Compendiu Aer Comprimat PDF

Table of contents
Contents Chapter Page
Part 1 1.1 The history of compressed air ............................................... 1

Fundamentals of 1.1.1 The origin of compressed air ................................................ 1
compressed air 1.1.2 The first applications of compressed air ............................... 2
1.2 Units and formula symbols .................................................... 6
1.2.1 Basic units ............................................................................ 6
1.2.2 Compressed air units ........................................................... 6
1.3 What is compressed air ? ....................................................... 7
1.3.1 The composition of air .......................................................... 7
1.3.2 The properties of compressed air ........................................ 7
1.3.3 How does compressed air behave? ..................................... 7
1.4 Physical fundamentals ........................................................... 8
1.4.1 Temperature ......................................................................... 9
1.4.2 Volume ................................................................................. 9
1.4.3 Pressure ............................................................................. 10
1.4.3 Volume flow ........................................................................ 11
1.5 Compressed air in motion .................................................... 13
1.5.1 Flow behaviour ................................................................... 13
1.5.2 Types of flow ...................................................................... 13
Part 2 2.1 The advantages of compressed air ..................................... 14

Applications for 2.2 Pressure ranges .................................................................... 17
pneumatics 2.3 Possible applications for compressed air ........................... 18
2.3.1 Tensioning and clamping with compressed air ................... 18
2.3.2 Conveyance by compressed air ......................................... 18
2.3.3 Pneumatic drive systems ................................................... 19
2.3.4 Spraying with compressed air ............................................ 19
2.3.5 Blowing and flushing with compressed air .......................... 19
2.3.6 Testing and inspection with compressed air ....................... 20
2.3.7 Using compressed air for process control .......................... 20
2.4 Examples of specialised applications ................................. 21
Part 3 3.1 Compressors (Compactors) ................................................. 24

Compressed air 3.1.1 Dynamic compressors ( Turbo-compressors ) .................... 24
3.1.2 Displacement compressors ................................................ 24
generators
3.2 Types of compressor ............................................................ 25
3.2.1 Standard compressors ....................................................... 26
3.2.2 Piston (reciprocating) compressor ...................................... 27
3.2.3 Diaphragme compressor .................................................... 29
3.2.4 Free piston compressor ...................................................... 30
3.2.5 Rotary vane compressor .................................................... 31
3.2.6 Liquid ring compressor ....................................................... 32
3.2.7 Screw compressor ............................................................. 33
3.2.8 Roots compressor .............................................................. 34
3.2.9 Axial compressor ................................................................ 35
3.2.10 Radial compressor ............................................................. 36
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3.3 Piston compressors .............................................................. 37

3.3.1 General .............................................................................. 37
3.3.2 Suction capacity - Output ................................................... 38
3.3.3 Cooling ............................................................................... 39
3.3.4 Coolant ............................................................................... 40
3.3.5 Control of reciprocating piston compressors ...................... 40
3.3.6 Advantages of reciprocating piston compressors ............... 40
3.3.7 Components of a piston compressor .................................. 41
3.4 Screw compressors .............................................................. 42
3.4.1 General .............................................................................. 42
3.4.2 Compression process ........................................................ 42
3.4.2 Method of operation ........................................................... 43
3.4.3 Oil circuit ............................................................................ 44
3.4.4 Pneumatic circuit ................................................................ 45
3.4.5 Heat reclamation ................................................................ 46
3.4.6 Intake control ...................................................................... 46
3.4.7 Advantages of screw compressors ..................................... 46
3.4.8 Components of a screw compressor .................................. 47
3.5 Components .......................................................................... 48
3.5.1 Drive motor ......................................................................... 48
3.5.2 Drive belts .......................................................................... 48
3.5.3 Belt tensioning .................................................................... 48
3.5.4 Inlet and pressure valves ................................................... 49
3.5.5 Safety valve ........................................................................ 49
3.5.6 Intake filter .......................................................................... 49
3.6 Compressor lubricants and coolants .................................. 50
Part 4 4.1 Pressure definitions .............................................................. 51

Control of compressors 4.2 Operating status .................................................................... 52
4.2.1 Stopped ( L0 ) ..................................................................... 52
4.2.2 Idle ( L1 ) ............................................................................. 52
4.2.3 Part-load ............................................................................ 53
4.2.4 Operating load ( L2 ) .......................................................... 53
4.3 Controlling individual compressors .................................... 54
4.3.1 Intermittent control ............................................................. 54
4.3.2 Idle mode control ................................................................ 54
4.3.3 Delayed intermittent control ................................................ 55
4.3.4 Part-load control ................................................................. 56
4.3.4.1 Infinite output control .......................................................... 56
4.3.4.2 Frequency control ............................................................... 56
4.4. The ARS control concept ..................................................... 57
4.4.1 Automatic ........................................................................... 58
4.4.2 Autotronic ........................................................................... 58
4.4.3 Ratiotronic .......................................................................... 59
4.4.4 Supertronic ......................................................................... 59
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4.5 Control of several compressors .......................................... 60

4.5.1 MCS 1 and MCS 2 ............................................................. 60
4.5.2 MCS 3 ................................................................................ 61
4.5.3 MCS 4 ................................................................................ 62
4.5.4 MCS 5 ................................................................................ 63
4.5.5 MCS 6 ................................................................................ 64
4.5.6 MCS 7 ................................................................................ 65
Part 5 5.1 Why treatment ? .................................................................... 66

Compressed air treatment 5.1.2 Planning information .......................................................... 67
5.1.3 Consequences of poor treatment ....................................... 68
5.1.3 Impurities in the air ............................................................. 69
5.2 Water in the compressed air ................................................ 70
5.2.1 Atmospheric humidity ......................................................... 70
5.2.2 Dew points ......................................................................... 71
5.2.3 Air moisture content ........................................................... 71
5.2.4 Quantity of condensate during compression ...................... 72
5.2.5 Example for calculating quantities of condensate .............. 73
5.2.6 Quantity of condensate on a humid summer day ............... 74
5.2.7 Determining the pressure dew point ................................... 75
5.2.8 Pressure dew point after removal of pressure .................... 76
5.3 Compressed air quality ......................................................... 77
5.3.1 Quality classes defined in DIN ISO 8573-1 ....................... 77
5.4 Methods of drying ................................................................. 78
5.4.1 Operating conditions .......................................................... 79
5.4.2 Condensation by over-compression ................................... 80
5.4.3 Condensation by refrigeration drying ................................ 81
5.4.4 Diffusion by membrane drying ............................................ 82
5.4.5 Sorption by Absorption ....................................................... 83
5.4.6 Sorption by Adsorption ....................................................... 84
5.4.6.1 Cold regeneration ............................................................... 85
5.4.6.2 Internal hot regeneration .................................................... 86
5.4.6.3 External hot regeneration ................................................... 87
5.4.6.4 Vacuum regeneration ......................................................... 88
5.4.7 Arrangement of the refrigeration compressed air dryer ...... 89
5.4.7.1 Dryer before the compressed air receiver .......................... 89
5.4.7.2 Dryer behind the compressed air receiver .......................... 90
5.5 Compressed air filters .......................................................... 91
5.5.1 Basic terminology of filters ................................................. 91
5.5.1.1 Filter separation rate [ % ] ............................................... 91
5.5.1.2 Pressure drop p ............................................................... 92
5.5.1.3 Operating pressure ............................................................ 92
5.5.2 Dust separators .................................................................. 93
5.5.3 Pre-filters ............................................................................ 94
5.5.4 Microfilters .......................................................................... 95
5.5.5 Active carbon filters ............................................................ 97
5.5.6 Active carbon adsorbers ..................................................... 98
5.5.7 Sterile filters ....................................................................... 99
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Part 6 6.1 Condensate .......................................................................... 100

Disposal of condensate 6.2 Condensate drains .............................................................. 101
6.2.1 Condensate drains with manual valves ............................ 102
6.2.2 Condensate drains with float control ............................... 102
6.2.3 Condensate drains with
time-dependent magnetic valves ...................................... 103
6.2.4 Condensate drains with
electronic volume measurement ...................................... 104
6.2.5 Condensate drains with level floats
for measuring the level ..................................................... 105
6.3 Condensate treatment ........................................................ 106
6.3.1 Oil-water separators ......................................................... 107
Part 7 7.1 Consumption of compressed air by pneumatic devices . 108

Compressed air 7.1.1 Consumption of nozzles ................................................... 108
7.1.1.1 Compressed air consumption of cylindrical nozzles ......... 109
requirement
7.1.1.2 Compressed air consumption of paint spray guns ........... 110
7.1.1.3 Compressed air consumption of jet nozzles ..................... 111
7.1.2 Compressed air consumption of cylinders ....................... 112
7.1.3 Compressed air consumption of tools .............................. 113
7.2 Determining compressed air requirement ........................ 115
7.2.1 Average operation time .................................................... 115
7.2.2 Simultaneity factor ............................................................ 116
7.2.3 Defining compressed air requirement .............................. 117
7.2.3.1 Automatic consumer devices ............................................ 117
7.2.3.2 General consumer devices ............................................... 118
7.2.3.3 Total compressed air consumption ................................... 118
7.2.4 Allowances for losses and reserves ................................. 119
7.2.5 FAD required LB ............................................................... 119
7.3 Compressed air loss ........................................................... 120
7.3.1 Costs of compressed air loss ........................................... 120
7.3.2 Quantifying leakage ......................................................... 121
7.3.2.1 Quantifying leakage by emptying the receiver .................. 121
7.3.2.2 Quantifying leakage by measuring working time .............. 122
7.3.3 Limits for leakage ............................................................. 123
7.3.4 Measures for minimising compressed air loss .................. 123
7.3.5 Reconstructing a pneumatic network ............................... 124
Part 8 8.1 The type of compressor ...................................................... 125

Determining the size of the 8.1.1 Screw compressors .......................................................... 125
compressor station 8.1.2 Piston compressors .......................................................... 125
8.2 Maximum pressure Pmax ..................................................... 126
8.2.1 Factors influencing cutout pressure Pmax ......................... 126
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8.3 Determining the volume of a compressed air receiver ... 127

8.3.1 Recommendations for the volume of compr. air receivers 127
8.3.2 Norm series and operating pressures
for sizes of compressed air receivers ............................... 127
8.3.3 Volumes of compressed air receivers for compressors .... 128
8.4 Compressor cycle intervals ................................................ 129
8.4.1 Compressor idle times ..................................................... 129
8.4.2 Compressor running times ............................................... 129
8.4.3 Determining the number of motor switch cycles ............... 130
8.5 Examples for compressor configuration ........................... 131
8.5.1 Samples calculation for piston compressors .................... 131
8.5.1.1 Determining the maximum pressure Pmax ........................ 131
8.5.1.2 Determining compressor size ........................................... 132
8.5.1.3 Volume of the compressed air receiver ............................ 132
8.5.1.4 Compressor cycle interval ................................................ 133
8.5.1.5 Motor cycling rate of compressor ..................................... 134
8.5.2 Samples calculation for screw compressors .................... 135
8.5.2.1 Example for determining the maximum pressure Pmax .... 135
8.5.2.2 Determining compressor size ........................................... 135
8.5.2.3 Dimensioning the compressed air receiver ...................... 136
8.5.2.4 Compressor cycle interval ................................................ 136
8.5.3 Summary on compressor selection .................................. 137
8.6 Information on compressor configuration ........................ 138
8.6.1 Performance and working pressure .................................. 138
8.6.2 Varying working pressure of consumer devices ............... 139
8.6.3 Combined compressor systems ....................................... 139
Part 9 9.1 The compressor air receiver .............................................. 140

The pneumatic system 9.1.1 Storing compressed air .................................................... 140
9.1.2 Pulsation damping ............................................................ 140
9.1.3 Condensate collection ...................................................... 141
9.1.4 Operation of compressed air receivers ............................. 141
9.1.5 Installation of compressed air receivers ........................... 141
9.1.6 Safety rules for compressed air receivers ........................ 142
9.1.6.1 Division into test groups ................................................... 142
9.1.6.2 The manufacture of compressed air receivers ................. 143
9.1.6.3 Registration and inspection obligations ............................ 143
9.1.6.4 Expert and proficient persons as defined in 31 and
32 of the German Directive for pressure receivers ........ 143
9.1.6.5 Inspection of compressed air receivers ............................ 144

9.1.6.6 Types of inspection ........................................................... 146
9.1.6.7 Addtional excerpts from the directive for
compressed air receivers ................................................. 146
9.1.7 Fittings on the compressed air receivers .......................... 147
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9.1.7.1 Safety valve ...................................................................... 148

9.2 The compressed air circuit ................................................. 149
9.2.1 The structure of a compressed air circuit ......................... 149
9.2.1.1 The main line .................................................................... 149
9.2.1.2 The distribution line-ring line ............................................ 150
9.2.1.3 The distribution line-stub line ............................................ 151
9.2.1.4 The connection line .......................................................... 151
9.2.1.5 Connecting to a collective line with multiple systems ....... 152
9.3 Tips for planning pipe systems .......................................... 153
9.3.1 General planning tips ....................................................... 153
9.3.2 Pipeline without compressed air dryer ............................. 154
9.3.3 Pipeline system with compressed air dryer ...................... 155
9.4 Pressure loss p ................................................................. 156
9.4.1 Type of flow ...................................................................... 156
9.4.2 The Reynolds number Re ................................................ 156
9.4.3 Pressure loss in the pipe system ...................................... 157
9.5 Dimensioning pipelines ...................................................... 158
9.5.1 Maximum pressure drop p ............................................. 158
9.5.2 Nominal width of pipelines
Comparison [ DN Inch ] ................................................. 159
9.5.3 Equivalent pipe length ...................................................... 160
9.5.4 Determining the inside diameter di
of pipe by calculation ........................................................ 161
of pipe by graphics ........................................................... 162
of the pipe with the aid of a bar graph .............................. 163
9.6 Choosing the material for pipelines .................................. 164
9.6.1 Threaded pipes ................................................................ 164
9.6.2 Seamless steel pipes ....................................................... 165
9.6.3 Stainless steel pipes ........................................................ 165
9.6.4 Copper pipes .................................................................... 166
9.6.5 Plastic pipes ..................................................................... 167
9.7 Marking pipelines ................................................................ 168
Part 10 10.1 Cooling the compressor ..................................................... 169

The installation room 10.2 Compressor installation ..................................................... 170
10.2.1 General information regarding the installation room ......... 170
10.2.2 Admissible ambient temperature ...................................... 170
10.2.3 Fire safety rules for installation rooms .............................. 171
10.2.4 Disposal of condensate .................................................... 171
10.2.5 Compressor installation instructions ................................. 172
10.2.6 The space requirement of a compressor .......................... 172
10.2.7 Conditions for installing compressed air receivers ........... 173
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10.3 Ventilation of a compressor station .................................. 174

10.3.1 Factors influencing the flow of

cooling air of a Vc of a compressors ................................. 174
10.3.2 Definition of the factors influencing the flow

of cooling air Vc to and from a compressor ..................... 175
10.3.3 General information for ventilation of compressor rooms . 176
10.3.4 Natural ventilation ............................................................ 177
10.3.4.1 Outlet air aperture required for natural ventilation ............ 177
10.3.5 Artificial ventilation ........................................................... 178
10.3.5.1 Required ventilator output with artificial ventilation ........... 178
10.3.5.2 Required inlet air aperture with artificial ventilation .......... 179
10.3.5.3 Example of artificial ventilation of a compressor station ... 180
10.3.6 Circulation of cooling-air with inlet and outlet ducts .......... 181
10.3.6.1 Air inlet ducts .................................................................... 181
10.3.6.2 Extraction of air through a cool-air duct ............................ 182

10.3.6.3 Required flow of cooling-air Vd and cross-section
of duct Ad when using a cool-air ducting ......................... 182
10.3.6.4 Information concerning ventilation by duct ....................... 183
10.3.6.5 Dimensioning the air inlet aperture
when using an outlet duct ................................................ 184
10.3.6.6 Variations of duct-type ventilation ..................................... 185
10.4 Example installation plans ................................................. 186
10.4.1 Installation of a screw compressor: an example ............... 186
10.4.2 Installation of piston compressor: an example ................. 187
Part 11 11.1 The heat balance of a compressor station ........................ 188

Heat reclamation 11.2 Room heating ...................................................................... 189
11.2.1 Room heating through ducting ......................................... 189
11.2.2 Operation of room heating ................................................ 190
11.2.3 Economy of room heating ................................................ 190
11.3 The Duotherm heat exchanger ........................................... 191
11.3.1 Duotherm BPT ................................................................. 191
11.3.2 Duotherm BSW ................................................................ 192
11.3.3 How much energy is it possible to save ? ......................... 193
11.4 Closing remarks concerning heat reclamation ................. 194
Part 12 12.1 The nature of sound ............................................................ 195

Sound 12.1.1 Sound perception ............................................................. 195
12.2 Important terminology in acoustics .................................. 196
12.2.1 Sound pressure ................................................................ 196
12.2.2 Sound level ....................................................................... 196
12.2.3 Sound intensity ................................................................. 196
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12.3 Human perception of sound ............................................... 197

12.3.1 The sound intensity level .................................................. 197
12.3.2 Assessed sound level dB ( A ) .......................................... 197
12.3.3 Loudness in comparison .................................................. 198
12.4 Behaviour of sound ............................................................. 199
12.4.1 Distance from the sound source ....................................... 199
12.4.2 Reflection and Absorption ................................................ 199
12.4.3 Damping sound ................................................................ 200
12.4.5 Dessemination of sound in pipes and ducts ..................... 200
12.4.6 Sound pressure level from many sound sources .............. 201
12.4.6.1 Several sound sources with the same level ...................... 201
12.4.6.2 Two sound sources with different levels ........................... 201
12.5 The effects of noise ............................................................ 202
12.6 Noise protection directives ................................................ 203
12.6.1 Safety rules for noise generating operations, Date 12/74 ... 203
12.6.2 Safety rules for compressors ( VBG 16 ), Date 4/87 .......... 203
12.6.3 National workplace directive, Date 4/75 ........................... 203
12.6.4 National general administrative rules concerning
noise, Date 7/84 ............................................................... 204
12.7 Noise measurement ............................................................ 205
12.8 Silencing on compressors ................................................. 205
Part 13 13.1 Composition of compressed air costs .............................. 206

Costs of compressed air 13.1.1 Cost factor ratios .............................................................. 206
13.2 Cost-effectiveness calculation for energy costs .............. 207
Part 14 14.1 Introduction ......................................................................... 208

CE-Certification 14.1.1 EC Machinery Directive .................................................... 208
14.1.2 Areas of application .......................................................... 208
14.2 Putting machinery into circulation .................................... 209
14.2.1 CE-symbol ........................................................................ 209
14.2.2 EC Declaration of Conformity ........................................... 210
14.2.3 EC Maker's Declaration .................................................... 212
Part 15 A.1 Symbols ............................................................................... 214

Appendix A.1.1 Picture symbols defined by DIN 28004 ............................ 214
A.1.2 Symbols for contact units and switching devices
as per ISO 1219 .............................................................. 216
VIII
Fundamentals of compressed air
1. Fundamentals of
compressed air
1.1 The history of compressed Compressed air, together with electricity, is the most fre-
air quently used carrier of energy in industry and the crafts today.
But whereas we learn to use electricity and electrical appli-
ances from a very early age, the possibilities, advantages and
essentials of compressed air are far less understood.
Peoples comprehension of compressed air grew parallel to

their understanding in other technical fields. Its development
was only furthered where it was seen to have advantages over
other technologies. But compressed air was always being
used, and so clever people were always thinking about how to
put it to better use.
1.1.1 The origin of compressed air The first compressor - the lung
Many technical applications originate from the earliest days of

mankind. The first use of compressed air was blowing on tinder
to fan a flame. The air used for blowing was compressed in the
lungs. Indeed, the lung could be called a kind of natural
compressor. The capacity and performance of this compres-
sor is extremely impressive. The human lung can process
100 l/min or 6 m3 of air per hour. In doing so it generates a
pressure of 0,02 - 0,08 bar. In a healthy condition, the reliabil-
ity of the human compressor is unsurpassed and it costs
nothing to service.
The further development of the lung
However, the lung proved to be wholly inadequate when

people began to smelt pure metals such as gold, copper, tin
and lead more than 5000 years ago. And when they started
to make high grade metals, such as iron from ore, further
development of compressed air technology was essential.
More powerful aids than the lung were needed to generate
temperatures of over 1000 C. At first they used the high winds
Fig. 1.1: on uplands and the crests of hills. Later, Egyptian and Sumerian
The first compressor - the lung goldsmiths made use of the blast pipe. This brought air directly
into the embers, which increased the temperature decisively.
Even today, goldsmiths all over the world use a similar device.
However, this is only useful for melting small quantities of
metal.
1
The first mechanical compressor - the bellows
The first mechanical compressor, the hand-powered bellows,

was developed in the middle of the third millennium BC. The
much more powerful foot-powered bellows was invented around
1500 BC. This progress was necessary when the alloying of
copper and tin to make bronze developed into a stable manu-
facturing process. The development can be seen in a wall-
painting of an ancient Egyptian grave. It was the birth of
compressed air as we know it today.
Fig. 1.2:
Picture of the foot-powered bellows in ancient Egypt
1.1.2 The first applications of com- Hydraulic organ

pressed air Storage and suppression of pulsation
Recognising the properties of compressed
air The first deliberate exploitation of energy in the air is handed
down to us by the Greek Ktesibios ( ca. 285 to 222 BC ). He
built a hydraulic organ and used compressed air for the
storage and reduction of vibration.
Catapult
Storage of energy
Ktesibios used another property of compressed air, stored

energy, for his catapult. With the aid of air compressed in a
cylinder, the Greeks catapult generated enough tension to
propel missiles.
Fig. 1.3:
The catapult of Ktesibios
Temple doors
Expansion and the performance of work
Heron, an engineer living in Alexandria in the first century BC,

found a way to open the doors of a temple automatically by
keeping the flame at the altar inside the building permanently
alight. The secret was to use the expansion of hot air to force
water out of one container and into another. Heron recognised,
even if unwittingly, that it was possible to perform work by
changing the condition of air.
Fig.1.4:
The temple doors of Heron
2
Pascals law
Increasing energy
It was only in the 17th century that a series of learned people

began to study the physical laws applicable to compressed air.
In 1663 Blaise Pascal published an essay on increasing
energy by using liquids( hydraulics ), that was also valid for the
technology of compressed air. He found that the energy
exerted by one man at one end of a closed container of water
was equivalent to the energy exerted by 100 men at another
Fig. 1.5 :
Compressed air to increase energy end.
Transporting objects through pipes

Pneumatic conveyance
Taking up where Heron left off, the French physicist Denis

p1 p2 Papin described in 1667 a method of transporting objects
through pipes. He exploited the slight difference in pressure
inside a pipe. In doing so he found out that energy was
Fig. 1.6 : generated at an object inside the pipe. This was recognition of
Compressed air as a means of transport the advantage of the high work speeds obtainable by using air.
Papin thus laid the foundation stone for pneumatic convey-
ance.
Pneumatic brakes
Power transmission
As early as around 1810, trains were being powered by

compressed air. In 1869 Westinghouse introduced his pneu-
matic brake. His brake motor followed three years later. In this
system the brakes were applied by over-pressure i.e., the full
braking effect is obtained if there is a drop in pressure e.g., by
the bursting of a hose.
This was the first use of a fail-safe system. Brake systems

Fig. 1.7 : based on this principle are still used in HGVs today.
Pneumatic brakes in a train ca. 1870
3
Pneumatic post
Conveyance by compressed air
The idea of trains powered by compressed air was not forgot-

ten. In 1863, Latimer Clark together with an engineer named
Rammel built a pneumatic conveyance system in London. It
featured small trolleys moving completely inside conveyor
tubes and was designed to transport postal bags and parcels.
This system was much more flexible than the heavy, atmos-
pheric railways of 1810, and led eventually to the introduction
of pneumatic post.
Pneumatic post networks soon sprung up in Berlin, New York

and Paris. The Paris network reached its peak length of 437 km
in 1934. Even today, pneumatic post systems are still used in
large industrial operations.
Pneumatic tools
Transporting energy
When the tunnel through Mont Cenis was being built in 1857,
the new technology was used in a pneumatically-powered
hammer drill to cut through the rock. From 1861 they used
pneumatically-powered percussion drills, these being sup-
plied with compressed air from compressors at both ends of
the tunnel. In both cases the compressed air was transported
over long distances.
When in 1871 the breakthrough in the tunnel was achieved,

there were over 7 000 m of pipelines on both sides. Thus, for
the first time, the transportability of energy was demon-
Fig. 1.8 : strated and made known to a wide public as one of the
Pneumatic drills in tunnel construction advantages of compressed air. And from here on, pneumatic
tools of even greater performance and versatility were devel-
oped.
Pneumatic networks
Central generation of compressed air and signal transmission
The experience gained using networks of pneumatic lines and

the development of more powerful compressors led to a
pneumatic network being installed in the sewage canals of
Paris. It was put into commission in 1888 with a central
compressor output of 1 500 kW. By 1891 its output rating had
already reached 18 000 kW.
The all-round success of the pneumatic network was under-

lined by the invention of a clock, the minute hand of which was
moved on every sixty seconds by an impulse from the com-
Fig. 1.9 :
pressor station. People had not only seen the possibility of
Compressed air station in Paris 1888
transporting energy, but also of moving signals over great
distances through a pneumatic network.
The pneumatic network in Paris is unique to this day, and is still

in use.
4
Signal processing
Compressed air for the transmission and processing of signals
In the 1950s in the USA the high flow speed of compressed air
was first used for the transmission and processing of signals.
Low-pressure pneumatics, also known as fluidics or
pneumonics ( pneumatic logic ), allow the integration of
logical switching functions in the form of fluidic elements in a
very small area at pressures of 1.001 to 1.1 bar.
The high operating precision of the fluidic logic elements under
extreme conditions allowed them to be used in the space and
defence programmes of the USA and the USSR. Immunity to
Fig. 1.10 : electromagnetic radiation from exploding nuclear weapons
Four-stage adding device with wall radiation ele- gives fluidics a special advantage in several sensitive areas.
ments
Even so, over the course of time fluidics has largely been
superseded by electrical and microelectronic technology in the
fields of signal and information processing.
5
1.2 Units and formula symbols The SI-units ( Systme International d'Units ) were agreed
at the 14th General Conference for Weights and Measures.
They have been generally prescribed since 16.10.1971.
1.2.1 Basic units The basic units are defined independent units of measure
and form the basis of the SI-system.
Basic unit Formula symbol Symbol Name
Length l [m] Metre
Mass m [ kg ] Kilogramme
Time t [s] Second
Strength of current I [A] Ampere
Temperature T [K] Kelvin
Strength of light I [ cd ] Candela
Qty of substance n [ mol ] Mol
1.2.2 Compressed air units Engineering uses measures derived from the basic units. The
following table shows the most frequently used units of meas-
ure for compressed air.
Unit Formula symbol Symbol Name
Force F [N] Newton
Pressure p [ Pa ] Pascal
[ bar ] Bar 1 bar = 100 000 Pa
Area A [ m2 ] Square metre
Volume V [ m3 ] Cubic metre

[l] Litre 1 m3 = 1 000 l
Speed v [m/s] Metre per Second
Mass m [ kg ] Kilogramme
[t] Tonne 1 t = 1 000 kg
Density [ kg / m3 ] Kilogramme per cubic metre
Temperature T [ C ] Degree Celsius
Work W [J] Joule
Energy P [W] Watt
Tension U [V] Volt
Frequency f [ Hz ] Hertz
6
1.3 What is compressed air ?
1.3.1 The composition of air The air in our environment, the atmosphere, consists of:
Nitrogen 78 % Nitrogen
78 %
21 % Oxygen
1 % other gases
Oxygen ( e.g.. carbon-dioxide and argon )
21 %
other gases
1%
Fig. 1.11:
The composition of air
1.3.2 The properties of compressed air Compressed air is compressed atmospheric air.
Compressed air is a carrier of heat energy.

