This TECHNICAL SEMINAR

IS INTENDED FOR PLANT PERSONELLS

WHO WANT TO GAIN AN
UNDERSTANDING OF THE BASICS OF
INDUSTRIAL COMPRESSED AIR SYSTEM
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

INPUT POWER FOR A FLUID SYSTEM

is ALWAYS electrical (electric motor)
or mechanical (from an engine)

THE POWER IS THEN CONVERTED TO

EQUIVALENT AMOUNT of FLUID POWER
by means of an AIR COMPRESSOR or
HYDRAULIC POWER PACK

IT CAN BE TRANSMITTED THRU

moderate distance and then be converted
back to MECHANICAL POWER by means
of A LINEAR MOVING PISTON or a
s = 0.025 m
ROTATING FLUID MOTOR
F=100N

v = 1 m/s
 KINETIC FLUIDTRONICS INCORPORATED

Actuator/action
DURING IT’S TRANSITION
- +
suitable VALVING(valves) is a0 a1

added CONTROL direction of A

FLOW
CONTROL
TO REGULATE the rate of 4 2
FLOW and to limit the 14 12
maximum PRESSURE in the 5 1 3
PISTON and transmitting PIPES 2
10
or tubings 12
Run/End 3 1
2 2
12 10 12 10
THE WHOLE ARRANGEMENT IS CALLED a0 3 1 a1 3 1
THE “FLUID POWER CIRCUIT”
INPUT/signal
COMPRESSED AIR SYSTEM
Consist of a SUPPLY SIDE, which includes
COMPRESSORS and AIR TREATMENT
COMPRESSED AIR SYSTEM

And a DEMAND SIDE, which includes

DISTRIBUTION and STORAGE systems,
and END-USE equipment
A properly managed SUPPLY SIDE
Will result in CLEAN, DRY, STABLE air
being DELIVERED at the proper
PRESSURE in a dependable COST
EFFECTIVE manner
IMPROVING and MAINTAINING
peak

COMPRESSED AIR performance requires

addressing both the SUPPLY SIDE and
DEMAND SIDE and how they INTERACT
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

WHAT TO EXPECT AFTER THE PRESENTATION

To understand better COMPRESSED AIR FACILITY
configuration and management
To know how to specify CORRECT PIPE sizing relative
to type of compressor
To be able to assign appropriate TANK OR RECEIVER
size in relation to your compressed air plant

To be able to calculate amount of moisture in a given

compressed air system
To be able to know and size the various components
needed in COMPRESSED AIR TREATMENT
 KINETIC FLUIDTRONICS INCORPORATED

To introduce participants to the advantages of

the FREE TRAINING MATERIALS we are also
going to provide for “follow on thru” learning
and eventually establish their own in-house
training
COMPRESSED AIR SYSTEM

Consist of a SUPPLY SIDE, which includes

COMPRESSOR and AIR TREATMENT

And a DEMAND SIDE, which includes

DISTRIBUTION and STORAGE systems and END-
USE equipment
 KINETIC FLUIDTRONICS INCORPORATED
YOUR COMPRESSED AIR FACILITY

COMPRESSED AIR
CONSUMING
COMPRESSED AIR
PRODUCING
A properly managed SUPPLY SIDE

Will result in CLEAN, DRY, STABLE air

being DELIVERED at the proper
PRESSURE in a dependable COST
EFFECTIVE manner
 KINETIC FLUIDTRONICS INCORPORATED

Typical compressed air facility

Improving and maintaining peak
air performance
Requires addressing both the SUPPLY
SIDE and the DEMAND SIDE and how they
interact
COMPONENTS of an INDUSTRIAL
COMPRESSED AIR SYSTEM
A COMPRESSOR IS MACHINE THAT
INCREASES PRESSURE BY REDUCING A
SPECIFIC CHAMBER VOLUME
 KINETIC FLUIDTRONICS INCORPORATED

Reciprocating compressors were the first of the

modern air air compressor designs. Reciprocating
compressors utilize a piston moving within a cylinder
to compress low-pressure air to high pressure. They
are available in single-acting and double-acting
configurations. Each of these configurations utilizes a
variety of cylinder layouts.
 KINETIC FLUIDTRONICS INCORPORATED

The compressor
                
Compressed air can be produced via two processes :
*Dynamic compression (conversion of the air velocity
into pressure) :
radial and axial compressors.

*Displacement compression (reduction of the air

volume) :
reciprocating compressors (piston type) and rotary
compressors ( screw- , vane-, roots- or liquid ring
compressors).
 KINETIC FLUIDTRONICS INCORPORATED

Compressor installation
 Typical medium size compressor installation
 Integrated compressor unit including inlet filter,
electrically driven compressor, after cooler and water
separator
 Air receiver to smooth demand surges, and provide
additional cooling and water collection
Safety valve
Pressure gauge
Distribution pipe Symbol for contents of the
Integrated compressor Integrated compressor
and after cooler
SWP
10bar
Isolating valve

Air receiver
M

Drain valve

Condensate drain
 KINETIC FLUIDTRONICS INCORPORATED

Compressor, receiver, dryer

 Suction side
 Inlet filter
 Compressor
 After cooler
 Moisture trap
 Auto drain
SWP
10bar
 Shut off valve
 Receiver w/ Auto drain
 Shut off valve
 Bypass option
 Mechanical main line filter
 Compressed air dryer
 Coalescing main line filter
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

32 degrees Celcius 90% RH , 25.05 grams of water per meter cube

 KINETIC FLUIDTRONICS INCORPORATED

As shown in figure ACT1.1, positive-displacement

compressors are available in two basic styles,
reciprocating and rotary. Each of these basic styles
is then further segmented by different technologies.

