CHAPTER 1 INTRODUCTION

Prepared by: ELLA MAE ARAO and MARIA ROSILYN ORTUA 1.1 Introductory Statement Compressed air systems are one of the most useful applications of Pneumatics to humankind. It is primarily governed by the concept that compressed air is highly pressurized, and thus can be utilized for many functions in the industry. Compressed air, commonly called Industry's Fourth Utility, is air that is condensed and contained at a pressure that is greater than the atmosphere. The process takes a given mass of air, which occupies a given volume of space, and reduces it into a smaller space. In that space, greater air mass produces greater pressure. The pressure comes from this air trying to return to its original volume. This pressure creates an energy that can be used in a variety of application. Applications of compressed air systems can be as simple as in bottled spray paints or perfumes and can also be as complex as a compressed air system for aeronautics purposes. Compressed air is used for many purposes, including Pneumatics or the use of pressurized gases to do work, air tools, HVAC control systems, vehicle propulsion, energy storage, air brakes including railway braking systems, road vehicle braking systems, scuba diving and inflation of buoyancy devices, refrigeration using a vortex tube, air start systems in engines, ammunition propulsion in air guns, airsoft equipment, paintball equipment. Other applications include shop air, sand blasting, coating and packing machines, food industry, dairy industry, laboratories, outdoor pipelines, pneumatic transport of hygroscopic material, breweries, chemical and pharmaceutical industry, electronics industry.

Compressed air supplies power for many different manufacturing operations. At a pressure of 100 psig (7 bar), compressed air serves as a utility. It supplies motive force, and is preferred to electricity because it is safer and more convenient. There are many reasons why compressed air is preferable compared to other power sources like electricity because of many advantages. First and foremost is because of its safety. Compressed air system leakage will not contaminate a work place. Electric shock is potentially reduced. Typically, pneumatic tools will weigh less than electric tools electric tools and make the tools more ergonomically friendly. Compressed air has more flexibility than electrical tools because the compressor can be made to be mobile. And the greatest advantage of compressed air is the high ration of power to weight or power to volume. Compared to electric motors, compressed air produces smooth translation with much more uniform force. Compressed air equipment can be more economical and more durable as well. Thus, proper design, installation, operation and maintenance of a compressed air system must be taken into consideration. Compressed air can be costly to manufacture, so a poorly designed compressed air system can consequently lead to undesired implications. 1.2 Objectives of the Engineering Report This engineering report seeks to accomplish the following objective: To prepare a mechanical plan of a compressed air system that would supply compressed air to Machine Shop, Assembly Shop, Core Shop, Painting Shop, Machine Moulding, Hand Moulding, Cleaning Shop, Sheet Metal Shop.

1.3

Importance of the Engineering Report The foremost importance of this engineering report is to help the students familiarize the

tasksneeded in the installation, operation and maintenance of a compressed air system. It includes the computation of pipe sizes based on the given the specifications of different tools and equipment, as well as the selection process of different compressed air system equipment.

1.4

Limitation of the Engineering Report This engineering report limits itself to the design of a compressed air system only. It also

discussed the pipe sizing and selection of the equipment such as the compressors, filters, dryers and aftercoolers. The report focuses on the selection only and not the actual assembly of the system.

CHAPTER 2 SYSTEM DESIGN

Prepared by: JANINE BIEN, JAN JERKIN CARDIO, and RUPERT CONDAT 2.1 Design Overview Design of a Compressed Air System to supply the needed requirements of the following shop: A. B. C. D. E. F. G. H. I. Machine Shop Cleaning Shop Core Shop Painting Shop Machine Moulding Hand Moulding Compressed Air Plant Assembly Shop Sheet Metal Shop The design should have a compressor, filter, air receiver, aftercooler, and piping system.

2.2

System Requirement and Layout

2.3

Pipe Sizing Calculation

Usual for the compressor to deliver 7 bars (gauge) of compressed air and compressed air equipment uses 6 bars (gauge) of compressed air. MAIN LINE Main line air flow must be less than 6 m/sec : 321 L/sec via interpolation from Table 1 : Use : 4 in Sch 40, di = 4.026 in = 102.26041 mm = 0.10226041 m Check for air velocity, V= BRANCH SIZING =
( )

= 4.88551 m/s

BRANCH LINE Use applied gauge pressure of 6.3 bar gauge. Branch A: Machine Shop V =5.2 L/s

From Table 2, at 6.3 bar V 2.5 5.2 5.7 x = 7.6875 mm = 0.30266 in Therefore, use 3/8 Sched 40, ID = 0.493 in = 0.01253 m v= Branch B: Cleaning Shop V =120.5 L/s From Table 2, at 6.3 bar V 65 120.5 133 x = 30.7132 mm = 1.2089 in Therefore, use 1 1/4 Sched 40, ID = 1.38 in = 0.03506 m v= Branch C: Core Shop V =18.5 L/s From Table 2, at 6.3 bar V 12.6 18.5 23.4 x = 12.7315 mm = 0.5012 in Therefore, use 3/4 Sched 40, ID = 0.824 in = 0.02093 m v= =
( )

6 x 8

= 5.78 m/s

25 x 32

= 17.01 m/s

10 x 15

= 7.37 m/s

Branch D: Painting Shop V =38.2 L/s From Table 2, at 6.3 bar V 35 38.2 65 20 x 25

x = 20.5333 mm = 0.8082 in Therefore, use 1 Sched 40, ID = 1.049 in = 0.02665 m v= Branch E: Machine Moulding V =28.6 L/s From Table 2, at 6.3 bar V 23.4 28.6 35 x = 17.2414 mm = 0.6786 in Therefore, use 3/4 Sched 40, ID = 0.824 in = 0.02093 m v= Branch F: Hand Moulding V =10.5 L/s From Table 2, at 6.3 bar V 5.7 10.5 12.6 x = 9.3913 mm = 0.3696 in Therefore, use 3/8 Sched 40, ID = 0.493 in = 0.01253 m 8 x 10 =
( )

= 9.38 m/s

15 x 20

= 11.39 m/s

v= Branch H: Assembly Shop V =2.2 L/s From Table 2, at 6.3 bar

= 11.66 m/s

V 2.2 2.5 3.7 x = 5.8125 mm = 0.2288 in

x 6 8

Therefore, use 1/4 Sched 40, ID = 0.364 in = 0.009248 m v= Branch I: Sheet Metal Shop V =97.3 L/s From Table 2, at 6.3 bar V 65 97.3 133 x = 28.325 mm = 1.1149 in Therefore, use 1 1/4 Sched 40, ID = 1.38 in = 0.03506 m v= 2.4 =
( )

= 4.49 m/s

25 x 32

= 13.81 m/s

Piping Pressure Drop Calculation The longest and largest pipe is toward the outlet B, Cleaning Shop. First, look for the air flow distribution in the loop. USE: 40 mm pipe for piping or 1.25 in Sched 40, ID = 1.38 in = 0.115 ft

Node 1-F Q = 321 L/s (x)( From Table 3: Equivalent Length (m) 12 0.8 ---------------------12.8 m = 41.984 ft = 680.52 x CFM

Actual Length Run of Tee, 40 mm

Node F-E Q = [321 L/s (x) 10.5 L/s]( From Table 3: Equivalent Length (m) 5 0.8 ---------------------5.8 m = 19.024 ft = 680.52 x CFM 22.26 CFM

Actual Length Run of Tee, 40 mm

Node E-D Q = [321 L/s (x) (10.5 L/s + 28.6 L/s)]( = 680.52 x CFM 82.892 CFM

From Table 3: Equivalent Length (m) 5 0.8 ---------------------5.8 m = 19.024 ft

Actual Length Run of Tee, 40 mm

Node D-C Q = [321 L/s (x) (10.5 L/s + 28.6 L/s + 38.2)]( From Table 3: Equivalent Length (m) 5 0.8 ---------------------5.8 m = 19.024 ft = 680.52 x CFM 163.876 CFM

Actual Length Run of Tee, 40 mm

Node C-A Q = [321 L/s (x) (10.5 L/s + 28.6 L/s + 38.2 L/s +18.5 L/s)]( Q = 680.52 x CFM 203.096 CFM From Table 3: Equivalent Length (m) 12 + 2 0.8 2.4 ---------------------17.2 m = 56.416 ft

Actual Length Run of Tee, 40 mm Milter Bend, 40 mm

Node A-B Q = [321 L/s (x) (10.5 L/s + 28.6 L/s + 38.2 L/s +18.5 L/s + 5.2 L/s)]( Q = 680.52 x CFM 214.12 CFM

10

From Table 3: Equivalent Length (m) 5 0.8 ---------------------5.8 m = 19.024 ft

Actual Length Run of Tee, 40 mm

Node 1-I Q = 321 L/s (1-x) ( From Table 3: Equivalent Length (m) 2+5 2.4 ---------------------9.4 m = 30.832 ft = 680.52 (1-x) CFM

Actual Length Side Outlet Tee, 40 mm

Node I-H Q = [321 L/s (1-x) 2.2 L/s] ( From Table 3: Equivalent Length (m) 5 0.8 ---------------------5.8 m = 19.024 ft = 680.52 (1-x) CFM 4.664 CFM

Actual Length Run of Tee, 40 mm

Node H-B Q = [321 L/s (1-x) (2.2 L/s + 97.3 L/s)] ( From Table 3: Equivalent Length (m) 5 + 2 + 2 + 39 0.8 2 (2.4) ---------------------53.6 m = 175.808 ft = 680.52 (1-x) CFM 210.94 CFM

Actual Length Run of Tee, 40 mm 2 Milter Bend

11

Use an average value for friction = 0.02 P = 7 bars = 100 psig = Node 1F FE ED DC CA AB 1I IH HB

=
scfm 332.978436 310.718436 227.826436 169.102436 129.882436 118.858436 347.541564 342.877564 136.601564

= 0.5955 lb per ft3

l/s 157.0653 146.5653 107.4653 79.7653 61.2653 56.0653 163.9347 161.7347 64.4347

Pline = 4.15 psig (total pressure drop in the line)

X 0.4893 FREE AIR SCFM (FORMULA) 680.52X 680.52X - 22.26 680.52X - 82.892 680.52X - 163.876 680.52X - 203.096 680.52X - 214.12 PIPE = 1 1/4 in ID = FREE AIR SCFM (VALUE) 332.978436 310.718436 227.826436 169.102436 129.882436 118.858436 0.12 VELOCITY, FT/S 66.79 62.32 45.70 33.92 26.05 23.84 ft PRESSURE DROP, PSI/100 FT 4.98 4.34 2.33 1.28 0.76 0.63 PRESSURE DROP 1-F-E-DC-A-B PRESSURE DROP, PSI/100 FT 5.43 5.28 0.84 PRESSURE DROP 1 I H -B

NODE 1-F F-E E-D D-C C-A A-B

EQUIVALENT LENGTH, FT 41.984 19.024 19.024 19.024 56.416 19.024

PRESSURE DROP,PSI 2.09 0.83 0.44 0.24 0.43 0.12

4.15 EQUIVALENT LENGTH, FT 30.832 19.024 175.808 PRESSURE DROP,PSI 1.67 1.00 1.47

NODE 1-I I-H H-B

FREE AIR SCFM (FORMULA) 680.52(1-X) 680.52(1-X) - 4.664 680.52(1-X) - 210.94

FREE AIR SCFM (VALUE) 347.541564 342.877564 136.601564

VELOCITY, FT/S 69.71 68.77 27.40

4.15

12

Pressure loss on the branch pipe: Outlet B V = 17.01 m/s 40 mm pipe for piping or 1.25 in Sched 40, ID = 1.38 in = 0.115 ft Equivalent Length Side Outlet Tee, 40 mm 90 Milter Bend, 40 mm 2 x 2.4 Actual Pipe Length (2 x 0.15) + 0.3 + 2.5 Total P = 6.3 Bars = 91.4 Psig v =7.37 m/s = 24.17 ft/s m 2.4 4.8 3.1 10.3 m = 33.784 ft

=
=

= 0.5955 lb per ft3

= 0.2204 psig

Pbranch=

Pressure loss in main pipe line: 4 in Sch 40, di = 4.026 in = 102.26041 mm = 0.10226041 m = 0.3354 ft P = 7 Bars = 100 Psig Q = 321 L/sec V = 4.88551 m/s = 16 ft/s =