Compressed air Compressed air can bridge certain distances ( in pipelines ),
be stored ( in compressed air receivers ) and perform work
Pressure energy ( decompress ).
Heat
Fig. 1.12:
Air compression
1.3.3 How does compressed air behave? As with all gases, the air consists of molecules. The molecules
are held together by molecular force. If the air is enclosed in a
tank ( constant volume ), then these molecules bounce off the
walls of the tank and generate pressure p.
p p The higher the temperature, the greater the movement of air
p p
molecules, and the higher the pressure generated.
p p
V Volume ( V ) = constant
p p
p p Temperature ( T ) = is increased
p p
Pressure ( p ) = rises
Boyle and Mariotte carried out experiments with enclosed
volumes of gas independently of each other and found the
following interrelationship:
T
The volume of gas is inversely proportional to pressure.
Fig. 1.13:
( Boyle-Mariottes Law )
Air in a closed container
7
1.4 Physical fundamentals The condition of compressed air is determined by the 3

measures of thermal state:
T = Temperature
V = Volume
p = Pressure
p V
= constant
T
This means:
Heat Volume constant ( isochore )

Pressure and temperature variable
p0 , T0 When the temperature is increased and the volume remains

p1 , T1 constant, the pressure rises.
p0 T0
=
constant volume p1 T1
isochore compression
Temperature constant ( isotherm )

Pressure and volume variable
p0 , V0
When the volume is reduced and the temperature remains
p1 , V1
constant, the pressure rises.
constant temperature
p0 V 0 = p1 V1 = constant
isotherm compression
Heat Pressure constant ( isobar )

Volume and temperature variable
V0 , T 0 When the temperature is increased and the pressure

V1 , T 1 remains constant, the volume increases.
V0 T0
=
constant pressure V1 T1
isobar compression
8
1.4.1 Temperature The temperature indicates the heat of a body and is read in C
on thermometers or converted to Kelvin ( K ).
T [K] = t [ C ] + 273,15
0C
Fig.1.14:
Showing temperature
1.4.2 Volume Volume V [ l, m3 ]

Compressed air in expanded state, open air
The volume is determined, for example, by the size of a cylin-

der. It is measured in l or m 3 and relative to 20 C and
1 bar.
The numbers in our documentation always refers to com-

pressed air in its expanded state.
d2
VCyl = h
Volume (V) 4
VCyl = Volume [m3]

d = Diameter [m]
h = Height [m]
Normal volume VNorm [ Nl, Nm3 ]

Compressed air in expanded state under normal conditions
The normal volume refers to the physical normal state as speci-

fied in DIN 1343. It is 8 % less than the volume at 20 C.
760 Torr = 1,01325 barabs = 101 325 Pa

273,15 K = 0 C
Norm volume + 8% = Volume

0C 20 C
Operating volume Voperat [ Bl, Bm3 ]

Compressed air in compressed state
The volume in operating state refers to the actual condition.

The temperature, air pressure and air humidity must be taken
into account as reference points.
When specifying the operating volume the pressure must

always be given, e.g., 1 m 3 at 7 bar means that 1 m 3 ex-
0 barabs 8 barabs panded (relaxed) air at 7 bar = 8 bar abs. compressed and
only occupies 1/8 of the original volume.
9
1.4.3 Pressure Atmospheric pressure pamb [ bar ]
Atmospheric pressure is caused by the weight of the air that

surrounds us. It is independent of the density and height of
the atmosphere.
At sea level, 1 013 mbar = 1,01325 bar

= 760 mm/Hg [ Torr ]
= 101 325 Pa
Under constant conditions atmospheric pressure decreases

the higher the measuring location is.
Fig.1.15:
Atmospheric pressure
Over-pressure pop [ barop ]
Over-pressure is the pressure above atmospheric pressure.

In compressed air technology, pressure is usually specified
as over-pressure, and in bar without the index op.
Over-
Absolute pressure pabs [ bar ]
pop
pressure
The absolute pressure pabs is the sum of the atmospheric
pressure pamb and the over-pressure pop.
barometric
air pressure
pabs
pabs = pamb + pop

pvac
Partial
vacuum
According to the SI-System pressure is given in Pascal [ Pa ].
pamb
In practice, however, it is still mostly given in bar . The old

measure atm ( 1 atm = 0,981 bar-op ) is no longer used.
Force F
100 % Vacuum Pressure = p =
Area A
pamb = Atmospheric pressure

pop = Over-pressure
pvac = Partial vacuum 1 Newton 1N
pabs = Absolute pressure 1 Pascal = 1 Pa =
1 m2 1 m2
Fig.1.16: 1 bar = 10195 mmWH [ mm water head ]

Illlustration of different pressures
10

1.4.3 Volume flow Volume flow V [ l/min, m/min., m/h ]
The volume flow describes the volume ( l or m ) per unit of

time ( minute or hour ).
Working volume flow A distinction is made between the working volume flow ( in-
Induction rate duction rate ) and the volume flow ( output rate ) of a com-
pressor.

Working volume flow VWor [ l/min, m/min., m/h ]
Volume flow Induction rate
Output rate
The working volume flow is a calculable quantity on piston
compressors. It is the product of the cylinder size ( piston ca-
pacity ), compressor speed ( number of strokes ) and the
number of cylinders working. The working volume flow is given
in l/min, m/min or m/h.

VWor = A s n c
Fig. 1.17:
Working volume flow and volume flow

VWor = Working volume flow [ l / min ]
A = Cylinder area [ dm2]
s = Stroke [ dm]
n = Number of strokes [ 1/ min ]
(compressor speed)
c = Number of working cylinders

Volume flow V [ l/min, m/min, m/h ]
TDC Output rate
The output rate of a compressor is normally declared as the

volume flow.
BDC
In contrast to the working volume flow, the volume flow is not
a calculated value, but one measured at the pressure joint of
a compressor and calculated back to the induction state. The
volume flow is dependent on the final pressure relative to the
induction conditions of pressure and temperature. This is why
when calculating the induction state the measured volume flow
to induction pressure must be relaxed and to induction tem-
TDC = Top dead centre perature it must be re-cooled.
BDC = Bottom dead centre
The volume flow is measured according to VDMA 4362,
DIN 1945, ISO 1217 or PN2 CPTC2 and given in l/min, m3/min
Fig. 1.18: or m3/h. The effective volume flow, i.e., the output that can
Cylinder movement actually be used, is an important consideration for the design
of a compressor. Volume flows can only usefully be compared
when measured under the same conditions. This means that
the induction temperature, pressure, relative air humidity and
measured pressure must match.
11

Norm volume flow VNorm [ Nl/min, Nm3/min, Nm3/h ]
As with the volume flow, the norm volume flow is also meas-
ured.
However, it does not refer to the induction state, but to a theo-

retical comparative value. With the physical norm state the
theoretical values are:
Volume flow + 8% = Norm volume flow
20C 0C Temperature= 273,15 K ( 0 C )
Pressure = 1,01325 bar ( 760 mm HG )
Fig. 1.19: Air density = 1,294 kg/m3 ( dry air )
Norm volume flow

Operating volume flow VOperat [ Ol/min, Om3/min, Om3/h ]
The operating volume flow gives the effective volume flow of

compressed air.
To be able to compare the operating volume flow with the other

volume flows, the pressure of he compressed air must always
be given in addition to the dimension Ol/min, Om3/min or
0 barabs 8 barabs
Om3/h.
Fig. 1.20:
Operating volume flow
12
1.5 Compressed air in motion Different laws apply to compressed air in motion than to sta-
tionary compressed air.
1.5.1 Flow behaviour The volume flow is calculated from area and speed.

V = A1 v 1 = A2 v2
A1 A2
A1 v2
=
A2 v1
v1 v2
V = Volume flow
A 1, A 2 = Cross section
v 1, v 2 = Speed
Fig. 1.21:
Flow behaviour The result of the formula is that:
The speed of flow is inversely proportional to

the cross section.
1.5.2 Types of flow Flow can be laminar or even (Ideal), or

turbulent ( with backflow and whirling ).
Laminar flow ( even flow )
low drop in pressure

slight heat transition
Fig. 1.22:
Laminar flow
Turbulent flow ( whirl flow )
high drop in pressure

great heat transition
Fig. 1.23:
Turbulent flow
13
Applications for pneumatics
2. Applications for pneumatics
2.1 The advantages of Pneumatics faces increasing competition from mechanical,

compressed air hydraulic and electrical appliances on all fronts. But pneumatic
devices have fundamental advantages over the other tech-
nologies:
Easily transported
Air is available everywhere, and there is plenty of it. Since

outlet air escapes into the open, there is no need for return
lines. Electrical and hydraulic systems need a return line to
the source.
Compressed air can be transported over great distances in

pipelines. This allows the installation of central generation sta-
tions that can supply points of consumption via ring mains
with a constant working pressure. The energy stored in com-
pressed air can be widely distributed in this way.
Easily stored
It is easy to store compressed air in purpose-built tanks. If

there is a storage tank integrated in a pneumatic network, the
compressor only needs to work when the pressure drops
below a critical level. And because there is always a cushion
of pressure, a work cycle can completed even if the power
network fails.
Transportable compressed air bottles can also be used at

locations where there is no pipe system (e.g., under water).
Clean and dry
Compressed air does not cause soiling or leave drops of oil if

the lines are defective. Cleanliness in fitting and operation are
extremely important factors in many sectors of industry, e.g.,
food, leather, textiles, and packing.
Lightweight
Pneumatic devices are usually much lighter than comparable

equipment and machinery with electrical power units. This
makes a big difference with manual and percussion tools
( pneumatic screwdrivers and hammers).
14
Safe to use
Compressed air works perfectly even when there are great

temperature fluctuations and the temperatures are extreme. It
can also be used where there are very high temperatures,
e.g., for operating forge presses and blast furnace doors.
Pneumatic devices and lines that are untight are no risk to the
safety and serviceability of the system.
Pneumatic systems and components in general wear very

little. They therefore have a long working life and a low failure
rate.
Accident-proof
Pneumatic elements are very safe with regard to fire, explo-

sion and electrical hazards. Even in areas where there is a
risk of fire, explosion and extreme weather conditions, pneu-
matic elements can be used without large and expensive safety
apparatus. In damp-rooms or outdoors too, there is no danger
with pneumatic equipment.
Rational and economical
Pneumatics is 40 - 50 times more economical than muscle

power. This is a major point, particularly in mechanisation and
automation.
Pneumatic components are cheaper than the equivalent hy-

draulic components.
There is no need for regular medium changes, as with hy-

draulic equipment, for instance. This reduces costs and the
servicing requirement, and increases operating times.
Simple
The design and operation of pneumatic equipment is very

simple. For this reason it is very robust and not susceptible
to malfunctioning. Pneumatic components are easy to install
and can be re-used later without difficulty. Installation times
are short because of the simple design. The fitters require no
expensive special training.
Straight-line movements can be executed without extra me-

chanical parts such as levers, cams, eccentric disks, screw
spindles and the like..
15
Overload-proof
Compressed air equipment and pneumatic working parts can

be loaded until they stop without being damaged. This is why
they are considered to be overload-proof.
In contrast to electrical systems, the output of a pneumatic

network can be overloaded without risk of danger. If the pres-
sure drops too much, the work can not be done, but there will
be no damage to the network or its working elements.
Fast work medium
The very high flow speeds allow rapid completion of work

cycles. This provides short cut-in times and fast conversion of
energy into work.
Compressed air can achieve flow speeds of over 20 m/s.

Hydraulic applications only manage 5 m/s.
The pneumatic cylinders reach linear piston speeds of 15 m/s.
Maximum control speeds in signal processing lie between 30

and 70 m/s at operating pressures of between 6 and 8 bar.
With pressures of less than 1 bar it is even possible to obtain
signal speeds of 200 to 300 m/s.
Fully adjustable
Travel speeds and exerted force are fully and easily adjust-
able. Both with linear and rotary movement, force, torque and
speeds can be fully adjusted without difficulty by using throt-
tles.
16
2.2 Pressure ranges
Low pressure range to 10 bar
Most pneumatic applications in industry and the crafts lie in

the low pressure range of 10 bar and below.
Compressors used :
one and two-stage piston compressors
one-stage screw compressors with oil-injection cooling
two-stage compressors
rotary compressors
Compaction pressure in bar
Medium pressure range to 15 bar

High pressure range
HGV and other heavy vehicle tyres are filled with compressed
air from 15 bar compressors. There are also other special
machines that operate with such pressures.
High pressure range Compressors used :

two-stage piston compressors
Medium pressure range one-stage screw compressors ( up to 14 bar )
with oil-injection cooling
Low pressure range

High pressure range to 40 bar
The compressors in this pressure range are generally used

for starting large diesel engines, testing pipelines and flushing
plastic tanks.
Compressors used :
Fig 2.1 :
Pressure ranges two and three-stage piston compressors
multi-stage screw compressors
High pressure range to 400 bar
One example of the use of compressed air in the high pres-

sure range is the storage of breathing air in diving bottles.
High pressure compressors are used in power stations, roll-
ing mills and steel works and for leak testing. Compressors of
this type are also used for compressing utility gases, such as
oxygen.
Compressors used:
three and four-stage piston compressors
17
2.3 Possible applications for Compressed air is used intensively in all sectors of industry,
compressed air the crafts, and everyday life. The range of possible applica-
tions is diverse and all-embracing. Some of the technical uses
are mentioned and explained briefly below.
In view of the versatility of this medium it is only possible to

outline a few of the possible applications. The arrangement of
the chapter can not be unambiguous since the criteria for
assessment and differentiation are too varied.
2.3.1 Tensioning and clamping with Tensioning and clamping with compressed air is mainly used
compressed air in applications involving mechanisation and automation. Pneu-
matic cylinders or motors fix and position the tools needed for
work processes. This can be done by linear and rotary move-
ment, and also by swivel movement. The energy in the com-
pressed air is converted directly into force and movement
through the exertion of pressure. The amount of tensioning
force required must be dispensed with precision.
Fig. 2.2:
Pneumatic-mechanical clamp
2.3.2 Conveyance by compressed air Conveyance by compressed air is found in mechanisation

and automation. In these applications, motors and cylinders
are used for timed or untimed conveyance, or according to
work processes. Automated storage and receipt also belongs
in this category, as does the turn-around of tools and other
items on longer conveyor belts.
Another variation of pneumatic transport is the conveyance of

bulk material and liquids through pipes. With this method,
granulates, corn, powder and small parts can be quickly and
comfortably conveyed over relatively long distances. The pneu-
matic post concept also belongs in this category.
Fig. 2.3:
Bridging the heights with a pneumatically powered
elevator
18
2.3.3 Pneumatic drive systems Pneumatic drive systems are found in all areas of industry
and the crafts. These can perform rotary and linear move-
ments. Linear movement with the aid of cylinders in particular
is seen as a highly economical and rational application. The
utility work is performed by dropping the pressure and chang-
ing the volume of the compressed air.
Pneumatic percussion machinery and tools (e.g., pneumatic

hammers) are of great importance in this category. The en-
ergy in the compressed air is converted into kinetic energy for
a moving piston. Vibrators and jolting devices belong to this
category.
Fig. 2.4:
Valveless pneumatic hammer Pneumatic power is also used by a multitude of valves and
slides, tools, adjustment devices, feed systems and vehicles.
2.3.4 Spraying with compressed air With Spraying applications, the energy of the expanding com-
pressed air is used to force materials or liquids through a spray
nozzle. This procedure is used to apply or atomise various
substances.
Surface treatment processes, such as sand and gravel blast-

ing, shot peening and painting with spray-guns belong to this
category. Concrete and mortar are also applied using this
method.
If high temperatures are also used, compressed air can be

utilised for applying liquid metals. Arc-type spraying is an ex-
Fig. 2.5:
ample worthy of mention here..
Arc-type metal spraying system
Another application is the atomisation of liquids through spray
nozzles, e.g., for spraying weedkillers and insecticides.
2.3.5 Blowing and flushing with When blowing and flushing the compressed air itself is the
compressed air work medium and tool. The flow speed generated by dropping
pressure and/or the expanding volume performs the utility work.
Examples of this type of work are blowing out glass bottles,

blowing out and cleaning tools and moulds, fixing light tools
for processing or conveyance and flushing out metal chips
and residue. Compressed air in this form can also be used to
let off heat.
Fig. 2.6:
Air gun with spiral hose
19
2.3.6 Testing and inspection with In pneumatic testing and inspection procedures, the
compressed air changes in pressure at the measuring point are used to deter-
mine spacings, weights and changes in shape. This allows
passing articles to be counted, correct positioning to be
checked and the presence of workpieces to be ascertained.
This process is an integral part of many sorting, positioning

and processing systems.
Fig. 2.7:
Reflex nozzle with impulse emitter
2.3.7 Using compressed air for process All pneumatic applications must be controlled by some means.
control They must receive instructions.
In general this is done by press-switches, direction valves and

so forth. These control mechanisms are in turn actuated in
many different ways, e.g., by mechanical switches, cams, or
by hand. Electrical and magnetic switches are also in wide-
spread use. The results determined by pneumatic process
control systems can be used directly by direction valves or
press-switches.
Pneumatics is of great importance for checking flow processes

with liquids and gases. It is used for the remote control of
valves, slides, and flaps in large industrial installations.
Pneumatics (fluidics) is also used for information processing

and logical switching. These logic plans are comparable with
integrated electronic circuits. They require much more space,
but are characterised by high operating precision in certain
applications. If the demands on the logic elements are not too
Fig. 2.8: high, fluidics can offer an alternative.
Flow diagram of a BOGE screw compressor, air-
cooled version with fully-adjustable output control
20
2.4 Examples of specialised The following list will give the reader an idea of the many ap-
applications plications of compressed air in industry, the crafts and every-
day life. Obviously, it is not possible to list all the possibilities
for pneumatics since new areas appear and old ones become
disused in the course of development and progress. This can
therefore only be an incomplete summary of typical applica-
tions to be found in the various sectors of the economy.
A list of the typical applications in general mechanical engi-
neering has not been included, since pneumatics touches prac-
tically every area, and mentioning all would be beyond the
scope of this manual.
Construction trade
Drill and demolition hammers ( hand rams )

Concrete compactors
Conveyor systems for brickworks and artificial stone
factories
Conveyor systems for concrete and mortar
Mining
Rock drilling hammers and carriage systems

Loading machinery, shuttle and demolition cars
Pneumatic hammers and chisels
Ventilation systems
Chemicals industry
Raw material for oxidation processes

Process control
Remote-controlled valves, and slides in process circuits
Energy industry
Inserting and withdrawing reactor rods

Remote-controlled valves and slides in steam and
coolant circuits
Ventilation systems for boiler houses
21
Health system
Power packs for dentists drills

Air for respiration systems
Extraction of anaesthetic gases
The crafts
Staplers and nail guns

Paint spray-guns
Drills and screwdrivers
Angle grinders
Wood processing industry
Roller adjustment for frame saws

Drill feed systems
Frame, glue and veneer presses
Contact and transport control of wooden boards
Removal of chips and sawdust from work areas
Automatic pallet nailing
Steel mills and foundries
Carbon reduction in steel production

Jolt squeeze turnover machines
Bundling machinery for semi-finished products
Coolants for hot tools and systems
Plastics industry
Transport of granulate in pipes

Cutting and welding equipment
Blowing workpieces from production moulds
Locking mechanisms for casting moulds
Shaping and adhesive stations
Agriculture and forestry
Plant protection and weed control

Transport of feed and grain to and from silos
Dispensing equipment
Ventilation systems in glasshouses
22
Food and semi-luxury food industry
Filling equipment for drinks

Closing and checking devices
Bulk packing and palleting machinery
Labelling machines
Weighing equipment
Paper-processing industry
Roller adjustment and feed machinery

Cutting, embossing and pressing machinery
Monitoring of paper reels
Textiles industry
Thread detectors
Clamping and positioning equipment in sewing machines
Sewing needle and system cooling
Stacking devices
Blowing out residual material and dust from sewing
Environmental technology
Forming oil barriers in the water

Enriching water with oxygen
Keeping lock gates free of ice
Slide actuation in sewage plants
Increasing pressure in the drinking water supply
Mammoth pump for submarine applications
Traffic and communications
Air brakes in HGVs and rail vehicles

Setting signals, points and barriers
Road-marking equipment
Starting aids for large diesel engines
Blowing out ballast tanks in submarines
23
Compressed air generators
3. Compressed air Compressors (compactors)
generators are engines used for pumping and compressing gases to any
pressure.
Ventilators
are flow machines that pump nearly atmospheric air.
With ventilators only slight changes to density and tempera-

ture occur.
Vacuum pumps
are machines that induct gases and steam in order to create a

vacuum.
3.1 Compressors ( compactors )
3.1.1 Dynamic compressors Dynamic compressors are for instance turbo-compressors, by

( Turbo-compressors ) which running wheels equipped with blades accelerate the
gas to be compressed. Fixed direction gear on the blades
converts speed energy into pressure energy.
Dynamic compressors are to be preferred for

large quantities of medium and low medium
pressures.
3.1.2 Displacement compressors On displacement compressors the compression chamber

closes completely after taking in the air. The volume is re-
duced and the air compressed by force.
Displacement compressors are to be preferred

for small quantities of medium and high me-
dium pressures.
24
Compressed air generators
3.2 Types of compressor The summary shows the compressors divided according to
their operating principle.
With all compressors, a distinction is drawn between non-oil-

lubricated and oil-lubricated compressors.
Compressors ( compactors )
displacement compressors Turbo-compressors
Axial compressor Radial compressor
oscillatory rotary
without multiple-
with crank drive single-shaft
crank drive shaft
piston
compressor
Rotary vane Screw

compressor compressor
Plunger Diaphragm Free-piston

compressor compressor compressor
Crosshead Liquid ring Roots-

compressor compressor compressor
25
Control of compressors
1.1
4.5 Control of several For users of compressed air with high, much fluctuating con-
compressors sumption a single, large compressor is not the best solution.
In these cases, a combined compressor system consisting of
several compressors is much the better alternative. Greater
operating reliability and economy are the aguments in favour
of this.
Organisations that are very dependent on compressed air can

guarantee their supply at all times by a combined compressor
system. If one compressor fails or servicing work is neces-
sary, the other compressors continue the supply.
Several small compressors can be adjusted more easily to

compressed air consumption than one large compressor. The
idling costs of a large compressor are moreover higher than
those of small, stand-by compressors. These facts provide the
greater economy.
A combined compressor is operated economically and low on

wear by a master control system.
4.5.1 MCS 1 and MCS 2 MCS 1 controls 2 compressors of the same size as basic load
and peak load. The compressors are cyclically changed and
switched on and off via their own pressure switches. The con-
trol unit offers:
Cyclic change via a timer.