                                                                    
 POSITIVE DISPLACEMENT
COMPRESSOR
 RECIPROCATING

 ROTARY SCREW
KINETIC FLUIDTRONICS INCORPORATED
COMPRESSOR PRIME MOVERS
ELECTRIC MOTOR

PETROL COMBUSTION ENGINE

COMPRESSED AIR SYSTEM
CONTROL

Are various SYSTEM CONTROLS that

serve to match COMPRESSOR SUPPLY
with SYSTEM DEMAND
 COMPRESSOR ACCESSORIES
 AIR INLET FILTER
 COMPRESSOR COOLING
 INTERCOOLING for multi stage
 AFTERCOOLERS ( fan cooled / watercooled )
 CONDENSATE or WATER SEPARATORS
 AIR RECEIVER
 COMPRESSED AIR DRYERS
 VARIOUS FILTERS ( mainline / end-use )
 Shut-off & by-pass VALVES
 REGULATING VALVES
 DISTRIBUTION ( pipings )
 INSTRUMENTATION
KINETIC FLUIDTRONICS INCORPORATED
AIR INLET FILTER
AIR INLET FILTER
KINETIC FLUIDTRONICS INCORPORATED
INTERCOOLING FOR MULTI
STAGE COMPRESSORS
 KINETIC FLUIDTRONICS INCORPORATED

Compute for VOLUME of cylinder as shown

D mm
4 in.

8 in

Volume = area (height)

 KINETIC FLUIDTRONICS INCORPORATED

One cubic unit of air space at varying conditions

Cubic feet Cubic meter

liters decimeter

Per hour
Per minute
 KINETIC FLUIDTRONICS INCORPORATED
CU.INCH DIVIDE BY
1728=CU.FEET CU.MM DIVIDE BY
multiplier 28316846=CU.FEET

18 CU.METER PER MINUTE (35.31) = 635.58 CFM

1 CU.METER PER MINUTE = 35.31 CFM

1 decimeter per min. = 1.0 liter per min.

635.58 CFM (28.3) = 17986.91 LITERS PER MINUTE

1 CFM = 28.3 LITERS PER MINUTE

 KINETIC FLUIDTRONICS INCORPORATED

RULE OF THUMB

A good compressor, per true HP, will deliver about 4 true CFM at
100 psig.

The tank should be sized to be at least 1 gallon of volume per

CFM of the compressor.
Uncooled compressed air is hot, as much as 250 to 350 deg F!
121 to 176 degrees celcius.
Beware also, that the CFM figure given as the required air power on many tools (e.g., air
chisels/hammers, sandblasters) is for an absurdly low duty cycle.
You just can't run these constantly on anything but a monster compressor, but
the manufacturer still wants you to believe you can, so you will buy the tool

Reference: Machinery's Handbook (26th edition, see http://www.industrialpress.com/mh.htm) has an

excellent section on analyzing compressed-air systems, including formulas and tables on the horsepower
required to compress air, and losses in pipes and hoses. Marks' Standard Handbook for Mechanical
Engineers describes the thermodynamics of expansion and compression of air in the section on "General
Principles of Thermodynamics", subsection "Special Changes of State for Ideal Gases", item 5
"Polytropic"; and practical compressor technology in the "Pumps and Compressors" chapter.
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Air receivers serve several important

purposes.

Decrease wear and tear on the

compression module, by reducing excessive
compressor cycling.
Eliminate pulsations from the discharge line.
Separate some of the moisture, oil and solid
particles that might be present
Help reduce dew point and temperature spikes
that follow regeneration.
Offer additional storage capacity made to
compensate for surges in compressed air
usage.
 KINETIC FLUIDTRONICS INCORPORATED

One gallon per CFM of capacity is the

minimum amount of storage
recommended

HANDOUTS FOR TANK SIZING

 KINETIC FLUIDTRONICS INCORPORATED

Pressure and force

 Compressed air exerts a
force of constant value to
every internal contact
surface of the pressure
containing equipment.
 Liquid in a vessel will be
pressurised and transmit
this force
 For every bar of gauge
pressure, 10 Newtons are
exerted uniformly over
each square centimetre.
 KINETIC FLUIDTRONICS INCORPORATED

Why is aftercooling required?

The compressed air discharged from an air
compressor is hot . Compressed air at these
temperatures contains large quantities of water
in vapor form. As the compressed air cools this
water vapor condenses into a liquid form. As an
example if an aftercooler is not used, a 200 scfm
compressor operating at 100 psig introduces 45
gallons of water into the compressed air system
each day.
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED
Air Cooled Aftercooler
                        
Air cooled aftercoolers (fig. AC1-2) use ambient air to
cool the hot compressed air. The compressed air enters
the air cooled aftercooler. compressed air travels through
finned tubes or corrugated aluminum sheets of the aftercooler
while ambient air is forced over the cooler by a motor-driven
fan. The cooler, ambient air removes heat from the
compressed air.
 KINETIC FLUIDTRONICS INCORPORATED

The disadvantages of a water-cooled aftercooler include high water usage

and difficult heat recovery. Advantages to using a water-cooled
aftercooler include better heat transfer and no required electricity.
 KINETIC FLUIDTRONICS INCORPORATED

