WILKERSON C O R P O R A
- Slides: 65
WILKERSON C O R P O R A T I O N Training For Growth Into the 21 st 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 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. . . dy n Ra 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 dy n Ra x One Cubic Foot Ambient Air has UP TO 4, 000 Solids The Problem is Magnified! 7. 8 = One Cubic Foot Compressed Air 31, 200, 000 Solids 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 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 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 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, 100 scfm system = 114 Gallons H 2 O / day • Pressure Drop - Each 2 psid = about 1% BHP
The Problems èPremature valve failure, sticky valves èSwelling of O-Rings in valves and cylinders èLoss of lubrication in pre-lubricated valves and cylinders èEquipment failure and down time èProblems 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 N 2 Oxygen molecules O 2 Water molecules H 2 O 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 spring Valve Main Spring Panel nut Adjusting stem assy. Courtesy of Wilkerson Bonnet Knob 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 100 psig Atmospheric
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!
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