Time lag cycling of the compressors by the control unit
through pressure graduation.
Even use of compressors.
Constant pressure in the pressure range.
Minimal cycle difference p = 0,8 bar
MCS 2 controls up to 3 compressors of the same size as

Fig. 4.12 :
The BOGE Master Control System 2
basic load, medium load and peak load. The compressors are
cyclically changed and switched on and off via their own pres-
sure switches. The upgrade to 3 compressors and the greater
cycle difference is the only difference to the MCS 1. The fea-
tures are otherwise the same.
Fig. 4.13 :
The circuit diagram of the BOGE MCS 2
60
4.5.2 MCS 3 MCS 3 controls a maximum of 4, 8, or 12 compressors of the

same and/or different size and type in a system. All compres-
sors are controlled by a common pressure sensor on the com-
pressed air receiver.
The MCS 3 has at 0.5 bar a very small cut-in difference. The
individual compressors are not given fixed cut-out and cut-in
pressures. All compressors work in the same pressure range
( p = 0.5 bar ). The compressors cut-in dynamically accord-
ing to requirement via set intermediate pressure values. The
speed of pressure rise and fall is measured. The compres-
sors switch on and off dynamically.
Fig. 4.14 :
The control offers:
Dynamic pressure control by microcontroller in connec-

tion with electronic pressure controllers for a minimum
cut-in difference of 0.5 bar.
( no over-compression energy saving )
Cut-in Cycle
Time dependent allotment of compressors in rank
pressure
[bar]
difference stages for shift operation with differing compressed air
requirement.
Individual assignment of individual compressors to load
range groups, uniform usage of compressors.
Adjustable basic load changeover cycle.
Independent rotation of compressors into the load range
groups.
Fig. 4.15 : Time offset allocation of compressors if demanded by
Circuit diagram of the BOGE MCS 3 the control unit.
Well arranged LCD-display with 4 x 20 characters and
clear text.
Possibility of checking all inlets and outlets via a test-
menu.
Automatic reverting to pressure switches of individual
compressors in the event of voltage loss.
The individual compressors work independently without
the MCS 3. They are then controlled from their own
pressure switches.
61
4.5.3 MCS 4 MCS 4 controls a maximum of 4 or 8 compressors of the same

and/or different sizes and types in a system. All compressors
are controlled by a common pressure sensor at the com-
The basic load with this control unit is normally covered by the
largest compressor or combination of compressors. The small-
est compressor takes the peak load. Compressors of the same
size change over in providing the basic load.
The MCS 4 computes compressed air consumption continu-

ally from programmed compressor performance data and in-
Fig. 4.16 : formation from the pressure sensor. It selects the compressor
The BOGE Master Control System 4 that most closely matches the requirement.
The control offers:

Cut-in Cycle
pressure difference
[bar]
need-oriented use of the various compressors and
compressor combinations.
ideal use of the benefits of screw and piston compressors.
minimal cut-in difference of 0.5 bar.
( no over-compression energy-saving )
three different pressure profiles per day by a timer
programme to adapt the control to differing compressed
Fig. 4.17 : air requirement.
Op. diagram of the BOGE MCS 4
Time adjusted use of compressors on demand by the
control unit.
Well-organised LCD-display with 2 x 20 characters and
clear text output.
Possibility to check all inlets and outlets via a test menu.
Automatic switchover to pressure switches in the event of
voltage loss.
The individual compressors operate independently
without the MCS 4. They are then controlled by their own
pressure switches.
Two potential-free timer contacts for control of additional
components.
62
4.5.4 MCS 5 MCS 5 controls a maximum of 4, 8, or 12 compressors with

infinite output control of the same and/or different size and
construction in a system. All compressors are controlled by a
common pressure sensor on the compressed air receiver. The
peak load compressor controls accordingly the requirement
of compressed air via its infinite output control.
If the compressed air demand drops this compressor switches

off and the medium load compressor takes over via its infinite
output control,dependng on the level of priority.
Fig. 4.18 : Up to their use of infinite control the MCS 3 and MCS 5 are
The BOGE Master Control System 5 similar.
The control unit offers:
Adaptation of FAD to the compressed air demand by

infinite output control by the peak load compressor.
Cut-in Cycle Minimal pressure fluctuations in the pneumatic network.

pressure difference
Dynamic pressure control by microcontroller in conjunc-
tion with the electronic pressure control for a minimum
( no over-compression energy savings )
Time-independent allocation of compressors in level of
priority for shift operation with differing compressed air
demand.
Individual allocation of compressors in the load range
Fig. 4.19 : groups with even usage of compressors.
Op. diagram for the BOGE MCS 5
Adjustable basic load change cycle.
Independent rotation of compressors in the load range
groups.
control unit.
clear text output.
Automatic change to pressure switches of individual
pressure switches.
63
4.5.5 MCS 6 MCS 6 Controls a maximum of 4, 8, or 12 compressors with

speed frequency control of the same, and/or different size and
design/type in a system. All compressors in the system are
controlled through a common pressure sensor on the com-
pressed air receiver. The peak load compressor controls the
compressed air demand via its speed frequency control.
When the compressed air demand falls this compressor

switches off and the medium load compressor takes over the
control through its speed frequency control.
Fig. 4.20 : Apart from the speed frequency control the MCS 3 and the
The BOGE Master Control System 6 MCS 6 systems are similar.
The control system offers:
Adaptation of the FAD to the compressed air demand

through speed frequency control of the peak load com-
pressor.
Cut-in Cycle
pressure
[bar]
difference
Minimum pressure fluctuations in the pneumatic system.
tion with the electronic pressure controller for a minimum
Time-dependent allocation of compressors in priorities
for shift operation with differing compressed air demand.
Fig. 4.21 : Individual allocation of individual compressors in the load

Op. diagram for the BOGE MCS 6 range groups with even work rates among the compres-
sors.
groups.
control unit.
Well-arranged LCD-display with 4 x 20 characters
and clear text output.
Automatic switchover to the pressure switches of indi-
vidual compressors in the event of power failure.
the MCS 6. They are then controlled by their own pres-
sure switches.
64
4.5.6 MCS 7 MCS 7 controls, regulates and monitors a complete pneumatic

station with the Siemens-control S 5 ( S7 ) and the operator
terminal OP 15.
The basic features include:
8 Compressors.
2 Refrigeration compressed air dryers.
2 Adsorption dryers.
10 Bekomats.
2 Potentional-free switch channels for control of addi-
tional devices.
The MCS 7 is available in three versions:

Fig. 4.22 :
Version 1
Version 1 offers an extended software program of MCS 3. It
uses pressure-dependent control of up to 8 or 12 compres-
sors of the same and/or different size by priorities and timer
Cut-in Cycle
pressure difference programmes.
[bar]
Version 2

sors of the same and/or different size with infinite output con-
trol.
Version 3
Fig. 4.23 :
Op. diagram for the BOGE MCS 7 Version 3 offers an extended software program of MCS 6. It
sors of the same and/or different size with speed frequency
control.
In addition to the basic individual software functions the con-

trol offers:
Recording of the operating status of the compressors

and additional components of the compressor station.
Storage of operating, warning and malfunction mes-
sages. This makes servicing and repair of the compres-
sor system much simpler.
Control and monitoring of the compressed air treatment
components and the pneumatic system.
BUS-coupling with Profibus ( optional )
This allows connection to a central control facility.
System visualisation in master control equipment (optional)
Comprehensive information can be obtained about the
entire compressed supply.
65
Compressed air treatment
5. Compressed air treatment
5.1 Why treatment ? Modern production equipment needs compressed air. The
many conditions in which it is used range from untreated blow-
ing air to absolutely dry, oil-free and sterile compressed air.
The impurities in our atmosphere are usually invisible to the

naked eye. But they can seriously impede the reliable opera-
tion of a pneumatic system and consumer devices, and have
an adverse effect on the quality of products.
1 m3 of atmospheric air contains many impurities such as
Up to 180 million particles of dirt.

These are between 0.01 and 100 m in size.
5 - 40 g/m Water in the form of atmospheric humidity.
0.01 to 0.03 mg/m3 Oil in the form of mineral oil aerosols
and unburnt hydrocarbons
Traces of heavy metals such as lead, cadmium, mercury,
iron.
Compressors draw in atmospheric air and the impurities they

contain and concentrate them many times. At compression
of 10 bar-op ( 10 bar over-pressure = 11 bar absolute ) the con-
centration of impurities rises by 11 times. In 1 m3 compressed
air there will then be up to 2 billion particles of dirt. Lubrication
oil and scuff also passes from the compressor in the com-
pressed air.
Correct treatment of compressed air brings benefits :
Increased working life of consumer devices.

Improved and consistent product quality.
Pneumatic lines free of condensate and rust.
Fewer malfunctions.
Pipelines without condensate collectors.
Lower servicing outlay.
Fig. 5.1 :
Concentration of impurities in the air during com- Lower pressure loss from leakage and flow resistance.
pression Lower energy consumption due to lower pressure loss.
66
5.1.2 Planing information BOGE recommends the processing described on this page
for the various applications of compressed air.
Refrigeration dryer
*)
Active carbon filter

Area of application Quality
Adsorption dryer
Membrane dryer
of compressed air classes
Dust separator
Active carbon
Compressor
Sterile filter
DIN ISO 8573-1
Microfilter
absorber
Prefilter
prefilter
Particle
Water
Oil
General air
Blowing air
Sand blasting 3
Simple varnishing work 3
General works air 5 3 4

Conveyance air 5 3 4
BOGE screw and piston compressors
Simple spray painting 5 3 4

Sandblasting with higher
quality requirements 5 3 4
Pneumatic tools 1 1 4
Control air 1 1 4
Process control eqpt. 1 1 4
Spray painting 1 1 4
Conditioning 1 1 4
Fluid elements 1 1 4
Dental laboratories 1 1 4
Photo laboratories 1 1 4
Breathing air 1 1 1-3

Instrument. air 1 1 1-3
Pneumatics 1 1 1-3
Spray painting with higher
quality requirements 1 1 1-3
Surface treatment 1 1 1-3
Medical equipment 1 1 3-4

Conveyance air with higher
Food and luxury
food industry 1 1 3-4
Breweries 1 1 1-3
Dairies 1 1 1-3
Pharmaceuticals industry 1 1 1-3
*) The dust separator is not required under certain circumstances.

The quality classes are explained on page 5.12 .
67
5.1.3 Consequences of poor treatment If the impurities and water from atmospheric air remain in the
compressed air the consequences can be unpleasant. This
applies to the pipeline and the consumer devices, and prod-
ucts can also suffer if the quality of compressed air is poor. In
some applications the use of compressed air without adequate
treatment is dangerous and a health hazard.
Solid matter particles in compressed air
Wear on pneumatic systems.

Dust and other particles cause scuff. This effect is increased
if the particles combine with lubricating oil or grease to form
a grinding paste.
Particles that are hazardous to health.
Chemically aggressive particles.
Oil in the compressed air
Old and different oil in the pneumatic system.

Resinified oil can reduce pipe diameters and cause block-
ages. This increases flow resistance.
Oil-free compressed air.

With pneumatic conveyance, oil can stick to the product
being conveyed and thus cause blockages.
In the food and pharmaceutical industries compressed air
must be free of oil for health reasons.
Water in the compressed air
Corrosion in the pneumatic system.

Rust forms in the pipelines and operating elements and
causes leaks.
Gaps in lubricant films.

Gaps in lubricant films lead to mechanical defects.
Formation of electrical elements.

Electrical elements can form when some metals come in
contact with water.
Formation of ice in the pneumatic network.

In low temperatures water in the network can freeze and
cause frost damage, reduce pipe diameter and block pipes.
68
5.1.3 Impurities in the air In our atmosphere there are particles of dirt that are not vis-
ible to the naked eye. This chapter contains a general sum-
mary of the type, size and concentration of these particles.
Concentration of particles Limits Average values

3
in atmospheric air [ mg/ m ] [ mg/ m3 ]
In the country 5 - 50 15
In the town 10 - 100 30
In an industrial area 20 - 500 100
In large factory plants 50 - 900 200
Particle diameter [ m ]
69
5.2 Water in the compressed air
5.2.1 Atmospheric humidity There is always a certain amount of moisture in the atmos-
phere. This is known as atmospheric humidity and its content
varies depending on the time and place. At any temperature
a certain volume of air can only contain a maximum quantity
of moisture. However, atmospheric air usually contains less
than this maximum amount.
Maximum humidity humax [ g/m3 ]
Maximum humidity hu max ( saturation quantity ) means the

maximum quantity of moisture that 1 m air can hold at a cer-
Maximum humidity humax [ g /m3 ]
tain temperature. The maximum humidity does not depend on

pressure.
Absolute humidity hu [ g/m3 ]
Absolute humidity hu means the actual quantity of moisture

held by 1 m air.
Relative humidity [ % ]
Relative humidity means the ratio of absolute to maximum

humidity.
hu
= 100 %
hu max
= relative humidity [%]

Dew point[ C ] hu = absolute humidity [ g/m 3 ]
humax = maximale humidity [ g/m 3 ]
Fig. 5.2 :
Maximum humidity
depending on dew point
Since maximum humidity humax depends on the temperature
the relative humidity changes with the temperature, even if
the absolute humidity remains constant. On cooling to dew
point, the relative humidity rises to 100 %.
70
5.2.2 Dew points Atmospheric dew point [ C ]
Atmospheric dew point means the temperature to which at-

mospheric air ( 1 bar abs ) can be cooled without precipita-
tion.
The atmospheric dew point is of minor importance for pneu-

matic systems.
Pressure dew point [ C ]
The pressure dew point means the temperature to which com-

pressed air can be cooled without precipitation of conden-
sate. The pressure dew point depends on the final compres-
sion pressure. If pressure drops, the pressure dew point drops
with it.
5.2.3 Air moisture content The following table shows the maximum air humidities at cer-
tain dew points:
dew max. dew max. dew max. dew max. dew max. dew max. dew max.
point humidity point humidity point humidity point humidity point humidity point humidity point humidity
[ C ] [ g/ m3 ] [ C ] [ g/m3 ] [ C ] [ g/m3] [ C ] [ g/m3] [ C ] [ g/m3 ] [ C ] [ g/m3] [ C ] [ g/m3]
+100 588,208 +76 248,840 +52 90,247 +28 26,970 +4 6,359 -19 0,960 -43 0,083
+99 569,071 +75 239,351 +51 86,173 +27 25,524 +3 5,953 -20 0,880 -44 0,075
+98 550,375 +74 230,142 +50 82,257 +26 24,143 +2 5,570 -21 0,800 -45 0,067
+97 532,125 +73 221,212 +49 78,491 +25 22,830 +1 5,209 -22 0,730 -46 0,060
+96 514,401 +72 212,648 +48 74,871 +24 21,578 -23 0,660 -47 0,054
0 4,868
+95 497,209 +71 204,286 +47 71,395 +23 20,386 -24 0,600 -48 0,048
+94 480,394 +70 196,213 +46 68,056 +22 19,252 -1 4,487 -25 0,550 -49 0,043
+93 464,119 +69 188,429 +45 64,848 +21 18,191 -2 4,135 -26 0,510 -50 0,038
+92 448,308 +68 180,855 +44 61,772 +20 17,148 -3 3,889 -27 0,460 -51 0,034
+91 432,885 +67 173,575 +43 58,820 +19 16,172 -4 3,513 -28 0,410 -52 0,030
+90 417,935 +66 166,507 +42 55,989 +18 15,246 -5 3,238 -29 0,370 -53 0,027
+89 403,380 +65 159,654 +41 53,274 +17 14,367 -6 2,984 -30 0,330 -54 0,024
+88 389,225 +64 153,103 +40 50,672 +16 13,531 -7 2,751 -31 0,301 -55 0,021
+87 375,471 +63 146,771 +39 48,181 +15 12,739 -8 2,537 -32 0,271 -56 0,019
+86 362,124 +62 140,659 +38 45,593 +14 11,987 -9 2,339 -33 0,244 -57 0,017
+85 340,186 +61 134,684 +37 43,508 +13 11,276 -10 2,156 -34 0,220 -58 0,015
+84 336,660 +60 129,020 +36 41,322 +12 10,600 -11 1,960 -35 0,198 -59 0,013
+83 324,469 +59 123,495 +35 39,286 +11 9,961 -12 1,800 -36 0,178 -60 0,110
+82 311,616 +58 118,199 +34 37,229 +10 9,356 -13 1,650 -37 0,160 -65 0,00640
+81 301,186 +57 113,130 +33 35,317 +9 8,784 -14 1,510 -38 0,144 -70 0,00330
+80 290,017 +56 108,200 +32 33,490 +8 8,234 -15 1,380 -39 0,130 -75 0,00130
+79 279,278 +55 103,453 +31 31,744 +7 7,732 -16 1,270 -40 0,117 -80 0,00060
+78 268,806 +54 98,883 +30 30,078 +6 7,246 -17 1,150 -41 0,104 -85 0,00025
+77 258,827 +53 94,483 +29 28,488 +5 6,790 -18 1,050 -42 0,093 -90 0,00010
71
5.2.4 Quantity of condensate Air contains water in the form of moisture. Since air can be
during compression compressed and water can not, when air is compressed the
water precipitates in the form of condensate. The maximum
humidity of the air depends on temperature and volume. It
does not depend on quantity.
Atmospheric air can be imagined as a moist sponge. It can

take in a certain amount of water when it is relaxed. But if it is
squeezed, part of the water runs out. Some of the water will
always stay in the sponge regardless of how hard it is squeezed.
Compressed air is very similar.
The following examples illustrate the quantity of condensate

to be expected qc when air is compressed. The example as-
Fig. 5.3 :
sumes a humid Summer day with 35 C and 80 % atmospheric
A wet sponge being squeezed humidity.
V1 humax 1 1 V2 humax 1 2
qc = -
100 100
6,5 39,286 80 0,59 39,286 100

qc = -
100 100
m g / m % m g / m %
qc = -
% %
qC qc = 181,108 g
V1 = 6,5 m3 V2 = 0,59 m3
p1 = 0 bar-op = 1 bar abs p2 = 10 bar-op = 11 bar abs
T = 35 C T = 35 C qc = precipitated condensate [g]
1 = 80 % 2 = 100 % V1 = Volume at 0 bar-op [ m3 ]
hu max = 39,286 g/ m3 V2 = Volume at 10 bar-op [ m 3]
humax 1 = max. humidity at 35 C [ g/m3 ]

Fig. 5.4 :
Precipitation of condensate during compression 1 = relative humidity of V 1 [%]
2 = relative humidity of V 2 [%]
Because the water that comes out of the compressed air is

the part the air can not store, the humidity of the compressed
air rises to 100 %.
When compressing 6,5 m 3 air to 10 bar pressure, at a con-

stant temperature 181,108 g water will precipitate in the
form of condensate.
72
5.2.5 Example An example shows the amount of condensate qc that actually

for calculating quantities of occurs when air is compressed. It is to be noted that the con-
condensate densate occurs at several points of the compressor station
and at different times.
The task here is to calculate the occurrence of condensate on

a screw compressor with an output of V = 2 720 m/h and a
final compression pressure of pop = 10,5 bar. Connected in
series to the compressor are a compressed air tank and a
refrigeration compressed air dryer.
Ambient air The atmospheric air contains a certain amount of water under
these conditions:
V 1 = 2 720 m/h
p1 =1 bar abs
T1 = 33 C
qw = V 1 humax 1 1 /100
1 = 80 %
humax 1 = 35,317 g/m g/h = m/h g/m %/%
qw = 2 720 35,317 80/100

^ 76,85 l/h
qW = 76 849,79 g/h =
Compressor During the compression process, the temperature rises above

the pressure dew point of the compressed air, and therefore
p2 = 11,5 bar abs no moisture will precipitate. In the aftercooler of the compres-
T2 = 40 C sor the compressed air is cooled down to T 2 = 40 C. The first
2 = 100 % condensate occurs and is taken with the air into the com-
pressed air receiver. The volume flow calms down and the
humax 2 = 50,672 g/m
droplets of water precipitate. A considerable amount of con-
densate collects there:
V1
V 2 = = 236,5 Bm3/h
P2

qc1 = qW ( V 2 humax 2 2 /100 )
qc1 = 76 849,79 ( 236,5 50,672 100/100 )
qc1 = 64 865,86 g/h ^

= 64,87 l/h
V = 236,5 m3/h qc1
Refrigeration compressed After this the compressed air is cooled down in the refrigera-
air dryer tion compressed air dryer to a temperature corresponding
to a pressure dew point of 3 C. The condensate precipitates
p3 = 11,5 bar abs in the dryer and is drained off.
T3 = 3 C
3 = 100 %
qc2 = ( V 2 humax 2 ) ( V 2 humax 3 )
qc2
humax 3 = 5,953 g/m
qc2 = ( 236,5 50,672 ) ( 236,5 5,953 )

V 2 = 236,5 Bm3/h qc2 = 10 576,04 g/h ^
= 10,58 l/h
Fig. 5.5 :
Condensate precipitation when compressing with a
dryer
73
In addition to the individual flows of condensate, there is also

the quantity of condensate that needs to be dealt with by the
condensate treatment equipment.
Condensate quantity qc = qc1 + qc2
Condensate quantity qc = 75441,9 g/h

= 75,4 l/h
With 3-shift operation working at 100 % efficiency the com-

pressor is running 24 hrs. per day. This means, with the basic
Fig. 5.6 : assumptions unchanged:
Approx. 8 10 l buckets of condensate precipitate in
24 hours Condensate quantity qcD = 1810605,6 g/D
= 1810,6 l/D
The following quantity of condensate will then occur in one

year:
Condensate quantity qcY = 659 060 438 g/Y

= 659 060 l/Y
5.2.6 Quantity of condensate on a humid The quality of compressed air must always remain the same if
Summer day the surrounding conditions are unchanged. i.e., the pres-
sure dew point of the compressed air must be 3C even on a
humid Summer day with an air temperature of 40 C and 90 %
atmospheric humidity.

FAD V 1 = 2 720 m/h
Inlet pressure p1 = 1 bar abs
Inlet temperature T1 = 40 C
Relative humidity 1 = 90 %
Pressure dew point T3 = 2 C
Under these conditions the quality of compressed air remains

constant but the quantity of condensate is much higher.
Condensate quantity qc = 122,6 l/h

assumptions unchanged:
Condensate quantity qcD = 2 943,3 l/D

year:
Condensate quantity qcY = 1 071 358 l/Y
74
5.2.7 Determining the pressure dew The pressure dew point means the temperature to which the
point compressed air can be cooled without condensate precipi-
tating. The pressure dew point depends on the final compres-
sion pressure. If the pressure drops, the pressure dew point
drops with it.
The following diagrams are used to determine the pressure

dew point of the compressed air after compression:
sure
pres
sion
re
pres
tu
ra
lcom
pe
m
Example2
Fina
te
let
In
Example1
Relative humidity [ % ] Pressure dew point [ C ]
Example 1 Example 2
Intake air Intake air

relative atmospheric humidity = 70 % relative atmospheric humidity = 80 %
inlet temperature T = 35 C inlet temperature T = 35 C
Compressed air Compressed air
Final compression pressure pop = 8 bar Final compression pressure pop = 10 bar
The pressure dew point is approx. 73 C The pressure dew point is approx. 82 C
75
5.2.8 Pressure dew point after removal When compressed air relaxes (pressure released) the pres-
of pressure sure dew point drops. The following table is used to determine
the new pressure dew point and atmospheric dew point after
relaxation:
max. humidity [ g/m3 ]
]
op
ar-
[b
Example1
op
p
re
su
res
erp
Ov
Example 2
Atmospheric dew point [ C ]
Example 1 Example 2

pop = 35 bar air pressure pop = 7 bar air pressure
Pressure dew point 10 C Pressure dew point 20 C
relaxed compressed air relaxed compressed air
pop = 4 bar air pressure atmospheric air pressure pop = 0 bar
The new pressure dew point is approx. -23 C The atmospheric dew point is approx. -8 C
76
5.3 Compressed air quality
5.3.1 Quality classes defined in The quality classes for compressed air defined in DIN ISO
DIN ISO 8573-1 8573-1 make it easier for the user to set his requirements and
choose the equipment he needs to treat the air. The norm is
based on makers specifications giving defined limits for their
equipment and machinery pertaining to purity of compressed
air.
The DIN ISO 8573-1 norm defines quality classes for com-
pressed air according to:
Oil content
Definition of the residual quantity of aerosols and hydrocar-
bons contained in the compressed air.
Particle size and density

Definition of the size and concentration of solid matter parti-
cles that may remain in the compressed air.
Pressure dew point

Definition of the temperature to which the compressed air
can be cooled without condensation of the moisture it con-
tains. The pressure dew point changes with the air pressure.
Class max. oil content max. residual dust content max. residual water content
particle size particle density res. water press. dew point
[ mg/ m3] [ m ] [ mg/ m3] [ g/ m3 ] [ C ]
1 0,01 0,1 0,1 0,003 -70

2 0,1 1 1 0,117 -40
3 1 5 5 0,88 -20
4 5 15 8 5,953 +3
5 25 40 10 7,732 +7
6 9,356 +10
77
5.4 Methods of drying The summary presents the methods of drying compressed
air according to their principle of operation. A distinction is
always made between condensation, sorption and diffusion.
Condensation is the separation of water by going below the

dew point.
Sorption is drying by removal of moisture.
Diffusion is drying by molecular transfer.
Process of drying compressed air
Over-compression
Condensation
Refrigeration drying
Diffusion Membrane drying
Solid dryers
Absorption Soluble dryers
Liquid dryers
Sorption
Cold regeneration
Int. heat regeneration
Adsorption
Ext. heat regeneration
Vacuum regeneration
78
5.4.1 Operating conditions The through-flow rate of a dryer refers to the intake rate of
air during compression by a compressor according to PN2
CPTC2, ISO 1217 ( DIN 1945 Part 1 ).
Intake pressure p = 0 barop ^ 1 barabs

=
Intake temperature T0 = 293 K ^ 20 C
=
Drying equipment is designed according to DIN ISO 7183 for

certain operating conditions. The performance data given for
the equipment is only correct under these conditions:
Operating pressure p = 7 barop ^ 8 barabs

=
Ambient temperature tA = 298 K ^ 25 C
=
Entry temperature tEn = 308 K ^ 35 C
=
If a dryer is used under different operating conditions, appro-

priate conversion factors must be taken into account. These
factors differ in the various drying processes.
Example for the layout of a refrigeration compressed air

dryer
Conversion factors for operating conditions and ambient tem-

perature:
Op. pressure p [ barop ] 2 3 4 5 6 7 8 9 10 11 12 14 16
Factor f 0,62 0,72 0,81 0,89 0,94 1 1,04 1,06 1,09 1,1 1,12 1,15 1,17
Ambient temperature tA [ C ] 25 30 35 40 43
Factor t 1,00 0,92 0,85 0,79 0,75
A BOGE refrigeration compressed air dryer, model D8, has a

through-flow rate R of 45 m3/h. It is operated at an average
ambient temperature of t A = 40 C and an operating pressure
of p = 10 barop.
R = 45 m3/h
RAd = R f t
p = 10 barop f = 1,09
RAd = 45 m3/h 1,09 0,79
tA = 40 C t = 0,79
RAd = 38,75 m3/h
RAd = Adjusted through-flow rate [ m3/h ]
R = Through-flow rate [ m3/h ]
f = Conversion factor for p = 10 barop
t = Conversion factor for t A = 40 C
With changed operating conditions the dryer has through-flow

rate of 38,75 m 3/h.
79
5.4.2 Condensation With over-compression the air is compressed far beyond the
by over-compression necessary pressure, and afterwards cooled and relaxed to
operating pressure.
Pressure Operating Volume Entry

dew point pressure flow temperature Operating principle
[C] [ barop ] [ m3/h ] [C]
With rising pressure and thus reduced volume the air is able
approx. -70 Depends on Depends on to hold less water. During pre-compression at high pressure
C compressor compressor a large amount of condensate precipitates. The absolute
humidity of the air goes down. If the compressed air is now
relaxed, the relative humidity drops and with it the dew point.
Example:
Compressed air is pre-compressed to 36 bar. The dew point

is 10 C. The condensate precipitates. After relaxation to 4 bar
the compressed air has a new pressure dew point of approx.
- 23 C.
( see chapter 5.2.7 example 1 )
mK
Features
p = 1 bar p = 36 bar p = 4 bar
Simple process with continuous volume flow.
Fig. 5.7 : No expensive refrigeration and drying equipment.
Over-compression with subsequent relaxation
Only economical for small output quantities.
Very high energy consumption.
80
5.4.3 Condensation When the temperature falls, air loses its ability to hold water.
by refrigeration drying To reduce the moisture content, compressed air can be cooled
down in a refrigeration dryer.
Pressure Operating Through- Entry tem- Refrigeration drying is a process by which compressed air is
dew point pressure flow rate perature cooled down by a dryer in a heat exchanger. The moisture
[C] [ barop ] [m3/h ] [C] contained in the air precipitates in the form of condensate.
The quantity of condensate that precipitates rises with the
to - 2 C to 210 11-35 000 to +50 C difference between the entry and exit temperature of the com-
pressed air.
Dry compressed air Operating principle
Moist compressed air Refrigeration drying runs in two phases. This is done to im-
3
prove effectiveness and to obtain maximum use of the refrig-
1
erant.
2 1st Phase
Inside an air/air heat exchanger the compressed air already

cooled by the refrigeration dryer cools new air flowing in. 70 %
of the moisture contained in the air precipitates here in the
form of condensate.
4
2nd Phase
The compressed air flows through a refrigerant/air heat ex-

changer and cools down almost to freezing point. The precipi-
tated condensate is directed off before re-heating in the first
cooling phase.
Features:
6 4 Highly economical.
Refrigeration drying is the most economical process in
5 approx. 90 % of all applications.
Separation of impurities.
1 = Air/Air heat exchanger Almost 100 % of all solid particles and water droplets
2 = Air/refrigerant heat exchanger larger than 3 m are separated.
3 = Refrigerant/air heat exchanger Lower pressure loss in the dryer.
4 = Condensate drain The pressure loss p from the dryer is approx. 0,2 bar.
5 = Refrigerant compressor
6 = Vapour outlet
Fig. 5.8 :
Op. diagram of a refrigeration compressed air dryer
81
5.4.4 Diffusion The principle of the membrane dryer is based on the fact that
by membrane drying water penetrates a specially coated hollow fibre 20 000 times
faster than air.
Pressure Operating Through- Entry tem- The membrane dryer consists of a bundle of thousands of
dew point pressure flow rate perature coated hollow fibre membranes. These hollow fibres are made
[C] [ barop ] [ m3/h ] [C] of a solid, temperature and pressure-resistant plastic. Their
inside surface is coated with an ultra-thin (less than the length
0 to -20 C 5 -12,5 11 - 130 2 to 60 C
of a light wave) coating of a second plastic. The hollow fibres
( membranes ) are installed in a pipe where the inner channel
of the fibres is open at the end.
Moist air
Operating principle
The moist compressed air flows through the inside of the hol-
low fibres ( internal flow ). The moisture contained in the air
penetrates through the layer of coating on the hollow fibres
Moist towards the outside. To do this a concentration gradient of
flushing air moisture is required between the inside and outside of the
hollow fibres.
Inside flow
A quantity of air for flushing is taken from the main volume
Water flow of the compressors and relaxed (decompressed). Since
the maximum air humidity depends on volume, the relative air
humidity drops. The flushing air becomes very dry. The flush-
ing air flows around the hollow fibres and provides the neces-
sary concentration gradient of moisture. The flushing air can
escape unfiltered into the open.
Dry flushing
air
Features
Low level of particles in the air.