A moisture separator installed at the

discharge of the aftercooler removes
most of the liquid moisture and solids
from the compressed air. Utilizing
centrifugal force, moisture and solids
collect at the bottom of the moisture
separator. An automatic drain should be
used to remove the moisture and solids.
KINETIC FLUIDTRONICS INCORPORATED
WATER SEPARATOR
 KINETIC FLUIDTRONICS INCORPORATED
93.3 °C Oil flooded rotary
176 °C Oil free rotary
Temperature at discharge
148 °C 2 stage reciprocating
107 °C Vane compressors
30 – 34 °C 50 - 65 °C
Compressed Air System Components
Suction side Inlet filter Compressor After cooler

 
42 °C
Receiver w/ Auto drain Shut off valve Auto drain Moisture trap

Shut off valve Bypass option Mechanical main line filter

                                                                                                     
temperature shall more or less be lower than the ambient

Coalescing main line filter Compressed air dryer

Compressed air consuming

 KINETIC FLUIDTRONICS INCORPORATED

Typical compressed air facility

KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

COUNTRY 1 COUNTRY 2 COUNTRY 3

50% RH 65% RH 90% RH

Here in the Philippines our RELATIVE HUMIDITY averages whole year

round at 90% RH.

Different global regions has different RELATIVE HUMIDITY.

Country 1 has less water in air than Country 3

 KINETIC FLUIDTRONICS INCORPORATED

Air cooled to a lower temperature

 The amount of water vapour contained in a sample of the
atmosphere is measured as relative humidity %RH. This
percentage is the proportion of the maximum amount that
can be held at the prevailing temperature.
25% RH 50% RH 100% RH

40
Temperature Celsius

At 20o Celsius
20
100% RH = 17.4 g/m3
50% RH = 8.7 g/m3
0
25% RH = 4.35 g/m3
-20

-40
0 10 20 30 40 50 60 70 80
Grams of water vapour / cubic metre of air g/m 3
 KINETIC FLUIDTRONICS INCORPORATED

Air cooled to a lower temperature

 If 1 cubic metre of fully saturated compressed air ( 100 %
RH ) is cooled to just above freezing point, approximately
75% of the vapour content will be condensed out. When it
is warmed back to 20OC it will be dried to nearly 25% RH
25% RH 50% RH 100% RH

40
Temperature Celsius

20

-20

-40
0 10 20 30 40 50 60 70 80
Grams of water vapour / cubic metre of air g/m 3
 KINETIC FLUIDTRONICS INCORPORATED

Low temperature drying

 If 1 cubic metre of fully saturated compressed air ( 100 %
RH ) is cooled to just above freezing point, approximately
75% of the vapour content will be condensed out. When it
is warmed back to 20OC it will be dried to nearly 25% RH
25% RH 50% RH 100% RH

40
Temperature Celsius

20

-20

-40
0 10 20 30 40 50 60 70 80
Grams of water vapour / cubic metre of air g/m 3
 KINETIC FLUIDTRONICS INCORPORATED

Low temperature drying

 If 1 cubic metre of fully saturated compressed air ( 100 %
RH ) is cooled to just above freezing point, approximately
75% of the vapour content will be condensed out. When it
is warmed back to 20OC it will be dried to nearly 25% RH
25% RH 50% RH 100% RH

40
Temperature Celsius

20

-20

-40
0 10 20 30 40 50 60 70 80
Grams of water vapour / cubic metre of air g/m 3
 KINETIC FLUIDTRONICS INCORPORATED

Water in compressed air

 When large quantities of
air are compressed,
noticeable amounts of
water are formed
 The natural moisture
fully vapour contained in the
saturated atmosphere is squeezed
air out like wringing out a
damp sponge
 The air will still be fully
saturated (100% RH)
within the receiver
Condensate
Drain
 KINETIC FLUIDTRONICS INCORPORATED

Water in compressed air

 The illustration shows four cubes each representing 1
cubic metre of atmospheric air at 20oC. Each of these
volumes are at a relative humidity of 50% (50%RH). This
means that they actually contain 8.7 grams of water
vapour, half of the maximum possible 17.4 grams
KINETIC FLUIDTRONICS INCORPORATED
TYPES OF COMPRESSED AIR
DRYER
COMPRESSED AIR DRYER

Have different operating characteristics

and degrees of DEWPOINT
Compressed air DRYER RATINGS

Are usually based on STANDARD DRYER

INLET CONDITIONS
KINETIC FLUIDTRONICS INCORPORATED
REGENERATIVE DESSICANT
TYPE DRYERS
Use POROUS dessicant that ADSORBS moisture by
collecting it in PORES

Silica gel
Activated alumina
Molecular sieve
MEMBRANE TECHNOLOGY
compressed air dryer
Use mainly for GAS SEPARATION allows
molecules of certain gases to pass thru
SEMI-PERMEABLE membrane fiber
Membrane dryer
MEMBRANES allow WATER VAPOR to pass thru
PORES of MEMBRANE faster than other GASES

REDUCING amount of MOISTURE at AIR STREAM

outlet
Membrane technology dryer
 KINETIC FLUIDTRONICS INCORPORATED

Why Filter Compressed Air?

Oil, dust, dirt and water contaminate
compressed air systems. Contaminants can plug
orifices wear out seals, erode system
components, reduce the efficiency of air-operated
tools, damage finished products and otherwise
contribute to product rejects The best defense
against oil and dirt is effective compressed air
filters.
KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Typical compressed air facility

KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Types of compressed air inlet filters

Compressor Intake Filter
The first line of defense is the intake air filter, which
reduces the bulk contaminant load protecting the
compressor from dirt and solids. Generally, these are
cartridge type filters with a greater than 98% air
efficiency rating at 10µm. There has been a recent move
to 3µm filtration. Over 80% of the contaminants
challenging an intake filter are less than 2 um and
therefore the majority of these contaminants enter the
compressed air system with the intake air. Other
compressed air filters are available to remove
particulate contaminants down to 0.3 um and to remove
chemical contaminants.
Typical compressor inlet filter
 KINETIC FLUIDTRONICS INCORPORATED

In terms of particle size, contaminants in a typical compressed air

system range from 10 microns to 0.01 micron. A micron (or
micrometer) is one-millionth of a meter or approximately 0.00004 inch.
                           