= 0.5955 lb per ft3

13

Equivalent Length 90 Milter Bend, 125 mm 2 x 7.5 Actual Pipe Length 3+6 Valves 5 x 1.6 Total Pmain= =

15 9 8 32 m = 104.96 ft = 0.1029 psig

Pressure loss in the main reducer: P @ reducer, 40 mm 40 mm pipe for piping or 1.25 in Sched 40, ID = 1.38 in = 0.115 ft = V=

=
m 0.8 m = 2.624 ft

= 41.4678 m/s = 136.0144 ft/s

Equivalent Length Reducer, 40mm = Preducer= Total:

=
=

= 0.5955 lb per ft3

= 0.5421psig

Pline = 4.15 psig Pbranch =0.2204 psig Pmain =0.1029 psig Preducer = 0.5421psig -----------------------------------------Ptotal =5.0154 psig

14

2.5

Filter Selection

Max Rate of Standard Air = 321 L/sec(free air) = 680.52 SCFM Brand: Kaeser KLS Kaeser Liquid Separator KLS 780 Location: Downstream of Aftercooler Liquid Removal: 99 + % of Water Maximum Liquid Loading: 30, 000 ppm w/w Solid Particle Removal: 10 Microns Oil Carry-Over: N/A Pressure Drop: Wet: 0.8 Psi Connection Size: 2.5 NPTF Dimension: W x H = 7 5/8 x 41 Weight: 38 Lbs Automatic Drain Maximum Working Pressure: 250 Psig Maximum Initial Temperature: 150 F Modular Housing Type KFS Kaeser Filtered Separator KFS 780 Location: Downstream of Aftercooler Liquid Removal: 99 + % of Water Maximum Liquid Loading: 25, 000 ppm w/w Solid Particle Removal: 3 Microns Oil Carry-Over: 5 ppm w/w Pressure Drop: Wet: 1.5 Psi Dry: 1 Psi Connection Size: 2.5 NPTF Dimension: W x H = 7 5/8 x 41 Weight: 38 Lbs Automatic Drain Maximum Working Pressure: 250 Psig Maximum Initial Temperature: 150 F Modular Housing Type

15

2.6

Dryer Selection

To select for refrigerated compressed air dryer, we should calculate for the corrected SCFM with the following conditions: Conditions Inlet Air Pressure Inlet Air Temperature Ambient Air Temperature System Condition 100 Psig (7 Bar) 120 F (48.8 C) 110 F Correction Factor 1.00 1.51 1.16

Dew Point = 38 F Pressure Drop at 100 % Air Flow = 4.6 Psig Compressor Flow = 321 L/sec(free air) = 680.52 SCFM Corrected Flow Rate = 680.52 SCFM (1) (1.51) (1.16) = 1191.9988 SCFM UseDELTECHRefrigerated Compressed Air Dryer for Selection Conditions Inlet Air Press. and Temp. Ambient Temperature Dew Point System Condition 100 Psig (7 Bar), 120 F 110 F 38 F Correction Factor 0.70 0.94 1.00

For water cooled model, use a 1.15 multiplier if cooling water is less than 95 F (35 C). Source: Table 2, Deltech Brochure Calculate for the capacity of HGE 1250 Model When compressed air is at: 100 PsigInlet Air Pressure 120 F Inlet Temperature 110 F Ambient Temperature 38 F Dew Point Capacity = = 715.2174 SCFM Product Specifications (Deltech) Model HGE Series: HGE1250 Pyramid Series: PYR1250 Rated Flow: 1250 SCFM Voltage: 460/3/60 V/ph/Hz

16

Power: 6.73 Kw Connection: 4 ANSI Flange Dimensions HxWxD 85 x 48 x 49 Weight: 1600 Lbs 2.7 Receiver Selection

The table belowindicates normal receiver volumes at given consumptions. The table is based on the design pressure of 140 Psig (95 Bar).

Based for an air flow capacity of 321 L/sec or 680.52 SCFM Recommended Receiver Volume Airflow Capacity m3 600 1.5 680.52 x 700 2 x = 1.9026 m3= 1902.6 L y = 67.4936 cu ft z = 512.728 gal

cu ft 53 y 71

Gallons 400 z 540

17

Based on Atlas Copco Air Receiver Manufacturer

Use Atlas Copco Air Receiver Model: LV 2100 Volume: 2000 Liters Maximum Working Pressure: 11 Bar Height: 2640 mm Diameter: 1150 mm Weight: 421 kg 2.8 Air Compressor and Aftercooler Selection

Air Compressor Selection Pressure for end-use = 6.3 Bar Compressed Air Flow Requirement (free air) = 680.52 SCFM Atlas Copco XAS 750 CD6 750 CFM, 100 PSI ROTARY SCREW COMPRESSOR

18

TECHNICAL SPECIFICATIONS FAD Rating 750 cfm/100psi Min./Max. Working Pressure 58/125 Engine - Caterpillar C6.6 Acert EPA Tier 3 Engine Control Electronic Aspiration Turbocharged Horsepower 200 Number of Cylinders 6 Cooling System Water Full Load Speed 2,100 Fuel Tank Capacity (Gal.) 76 Fuel Consumption @ 0% load (Gal/hr) 3.8 Fuel Consumption @ 100% load (Gal/hr) 10 Aftercooler Selection Compressed Air Flow = 321 L/s = 680.52 scfm Compression Stages 1 Outlet Valve Configuration 1x1.5/2x Compressor Cooling System Air/Oil Compressor Oil Capacity (Gal.) 12 Air receiver Capacity (Gal.) 16.78 Sound pressure level @ 23 Ft. 76 dBa Dimensions LxWxH (wheel mtd.) 203x78x78 Wheel Mtd Wet Weight (lbs.) 6,405 Dimensions LxWxH (skid mtd.) 132x62x72 Skid Mtd Wet Weight (lbs.) ) 5,835

Data Specifications: Compressed Air Aftercooler, Air AB SERIES Rotary Screw, 200 F Inlet, 955 scfm Capacity in Tube

19

Model AB 1206 C6 0 Pressure Drop : 0.6 psi Water Flow = 3 gpm per 100 scfm (680.52 scfm) Water Flow = 20.4156 gpm 2.9 Final Layout

20

CHAPTER 3 PRODUCT SPECIFICATION

Prepared by: LEE ANTHONY BACSAIN, BENJAMIN BONAGUA I, and RUPERT CONDAT 3.1 Scope

3.1.1 Introduction This specification details the design, fabrication, installation, testing and commissioning of compressed air systems for shops utilizing compressed air, and is to be used for both new and altered systems. The compressed air system includes, but is not limited to, air Compressor Rooms (consisting of air compressors, dryers, and controls), air receivers, pipe-work and associated piping components such as manifolds and valves. The compressed air systems will be used to operate Machine Shop, Cleaning Shop, Core Shop, Painting Shop, Machine Moulding, Moulding, Assembly Shop, and Sheet Metal Shop 3.1.2 Reference Documents, Standards and Codes The following reference documents form part of this specification. M11-349-1 & 2 Standard Air System Drawing Symbols for Air Systems M11-351-1 & 2 Compressed Air Piping Arrangement M11-350 Connection Single Trainstop to Main M11-352 Anchor Points M11-353 Steel Air Main Bracket M11-355 Label Holder Installation, Part: Carrington Tang Clamp, 1/2 and M11-354 Label Holder Installation Example on General Manifold Arrangement SPG 1870 Air Compressors for Signalling Systems M11-307 Air Hose, P.V.C. detail of Fittings Drawings produced from design phase DS-P-001 GMS01 Piping DS-P-002 MS01 Piping DS-P-003 SS01 Piping DS-P-004 Halogen Free Flexible Piping DS-EQ-001 Air Compressor DS-EQ-002 Compressed Air Dryer DS-EQ-003 Air Receiver SPG 0705 Construction of Cable Route and Associated Civil works ESG 100.25 Compressed Air Systems SPG 0703 Signalling Documentation and Drawings

21

The following Australian Standards and statutory codes form part of this specification. AS 1074 Steel Tubes and Tubulars for Ordinary Service AS 1210 Pressure Vessels AS 1345 Identification of the Contents of Piping, Conduits and Ducts AS/NZS 1477 PVC Pipes and Fittings For Pressure Applications AS/NZS 1518 External Extruded High-density Polyethylene Coating System for Pipes AS 2129 Flanges for Pipes, Valves and Fittings AS/NZS 2554 Hose and Hose Assemblies for Air AS 2660 Hose and Hose Assemblies Air/water For Underground Coal Mines AS 4041 Pressure Piping AS/NZS 4680 Hot-dip Galvanized (Zinc) Coatings on Fabricated Ferrous Articles AS/NZS 4792 Hot-dip Galvanized (Zinc) Coatings on Ferrous Hollow Sections, Applied by a Continuous or a Specialized Process NSW Work, Health and Safety Act 2010. NSW Work, Health and Safety Regulations 2011 Rail Safety Act 2002

3.1.3 Installer Supplied Data Refer to Appendix A for Installer supplied data. 3.2 Design

3.2.1 Design Inputs The following data shall form part of the design inputs, along with other data listed in the Particular Specification (eg scope of work): Reference documents, standards and codes (refer Section 1.2); Available information on the existing air reticulation system in the project area to which the new work is to be connected; and/or plans showing the proposed location of the new equipment; Available information on the location of existing cable routes and any existing air reticulation system which is to be replaced by the new work; Available information on the current noise, air and waste emission approval limits, including any information on any new limits which may apply to the works; Fluid parameters (refer Section 3.1); Environmental and site factors (refer Section 3.2); Operating and control philosophy (refer to document ESG 100.25); Design life of 25 years for equipment, and 50 years for pipework and structures;

22

Maximum thermal expansion of -10 C to 60 C, and maximum thermal movement of a manifold or cross tie branch to be +/- 25 mm;

The equipment and pipe work shall be designed and installed to provide maximum protection and safety for operating and maintenance personnel. Safety equipment shall include guards, access covers, inspection covers, emergency stop equipment, safety interlocks, and other devices required by the statutory authorities; The pipework shall be designed to ensure all manually operated valves are in positions where the valve hand wheel can be comfortably reached and operated from an access platform, floor, walkway or stairway; and All equipment proposed for the air system shall require type approval. 3.2.2 Design Documentation The following design documentation shall be generated, as a minimum, during the design process: Process flow diagram, mass balance, and/or network hydraulic model, to document the capacity of the extended/new system; Equipment, piping and instrument data sheets in sufficient detail to allow procurement of these items; General arrangement, layout and detail drawings of the Compressor Room equipment and instrument installation; Electrical power and control details, including protection scheme and interface list; Schematic books, similar to current books, detailing the new pipework involved, connections to existing pipework, and corrections to existing schematics; Specifications to cover fabrication, installation, and commissioning requirements; and Functional description in sufficient detail to allow software coding to proceed. Maintain VDU + Compressor PLC system design user manual, including all software & licences. Fluid Parameters, Site Details and Equipment Parameters

3.3

3.3.1 Fluid Parameters Fluid parameters are: Fluid is compressed air to quality class 2.4.2 of ISO 8573, downstream of dryer postfilter; Temperature range 10C to 50C between compressors and receivers; and Temperature range -10C to + 60C downstream of receiver.

23

3.3.2 Environmental and Site Factors Environmental and site factors are: Ambient temperature range 10 to +60C; Rainfall range 600 mm to 2000 mm per annum; Humidity range 40% RH to 100% RH; Potential close proximity to noise sensitive areas; and Other environmental factors are vibration and mechanical damage

3.3.3 Equipment Parameters 3.3.3.1 Points An EP points motor with 125 mm bore and 180 mm stroke has a volumetric capacity of 0.0022 cu M. 3.4 Equipment Supply

3.4.1 Compressors Compressors shall be in accordance with SPG 1870 complete with integral oil separator and after cooler where necessary. The minimum size shall be 10 Litres/Second capacity. Units shall be delivered, handled and stored in a manner which maintains the new condition of the units. Compressors shall be connected to the fixed pipework by flexible stainless steel hoses. 3.4.2 Receivers Receivers shall be horizontal or vertical cylindrical pressure vessels of carbon steel welded construction in accordance with AS 1210. Integration of the receiver into the compressor skid should be considered for smaller systems. Units shall be delivered, handled and stored in a manner which maintains the new condition of the units. 3.4.3 Dryers Dryers shall be refrigerated type units. Units shall be delivered, handled and stored in a manner which maintains the new condition of the units. 3.4.4 Expansion Joints Expansion joints shall be externally pressurised bellows type units, complete with drain port. Bellows shall be stainless steel, and other components shall be carbon steel.

