Compressed Air capacity VS Demand & Air quality

1. Types on working pressure.
COMPRESSED AIR

2. COMPRESSOR TYPES.
1. According to the working principle…
a) Reciprocating and b) Rotary-screw
2. According to the cooling system…..
a) Water cooled and b) Air Cooled
3. According to the oil with delivery air……
a) Oil free lubrication b) Oil Lubrication
4. According to the Cylinder position ……
a) Horizontal in line b) PET-Star c) L-Shaped

3. 1. IR ( LP & HP Air)
2. ELGI ( LP)
3. ABC ( HP)
4. AF ( HP)
COMPRESSOR BRAND

4. LP AIR PRODUCTION
New two elgi = 10.5 x 2 = 21 M3/min ( 25.04.15)

5. HP AIR PRODUCTION
SL
#
Compressor Model CFM M3/Min Motor,
KW
Section
1 IR PS3-1510C 882 25 270 RJM-10
2 IR Pet PET Star* 310 168.80 4.78 55 2 Ltr
Bottle
3 ABC 4HA-6-TER -LT 882 25 280 SBO-14
HR
4 AF -1(HF) 5 LA 882 25 250/300 SBO-14
5 AF-2(PCL) CE46XS 442 12.5 132 Jar
Blowing
TOTAL 3256.8 92.28 987/1037

6. AIR REQUIREMENT CALCULATION

7. FUTURE LP AIR DEMAND

8. PRODUCTION VS DEMAND

9. POWER FOR AIR
SL# AIR PRODUCTION TYPE POWER,KW TOTAL, KW
1 LP AIR 315
1482
2 MP AIR 185
3 HP AIR 982

10. Air Quality
Air should be free from fine particles, water vapor
and oil. Usually oil free air is best air quality.
Air quality depends on non-lubricated compressor , filtered air intake and
compressor design.
Air Quality Standard
ISO 8573-1 : 1991
Oil free air by high efficiency filters. Defined class 1 to 6.
ISO 8573-1 : 2010
Oil free air by high efficiency filters. Defined class 0 to X .
Filters
1.Intake filter 5 microns
2.Two high efficiency
filters’….
a) Pre-filter
b) Post filter/Fine filter

11. Compressed Air Quality & Production Selection.
The international standard for compressed air quality provides a simple system
of classification for the three main contaminants present in any compressed air
system – DIRT, WATER and OIL. To specify the quality class required for
particular application, simply list the class for each contaminant in turn
Compressed Air Quality ISO 8573-1: 1991
Class
Solid Particle
Maximum number of particles per m3
Water
Pressure Dew
point° C
Oil
(incl. vapor)
Mg/m3
0.1-0.5micron 0.5-1.0micron 1.0-5.0micron
1 100 1 0 -70 0.01
2 10,000 1,000 10 -40 0.1
3 - 10,000 500 -20 1
4 - - 1,000 3 5
5 - - 20,000 7 -
6 - - - 10 -

12. Classes
ISO
8573-
1:2010
Particles Water Oil
Number of particles per m3
Concentr
ation
mg/m3
PDP
°C
Liquid
g/m3
Aerosol
mg/m3
0.1- 0.5gm 0.5- 01 gm 1- 5gm
0 Stronger than class “1”, according specification of manufacturer / user
1
2
3
4
5
≤ 20000
≤400000
≤ 400
≤ 6000
≤ 90000
≤ 10
≤ 100
≤ 1000
≤ 10000
≤ 100000
≤ -70
≤ -40
≤ - 20
≤ + 3
≤ + 7
0,01
0,1
1
5
6
7
8
9
X
≤ 5
5-10
> 10
≤ +10
≤ 0,5
0,5-5
5-10
> 10 > 10
Technically oil free air solution.
ISO 8573-1: 2010 Table

13. OTHERS STANDARDS
BRC Global Standard for FoodSafety,Codex
Alimentarius-CAC/RCP1,EHEDGDoc.23(2nd
Edition)Part1,ISO85731-- 5and7,‐
ISO22000 Foodsafetymanagementsystems
and
ISO-TS-22002-- 1.‐

14. British Compressed Air Society
BCAS Food and Beverage Grade Compressed Air Best Practice Guideline 102
ISO 8573-
1: 2010
Purity
Class
Particles Water OIl
By particle Size
(maximum no of particle per m3)
Vapor Pressure Dew
Point
Aerosol &
Vapor
0.1-0.5
micron
0.5-1.0
micron
1.0-5.0
micron
Deg C Deg F mg/m3
Direct
Contact
2:2:1
400,000 6000 100 ≤-40 ≤ -40 ≤ 0.01
Indirect
Contact
2:4:2
400,000 6000 100 ≤ +3 ≤ + 37 ≤ 0.1
Microbial
Contamin
Hazard analysis shall establish the risk of contamination by
microbiological contaminants from compressed air. Refer to ISO 8573-7

15. TO Meet ISO 8573-1 What should we do?
Filter selection
Brand Precede Post
Filter grade Size Filter Grade Size
IR Grade GP < 0.5 ppm Grade HE < 0.01 ppm
Grade HE < 0.01 ppm Grade AC < 0.003 ppm
Grade DP Intake air filter, 1 micron.
ELGI FT (P)120 < 0.5 ppm FT (S)120 < 0.01 ppm

16. Filter

17. Air Drying System
Moisture separator – Auto Drain Valves –
Pre-filter--- Air Dryer ---- Fine Filter.
Air Filter selection:
 Flow rate, inlet size and pressure have to match properly.
 Minimum pressure drop.
 Quickest , simplest maintenance design.
 4. Built in safety protection.
 5.Lowest pressure drop
 6.Corrosion resistant alocrom treatment.

18. 40 BAR VALVE OPERATION

19. Compressor Oil

20. Lubricant Chart