WILKERSON®

C O R P O R A T I O N

Training For Growth

Into the

21st Century

A Marketing Services Presentation ©1998 Wilkerson Corporation

Having trouble seeing your customer’s problem?

To Be Continued…………...To Be Continued…………... To Be Continued…………...To Be Continued…………...

Basic Air PreparationBasic Air PreparationBasic Air PreparationBasic Air Preparation•A Look At:

•The Air System•The Components•The Mechanisms

You are what you breathe...…or,Life at the Compressor Inlet

AcmeCompressor

Each Cubic Footof AtmosphericAir Contains....DirtWaterVapors

Intake Filter 25 - 50m

ACMECORPORATION

NO WHERE, USA

Atmospheric ContaminationCompressor Intake

AcmeCompressor

Each Cubic Footof AtmosphericAir Contains....

4,000,000 solid particles5 ppm / wt. various vapors

Intake Filter 25 - 50 m

ACMECORPORATION

NO WHERE, USA

A Closer Look at the Discharge

x

One Cubic Foot Ambient Air

7.8 =

Compression Ratio @ 100 psig

Look at all those molecules !!! 1,2,3,4,5.…yadda yadda yadda...

Randy

The Problem is Magnified!

A Closer Look at Discharge Contamination

One Cubic Foot Compressed Air 31,200,000 Solids

x

One Cubic Foot Ambient Air has UP TO4,000,000 Solids

7.8 =

Compression Ratio @ 100 psig

Look at all those solids !!! 1,2,3,4,5....4,000,000

Randy

The Problem is Magnified!

A Typical Compressed Air Supply System

Dryer Compressor

Mainline Filtration

Drains

Point of Use FRL

Aftercooler here (heat removal)

Dryer Compressor

Mainline Filtration

Drains

Point of Use FRL

Aftercooler here (heat removal)

A Typical Compressed Air Supply System

(Heat removal)

Minimum of turns and bends

Clean, properly-sized pipingTake drops off top of main header

Be a plumber’sfriend!

Drains at all low points

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 DropHeat

3 Sources of Compressed Air Contamination

AtmosphericContamination Compressor

Contamination

Piping Contamination

Compressor ContaminationDischarge Air

Compressor

Carryover Oil (per year)

.5

47 Gallons

38,600,000 Solid Particles (intake air) &Compressor WearParticles &

Discharge Contamination continued

Oil, Oil Everywhere. Where’s it all coming from ??

AcmeCompressor

AcmeCompressor

AcmeCompressor

AcmeCompressor

Oilless

Rotary Vane

Flooded Screw

Reciprocal

12 oz - 60 oz.

5.6 gal - 188 gal

3.8 gal - 47 gal

47 gal - 188 gal

Bypass Oil Per Yr

JEFF

Piping Contamination

AIR AIR

OIL WATER

PIPE SCALE

PIPE RUST

YUK!!

BOB

The Ugly Truth

• Dirt - 4 Million particles/cubic ft. @ ambient

• Oil - 5 ppm carryover = several gallons / year

• Water - @70°F@70% RH, 100scfm system = 114 Gallons H2O / day

• Pressure Drop - Each 2 psid = about 1% BHP

The ProblemsPremature valve failure, sticky valves

Swelling of O-Rings in valves and cylinders

Loss of lubrication in pre-lubricated valves and cylinders

Equipment failure and down time

Problems 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-cooledaftercooler

Air-cooled aftercooler

Shell and tube heat exchanger

Cool water inHot air in

Warm water out Separator

Condensate out

Water-cooled aftercooler and separator

Coolair 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 RegenerativeTwin TowerPressure Swing CycleDesiccant Dryer

Heatless RegenerativePressure 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

Nitrogen molecules

Oxygen molecules

Membrane

N2

O2

Water molecules

H2O

Membrane pore size allows water to pass,but Nitrogen and Oxygen molecules bondin pairs and are too large to pass.

Membrane Dryer Cutaway

(Not a true cross-sectional drawing)

Bowl

Purge orifice

MembraneModule

Purge air exhaust

Body casting w/ coverIn Out

Membrane DryerwithCoalescing Filter

Compressed Air Preparation:

• Temperature Conditioning

• Drying

• Filtering

• Regulating

• Lubricating (when appropriate)

Filtration Locations

AcmeCompressor

Compressor Room Point - of - Use

AcmeMa Tc oh oi lne

Particulate filtersTWO-STAGE ACTION

SEPARATION

FILTRATION

Courtesy of Wilkerson

Filtration is outside-to-inside on particulate elements

5-micron element

Quiet Zone Baffle

Courtesy of Wilkerson

Oil Carryover

Used compressor oilis a POOR lubricant!It is a sticky, gummy mess!

Coalescing Filters

Flow path is inside to

outside element

DP indicator

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

• To Regulate Downstream Pressure1. 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.

1

2

3

Courtesy of Wilkerson

Body

Main Spring

Panel nut

BonnetAdjusting stem assy.

Knob

Bottom Plug Valve spring

Valve

Diaphragm

Courtesy of Wilkerson

Regulators

If I had only known what a regulator does…..

Demand side control devices

Demand side control devices

Demand side control devices

Compressed Air BasicsDEW POINT CONVERSION CHART

-100

-80

-60

-40

-20

0

20

40

60

80

100

120

140

-100 -80 -60 -40 -20 0 20 40 60 80 100

Dew Point °F at Atmospheric Pressure

Dew

Poi

nt °

F at

Ele

vate

d Pr

essu

re100psig

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!

(spare slide section follows)