24

Flanges shall be AS 2129 Table E. Joints shall be designed and manufactured in accordance with Expansion Joint Manufacturers Association recommendations. An anchor point is to be provided midpoint between expansion joints.

3.4.5 Miscellaneous Equipment Miscellaneous equipment will be as follows: All air filters shall be fitted with differential pressure (dp) valves;

3.4.6 Pressure Containment Valves Each manifold shall be fed through a non-return valve located after the main shut off valve. This valve is to prevent loss of air from the equipment in the event of an air main failure. The pressure containment valve shall be of stainless steel construction with either metalmetal or metal/Teflon seats. These valves shall be maintenance-free. 3.4.7 Local Reservoirs Local reservoirs shall be provided when required to even out airflow demand and to backup the air supply pressure where a number of equipment items are fed from the one manifold. The local reservoir shall be of stainless steel construction with the air connection at the low point, small diameter and vertically mounted. They may require Workcover design registration, but not require any other ongoing registration or maintenance other than inspection. The units shall not exceed a PV of 100 MPaL, based on a design pressure of 720 kpa (approximately 135 L capacity maximum Hazard Level D to AS4343). If the design requires, more than one unit may be installed to provide a greater capacity. Usually they shall be installed at manifolds. A point orifice plate shall be fitted at the manifold if connected via a PVC hose. 3.5 Pipework

3.5.1 Piping Classes Piping classes are listed in the piping data sheets (refer Appendix C), and contain details of design pressures, temperatures, materials etc. All pipework shall be selected from these piping classes only, and shall comply with AS 4041.

25

3.5.2 Pipework Arrangement Pipework design principles are shown in the reference drawings (refer Appendix B). These demonstrate preferred methods for manifolds, branches, drains, etc and shall be adhered to in the design of the new work. Underground cross ties shall be flexible hose within PVC pressure pipe conduit or galvanised steel pipe with 450g/m2 coating. No joints shall be allowed in flexible hose. A cross tie using flexible hose may be installed in a single conduit with up to two large radius bends at each end to avoid the need for a pit. Pipework shall be designed to ensure that there is sufficient flexibility to absorb any expansion or contraction, without excessive stresses or loads on equipment, or cause leakage at joints. Expansion joints, expansion loops, anchor points, pipe bends and other items as necessary shall be considered for this purpose. Compressed air lines shall slope downward in direction of flow, at 1:200. Condensate trap points shall be placed at the bottom of vertical risers. Inline drainage trap points for compressed air shall consist of a tee, drop leg, ball valve and auto drain. Waste water lines shall slope downward in direction of flow, at 1:40. Notwithstanding this valves and equipment shall not be located in pits. Valving arrangements shall facilitate the blowing out of water that may accumulate in low sections. Except at anchor points, the brackets supporting the main shall allow axial freedom for expansion and contraction but shall not permit vertical or lateral movement exceeding 5mm (2mm either side of expansion joints). The bracket shall be manufactured from hot dip galvanised steel except in tunnels where it shall be manufactured from stainless steel. All pipework shall be easily accessible. Where pipeconnections are unavoidably elevated, a union shall be provided at an accessible position to permit work on the piping without the necessity to access the elevated portions. 3.5.3 Steel Piping The compressed air lines shall generally be constructed from galvanised carbon steel pipe, or stainless steel pipe. For carbon steel lines, joints shall generally be screwed or flanged, as required. Welding procedures to be used by the Installer shall be submitted for approval before commencing work. These shall include weld repair procedures. Welded pipe spools are to be hot dipped galvanised after fabrication.

26

For stainless steel lines, joints shall generally be screwed, welded or flanged. Weld filler metal shall have corrosion resistant properties similar to or better than the base metal. The welding procedure followed shall preserve corrosion resistance in the weld and heat affected zone to maintain optimum mechanical properties in the joint and minimise heat distortion. Fabrication shall be carried out with equipment made from stainless steel, free from contaminants and which has not previously been used on carbon steel or non ferrous material. Joint cleaning shall not use chlorinated solvent. All joints shall be aligned with mechanical devices and shall be free of depressions and bumps. Heat shall not be used to obtain alignment. Steel air mains must never be attached to overhead wiring structures or signal gantries (Except for cross ties addressed in Section 5.4). A minimum clearance of 75mm must be maintained between the air line and overhead wiring structure or signal gantry. Wherever practical steel air main should be placed two metres from any overhead wiring structure or signal gantry. 3.5.4 Insulation Joints Insulation joints shall be rated for 2500V AC for one second. Insulation joints shall be installed in the following locations: Between the main and the Compressor Room; Where the main enters or leaves the ground or a pit; Within 1 m of each end of any steel bridge; Every 500 m in the steel mains; and Coincident with steel troughing insulated joints, where both pipe and troughing utilise the same support.

Where the air line is within 2 m of an overhead wiring structure that is not fitted with a spark gap, the line is to be covered with an insulating sleeve (eg class 12 PVC pipe) for a distance of 2 m either side of the structure. Suitable clamps or clips are to be provided to prevent movement. Where steel pipe is used for an overhead cross tie, it must be separated from the steel main by at least 2.0 metres of flexible PVC air hose. Insulated joints shall not be located where they could be bypassed by a metal structure (e.g. a metal bridge).

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3.5.5 Manifolds Manifolds shall be constructed from stainless steel pipe or stainless steel RHS tube, and comply with the requirements of the drawings listed in Appendix B. Manifolds shall be placed adjacent to the equipment to which they are to be connected. Where it is physically impossible to place a manifold within 75 metres from the equipment it supplies the installer must seek additional approval. Take offs from the main air lines shall preferably be vertically upwards. Where the manifolds are to be located below the main air line a low point & drain shall be provided below the take off points. 3.5.6 Flexible Hose All polymeric hoses not in tunnels shall be fabricated in accordance with AS/NZS 2554 Class B. All polymeric hoses in tunnels shall generally be in accordance with AS 2660 Class A, and must be low smoke halogen free as required by cable specification RHG-3 of AS 4507. All hoses are to be subject to approval. Stainless steel hoses shall be fabricated in accordance with relevant ISO standards, and to be an approved type. Flexible hose shall always be used for the connection between manifold and pneumatic equipment. All flexible air hoses shall be protected from sunlight by conduit. Hose connections to equipment within five metres of a manifold shall be run on the surface within a flexible orange coloured PVC conduit. If the equipment is more than five metres from the manifold, the hose and conduit shall be buried as per SPG 0705 Construction of Cable Route and Associated Civil Works. The flexible conduit is to be carried to within 100mm of the connection at each end of the hose whether buried or surface run. Where stainless steel hoses are used, they shall be insulated at the connection to the manifold ball valve. Stainless steel hoses that run beneath the rails shall be enclosed in flexible orange coloured PVC conduit. Where flexible air hose is used for the main air line, it shall be installed in a properly constructed cable route in accordance with SPG 0705. Tails for flexible hoses shall be: For hoses less then 18 mm Nominal Bore (NB) a single non-serrated bulb tail with one single stainless steel Bandit Clamp or approved equivalent. For hoses 18 mm NB or greater a double non-serrated bulb tail with two stainless steel Bandit Clamp or approved equivalent.

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Tails shall be of a type that does not damage the hose. Tail size shall be specifically assessed as the correct size for the hose type. Specifically the end of the tail shall be smooth and rounded to prevent damage to the pipe when flexed. Bandit type clamps or approved equivalent shall only be applied using an approved tool which applies a pre set consistent application pressure. Clamps shall apply an even pressure around the entire circumference of the hose. The female union nut shall be capable of rotating without twisting the hose. Where a main flexible air hose is to be bent through a radius less than the manufacturers recommended minimum radius, a stainless steel elbow shall be installed. Flexible hoses shall not be bent within a distance of (5 x Hose Outside Diameter) to the tail. Additional hose supports / clamps shall be provided where necessary to achieve this. Flexible air hoses shall be buried in a separate conduit, in buried cable routes. In GST and GLT installations the air hose must be laid on top of all cables to avoid compression of the air line. The ends of all flexible air hoses shall be sealed during installation to prevent the ingress of dirt or water. 3.5.7 Identification and Painting Individual pipework items such as valves, manifolds, instruments, and expansion joints shall be fitted with permanent labels. The label shall be made of stainless steel, and fixed to the equipment using split rings or screws. Characters shall be a minimum of 4 mm high. Identification label inscriptions shall include the following information: Valve/manifold/instrument/joint code (up to 8 characters); Manufacturer's model number and size; and Design rating. Valve codes shall be as follows: Air user control valves SY 456S TS, 333 PTS; Stop valves on mains, cross ties, manifolds etc N.O. or N.C.; Stop valves on sub-main feeds Sub-main 111 PTS, 113 PTS, 444 TS; and Stop valves on outlet of receivers/compressors feeding certain areas Down Main West;

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Manifold codes shall be determined during the design phase, in consultation with the Asset Owner and Asset Maintainer. All pipeline contents shall be identified by self-adhesive labels, in accordance with the methods given in AS 1345. The direction of flow shall be suitably indicated at each label. When the pipe size is very small, the strip is to be affixed by a suitable flag off the pipe in accordance with the standard. The following method of colour coding is to be used: An identifying strip is to be fixed to the pipe at the intervals recommended by the standard. The identifying strip is to have coloured lettering on a white background. The coloured lettering is to be in accordance with the pipeline colour as shown in Table 1 below; The arrow indicating the direction of flow shall be the same colour as the lettering on the identifying strip; and Where necessary, warning flags are to be located at the ends of the identifying strip in accordance with the standard. Pipe Contents Compressed Air Waste Water Letters shall be as follows: 25 mm Letters up to DN 80 50 mm Letters above DN 80 Colour (to AS 2700 u.n.o.) B25 Aqua Black Table 1 - Pipe Colours

The location of identification labels shall be at intervals of not more than 8 m, adjacent to changes in direction, branches, junctions, valves, wall penetrations and control points. Labels shall be placed so that they are easily seen. Uninterrupted lengths of external services, visible along their length, shall have labels at 50 m maximum intervals. Manifold label holders shall be constructed from stainless steel, and incorporate traffolyte labels for manifold, valves, etc. The label holder installation shall be as shown in attached drawings M11-355 and M11-354. Protective coatings are required for all ferrous pipework, pipe supports, and miscellaneous items. Equipment (compressors, dryers, receivers) will be supplied painted, in accordance with the manufacturers recommendations. Protective coatings shall be hot dipped galvanising to AS/NZS 4680 with 450g/m2 coating, unless noted otherwise. Damaged sections of galvanising shall be repaired in accordance with Galvanizers Association recommendations.

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3.5.8 Orifice Plates Orifice plates shall be of nylon not less than 3.0 mm thick and shall be provided to protect against failure of flexible hoses. Orifice sizes shall be: 1.6 mm for trainstops 3.2 mm for points

Unless approved otherwise and shall be installed at manifolds. Orifice plates sizes in flexible mains hoses shall be determined in the design. Orifice plates shall be securely installed between the flat faces of the nipples where inserted into the ball valves. 3.5.9 Valves Valves shall be full bore stainless steel, Teflon seat ball valve type to AS4796 with the following characteristics: 3.6 Full bore ball valve. Two piece body construction (small valves threaded together and larger valves greater than 50mm bolted together) which allows for the replacement of seals. Body made from stainless steel Grade 304 (needs to be Grade 316 in areas where high levels of chlorine are present) Female threaded connections to AS1722.1 (British Standard Whitworth parallel form). 90 degree operation between open and closed positions. Whilst handle is attached, it can be locked in open or closed position. Installation

3.6.1 Equipment / Compressor Room Equipment shall be installed on foundations or support structures. The Installer is responsible for supply of all materials needed (such as hold down bolts, grout, lubricants, etc) to complete the installation. The Installer shall follow all manufacturers instructions for the installation of the equipment and shall recheck all drive alignments prior to testing of the equipment. The Installer shall check the dimensions on site of all interface points. Where required, the Installer is to assemble equipment on site, in accordance with the manufacturers instructions. Compressors shall be installed in their own room, with sufficiently large entrances to

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permit the equipment to be removed & maintained. Adequate provision shall be provided for the supply of clean dry air for the compressor intakes in the quantity required to deliver the compressor outputs at their maximum demand. In particular, humid moist areas shall not be used for drawing air. Ventilation shall consider noise levels and be arranged so that the building itself reduces any noise in the direction of adjacent houses. 3.6.2 Pipework Installation 3.6.2.1 General All pipework installation and testing shall be in accordance with AS 4041, and shall include jointing, supporting, provision for flexibility, protection and anchoring. The Installer shall submit tie-in procedures for approval prior to any tie-in work. The procedure shall detail method/direction of system isolation, in situ work and weld procedure, branch isolation, and method of system repressurisation. Pipeline components must be fitted together in proper alignment and stress free before bolting or welding. Pipelines shall not be forced or sprung into line to be held with welding or bolting, unless cold pull is specified on the drawings. During erection, all pipes shall be supported and lined up. Gaskets are to be centrally located on flanges, to ensure the gasket does not protrude into the pipe bore. It shall be the Installer's responsibility to allow closing lengths of pipework to be cut to suit site measurements and to make sure flanges are site welded. The Installer shall ensure that the site run piping is sufficiently flexible to absorb any expansion or contraction without excessive stresses or loads on equipment or cause leakage at joints. The Installer shall install expansion joints, expansion loops, pipe bends and other items as necessary for this purpose. The Installer shall follow all manufacturers instructions for the installation of the instrumentation, and is responsible for supply of all materials needed to complete the installation. All joints shall be sealed with Loctite Master Pipe Sealant or approved equivalent, or taped with Teflon thread sealing tape. Underground air systems shall never be directly buried, but shall be installed as per the requirements of SPG 0705 Construction of Cable Route and Associated Civil Works.

