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ATLAS COPCO COMPRESSED AIR MANUAL

ATLAS COPCO COMPRESSED AIR MANUAL8th editionCompressed Air MANUAL 8th , 2015, 9780 0380 11 113/04/15 14:54 COMPRESSED AIR MANUAL8th 113/04/15 14:49 This MANUAL is published by: ATLAS COPCO Airpower NVBoomsesteenweg 957B -2610 WilrijkBelgiumReproduction of the contents of this publication, fully or in part, is forbidden in accordance with copyright laws without prior written permission from ATLAS COPCO Airpower NV. This applies to any form of reproduction through printing, dupli-cation, photocopying, recording, the production of this material we have gratefully received pictures and contributions from our customers and suppliers, of which we would especially like to name: ABB, Siemens, Vattenfall and COPCO Airpower NVISBN: 9789081535809 ATLAS COPCO Airpower NV, Belgium, 213/04/15 14:49 WELCOME!

3.8.3 Room Constant 97 3.8.4 Reverberation 97 3.8.5 Relationship between sound power level and sound pressure level compressor room98 3.8.6 Sound measurements 98 3.8.7 Interaction of several sound sources 99 3.8.8 Sound reduction 99 3.8.9 Noise within compressor installations 100 4 ECONOMY 4.1 COST 102 4.1.1 Compressed air production cost 102

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Transcription of ATLAS COPCO COMPRESSED AIR MANUAL

1 ATLAS COPCO COMPRESSED AIR MANUAL8th editionCompressed Air MANUAL 8th , 2015, 9780 0380 11 113/04/15 14:54 COMPRESSED AIR MANUAL8th 113/04/15 14:49 This MANUAL is published by: ATLAS COPCO Airpower NVBoomsesteenweg 957B -2610 WilrijkBelgiumReproduction of the contents of this publication, fully or in part, is forbidden in accordance with copyright laws without prior written permission from ATLAS COPCO Airpower NV. This applies to any form of reproduction through printing, dupli-cation, photocopying, recording, the production of this material we have gratefully received pictures and contributions from our customers and suppliers, of which we would especially like to name: ABB, Siemens, Vattenfall and COPCO Airpower NVISBN: 9789081535809 ATLAS COPCO Airpower NV, Belgium, 213/04/15 14:49 WELCOME!

2 Welcome to the universe of COMPRESSED air! This MANUAL offers a comprehensive guidance to anyone who is looking forward to further explore and get insights in COMPRESSED air technology. Whether you are a business person, manufacturing expert, scientist, university student or technical consultant, we believe that the knowledge collected in the MANUAL will prove very useful to you. The COMPRESSED air MANUAL is unique of its kind and has been widely used and hugely appreciated by many thousands of interested readers over the years. We are now proud to present the eight edition of the MANUAL , several decades after the very first MANUAL was introduced. A lot of the information in the MANUAL has been gathered around the world and over many years by a number of leading COMPRESSED air technology engineers from ATLAS COPCO .

3 By sharing their knowledge with you, we want to ensure that efficiency gains can be realized faster and better throughout the many industries that depend on COMPRESSED we all know, there will always be room for new technical improvements and better ways of doing things. Our mission at ATLAS COPCO is to continuously deliver superior sustainable productivity through safer, cleaner, more energy-efficient cost effective COMPRESSED air solutions. To accomplish this, we depend on the voice of our customers. We are very grateful for any suggestions or comments that you might have which can help to make this this MANUAL even more complete. I wish you interesting readings and much success with your COMPRESSED air applications. Nico DelvauxPresident of Compressor TechniqueAtlas CopcoWe welcome your 313/04/15 14.

4 491 PHYSICS 10 The structure of matter 10 The molecule and the differend states of matter PHYSICAL UNITS 11 Pressure 11 Temperature 11 Thermal capacity 11 Work 13 Power 13 Volume rate of flow THERMODYNAMICS 13 Main principles 13 Gas laws 14 Heat transfer 14 Changes in state 16 Isochoric process 16 Isobaric process 16 Isothermal process 17 Isentropic process 17 Polytropic process 17 Gas flow through a nozzle 18 Flow through pipes 18 Throttling AIR 19 Air in general 19 Moist air TYPES OF COMPRESSORS 20 Two basic principles 20 Positive displacement compressors 20 The compressor diagram for displacement compressors 20 Dynamic compressors 22 Compression in several stages 23 Comparison.

5 Turbocompressor and positive displacement ELECTRICITY 24 Basic terminology and definitions 24 Ohm s law for alternating current 24 Three-phase system 25 Power 25 The electric motor 27 Rotation speed 27 Efficiency 27 Insulation class 27 Protection classes 27 Cooling methods 27 Installation method 28 Star (Y) and delta ( ) connections 28 Torque 292 COMPRESSORS AND AUXILIARY DISPLACEMENT COMPRESSORS 32 Displacement compressors 32 Piston compressors 32 Oil-free piston compressors 32 Diaphragm compressor 34 Twin screw compressors 34 Oil-free screw compressors 34 Liquid-injected screw compressors 37 Tooth compressors 37 Scroll compressors 38 Vane compressors 40 Roots blowers DYNAMIC COMPRESSORS 41 Dynamic compressors in general 41 Centrifugal compressors 41 Axial compressors OTHER COMPRESSORS 43 Vacuum pumps 43 Booster compressors 43 Pressure intensifiers TREATMENT OF COMPRESSED AIR 44 Drying COMPRESSED air 44 2.