If a 5-micron particle were represented by a basketball, then on the

same scale, a 0.5-micron particle would be the size of a golf ball. This
size difference (golf ball vs. basketball) explains why filters designed to
remove particles 5 microns in diameter cannot take out oil mist at 0.5
micron and smaller.
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

PARTICLE SIZES
Distribution pressure drop points
 KINETIC FLUIDTRONICS INCORPORATED

YOUR COMPRESSED AIR FACILITY

COMPRESSED AIR
CONSUMING
COMPRESSED AIR
PRODUCING

DEMAND
SUPPLY
Filters in general
 KINETIC FLUIDTRONICS INCORPORATED

Filtration Mechanisms
What makes a filter work? How do filters go about
doing their job? By what principles do they operate?

Technically speaking, filters use the mechanisms of

interception, inertial impaction, diffusion and
adsorption. Each mechanism is effective in removing
certain contaminants and certain particle sizes.
Mechanism of Capture

There are at least seven mechanisms by which a

filter can capture particles. All of these mechanisms
are at work in a filter at any given time to varying
degrees and may change as operating conditions
change. The seven mechanisms of particle capture
are listed below:
Direct Interception

Direct interception is
usually the governing
mechanism in liquid
filtration. Interception of
a particle occurs by this
method when a particle
approaches
obstruction a
a media
distance
equal to or less than the
                    

                          
   

particle radius. In
essence, if the particle
“runs into” a physical
barrier, it becomes
captured.
 KINETIC FLUIDTRONICS INCORPORATED

Direct Interception (particulate filters)

Interception, or mechanical separation, is the easiest filtration
mechanism to envision. A moving particle is blocked when it
encounters a passageway or hole smaller than itself. The larger
the particle relative to the hole size, the greater the chance of
interception.

                                                         
Element designs
Bridging
One single particle may be too small to be
directly intercepted or blocked by the filter
medium. However, two particles hitting the
obstruction at the same time may stick together
and be deposited. Particles form a bridge across
a pore by hitting the pore simultaneously, or by
adhering to each other earlier in the process and
then becoming deposited. Bridged particles may
not clog the opening completely, thus creating a
smaller pore that is more difficult to pass
through. The gradual accumulation of particles
on the filter medium is known as the formation
of a filter cake. This cake creates a finer matrix
for subsequent interception.
Sieving
Similar to bridging, sieving is
a specialized case of direct
interception. Sieving occurs
when the opening or pore in
the medium is more
constrictive than the diameter
of the particle. The particle is
simply too large to pass
through the pore. Sieving may
occur on the surface of the
filter or through the pore.
Sieving may occur on the
surface of the filter or
throughout the depth of the
medium.
Inertial Impaction

Inertial impaction is based on the scientific principle of inertia, stating

that a moving object will continue to move in a straight line unless
acted on by an outside force. As particles flow through a filter, they
may encounter an obstruction and become captured while the fluid
flows around the barrier. Due to the inertia of the particle, it continues
to move in a straight line and becomes impacted. Fluid viscosity also
greatly affects inertial impaction.
 KINETIC FLUIDTRONICS INCORPORATED
Inertial impaction, also referred to as impingement, occurs as the air-stream
passes through a random network of fibers. Some particles will impact onto
the filter medium and be caught due to their inertia driving them into the
filter media. The compressed air-stream, because of its relatively low
density and inertia, changes direction and flows around the fibers. Particles
in the size range of 0.5 micron and larger, however, because of their higher
density and inertia, randomly collide with the fibers. Hence, inertial
impaction works to trap a high percentage of particles not trapped by
interception.

                                                         
Diffusion Interception
The mechanism of diffusion interception is attributable to the
fact that molecules are in constant random motion. This motion
enhances the opportunity for a particle to become intercepted by
the filter medium.

Diffusion interception is more prevalent in particles that are 0.1

to 0.3 microns in size, since small particles are most affected by
molecular bombardment. Diffusion interception is primarily
found in gases due to their inherently low viscosity and high
degree of molecular mobility.
 KINETIC FLUIDTRONICS INCORPORATED

Diffusional interception
Extremely small particles will bounce around randomly
in a gas stream as they strike liquid or gas molecules.
This motion is called Brownian Motion and is more
pronounced in gases. The random path of the particle
increases the chance it will strike the compressed air
filter and be captured.
 KINETIC FLUIDTRONICS INCORPORATED

Diffusion
Diffusion refers to the random motion of small particles, also known as
Brownian motion. This motion is caused by collisions with gas
molecules, Particles in the size range of 0.1 micron and smaller do not
tend to follow the air-stream.. The random path of the particle increases
the chance it will strike the filter and be captured.