A filter must always be connected upstream of the mem-
brane dryer, in order to filter out particles up to a size of
0.01 m. If installed directly downstream of the compres-
Dry air sor, the filter should be connected to dust separator.
Low pressure loss in the dryer.
Fig. 5.9 : The pressure loss p from the dryer is max. 0.2 bar.
The principle of a membrane dryer
Compact construction.
The dryer can be installed as a component of the pipeline.
No servicing.
There are no moving parts in the dryer.
No precipitation of condensate during drying
No additional energy costs.
Silent.
No fluorocarbons.
No moving parts.
No motor.
82
5.4.5 Sorption by Absorption With absorption drying the moisture is separated by a chemi-
cal reaction with a hygroscopic drying agent. Since the ab-
sorption properties of the drying agent diminish over time, pe-
riodic renewal is necessary.
There are 3 different types of drying agent. The soluble agents

Pressure Operating Through- Entry tem-
liquify with increased absorption. The solid and liquid agents
dew point pressure flow rate perature
react with the moisture without changing their aggregate sta-
[C] [ bar op ] [ m3 /h ] [C]
tus.
Depends on to 30 C
entry
temperature
Drying agent
Solid Soluble Liquid
1 Dehydrated Lithium chloride Sulphuric acid

chalk
oversour Calcium chloride Phosphoric acid
2 magnesium salt
Glycerine
Triethylene glycol
Operating principle
1
During absorption the compressed air flows upwards through
4 a drying middle bed. During this it gives up some of its mois-
3 ture to the drying agent. A drain directs the condensate to a
floor tank. The pressure dew point is lowered by 8 - 12 %.
Example
1 = Screen
Compressed air enters a dryer operating with calcium chlo-
2 = Solid drying agent
ride at a temperature of + 30 C. The pressure dew point
3 = Cover
achieved here is between 18 and 22 C.
4 = Condensate drain
Fig. 5.10 :
Absorption dryer with solid drying agent Features
Low entry temperature.

High temperatures soften the drying agent and bake it
together.
Very corrosive drying agents.
The dried compressed air can take drying agent with it
into the pneumatic system. This can cause considerable
damage.
No input of outside energy.
Due to its properties, absorption drying has only become

established in fringe applications of pneumatic engineering.
One example of this is its use for compressed treatment air in
laboratories.
83
5.4.6 Sorption by Adsorption Drying compressed air by adsorption is a purely physical proc-
ess. The moisture is bound to the drying agent by force of
adhesion ( unbalanced molecular attraction ). The moisture stays
on the inner and outer surfaces of the adsorption material with-
out a chemical reaction taking place.
The adsorption material has an open porous structure and a

large inner surface. The most common adsorption materials
are aluminium oxide, silicagel, active carbon and molecular
screens. Different adsorption materials are used for the vari-
ous regeneration processes.
Adsorption material Properties of Adsorption material *)
Obtainable Entry Regeneration Surface

press. dew point temperature temperature
[C] [C] [C] [ m2/g ]
Silicagel ( SiO2 ), raw - 50 + 50 120 - 180 500 - 800
Silicagel ( SiO2 ), spherical -50 + 50 120 - 180 200 - 300
Activated - 60 + 40 175 - 315 230 - 380

Aluminium oxide ( Al2O3 )
Molecular screens - 90 + 140 200 - 350 750 - 800

( Na, AlO2, SiO2 )
*) The properties of the adsorption material change with the pressure and temperature of the gas to be dried
Operating principle
During the drying process the moist compressed air flows

through an adsorption tank. The moisture is bound, which dries
the compressed air. This process generates heat. The adsorp-
tion material must be regenerated when the adhesive forces
are balanced by water deposits. This means that the water
must be removed from the adsorption material. For this rea-
son there must be two parallel drying tanks with continual
operation. The active tank A dries the compressed air, while
the inactive tank B regenerates without pressure.
The following processes are mainly used to regenerate the

A B adsorption material :
cold regeneration
internal hot regeneration
external hot regeneration
vacuum regeneration
84
5.4.6.1 Cold regeneration With cold regeneration the drying and regeneration time is
around 5 min. For this reason the moisture only deposits on
the outer surface of the drying agent.
dew point pressure flow rate perature Cold regeneration adsorption dryers operate according to the
[C] [ barop ] [ m/h ] [C] pressure alternation process. With this method the desorption
( regeneration ) takes place without additional input of heat. A
to - 70 C 4 - 16 4 - 5600 to + 60 C part of the dried volume flow is branched off. This part-flow
relaxes to a pressure of just over 1 bar and is thus extremely
dry. This dry air then flows through the regeneration drying
tank B. In this process it takes on the moisture stored in the
drying agent and directs it out into the open through an outlet
valve.
Features
Fig. 5.11 :
Adsorption material after 5 min. drying time Economical on smaller systems with low volume
flows.
Simple dryer construction.
2 3 2 Dry compressed air Can be used at high ambient temperatures.
Low volume of drying agent.
Drying and regeneration times approx. 5 min.
High operating costs.
The regeneration air is taken from the pneumatic system
6 and can not be used further .
Regeneration without outside energy.
The percentage ratio of regeneration air to the output of
the compressor falls with a higher final compression pres-
sure.
A B
Final comp. Ratio of regeneration air [ % ]
Regeneration
pressure Press. dew point Press. dew point
air
[ barabs ] -25 to - 40 C - 40 to -100 C
5 25,83 27,14
5 7 17,22 18,1
10 11,49 12,07
15 7,39 7,77
20 5,46 5,47
4 1 These values are physically fixed and it is not possible to

Moist compressed air go below them. They are taken from the correlation be-
tween air moisture and compressed air pressure relief.
1 = Valve block Prefiltration of intake air.
2 = Non-return valve A prefilter removes most of the oil, water droplets and par-
3 = Perforated cover ticles of dirt.
4 = Outlet valve
Postfiltration of dried compressed air.
5 = Pre-filter
Drying material taken with the compressed air from the
6 = After-filter
drying tank must be filtered out.
Fig. 5.12 :
Op. diagram of an adsorption dryer,
cold regeneration
85
5.4.6.2 Internal hot regeneration With hot regeneration the drying and regeneration times are
around 6 - 8 hrs. During the long drying time the moisture
deposits on the inner and outer surfaces of the adsorption
Pressure Operating Through- Entry tem- material. To reverse this process heat must be brought from
dew point pressure flow rate perature outside. If the regeneration temperature of the drying material
[C] [ barop ] [ m3/h ] [C] is exceeded by heat from outside, the surface energies that
occur outweigh the adhesive forces in the drying material and
to - 40 C 2 - 16 200 - 5600 to + 50 C the water evaporates. A small flow of regeneration air drains
off the moisture.
The regeneration temperature depends on the pressure dew

point of the regeneration air. The lower it is, the lower the re-
generation temperature of the dryer.
Fig. 5.13 :
Adsorption material after 6 - 8 hrs drying time With internal regeneration the heat is transmitted directly
from a heater in the drying tank to the adsorption material.
This happens in two phases:
Dry compressed air
1st Phase
4
Drying tank B is slowly heated by the internal heating to the
2 necessary regeneration temperature. If the regeneration tem-
3 perature is exceeded, the moisture releases itself from the
adsorption material. Approx. 2 - 3 % of the dried flow of com-
5 pressed air from the compressor relaxes and at slight pres-
9
sure is directed through a diversion line through drying tank B.
This flow of regeneration air absorbs the moisture and directs
it out into the open through an outlet valve.
2nd Phase
A B In a cooling phase the operating pressure drops back to the
temperature of the drying bed. A second diversion line opens
for this purpose. Approx. 5 % of the compressor FAD is directed
through drying tank B. The internal heating is no longer oper-
ating at this point.
1
8
Features
6
7 Economical with high volume flows.
Regeneration
air Little dried compressed air is required to regenerate the
Moist compressed air dryer.
Prefiltration of intake air.
1 = Valve block A pre-filter removes most of the oil, water droplets and dirt
2 = Non-return valve particles from the compressed air.
3 = Diversion line with perf. cover 1st Phase Postfiltration of dried compressed air.
4 = Diversion line with perf. cover 2nd Phase Drying materials taken with the compressed air from the
5 = Heating drying tank must be filtered out of the compressed air.
6 = Stop valve
7 = Outlet valve
8 = Prefilter
9 = After-filter
Fig. 5.14 :
86
5.4.6.3 External hot regeneration With hot regeneration the drying and regeneration times are
Pressure Operating Though Entry tem- material. To reverse this process heat must be brought from
off the moisture.

With external regeneration air is drawn in from the atmos-

phere by a fan and heated in a heating register. This happens
Fig. 5.15 :
in three phases:
Adsorption material after 6 - 8 hrs drying time
1st Phase
The drying tank B is slowly heated to the necessary rege-
2 3 Dry compressed air neration temperature by the flow of hot air. Once the rege-
7 neration temperature is reached, the water releases itself from
the Adsorption material. The fan continues to supply hot rege-
4 neration air through drying tank B. This flow of regeneration
5 air takes on the moisture and transports it into the open through
an outlet valve.
9 2nd Phase
In a cooling phase the operating temperature drops back to
the temperature of drying tank B. For this purpose the heating
register of the fan is switched off and cold air from the atmos-
phere is directed through the drying tank.
A B
3rd Phase
At the end of cooling, dry, relaxed compressed air flows from
the compressor and through the drying tank, in order that the
atmospheric does not bring moisture back into the dryer.
8
Regeneration Features
air
Economical with high volume flows
1 6 Higher regeneration temperatures allow a lower pressure
Moist compressed air dew point.
1 = Bottom valve block Low additional consumption of compressed air.
2 = Top valve block Only a small part of the regeneration air is taken from
3 = Diversion line with perf. cover 3rd Phase the pneumatic system.
4 = Heating register Prefiltration of inlet air.
5 = Fan A pre-filter removes most of the oil, water droplets and dirt
6 = Stop valve particles from the compressed air.
7 = Non-return valve
8 = Prefilter
Drying materials taken with the compressed air from the
9 = After-filter
drying tank must be filtered out of the compressed air.
Fig. 5.16 :
87
5.4.6.4 Vacuum regeneration Vacuum regeneration is a variation of external hot regeneration.

As with hot regeneration the drying and regeneration times
are around 6 - 8 hrs. During the long drying time the moisture
Pressure Operating Through- Entry tem- deposits on the inner and outer surfaces of the adsorption
dew point pressure flow rate perature material. To reverse this process heat must be brought from
[C] [ barop ] [ m3/h ] [C] outside. If the regeneration temperature of the drying material
is exceeded by heat from outside, the surface energies that
to - 80 C 4 - 16 bar 400 - 7400 to + 40 C occur outweigh the adhesive forces in the drying material and
the water evaporates. A small flow of regeneration air drains
off the moisture.

Fig. 5.17 : With vacuum regeneration atmospheric air is drawn with a

Adsorption material after 6 - 8 hrs drying time partial vacuum into the drying tank. This flow of air heats ex-
ternally. Vacuum regeneration occurs in two phases.
3 2 Dry compressed air 1st Phase

A vacuum pump draws in air from the outside. This flow of air
5 is heated by a heating register and drawn through the drying
tank. Once the regeneration temperature is reached, the wa-
6 ter releases itself from the Adsorption material. The flow of
regeneration air takes on the moisture and transports it into
the open through an outlet valve.
8
2nd Phase
the temperature of the drying tank. For this purpose the heat-
A B ing register is switched off and cold air from the atmosphere is
directed through the drying tank.
Features

7 No additional compressed air consumption.
Regeneration No compressed air is taken from the system for regen-
air eration.
Long utility time of drying agent.
1 4 Thermal stress on the drying agent is low.
Energy savings through lower regeneration temperature.
Moist compressed air
Prefiltration of inlet air.
1 = Bottom valve block A pre-filter removes most of the oil, water droplets and dirt
2 = Top valve block particles from the compressed air.
4 = Heating register
5 = Fan
6 = Silencer
7 = Prefilter
8 = After-filter
Fig. 5.18 :
Vacuum regeneration
88
5.4.7 Arrangement of the refrigeration There are two basic possibilities for arranging a refrigeration
compressed air dryer compressed air dryer in a compressor station. It can either be
installed before or after the compressed air receiver. No gen-
eral decision on this matter is possible because there are
advantages and disadvantages with both constellations.
5.4.7.1 Dryer before the compressed air Advantages:

receiver
Dried air in the compressed air receiver.
No precipitation of condensate in the compressed air
receiver.
Consistent compressed air quality.
Even with abrupt, heavy withdrawal of compressed air
the pressure dew point of the compressed air remains
unchanged.
Disadvantages:
Large size dryer.

Fig. 5.19 : The dryer must be designed for the entire effective output
Dryer before the compressed air receiver of installed compressor. The dryer is often over-dimen-
sioned if consumption is low.
Drying of pulsating compressed air.
As a result of their construction, piston compressors in
particular deliver a pulsating flow of air. This puts stress
on the dryer.
High entry temperature of compressed air.
The compressed air comes directly from the after-cooler
of the compressor.
Drying of a partial air flow is not possible.
Large quantity of condensate.
The entire quantity of condensate precipitates in the dryer.
With systems containing several compressors, each
compressor must have a dryer connected.
Conclusion
Installing a dryer before the compressed air receiver can sel-

dom be recommended. However, an arrangement of this type
makes good sense when sudden peaks of requirement are
anticipated and the quality of the compressed air must not
deteriorate.
89
5.4.7.2 Dryer behind the compressed air Advantages:

receiver
Favourable dryer size.
The dryer can be sized according to the actual consump-
tion of compressed air, or for a partial flow of compressed
air that needs to be dried.
Drying of a non-turbulent volume flow.
Low compressed air entry temperature.
The compressed air has the opportunity to cool down
further in the compressed air receiver.
Low quantities of condensate.
The droplets of condensate collect in the compressed air
receiver and do not burden the rest of the system.
Fig. 5.20 :
Dryer behind the compressed air receiver
Disadvantages:
Condensate in the compressed air receiver.

Moisture in the compressed air receiver leads to corrosion.
Overload of the Dryer.
The dryer is overloaded if there is any abrupt, heavy
withdrawal of compressed air. The pressure dew point of
the compressed air rises.
Conclusion
In most cases, BOGE recommends installing the dryer be-

hind the compressed air receiver. The argument of economy
is in favour of it. A smaller dryer can normally be chosen. Its
efficiency rate is better.
90
Compressed air processing
5.5 Compressed air filters
5.5.1 Basic terminology of filters To assess and operate filters it is first necessary to define and
explain certain sizes and factors.
5.5.1.1 Filter separation rate [ % ] The filter separation rate gives the difference in concentra-
tion of impurities before and after the filter. It is also called the
efficiency rate. The filter separation rate is a measure of the
efficiency of the filter. The minimum grain size [ m ] that the
filter can separate must always be specified.
C1
= 100 100
C2
unfiltered Purified C1 = Concentration of impurities before the fil-

compressed air (C2 ) ter.
air ( C1 )
C2 = Concentration of impurities after the filter.
= Filter separation rate [%]
The concentration is usually measured in proportion of weight

per unit of volume [ g/m3 ] of compressed air. With weaker con-
centrations, the concentration is usually defined by counting
the particles per unit of volume [ Z/cm3 ]. The particles per unit
of volume method is nearly always used to measure the effi-
ciency of high-performance filters. Measuring the weight pro-
portion per unit of volume with sufficient accuracy would in-
Fig. 5.21 : volve a disproportionate amount of effort.
BOGE Pre-filter, series V
= 99,99 % relevant to 3 m
Example
Compressed air contains an impurity particle concentration of

C1 = 30 mg/m3 prior to filtering. The purified air after the filter
still has an impurity particle concentration of C2 = 0,003 mg/
m3 with particle sizes over 3 m.
30
= 100 100
0,003
= 99,99 %
The filter has a separation rate in per cent of 99,99 % relative

to 3 m.
91
5.5.1.2 Pressure drop p The pressure drop p is the difference in pressure before
and after the filter caused by flow. The pressure drop p in the
filter grows with time as particles of dust and dirt are collected
in the filter element.
p0 is the pressure drop for new filter elements.

It is between 0,02 and 0,2 bar, depending on the type of
filter.
The economically acceptable limit for pressure drop p is
around 0,6 bar.
Fig. 5.22 : Devices that measure the pressure difference are installed in
General filter with p measuring device most filters.
If the pressure drop p exceeds the limit, either the filter must
be cleaned or the element replaced.
5.5.1.3 Operating pressure The maximum volume flow of a filter always refers to the norm
pressure pop = 7 bar. When pressure changes the maximum
through-flow rate of the filter also changes. The change to the
through-flow rate can be easily calculated with the aid of ap-
propriate conversion factors f.
Pressure [ barop ] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Factor f 0,25 0,38 0,5 0,65 0,75 0,88 1 1,13 1,25 1,38 1,5 1,63 1,75 1,88 2
Example
A BOGE pre-filter V50 with a nominal performance of 300

m3/h at a norm pressure of pop = 7 bar is to be operated at
pop = 10 bar.
R7 = 300 m3/h R10 = R7 f
pop = 10 bar f = 1,38 R10 = 300 m/h 1,38
R10 = 414 m/h
R10 = effective rate at pop = 10 bar

[ m3/h ]

[ m3/h ]
f = Conversion factor for pop = 10 bar
At a pressure of pop = 10 bar the filter has an effective nominal

performance of 414 m3/h.
92
5.5.2 Dust separators After coming out of the compressor, the compressed air con-
tains water in the form of steam and also droplets of conden-
sate. These droplets are formed during the compression proc-
ess because the air is no longer able to accommodate it when
Pressure Separation Particle Residual oil
its volume is reduced.
difference rate size content
p [ bar ] [ %] [ m ] [ mg/m3] This water normally deposits in the storage tank as the com-
pressed air become more inert. From there the condensate is
> 0,05 bar 95 % > 50 m not influ-
drained off.
enced
Operating principle
The dust separator operates according to the principle of mass

Purified air inertia. It consists of a vortex cartridge and a catch pan. The
vortex cartridge is designed to put the compressed air into
rotary movement. Solid and liquid components in the air are
forced against the inside walls of the pan by their own mass
1
inertia. This causes heavy particles of dirt and water to sepa-
rate. These separated impurities flow past a baffle plate into
the collection chamber. The baffle plate also prevents the flow
of air from taking the separated liquid with it.
Compressed
air flowing in The condensate can be drained off automatically or by hand
from the collection chamber and properly disposed of or treated.
2 Features
Almost complete separation of water droplets.

3
Heavy particles of dust and dirt filtered out.
4
The filtering capacity of the dust separator depends on the
flow speed of the air. The higher the flow speed, the more
1 = Vortex insert efficient the filter is. Of course, when the flow speed in-
2 = Baffle plate creases the pressure loss in the separator rises also.
3 = Collection chamber
Areas of application
Fig. 5.23 : No compressed air receiver in the pipeline system.
Cyclone separator
Large distances between the compressor and the receiver.
If the receiver is a long way from the compressor, then it
makes sense to install a cyclone separator directly down-
stream of the compressor. It prevents unnecessary trans-
port of water in the pipeline.
Rising lines between the compressed air receiver and the
compressor. The line between the compressor and the re-
ceiver goes vertically upwards. When the compressor is idle
the condensate flows back into the compressor. In this case
it makes sense to install a cyclone separator directly down-
stream of the compressor.
93
1.1
4.5 Control of several For users of compressed air with high, much fluctuating con-
compressors sumption a single, large compressor is not the best solution.
In these cases, a combined compressor system consisting of
several compressors is much the better alternative. Greater
operating reliability and economy are the aguments in favour
of this.
Organisations that are very dependent on compressed air can

guarantee their supply at all times by a combined compressor
system. If one compressor fails or servicing work is neces-
sary, the other compressors continue the supply.
Several small compressors can be adjusted more easily to

compressed air consumption than one large compressor. The
idling costs of a large compressor are moreover higher than
those of small, stand-by compressors. These facts provide the
greater economy.
A combined compressor is operated economically and low on

wear by a master control system.
4.5.1 MCS 1 and MCS 2 MCS 1 controls 2 compressors of the same size as basic load
and peak load. The compressors are cyclically changed and
switched on and off via their own pressure switches. The con-
trol unit offers:
Cyclic change via a timer.

