kaeser compressor and valve (of)-11
TRANSCRIPT
04/10/23 MUHAMMAD SAJID
• Operation of Screw Compressors
• Operation of Valves• Operation Of Dessicant Dryer• Sigma Controller• Introduction of Microfilters
04/10/23 MUHAMMAD SAJID
Construction1 Airend2 Energy-saving electric motor3 Motor grease nipples4 Inlet valve5 Minimum pressure/check valve6 Combined Auxiliary Vent Valve7 Fluid cooler with mounted thermostatic valve and fluid-micro filter8 Compressed air after cooler9 Two-stage air inlet filter10 Fluid separator tank with separator cartridge11 Safety Valve12 Anti Vibration Dampers13 Sigma Control
04/10/23 MUHAMMAD SAJID
04/10/23 MUHAMMAD SAJID
98-99%
1st stage,centrifugal
2nd stage, fluidFluid Separation
separator elementa) coarse filter layer
b) fine filter layer
04/10/23 MUHAMMAD SAJID
04/10/23 MUHAMMAD SAJID
04/10/23 MUHAMMAD SAJID
•
04/10/23 MUHAMMAD SAJID
Tasks of Fluid
First task:
Second task:
Third task:
Fourth task
Heat transfer, discharge temp.approximately 75 - 80 oC
Lubrication of Airend Bearings
Sealing gap between rotors and casing, prevention of metallic contact
absorbing dust,sulphur, etc.
04/10/23 MUHAMMAD SAJID
Inlet Valve
04/10/23 MUHAMMAD SAJID
Min Pressure Check Valve
Off Load Position
04/10/23 MUHAMMAD SAJID
Full Load Position
04/10/23 MUHAMMAD SAJID
Air Oil Separation
04/10/23 MUHAMMAD SAJID
04/10/23 MUHAMMAD SAJID
04/10/23 MUHAMMAD SAJID
Thermostatic Element Function
04/10/23 MUHAMMAD SAJID
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.
04/10/23 MUHAMMAD SAJID
• 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).
04/10/23 MUHAMMAD SAJID
Sigma Control
04/10/23 MUHAMMAD SAJID
Traffic light function
Plain text display
Basic function:
ON/OFF
Preselect functions
Traffic light functions
04/10/23 MUHAMMAD SAJID
Quick and simple operation thanks to menu guidance
UP keyScrolls the display text downard line for line
DOWN keyscrolls the display text upward line for line
Escape keyreturns to next higher level
Return keyinitiates jump to next sub-menuor accepts value
Acknowledge keyacknowledges alarms and-when permitted - resets the alarm memory
Info keyaccess to additional informationor to the event information memory.
Menu-functions
04/10/23 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
COSTSCOSTS
04/10/23 MUHAMMAD SAJID
condensate collection
cyclonicair movement
deflector
air outletair inletCondensate 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 .
04/10/23 MUHAMMAD SAJID
1 Microfilter FE (0.01 µm, 0.01 ppm)
2 Flow Distributor3 Stainless Steel Flow diffuser4 Desiccant bed: moisture
adsorption5 Upper Part of Dessicant chamber6 Security Reserve7 Flow distributor8 Particulate filter FD 1 µm9 Purge (regeneration ) air valve10 Desiccant bed: regeneration11 Purge air exhaust silencer
Desiccant Dryer
04/10/23 MUHAMMAD SAJID
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 μm).
• 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 1μm) in the dust filter FD (8).
04/10/23 MUHAMMAD SAJID
• 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.
04/10/23 MUHAMMAD SAJID
How large are the impurities in the air?Description: vapour / mist / smoke dust fog: spray rain
Perception: Description: microscopic visual
Falling time at 1 m heightSec.
Min.
foundry sand
heavy industrial smogwater mist
carbon dust
traffic dust
cement dust
pollen
plant spores
bacteria
metallurgical dust
oil mistoil vapoursViruses
tobacco smoke
gas molecules
pore dia, activ. carbon, silica-gel, etc.
centrifugal
normalheavy
bag-typeair filter
separation and filtration performance
paint spray mist
Influence of the Brownian Molecular movement
Particle size in microns
04/10/23 MUHAMMAD SAJID
Streamed from the inside to the outside.
Prefilter (FB, FC Type)
used as a coarse filter for 100% saturated compressed air (or for water vapour components in the liquid phase)
FB is used to remove particles > 3 umFC is used to remove particles > 1 um
04/10/23 MUHAMMAD SAJID
Microfilter (FE, FF Type)
0.01 micron
for liquids (aerosols)
and particles
oil aerosol content: 0,01 ppmto 0,001 ppm
04/10/23 MUHAMMAD SAJID
contaminated air filter medium (deep-bed filter) technically oil-free clean air
Direct interception
Impact
Diffusion /Coalescence
How does the microfilter work?
04/10/23 MUHAMMAD SAJID
THANK YOU