                                                         
Electrokinetic Effects

Electrical charges may be present on the filter medium and /

or on the particles. Particle deposition can occur due to
attractive forces between charges or induced forces due to
the proximity of the particle to the medium. Some
manufacturers purposely alter the surface of the filter
medium to enhance electrokinetic capture.
Gravitational Settling

Particles have mass and are therefore affected by gravity. It is

possible that a particle may leave the fluid streamlines and
settle in the same fashion as sediment in a settling tank.
Particles may be deposited within a filter medium or in the up-
stream chamber of a filter housing.
Mechanical Retention

Mechanical retention occurs when a particle is

mechanically restricted from passing through the filter
medium. Direct interception, sieving, and bridging are
mechanisms of capture that facilitate mechanical
retention. Of these three methods of capture, sieving is the
most dependable under normal forward flow conditions.
Sieving Bridging
Direct Interception
Adsorptive Retention

Adsorptive retention refers to the adherence of a particle

to the filter medium due to interactions between the
particle and the surface of the medium. The particle
“sticks” to the filter. Phenomena behind this adsorptive
affect include electrical and hydrophobic interactions.
Smaller particles adsorb more strongly than larger
particles. The tendency of particles to adsorb, however, is
very condition dependent; a particle that is adsorbed can
be desorbed. Adsorptive retention predominates for
particles captured by inertial impaction, diffusion
interception, and electrokinetic attraction.
Surface vs. Depth Filtration

The terms “surface filtration” and “depth filtration”

describe parameters of the particle size / pore size
relationship present during the filtration process. Although
filters are often generalized as being surface or depth
filters, in reality, the label is inappropriate unless the
particle size / pore size relationship is known.
Surface Filtration
A true surface filter can be thought of as a screen that is challenged
with particles that are too large to pass through its openings. The
particles will collect on the surface, forming a filter cake. Retention will
be absolute since no particles will be able to penetrate through the
surface. This mechanism of capture is recognized as sieving. Note,
however, that if the same screen was challenged with small enough
particles, it would no longer capture all of the contaminant’s at the
surface. Hence, the process of surface filtration is strictly dependent
upon the particle size / pore size relationship.
Compressed air filter locations
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

CONTAMINANTS
Contaminants include:
Solids
Water
Oil in various forms
Oil comes from the air compressor, moisture comes
from the cooling compressed air and dirt is present in
the intake air. More contaminants are made as these
contaminants damage pipe and compressed air
components. In addition to hard particles, bacteria
will grow and a sludge of oil, water, bacteria and hard
particles forms.
PARTICULATE FILTER
PARTICULATE FILTER
For SOLID CONTAMINANTS
KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Particulate filtration is used to combat the destructive effects of

solid contaminants in a compressed air system. Particulate filters
down to 0.003µm protect air systems from contaminants. The
smallest particle the human eye can see is 40µm.
An additional effect of compressing air is aerosol and vapor
concentration. Compressed air is saturated with water. Since the
compressed air is heated during the compression process, an
aftercooler is then used to remove the heat of compression. During
this stage a significant quantity of aerosols and vapors are
condensed into liquid at temperature.
 KINETIC FLUIDTRONICS INCORPORATED

LIQUID OIL
Oil mist particles have diameters in the range of 0.01
micron to 10.0 microns. Conventional air line filters
remove only the larger particles. The smaller particles
that pass through the filter eventually collide with one
another and with confining surfaces, forming droplets
large enough to settle out in the air line network as
liquid oil. The formation of larger droplets from small
particles is known as coalescence, and occurs more
readily in regions of high turbulence where small oil
particles are forcefully thrown against enclosing
surfaces and against each other. This is why liquid oil
is commonly found in orifices, pressure reducers and
nozzles as well as in other areas of turbulence
downstream of these devices.
COALESCING FILTER
COALESCING FILTERS
Use to remove lubricant oil and MOISTURE
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Coarse Coalescer Filter

A coarse coalescing filter separates large water and oil
droplets from the compressed air stream before the coalescing
filter. The coarse coalescer also removes large solids.
Typically, the coarse coalescer is a 3µm coalescer. By using
staged filtration you protect the more expensive coalescer
filter, making it last longer online. The idea is to change the
less expensive coarse coalescing filter more often to reduce
overall filtration cost. A coarse coalescer filter is optional
equipment. Not all air systems utilize it.
KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

At discharge pressures of 100 psig, most

water-cooled aftercoolers will need
about 3 gpm per 100 CFM of compressed
air.
The water vapor content at 100°F
(37.78°C) of saturated compressed air is
equal to about two gallons per hour for
each 100 CFM of compressor output.
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Drip leg drain

 Automatic drain valve for
terminating a dead leg
 Water automatically
drained when pressure is
on, also when shut down
 Fit with an isolating shut
off valve for maintenance
 Incorporates a course
mesh filter to retain large
solid particles
 Built in bleed valve to
depressurise the unit
prior to maintenance
 KINETIC FLUIDTRONICS INCORPORATED

To eliminate oil, condensate, or cooling water

(if the water-cooled aftercooler leaks), a low
point drain should be installed in the discharge
pipe before the aftercooler. Be sure to connect
the aftercooler outlet to the separator inlet
when connecting the aftercooler and the
moisture separator together. If they are not
connected properly, it will result in either poor
aftercooling or poor separation.
 KINETIC FLUIDTRONICS INCORPORATED

The main header pipe in the system should be

sloped downward in the direction of the
compressed air flow. A general rule of thumb is
1" per 10 feet of pipe. The reason for the slope
is to direct the condensation to a low point in
the compressed air piping system where it can
be collected and removed.
 KINETIC FLUIDTRONICS INCORPORATED