6 4 . Af te r- c oole r 4 5 Refrigerant dryer 46 Over-compression 47 Absorption drying 47 Adsorption drying 47 Membrane dryers 50 Filters CONTROL AND REGULATION SYSTEMS 52 Regulation in general 52 Regulation principles for displacement compressors 53 Pressure relief 53 Bypass 413/04/15 14:49 Throttling the inlet 54 Pressure relief with throttled inlet 54 Start/stop 54 Speed regulation 54 Variable discharge port 55 Suction valve unloading 55 Load unload stop 55 Regulation principles for dynamic compressors 56 Inlet regulation 56 Outlet regulation 56 Load unload stop 56 Speed regulation 56 Control and monitoring 57 General 57 Load unload stop 57 Speed control 58 Data monitoring 58 Temperature measurement 58 Pressure measurement 58 Monitoring 59 Comprehensive control system 60 Start sequence selector 60 Central control 61 Remote monitoring MOBILE COMPRESSORS

7 63 General 63 Noise level and exhaust emissions 63 Operational flexibility 643 DIMENSIONING AND SERVICING COMPRESSOR DIMENSIONING COMPRESSOR INSTALLATIONS 66 G e n e r a l 6 6 Calculating the working pressure 66 Calculating the air requirement 67 Measuring the air requirement 68 Centralization or decentralization 69 3 .1. G e ne ral 6 9 Centralized compressor installations 69 Decentralized compressor installations 69 Dimensioning at high altitude 69 General 69 The effect on a compressor 70 Power source 71 Dimensioning electric motors 71 Dimensioning IC engines AIR TREATMENT 72 General 72 Water vapor in COMPRESSED air 72 Oil in COMPRESSED air 73 Micro-organisms in COMPRESSED air 74 Filters 74 After-cooler 75 Water separator 75 Oil / water separation 75 Medical air COOLING SYSTEM 77 Water-cooled compressors 77 General 77 Open system without circulating water 77 Open system with circulating

8 Water 77 Closed system 78 Air cooled compressors ENERGY RECOVERY 79 General 79 Calculation of the recovery potential 81 Recovery methods 82 General 82 Air-cooled system 82 Water-cooled system THE COMPRESSOR room 84 General 84 Placement and design 85 Foundation 85 Intake air 85 Compressor room ventilation COMPRESSED AIR DISTRIBUTION 89 General 89 Air receiver 89 Design of the COMPRESSED air network 90 Dimensioning the COMPRESSED air network 90 Flow measurement ELECTRICAL INSTALLATION 94 General 94 Motors 94 Starting methods 513/04/15 14:49 Control voltage 95 Short-circuit protection 95 Cables 95 Phase compensation SOUND 96 General 96 Absorption 97 room Constant 97 reverberation 97 Relationship between sound power level and sound pressure level 98 Sound measurements 98 Interaction of several sound sources 99 Sound reduction 99 Noise within compressor installations 1004 COST 102 COMPRESSED air production cost 102 4.

9 G e ne ral 102 Cost allocation OPPORTUNITIES FOR SAVING 103 Power requirement 103 Working pressure 103 Air consumption 104 Regulation method 105 Air quality 106 Energy recovery 107 Maintenance 108 Maintenance planning 108 Auxiliary equipment LIFE CYCLE COST 109 General 109 LCC calculation 110 5 CALCULATION EXAMPLE OF DIMENSIONINGCOMPRESSED AIR INSTALLATIONS INPUT DATA 114 COMPRESSED Air Requirement 114 Ambient conditions for dimensioning 114 Additional specifications COMPONENT SELECTION 115 Dimensioning the compressor 115 Final compressor selection 116 Dimensioning the air receiver volume 116 Dimensioning the dryer 116 Summary for continued calculation 117 Checking calculations ADDITIONAL DIMENSIONING WORK 118 Condensation quantity calculation 118 Ventilation requirement in the compressor room SPECIAL CASE: HIGH ALTITUDE SPECIAL CASE: INTERMITTENT OUTPUT SPECIAL CASE: WATERBORNE ENERGY RECOVERY 121 Assumption 121 Calculation of the water flow in the energy recovery circuit 122 Energy balance across the recovery heat exchanger 122 Summary SPECIAL CASE.

10 PRESSURE DROP IN THE PIPING 1236 THE SI SYSTEM DRAWING SYMBOLS DIAGRAMS AND TABLES COMPILATION OF APPLICABLE STANDARDS AND REGULATIONS General Standards Compilation 135 Machinery safety 135 Pressure equipment safety 135 Environment 136 Electrical safety 136 Medical devices general 136 Standardization 136 Specifications and testing 136 613/04/15 14:49 CHAPTER 1 THEORYCHAPTER 2 COMPRESSORS AND AUXILIARY EQUIPMENTCHAPTER 3 DIMENSIONING AND SERVICING COMPRESSOR INSTALLATIONSCHAPTER 4 ECONOMYCHAPTER 5 CALCULATION EXAMPLECHAPTER 713/04/15 14 813/04/15 14:501 913/04/15 14 P HYS I C The structure of matterAll matter, be it in gaseous, liquid or solid form, is composed of atoms.


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