Compressed Air System Expert associated with this product. send mail Phone Call Online Interview Share: Send to a Friend Description Technical Specifications Product videos Compressed Air System Two common types of compressed air package Dryer inlet flow rate is only a part of the compressor capacity Dryer inlet flow rate is equal to the compressor capacity Air Compressor Final refrigerator Condensate separator Filter 5 micron Filter 1 micron HDT Adsorption Dryer Compressed air tank Dried Air Outlet Condensate drain Compressed Air Contamination: In a typical compressed air system (such as Figure 1), compressed air contamination comes from different sources. The first source of these contaminations comes from atmospheric air. Atmospheric air consists of huge amount of contaminants such as water vapor, micro-organisms, atmospheric dirt and even oil vapor (atmospheric air typically contains between 0.05 mg/m3 and 0.5 mg/m3 of oil vapor from sources such as car exhausts and industrial processes). In addition to the contaminants drawn in through the compressor intake, the compressor also adds additional wear particulates from its operation. Additionally, oil lubricated compressors carry over liquid oil, oil aerosols & oil vapor from the compression process. Once through the compression stage, the after-cooler will also condense water vapor, introducing it into the compressed air in both a liquid and aerosol form. Compressed air storage devices and system piping are other sources of compressed air contamination. Generally, contaminants found in a typical compressed air system are as follows: Liquid Oil Oil vapor Rust Atmospheric Dirt Water Aerosols Micro organisms Oil Aerosols Liquid Water Pipe scale Reference Standard ISO 8573 – part 1: Contaminants and purity classes, provides a classification system for the main contaminants of a compressed air system and specifies purity classes of compressed air with respect to particles, water and oil, independent of the location in the compressed air system at which the air is specified or measured. Compressed Air Filters Due to these large amounts of surplus contamination in compressed air, Compressed air filters, often referred to as line filters, are used to remove contaminates from compressed air. Reliability is one of the strongest reasons to use compressed air, and proper filtration is the key to maximizing reliability and longevity. Filters are rated according to the minimum particle size that their elements will trap. Note that finer ratings increase the pressure drop through the filter, which equates to higher energy cost to compress the air. In addition, finer filters clog more rapidly, also increasing pressure drop. (In other words, while filters finer than necessary do no harm to downstream components, they will have a negative impact on air system operating cost.) Filters must be sized and selected based on the intended airflow. Filters are defined by the maximum flow rate passing through the filter. This maximum flow rate, also referred to as nominal capacity, is specified by filter manufacturer and it is measured at a reference condition (7 barg & 20°C) and correction factors are available by manufacturer for other working conditions. Please refer to table 2 to see correction factors Types of Filters Havayar’s routine filters are designed and manufactured to meet client’s specifications. As it can be seen from picture below, different elements and accessories can be installed on filters for any working condition. Special Case Havayar industrial group is ready to design and manufacture special filters for severe working conditions and to meet any specification. South Pars Gas Field As an EPC project, Havayar industrial group provided the whole compressed air package (unit 123) of four phases of South Pars Gas Field, including special air filters. Based on project specification, filters were installed on the air dryer’s skid (figure 2). Filters housing were designed and manufactured in accordance with ASME Sec. VIII Div. 1. Filters are provided at the upstream and downstream of the Air dryers. The upstream filters (Micro Filter 123-F-104) prevent any condensed water droplet from entering the Air dryers. The downstream filters (Dust Filter 123-F-108) catch the fine desiccant that carried over by the compressed air from the desiccant bed. Two filter set has been considered for each Micro Filter and Dust Filter and each filter equipped with PDG. One filter is in service, whenever filter is dirty and pressure drop increase then operator should change over to other filter. For this project, another kind of filtering was designed and manufactured. A demister pad is installed in water separator in order to filter the liquid droplets entrained from a gas stream. As the name suggests the demister is used for removal of the mist from gaseous phase. Demister pad is often fitted just below the top vapor outlet of a vapor liquid separator, as shown in the figures below. There are three stages of water separator between each stage of compressor and cooler. The cooled compressed air leaving air cooler to water separator. A water separator shall be located at the discharge of the intercooler. The partially dried air leaves water separator to the next stage of compressor to be further compressed. At each stage of water separator vessel there is demister pad which is used to given liquid from wet air. Demisters are often used where vapor quality is important with regard to entrained liquids particularly where separator equipment costs are high (e.g., high pressure systems) or where space or weight savings are advantageous.