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3.6.2.2 Access The Installer shall arrange piping to allow removal of connected or other plant items and access to plant items for maintenance and operating purposes. Where drawings issued for construction show piping and/or fittings interfering with access to or removal of plant items, then the Installer shall report such interferences to the Asset Owner, who will decide on changes to the pipe routing. Where the positions are not specified on the drawings or pipelines are site run, the Installer shall locate all manually operated valves in positions where the valve hand wheel can be comfortably reached and operated from an access platform, floor, walkway or stairway. The location of the pipe, valve and valve operator shall not impede accessways. 3.6.2.3 Storage Pipe, fittings and valves are to be protected from damage during transport, storage and installation. Pipework spools shall have their ends temporarily plugged or covered after fabrication to prevent ingress of foreign matter during transport and storage. Pipework items shall be inspected and have all foreign matter removed prior to installation. Items such as valve stems shall be lubricated where necessary prior to installation. 3.6.2.4 Supports The Installer shall supply and install all necessary hangers, supports, brackets, anchors, and pipe support structural steelwork. Unless approved otherwise, supports shall be standard proprietary saddles. Where necessary during erection and testing, the Installer shall provide and install adequate temporary supports to prevent overstressing of pipework or the equipment to which piping is connected. Unless specified otherwise on the drawings, horizontal piping shall be supported at not more than the maximum spacings shown in AS 4041 except where the pipe run is a main run along the railway corridor where the maximum spacing shall be 3.0 m. Where mounted on GST posts at 2.0 m spacing, the pipe shall be supported at each post. Vertical pipes shall be supported at 2.0 m intervals unless noted otherwise. Where a valve, line fitting or other item is installed in a pipeline, a support or hanger shall be located as near as practicable and within 0.5 m. Piping shall be supported not more than 0.5 m from any point where the piping changes direction, with the support or hanger located on the section having the longer span. Pipe support steel posts shall be typically 100 mm x 50 mm x 10 mm channel, galvanised to AS/NZS 4680 with 450g/m2 coating. Air main brackets should be as per drawings M11-

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354 and M11-355. The pipe shall be anchored: Every 300 metres on straight runs Where the main enters/leaves a pit Where a steel branch, sub main, or steel cross tie intersects with the main To restrict the movement of any manifold to +/-25mm Where there are larger offsets or changes of direction the line shall be anchored in both directions as shown on drawing M11-352 An air main shall be considered to be straight where: Its curved to a horizontal or vertical radius greater than 250 metres. There are minor offsets of 900 mm maximum around abutments or structures Use of structures for anchor points shall be subject to approval. 3.6.3 Cleaning Prior to cleaning, all inlets to equipment that may get blocked during cleaning shall be protected using removable in-line strainers. These strainers shall be removed upon the completion of cleaning. The Installer must ensure that line mounted items likely to be damaged by the cleaning are removed. The Installer shall supply, install and remove any temporary closures required. Cleaning shall consist of air blowing the pipework at a sufficient velocity to remove the dirt in the pipe. Such flow shall continue at least 5 minutes and until the pipeline is clean. Only dry air shall be used for cleaning. 3.6.4 Safety Equipment The equipment and pipework shall be designed and installed to provide maximum protection and safety for operating and maintenance personnel. Safety equipment shall include signage, guards, access covers, inspection covers, emergency stop equipment, safety interlocks, and other devices as specified or implied or as required by any Statutory Authority having jurisdiction. 3.6.5 Drainage & Ventilation Pits shall be provided with adequate drainage to a waste water system, or other approved discharge points, to continuously remove stormwater and other liquids; and

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Compressor Room shall be provided with adequate drainage to a waste water system, or other containment devices, to control contaminants such as oily water; and Compressor Room shall be provided with adequate ventilation to maintain recommended compressor operating temperatures and room air balance louvres, ridge vents and other building openings shall utilise acoustic louvres. Other noise attenuation devices shall also be supplied to comply with noise criteria. EPA approvals shall be obtained for the proposed waste water arrangements. 3.6.6 Control & Maintainers System A system to permit the control and remote monitoring of the air system & its performance shall be developed & installed. This system shall include: Analogue display of pressure. Visual and audible alarms. Schematic diagram VDU display showing all main elements of the system & their status. Power supply status. Compressor and dryer status and alarms. Logging of all events.

The indications shall be available in the compressor room, and at least one remote site through a TCP/IP interface. The system shall be expandable to permit other remote sites to be added. A non-interruptible power supply shall ensure the continued functioning of the control and maintainers system when the power is interrupted or failed. The design of the system shall fulfil the requirements of Air System Design Principle ESG 100.24. All sensors proposed shall be submitted for type approval, including a proposed system configuration. Where sensors are located remotely from the compressor room care is to be taken that surge protection is provided and galvanic isolation provided in cable troughs and air lines is not by passed. Where fibre optic is available between locations, it shall be used for the air monitoring in lieu of cables. Copper cabling shall be kept short. The electrical design of this system shall be documented. Where the equipment and wiring is installed, it shall be physically separate from vital equipment. All software code, programming manuals, maintenance and user manuals shall be provided, including any necessary licences for the ongoing operation and modification of the

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system. 3.7 Testing and Commissioning

3.7.1 Testing 3.7.1.1 Mechanical Equipment Testing No-load testing of rotating equipment shall be carried out in coordination with other Installers. Drives shall be checked for direction of rotation, and then tested for no load running. Testing shall comprise running the equipment to check for smoothness of operation, vibration, overheating, and operation of safety switches, instruments and appurtenances. 3.7.1.2 Pipework Testing All pipework shall be pneumatically tested at the test pressures nominated in the pipe data sheets, using dry air. The Installer must ensure that line mounted items likely to be damaged by the pressure testing are removed. The Installer shall supply, install and remove any temporary closures required. All flanged or threaded joints, mechanical couplings, field welds, valves and fittings whether above ground or underground, shall be left exposed, with joints unpainted, until testing has been completed to the satisfaction of the Asset Owner. Drains, vents, safety valve discharges, etc. which are open to atmosphere do not require testing. Such lines shall be checked to ensure all joints are properly made and are tight. Test pressure shall be applied for at least 20 minutes. If no leakage is observed and the pressure drop is not more than 5% of the test pressure, then the section of pipe will be deemed to have passed the test. Where leaks are observed or the pressure drops by more than 5% of test pressure, the Installer shall locate and repair any defects and retest the repaired section. The repair procedure is to be approved by Asset Owner prior to performing the repair. The section shall then be retested as above. When testing is completed, all temporary blanking pieces shall be removed and the pipework drained. Any items removed for testing shall be re-installed and valves closed. Written records of all tests shall be retained and these and any test certificates shall be forwarded to the Asset Owner and shall in addition be included in the operation and maintenance manuals.

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3.7.1.3 System Testing A System Testing Plan shall be provided to test that the design concepts have been achieved in the installed system. The Test Plan shall itemise each design criteria and the method of testing for each criteria. Examples of the testing to be conducted include: Time to reach working pressure from empty. Line flow restrictors perform as expected. All monitoring points are functional. All compressor on / off controls are proved to function at the correct pressures. All labelling is correct to design. All electrical changeovers function as designed The test plan shall be independently verified and submitted for approval. Testing shall be conducted in the presence of the asset owner. The results of all testing shall be recorded and submitted to the asset owner. Testing shall include all functions remotely monitored by the Maintainers VDU. Where analogue monitoring is provided (such as pressure) the testing shall include calibration & correct correspondence through the pressure range between system limits. Any tests that failed to meet the design criteria shall have the design reviewed and appropriate corrective action agreed with the asset owner. 3.7.2 Precommissioning The Installer shall precommissiong the equipment in all operation modes. Precommissioning is the running of the plant and equipment and carrying out all necessary adjustments until it is ready and suitable for normal starting and running under service conditions. Precommissioning shall be conducted in a logical sequence in accordance with the programme prepared by the Installer and approved by the Asset Owner. The Installer shall prepare schedules and record the results of the tests on the appropriate log sheets.

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The Installer shall furnish the Asset Owner with a complete list of control instrument set points and alarm signal settings recommended by the Installer as a result of his precommissioning programme. These recommended settings may be supplied progressively during the precommissioning period but no later than at the end of the period. 3.7.3 Commissioning Commissioning is the running of the plant and equipment and carrying out all necessary adjustments until it runs under service condition from part to full load. Commissioning shall include the tuning of interacting components of control loops to achieve the required control response. Where equipment items or systems are duplicated in the design to provide Running and Stand-by facilities, all items of equipment and/or systems of both the Running and S tandby facilities shall be fully tested and commissioned. At completion of commissioning, acceptance certificate as per SPG 0711 is to be completed.

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CHAPTER 4 INSTALLATION
Prepared by: ARJEE MIJARES and ED RICHARD RAYALA 4.1 Filter

Installation Instructions: 1. Install the filter so that the direction of flow corresponds to the flow arrow on the vessel or inlet and outlet markings on the drawings. If neither available, consult the catalog or the factory for proper installation documentation. 2. Proper drainage of the fitter is essential for proper operation. Connect the drain to a drain trap, or whatever mechanism you intend to use in order to remove the separated liquids from the separator. Should the trap or dumping mechanism require an equalizing line, or instrument supply gas, this should be connected to the vent connection or instrument supply. 3. Connect the filter by the standard piping methods as prescribed by local, state, and government authorities. Pipe all connections on first and second stages independently. Gauge glass, liquid level controls, and drains should never be manifolded between the inlet (primary) and outlet (secondary) stages. All electrical wiring should be performed accordance with all local state and national fire and safety codes for the hazardous designation of the area of operation. 4. Do not operate without first removing the closure head to make sure the element hold down nuts are tight. 5. Verify that the closure is securely fastened per code standards. Build up pressure in system, check all field connections and closures for leaks. If leaks exist de-pressurize system and repair leak sites by approved method.

6.

If no leaks are found, check to insure that all instruments are ready for online operation. Refer to the specific operation manual for the appropriate piece of equipment for proper on-line operation and maintenance.

Parts which will be used in the installation are 2.5" NPT x 2-1/2" Brass Nipple,), 2.5" NPT Brass Tee and Two 2.5 NPT Quick Connectors. Unplug the compressor and empty the tank. Using a crescent wrench, remove one of the factory installed quick connectors. Then wrap the male part of the Tee with Teflon tape. If the pipe is 2.5", make sure to do at least two full turns. Thread the Tee on the air filter. All filters have an arrow engraved on the body which indicates the air flow. Make sure to install the Tee on the output side of the air filter.