Time lag cycling of the compressors by the control unit
through pressure graduation.
Even use of compressors.
Constant pressure in the pressure range.
MCS 2 controls up to 3 compressors of the same size as

Fig. 4.12 :
basic load, medium load and peak load. The compressors are
cyclically changed and switched on and off via their own pres-
sure switches. The upgrade to 3 compressors and the greater
cycle difference is the only difference to the MCS 1. The fea-
tures are otherwise the same.
Fig. 4.13 :
The circuit diagram of the BOGE MCS 2
60
4.5.2 MCS 3 MCS 3 controls a maximum of 4, 8, or 12 compressors of the

same and/or different size and type in a system. All compres-
sors are controlled by a common pressure sensor on the com-
The MCS 3 has at 0.5 bar a very small cut-in difference. The
individual compressors are not given fixed cut-out and cut-in
pressures. All compressors work in the same pressure range
( p = 0.5 bar ). The compressors cut-in dynamically accord-
ing to requirement via set intermediate pressure values. The
speed of pressure rise and fall is measured. The compres-
sors switch on and off dynamically.
Fig. 4.14 :
The control offers:
Dynamic pressure control by microcontroller in connec-

tion with electronic pressure controllers for a minimum
Cut-in Cycle
Time dependent allotment of compressors in rank
pressure
[bar]
difference stages for shift operation with differing compressed air
requirement.
Individual assignment of individual compressors to load
range groups, uniform usage of compressors.
Adjustable basic load changeover cycle.
Independent rotation of compressors into the load range
groups.
Fig. 4.15 : Time offset allocation of compressors if demanded by
Circuit diagram of the BOGE MCS 3 the control unit.
clear text.
Possibility of checking all inlets and outlets via a test-
menu.
Automatic reverting to pressure switches of individual
the MCS 3. They are then controlled from their own
pressure switches.
61
4.5.3 MCS 4 MCS 4 controls a maximum of 4 or 8 compressors of the same

and/or different sizes and types in a system. All compressors
are controlled by a common pressure sensor at the com-
The basic load with this control unit is normally covered by the
largest compressor or combination of compressors. The small-
est compressor takes the peak load. Compressors of the same
size change over in providing the basic load.
The MCS 4 computes compressed air consumption continu-

ally from programmed compressor performance data and in-
Fig. 4.16 : formation from the pressure sensor. It selects the compressor
The BOGE Master Control System 4 that most closely matches the requirement.
The control offers:

Cut-in Cycle
pressure difference
[bar]
need-oriented use of the various compressors and
compressor combinations.
ideal use of the benefits of screw and piston compressors.
minimal cut-in difference of 0.5 bar.
( no over-compression energy-saving )
three different pressure profiles per day by a timer
programme to adapt the control to differing compressed
Fig. 4.17 : air requirement.
Op. diagram of the BOGE MCS 4
control unit.
Well-organised LCD-display with 2 x 20 characters and
clear text output.
Automatic switchover to pressure switches in the event of
voltage loss.
pressure switches.
Two potential-free timer contacts for control of additional
components.
62
4.5.4 MCS 5 MCS 5 controls a maximum of 4, 8, or 12 compressors with

infinite output control of the same and/or different size and
construction in a system. All compressors are controlled by a
common pressure sensor on the compressed air receiver. The
peak load compressor controls accordingly the requirement
of compressed air via its infinite output control.
If the compressed air demand drops this compressor switches

off and the medium load compressor takes over via its infinite
output control,dependng on the level of priority.
Fig. 4.18 : Up to their use of infinite control the MCS 3 and MCS 5 are
The BOGE Master Control System 5 similar.
The control unit offers:
Adaptation of FAD to the compressed air demand by

infinite output control by the peak load compressor.
Cut-in Cycle Minimal pressure fluctuations in the pneumatic network.

pressure difference
tion with the electronic pressure control for a minimum
( no over-compression energy savings )
Time-independent allocation of compressors in level of
priority for shift operation with differing compressed air
demand.
Individual allocation of compressors in the load range
Fig. 4.19 : groups with even usage of compressors.
Op. diagram for the BOGE MCS 5
groups.
control unit.
clear text output.
Automatic change to pressure switches of individual
pressure switches.
63
4.5.5 MCS 6 MCS 6 Controls a maximum of 4, 8, or 12 compressors with

speed frequency control of the same, and/or different size and
design/type in a system. All compressors in the system are
controlled through a common pressure sensor on the com-
pressed air receiver. The peak load compressor controls the
compressed air demand via its speed frequency control.
When the compressed air demand falls this compressor

switches off and the medium load compressor takes over the
control through its speed frequency control.
Fig. 4.20 : Apart from the speed frequency control the MCS 3 and the
The BOGE Master Control System 6 MCS 6 systems are similar.
The control system offers:
Adaptation of the FAD to the compressed air demand

through speed frequency control of the peak load com-
pressor.
Cut-in Cycle
pressure
[bar]
difference
Minimum pressure fluctuations in the pneumatic system.
tion with the electronic pressure controller for a minimum
Time-dependent allocation of compressors in priorities
for shift operation with differing compressed air demand.
Fig. 4.21 : Individual allocation of individual compressors in the load

Op. diagram for the BOGE MCS 6 range groups with even work rates among the compres-
sors.
groups.
control unit.
Well-arranged LCD-display with 4 x 20 characters
and clear text output.
Automatic switchover to the pressure switches of indi-
vidual compressors in the event of power failure.
the MCS 6. They are then controlled by their own pres-
sure switches.
64
4.5.6 MCS 7 MCS 7 controls, regulates and monitors a complete pneumatic

station with the Siemens-control S 5 ( S7 ) and the operator
terminal OP 15.
The basic features include:
8 Compressors.
2 Refrigeration compressed air dryers.
2 Adsorption dryers.
10 Bekomats.
2 Potentional-free switch channels for control of addi-
tional devices.
The MCS 7 is available in three versions:

Fig. 4.22 :
Version 1
sors of the same and/or different size by priorities and timer
Cut-in Cycle
pressure difference programmes.
[bar]
Version 2

sors of the same and/or different size with infinite output con-
trol.
Version 3
Fig. 4.23 :
Op. diagram for the BOGE MCS 7 Version 3 offers an extended software program of MCS 6. It
sors of the same and/or different size with speed frequency
control.
In addition to the basic individual software functions the con-

trol offers:
Recording of the operating status of the compressors

and additional components of the compressor station.
Storage of operating, warning and malfunction mes-
sages. This makes servicing and repair of the compres-
sor system much simpler.
Control and monitoring of the compressed air treatment
components and the pneumatic system.
BUS-coupling with Profibus ( optional )
This allows connection to a central control facility.
System visualisation in master control equipment (optional)
Comprehensive information can be obtained about the
entire compressed supply.
65
5. Compressed air treatment
5.1 Why treatment ? Modern production equipment needs compressed air. The
many conditions in which it is used range from untreated blow-
ing air to absolutely dry, oil-free and sterile compressed air.
The impurities in our atmosphere are usually invisible to the

naked eye. But they can seriously impede the reliable opera-
tion of a pneumatic system and consumer devices, and have
an adverse effect on the quality of products.
1 m3 of atmospheric air contains many impurities such as
Up to 180 million particles of dirt.

These are between 0.01 and 100 m in size.
5 - 40 g/m Water in the form of atmospheric humidity.
0.01 to 0.03 mg/m3 Oil in the form of mineral oil aerosols
and unburnt hydrocarbons
Traces of heavy metals such as lead, cadmium, mercury,
iron.
Compressors draw in atmospheric air and the impurities they

contain and concentrate them many times. At compression
of 10 bar-op ( 10 bar over-pressure = 11 bar absolute ) the con-
centration of impurities rises by 11 times. In 1 m3 compressed
air there will then be up to 2 billion particles of dirt. Lubrication
oil and scuff also passes from the compressor in the com-
pressed air.
Correct treatment of compressed air brings benefits :
Increased working life of consumer devices.

Improved and consistent product quality.
Pneumatic lines free of condensate and rust.
Fewer malfunctions.
Pipelines without condensate collectors.
Lower servicing outlay.
Fig. 5.1 :
Concentration of impurities in the air during com- Lower pressure loss from leakage and flow resistance.
pression Lower energy consumption due to lower pressure loss.
66
5.1.2 Planing information BOGE recommends the processing described on this page
for the various applications of compressed air.
Refrigeration dryer
*)
Active carbon filter

Area of application Quality
Adsorption dryer
Membrane dryer
of compressed air classes
Dust separator
Active carbon
Compressor
Sterile filter
DIN ISO 8573-1
Microfilter
absorber
Prefilter
prefilter
Particle
Water
Oil
General air
Blowing air
Sand blasting 3
Simple varnishing work 3
General works air 5 3 4

Conveyance air 5 3 4
BOGE screw and piston compressors
Simple spray painting 5 3 4

Sandblasting with higher
quality requirements 5 3 4
Pneumatic tools 1 1 4
Control air 1 1 4
Process control eqpt. 1 1 4
Spray painting 1 1 4
Conditioning 1 1 4
Fluid elements 1 1 4
Dental laboratories 1 1 4
Photo laboratories 1 1 4
Breathing air 1 1 1-3

Instrument. air 1 1 1-3
Pneumatics 1 1 1-3
Spray painting with higher
Surface treatment 1 1 1-3
Medical equipment 1 1 3-4

Conveyance air with higher
Food and luxury
food industry 1 1 3-4
Breweries 1 1 1-3
Dairies 1 1 1-3
Pharmaceuticals industry 1 1 1-3
*) The dust separator is not required under certain circumstances.

The quality classes are explained on page 5.12 .
67
5.1.3 Consequences of poor treatment If the impurities and water from atmospheric air remain in the
compressed air the consequences can be unpleasant. This
applies to the pipeline and the consumer devices, and prod-
ucts can also suffer if the quality of compressed air is poor. In
some applications the use of compressed air without adequate
treatment is dangerous and a health hazard.
Solid matter particles in compressed air
Wear on pneumatic systems.

Dust and other particles cause scuff. This effect is increased
if the particles combine with lubricating oil or grease to form
a grinding paste.
Particles that are hazardous to health.
Chemically aggressive particles.
Oil in the compressed air
Old and different oil in the pneumatic system.

Resinified oil can reduce pipe diameters and cause block-
ages. This increases flow resistance.
Oil-free compressed air.

With pneumatic conveyance, oil can stick to the product
being conveyed and thus cause blockages.
In the food and pharmaceutical industries compressed air
must be free of oil for health reasons.
Water in the compressed air
Corrosion in the pneumatic system.

Rust forms in the pipelines and operating elements and
causes leaks.
Gaps in lubricant films.

Gaps in lubricant films lead to mechanical defects.
Formation of electrical elements.

Electrical elements can form when some metals come in
contact with water.
Formation of ice in the pneumatic network.

In low temperatures water in the network can freeze and
cause frost damage, reduce pipe diameter and block pipes.
68
5.1.3 Impurities in the air In our atmosphere there are particles of dirt that are not vis-
ible to the naked eye. This chapter contains a general sum-
mary of the type, size and concentration of these particles.
Concentration of particles Limits Average values

3
in atmospheric air [ mg/ m ] [ mg/ m3 ]
In the country 5 - 50 15
In the town 10 - 100 30
In an industrial area 20 - 500 100
In large factory plants 50 - 900 200
Particle diameter [ m ]
69
5.2 Water in the compressed air
5.2.1 Atmospheric humidity There is always a certain amount of moisture in the atmos-
phere. This is known as atmospheric humidity and its content
varies depending on the time and place. At any temperature
a certain volume of air can only contain a maximum quantity
of moisture. However, atmospheric air usually contains less
than this maximum amount.
Maximum humidity humax [ g/m3 ]
Maximum humidity hu max ( saturation quantity ) means the

maximum quantity of moisture that 1 m air can hold at a cer-
Maximum humidity humax [ g /m3 ]
tain temperature. The maximum humidity does not depend on

pressure.
Absolute humidity hu [ g/m3 ]
Absolute humidity hu means the actual quantity of moisture

held by 1 m air.
Relative humidity [ % ]
Relative humidity means the ratio of absolute to maximum

humidity.
hu
= 100 %
hu max
= relative humidity [%]

Dew point[ C ] hu = absolute humidity [ g/m 3 ]
humax = maximale humidity [ g/m 3 ]
Fig. 5.2 :
Maximum humidity
depending on dew point
Since maximum humidity humax depends on the temperature
the relative humidity changes with the temperature, even if
the absolute humidity remains constant. On cooling to dew
point, the relative humidity rises to 100 %.
70
5.2.2 Dew points Atmospheric dew point [ C ]
Atmospheric dew point means the temperature to which at-

mospheric air ( 1 bar abs ) can be cooled without precipita-
tion.
The atmospheric dew point is of minor importance for pneu-

matic systems.
The pressure dew point means the temperature to which com-

pressed air can be cooled without precipitation of conden-
sate. The pressure dew point depends on the final compres-
sion pressure. If pressure drops, the pressure dew point drops
with it.
5.2.3 Air moisture content The following table shows the maximum air humidities at cer-
tain dew points:
dew max. dew max. dew max. dew max. dew max. dew max. dew max.
point humidity point humidity point humidity point humidity point humidity point humidity point humidity
[ C ] [ g/ m3 ] [ C ] [ g/m3 ] [ C ] [ g/m3] [ C ] [ g/m3] [ C ] [ g/m3 ] [ C ] [ g/m3] [ C ] [ g/m3]
+100 588,208 +76 248,840 +52 90,247 +28 26,970 +4 6,359 -19 0,960 -43 0,083
+99 569,071 +75 239,351 +51 86,173 +27 25,524 +3 5,953 -20 0,880 -44 0,075
+98 550,375 +74 230,142 +50 82,257 +26 24,143 +2 5,570 -21 0,800 -45 0,067
+97 532,125 +73 221,212 +49 78,491 +25 22,830 +1 5,209 -22 0,730 -46 0,060
+96 514,401 +72 212,648 +48 74,871 +24 21,578 -23 0,660 -47 0,054
0 4,868
+95 497,209 +71 204,286 +47 71,395 +23 20,386 -24 0,600 -48 0,048
+94 480,394 +70 196,213 +46 68,056 +22 19,252 -1 4,487 -25 0,550 -49 0,043
+93 464,119 +69 188,429 +45 64,848 +21 18,191 -2 4,135 -26 0,510 -50 0,038
+92 448,308 +68 180,855 +44 61,772 +20 17,148 -3 3,889 -27 0,460 -51 0,034
+91 432,885 +67 173,575 +43 58,820 +19 16,172 -4 3,513 -28 0,410 -52 0,030
+90 417,935 +66 166,507 +42 55,989 +18 15,246 -5 3,238 -29 0,370 -53 0,027
+89 403,380 +65 159,654 +41 53,274 +17 14,367 -6 2,984 -30 0,330 -54 0,024
+88 389,225 +64 153,103 +40 50,672 +16 13,531 -7 2,751 -31 0,301 -55 0,021
+87 375,471 +63 146,771 +39 48,181 +15 12,739 -8 2,537 -32 0,271 -56 0,019
+86 362,124 +62 140,659 +38 45,593 +14 11,987 -9 2,339 -33 0,244 -57 0,017
+85 340,186 +61 134,684 +37 43,508 +13 11,276 -10 2,156 -34 0,220 -58 0,015
+84 336,660 +60 129,020 +36 41,322 +12 10,600 -11 1,960 -35 0,198 -59 0,013
+83 324,469 +59 123,495 +35 39,286 +11 9,961 -12 1,800 -36 0,178 -60 0,110
+82 311,616 +58 118,199 +34 37,229 +10 9,356 -13 1,650 -37 0,160 -65 0,00640
+81 301,186 +57 113,130 +33 35,317 +9 8,784 -14 1,510 -38 0,144 -70 0,00330
+80 290,017 +56 108,200 +32 33,490 +8 8,234 -15 1,380 -39 0,130 -75 0,00130
+79 279,278 +55 103,453 +31 31,744 +7 7,732 -16 1,270 -40 0,117 -80 0,00060
+78 268,806 +54 98,883 +30 30,078 +6 7,246 -17 1,150 -41 0,104 -85 0,00025
+77 258,827 +53 94,483 +29 28,488 +5 6,790 -18 1,050 -42 0,093 -90 0,00010
71
5.2.4 Quantity of condensate Air contains water in the form of moisture. Since air can be
during compression compressed and water can not, when air is compressed the
water precipitates in the form of condensate. The maximum
humidity of the air depends on temperature and volume. It
does not depend on quantity.
Atmospheric air can be imagined as a moist sponge. It can

take in a certain amount of water when it is relaxed. But if it is
squeezed, part of the water runs out. Some of the water will
always stay in the sponge regardless of how hard it is squeezed.
Compressed air is very similar.
The following examples illustrate the quantity of condensate

to be expected qc when air is compressed. The example as-
Fig. 5.3 :
sumes a humid Summer day with 35 C and 80 % atmospheric
A wet sponge being squeezed humidity.
V1 humax 1 1 V2 humax 1 2
qc = -
100 100
6,5 39,286 80 0,59 39,286 100

qc = -
100 100
m g / m % m g / m %
qc = -
% %
qC qc = 181,108 g
V1 = 6,5 m3 V2 = 0,59 m3
p1 = 0 bar-op = 1 bar abs p2 = 10 bar-op = 11 bar abs
T = 35 C T = 35 C qc = precipitated condensate [g]
1 = 80 % 2 = 100 % V1 = Volume at 0 bar-op [ m3 ]
hu max = 39,286 g/ m3 V2 = Volume at 10 bar-op [ m 3]
humax 1 = max. humidity at 35 C [ g/m3 ]

Fig. 5.4 :
Precipitation of condensate during compression 1 = relative humidity of V 1 [%]
2 = relative humidity of V 2 [%]
Because the water that comes out of the compressed air is

the part the air can not store, the humidity of the compressed
air rises to 100 %.
When compressing 6,5 m 3 air to 10 bar pressure, at a con-

stant temperature 181,108 g water will precipitate in the
form of condensate.
72
5.2.5 Example An example shows the amount of condensate qc that actually

for calculating quantities of occurs when air is compressed. It is to be noted that the con-
condensate densate occurs at several points of the compressor station
and at different times.
The task here is to calculate the occurrence of condensate on

a screw compressor with an output of V = 2 720 m/h and a
final compression pressure of pop = 10,5 bar. Connected in
series to the compressor are a compressed air tank and a
refrigeration compressed air dryer.
Ambient air The atmospheric air contains a certain amount of water under
these conditions:
V 1 = 2 720 m/h
p1 =1 bar abs
T1 = 33 C
qw = V 1 humax 1 1 /100
1 = 80 %
humax 1 = 35,317 g/m g/h = m/h g/m %/%
qw = 2 720 35,317 80/100

^ 76,85 l/h
qW = 76 849,79 g/h =
Compressor During the compression process, the temperature rises above

the pressure dew point of the compressed air, and therefore
p2 = 11,5 bar abs no moisture will precipitate. In the aftercooler of the compres-
T2 = 40 C sor the compressed air is cooled down to T 2 = 40 C. The first
2 = 100 % condensate occurs and is taken with the air into the com-
pressed air receiver. The volume flow calms down and the
humax 2 = 50,672 g/m
droplets of water precipitate. A considerable amount of con-
densate collects there:
V1
V 2 = = 236,5 Bm3/h
P2

qc1 = qW ( V 2 humax 2 2 /100 )
qc1 = 76 849,79 ( 236,5 50,672 100/100 )
qc1 = 64 865,86 g/h ^

= 64,87 l/h
V = 236,5 m3/h qc1
Refrigeration compressed After this the compressed air is cooled down in the refrigera-
air dryer tion compressed air dryer to a temperature corresponding
to a pressure dew point of 3 C. The condensate precipitates
p3 = 11,5 bar abs in the dryer and is drained off.
T3 = 3 C
3 = 100 %
qc2 = ( V 2 humax 2 ) ( V 2 humax 3 )
qc2
humax 3 = 5,953 g/m
qc2 = ( 236,5 50,672 ) ( 236,5 5,953 )

V 2 = 236,5 Bm3/h qc2 = 10 576,04 g/h ^
= 10,58 l/h
Fig. 5.5 :
Condensate precipitation when compressing with a
dryer
73
In addition to the individual flows of condensate, there is also

the quantity of condensate that needs to be dealt with by the
condensate treatment equipment.
Condensate quantity qc = qc1 + qc2
Condensate quantity qc = 75441,9 g/h

= 75,4 l/h

Fig. 5.6 : assumptions unchanged:
Approx. 8 10 l buckets of condensate precipitate in
24 hours Condensate quantity qcD = 1810605,6 g/D
= 1810,6 l/D

year:
Condensate quantity qcY = 659 060 438 g/Y

= 659 060 l/Y
5.2.6 Quantity of condensate on a humid The quality of compressed air must always remain the same if
Summer day the surrounding conditions are unchanged. i.e., the pres-
sure dew point of the compressed air must be 3C even on a
humid Summer day with an air temperature of 40 C and 90 %
atmospheric humidity.

FAD V 1 = 2 720 m/h
Inlet pressure p1 = 1 bar abs
Inlet temperature T1 = 40 C
Relative humidity 1 = 90 %
Pressure dew point T3 = 2 C
Under these conditions the quality of compressed air remains

constant but the quantity of condensate is much higher.
Condensate quantity qc = 122,6 l/h

assumptions unchanged:
Condensate quantity qcD = 2 943,3 l/D

year:
Condensate quantity qcY = 1 071 358 l/Y
74
5.2.7 Determining the pressure dew The pressure dew point means the temperature to which the
point compressed air can be cooled without condensate precipi-
tating. The pressure dew point depends on the final compres-
sion pressure. If the pressure drops, the pressure dew point
drops with it.
The following diagrams are used to determine the pressure

dew point of the compressed air after compression:
sure
pres
sion
re
pres
tu
ra
lcom
pe
m
Example2
Fina
te
let
In
Example1
Relative humidity [ % ] Pressure dew point [ C ]
Example 1 Example 2
Intake air Intake air

relative atmospheric humidity = 70 % relative atmospheric humidity = 80 %
inlet temperature T = 35 C inlet temperature T = 35 C
Final compression pressure pop = 8 bar Final compression pressure pop = 10 bar
The pressure dew point is approx. 73 C The pressure dew point is approx. 82 C
75
5.2.8 Pressure dew point after removal When compressed air relaxes (pressure released) the pres-
of pressure sure dew point drops. The following table is used to determine
the new pressure dew point and atmospheric dew point after
relaxation:
max. humidity [ g/m3 ]
]
op
ar-
[b
Example1
op
p
re
su
res
erp
Ov
Example 2
Atmospheric dew point [ C ]
Example 1 Example 2

pop = 35 bar air pressure pop = 7 bar air pressure
Pressure dew point 10 C Pressure dew point 20 C
relaxed compressed air relaxed compressed air
pop = 4 bar air pressure atmospheric air pressure pop = 0 bar
The new pressure dew point is approx. -23 C The atmospheric dew point is approx. -8 C
76
5.3 Compressed air quality
5.3.1 Quality classes defined in The quality classes for compressed air defined in DIN ISO
DIN ISO 8573-1 8573-1 make it easier for the user to set his requirements and
choose the equipment he needs to treat the air. The norm is
based on makers specifications giving defined limits for their
equipment and machinery pertaining to purity of compressed
air.
The DIN ISO 8573-1 norm defines quality classes for com-
pressed air according to:
Oil content
Definition of the residual quantity of aerosols and hydrocar-
bons contained in the compressed air.
Particle size and density

Definition of the size and concentration of solid matter parti-
cles that may remain in the compressed air.
Pressure dew point

Definition of the temperature to which the compressed air
can be cooled without condensation of the moisture it con-
tains. The pressure dew point changes with the air pressure.
Class max. oil content max. residual dust content max. residual water content
particle size particle density res. water press. dew point
[ mg/ m3] [ m ] [ mg/ m3] [ g/ m3 ] [ C ]
1 0,01 0,1 0,1 0,003 -70

2 0,1 1 1 0,117 -40
3 1 5 5 0,88 -20
4 5 15 8 5,953 +3
5 25 40 10 7,732 +7
6 9,356 +10
77
5.4 Methods of drying The summary presents the methods of drying compressed
air according to their principle of operation. A distinction is
always made between condensation, sorption and diffusion.
Condensation is the separation of water by going below the

dew point.
Sorption is drying by removal of moisture.
Diffusion is drying by molecular transfer.
Process of drying compressed air
Over-compression
Condensation
Refrigeration drying
Diffusion Membrane drying
Solid dryers
Absorption Soluble dryers
Liquid dryers
Sorption
Cold regeneration
Int. heat regeneration
Adsorption
Ext. heat regeneration
Vacuum regeneration
78
5.4.1 Operating conditions The through-flow rate of a dryer refers to the intake rate of
air during compression by a compressor according to PN2
CPTC2, ISO 1217 ( DIN 1945 Part 1 ).
Intake pressure p = 0 barop ^ 1 barabs

=
Intake temperature T0 = 293 K ^ 20 C
=
Drying equipment is designed according to DIN ISO 7183 for

certain operating conditions. The performance data given for
the equipment is only correct under these conditions:
Operating pressure p = 7 barop ^ 8 barabs

=
Ambient temperature tA = 298 K ^ 25 C
=
Entry temperature tEn = 308 K ^ 35 C
=
If a dryer is used under different operating conditions, appro-

priate conversion factors must be taken into account. These
factors differ in the various drying processes.
Example for the layout of a refrigeration compressed air

dryer
Conversion factors for operating conditions and ambient tem-

perature:
Op. pressure p [ barop ] 2 3 4 5 6 7 8 9 10 11 12 14 16
Factor f 0,62 0,72 0,81 0,89 0,94 1 1,04 1,06 1,09 1,1 1,12 1,15 1,17
Ambient temperature tA [ C ] 25 30 35 40 43
Factor t 1,00 0,92 0,85 0,79 0,75
A BOGE refrigeration compressed air dryer, model D8, has a

through-flow rate R of 45 m3/h. It is operated at an average
ambient temperature of t A = 40 C and an operating pressure
of p = 10 barop.
R = 45 m3/h
RAd = R f t
p = 10 barop f = 1,09
RAd = 45 m3/h 1,09 0,79
tA = 40 C t = 0,79
RAd = 38,75 m3/h
RAd = Adjusted through-flow rate [ m3/h ]
R = Through-flow rate [ m3/h ]
f = Conversion factor for p = 10 barop
t = Conversion factor for t A = 40 C
With changed operating conditions the dryer has through-flow

rate of 38,75 m 3/h.
79
5.4.2 Condensation With over-compression the air is compressed far beyond the
by over-compression necessary pressure, and afterwards cooled and relaxed to
operating pressure.
Pressure Operating Volume Entry

dew point pressure flow temperature Operating principle
[C] [ barop ] [ m3/h ] [C]
With rising pressure and thus reduced volume the air is able
approx. -70 Depends on Depends on to hold less water. During pre-compression at high pressure
C compressor compressor a large amount of condensate precipitates. The absolute
humidity of the air goes down. If the compressed air is now
relaxed, the relative humidity drops and with it the dew point.
Example:
Compressed air is pre-compressed to 36 bar. The dew point

is 10 C. The condensate precipitates. After relaxation to 4 bar
the compressed air has a new pressure dew point of approx.
- 23 C.
( see chapter 5.2.7 example 1 )
mK
Features
p = 1 bar p = 36 bar p = 4 bar
Simple process with continuous volume flow.
Fig. 5.7 : No expensive refrigeration and drying equipment.
Over-compression with subsequent relaxation
Only economical for small output quantities.
Very high energy consumption.
80
5.4.3 Condensation When the temperature falls, air loses its ability to hold water.
by refrigeration drying To reduce the moisture content, compressed air can be cooled
down in a refrigeration dryer.
Pressure Operating Through- Entry tem- Refrigeration drying is a process by which compressed air is
dew point pressure flow rate perature cooled down by a dryer in a heat exchanger. The moisture
[C] [ barop ] [m3/h ] [C] contained in the air precipitates in the form of condensate.
The quantity of condensate that precipitates rises with the
to - 2 C to 210 11-35 000 to +50 C difference between the entry and exit temperature of the com-
pressed air.
Dry compressed air Operating principle
Moist compressed air Refrigeration drying runs in two phases. This is done to im-
3
prove effectiveness and to obtain maximum use of the refrig-
1
erant.
2 1st Phase
Inside an air/air heat exchanger the compressed air already

cooled by the refrigeration dryer cools new air flowing in. 70 %
of the moisture contained in the air precipitates here in the
form of condensate.
4
2nd Phase
The compressed air flows through a refrigerant/air heat ex-

changer and cools down almost to freezing point. The precipi-
tated condensate is directed off before re-heating in the first
cooling phase.
Features:
6 4 Highly economical.
Refrigeration drying is the most economical process in
5 approx. 90 % of all applications.
Separation of impurities.
1 = Air/Air heat exchanger Almost 100 % of all solid particles and water droplets
2 = Air/refrigerant heat exchanger larger than 3 m are separated.
3 = Refrigerant/air heat exchanger Lower pressure loss in the dryer.
4 = Condensate drain The pressure loss p from the dryer is approx. 0,2 bar.
5 = Refrigerant compressor
6 = Vapour outlet
Fig. 5.8 :
Op. diagram of a refrigeration compressed air dryer
81
5.4.4 Diffusion The principle of the membrane dryer is based on the fact that
by membrane drying water penetrates a specially coated hollow fibre 20 000 times
faster than air.
Pressure Operating Through- Entry tem- The membrane dryer consists of a bundle of thousands of
dew point pressure flow rate perature coated hollow fibre membranes. These hollow fibres are made
[C] [ barop ] [ m3/h ] [C] of a solid, temperature and pressure-resistant plastic. Their
inside surface is coated with an ultra-thin (less than the length
0 to -20 C 5 -12,5 11 - 130 2 to 60 C
of a light wave) coating of a second plastic. The hollow fibres
( membranes ) are installed in a pipe where the inner channel
of the fibres is open at the end.
Moist air
Operating principle
The moist compressed air flows through the inside of the hol-
low fibres ( internal flow ). The moisture contained in the air
penetrates through the layer of coating on the hollow fibres
Moist towards the outside. To do this a concentration gradient of
flushing air moisture is required between the inside and outside of the
hollow fibres.
Inside flow
A quantity of air for flushing is taken from the main volume
Water flow of the compressors and relaxed (decompressed). Since
the maximum air humidity depends on volume, the relative air
humidity drops. The flushing air becomes very dry. The flush-
ing air flows around the hollow fibres and provides the neces-
sary concentration gradient of moisture. The flushing air can
escape unfiltered into the open.
Dry flushing
air
Features
Low level of particles in the air.

