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…………... Basic Air Preparation A Look At: The Air System The Components The Mechanisms

You are what you breathe... …or,Life at the Compressor Inlet Acme Compressor Each Cubic Foot of Atmospheric Air Contains.... Dirt Water Vapors Intake Filter  m ACME CORPORATION NO WHERE, USA

Atmospheric Contamination Compressor Intake Acme Compressor Each Cubic Foot of Atmospheric Air Contains.... 4,000,000 solid particles 5 ppm / wt. various vapors Intake Filter m ACME CORPORATION NO WHERE, USA

A Closer Look at the Discharge x One Cubic Foot Ambient Air 7.8 = Compression 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 TO 4,000,000 Solids 7.8 = Compression 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 DryerCompressor Mainline Filtration Drains Point of Use FRL Aftercooler here (heat removal)

DryerCompressor 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 piping Take drops off top of main header Be a plumber’s friend! 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 Drop Heat

3 Sources of Compressed Air Contamination Atmospheric Contamination Compressor Contamination Piping Contamination

Compressor Contamination Discharge Air Compressor Carryover Oil (per year).5 47 Gallons 38,600,000 Solid Particles (intake air) & Compressor Wear Particles &

Discharge Contamination continued Oil, Oil Everywhere. Where’s it all coming from ?? Acme Compressor Acme Compressor Acme Compressor Acme Compressor Oilless Rotary Vane Flooded Screw Reciprocal 12 oz - 60 oz. 5.6 gal gal 3.8 gal - 47 gal 47 gal gal Bypass Oil Per Yr JEFFJEFF

Piping Contamination AIR OIL WATER PIPE SCALE PIPE RUST YUK!! BOB

Sources of Contamination Ambient Air –Dirt + Oil +Water Compressor –Wear Metals –Oil Carryover –Pressure Drop The Air System –Pipe Scale –Pressure Drop

The Ugly Truth Dirt - 4 Million particles/cubic ambient Oil - 5 ppm carryover = several gallons / year Water - RH, 100scfm system = 114 Gallons H 2 O / day Pressure Drop - Each 2 psid = about 1% BHP

The Problems  Premature 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

The Problems Premature 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-cooled aftercooler

Air-cooled aftercooler

Shell and tube heat exchanger Cool water in Hot air in Warm water out Separator Condensate out Water-cooled aftercooler and separator Cool air 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 Regenerative Twin Tower Pressure Swing Cycle Desiccant Dryer

Heatless Regenerative Pressure 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 N2N2 O2O2 Water molecules H2OH2O Membrane pore size allows water to pass, but Nitrogen and Oxygen molecules bond in pairs and are too large to pass.

Membrane Dryer Cutaway (Not a true cross-sectional drawing) Bowl Purge orifice Membrane Module Purge air exhaust Body casting w/ cover In Out

Membrane Dryer with Coalescing Filter

Compressed Air Preparation: Temperature Conditioning Drying Filtering Regulating Lubricating (when appropriate)

Filtration Locations Acme Compressor Compressor RoomPoint - of - Use Acme M a T c o h o i l n e

Particulate filters TWO-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 oil is 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 Pressure 1. 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 Courtesy of Wilkerson

Body Main Spring Panel nut Bonnet Adjusting 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

Compressed Air Basics 100psig 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)

What’s been removed? >95% LIQUID WATER AND OIL GONE % SOLIDS GONE % SOLIDS REMAINING <5% REMAINS

40 can be seen with the human eye (A grain of table salt) What remains? Solid Contamination smaller than filter element rating Household Scouring Powder micron Bacteria

Coalescing Filter WILKERSON Liquids Collect Here Air travels from “inside to outside” through four stages: 1) support screens 2) pre-filter support layers 3) filter media 4) anti-reentrainment barrier

LIQUID WATER AND AEROSOLS GONE TO 0.01 ppm/wt. What’s been removed? % SOLIDS GONE ISO SPECS HERE

.01 Micron 1.0 Micron What Remains ?