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Holding the filter in one hand, use a crescent wrench to tighten the Tee. It is important connections are tight but not too tight. The Tee has a hexagonal shank which facilitates installation. Now, wrap the male part of the quick coupler with two full turns of Teflon tape. Thread it on the Tee and use two crescent wrenches to tighten the connection. Wrap two turns of Teflon tape on one end of the brass nipple and thread it onto the air compressor's output. Using a pipe wrench, tighten the connection. Wrap Teflon tape on the other end of the nipple, remove the bowl from the air filter and thread the whole filter I quick connector assembly onto the brass nipple. Tighten it. If there is very little clearance between the tank and the bowl, it will be easier and safer to remove the bowl when installing the filter. Re-install the bowl, making sure the gasket between the filter body. Note that after installation, the bowl must be vertical. This is required for water to condense and accumulate at the bottom of the bowl where it can be drained. Finally, turn the compressor on, hook up a hose and with a tool. Pressure the gun and try it. Put a little bit of soapy water on all connections to check for leaks. Any air leak will cause the soapy water to bubble, making it very easy to locate any leak. It is important to ensure there are no leaks when fitting an air hose. Tools Used: Two Crescent Wrenches Pipe Wrench Materials Used: Brass Nipple NPT 2.5" x 2-1/2" Tee NPT 2.5" Universal Quick Connector Coupler 2.5" NPT(2) General Purpose Ai Fitter Teflon Tape Dish soap and Water

4.2

Dryer

Check for visible loss or damage, if no visible damage is found place the unit near to the installation point and unpack the contents. Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid on its side or if placed upside down. Store machine in a dean, dry environment, do not expose to severe weather environments. The packaging materials are recyclable, Dispose of material in compliance with the rules and regulations in force in the destination country. Installation Site Failure to install dryer in the proper ambient conditions will affect the dryer's ability to condense refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and performance, overheated condenser fan motors, electrical component failure and dryer

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failure due to the following: compressor loss, fan motor failure and electrical component failure. Failures of this type will affect warranty considerations. Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous gasses; steam heat, areas of high ambient conditions or extreme dust and dirt. In case of fire, use an approved fire extinguisher, Water is not an acceptable means in cases of electrical fire. Minimal installation requirements: Select a clean dry room, free from dust, and protected from atmospheric disturbances. The supporting plate must be smooth, horizontal and able to hold the weight of the dryer. Minimum ambient temperatures 34F see the data plate for maximum temperature. Allow at least 40 inches of clearance on each side of the dryer for proper ventilation and to facilitate maintenance operations. The dryer doesn't require to be fixed to the supporting surface. Locks win be required for special installations (on brackets, hanging, etc.). INSTALLATION LAYOUT 1. Air compressor 2. Pre-filter 3. Compressed air tank 4. Afterfilter 5. Dryer 6. By-pass 7. Condensate drain

Type A installation is suggested when the compressor operates at reduced intermittence and the total consumption equals the compressor flow rate. Type B installation is suggested when the air consumption can consistently change with peak values highly exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensate for more demanding conditions (peak air consumption). Connection To The Compressed Air System

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Operations to be performed by qualified personnel only. Never work on compressed air piping under pressure. The user is responsible to ensure that the dryer will never be operated with pressure exceeding the maximum pressure rating on the unit data tag. Over pressurizing the dryer could be dangerous for both the operator and the machine. The air temperature and the scfm entering the dryer must comply with the limits reported on the data nameplate. The system connecting piping must be kept free from dust, rust, chips and other impurities, and must be consistent with the flow-rate of the dryer. In order to perform maintenance operations, it recommended that by-pass piping be installed. Particular measures have been taken to reduce the amount of vibration that could occur during the operation. Therefore, we recommend the use of connecting pipes that are able to insulate the vibration. (Flexible hoses, vibration damping fittings, etc.) Electrical Connections Qualified personnel should carry out connections to the main power. Be sure to check the focal codes in your area. Before connecting the unit to the electrical supply, verify the data nameplate for the proper electrical information. Voltage tolerance is +/-5%. 115/1J60 dryers are supplied with a standard North American power cord and plug assembly (two poles and a ground. 230/1/60 is supplied with a junction box. Be sure to provide the proper fuses or breakers based on the data tag information located on the back of the unit. The main power receptacle must be protected with a thermal overload relay (ln+0.03A), rated to the power consumption of the dryer (refer to data nameplate for nominal values). The power supply cord must meet or exceed ratings for the total amp draw of the unit. Connect to a properly grounded outlet. Improper connection of the equipment grounding conductor can result in risk of electric shock. Do not use adapters on the plug receptacle- if it will fit the outlet, have a proper outlet installed by a qualified electrician. Condensate Drain Discharge is at system pressure. Drain line should be secured. Never point the condensate drain line towards anybody. The dryer comes with a flexible plastic drain tube (1/4"in diameter and 6 in long) for the connection to suitable drain. Removal of the condensate occurs through a solenoid valve protected with a mechanical filter. In order to avoid clogging of the solenoid valve, the condensate from the cyclone separator is previously filtered, than discharged. An adjustable electronic timer operates the solenoid valve coil. The drain cannot be connected to pressurized systems.

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Condensate may contain oil. Comply with applicable laws concerning disposal. A wateroil separator should be installed before the air inlet to the dryer for the purpose of removing condensate drainage coming from compressors, dryers, tanks, filters, etc. 4.3 Receiver

Installation Recommendations: Wet receivers should be installed downstream of the moisture separator and before other purification equipment. Dry receivers are installed after purification equipment. All air receivers should be on blocks or some other small foundation to keep them dry and rust-free. There also should be enough space left around the receiver to allow for easy draining. Exercise care when installing air receivers outdoors because any condensed moisture may freeze and interfere with the operation of drain valves, pressure gauges and safety valves. Never install a valve between the air receiver and the safety valve. The exhaust from the safety valves should be directed away from personnel and in a way that the thrust will tighten threaded pipe fittings if it lifts and blows, as opposed to unthreading them. Pressure gauges should be of good quality and large enough to read while standing on the floor. Install an isolation valve between the gauge and the tank so that the gauge can be removed and replaced or recalibrated every six months without depressurizing the tank. It is essential that air receivers have an automatic trap/drainage system. Also, the receiver needs to be bolted or clamped to the floor or base on which it is mounted in case of a line fracture. 4.4 Aftercooler (WATERCOOLED)

All models may be installed indoors or outdoors. Where outdoor temperatures fall below freezing (32F), a low ambient fan control kit is required. For units installed outdoors where ambient temperatures fall below freezing (32F), special low ambient fan control kits are required. These kits include temperature-sensing thermostats to cycle fan motors off when predetermined ambient temperatures are reached. IMPORTANT!! CUSTOMER MUST SUPPLY SELF REGULATING HEAT TAPE TO WRAP INLET/OUTLET HEADERS AND SEPARATORS TO PREVENT FREEZING. HEAT TAPE MUST HAVE SEPARATE POWER SUPPLY!! Install the aftercooler as dose to the compressor discharge as possible. Be sure to install the aftercooler in a well-ventilated area. The ambient airflow enters the back of the finned coil and exhausts through the fan guard at the front of the aftercooler. (On vertical draft models air enters the bottom and exits through the fan guards at the top.) The

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clearance between the finned coil inlet and nearest obstruction (wall, floor, etc.) should be, as a minimum, equal to the diameter of the fan(s) *(see specifications for fans diameter size). The air discharge must not be obstructed to permit continuous circulation of cool ambient air through the finned coif. For indoor installation adequate ventilation of the location MUST be provided to prevent heat buildup when the aftercooler is in operation. Remember, the aftercooler is designed to cool the compressed air to within 5F to 30F of the ambient air entering the finned coil. As the ambient air temperature increases, so does the temperature of the compressed air leaving the aftercooler. Outdoor installations are recommended, wherever possible to insure adequate ventilation. All piping must, as a minimum, be equal to the inlet-outlet size of the aftercooler. Bypass piping to include isolation valves and safety valves must be installed to permit maintenance on the aftercooler and/or separator-drain. A flexible line type vibration absorber must be installed at the aftercooler inlet to prevent damage to the aftercooler manifolds and finned coil or the unit warranty will be voided. A separator must be installed at the aftercooler outlet to remove water condensed from the compressed air as it is coofed or the unit warranty witt be voided. Remember, a floor drain must be provided to collect this water as it is ejected from the drain discharge. The aftercooler cabinet and supporting legs are designed to support only the weight of the aftercooler. DO NOT support piping with braces attached to the legs of cabinet. All piping MUST be supported from the floor or ceiling as illustrated. Mounting holes are provided in each leg base for bolting to a LEVEL floor or structural steel support. Note: For units with air motors - Adjust motor(s) using regulator(s) between 60 100 psig. WIRING (electric motors only) All motors have built-in thermal overload protection and are suitable for outdoor installation. AU motor wiring is terminated inside a NEMA 3R (watertight) junction box mounted on the outside of the cabinet for easy access. A ground wire connection is provided. If the unit is to be installed outdoors use "Sealtite" conduit with watertight electrical connectors. It is recommended a separate fused disconnect switch be provided for the aftercooler to enable all power to the unit to be disconnected in the event maintenance is required and it is necessary to operate the compressor during this period of time. The aftercooler fan motors may be interlocked with the air compressor starter if desired. Smaller units with a total current draw less than 10 amperes may be wired through a normally

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open contact located on the air compressor magnetic starter. Larger units with a greater current draw or with single-phase motors (230V or 460V) wired for connection to a three-phase power supply may be wired through a contactor of suitable size. The contactor holding coil may then be wired in parallel with the air compressor starter holding coil or connected to a normally open auxiliary contact located inside the air compressor magnetic starter. This procedure ensures the aftercooler fan motors will operate only when the air compressor operates. For units installed outdoors where ambient temperatures faU below freezing (32F), special low ambient fan control kits are required. These optional kits include temperaturesensing thermostats to cycle fan motors off when predetermined ambient temperatures are reached. All aftercoolers with 460 volt phase motors include contactors to control fan motors and a transformer to provide power to the heat tape (460 volt heat tape not available). Remember, all aftercoolers with two or more 230 or 460 volt motors may be ordered with fan motors wired for connection to three phase 230 or 460 volt power supplies. IMPORTANT all wiring diagrams are typical, consult the wiring diagram provided with each aftercooler for specific wiring instructions. 4.5 Air Compressor

Equipment shall be installed on foundations or support structures. The Installer is responsible for supply of all materials needed (such as hold down bolts, grout, lubricants, etc.) to complete the installation. The Installer shall follow all manufacturers' instructions for the installation of the equipment and shall recheck all drive alignments prior to testing of the equipment The Installer shall check the dimensions on site of all interface points. Where required, the Installer is to assemble equipment on site, in accordance with the manufacturers' instructions. Compressors shall be installed in their own room, with sufficiently large entrances to permit the Equipment to be removed & maintained. Upon receipt of the compressor, be sure to completely inspect machine for any signs of possible shipping damage. The carrier should be immediately notified of damage or missing parts. Care must be exercised when transporting or moving the compressor to avoid damage to the unit. The compressor base is equipped with slots for forklifts. These slots should also be used when moving the compressor with an overhead crane. Use spacers and spreader bars to avoid damage to the compressor and to keep it balanced.

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When moving the machine using a forklift or a crane, protect the sound proof enclosure with a padded cloth or padding to prevent damage. Do not drop the machine or carry it at a slant of 45degree or more when moving it. Location The unit should be installed indoors in a clean, dust free, moisture free, and well ventilated environment. Process gasses or chemicals ingested in the compressor may react with the lubricant or materials. in compressor and significantly reduce life. Avoid placing compressor anywhere near non-air vapors. The unit must be protected against freezing and excessive ambient temperatures. Failure to properly protect the machine may result in catastrophic failure of components. For ease of maintenance provide ample clearance around the compressor that is clutter free. It is recommended to have at least four feet in front of the compressor and a minimum of three feet on both sides and rear. See the following illustrations for specific minimum work envelopes. Do not install machine outdoors or semi-outdoors. Installation in a place exposed to rain or in a humid basement can cause an electric leak, drain and/or rust. Installation in a place where dust such as iron powder, paper pulp or sand is lifted can cause low insulation performance of electrical parts and can damage the rotor. Installation in the atmosphere containing toxic gas can cause deterioration of lubricant and corrosion in parts. Foundation The compressor does not require a heavy foundation. To prevent vibration the compressor should be supported at all base bolt locations on a level surface. The mounting bolts must be carefully mounted to prevent distortion of the compressor base. Do not weld on compressor, cabinet, or base as it could cause damage to bearings, electrical and other mechanical components and wil1void warranty. Ventilation The compressor must be located in a clean, cool and dry source of air for the inlet filter and cooler. Since the compressor is air-cooled it requires a large amount of cooling air to reject the heat loads. The compressor must not be operated at full load for extended periods of time in ambient temperature greater than 1000 F (380 C). If required, contact your distributor for air flow and heat rejection numbers of your model.