A filter must always be connected upstream of the mem-
brane dryer, in order to filter out particles up to a size of
0.01 m. If installed directly downstream of the compres-
Dry air sor, the filter should be connected to dust separator.
Low pressure loss in the dryer.
Fig. 5.9 : The pressure loss p from the dryer is max. 0.2 bar.
The principle of a membrane dryer
Compact construction.
The dryer can be installed as a component of the pipeline.
No servicing.
There are no moving parts in the dryer.
No precipitation of condensate during drying
No additional energy costs.
Silent.
No fluorocarbons.
No moving parts.
No motor.
82
5.4.5 Sorption by Absorption With absorption drying the moisture is separated by a chemi-
cal reaction with a hygroscopic drying agent. Since the ab-
sorption properties of the drying agent diminish over time, pe-
riodic renewal is necessary.
There are 3 different types of drying agent. The soluble agents

liquify with increased absorption. The solid and liquid agents
dew point pressure flow rate perature
react with the moisture without changing their aggregate sta-
[C] [ bar op ] [ m3 /h ] [C]
tus.
Depends on to 30 C
entry
temperature
Drying agent
Solid Soluble Liquid
1 Dehydrated Lithium chloride Sulphuric acid

chalk
oversour Calcium chloride Phosphoric acid
2 magnesium salt
Glycerine
Triethylene glycol
Operating principle
1
During absorption the compressed air flows upwards through
4 a drying middle bed. During this it gives up some of its mois-
3 ture to the drying agent. A drain directs the condensate to a
floor tank. The pressure dew point is lowered by 8 - 12 %.
Example
1 = Screen
Compressed air enters a dryer operating with calcium chlo-
2 = Solid drying agent
ride at a temperature of + 30 C. The pressure dew point
3 = Cover
achieved here is between 18 and 22 C.
Fig. 5.10 :
Absorption dryer with solid drying agent Features
Low entry temperature.

High temperatures soften the drying agent and bake it
together.
Very corrosive drying agents.
The dried compressed air can take drying agent with it
into the pneumatic system. This can cause considerable
damage.
No input of outside energy.
Due to its properties, absorption drying has only become

established in fringe applications of pneumatic engineering.
One example of this is its use for compressed treatment air in
laboratories.
83
5.4.6 Sorption by Adsorption Drying compressed air by adsorption is a purely physical proc-
ess. The moisture is bound to the drying agent by force of
adhesion ( unbalanced molecular attraction ). The moisture stays
on the inner and outer surfaces of the adsorption material with-
out a chemical reaction taking place.
The adsorption material has an open porous structure and a

large inner surface. The most common adsorption materials
are aluminium oxide, silicagel, active carbon and molecular
screens. Different adsorption materials are used for the vari-
ous regeneration processes.
Adsorption material Properties of Adsorption material *)
Obtainable Entry Regeneration Surface

press. dew point temperature temperature
[C] [C] [C] [ m2/g ]
Silicagel ( SiO2 ), raw - 50 + 50 120 - 180 500 - 800
Silicagel ( SiO2 ), spherical -50 + 50 120 - 180 200 - 300
Activated - 60 + 40 175 - 315 230 - 380

Aluminium oxide ( Al2O3 )
Molecular screens - 90 + 140 200 - 350 750 - 800

( Na, AlO2, SiO2 )
*) The properties of the adsorption material change with the pressure and temperature of the gas to be dried
Operating principle
During the drying process the moist compressed air flows

through an adsorption tank. The moisture is bound, which dries
the compressed air. This process generates heat. The adsorp-
tion material must be regenerated when the adhesive forces
are balanced by water deposits. This means that the water
must be removed from the adsorption material. For this rea-
son there must be two parallel drying tanks with continual
operation. The active tank A dries the compressed air, while
the inactive tank B regenerates without pressure.
The following processes are mainly used to regenerate the

A B adsorption material :
cold regeneration
vacuum regeneration
84
5.4.6.1 Cold regeneration With cold regeneration the drying and regeneration time is
around 5 min. For this reason the moisture only deposits on
the outer surface of the drying agent.
dew point pressure flow rate perature Cold regeneration adsorption dryers operate according to the
[C] [ barop ] [ m/h ] [C] pressure alternation process. With this method the desorption
( regeneration ) takes place without additional input of heat. A
to - 70 C 4 - 16 4 - 5600 to + 60 C part of the dried volume flow is branched off. This part-flow
relaxes to a pressure of just over 1 bar and is thus extremely
dry. This dry air then flows through the regeneration drying
tank B. In this process it takes on the moisture stored in the
drying agent and directs it out into the open through an outlet
valve.
Features
Fig. 5.11 :
Adsorption material after 5 min. drying time Economical on smaller systems with low volume
flows.
2 3 2 Dry compressed air Can be used at high ambient temperatures.
Low volume of drying agent.
Drying and regeneration times approx. 5 min.
High operating costs.
The regeneration air is taken from the pneumatic system
6 and can not be used further .
Regeneration without outside energy.
The percentage ratio of regeneration air to the output of
the compressor falls with a higher final compression pres-
sure.
A B
Final comp. Ratio of regeneration air [ % ]
Regeneration
pressure Press. dew point Press. dew point
air
[ barabs ] -25 to - 40 C - 40 to -100 C
5 25,83 27,14
5 7 17,22 18,1
10 11,49 12,07
15 7,39 7,77
20 5,46 5,47
4 1 These values are physically fixed and it is not possible to

Moist compressed air go below them. They are taken from the correlation be-
tween air moisture and compressed air pressure relief.
1 = Valve block Prefiltration of intake air.
2 = Non-return valve A prefilter removes most of the oil, water droplets and par-
3 = Perforated cover ticles of dirt.
4 = Outlet valve
5 = Pre-filter
Drying material taken with the compressed air from the
6 = After-filter
drying tank must be filtered out.
Fig. 5.12 :
cold regeneration
85
5.4.6.2 Internal hot regeneration With hot regeneration the drying and regeneration times are
Pressure Operating Through- Entry tem- material. To reverse this process heat must be brought from
off the moisture.

Fig. 5.13 :
Adsorption material after 6 - 8 hrs drying time With internal regeneration the heat is transmitted directly
from a heater in the drying tank to the adsorption material.
This happens in two phases:
Dry compressed air
1st Phase
4
Drying tank B is slowly heated by the internal heating to the
2 necessary regeneration temperature. If the regeneration tem-
3 perature is exceeded, the moisture releases itself from the
adsorption material. Approx. 2 - 3 % of the dried flow of com-
5 pressed air from the compressor relaxes and at slight pres-
9
sure is directed through a diversion line through drying tank B.
This flow of regeneration air absorbs the moisture and directs
it out into the open through an outlet valve.
2nd Phase
A B In a cooling phase the operating pressure drops back to the
temperature of the drying bed. A second diversion line opens
for this purpose. Approx. 5 % of the compressor FAD is directed
through drying tank B. The internal heating is no longer oper-
ating at this point.
1
8
Features
6
7 Economical with high volume flows.
Regeneration
air Little dried compressed air is required to regenerate the
Moist compressed air dryer.
Prefiltration of intake air.
1 = Valve block A pre-filter removes most of the oil, water droplets and dirt
2 = Non-return valve particles from the compressed air.
3 = Diversion line with perf. cover 1st Phase Postfiltration of dried compressed air.
4 = Diversion line with perf. cover 2nd Phase Drying materials taken with the compressed air from the
5 = Heating drying tank must be filtered out of the compressed air.
6 = Stop valve
7 = Outlet valve
8 = Prefilter
9 = After-filter
Fig. 5.14 :
86
5.4.6.3 External hot regeneration With hot regeneration the drying and regeneration times are
Pressure Operating Though Entry tem- material. To reverse this process heat must be brought from
off the moisture.

With external regeneration air is drawn in from the atmos-

phere by a fan and heated in a heating register. This happens
Fig. 5.15 :
in three phases:
Adsorption material after 6 - 8 hrs drying time
1st Phase
The drying tank B is slowly heated to the necessary rege-
2 3 Dry compressed air neration temperature by the flow of hot air. Once the rege-
7 neration temperature is reached, the water releases itself from
the Adsorption material. The fan continues to supply hot rege-
4 neration air through drying tank B. This flow of regeneration
5 air takes on the moisture and transports it into the open through
an outlet valve.
9 2nd Phase
the temperature of drying tank B. For this purpose the heating
register of the fan is switched off and cold air from the atmos-
phere is directed through the drying tank.
A B
3rd Phase
At the end of cooling, dry, relaxed compressed air flows from
the compressor and through the drying tank, in order that the
atmospheric does not bring moisture back into the dryer.
8
Regeneration Features
air
1 6 Higher regeneration temperatures allow a lower pressure
Moist compressed air dew point.
1 = Bottom valve block Low additional consumption of compressed air.
2 = Top valve block Only a small part of the regeneration air is taken from
3 = Diversion line with perf. cover 3rd Phase the pneumatic system.
4 = Heating register Prefiltration of inlet air.
5 = Fan A pre-filter removes most of the oil, water droplets and dirt
6 = Stop valve particles from the compressed air.
8 = Prefilter
9 = After-filter
Fig. 5.16 :
87
5.4.6.4 Vacuum regeneration Vacuum regeneration is a variation of external hot regeneration.

As with hot regeneration the drying and regeneration times
are around 6 - 8 hrs. During the long drying time the moisture
Pressure Operating Through- Entry tem- deposits on the inner and outer surfaces of the adsorption
dew point pressure flow rate perature material. To reverse this process heat must be brought from
[C] [ barop ] [ m3/h ] [C] outside. If the regeneration temperature of the drying material
is exceeded by heat from outside, the surface energies that
to - 80 C 4 - 16 bar 400 - 7400 to + 40 C occur outweigh the adhesive forces in the drying material and
the water evaporates. A small flow of regeneration air drains
off the moisture.

Fig. 5.17 : With vacuum regeneration atmospheric air is drawn with a

Adsorption material after 6 - 8 hrs drying time partial vacuum into the drying tank. This flow of air heats ex-
ternally. Vacuum regeneration occurs in two phases.
3 2 Dry compressed air 1st Phase

A vacuum pump draws in air from the outside. This flow of air
5 is heated by a heating register and drawn through the drying
tank. Once the regeneration temperature is reached, the wa-
6 ter releases itself from the Adsorption material. The flow of
regeneration air takes on the moisture and transports it into
the open through an outlet valve.
8
2nd Phase
the temperature of the drying tank. For this purpose the heat-
A B ing register is switched off and cold air from the atmosphere is
directed through the drying tank.
Features

7 No additional compressed air consumption.
Regeneration No compressed air is taken from the system for regen-
air eration.
Long utility time of drying agent.
1 4 Thermal stress on the drying agent is low.
Energy savings through lower regeneration temperature.
Moist compressed air
Prefiltration of inlet air.
1 = Bottom valve block A pre-filter removes most of the oil, water droplets and dirt
2 = Top valve block particles from the compressed air.
4 = Heating register
5 = Fan
6 = Silencer
7 = Prefilter
8 = After-filter
Fig. 5.18 :
Vacuum regeneration
88
5.4.7 Arrangement of the refrigeration There are two basic possibilities for arranging a refrigeration
compressed air dryer compressed air dryer in a compressor station. It can either be
installed before or after the compressed air receiver. No gen-
eral decision on this matter is possible because there are
advantages and disadvantages with both constellations.
5.4.7.1 Dryer before the compressed air Advantages:

receiver
Dried air in the compressed air receiver.
No precipitation of condensate in the compressed air
receiver.
Consistent compressed air quality.
Even with abrupt, heavy withdrawal of compressed air
the pressure dew point of the compressed air remains
unchanged.
Disadvantages:
Large size dryer.

Fig. 5.19 : The dryer must be designed for the entire effective output
Dryer before the compressed air receiver of installed compressor. The dryer is often over-dimen-
sioned if consumption is low.
Drying of pulsating compressed air.
As a result of their construction, piston compressors in
particular deliver a pulsating flow of air. This puts stress
on the dryer.
High entry temperature of compressed air.
The compressed air comes directly from the after-cooler
of the compressor.
Drying of a partial air flow is not possible.
Large quantity of condensate.
The entire quantity of condensate precipitates in the dryer.
With systems containing several compressors, each
compressor must have a dryer connected.
Conclusion
Installing a dryer before the compressed air receiver can sel-

dom be recommended. However, an arrangement of this type
makes good sense when sudden peaks of requirement are
anticipated and the quality of the compressed air must not
deteriorate.
89
5.4.7.2 Dryer behind the compressed air Advantages:

receiver
Favourable dryer size.
The dryer can be sized according to the actual consump-
tion of compressed air, or for a partial flow of compressed
air that needs to be dried.
Drying of a non-turbulent volume flow.
Low compressed air entry temperature.
The compressed air has the opportunity to cool down
further in the compressed air receiver.
Low quantities of condensate.
The droplets of condensate collect in the compressed air
receiver and do not burden the rest of the system.
Fig. 5.20 :
Dryer behind the compressed air receiver
Disadvantages:
Condensate in the compressed air receiver.

Moisture in the compressed air receiver leads to corrosion.
Overload of the Dryer.
The dryer is overloaded if there is any abrupt, heavy
withdrawal of compressed air. The pressure dew point of
the compressed air rises.
Conclusion
In most cases, BOGE recommends installing the dryer be-

hind the compressed air receiver. The argument of economy
is in favour of it. A smaller dryer can normally be chosen. Its
efficiency rate is better.
90
5.5 Compressed air filters
5.5.1 Basic terminology of filters To assess and operate filters it is first necessary to define and
explain certain sizes and factors.
5.5.1.1 Filter separation rate [ % ] The filter separation rate gives the difference in concentra-
tion of impurities before and after the filter. It is also called the
efficiency rate. The filter separation rate is a measure of the
efficiency of the filter. The minimum grain size [ m ] that the
filter can separate must always be specified.
C1
= 100 100
C2
unfiltered Purified C1 = Concentration of impurities before the fil-

compressed air (C2 ) ter.
air ( C1 )
C2 = Concentration of impurities after the filter.
= Filter separation rate [%]
The concentration is usually measured in proportion of weight

per unit of volume [ g/m3 ] of compressed air. With weaker con-
centrations, the concentration is usually defined by counting
the particles per unit of volume [ Z/cm3 ]. The particles per unit
of volume method is nearly always used to measure the effi-
ciency of high-performance filters. Measuring the weight pro-
portion per unit of volume with sufficient accuracy would in-
Fig. 5.21 : volve a disproportionate amount of effort.
BOGE Pre-filter, series V
= 99,99 % relevant to 3 m
Example
Compressed air contains an impurity particle concentration of

C1 = 30 mg/m3 prior to filtering. The purified air after the filter
still has an impurity particle concentration of C2 = 0,003 mg/
m3 with particle sizes over 3 m.
30
= 100 100
0,003
= 99,99 %
The filter has a separation rate in per cent of 99,99 % relative

to 3 m.
91
5.5.1.2 Pressure drop p The pressure drop p is the difference in pressure before
and after the filter caused by flow. The pressure drop p in the
filter grows with time as particles of dust and dirt are collected
in the filter element.
p0 is the pressure drop for new filter elements.

It is between 0,02 and 0,2 bar, depending on the type of
filter.
The economically acceptable limit for pressure drop p is
around 0,6 bar.
Fig. 5.22 : Devices that measure the pressure difference are installed in
General filter with p measuring device most filters.
If the pressure drop p exceeds the limit, either the filter must
be cleaned or the element replaced.
5.5.1.3 Operating pressure The maximum volume flow of a filter always refers to the norm
pressure pop = 7 bar. When pressure changes the maximum
through-flow rate of the filter also changes. The change to the
through-flow rate can be easily calculated with the aid of ap-
propriate conversion factors f.
Pressure [ barop ] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Factor f 0,25 0,38 0,5 0,65 0,75 0,88 1 1,13 1,25 1,38 1,5 1,63 1,75 1,88 2
Example
A BOGE pre-filter V50 with a nominal performance of 300

m3/h at a norm pressure of pop = 7 bar is to be operated at
pop = 10 bar.
R7 = 300 m3/h R10 = R7 f
pop = 10 bar f = 1,38 R10 = 300 m/h 1,38
R10 = 414 m/h

[ m3/h ]

[ m3/h ]
f = Conversion factor for pop = 10 bar
At a pressure of pop = 10 bar the filter has an effective nominal

performance of 414 m3/h.
92
5.5.2 Dust separators After coming out of the compressor, the compressed air con-
tains water in the form of steam and also droplets of conden-
sate. These droplets are formed during the compression proc-
ess because the air is no longer able to accommodate it when
its volume is reduced.
p [ bar ] [ %] [ m ] [ mg/m3] This water normally deposits in the storage tank as the com-
pressed air become more inert. From there the condensate is
> 0,05 bar 95 % > 50 m not influ-
drained off.
enced
Operating principle
The dust separator operates according to the principle of mass

Purified air inertia. It consists of a vortex cartridge and a catch pan. The
vortex cartridge is designed to put the compressed air into
rotary movement. Solid and liquid components in the air are
forced against the inside walls of the pan by their own mass
1
inertia. This causes heavy particles of dirt and water to sepa-
rate. These separated impurities flow past a baffle plate into
the collection chamber. The baffle plate also prevents the flow
of air from taking the separated liquid with it.
Compressed
air flowing in The condensate can be drained off automatically or by hand
from the collection chamber and properly disposed of or treated.
2 Features
Almost complete separation of water droplets.

3
Heavy particles of dust and dirt filtered out.
4
The filtering capacity of the dust separator depends on the
flow speed of the air. The higher the flow speed, the more
1 = Vortex insert efficient the filter is. Of course, when the flow speed in-
2 = Baffle plate creases the pressure loss in the separator rises also.
3 = Collection chamber
Fig. 5.23 : No compressed air receiver in the pipeline system.
Cyclone separator
Large distances between the compressor and the receiver.
If the receiver is a long way from the compressor, then it
makes sense to install a cyclone separator directly down-
stream of the compressor. It prevents unnecessary trans-
port of water in the pipeline.
Rising lines between the compressed air receiver and the
compressor. The line between the compressor and the re-
ceiver goes vertically upwards. When the compressor is idle
the condensate flows back into the compressor. In this case
it makes sense to install a cyclone separator directly down-
stream of the compressor.
93
5.5.3 Pre-filters Pre-filters filter solid impurities to a particle size of approx.

3 m out of the compressed air but filter out very little oil and
moisture. Pre-filters take the load off high performance filters
and dryers when the air is very dusty. Finer filters can be dis-
pensed with if the demands on the quality of the compressed
air are low.
p [ bar ] [%] [ m ] [ mg/m3]
> 0,03 bar 99,99 % > 3 m not influ-

enced Operating principle
Pre-filters operate according to the principle of superficial fil-

tration. They have a purely sifting effect. The pore size deter-
mines the size of particle that can be filtered out. The impuri-
ties remain only on the outer surface of the filter elements.
Standard materials for filter elements are:
Sintered bronze.
Highly molecular polyethylene.
Sintered ceramics.
Fig. 5.24 :
Filtrations mechanism of surface filters Bronze or brass wire ( coarse filtration ).
Pleated cellulose paper inserts.
Air flows through the filter from the outside towards the in-
side. An opposite direction of flow would allow the separated
particles to build up inside the filter element. The growing col-
lection of solid matter would block the effective area of the
filter.
Features
Re-usability.
Because the separated particles are only collected on the
surface of the pre-filter element it is possible to clean the
element.
Fig. 5.25 :
BOGE Pre-filter, Series V
94
5.5.4 Microfilters Microfilters are used when high quality compressed air is
required. They deliver technically oil-free compressed air.
Microfilters reduce the residual oil content of compressed air
to 0,01 mg/m. They filter out dirt particles with a separation
rate of 99,9999 % relative to 0,01 m.
p [ bar ] [%] [ m ] [ mg/m3]
> 0,1 bar 99,9999 % > 0,01 m > 0,01 Operating principle
Microfilters, also called high-performance filters, are deep-bed

filters. The filter the water and oil condensate phase from the
compressed air in the form of fine and ultra-fine droplets.
The deep-bed filter is a fibrous web consisting of a tangle of

very fine individual fibres. The fibres are randomly intertwined
and thus form a porous structure. Between the fibres there is
a labyrinth-like system of passages and openings. This sys-
tem has flow channels that are sometimes much larger than
the particles than the particles to be filtered. Filtration occurs
along the entire path travelled by the compressed air on its
way through the filter element.
Fig. 5.26 :
Filtrations mechanism of deep-bed filters Microfilters work with pleated filter material. This enlarges the
effective filter surface by approx. 1/3 in comparison to wound
filters. The pressure drop p is also considerably reduced.
Filter material There are several advantages in this:
Increased through-flow rate.

Lower energy loss.
Longer service life.
Fig. 5.27 : Air passes through deep-bed filters from the inside towards
Pleated and wound filter material the outside. The liquid phase from oil and water deposits on
the fibrous web when passing through the filter. The flow of air
then drives the condensate and growing droplets further on
through the filter towards the outside. A part of the conden-
sate leaves the filter element again as a result of this effect.
Following the laws of gravity, the condensate collects in the
collection chamber of the filter.
The working lives of the filters are longer because the con-
densate filtered out is no longer a burden to the element with
this direction of flow.
Fig. 5.28 :
BOGE-Microfilter, Series F
95
Filter mechanisms
Three different mechanisms operate together to separate fine

particles from the air.
Unfiltered
compressed air Direct contact.
Larger particles and droplets hit the fibres of the filter
materials directly and are bound.
Impact.
Particles and droplets hit the randomly arranged fibres of
the filter material. There they bounce off, are directed out
of the path of flow and are absorbed by the next fibre.
Diffusion.
Filter medium Small and ultra-fine particles coalesce in the field of flow
and following Browns law of molecular movement come
together to form ever-growing particles. These particles are
then filtered out.
Borosilicate fibre in the form of fibreglass layers is the most

Technically oil-free and widespread material in high performance filters. It is used as a
clean compressed air material for deep-bed filters. The following are also used:
Metallic fibres.
Fig. 5.29 Synthetic fibres.

Mechanisms of deep-bed filtration
Features
Separation of oil in the liquid phase.

Hydrocarbons are found in two aggregate conditions in com-
pressed air: - in gaseous form as oil gas.
- liquid in the form of droplets.
A high-performance filter removes almost 100% of the oil
droplets. The oil gas can not be filtered out.
Low operating temperatures.
The efficiency of the filter drops when the operating tem-
perature rises. Some of the oil droplets vaporise and go
through the filter. With a rise in temperature from + 20 to
+ 30 C, 5 times as much oil passes through the filter.
Recyclable.
The materials used are chosen with ecological aspects in
mind.
96
5.5.5 Active carbon filters After passing through high-performance filters and dryers, the
technically oil-free compressed air still contains hydrocarbons
and diverse odorous and taste substances.
p [ bar ] [%] [ m ] [ mg/m3] There are many applications of pneumatics where these resi-
dues would lead to disruptions of production, adverse quality
> 0,02 bar 99,9999 0,01 > 0,005 and unpleasant smells.
An active carbon filter removes the hydrocarbon vapours from

the compressed air. The residual oil-content can be reduced
to 0.005 mg/m. The quality of the compressed air is better
than that demanded for breathing air by DIN 3188. The
condensated droplets of oil are already removed by the se-
ries-connected filter ( BOGE-Microfilter Series F ).
Operating principle
The filtration of compressed air by absorption is a purely physi-

cal process. The hydrocarbons are bound to the active car-
bons by powers of adhesion ( uneven molecular attraction ).
Chemical compounding does not take place in this process.
The dried and pre-filtered compressed air is directed through

a pleated active carbon filter element. The appearance of this
filter element is similar to that of the microfilter. As with the
microfilter, the compressed air is directed through the filter
element from the inside towards the outside.
Fig. 5.30 : Features

BOGE-Filter combination, Series AF
An active carbon filter with microfilter connected in Pre-filtration.
series An active carbon filter must always be connected upstream
from a high-performance filter and a dryer. Unfiltered com-
pressed air destroys the adsorbant and reduces the filtra-
tion effect.
No Regeneration.
The active carbon filling can not be regenerated. It must be
replaced, depending on the degree of saturation.
Working life.
The filter element of an active carbon filter must be replaced
after approx. 300 - 400 hours of operation.
Food and luxury food industry.

