Kaeser Compressor and Valve (of)-11

04/10/23 MUHAMMAD SAJID

• Operation of Screw Compressors

• Operation of Valves• Operation Of Dessicant Dryer• Sigma Controller• Introduction of Microfilters


Construction1 Airend2 Energy-saving electric motor3 Motor grease nipples4 Inlet valve5 Minimum pressure/check valve6 Combined Auxiliary Vent Valve7 Fluid cooler with mounted thermostatic valve and fluid-micro filter8 Compressed air after cooler9 Two-stage air inlet filter10 Fluid separator tank with separator cartridge11 Safety Valve12 Anti Vibration Dampers13 Sigma Control


98-99%

1st stage,centrifugal

2nd stage, fluidFluid Separation

separator elementa) coarse filter layer

b) fine filter layer


•


Tasks of Fluid

First task:

Second task:

Third task:

Fourth task

Heat transfer, discharge temp.approximately 75 - 80 oC

Lubrication of Airend Bearings

Sealing gap between rotors and casing, prevention of metallic contact

absorbing dust,sulphur, etc.


Inlet Valve


Min Pressure Check Valve

Off Load Position


Full Load Position


Air Oil Separation


Thermostatic Element Function


Thermostatic valve

• The purpose of the thermostatic valve is to bring the cooling fluid up to operating temperature as quickly as possible and to keep it at this level under all operating

conditions (idle running, winter operation, etc.). This keeps the compressed air/fluid mixture above the pressure dew point**, preventing condensation in the fluid separator tank.

• Water in the fluid circuit leads to corrosion in metal parts and reduces the cooling and lubricating qualities of the fluid.

• Operating temperature, determined by the choice of working element within the• thermostatic valve, is dependent on the pressure range and the climatic zone in

which the compressor is used. ** Pressure dew point is the temperature at which the air is saturated with moisture.• If the air picks up any more moisture it is precipitated out as water (condensate).• II Fluid filter• The valve also serves as a filter head to which a spin-on element is attached. The

element is mounted directly on the valve outlet so that 100% of the fluid flow is filtered before returning to the airend. Direct mounting avoids the need for connecting pipes.


• A Cold fluid• Fluid flows from the separator tank to the valve inlet(1). When the fluid is cold,

the working element (2) and the actuating piston (3) remain in their initial positions. The fluid flows past the cooler through the bypass (4) (as the cooler presents a higher resistance to the fluid than the bypass, the fluid takes the path of least resistance). The fluid flows through the fluid filter (5) directly to the airend (6). In this way, it reaches operating temperature in the shortest possible time.

• B Warm fluid• The fluid flows from the separator tank to the valve inlet (1). The heated fluid

flows around the thermostatic working element (2). The working element forces the actuating

piston (3) downwards. The passage to the bypass (4) narrows continuously and some of the fluid

flows through the cooler.• When the fluid reaches operating temperature, the actuating piston (3) is

forced down completely by the working element (2). The bypass (4) is closed. All the fluid is routed through the cooler. The fluid flowing out of the cooler is fed to the filter (5). Cooled and filtered fluid is now routed directly to the airend (6).


Sigma Control


Traffic light function

Plain text display

Basic function:

ON/OFF

Preselect functions

Traffic light functions


Quick and simple operation thanks to menu guidance

UP keyScrolls the display text downard line for line

DOWN keyscrolls the display text upward line for line

Escape keyreturns to next higher level

Return keyinitiates jump to next sub-menuor accepts value

Acknowledge keyacknowledges alarms and-when permitted - resets the alarm memory

Info keyaccess to additional informationor to the event information memory.

Menu-functions


Untreated air

dirt

oil aerosols

moisture

Problems in the air main

corrosion

pressure loss

contamination

Maintenance

Problems with equipment

contamination

tool wear

scrap

downtime

COSTSCOSTS


condensate collection

cyclonicair movement

deflector

air outletair inletCondensate separation

To ensure sufficient separation,

liquids and heavy particles are

subjected to centrifugal forces at

high rates of flow.

The degree of separation is around

95% at 6 bar, 20 °C and the nominal

volumetric flow rate. The pressure

drop is approximately 0.05 bar .


1 Microfilter FE (0.01 µm, 0.01 ppm)

2 Flow Distributor3 Stainless Steel Flow diffuser4 Desiccant bed: moisture

adsorption5 Upper Part of Dessicant chamber6 Security Reserve7 Flow distributor8 Particulate filter FD 1 µm9 Purge (regeneration ) air valve10 Desiccant bed: regeneration11 Purge air exhaust silencer

Desiccant Dryer


Drying cycle• The incoming compressed air from the receiver

tank is filtered by the inlet filter FE (1) from liquid and dust particles (particle size 0,01 μm).

• The air passes through inlet air valve via stainless steel flow distributor (3) where the air is distributed to the whole cross section of the chamber.

• In the mass transfer zone (4) most of the moisture is transferred to the desiccant

granules.The second part of the chamber (5) takes away the remaining moisture to reach the needed dew point.

• The last part is a security reserve (6). The dried compressed air then flows through the flow

distributor (7) and the shuttle valve to the compressed air outlet.

• Then the air is filtered from dust particles (particle size 1μm) in the dust filter FD (8).


• Regeneration of desiccant• The regeneration is done by a part of the air flow of the

dried air of the first chamber. • The part air flow is passing through the shuttle valve (9)

and going from top down through the second chamber.• As expanding air is able to take up moisture, the dry air

is regenerating the desiccant (10).• The amount of needed regenerating air is a physical size

and can be optimised by an adjustable regeneration nozzle (9). The wet purge air is passed through top flow distributor (2), purge air valve and purge air muffler (11) into the atmosphere.


How large are the impurities in the air?Description: vapour / mist / smoke dust fog: spray rain

Perception: Description: microscopic visual

Falling time at 1 m heightSec.

Min.

foundry sand

heavy industrial smogwater mist

carbon dust

traffic dust

cement dust

pollen

plant spores

bacteria

metallurgical dust

oil mistoil vapoursViruses

tobacco smoke

gas molecules

pore dia, activ. carbon, silica-gel, etc.

centrifugal

normalheavy

bag-typeair filter

separation and filtration performance

paint spray mist

Influence of the Brownian Molecular movement

Particle size in microns


Streamed from the inside to the outside.

Prefilter (FB, FC Type)

used as a coarse filter for 100% saturated compressed air (or for water vapour components in the liquid phase)

FB is used to remove particles > 3 umFC is used to remove particles > 1 um


Microfilter (FE, FF Type)

0.01 micron

for liquids (aerosols)

and particles

oil aerosol content: 0,01 ppmto 0,001 ppm


contaminated air filter medium (deep-bed filter) technically oil-free clean air

Direct interception

Impact

Diffusion /Coalescence

How does the microfilter work?


THANK YOU

Kaeser Compressor and Valve (of)-11

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