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4.6

Intake Air Filter 1. After conducting a pre-operative inspection, remove the unit from the shipping skid and position it in the designated operation location. The standard unit can simply be lifted from its skid and walked or transported by lift to its predesignated operation location (if in close proximity to the skid), according to facility safety requirements. Large units must be adequately supported to minimize rocking and misalignment of doors. 2. Fill and install the modules or Pura GRID filters. 3. Install the particulate filters. Proper selection and installation of particulate filters for use in the PURAFIL unit will require replacement during the normal lifetime of the equipment. 4. Perform post-start inspection check.

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CHAPTER 5 OPERATION
Prepared by: ALLAN CAS and SHERWIN NOE SABATER 5.1 Filter

Fitters of all kinds are found everywhere in the world, and most of us are familiar with some of them. On www.about-air-compressors.com we're most interested in filters for compressed air systems, items that are essential for most compressed air applications. The proper selection and use of compressed air filters will prevent many short and long term problems with your compressed air equipment and systems and save you substantially in down-time and component replacement costs over the life of your compressed air system. The standard compressed air filter will contain the following components. The numbers on the picture of the compressed air filter picture correspond to the description in the text. 1) Air inlet; in North America usually a female NPT thread, although lately it could be a metric thread, into which the airline is connected, using the fitting of choice. Air flows through the inlet. The cap is plumbed internally to force the air to flow downwards and spiral into to the filter bowl. This "cyclonic action" will "throw" free water and debris that may be in the air against the walls of the bowl, where it will flow down into the bottom. 2) The filter cap; may be a composite plastic or metal depending on the manufacturer. Correct air filter operation depends on the air flowing through the unit in the correct direction from the supply line out the filter discharge. The correct air flow direction will almost always be identified on the cap of the filter, usually with an arrow. The arrow points in the desired direction of air flow from the supply line to the filter discharge. The air filter will not work properly if you inadvertently reverse the air flow.

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3) The dotted line shows the flight path of the compressed air as flows toward the filter discharge. In order to exit the filter through this path, the compressed air must have undergone the cyclonic action phase, and then passed through the filter element, further purifying the airstream.

4) This is the filter discharge; allowing the flow of the filtered compressed air from the filter and down the airline to your applications. The fitting size of the discharge port will usually be the same as the inlet port. Most filter manufacturers offer adapters to allow you to change the "port" fitting size to one that best suits your application. In order to reduce inventory of spare parts, some companies will keep a standard 3/8" NPT filter as their base unit, and add adapters to the inlet I outlet ports to fit them to the smaller NPT sizes. While it's feasible to use a larger filter unit on the small air line, attempting the reverse may impede compressed air flow. Do not do this unless you've checked to ensure that the flow of the smaller air filter has sufficient flow capacity for your application. This will be a choke point if you under size the air filter. 5) This is the filter element; insufficient air supply problems encountered downstream from your compressed air filter are often caused by the element becoming plugged and choking your air supply. If your air tool or applications isn't getting enough air, check the element. Clean it or replace it, depending on the type. Some manufacturers offer a Delta P gauge as part of their filter assembly. The Delta P will indicate pressure drop across the filter, and the increase of pressure drop indicates that the filter element is doing its job, and trapping debris and removing it from the compressed air stream. The dirtier your air, the sooner your elements will plug. Filter elements have a specific flow capacity measured in CFM, and a particulate size rating measured in Microns. The chart below tells you the actual size particle that a specific Micron rating represents.

General purpose filter elements are 30 or 40 Micron sized. For some applications, you'll want a 5 Micron element, however, depending on your air quality, an element that 'fine' will clog quickly. It's

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common, then, to use a general purpose filter upstream from the unit with the 5 Micron element, to increase its life. So too, when you move into even finer air filter elements such as coalescing filter types. You will definitely want to have a general purpose first, then a 5 Micron unit, and then the coalescing filter.

Operating Instructions: 1. Once the Anderson AFS filter separator is installed, it needs no other action by the operator. The filter separator is complete in itself, and will function whenever there is flow through the unit. Please read each manual for each instrument supplied on the unit for the proper operation and installation procedures. 2. If possible, an initial check of differential pressure should be made across the filter element for reference. If solids are present in the gas, the filter cartridge will gradually become plugged and the differential pressure will increase.

3. After the filter has been in service for a few hours, check the gage glasses in the two stages for the amount of condensate that has collected. Jergusonbrand gage glasses are highly recommended for proper level monitoring in this highly critical operation. If automatic draining devices are not installed, the condensate must be removed manually on a regular inspection schedule per the cycle load requirements. 5.2 Dryer

Compressed air dryers remove moisture that might otherwise condense in airlines, air tools, and pneumatic instruments. This condensate can cause damage to equipment from corrosion, freezing, and water hammer, and can cause malfunctioning of instruments and controls. Three types of air dryers are available: Adsorption Type. The adsorptive or desiccant dryer contains a bed of an inert desiccant material, either silica gel or activated alumina, which has high adsorptive surface area for a given weight and volume. This area is in submicroscopic cavities that can hold water vapor removed from the air. When the adsorptive desiccant is completely saturated with water, the water can be driven off again by heating. An airstream passed through the desiccant will carry away the released water vapor restoring the desiccant to its initial adsorptive condition. Adsorption type dryers (figure 4-9) generally consist of two drying towers, each containing an adsorbent, plumbed in parallel. The dryer towers are cycled either manually, semi automatically, or automatically, so that one drying tower is on stream while the other tower is being reactivated. Reactivation is accomplished by means of electric or steam heaters embedded in the adsorbent or by passing dried process air through the unit.

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Deliquescent (Absorption) Type. The deliquescent or absorption dryer is lowest in initial cost but requires continual replenishment of the drying medium (figure 4-10). Simple in design, this type of dryer is a pressure vessel in which a bed of crystalline solids is placed on top of a screen which is located close to the bottom of the vessel. Wet air from the aftercooler and separator enters the bottom of the vessel and flows upward through the bed. As it passes through the bed, the liquid water and vapor present in the air, dissolve the drying medium in what is termed a deliquescent effect. The resulting solution trickles to the bottom of the dryer where it is removed by a trap. The frequency with which the crystalline absorbent material must be replaced is a function of the design thickness of the bed and the amount at water and vapor present in the air entering the dryer. Refrigeration Type. Dryers that remove moisture from the air by condensation incorporate a mechanical refrigeration unit (figure 4-11) or cold water, if available. Inlet air passes through the pre-cooler/ re-heater to the air-to-refrigerant exchanger which contains the refrigeration coils. As the air passes over the coils, further cooling takes place and moisture condenses into droplets. The droplets of oil or water then pass through the moisture/oil separator and are collected and drained through a condensate trap. The cool, dry air is then directed back through the pre-cooler/ re-heater warmed by the incoming air and discharged for reuse by the system. NORMAL OPERATION CAUTION: Do not overrun the unit. Overrunning will result in the tower becoming saturated and unable to adsorb any more moisture. Moisture laden air will then be carried over into the distribution system. On systems where oil carryover from the compressor is present, provision should be made to protect the desiccant bed of the dryer from becoming oil saturated. Oil deposits in the desiccant bed cause a decrease in drying efficiency and necessitate frequent replacement of the desiccant. Refrigeration Type Dryer: Ensure condensate trap is draining properly and condensate is not allowed to build up. 5.3 Receiver

Air receivers serve as reservoirs for the storage of compressed air so that air is available to meet peak demands in excess of the compressor capacity. They also function as pulsation dampers on reciprocating compressor installations. Air receivers are usually vertically mounted, but may be horizontal in the smaller sizes. Receivers are furnished with a relief valve, pressure gauge, drain valve, and inspection openings. NORMAL OPERATION.

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Drain receivers of accumulated condensate at least once each shift if an automatic drainer is not provided.

Air receivers serve several important purposes: Decrease wear and tear on the compression module, capacity control system and motor by reducing excessive compressor cycling. Eliminate pulsations from the discharge line. Separate some of the moisture, oil and solid particles that might be present from the air as it comes from the compressor or that may be carried over from the aftercooler. Help reduce dew point and temperature spikes that follow regeneration. Offer additional storage capacity made to compensate for surges in compressed air usage. Contribute to reduced energy costs by minimizing electric demand charges associated with excessive starting of the compressor motor.

The benefit of extra storage capacity alone outweighs the additional cost of this component. Wet vs. Dry Receiver: There are wet air receivers (supply) and dry air receivers (demand). (fig. AR1-3) Wet Receivers: Wet receivers provide additional storage capacity and reduce moisture. The large surface area of the air receiver acts as a free cooler, which is what removes the moisture. Because the moisture is being reduced at this point in the system, the load on filters and dryers will be reduced. The term "wet receiver" refers to the storage vessel or tank placed immediately after the compressor. This device helps with contaminant removal, pressure stabilization and pulsation reduction. Dry Receivers: When sudden large air demands occur, dry air receivers should have adequate capacity to minimize a drop in system air pressure. If these pressure drops were not minimized here, the performance of air dryers and filters would be reduced because they would no longer be operating within their original design parameters. The term "dry receiver" refers to the receiver placed after the air dryer and other air preparation equipment. Air Receiver Sizing: The size of the air receiver is dependent upon air usage and the compressor style. The general rule to size a air receiver is: Receiver Size = Compressor ACFM * 1 Gallon/ACFM For a 200 ACFM Compressor = 200 Gallons With a Conversion Factor of 7.48 Gallons/Cubic Ft. = 27 Cubic Ft.

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5.4

Aftercooler (WATERCOOLED)

Your air-cooled aftercooler has been designed to remove the heat of compression from the compressed air discharged from your air compressor(s) and remove approximately 70% of the moisture contained in the compressed air. The temperature of compressed air discharged from a two stage reciprocating compressor is approximately 350F. Single stage compressor discharge temperatures may exceed 430F. Rotary screw and rotary vane compressors normally operate with a discharge temperature 100F above ambient. These temperatures must be reduced to remove moisture from the compressed air. When air dryers (refrigeration, deliquescent or desiccant type) are included in a compressed air system it is mandatory to reduce the compressed air inlet temperature to the dryer to 100F or less to permit the dryer to function properly. Compressed air enters the aftercooler inlet and makes multiple passes through the copper tubes due to serpentine circuiting of the copper tubes. The copper tubes include multiple aluminum fins with full collars to insure a mechanical bond to the copper tubes. These fins provide a large amount of secondary surface to further improve the heat transfer from the compressed air to the water. This ambient air is pulled into the finned coil by an axial flow fan direct driven by the motor(s). Heat from the compressed air is transferred through the copper tubes and aluminum fins to the water and discharged to the cooling sump, induced by a pump. The aftercooler is located at the discharge of the last cylinder to cool the air, reduce its volume, and to liquefy any condensable vapors.

STARTUP Prestart Inspection. Carefully inspect the intercooler or aftercooler ensuring the following prestart requirements have been fulfilled. a) Verify completion of all installation or repair work. b) Ensure equipment has been cleaned and tested for leaks. c) Ensure thermometers, pressure gauges, and controls are in good operating condition. d) Ensure safety valves are operating.