Pharmaceuticals industry.
Chemicals industry.
Surface treatment.
Medical equipment.
97
5.5.6 Active carbon adsorbers After passing through high-performance filters and dryers, the
technically oil-free compressed air still contains hydrocarbons
and diverse odorous and taste substances. There are many
applications of pneumatics where these residues would lead
to disruptions of production, adverse quality and unpleasant
smells.
p [ bar ] [%] [ m ] [ mg/m3 ]
An active carbon adsorber removes the hydrocarbon vapours
> 0,1 bar > 0,003
from the compressed air. The residual oil-content can be re-
duced to 0.003 mg/m. The quality of the compressed air is
better than that required for breathing air by DIN 3188. The
Pre-filter After-filter condensated droplets of oil are already removed by the se-
ries-connected filter ( BOGE-Microfilter Series F ).
Operating principle
The filtration of compressed air by adsorption is a purely physi-

cal process. The hydrocarbons are bound to the active car-
bons by powers of adhesion ( uneven molecular attraction ).
Chemical compounding does not take place in this process.
The dried and filtered compressed air is directed through a

diffusor into the loosely piled active carbon bed. The diffusor
distributes the compressed air evenly over the entire bed. This
allows long contact times and ideal use of the adsorption
material. After the adsorber bed the compressed air passes
through emission collector and leaves the active carbon
adsorber.
Features
Pre-filtration.
An active carbon filter must always be connected upstream
from a high-performance filter and a dryer. Unfiltered com-
Fig. 5.31 :
Op. plan of a pressed air destroys the adsorbant and reduces the filtra-
BOGE active carbon adsorber Type DC tion effect.
After-filtration.
For safety reasons a high performance filter should be con-
nected downstream from the adsorber. The compressed
air take very fine particles of carbon dust ( smaller than
1 m ) from the active carbon bed with it.
No Regeneration.
The active carbon filling can not be regenerated. It must be
replaced, depending on the degree of saturation.
Long working life.
The active carbon filling must only be replaced after 8000
- 10000 hours of operation.
As for active carbon filters.
98
5.5.7 Sterile filters Living organisms such as bacteria, bacteriophages and vi-
ruses are a big health problem in many areas. Sterile filters
create 100 % sterile and germ-free compressed air.
p [ bar ] [%] [ m ] [ mg/m3 ] Operating principle
> 0,09 bar 99,9999 0,01 The pre-purified flow of air is directed from outside towards
the inside through the filter element. The filter element is com-
posed of two filter stages. The pre-filter retains microorgan-
isms up to a size of 1 m. The second filter stage consists of a
chemically and biologically neutral, three-dimensional micro-
fibre web made of borosilicate. The remaining organisms are
filtered out here. The filter elements are fixed in place by a
stainless steel cage.
The filters can be cleaned and sterilised up to 100 times. They

are steamed for this purpose. In this process, hot steam of up
to +200 C flows through the filter. The steam can be sent
through the filter from both sides. Sterilisation by other media
is also possible.
Hot water
Hot air
Gas ( ethylene oxide, formaldehyde )
H 2O 2
Features
Stainless steel material.

All metal parts of the filter are made of high-alloy stainless
steel. Stainless steel offers microorganisms no nutritive
substratum and can neither corrode nor rot.
Resistent.
The filter medium is inactive and resistent to chemicals
and high temperatures. Bacteria can not grow on or through
it.
Fig. 5.31 : Short sterile contact distances.
BOGE Sterile filter, Series ST A sterile filter should be installed directly on the end con-
sumer device.
Food and luxury food industry.

Pharmaceuticals industry.
Chemicals industry.
Packing industry.
Medical equipment.
99
Disposal of condensate
6. Disposal of condensate
6.1 Condensate Condensate consists primarily of the water contained in the

air drawn into the compressor and which forms during com-
pression. The Condensate also contains many impurities.
Mineral oil aerosols and unburnt hydrocarbons from the

air.
Particles of dust and dirt of the most varied kinds from
the air.
Cooling and lubricating oil from the compressor.
Rust, scuff, pieces of sealing material and weld from the
pipeline.
Condensate is highly contaminated because of its high con-

tent of harmful substances, and for this reason it must be dis-
posed of responsibly. The mineral oils in the condensate are
hard to biodegrade and are detrimental to oxygen enrichment
and material disintegration in sewage works. This reduces the
efficiency of the entire water treatment effort. The conse-
quences are a hazard to nature and human health.
Distinctions must be made between condensate from differ-

ent pneumatic systems. The condensate has different proper-
ties, depending on environmental conditions and the compres-
sor. For example :
Oil lubricated compressor systems.

On compressors of this type the oil washes a part of the
aggressive and solid matter out of the air in the compres-
sion chamber. The result of this is that oil-lubricated sys-
tems normally produce condensate that has a pH-value in
the neutral range.
Oil-free compressor systems.
Most of the harmful substances in oil-free systems are dis-
charged with the condensate. This is why the condensate
has an acidic pH-value. pH-values between 4 and 5 are not
uncommon.
The consistency of the condensates also changes with mar-

ginal conditions. Most condensates are as fluid as water. But
pasteous condensates can occur in exceptional cases.
100
6.2 Condensate drains Everywhere condensate occurs in a pneumatic system it also

has to be drained. If it is not, the flow of air takes it with it, and
it enters the pipeline.
The fact that condensate collection tanks are under pressure

makes condensate drains costly. The condensate must be
drained off under control to unnecessary pressure loss.
It should also be taken into account that condensate does not

occur on a continuous basis. The quantity of condensate changes
with the temperature and moisture of air drawn in by the com-
pressor.
The summary shows the various construction types accord-

ing to their method of operation.
Types of condensate drains
Manual Automatic
Condensate drain Condensate drain

Condensate drain
Manual valve with time-dependent with volume
with float control
magnetic valve measuring
Electronic measuring
Level float
probe
When selecting condensate drains, regardless of the construc-

tion type, the condensate itself and the marginal conditions
must always be taken into consideration. Special applications
require special forms of condensate drain :
very aggressive condensates.

pasteous condensates.
explosion danger areas.
low pressure and partial vacuum networks.
high and very high pressure networks.
Condensate drains can not be used without heating in sub-

zero temperatures. The water component of the condensate
will freeze.
101
6.2.1 Condensate drains with manual The condensate collects in an appropriate tank (vessel). The
valves servicing or operating staff must check the level of the collec-
tion tank at regular intervals. If necessary, the condensate must
be drained off with the aid of a valve fitted to the bottom of the
tank.
Features
Simple, inexpensive construction.

No electricity connection required.
No alarm function.
Regular checks necessary.
The condensate must be drained at regular intervals.
6.2.2 Condensate drains with float Inside the condensate tank there is a float which controls an
control outlet valve at the bottom of the tank by means of a lever. If the
level in the tank rises above a certain level, the outlet valve is
opened. Excess pressure in the system forces the conden-
sate out. If the level in the tank falls below the minimum, the
4 valve closes automatically before compressed air can escape.
The condensate is now separated from the compressed air

and can now be sent by pipe to the treatment equipment.
Features
Simple, inexpensive design.

No electricity connection required.
Ideal for use in explosion danger areas.
1
No blowing off of compressed air.
Susceptible to malfunctions.
2
3 The moving parts of the system can solidify, stick or cor-
rode through direct contact with condensate.
1 = Inlet line Regular servicing required.
2 = Outlet line As a result of its susceptibility to malfunctions, it does re-
3 = Drain plug quire regular servicing.
4 = Vent No external alarm signal.
Fig. 6.1 : Inflexible.
Condensate drain with float control Float valves must be specially adapted for the condition of
the condensate.
102
6.2.3 Condensate drains with The condensate is collected in an appropriate tank. At fixed,
time-dependent magnetic valves regular intervals ( 1.5 to 30 min. ) a magnetic valve with timer
opens the drain at the bottom of the tank. After an opening
time of 0.4 to 10 s the valve closes again. The condensate is
forced out of the drain by system pressure.
The drain valve is connected condensate disposal facility by

pipes.
Note
If you wish to avoid having condensate in the pipe system the

entire volume of condensate must be drained off. Individually
adjustable opening times for the magnetic valve guarantee
perfect drainage of the condensate.
The quantity of condensate in Summer is far greater than in
Winter because atmspheric humidity is higher. If the opening
times set in Summer for the high humidity are not changed
later for Winter, low temperatures will cause high pressure
loss because the magnetic valves will be open for too long.
Not only the condensate but also large quantities of com-
pressed air will be blown off too.
To minimise compressed air loss the cycle times of the valves
must always be adjusted to suit local conditions.
Because the weather is not always consistent, it is not possi-
ble to set time intervals and valve opening times and not lose
compressed air at all. Either a part of the condensate remains
in the system or some compressed air is lost.
Fig. 6.2 : Features

Electromagnetic drain valve
Very reliable operation.
The system operates reliably, even with problematic con-
densates.
Electricity connection required.
No external malfunction signal.
No alarm function.
The magnetic valve operates when the pneumatic station
is switched on, even if no compressed air is required
( e.g., at weekends ).
103
6.2.4 Condensate drains with electronic

volume measurement
Operation
The condensate is collected in an appropriate tank. As soon

as the capacity level sensor Ni2 reports that maximum level, a
magnetic valve opens a pre-control line. The pressure on the
valve diaphragm is released and the outlet line is opened. The
1 excess pressure in the housing forces the condensate out
through the line to the reprocessing facility.
3
As soon as the level reaches capacity sensor Ni1, the mag-
Ni2
4 netic valve is electronically closed. The valve diaphragm closes
before compressed air can escape.
Ni1 5
Features
2 Very reliable operation.

The system operates reliably, even with problematic con-
densates.
6 Large cross-section.
Even large impurities and coagulated matter can be dis-
charged without difficulty.
Ni2 No pressure loss.
7
2 Ni1 Electricity connection required.
Flexible application.
The system adapts itself automatically to changing operat-
ing conditions( e.g., varied condensate viscosity and pres-
8 sure fluctuations ).
Alarm function.
1 = Inlet line If there is a malfunction in draining the condensate the
2 = Collection tank alarm mode is switched after 60 s. The magnetic valve then
3 = Pre-control line opens the valve diaphragm at certain intervals.
4 = Magnetic valve External malfunction signal.
5 = Valve diaphragm A red LED blinks and a potential-free signal is ready.
6 = Dipstick
7 = Valve seat Wide performance range.
8 = Outlet line
Fig. 6.3 :
Condensate drain with electronic volume measure-
ment
104
6.2.5 Condensate drains with level floats The collected condensate is directed into the collection cham-
for measuring the level ber of the condensate drain. A float moves on a guide together
with the level of the condensate in the chamber. The guide
has three contacts that electronically register the level in the
chamber. As soon as the float reaches Contact 2, the elec-
tronic control opens the magnetic valve. The pressure on the
7 valve diaphragm is released via a pre-control line and the outlet
line is opened. The system pressure forces the condensate
out of the condensate drain through a rising pipe.
The level of condensate in the pipe drops and after a set time
t the control closes the drain before compressed air can es-
cape. If the condensate level does not reach Contact 1 inside
the time t, the drain is opened at fixed time intervals and re-
closed after a set period. This guarantees that the condensate
3 collection chamber is completely emptied.
2 If the condensate level reaches Contact 3, the control actu-
6
ates the main alarm. The switching intervals and opening times
remain unchanged.
5 1
4 1
Features
3
Cleaning cycle times.
2 Even with longer idle times there is no dried condensate.
No pressure loss.
1 = Collection tank electricity connection required.
2 = Level float
3 = Guide
4 = Rising pipe
5 = Valve diaphragm
6 = Magnetic valve
7 = Control line
Fig. 6.4 :
Condensate drain with level float for measuring the
level
105
6.3 Condensate treatment Condensate from oil-lubricated compressors has an oil con-
tent of between 200 and 1000 mg/l, depending on the season.
This means that the condensate is around 99 % water and
only 1 % oil. Even so, the law requires that this condensate be
treated as waste water containing oil. As such it may not be
discharged into the public sewers. The stipulations for water
purity are set forth in 7a of the [German] Water Purity Act
( WHG ). This states that the level of harmful substances in
waste water is to be kept as low as the generally recognised
practices of engineering allow. These practices have been
defined by the German government in general administrative
rules.
According to ATV ( Waste Water Association, a non-profit-mak-

ing German organisation ) worksheet A 115 the limit for re-
sidual oil content in waste water is 20 mg/l. However, the local
authorities have the final word. In some areas the limits for
residual oil content are well below 20 mg/l.
This means that condensate must either be disposed of prop-

erly or treated.
Disposal
Disposal by a specialised company is a safe but involved and

very expensive procedure. Disposal costs currently run at
around 500 DM per m3 of condensate. The costs for approved
collection tanks and pipelines must also be taken into account.
Local treatment
Because of the high water content, it is always worth treating

oily condensate on site. Properly treated water can be dis-
charged into the public drainage lines. The oil separated from
it must be disposed of in an environmentally safe way.
The legal limits can not be reached by using normal light liquid
separators as per DIN 1999 and simple gravity separators.
Standard oil-water separators provide excellent law-compli-
ant treatment.
106
6.3.1 Oil-water separators The oil-water separator is suitable for treating condensates
that occur during the operation of screw compressors with
1 2 4 5 6 8 9 oil injection cooling and 1 and 2-stage piston compressors.
The oil-water separator parts condensate from piston and

screw compressors without difficulty as long as oils that do
not emulsify are used.
Operation
The oily condensate is directed into the pressure relief cham-

ber of the oil-water separator. There the excess pressure falls
without causing whirling movement in the vessel. The impuri-
ties carried with the condensate gather in the removable col-
lector.
Inside the separation vessel, the oil deposits on the surface

as a result of its lower specific density. Via a height-adjustable
3 7 10 overflow the oil is directed into the oil catch pan and is avail-
able for disposal.
1 = Condensate inlet
2 = Pressure relief chamber The pre-purified condensate flows through a pre-filter that fil-
3 = Impurity tank ters out the remaining droplets of oil. After that an adsorption
4 = Overflow pipe filter binds the last oil parts of the oil.
5 = Level reporter
6 = Pre-filter
7 = Adsorption filter
8 = Water outlet
9 = Oil overflow, height adjustable Note
10 = Specimen removal valve
All oil-water separation systems are water treatment plants
Fig. 6.5: and must be licensed by law. The oil-water separator should
Op. diagram of an oil-water separator have a specification inspection symbol. The expensive licens-
ing process is then no longer required. All that needs to be
done is to register at the local water authority.
Features
Weekly filter test.

A specimen of the condensate is compared with a refer-
ence liquid. A change of filter is necessary after the admis-
sible cloudiness is reached.
No separation of oil-water emulsions.
Special reprocessing systems with emulsion-splitting ap-
paratus is required for these stable emulsions.
Fig. 6.6 :
Oil-water separator
107
Compressed air requirement

7. Compressed air The first step in designing a compressor station and the re-
spective pneumatic network is to determine the requirement
requirement for compressed air and the resulting FAD of the compressor.
The first value to be found when determining the capacity of a

compressor station is the expected total consumption. The
consumption of the individual consumer devices is added
together and adjusted to operating conditions with the aid of
several multiplicators. The compressor can then be selected
according to the resulting FAD figure.
The procedure is similar for determining the size of pipelines.

Definition of the type and number of consumer devices on a
certain section of line comes first. The consumption of the
individual devices is added together and adjusted with the
appropriate multiplicators. The diameter of the respective sec-
tion of piping can then be deduced according to the result.
Loss through leakage must also be taken into account when

determining the expected consumption of compressed air.
7.1 Consumption of compressed Determining the total consumption of compressed air is often
air by pneumatic devices difficult due to lack of information about individual components.
This chapter provides guideline values for the requirements of
individual components.
The information given here concerning the consumption of

individual devices are average values. Please contact the
makers of the devices for exact figures.
7.1.1 Consumption of nozzles The consumption of compressed air by nozzles of different

shapes can vary greatly and depends on various factors :
Diameter of the nozzle.

The larger the nozzle, the greater the consumption.
Operating pressure of nozzle.
The higher the operating pressure, the greater the con-
sumption.
Shape of nozzle.
A simple, cylindrical through-hole consumes much less
compressed air than a conical or Laval-nozzle ( expansion
nozzle ).
Surface quality of aperture.
If the quality of the aperture is very good ( surface very
smooth, no grooves and unevenness ), more compressed
air can flow through.
Spraying or blowing.
The consumption of compressed air rises if the air is being
used as a medium for paint, sand, or the like.
108
7.1.1.1 Compressed air consumption Nozzles with a simple, cylindrical bore ( e.g., blow-out guns )
of cylindrical nozzles generate strong whirling and turbulence in the compressed
air that flows out. This reduces the speed of with which it flows.
Consumption is comparatively low.
The following table gives reference values for the compressed

air consumption of cylindrical nozzles depending on operat-
ing pressure and nozzle diameter :
Fig. 7.1 :
Blow-out gun
Nozzle Operating pressure [ barop ]

[ mm ] 2 3 4 5 6 7 8
0,5 8 10 12 15 18 22 28
1,0 25 35 45 55 65 75 85
1,5 60 75 95 110 130 150 170
2,0 105 145 180 220 250 290 330
2,5 175 225 280 325 380 430 480
3,0 230 370 400 465 540 710 790
Air consumption values in the table are given in l/min .
109
7.1.1.2 Compressed air consumption Paint applied by a spray gun must be even and not drip. The
of paint spray guns nozzles of spray guns are therefore designed for an expand-
ing, non-turbulent volume flow with a high exit speed. The con-
sequence is high consumption of compressed air, well above
that of cylindrical nozzles.
The consistency and desired quantity of paint to be applied

determines the operating pressure and the nozzle diameter of
the spray gun. These two values considerably influence the
compressed air requirement.
With paint spray guns, a distinction is made between flat, broad

and round spray nozzles. The type of spray influences the
application of paint. There is also a difference in the com-
pressed air requirement. On many spray guns it is possible to
switch the types of spray.
Fig. 7.2 :
Paint spray gun with paint tank

air consumption of spray paint nozzles depending on operat-
ing pressure, nozzle diameter and type of spray :

Flat and broad spray
[ mm ] 2 3 4 5 6 7 8
0,5 100 115 135 160 185
0,8 110 130 155 180 225
1,0 125 150 175 200 240
1,2 140 165 185 210 250
1,5 160 180 200 225 260
1,8 175 200 220 250 280
2,0 185 210 235 265 295
2,5 210 230 260 300 340
3,0 230 250 290 330 375

Round spray
[ mm ] 2 3 4 5 6 7 8
0,5 75 90 105
0,8 85 100 120
1,0 95 115 135
1,2 110 125 150
1,5 120 140 155
110
7.1.1.3 Compressed air consumption When spraying, the medium must hit the workpiece with great
of jet nozzles kinetic energy i.e., with high speed. This is the only method
that will achieve the desired result.
For this reason jet nozzles are designed for an extremely high
exit speed of the compressed air. This leads to comparatively
high consumption of compressed air.

air consumption of jet nozzles depending on operating pres-
sure and nozzle diameter :

[ mm ] 2 3 4 5 6 7 8
3,0 300 380 470 570 700
4,0 450 570 700 840 1000
5,0 640 840 7050 1270 1500
6,0 920 1250 1600 1950 2200
8,0 1800 2250 2800 3350 4000
10,0 2500 3200 4000 4800 6000
111
7.1.2 Compressed air requirement Compressed air cylinders are especially used in the area of
of cylinders automation. A distinction is made between two types of cylin-
der when determining the consumption of compressed air:
The single-action cylinders use compressed air to gener-

ate the movement of the working stroke only. The return
stroke is performed by spring power or from the outside.
Double-action cylinders use compressed air to generate
movement in both stroke directions. Force is used for both
strokes. Accordingly, he consumption of compressed air is
twice as high.
The compressed air consumption q of pressure cylinders is

determined by using the following formula:
d2
q = Spab
4
q = Air consumption( 1 barabs and 20 C ) [ l/min ]

Fig. 7.3 : d = Piston diameter [ dm ]
Clamping device with pneumatic cylinder
S = Length of piston path ( Stroke ) [ dm ]
p = Operating pressure [ barabs ]
a = Work cycles per minute [ 1/min ]
b = 1 with single-action cylinders

2 with double-action cylinders
Example
A singe-action cylinder with a piston diameter of 100 mm is

required to work at an operating pressure of 7 barabs . Its work-
ing stroke is 120 mm at 47 work cycles per minute.
12
q = 112 1,3 7 47 1
d = 100 mm ^
= 1 dm 4
S = 130 mm ^
= 1,3 dm
q = approx. 336 l/min
p = 7 barabs
a = 47 This cylinder consumes approx. 336 Litres of compressed

air per minute.
b = 1
112
7.1.3 Compressed air consumption Pneumatic tools are among the most frequent consumers of
of tools compressed air in industry and the crafts. They are large num-
bers of them in almost every environment.
They generally require a working pressure of 6 bar however,

there are versions that use other working pressures, depend-
ing on the application and the performance required. In these
cases the consumption of compressed air will differ from the
levels shown in the table.
The following table gives reference values for consumption of

compressed air by a number of pneumatic tools. These values
Fig. 7.4 :
may vary for individual tools and should be regarded as aver-
Drive screw powered by compressed air
ages.
Tool Air consumption

Working pressure 6 barop [ l/min ]
Drill Drill up to 4 mm 200

4 10 mm 200 450
10 32 mm 450 1750
Screw machine M3 180

M4 M5 250
M6 M8 420
Drive screw M10 - M24 200 1000
Angle grinder 300 700
1
Vibration grinder /4 Sheet 250
1
/3 Sheet 300
1
/2 Sheet 400
Belt grinder 300 400
Hand grinder Collet chucks 6 - 8 mm 300 1000

8 - 20 mm 1500 3000
Tacker, tack chuck 10 60
113
Device Air consumption

Working pressure 6 barop [ l/min ]
Nailer 50 300
Sash saw ( wood ) 300
Plastic and textile shears 250 350
Metal shears 400 900

Chamfer mortiser ( wood and plastic ) 250 400
Chamfer plane ( phases for welding seams ) 2500 3000
Rust remover 250 350
Needle rust remover 100 250
Light universal hammer 150 380

Rivet, chisel and mortise hammer 200 700
Light pick and shaft hammer 650 1500
Heavy pick and shaft hammer 3000
Pneumatic spade 900 1500
Drill hammer 500 3000
Stamp hammer( foundries ) 400 1200

Stamp hammer ( concrete and earth ) 750 1100
Vibrator ( inside - outside ) 500 2500
114
7.2 Determining compressed When determining the compressed air requirement of a pneu-
air requirement matic network, it is not simply a case of adding the consump-
tion values of the individual devices. Other factors that influ-
ence consumption must also be taken into account.
7.2.1 Average operation time Most pneumatic devices, such as tools, spray paint guns and
blow-out guns are not in continuous use. They are switched
on and off when needed. It is therefore necessary to find out
the average usage rate UR in order to obtain an accurate fig-
ure for the compressed air requirement.
The following formula is used to determine the average usage

rate UR:
TU
UR = 100 %
TR
UR = average usage rate [%]

TU = usage time [ min ]
TR = reference time [ min ]
Example
A semiautomatic screwdriver is in use for 25 min in the course

of one hour.
ON
25
UR = 100 %
60
UR = 41,6 %
OFF The usage rate UR of the tool is 41,6 %.
The average usage rates UR of some widely used pneumatic

TU = 25 min devices is given in the following table. The figures are based
on general experience and may deviate sharply in special
TR = 60 min
cases.
Fig. 7.5 :
Tool Average usage rate
Average operation time
Drill 30 %
Grinding machine 40 %
Mortise hammer 30 %
Stamp hammer 15 %
Forming machine 20 %
Blow-out gun 10 %
Tooling machine 75 %
115
7.2.2 Simultaneity factor The simultaneity factor f is an empirical value. It is based on

experience of pneumatic devices that are not in use at the
same time. The simultaneity factor f is a multiplicator that
adjusts the theoretical total consumption of a number of de-
vices to realistic conditions.
The following table gives the generally recognised values for

the simultaneity factor f:
Qty. consumer devices Simultaneity factor f
1 1,00
2 0,94
3 0,89
4 0,86
5 0,83
Fig. 7.6 :
Supplying several consumer devices on a pneumatic 6 0,80
network 7 0,77
8 0,75
9 0,73
10 0,71
11 0,69
12 0,68
13 0,67
14 0,66
15 0,64
16 0,63
The simultaneity factor f is used with the following pneumatic

devices:
Non-automatic nozzles as described in chapter 7.1.2.

Non-automatic pneumatic tools as described in chapter
7.1.3.
Machine tools, production machinery and the like,
if no other requirement is specified.
116
7.2.3 Defining compressed air When defining the total compressed air requirement for a pneu-
requirement matic network the consumer devices are divided into two
groups:
Automatic consumer devices.

General consumer devices.
7.2.3.1 Automatic consumer devices The consumer group includes automatic pneumatic cylinders,
machinery in continuous operation and longer work cycles
that require compressed air. These must be calculated at total
individual consumption q when working out the requirement.
Automatic consumer devices Working Quantity Individual

pressure consump. Qq
[ barop ] Q [ Units ] q [ l/min ] [ l/min ]
Automatic compressed air cylinders 6 2 336 672
Working machinery 5 1 310 310
Total TQ compressed air consumption of all automatic devices [ l/min ] 982 l/min
117
7.2.3.2 General consumer devices Most work cycles only run some of the time. An average us-
age rate UR can be calculated for these processes. Also, the
consumer devices are not usually all in use at the same time.
The average usage rate UR and the simultaneity factor f are

used for general consumer devices as requirement-reducing
multiplicators when making the calculation.
General compr. air consumers Working Usage Quantity Individual Q q UR / 100

pressure rate consump.
[ barop ] UR [ % ] Q [ Units ] q [ l/min ] [ l/min ]
Spray paint guns 1,5 mm 3 40 1 180 72
Blow-out guns 1,0 mm 6 10 3 65 19,5
Drive screw M10 6 20 3 200 120
Drills up to 20 mm 6 30 1 700 210
Angle grinders 6 40 2 500 400
Total T air consumption of all general consumer devices[ l/min ] 821,5
Simultaneity factor f 0,71
Air consumption Tf of general consumer devices Tf = f T [ l/min ] 583,3

7.2.3.3 Total compressed air consumption The theoretical total compressed air consumption T is the sum
of the consumption of automatic and general devices.

