Compressed Air:
Compressed air is air kept under a pressure that is greater than atmospheric pressure. Compressor is
the device used to compress the air. Compressors are classified as Dynamic and Positive displacement
type.
The output of compressor is generally categorized as service air and instrument air.
Service air is used generally for cleaning and other maintenance activities.
Instrument air is used for
o The use of sensors to determine the status of processes
o Information processing
o Switching of actuators by means of final control elements
Every 4OC drop in inlet air temperature results in lower energy consumption by 1% to achieve an
equivalent output.
For every 250mmwc pressure drop increase across the suction path due to chocked filters etc,
the compressor power increases by about 2% for the same output.
An increase of 5.5OC in the inlet air temperature to the second stage results in a 2% increase in
specific energy consumption.
A reduction in delivery pressure by 1 bar in a compressor would reduce the power consumption
by 6-10%.
Compressed air system consist of following major components: Intake filters, inter-stage coolers, after
coolers, air dryers, moisture drain traps, receivers, piping network, filters, regulators and lubricators
What is the difference between dew point and “pressure dew point?”
The term “pressure dew point” is encountered when measuring the dew point temperature of gases at
pressures higher than atmospheric pressure. It refers to the dew point temperature of a gas under
pressure. This is important because changing the pressure of a gas changes the dew point temperature
of the gas.
What is the typical range of dew point temperatures to be found in compressed air?
Dew point temperatures in compressed air range from ambient down to -80 °C (-112 °F), sometimes
lower in special cases. Compressor systems without air drying capability tend to produce compressed air
that is saturated at ambient temperature. Systems with refrigerant dryers pass the compressed air
through some sort of cooled heat exchanger, causing water to condense out of the air stream. These
systems typically produce air with a dew point no lower than 5 °C (41°F). Desiccant drying systems
absorb water vapor from the air stream and can produce air with a dew point of -40 °C (-40 °F) and drier
if required.
Refrigerant dryer
Operating Procedure:
These are used for the capacities lower than 250 CFM.
Reasons for the moist instrument air in downstream of Instrument Air Drier:
High inlet air temperature: Air increases its affinity to hold moisture when it is at high temperature than
ambient. If the air enters the drier with high temperature as the moisture content in the air is more the
silica gel of the drier will be over loaded to perform. This results in moisture at the outlet of air drier.
Improper Cooling: The purpose of the cooler at the outlet of drier is to remove moisture from the air. If
the water flow through the cooler is improper or if the tube of the cooler is leaking it results in the
moisture at the outlet of air drier.
Drain Failure: A typical compressed air dryer system will produce 10 gallons of water per day per 100
SCFM. So installation of dependable condensate drain valves is not a luxury, but a necessity. 80% of this
moisture is removed at the moisture separator installed after the air cooled after-cooler. A drain valve
failure here guarantees that the compressed air dryer will be flooded and that liquid water will be
pushed further downstream. Healthy moisture traps makes the drier system healthy.
Aging of the equipment: Every equipment deteriorates with the age i.e., increase in the clearances,
rusting of the equipment. These will have effect on the performance of the drier.
Depending on the air compressor specifications Air driers are installed, if there is any deviation of air
compressor it also effect the performance of Air drier.
HEALTHY AIR DRYING SYSTEM MAKES COMPRESSED AIR SYSTEM AND IT’s USERS STAY HEALTHY