Start-up Procedure. Always start intercooler and aftercooler cooling water flow before starting the air compressor. Proceed as follows: a) Open air vent valves on waterside of cooler. b) Open cooling water inlet and outlet valves. c) Close waterside vent valves after all air has been displaced

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Normal Operation Maintain rated cooling water flow. Check airside drain periodically to see that it is operating properly and unit is free of condensate. Shutdown if the compressor is going to be shut down, perform the following procedures. a) Maintain cooling water flow until coolers have reached ambient temperature. b) Drain all water from cooling system if the cooler will be exposed to freezing temperatures. 5.5 Air Compressor

Dangerous Objects. Do not pull any inflammables around the machine. Never use an open flame near the machine. The compressor can catch fire from work being carried out near the machine that produces spark, such as welding. Do not touch the exhaust outlet and the peripheral area which are heated during the operation of the compressor and could remain hot even after shut down of the machine. This area could cause a serious burn. Pressure. Operate the machine within the limits specified in the product's manual. Rotating Portions. When the power is on, never touch the rotating portions even if the compressor is stopped. If any maintenance needs to be performed be sure to disconnect and lock out the main power supply. 5.6 Intake Air Filter

The Purafil CIF unit is an air purification unit primarily designed for control of corrosive contamination while also eliminating particulate problems. Compression latch doors are provided so that the prefilters and Purafil modules/PuraGRID filters may be serviced without disturbing the operation of the final filters or shutting down the compressor. The particulate filters and modules are supported by extruded aluminum track. The unit is designed to house a perforated metal cone, which is supported by the discharge plate and protects the compressor in the event of particulate filter debris. A discharge opening is located in the center of the discharge plate and provides the bolt pattern for an A.S.A. 150lb. pipe flange. The inlet opening is rectangular to mate with existing duct work. The weatherproof exterior includes a cross-broken top pan with drip edge. Supported by sturdy support channels, the CIF unit is shipped assembled. The CIF includes one or more of the following sequential components:

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1. PREFILTER- as the air enters the unit it passes through a particular plate filter, the prefilter collects atmospheric dust and larger particles thereby preventing clogging of the perforated surfaces and pellet pores in the next stage of the unit. Prefilter options are: TP-25- A low efficiency (ASHRAE 20%) particulate filter which features include a self-sealing, progressive-density, non-woven synthetic media. PP-30- A medium efficiency (MERV 6) pleated particulate filter with high surface area and good service life. Special Prefilters- Special high efficiency particulate filters can be specified in prefilter section of the unit. Contact the factory or your Purafil representative for available options. 2. PURAFIL MODULES/PURAGRID FILTERS- the air passes through PK-12, PM12, CK-24 or PM-18 modules or PuraGRID filters, containing media manufactured by Purafil, Inc. The contaminant gases are removed by the process of adsorption, absorption and chemisorption in this stage. 3. FINAL FILTER- before leaving the unit, the air moves through a final filter. The final filter removes remaining contaminants, such as media dust and airborne contaminants. The options for final filters are: JFL-90- a high efficiency (MERV 13) rigid-type, final filter. PP-30- a medium efficiency (MERV 6) pleated particulate filter with high surface area and good service life. FF-90 a high efficiency (MERV 14) rigid type particulate filter with self-supportive rigid cartridges. HEPA Filter an ultra-high efficiency (99%) particulate filter. 4. Plenum Section the final stage houses a perforated metal cone to protect the compressor I the event of particulate filter debris. The discharge plate is designed with a hole that mates with inlet piping to the compressor. The plate has a 150lb. A.S.A. flange bolt pattern.

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CHAPTER 6 MAINTENANCE
Prepared by: JANINE BIEN, JAN JERKIN CARDIO and WILFREDO CELESTIAL JR. 6.1 Filter

Maintenance Instructions: There is very little required maintenance with this filter separator, except for the periodic cleaning/replacement of the filter elements or periodic blow down of the vessel housing. General requirements for filter replacement: a. When differential pressure reaches 7-8 psid, or b. When differential pressure reaches customers limit, or c. Once a year. It is recommended that after the filter separator shows a pressure drop across the elements of 4-6 psi, the unit to be taken off-stream, de-pressurized, and the filters to be inspected for the amount of dirt, wax, scale, etc., that has caked up on the elements. Do not violently backflow this unit!! It is recommended that the elements be removed manually and caked dirt be brushed off by alight brush. If the element sock is torn, waxy, or otherwise damaged it is recommended that the element be replaced. Check the spare parts list, or nameplate for proper part number for replacement. When changing filter elements, open up drain connections and blow down /wash out any debris. The primary separation stage & sump will have the highest concentration of debris and should be washed out frequently. Follow all local, state, and government codes and regulations when isolating and de-pressurizing filter for maintenance.

6.2

Dryer

Preventive Maintenance Inspection. WARNING: Do not attempt to repair or remove any compressor system parts without first retrieving pressure from the entire system. Refrigeration Type Dryer Daily Inspection. Inspect for the following conditions: a) Proper operation of condensate drainer b) Air leaks

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Periodic Inspection. Thoroughly inspect the installation at intervals prescribed by the manufacturer's maintenance schedule. Examine the following items: a) Condition of filter cartridge b) Condensate collection chamber and condenser-evaporator tubes for oil and dirt accumulation Maintenance procedures proceed as follows: Refrigeration Type Dryer. a) Clean or replace filter element as required. b) Clean deposits from condensate collection chamber and condenser evaporator tubes with compressed air or steam. Lubricate and repack leaking valves. 6.3 Receiver

Maintenance Requirements Moisture should be drained from the receiver regularly, especially in cold weather to avoid problematic accumulation. If you need to add any braces, struts, base supports or nozzles to an air receiver, use an ASME Coded weld shop for any welding or repairs. Many companies have a policy to annually hydro test the air receiver's integrity. Besides hydro testing, older air receivers should be checked periodically with an ultrasonic thickness gauge or meter. Corrosion effects can be determined by comparing readings of head and shell to the nameplate. Preventive Maintenance Inspection Daily Inspection. Check automatic drainer for proper operation, if one is provided. Periodic Inspection. Proceed as follows at intervals prescribed by the manufacturers maintenance schedule. a) Check operation of safety valve. b) Examine receiver for corrosion and peeling paint. c) Inspect the receiver internally for corrosion and dirt accumulation. d) Refer to NAVFAC MO-324, Inspection and Certification of Boilers and Unfired Pressure Vessels WARNING: Do not attempt to repair or remove any compressor system parts without first relieving pressure from the entire system. Do not use gasoline, kerosene, or other low flashpoint solvents. A serious explosion may result. a) Thoroughly clean the receiver internals annually. b) Calibrate pressure gauge semiannually. c) Repaint exterior of receiver where there is corrosion or damaged paint

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6.4

Aftercooler

Little maintenance is required with an air-cooled aftercooler. The most important maintenance consideration is keeping the cooling coil surface free from dirt. Large quantities of lint, dust, etc. will clog the aluminum fins and drastically impair heat transfer from the finned coil to the ambient air. Clean the coil on a REGULAR schedule using compressed air to "blow off" accumulated dust. DO NOT use stiff bristle brushes since the aluminum fins are easily damaged. If finned surfaces become clogged with oil laden particles that are not easily removed, the finned coil may be steam cleaned. Remove all open type motors when this cleaning operation is performed. The interior of the copper tubes may become dirty or clogged if large amounts of oil are present in the compressed air discharged from the compressor. These deposits may be removed by disconnecting inlet and outlet connections and pumping any degreasing grade solvent through the copper tubes. Be certain the solvent will not harm copper or aluminum and is safe for use by maintenance personnel. If it is not possible to clear tube interiors in this manner, the entire coil may be removed from the cabinet and taken to a radiator shop for cleaning. This should never be necessary if copper tubes are inspected on a regular basis to determine if clogging is a problem. If so, cleaning tube interiors with a degreasing grade solvent, also on a regular basis, will prevent complete clogging of the tubes. Check separator drains on a daily basis to be certain they are operational. All automatic drains are highly susceptible to clogging in the presence of dirt and oil and should be cleaned regularly. If a drain clogs, all water separated from the compressed air will pass downstream. Should a leak occur in one of the copper tubes within the coil or where copper tubes are connected to inlet-outlet manifolds they can be repaired using silver solder. Use of a flexible vibration absorber and proper installation in accordance with this manual will drastically minimize the possibility of leaks occurring. Electric motors are permanently lubricated and require no maintenance. Filters, regulators, and lubricators on air motor units require periodic changes of the filter elements and refills of lubricant. Replacement fans, motors, and fan guards are available. When ordering parts always include the unit model and serial number which may be found on a nameplate attached to the outside of the cabinet. The product brochure will provide specifications and performance data for each model. Operational Preventive Maintenance Observe the following procedures during normal operation: a) Maintain rated cooling water flow. Avoid excessive water flow which might cause erosion. b) Adjust water flow rates slowly to avoid sudden temperature changes in the cooler.

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c) Shut down compressor if condensate trap is collecting excessive amounts of water. Cooler tubes may be leaking. d) Shut down compressor if cooler air temperature is abnormally high. Leak in cooler tubes could be allowing air to displace cooling water in waterside of cooler. Preventive Maintenance Inspection Daily Inspection. Inspect the cooler daily for the following conditions: a) Proper operation of the automatic controls and instruments b) Water leaks, temperature, and flow rate c) Any deviations from normal temperature or pressure drops across the cooler Periodic Inspection. Inspect the following items at intervals prescribed by the manufacturer's maintenance schedule. a) Check cooler for corrosion and peeling paint b) Check safety valves for setting and proper operation. c) Check manual and automatic valves for leakage and corrosion d) Remove the tube bundle from the cooler and carefully inspect the internals of the unit for the following conditions. Corrosion to tubes, tube sheets, and baffles: Corrosion and electrolysis (galvanic corrosion) may appear very similar, but they are different and occur because of the presence of entirely different elements. Since carbon dioxide and oxygen are the main causes of corrosion, any operating method that reduces the content of carbon dioxide and/or oxygen will reduce corrosive effects. One method to control C02, and 02 levels in the coolant is to reduce coolant losses wherever possible. This reduces the entry of additional free C02 and 02 present in most makeup water. Different pretreatments of makeup water may be required such as: lime soda softening, hot Iime zeolite softening, acid cycle softening, and salt splitting. All types reduce the quantity of C02. Internally, corrosion of piping can be controlled by the use of corrosion inhibitors. For more information, refer to NAVFAC MO-225, Industrial Water Treatment. Electrolysis of tubes, tube sheets, and baffles: Electrolysis is an electrochemical corrosion associated with the current caused by dissimilar metals in an electrolyte (coolant). It resembles erosion in appearance, but the loss of material is due to the exposure of two metals of different compositions (such as steel and bronze or steel and aluminum) to an electrolyte (coolant). Two methods used for controlling the effects of electrolysis are electronic cathodic systems and sacrificial anode placement within the system (such as zinc compound plugs). Erosion to tubes, tube sheets, and baffles: Erosion may be evident at material edges, tube ends, and baffles, due to excessive flow rates and coolant impurities. Evidence of erosion is rounded edges or depression in material surfaces at locations where the flow changes direction or rate.

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Leaking tubes: Any leaks in the cooler between the tubes carrying coolant and the tubes carrying compressed air is detrimental to the system. If a leak is found during a disassembly inspection it should be repaired before reassembly. In many instances when the water pressure is greater than the air pressure, the first indication of a leak is the sudden increase of moisture at the separator or receiver. If the air pressure is higher than the water pressure, air then enters the coolant system resulting in higher temperatures. Plugged tubes: If tubes become plugged, it is an indication of an imbalance in the coolant-equipment relationship and conditioning of the coolant should be considered. Plugged tubes, depending on the number, usually result in higher system temperatures. Most plugged tubes can be cleaned without causing damage to the tube. Consult the manufacturer's instructions for details. Scale deposits: Scale deposits are an indication of an imbalance between the coolantequipment relationships. Conditioning of the coolant should be considered. Scale results in higher system temperatures. Refer to the manufacturer's instructions for correctional procedures. CAUTION: Never hammer on the tubes or use sharp edged scrapers which may damage the tubes. Chemical solutions used for cleaning should be capable of dissolving the scale or other deposits without attacking the metal. Cleaning. Tube interiors may be cleaned by flushing a stream of water through them. For more persistent deposits, tools may be required, brushes, rods, or other cleaning hot water tube exteriors can be cleaned by hosing with steam of a stiff bristle brush will aid in removing deposits from between tubes. Cooler interiors may be cleaned without dismantling the unit by circulating a chemical solution through it. All chemicals should be thoroughly washed out of the cooler before returning it to service. Tube Replacement and Repair. Coolers with leaking tubes must be repaired in accordance with manufacturers' recommendations. Refer to specific manufacturer's service manual for tube repair and replacement instructions. 6.5 Air Compressor

WARNING! Always disconnect the compressor from all sources of electrical power before performing any maintenance procedures. Scheduled Maintenance: The only scheduled maintenance required on the Compressor is replacement of the compressor absorber every 12 months. Removing the Compressor Absorber: 1. Shut down the compressor. 2. Disconnect the compressor input power cable from its electrical power source.