Typical compressed air facility

 KINETIC FLUIDTRONICS INCORPORATED

Filter Sizing
Inlet Flow and Inlet/Outlet Piping
The compressed air filter has to be rated for the inlet
flow. Inlet flow is generally measured in scfm. Locate
the filter at the highest pressure point available that
offers an acceptable temperature. Match the inlet and
outlet pipe size of the filter assembly to avoid
generating excessive pressure drop across the
compressed air filter.
 KINETIC FLUIDTRONICS INCORPORATED

High Temperature Particulate Filter

        Temperature spikes are common downstream of a heated desiccant
dryer. Spikes happen when a regenerated tower comes back online. The
heat generated during regeneration is picked up by the compressed air.
Often these heat spikes are considerably higher than the maximum
operating temperature of a particulate compressed air filter and housing.
The particulate filter can catch fire and damage your air system and
pneumatic devices.
A high temperature particulate filter protects against this risk of fire. A
particulate compressed air filter operates at 100°F (38°C) and has a
maximum temperature of 150°F (66°C). A high temperature particulate
filter can operate daily at 350°F (177°C) and has a maximum operating
temperature of 450°F (232°C). The level of protection with a high
temperature particulate filter and housing is significant.
 KINETIC FLUIDTRONICS INCORPORATED

Direct interception is the most common form of

retention in both gas and liquid service. Most filters
maximize their direct interception with torturous flow
paths, which increase the filters retention capability.

Coarser filters intercept larger particles. More densely

packed filters intercept smaller particles, but also
restrict the airflow, posing the problem of high-pressure
drop. Increasing the filter area can compensate for
high-pressure drop; but, a balance must be achieved
between filter area and practical physical limitations.
 KINETIC FLUIDTRONICS INCORPORATED

Filtration Theory

Inertial impaction
Particles travelling in a fluid have a mass and velocity.
The fluid will follow the path of least resistance. Some
particles will impact onto the filter medium and be
caught due to their inertia driving them into the filter.
This is not a primary mechanism for particle retention. It
is more common in gas streams.
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Other coalescers are designed with pleated elements, providing

significantly greater surface area than a non-pleated design, and
the inherent reduction in pressure drop and increase in element
life.

Still other coalescers are recommended for use in combination

with one or more filters, feeding the air-stream to a coarse
coalescer prior to a high efficiency coalescer. This type of
installation, while inherently higher in pressure drop than the
single filter, provides another approach to reducing the inlet
contamination to the high efficiency coalescer and results in
cleaner air at the outlet.
 KINETIC FLUIDTRONICS INCORPORATED

Oil removal filters typically employ the inertial impaction and

diffusion filtration mechanisms to remove oil in the liquid state.
These filters are commonly known as coalescers, since they rely
on the combination or coalescing of small droplets into larger
droplets in the filtration media. These larger droplets then fall away
from the element due to gravity. Coalescers are available in a
variety of efficiency ratings in order to suit the many applications
of compressed air.

Some designs have built-in pre-separation of gross contaminants,

such as water and large oil droplets or solid particulates.
 KINETIC FLUIDTRONICS INCORPORATED
Coalescing Filter
         A high efficiency coalescer filter removes water and oil
aerosols and solid particles to a specified level. Many compressed
air coalescers are rated at a liquid removal efficiency of 0.001 ppm
by weight and by liquid aerosols down to 0.01µm. A coalescer stops
particulate contamination through direct interception. Its main
function is to remove water and oil aerosols by coalescing the
aerosols into droplets. This happens partially because of torturous
path and membrane characteristics and partially due to pressure
drop. Coalescers remove both water and oil aerosols from the air
stream.

It is important to realize that a coalescer is excellent at removing

aerosols and liquids but not vapors. Vapors are organics like
hydrocarbons and odors. A vapor filter removes vapors with an
adsorbent.
 KINETIC FLUIDTRONICS INCORPORATED

Adsorption
Adsorption is a process that involves the adhering of contaminant
molecules to the surface of a solid adsorber. A packed bed of
porous materials with high surface-to-volume ratio performs
effectively in this capacity. While contaminant molecules lodge in
the small pores, cracks, voids and crevices of the adsorbent, air
passages remain free, and the effect on pressure drop is
negligible.

Adsorption filters are particularly effective in removing oil vapor

and are occasionally employed to remove oil aerosols.
 KINETIC FLUIDTRONICS INCORPORATED

Adsorbers typically employ the adsorption mechanism

of filtration to remove hydrocarbon tastes and odors
from the air-stream. Most use a special activated carbon
to accomplish this.

It is never advisable to install a carbon filter without

suitable pre-filtration, as carbon filters quickly become
ineffective when challenged with liquid oil or water.
Although these filters are often used as "final polishing"
filters in an air treatment system, they often tend to pass
small carbon fines downstream. Therefore, make sure
there is a particulate filter either built into the carbon
filter or downstream.
 KINETIC FLUIDTRONICS INCORPORATED

Vapor Filter (Charcoal Filter)

        A vapor filter removes organics from the air stream.
Organics, like tastes and odors need to be removed from
breathing air systems. In general, industrial applications of
vapor compressed air filters remove hydrocarbons and other
organic chemical vapors from the air system. Depending on the
airflow, vapor filters need to be replaced every few months
because the effectiveness of the activated carbon degrades as it
adsorbs.
 KINETIC FLUIDTRONICS INCORPORATED
YOUR COMPRESSED AIR FACILITY

