following units.1Reciprocating compressor2Screw compressor3Air tank4Filter5Refrigerant dryers6Adsorption dryers7Oil-water separator8Condensate drains352488110 Choosing the system8
448488687Choosing the system11
Recommendations - the choice of compressorwith equipmentCompressed Air RequirementsIntermittent operation:(one-shift, max. 4 hours/day)Quantity of compressed air 50-800 l/minOperating pressure 100-800 kPa (1-8 bar)Operating pressure 700-3,000 kPa (7-30 bar)(Single shift)Quantity of compressed air 100 l/min electric.moreOperating pressure 500-1,300 kPa (5-13 bar)CompressorOne-stage reciprocatorcompressor(with air tanks)Several-stage reciprocatorcompressor(with air tanks)Screw compressor with air tanksContinuous operation:Capacity 100 l/min and moreOperating pressure 500-1,300 kPa (5-13 bar)Quality requirementsOperational air for pneumatic toolsin heated rooms.Optional equipmentDryerWorking air in unheated rooms or outdoorpipes. Operational air for precision mechanicsand electronics up to - 70 in the dew pointAdsorption dryerWhen using the dryer as a post-filter.When using an adsorption dryer, and pre-filters.When spray painting, blasting and cleaning.Oil Separation FiltersBreathing Air, (using cold or adsorptiondryers). Laboratory Air.Oil Separation Filters Active carbon filterOperational air for precision mechanics andelectronics.Oily condensate cannot be releasedinto the sewer system.For a clean compressor and a healthyenvironment.Choosing the system12Oil-water separator
Choosing the system13
3.ReciprocatingcompressorsA reciprocal compressor consists of one ormore cylinders with pistons driven by a motor.The air is sucked into the cylinder and thencompressed, in one or more stages to theoperational pressure. After compression, thecompressed air passes through the aftercooler and continues on to the air tank.14Reciprocating compressors
The Reciprocating CompressorOil-lubricated and oil-free?An oil-lubricated compressor’s cylinders, pistons and cranks are lubricated by oil circulating in the compressor.The compressed air from an oillubricated reciprocal compressor contains a certain amount of residual oil,typically 10-15 mg/m³.Most versions of oil-free reciprocal compressors have permanently lubricated bearings. The pistons havegrease-free piston rings, usually of Teflon or carbon fiber. This type of compressor typically requires morefrequent replacement of bearings and piston rings than the oil-lubricated versions. In return, the compressedair is free of residual oil.Application areasReciprocal compressors are mostly suitable for small compressed air requirements; one-stage compressorsfor pressures up to about 800 kPa (8 bar), while several stage versions can produce up to 30,000 kPa (30 bar).Operation should be intermittent. An air-cooled reciprocal compressor’s load level must not exceed 60%.After 2 minutes of compression, the compressor must rest for at least 1.5 minutes. The total compressiontime per day should be kept to a max. of approx. 4 hours.The one-stage compressor Multi-stage compressorA one-stage compressor has one or more cylinders,each of which compresses air from atmosphericpressure to operational pressure.A multi-stage compressor has two or more cylindersconnected in series in which air is graduallycompressed to the final pressure.Between steps, the compressed air is cooled withair or water.Thereby improving efficiency, while achieving amuch higher pressure than from the one-stagecompressor.Reciprocating compressors 15
4.ScrewcompressorsThe screw compressor compresses the airin a space formed between two opposingrotating screws. These form, together withthe surrounding air compressor housing, thescrew drive. A screw compressor mainlyworks on two premises: liquid injection ordrying. Both versions come in one-and twostage models.16Screw compressors
The screw compressorLiquid-injected screw compressorsIn a liquid-injected screw compressor the compressed air is cooled with a cooling liquid in the compressionchamber between the screws. The coolant, usually oil, circulates in a closed system between (1) liquidtanks, (2) coolers and (3) screw units and mixed with air before compression. The compressor’s operatingtemperature is therefore kept at around 80 C whatever the load and pressure.Immediately after compression, the coolant is separated from the compressed air in (4) the oil separator.The com-pressed air then goes through an (5) after-cooler and then on to the air tank.(5) After-coolers(3) Screw drive(2) Coolers(4) Oil separator(1) Liquid tanksPrinciple of liquid injected screw compressorApplication areasDrying compressorsThe screw compressor is suitable for both intermittentand continuous operation. Operating budget isoptimal during continuous operation at high loadlevels (up to 100%). With modern technology; e.g.speed control, the screw compressor’s energyconsumption for low or varying air requirementscan be reduced significantly compared to previousmethods.The dry or “oil free” screw compressor compressesair without cooling the compression chamber. Thecompressor’s operating temperature therefore risesto about 200 C, even at an operating pressure of300 kPa (3 bar).Liquid-injected screw compressors in one-stagemodels currently dominate the industry, whereopera-tional pressures up to 1300 kPa (13 bar) anda capacity of up to approx. 30 m³/min are required.For normal industrialair pressure (about700 kPa/7 bar), thedrying compressor musttherefore compress the airin two stages and cool thecompressed air betweenthe compression stage.Screw compressors17