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3. Disconnect the flex lines from the gas-return and gas-supply connectors at the rear of the compressor. 4. Remove the screws holding the compressor rear grille, rear panel, front panel and cover (Figure 1-2). Front and rear panels remain in place. 5. Use the two wrenches (supplied) to avoid loosening the body of the coupling from its adapter. 6. Unscrew the two self-sealing coupling halves quickly to minimize gas leakage as shown in Figure 4-1. 7. Disconnect the adsorber-inlet self-sealing coupling as shown in Figure 4-1. 8. Remove the bolts, nuts, and washers that secure the adsorber to the base of the compressor. Save all nuts, bolts, and washers for installing the replacement adsorber. 9. Carefully lift the adsorber inward until the outlet self-sealing coupling clears the rear panel and remove the adsorber as shown in Figure 4-2. 10. Remove the adsorber from the compressor as shown in Figure 4-1

Installing the Compressor Adsorber 1. Install the replacement adsorber as follows: a) Remove the dust caps from the self-sealing coupling halves at each end of the replacement adsorber. b) Write installation date on the adsorber decal. c) Install the replacement adsorber fol1owing the steps for compressor adsorber removal in reverse order. Use the hardware saved in step 5 above. 2. Connect the adsorber to the compressor internal piping. Refer to Figure 4-1. a) Check the self-sealing connector flat rubber gasket to make sure that it is clean and properly positioned. CAUTION: Make sure to hold fast on the left coupling nut while tightening the right coupling nut, as shown in Figure 4-1

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b) Make the first turns by hand and then firmly seal the connection using the two wrenches until the fittings "bottom". Refer to Figure 4-1, for proper coupling of the self-sealing connection. 3. Replace the cover and the front and rear grilles and secure them 4. Ensure that the pressure gauge reads 245-250 psig (1690-1725 kPa). If additional gas pressure is required, follow the instructions in, Adding Helium Gas. 5. Reconnect the return and supply flex lines to the compressor. 6. Connect the compressor input power cable to the electrical power source. Unscheduled Maintenance Suggested Unscheduled Maintenance Equipment It is advisable to keep on hand the unscheduled maintenance equipment and disposable supplies listed below. Helium, 99.999% pure. Pressure regulator (0-300010-400 psig). Maintenance manifold, PIN 8080250K003*. Helium charging line terminating in a 1/4-inch female flare fitting, PIN 7021002P001. Installation and Scheduled Maintenance Tool Kit, PIN 8032040G004.

*Available from stock; consult the factory or your sales representative. 6.6 Intake Air Filter

Replacement Parts and Materials While Purafil, Inc. products are built with durability, some parts of the PURAFIL unit will require replacement during the normal lifetime of the equipment. Consumables In order to maintain proper performance levels, particulate filters and PURAFIL media must be replaced periodically, as they have a finite life. Modules Modules are constructed of high impact polystyrene. Particulate Filters to ensure proper efficiency of your system change particulate filters often. Dirty filters will inhibit proper functioning of the unit.

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CHAPTER 7 EVALUATION, OBSERVATION, RECOMMENDATION, AND CONCLUSION

Prepared by: LEE ANTHONY BACSAIN, ALLAN CAS, ARJEE MIJARES, and ED RICHARD RAYALA 7.1 Evaluation

In order to have high operating efficiency, inspections are delivered daily and periodically for it to be well-maintained. To avoid any related untoward events during the operation, piping system is measured, calculated, and well analyze. Precise pressure calculations are rendered to prevent pressure unbalance in the system in to help the operator to monitor the whole operating system.

7.2

Observation

To ensure that it will deliver desired pressure to the most remote and isolated branch and outlets, the piping system and equipment selection are well designed. The major reference for this project is based on ASME and PSME Code. 7.3 Recommendation

Standard procedure based on ASME/ANSI B31.3 and other related standard shall be consulted first before proceeding to the design to ensure safety and efficiency. The costing of the design is not included, the economics is not yet considered in the design. The use of individual filters for each shop is also recommended. If pipe sizes specified are not available use the size larger than the designed piping. 7.4 Conclusion

The design only considered or focused greatly the farthest and the most compressed air consuming outlet to arrive the greatest pressure drop. Sizing of the equipment is based on the demand of the system and the pressure drop developed in the system. All equipment are electric driven. For this installation which is a close loop system, the major equipment of the design that needs deep consideration of the required pressure is based on the farthest and most consuming branch.

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BIBLIOGRAPHY
Prepared by: ELLA MAE ARAO and SHERWIN NOE SABATER ATLAS COPCO XAS 750 CD6 750 CFM, 100 PSI ROTARY SCREW COMPRESSOR DELTECH Refrigerated Compressed Air Dryers HE Series Pyramid Series KAESER COMPRESSORS Compressed Air Cooling Air AB Series Compressed Air Filters PURAFIL Service Guide for Compressor Intake Filter SPG 0714COMPRESSED AIR SYSTEMS Engineering Specifications Version 3.0Issued March 2013

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APPENDIX
Prepared by: ELLA MAE ARAO, RUPERT CONDAT, SHERWIN NOE SABATER, and MARIA ROSILYN ORTUA APPENDIX A - TYPICAL SYSTEM DOCUMENTATION Insert tick (9) in applicable boxes.
AS-BUILTCOPIES 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 DESIGNCOPIES 2 2 2 2 2 2 2 2 PRELIMINARY COPY 1 1 1 1 1 1 1 1

DATA ITEM NO.

DESCRIPTION

GENERAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 QUALITYMANAGEMENT MECHANICAL GeneralAssembly&CrossSectionDrawings ShopFabricationDetails DriveAssemblyDetails EquipmentAssemblyDetails MechanicalFlowDiagrams Inlet/ OutletDetails MechanicalCompletion/TestCertificate4 LocationofServicesConnections PipingSchematic CIVIL Foundation&SupportPlan&Loads CompletedSpecificationDataSheets PerformanceCurvesData GeneralArrangementOutlineDimension Routine/TypeTestCertificates Manufacturing& DeliverySchedule TechnicalLiterature&Brochures PricedSparePartsfor1 yrsOperation Installation&RiggingDiagrams DesignCalculations&Criteria BillsofMaterials NamePlateDetails CompletePartsList InstallationInstructions OperatingInstructions MaintenanceInstructions LubricationSchedules CertifiedDimensions

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34 35 36 37 38 39 40 41 42 43 44

MaterialsSpecification CompletedQAComplianceMatrix QualityManual 2nd/3rdPartyAccreditation Inspection&TestPlans PerformanceTestCertificates&Data4 HydrostaticTestCertificates&Data NDTTestCertificates&Data4 MaterialTestCertificates4 StatutoryCodeCertificates WeldingProcedures
4

1 1 1

2 2 2 2 2

45 WeldersQualificationCertificates4 PRELI DATA 46 WeldingMaps/Records MINAR ITEM DESCRIPTION 47 NO. Y 1 REVIEWCODELEGEND: F: REVIEWREQUIREDPRIORTOFABRICATION. S: COPY REVIEWREQUIREDPRIORTOSHIPMENT. I: REQUIREDFORINFORMATIONONLY. 2 3

DESIGN COPIES

AS-BUILT COPIES

REVIEWCOPIESTOBEPROVIDEDWITHINTHETIMESHOWN(EXPRESSEDASTIME AFTERAWARD). AS-BUILTCOPIESSHALLBEPROVIDEDBEFOREEQUIPMENTDELIVERY. AS-BUILTDRAWINGSSHALLINCLUDEONEFULLSIZEWITHTHEREMAINDERA3 COPIESUNO. CERTIFICATESANDPERFORMANCEDATASHALLBEPROVIDEDONCOMPLETIONOF TESTS.

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APPENDIX B - DRAWINGS The attached technical drawing sheets form part of this document. M11-349-1 & 2 M11-351-1 & 2 M11-350 M11-352 M11-353 M11-355 M11-354 M11-307 M11-321 M11-701 Standard Drawing Symbols for Air System Compressed Air Piping Details Connection Single Trainstop to Main Anchor Points Steel Air Main Brackets Label Holder Installation, Part: Carrington Tang Clamp, 1/2and 3/4 Label Holder Installation Example on General Manifold Arrangement Air Hose, P.V.C. Detail of Fittings (13 & 20 BSP) 40 & 50 BSP Air Hose Fittings Details General Arrangement Compressor Room (Main Manifold)

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APPENDIX C DATA SHEETS The attached data sheets form part of this document. DS-P-001 DS-P-002 DS-P-003 GMS01Piping MS01Piping SS01Piping

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APPENDIX D EQUIPMENT SCHEDULE 1. Filter a. Liquid Separator Liquid removal: 99+% water Max liquid loading: 30,000 ppm w/w Solid particulate removal: 10 microns Oil carry over: n/a Pressure drop: Wet: 0.8 psi Dry Housing: modular type Connector size: 2.5 NPTF Max working pressure: 250 psig Maximum inlet temp.: 150 F Reference: KAESER b. Filtered Separator Liquid removal: 99+% water Max liquid loading: 25,000 ppm w/w Solid particulate removal: 3 microns Oil carry over: 5ppm w/w Pressure drop: Wet: 1.5 psi Dry: 1 psi Housing: modular type Connector size: 2.5 NPTF Max working pressure: 250 psig Maximum inlettemp.: 150 F Reference: KAESER 2. Dryer Type: refrigeration Capacity: 715.2174 cfm Dew point: 38 F Inlet air temp.: 120 F Inlet air pressure: 100 psig Power: 6.733 kW V / ph / Hz: 4600/3/60 Reference: Deltech 3. Receiver Volume: 2000 L Design pressure: 11 bars ( 160 psig) Type: Vertical Diameter x Height: 1150mmx 2640mm (w/ supporting valves)

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Weight: 421 kg Reference: Atlas Copco 4. Aftercooler Compressed Air Aftercooler, Air AB SERIES Rotary Screw, 200 F Inlet, 955 scfm Capacity in Tube Model AB 1206 C6 0 Pressure Drop : 0.6 psi Water Flow = 3 gpm per 100 scfm (680.52 scfm) Water Flow = 20.4156 gpm 5. Air Compressor FAD Rating 750 cfm/100psi Min./Max. Working Pressure 58/125 Engine - Caterpillar C6.6 Acert EPA Tier 3 Number of Cylinders 6 Cooling System Water Full Load Speed 2,100 Fuel Tank Capacity (Gal.) 76 Fuel Consumption @ 0% load (Gal/hr) 3.8 Fuel Consumption @ 100% load (Gal/hr) 10 Compression Stages 1 Outlet Valve Configuration 1x1.5/2x Compressor Cooling System Air/Oil Compressor Oil Capacity (Gal.) 12 Air receiver Capacity (Gal.) 16.78 Sound pressure level @ 23 Ft. 76 dBa Dimensions LxWxH (wheel mtd.) 203x78x78 Dimensions LxWxH (skid mtd.) 132x62x72

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APPENDIX E ISOMETRIC VIEW OF PIPING SYSTEM (INCLUDE PIPE SIZE, WALANG PAKINABANG ANG ISOMETRIC VIEW PAG WALANG SIZE)

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APPENDIX F CONTRIBUTORS LIST OF CONTRIBUTORS Name of Students ARAO, ELLA MAE Contribution to the Project Introductory Statement Objectives of the Engineering Report Bibliography Appendix Equipment Schedule Letter of Transmittal Filter Product Specification Dryer Product Specification Receiver Product Specification Evaluation Piping Pressure Drop Calculation Receiver Selection Air Compressor and Aftercooler Selection Air Compressor Maintenance Aftercooler Product Specification Air Compressor Product Specification Intake Air Filter Product Specification Pipe Sizing Calculation Filter Selection Dryer Selection Filter Maintenance Filter Operation Dryer Operation Receiver Operation Observation Dryer Maintenance Receiver Maintenance Aftercooler Maintenance Intake Air Filter Maintenance Design Overview System Requirement and Layout Final Layout Piping and Accessories Product Specification Isometric View of Piping Filter Installation Dryer Installation Receiver Installation Recommendation Acknowledgement

BACSAIN, LEE ANTHONY

BIEN, JANINE

BONAGUA, BENJAMIN I

CARDIO, JAN JERKIN

CAS, ALLAN

CELESTIAL, WILFREDO JR

CONDAT, RUPERT

MIJARES, ARJEE

ORTUA, MARIA ROSILYN

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RAYALA, ED RICHARD

SABATER, SHERWIN NOE

Importance of the Engineering Report Limitation of the Engineering Report Standard Details Aftercooler Installation Air Compressor Installation Intake Air Filter Installation Conclusion Aftercooler Operation Air Compressor Operation Intake Air Filter Operation Contributors

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