COMPRESSED AIR
CONSUMING
COMPRESSED AIR
PRODUCING
 KINETIC FLUIDTRONICS INCORPORATED

Typical compressed air facility

KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Rules of thumb:
There are several rules of thumb regarding compressed
air. These rules apply to the design and installation of
the system:
All compressors produce heat during the compression
process. This heat must be removed from the
compressor room for proper operation of the
compressor. Be sure to provide sufficient ventilation for
all equipment that may be installed in the compressor
room. All compressor manufacturers publish allowable
operating temperatures.
Leave sufficient space around the compressor to permit
routine maintenance. It is also suggested to provide
space for the removal of major components during
compressor overhauls.
 KINETIC FLUIDTRONICS INCORPORATED

Compressed Air Piping Systems

The purpose of the compressed air piping system is

to deliver compressed air to the points of usage. The
compressed air needs to be delivered with enough volume,
appropriate quality, and pressure to properly power
the components that use the compressed air.
Compressed air is costly to manufacture. A poorly designed
compressed air system can increase energy costs, promote
equipment failure, reduce production efficiencies, and
increase maintenance requirements. It is generally
considered true that any additional costs spent improving
the compressed air piping system will pay for themselves
many times over the life of the system.
 KINETIC FLUIDTRONICS INCORPORATED

Make sure that the piping following the aftercooler

slopes downward into the bottom connection of the air
receiver. This helps with the condensate drainage, as
well as if the water-cooled aftercooler develops a water
leak internally. It would drain toward the receiver and not
the compressor.

Another method of controlling the condensation is to

take all branch connections from the top of the airline.
This eliminates condensation from entering the branch
connection and allows the condensation continue to the
low points in the system.
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Pressure Drop
Pressure drop in a compressed air system is a critical factor.
Pressure drop is caused by friction of the compressed air flowing
against the inside of the pipe and through valves, tees, elbows and
other components that make up a complete compressed air piping
system. Pressure drop can be affected by pipe size, type of pipes
used, the number and type of valves, couplings, and bends in the
system. Each header or main should be furnished with outlets as
close as possible to the point of application. This avoids significant
pressure drops through the hose and allows shorter hose lengths to
be used. To avoid carryover of condensed moisture to tools, outlets
should be taken from the top of the pipeline. Larger pipe sizes,
shorter pipe and hose lengths, smooth wall pipe, long radius swept
tees, and long radius elbows all help reduce pressure drop within a
compressed air piping system.
 KINETIC FLUIDTRONICS INCORPORATED

In recent years several manufacturers have developed piping systems

especially for compressed air (fig. P1-2). These compressed air
piping systems typically have smooth walls, are lightweight, and
reduce the installation costs associated with copper and threaded
pipe. Follow the manufacturer's recommendations for installing
these systems.                          
 KINETIC FLUIDTRONICS INCORPORATED

Loop Pipe System

The layout of the system can also affect the compressed air system. A very
efficient compressed air piping system design is a loop design. The loop
design (fig. P1-3) allows airflow in two directions to a point of use. This can
cut the overall pipe length to a point in half that reduces pressure drop. It
also means that a large volume user of compressed air in a system may not
starve users downstream since they can draw air from another direction. In
many cases a balance line is also recommended which provides another
source of air.

Reducing the velocity of the airflow through the compressed air piping
system is another benefit of the loop design. In cases where there is a large
volume user an auxiliary receiver can be installed. This reduces the
velocity, which reduces the friction against the pipe walls and reduces
pressure drop. Receivers should be positioned close to the far ends or at
points of infrequent heavy use of long distribution lines. Many peak
demands for air are short-lived, and storage capacity near these points
helps avoid excessive pressure drop and may allow a smaller compressor
to be used.
 KINETIC FLUIDTRONICS INCORPORATED

Piping materials
Common piping materials used in a compressed air system include
copper, aluminum, stainless steel and carbon steel. Compressed
air piping systems that are 2" or smaller utilize copper, aluminum
or stainless steel. Pipe and fitting connections are typically
threaded. Piping systems that are 4" or larger utilize carbon or
stainless steel with flanged pipe and fittings.

Note: Plastic piping may be used on compressed air systems,

however caution must used since many plastic materials are not
compatible with all compressor lubricants. Ultraviolet light (sun
light) may also reduce the useful service life of some plastic
materials. Installation must follow the manufacturer's instructions.

It is always better to oversize the compressed air piping system

you choose to install. This reduces pressure drop, which will pay
for itself, and it allows for expansion of the system.
 KINETIC FLUIDTRONICS INCORPORATED

Corrosion-resistant piping should be used with any

compressed air piping system using oil-free
compressors. A non-lubricated system will experience
corrosion from the moisture in the warm air,
contaminating products and control systems, if this type
of piping is not used.
KINETIC FLUIDTRONICS INCORPORATED
KINETIC FLUIDTRONICS INCORPORATED
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KINETIC FLUIDTRONICS INCORPORATED
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 KINETIC FLUIDTRONICS INCORPORATED
93.3 °C Oil flooded rotary
176 °C Oil free rotary
Temperature at discharge
148 °C 2 stage reciprocating
107 °C Vane compressors
30 – 34 °C 50 - 65 °C
Suction side Inlet filter Compressor After cooler

42 °C
Receiver w/ Auto drain Shut off valve Auto drain Moisture trap

Shut off valve Bypass option Mechanical main line filter

temperature shall more or less be lower than the ambient

Coalescing main line filter Compressed air dryer

Compressed air consuming

 KINETIC FLUIDTRONICS INCORPORATED

Typical compressed air facility

 KINETIC FLUIDTRONICS INCORPORATED

Wet vs. dry receiver:

There are wet air receivers and dry air receivers. (fig. AR1-3)
                                                                                               