Frequency driven compressorsThe piggy bank for both your wallet and the environmentBuying a new compressor is a large investment for both large and small companies. But in fact, a compressor’sinvestment cost is very low if you look at a compressor’s life cycle. Approximately 75% of the total cost ispower/energy costs. If you are thinking of investing in a new compressor, it is this cost we will try to minimize.This chapter describes the smart savings that canbe made through minimizing power consumption.First, it can be as simple as choosing the rightmachine for a particular job. It has been shown inmany cases that companies choose a compressorthat is too big because uncertainty over the actualair demand, ,or the wrong technology due to badknowledge of what is the most efficient for yourapplication.To choose the right model of compressor can bedone in different kinds of ways. It can be done witha real measurement, where you measure the currentvalue and out of that simulate potential savings. Itcan also be done with some of the sophisticatedbusiness tools, or just by experience. If you havedone a measurement and a correct simulationof the previous compressor, you will not seldomexperience a big saving potential by replacing yourconventional load/unload compressor with frequencydriven unit. If we study the illustration below. Theblue/green fields show the working pattern of a load/unload compressor. In load mode the compressor isLoad/UnloadFrequency driven18Screw compressorsrunning 100% and pressure is rising, until it reachesits max pressure value, then the compressor turnsinto unload mode before shutting off after a setamount of time, until the compressor unit reachesthe minimum pressure value then the compressorstarts up the same routine.This leads to unnecessarily high power output andtherefore higher energy costs.A frequency driven compressor has a differentworking pattern, as you see in the below illustratedexample (blue), with lower peaks and a smootherair profile. The reason that the curve looks differentfor a frequency driven compressor is that it adjustsafter the air demands and produces the amountneeded for a specific moment. This is done by apressure sensor that reports the pressure to thecontroller that gives a signal to the inverter aboutthe situation. The inverter adjust the motor speeddepending on the pressure settings. This technologyis a real piggy bank both for the environment andfor your energy bill.
Examples of potential savingsA frequency driven compressor saves in average between 25-35% in electrical cost compared to your previouscompressor installation. This may not sound like a big saving, but by illustrating this with an example below,I’ll show you how much money you could save by choosing a frequency driven compressor.And remember that it is not the lowest price you should consider, it is the lowest cost that
The reciprocating compressor 15 Screw compressors 16 The screw compressor 17 Frequency driven compressors 18 Examples of potential savings 19 Savings summary 20 Heat recovery system 22 Airborne heat recovery 21 Drying compressed air 22 . CECCATO AIR GUIDE .
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at 150 fpm and the air conditioned air is delivered at 200 fpm. The air conditioned air completely pressurizes the untempered air toward the exhaust hood, thus preventing the hot air from entering the kitchen. The hot air is forced into the exhaust hood to be exhausted and the cool, air conditioned air is free to mix with the air in the conditioned
the air line may not be pushed all the way in or cut squarely. NOTE: The Air Command kit is designed to monitor the air pressure in the air springs not the pressure be-tween the air compressor and the gauge. If no air is reaching the air springs, or the pressure will not release from the air springs, the air line tubing connections may be reversed.
3 / 6 Das AIR-System. Das AIR-System führt der Verbrennung Aussenluft zu. Das VISIO brennt raumluftunabhängig. AIR système. Le système AIR alimente la combustion en air extérieur Le VISIO brûle indépendamment de l'air ambiant. The AIR system. The AIR system feeds outside air to the combustion. The VISIO burns independently of the room air.
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