Wet Receivers: Wet receivers provide additional storage capacity and
reduce moisture. The large surface area of the air receiver acts as a
free cooler, which is what removes the moisture. Because the moisture
is being reduced at this point in the system, the load on filters and
dryers will be reduced.
 KINETIC FLUIDTRONICS INCORPORATED

Pilot regulators
 Large pressure regulators
generate high forces,
unsuitable for direct
manual operation
P1 P2
 Often mounted in remote
locations difficult to reach
 A piloting regulator is
easy to operate and sends
a signal to adjust the
remote pilot regulator
 Independent or single P1 P2
loop feedback dependant
on piloting regulator type,
internal or external
 KINETIC FLUIDTRONICS INCORPORATED

Precision regulators
 Types R38, 11-818 and
R27
 For precisely set and
accurately held pressure
 Suitable for process
control, air gauging and
instrumentation
 Selection of pressure
ranges e.g. 0.02 -0.5 bar,
0.06-4 bar, 0.16-7bar etc.
 Manual, mechanical and
pilot operation
 KINETIC FLUIDTRONICS INCORPORATED

Lubrication
 For efficient running of pneumatic equipment and long life
of seals and wearing surfaces, correct lubrication is
essential
 Where non-lube equipment is used it has been pre-
lubricated on assembly and will last for the normal life
expectancy of that equipment without further lubrication.
It will not be detrimental however to include this
equipment on lubricated air supplies and is likely to result
in an extension of the normal life of the equipment
 For the best results light lubrication is applied
continuously from an air line lubricator. This is particularly
relevant in adverse applications where there may be high
speed and high temperature running or where the
condition of the compressed air has been poor
 KINETIC FLUIDTRONICS INCORPORATED

Lubrication
 Valves, actuators and accessories in a typical application
can operate at different rates and frequencies and require
lubrication rates to match. The airline lubricator provides a
very convenient method of satisfying this demand
 In a lubricator, oil drips are atomised and the tiny oil
particles form a very fine mist in the air supplying the
application
 The amount of oil delivered is automatically adjusted as
the air flow changes. The result is constant density
lubrication. For any setting the oil particles per cubic
meter of air are the same regardless of the flow rate
 KINETIC FLUIDTRONICS INCORPORATED

Lubricators
 There are two main types
of lubricator
 One is the conventional
high delivery Oil Fog
series ( coded green)
 The other is the unique
and more widely used
Micro Fog range (coded
red)
 Both types are easily
adjusted to pre-set the
lubrication density
Oil-Fog Lubricator Micro-Fog Lubricator
 KINETIC FLUIDTRONICS INCORPORATED

Oil fog lubricators

 Oil fog lubricators are often referred to as high delivery
units and can be identified by the green drip rate control
 All of the oil drips seen through the sight dome enter the
air stream and are atomised
 The size range of the oil particles produced are ideally
suited to lubricating single items of equipment on medium
to short runs of pipe
 The oil particles are carried along with the air flow, and
gradually "wet out" to provide adequate lubrication for
applications such as nut runners, screwdrivers and other
equipment requiring heavier lubrication
 KINETIC FLUIDTRONICS INCORPORATED

Oil fog lubricator

 For lubricating over short
distances where wet-out
is required early
 Suited for; air tools, air
motors, single large
cylinders etc.
 Oil drips are broken up in
the main air stream and
all particle sizes carried in
the air
 Drip rate is adjustable
 KINETIC FLUIDTRONICS INCORPORATED

Oil fog lubricator

 Oil drips visible through
the sight dome pushed by
the pressure difference
P2 between P1 and P2
 Syphon tube with check
valve to prevent oil drain
P1 P2 back when there is no
flow taking place
 Transparent
polycarbonate bowl to
inspect oil level
 Alternative metal bowl
P1
with sight glass
KINETIC FLUIDTRONICS INCORPORATED
 KINETIC FLUIDTRONICS INCORPORATED

Oil fog lubricator

 Turn the green control to
adjust the oil flow
restriction
 Observe the drip rate and
set to 2 drips/min at 10
dm3/s. Change from this
according to results
 Flexible flow sensor,
progressively bends flat
as the flow increases.
This controls the local
pressure drop to draw oil
drips in proportion to air
flow
 KINETIC FLUIDTRONICS INCORPORATED

Fill under pressure (oil fog)

 Filler plug with flats to
bleed the bowl pressure
 Crack open and wait for
pressure to drop then
remove the plug
 Remove bowl with simple
bayonet action, fill and
replace securely
 Replace plug and tighten
 Check valve with small
by-pass notch. Flow too
low to pressurise bowl
when plug removed
 KINETIC FLUIDTRONICS INCORPORATED

Micro-fog lubricators
 Micro-Fog lubricators are the most widely applied type and
can be identified by the red drip rate control
 The oil drips seen through the sight dome in this unit are
atomised in the bowl, but only a small percentage of the
particles produced actually enter the air stream
 Those that do, make up about 10% of the drip rate and are
the very smallest ones, so fine they can be likened to thin
smoke. The drip rate is 10 times that of the oil fog units for
the same oil delivered. Setting the drip rate is 10 times
quicker too as there is less time to wait between drips
 Wetting out of these oil particles occur gradually. This
allows them to be carried the long distances associated
with the maze of pipework, tight turns and fittings that form
part of the typical industrial pneumatic system
 KINETIC FLUIDTRONICS INCORPORATED

Micro-fog lubricator
 For lubricating over long
distances where particles
must reach the furthest
parts of intricate systems
 Suited to; control
circuitry, multiple valve /
actuator systems
 Oil drips are atomised in
the bowl
 Only the finest 10% of oil
particles leave the bowl
 Stay in suspension longer