T = TQ + Tf

T = 982 + 583,3

T = 1565,3 l/min = 1,57 m/min
However, the total compressed air consumption is not yet a

suitable figure for determining the capacity of the compressor
and the size of the pipes. Several allowances still have to be
made.
118
7.2.4 Allowances for losses and Several allowances must be taken into account to bring the
reserves total consumption figure for individual devices to the actual
output requirement of a compressor:
Allowances [%] Losses v [ % ]
Losses 5 - 25 Losses v through leakage and friction occur in all parts of a

Reserves 10 - 100 pneumatic system. New systems require an allowance of
approx. 5 % of total FAD to be added for losses. Since leak-
Error 5 - 15
ages and friction losses generally increase when the equip-
ment gets older, losses of up to 25 % should be assumed for
older systems.
Reserves r [ % ]
A pneumatic system is sized according to a current estimate

of compressed air consumption. Experience shows that con-
sumption usually rises later. It is advisable to take short and
medium-term extensions of the network into account when
planning the size of the compressor and main pipelines. If this
is not done, later extension of the system can be unnecessar-
ily expensive. An allowance for reserves r of up to 100 % can
be taken, depending on the outlook.
Margin for error f [ % ]
Despite the care taken in calculation, the figures for expected

compressed air consumption are still usually wrong. An exact
figure can seldom be arrived at because of marginal condi-
tions that are mostly unclear. If a pneumatic system is de-
signed too small and needs to be extended later it will cause
additional costs ( equipment out of action ), and so an allow-
ance f of 5 - 15 % is advisable to provide a margin for error.
7.2.5 FAD Required LB When calculating the FAD required LB, allowances of 5 % for
losses, 10 % for reserves and a 15 % margin for error are

added to the calculated total consumption value T

T ( 100 + v + r + e )
LB =
100
T = 1826 l/min
1826 ( 100 + 5 + 10 + 15 )
v = 5 % LB =
100
r = 10 % LB = 2035 l/min = 2,04 m/min
e = 15 %
The FAD quantity LB, required to give consumer devices an
adequate supply of compressed air is approx. 2035 l/min. This
value is the basis for determining the size of the compressor
and the main pipeline.
119
7.3 Compressed air loss Compressed air loss is consumption of air ( leakage ) in the
pipelines without work being performed. These losses can
amount to 25 % of the entire FAD of the compressor in unfa-
vourable circumstances.
The causes are manyfold:
Leaking valves.
Leaking screw and flange joints.
Leaking weld seams or soldered points.
Damaged hoses and hose connections.
Defective magnetic valves.
Jammed float drains.
Incorrectly installed dryers, filters and service facilities.
Corroded lines.
7.3.1 Costs of compressed air loss Leaks in a pipeline act like nozzles from which compressed
air escapes at high speed. These leaks consume compressed
air 24 hours per day. The energy needed to compensate for
this loss can be considerable. This does not cause physical
injury, but the resulting expense can seriously diminish the
cost-effectiveness of the pneumatic system.
One example demonstrates the magnitude of the addi-

tional cost :
With a network pressure of 8 bar approx. 75 l/min = 4,5 m/h

escape from a leak of 1 mm diameter. A motor output of 0,6 kW
is required for this volume flow. At a price of 0,25 DM/kWh and
8 000 hours of operation, the additional annual cost amounts
to approx. DM 1250, depending on the efficiency of the motor.
Leak Air escaping Losses

hole - at 8 barop Energy Cash
[ mm ] Size [ l/min ] [ kW ] [ DM/Y ]
1 75 0,6 1350
1,5 150 1,3 2900
2 260 2,0 4300
3 600 4,4 10200
4 1100 8,8 20300
5 1700 13,2 31100
120
7.3.2 Quantifying leakage The first step in minimising compressed air loss is to quantify

the leakage VL. There are two ways of doing this:

7.3.2.1 Quantifying leakage The simplest way of quantifying leakage VL is by emptying the
by emptying the receiver compressed air receiver.
The supply line to the receiver is plugged . All consumer

devices in the system must be switched off. The receiver pres-
sure pS drops as a result of the leak to pressure pF. The time t
is measured.
The following formula is used to roughly quantify the volume

of leakage VL :
VT V T ( pS p F )
VL =
t

VL
pS
VL = Volume of leakage [ l/min ]

pF VT = Volume of receiver [l]
pS = Receiver pressure at start [ barop ]

VT = 1000 l
pF = Receiver pressure at finish [ barop ]
pS = 8 bar
t = Time measured [ min ]
pF = 7 bar
t = 2 min
Example
A compressed air receiver with a large pipeline system has a

volume of 1000 l. Within 2 min. the receiver pressure drops
from 8 to 7 barop.
1000 ( 8 7 )
VL =
2

VL = 500 l/min
The leakage volume of this pneumatic system is approx. 500

l/min.
Note
This method of measuring is only suitable for systems where

the pipeline system is less than 10 % of the volume of the
receiver. Otherwise the results are too inaccurate.
121

7.3.2.2 Quantifying leakage by measuring The second method of quantifying the volume of leakage VL
working time is by measuring the operating time of the compressor. This
method can only be used with compressors having intermit-
tent and idling operation modes.
The consumer devices in the network are switched off. The

leaks in the system consume compressed air and the network
pressure drops. The compressor must replace this volume.
The total running time t of the compressor is measured over

a period of time T. To obtain a realistic result, the measuring
time T should last for at least 5 cycle intervals of the com-
pressor.
The following formula is used to roughly quantify the volume

of leakage : VL

V t 1000
VL =
T
m/min s 1000 l
l/min = -
s m

V = 1,65 m/min
t = 30 s
VL = Volume of leakage [ l/min ]
T = 180 s
V = Compressor FAD [m3/min ]
t = Total running time of compressor [s]
t = t1 + t2 + t3 + t4 + t5
T = Measuring time [s]
Example

A compressor with an effective FAD V of 1,65 m/min has five
actuations during a measuring time of T = 180 s. Its total run-
ning time t during the measuring time T is 30 s.
1,65 30 1000
VL =
180

VL = 275 l/min
The leakage volume of this pneumatic system is approx. 275

l/min.
122
7.3.3 Limits for leakage Unfortunately, compressed air loss through leakage is inevita-
ble in normal pneumatic systems. The additional costs caused
by leakage reduce the cost-effectiveness of the system con-
siderably. Measures can be taken to reduce the loss, but this
causes costs money as well. At some point, these costs will
outweigh the savings made by cutting the loss of compressed
air. The objective must therefore be to minimise the loss of
compressed air at acceptable expense.
There are therefore some levels of leakage that should be

tolerated for reasons of economy :
max. 5 % on smaller networks.

max. 7 % on medium-sized networks.
max. 10 % on larger networks.
max. 13 - 15 % on very large networks.
e.g., foundries, steel mills, shipyards etc.
7.3.4 Measures for minimising Staff should be instructed to report leaks and damage to the
compressed air loss network to the persons in charge. Damage should be rectified
immediately. If a system is looked after on a permanent basis,
there will normally be no need for expensive reconstruction of
the network. Compressed air loss will be kept at an accept-
able level.
Leaks
It is usually quite easy to find leaks. Large leaks can be heard.
However, small and very small leaks are harder to find and
can not usually be heard. In these cases, the joints, branches,
valves etc. are covered with seal checker or soapy water. Bub-
bles form immediately where there are leaks.
123
7.3.5 Reconstructing a pneumatic If the leakage volume lies clearly above the levels specified in
network chapter 7.3.3, reconstruction of the system should be con-
sidered.
When reconstructing a pneumatic system the following meas-

ures should be taken to reduce compressed air loss:
Tighten leaking joints or reseal them.

Replace leaking joints and slides.
Replace leaking hoses and hose connectors.
Weld leaks on pipelines.
Upgrade condensate drains.
Replace mechanical float drains and time-controlled
magnetic valves with level-controlled condensate drains.
Upgrade compressed air preprocessor.
Remove harmful impurities such as water, oil and dust
from the compressed air.
Check magnetic valves.
If possible, install normally closed valves.
Flush or replace old pipelines.
The inside diameter of old pipes is often reduced by
deposits. This causes a drop in pressure.
Check couplings and pipe connections.
Reductions in the size of cross-sections causes a drop in
pressure.
Reduce the size of the system for limited periods.
Cut off parts of large systems with stop valves when not
needed.
124
Determining the size of the compressor station
8. Determining the size of the compressor station
8.1 The type of compressor The primary decision when installing a compressor station is
choosing the type of compressor. Screw or piston compres-
sors are the right choice for nearly all applications.
8.1.1 Screw compressors Screw compressors are particularly suitable for certain appli-
cations.
Long usage rate UR.

Screw compressors are particularly suitable in situations
where consumption of compressed air is continuous and
without large peak loads ( UR = 100 % ). They are excel-
lent as base load machines in composite compressor sys-
tems.
High FAD.
The screw compressor is the most economical type where
high FAD is needed.
Pulse-free volume flow.
Through uniform compression the screw compressor can
also be used for very sensitive consumer devices.
Fig. 8.1 Screw compressors operate economically with final com-
BOGE screw compressor, Series S pression pressures of between 5 and 14 bar.
The normal maximum pressure pmax categories for screw
compressors are 8 bar, 10 bar and 13 bar.
8.1.2 Piston compressors Piston compressors also have their special areas of applica-
tion. They are an ideal supplement to those of the screw com-
pressors.
Intermittent requirement.
Piston compressors are suitable for fluctuating consump-
tion of compressed air with load peaks. They can be used
as peak-load machines in a compressor group system.
These compressors are the best choice for frequently
changing loads.
Small FAD quantities.
When FAD quantities are small, the piston compressor is
more economical than the screw compressor.
Piston compressors can compress to high final pressures.
The normal maximum pressure pmax categories for piston

compressors are 8 bar, 10 bar, 15 bar, 30 bar and 35 bar.
Fig. 8.2 :
BOGE piston compressor with horizontal com-
pressed air receiver
125
8.2 Maximum pressure pmax The next step in determining the size of a compressor with
compressed air receiver and air treatment is to define the maxi-
mum pressure of the compressor pmax.
The basis for the maximum pressure ( cutout pressure pmax )

is the cycle difference ( pmax - pmin ) of the compressor control,
the maximum operating pressure of the consumer devices
and the total pressure loss within the network.
8.2.1 Factors influencing cutout The receiver pressure, which fluctuates between pmin and pmax,
pressure pmax must always be much higher than the operating pressures of
the consumer devices in the network. Pressure loss always
occurs in pneumatic systems. This is why the pressure loss
caused by the various components of a pneumatic system
must be taken into consideration.
The following values must be considered when defining the

cutout pressure pmax:
Normal pneumatic networks 0,1 bar

Behaviour of pressure
The network should be designed so that the total pressure
loss p of the entire network does not exceed 0.1 bar.
Fig. 8.3 :
Behaviour of pressure in a compressed air receiver Large pneumatic networks 0,5 bar
On widely branched networks, e.g., in mines, quarries or
large building sites, a pressure loss p up t 0.5 bar can be
allowed.
Treatment of compressed air by dryer.
Diaphragm compressed air dryer with Filter 0,6 bar
Refrigeration compressed air dryer 0,2 bar
Adsorption compressed air dryer with filter 0,8 bar
Compressed air treatment by filters and separators.
Dust separator 0,05 bar
Filters generally 0,6 bar
The pressure loss p through filters rises from soiling. The
latest time at which the filter must be changed is specified.
The cycle difference of the compressor.
Screw compressors 0,5 - 1 bar
Piston compressors pmax - 20 %
Reserves.
Unforeseen pressure loss occurs time and again in pneu-
matic systems. An adequate contingency reserve should
always be planned for in order to avert performance loss.
126
8.3 Determining the volume of a Compressed air receivers are tanks used for storing com-
compressed air receiver pressed air, damping pulsation and separating condensate in
the pneumatic system. The receiver must be of the correct
size to be able in particular to fulfill its task of storing com-
pressed air.
8.3.1 Recommendations for the volume Determining receiver volume VR is accomplished primarily by
of compressed air receivers values gained from experience. BOGE recommends the fol-

lowing ratios of compressor FAD V [ l/min ] to receiver volume
VR [ l ] :

Piston compressors. VR =V
Intermittent running is aimed for due to the properties of
the compressor.

Screw compressors VR = V/3
Constant running is aimed for due to the properties of the
compressor.
After defining the volume of the receiver, with piston compres-

sors it is time to work out the cycle interval, which comprises
the compressor running and idling times. The number of com-
pressor cycles results from this.
8.3.2 Norm series and operating Compressed air receivers are available in sensibly graduated
pressures for sizes of compressed volume sizes. A standard size should always be chosen to
air receivers save unnecessary costs for custom-made equipment.
The maximum pressure for which the receiver is designed is,
for safety reasons, always at least 1 bar above the maximum
pressure of the compressor. 10 bar compressors have, for in-
stance, a compressed air receiver designed for 11 bar. The
safety valve is adjusted for 11 bar.
The following table shows the sizes of compressed air receiver
available for various operating pressures:
Compressed air Operating pressure up to

receiver vol. [ l ] 11 [ bar ] 16 [ bar ] 36 [ bar ]
18
30
50
Fig. 8.4 : 80
Compressed air receiver, standing 150
250
350
500
750
1000
1500
2000
3000
5000
127
8.3.3 Volumes of compressed air The ideal capacity of compressed air receiver for a compres-
receivers for compressors sor can be defined more precisely with the aid of a formula.
The formula is ideal when long idle periods are planned with
intermittent operation. The volume of the pneumatic system
can be considered as a part of the receiver volume.

V 60 [ LB/V - ( LB/V ) ]
VR =
Al ( pmax - pmin )

V VR
LB VR = Volume of compressed air receiver [ m3 ]

V = FAD of compressor [ m3/min ]
LB = Required FAD [ m3/min ]
Al = Allowed motor cycles / h [ 1/h ]

Fig. 8.5 : ( see chapter 8.4.3 )
Compressor and compressed air receiver
pmax = Cut-out pressure of compressor [ barop ]
pmin = Cut-in pressure of compressor [ barop ]
Despite taking all influencing factors into account, it is advis-

able to check the determined receiver size against the allowed
motor cycles of the compressor.
Obviously, compressors with small receiver volumes VRswitch

on and off more often. This is a strain on the motor. In contrast,
with a large receiver volume VR and a constant output the
motor of a compressor switches on less often. This spares the
motor.
Simple formulae for determining the size of the compres-
sed air receiver
Piston compressor Screw compressor

Q 15 Q 5
VR = --- VR = ---
Al p Al p
VR = Volume of compressed air receiver [ m 3]
Q = FAD of compressor [ m3/min ]
15 or 5 = Constant factor
Al = Allowed motor cycles / h [ 1/h ]

( see chapter 8.4.3 )
p = Pressure differential ON/OFF
128
8.4 Compressor cycle intervals The cycle interval is an important factor in a pneumatic sys-
tem. To check the correct size of the receiver in relation to the
FAD and compressed air consumption the cycle interval must
first be calculated. This is done by calculating the compressor
running time tR and the compressor idle time tI, the sum of
which provides the cycle interval.
8.4.1 Compressor idle times During the compressor idle time tI the compressed air require-
ment is covered from the volume of air stored in the receiver.
The pressure in the receiver thus drops from the cutout pres-
sure pmax to the cut-in pressure pmin. During this time the com-
pressor does not deliver compressed air.
The following formula is used to determine the compressor

idle time tI:
VR ( pmax - pmin )
tI =
LB
tI = Idle time of compressor [ min ]

VR = Volume of compressed air receiver [l]
LB = Required FAD [ l/min ]
pmax =Cut-out pressure of compressor [ barop ]
8.4.2 Compressor running times During running time the compressor compensates the pres-
sure loss in the receiver. At the same time the current com-

pressed air requirement is covered. The output V is higher than
the actual consumption LB. The pressure in the receiver rises
back to pmax.

running time tR:
VR ( pmax - pmin )
tR =
(V-L )
B
tR = Running time of compressor [ min ]


V = FAD of compressor [ l/min ]
129
8.4.3 Determining the motor cycle speed The maximum motor cycle speed depends on the size of the
drive motor. The drive motor can be damaged if the maximum
number of cycles is exceeded.
To determine the number of expected motor cycles A for the

compressor, the compressor running time tR and idle time tI
are added together, and the reference time ( normally 60 min )
divided by the result.
The compressed air receiver must be larger if the result is

above the maximum allowed number of cycles Al.
A second possibility would be to increase the cycle diferential

( pmax - pmin ).
60
A =
tI + tR
A = Cycle speed [ 1/h ]
The following table gives the allowed number of cycles for an

electric motor per hour depending on the power rating of the
motor.
Motor power rating Allowed cycles/ h Al

[ kW ] [ 1/h ]
4 - 7,5 30
11 - 22 25
30 - 55 20
65 - 90 15
110 -160 10
200 - 250 5
130
8.5 Examples for compressor configuration
8.5.1 Sample calculation for piston In chapter 7.2.5 the required FAD of LB = 2035 l/min was
compressors determined for a number of consumer devices. The maximum
required working pressure in this example is 6 barop. A piston
compressor is dimensioned for this case of application.
8.5.1.1 Determining the maximum The maximum compressor pressure pmax of the pneumatic
pressure pmax system must now be determined. Starting from the working
pressure of the consumer devices, all components in the pneu-
matic system must be taken into consideration:
Maximum working pressure in the system 6 barop

Pneumatic network Pressure loss 0,1 bar
Filters Pressure loss 0,6 bar
Refrig.compressed air dryer Pressure loss 0,2 bar

Minimum pressure in receiver 6,9 barop
The cut-in pressure pmin must always

be above this pressure.
Fig. 8.6 :
Cycle differential of piston compressors approx. 2 bar
Compressor station with piston compressor, com-
pressed air receiver, refrigeration compressed air
dryer and filter system
The cut-out pressure pmax is at least 8,9 barop
Selected maximum compressor pressure 10 bar op

( cut-out pressure of compressor )
131
8.5.1.2 Determining compressor size Piston compressors are designed with reserves of approx.
40 %. Reserves are included from experience, in order to have
a contingency for possible extensions to the system and to
use the compressor intermittently. Intermittent operation means
less wear.
The ideal usage rate UR for a piston compressor is around

60 %. BOGE piston compressors are designed for 100 % UR =
continuous operation. When calculating the ideal compressor
size this means: the required FAD L B must be divided by 0.6 in

order to obtain the minimum FAD Vmin of the piston compres-
sor.

Vmin = LB / 0,6

V min = 2035 / 0,6
Fig. 8.7 :
V min = 3392 l/min
BOGE piston compressor, type RM 3650-213
The choice is:
Piston compressor Type RM 4150-213
Max. pressure pmax : 10 bar

FAD V : 3350 l/min
Motor rating : 30 kW Al = 20
8.5.1.3 Volume of the compressed air The volume of the compressed air receiver should be deter-
receiver mined using the BOGE recommendation, compressor FAD

V volume of compressed air receiver VR. The graduations
among standardised sizes for receivers must be taken into
consideration.

V = 3350 l/min VR = 3000 l
132
8.5.1.4 Compressor cycle interval After defining the size of the compressed air receiver it is nec-
essary to determine the compressor running and idle times in
order to check the motor cycle rate C.
The following formula is used to find the compressor idle time

t I:
VR = 3000 l
VR ( pmax - pmin )
tI =
pmax = 10 barop LB
pmin = 8 barop 3000 ( 10 - 8 )
tI =
LB = 2035 l/min 2035
tI = 2,95 min


running time tR:
VR = 3000 l
VR ( pmax - pmin )
tR =
pmax = 10 barop -L )
(V B
pmin = 8 barop 3000 ( 10 - 8 )

tR =
V = 3650 l/min ( 3350 - 2035 )
LB = 2035 l/min
tR = 4,56 min


V = FAD of compressor [ l/min ]
133
8.5.1.5 Motor cycle rate of compressor The motor cycle rate is calculated from the compressor run-
ning and idle time and compared with the allowed figure Al.
tI = 2,95 min
60
C =
tR = 4,56 min tI + tR
60
C =
Motor output rating 22 kW Al = 25 2,95 + 4,56
C = 8
C = Cycles [ 1/h ]
Approx. 8 cycles per hour is well below the allowed number for
the 30 kW motor ( Al = 20 ). The compressed air receiver is of
a good size. It could even be somewhat smaller because of
the large reserve of motor cycles.
Note
If the exact compressed air consumption is not defined, 50%

of the of the compressor FAD can be assumed as consump-
tion when determining the motor cycle rate. In this case the
idle and running times of the compressor are the same. This
results in the maximum number of motor cycles.
134
8.5.2 Sample calculation for screw In chapter 7.2.5 the required FAD of LB = 2,04 m/min was
compressors determined for a number of consumer devices. The maximum
required working pressure in this example is 6 barop. A screw
compressor is sized for this application.
8.5.2.1 Example for determining the The maximum compressor pressure pmax of the pneumatic
maximum pressure pmax system must now be determined. Starting from the working
pressure of the consumer devices, all components in the pneu-
matic system must be taken into consideration:
Maximum working pressure in the system 6 barop

Pneumatic network Pressure loss 0,1 bar
Filters Pressure loss 0,6 bar
Refrig.compressed air dryer Pressure loss 0,2 bar

Minimum pressure in tank 6,9 barop
The cut-in pressure pmin must always

be above this pressure.
Fig. 8.8 :
Compressor station with screw compressor, Cycle differential of screw compressors 1 bar
compressed air receiver, refrigeration compressed
air dryer and filter system
The cut-out pressure pmax is at least 7,9 barop
Selected maximum compressor pressure 8 barop

( cut-out pressure of compressor )
8.5.2.2 Determining compressor size The ideal usage rate UR of a screw compressors is 100 %.
This means, the required FAD LB is equal to the minimum

output V of the compressor.
min

LB = 2,04 m/min = V min = ca. 2 m/min
The choice is:
Screw compressor, Type S 21
Maximum pressure pmax : 8 bar

FAD V : 2,42 m3/min
Fig. 8.9 :
BOGE screw compressor Motor output rate : 15 kW Al = 25
135
8.5.2.3 Dimensioning the compressed air The volume of the compressed air receiver for screw com-
receiver pressors is calculated with the aid of the following formula.
The usual sizes of standard compressed air receivers should
be taken into account.

V = 2,42 m3/min
V 60 [ LB/V - ( LB/V ) ]
LB = 2,04 m3/min VR =
Al ( pmax - pmin )
LB
/V = 0,843
2,42 60 [ 0,843 - 0,843 ]
Al = 25 1/h VR =
25 ( 9 - 8 )
pmax = 9 barop
VR = 0,77 m3
pmin = 8 barop
Selected receiver volume:
VR = 0,75 m3 = 750 l
VR = Volume of compressed air receiver [ m3 ]

V VB
Q
V = FAD of all compressors [ m3/min ]
LB = Required FAD [ m3/min ]
Al = Allowed motor cycle rate [ 1/h ]

Fig. 8.10 : pmin = Cut-in pressure of compressor [ barop ]
Compressor and compressed air receiver
The volume of the compressed air receiver can also be de-

fined according to the BOGE recommendation, compressor

FAD to volume of compressed air receiver VR = V/3.

V = 2,46 m3/min VR = 0,81 m
8.5.2.4 Compressor cycle interval The cycle intervals and maximum allowed cycle rate of the
motor do not have to be checked with BOGE screw compres-
sors because the microcontroller in the BOGE ARS control
unit does not allow the maximum rate to be exceeded.
136
8.5.3 Summary on compressor selection If a company expects fluctuating consumption of compressed

air and is planning later extensions, it needs a compressor
designed for intermittent operation. A piston compressor is
the ideal choice. If the FAD of a compressor can cover the
constant compressed air requirement then a screw compres-
sor should be used.
Both compressor systems are available with full silencing. Both

are supplied ready for use.
The choice of the right system should not depend on the pur-
chase price, because the system pays for itself quickly if over-
head operating costs are saved. Overhead operating costs
are not only the energy costs to produce compressed air but
also the costs of idling.
Piston compressor work in intermittent operation. The do not

have an idle mode. Screw compressors must, because of their
small cycle differential and relatively small compressed air
receiver, automatically run in idle mode in order to avoid hav-
ing too many motor cycles.
The ARS control unit aims for intermittent operation with mini-
mum idling time.
137
8.6 Information on compressor configuration
8.6.1 Performance and working pressure The working pressure of consumer devices should always be
complied with. The performance of a pneumatic device always
drops disproportionally if the network pressure pN falls below
its working pressure.
The following table shows the dependence of performance on

working pressure using the average pneumatic tools and ham-
mers as examples:
Effective Relative Relative

Fig. 8.11 :
Hammer screw with pneumatic drive
pressure performance air consumption
[ bar ] [%] [%]
at tool drill tool drill
connection hammer hammer
7 120 130 115 120

6 100 100 100 100
5 77 77 83 77
4 55 53 64 56
Fig. 8.12 :
Valveless pneumatic hammer
Example
The consequences of network pressure that is too low can be

shown using a pneumatic cylinder as an example.
If the pneumatic cylinder of a clamping device is not supplied

with the required working pressure, the clamping power of the
cylinders falls and the workpiece is no longer held with the
necessary force.
The workpiece falls loose from the clamp while being proc-
essed by a machine tool. This can result in the destruction of
Fig. 8.13 :
the workpiece and may also injure to the machine operator.
Pneumatic clamp
138
8.6.2 Varying working pressure of If the working pressure of the various consumer devices var-
consumer devices ies widely, the situation requires closer examination.
Some devices with a low compressed air requirement need a

much higher working pressure than others.
In this case a second, small compressor station with a sepa-
rate pneumatic network and an appropriately higher cut-out
pressure pmax should be installed.
The unnecessary overcompression of the main volume flow

of the pneumatic system causes considerable costs. In most
cases, these additional costs justify the installation of a sec-
ond system.
The second system usually amortises itself quickly by reduc-

ing operating costs.
8.6.3 Combined compressor systems For users of compressed air with high, heavily fluctuating con-
sumption, a single, large compressor is not the best solution.
The alternative is to have a combined compressor system con-
sisting of several compressors. Greater operational reliability
and greater economy are the arguments for this option.
One or more compressors cover the continuous basic require-

ment for compressed air ( basic load ). If the requirement rises,
additional compressors are switched on ( medium and peak
load ), until the output covers the requirement. If the require-
ment drops, the compressors are switched back off again,
one after the other.
The configuration of individual compressors ( free air deliv-

ered ) in a combined compressor system is individually so
different that no general statement are possible. The configu-
ration depends on the pneumatic behaviour of all consumer
devices connected to the system.
Advantages
Operational reliability.
Operations heavily reliant on compressed air can guaran-
tee their supply at all times with a combined compressor
system. If one compressor fails, or if servicing work needs
to be done, the other compressors take over the work.
Economy.
Several small compressors are easier to adjust to com-
Fig. 8.14 :
pressed air consumption than one large compressor. This
Diagram of a combined compressor system
fact makes a system of this type more economical. If the
system is only running at half-load, there are no high run-
ning costs for a large compressor but low idling costs for
small compressors in readiness in a combined system.
139
The pneumatic system
9. The pneumatic system
9.1 The compressed air receiver The size of the compressed air receiver is determined by the
FAD of the compressor, the control system, and compressed
air consumption. Compressed air receivers have various im-
portant tasks in a pneumatic system.
9.1.1 Storing compressed air The compressor builds up a store of compressed air inside
the receiver. The compressed air requirement can be covered
at intervals from this store. The compressor does not supply
compressed air during this time. It is in readiness and does
not use electricity. Additionally, fluctuating use of compressed
air is compensated for and peak requirements covered. The
motor is switched on less often and wear on it reduced.
In some circumstances several receivers are needed to build

up an adequate store of compressed air. Very large pneu-
matic systems usually have an adequate storage capacity. In
this case, smaller receivers can be used.
Fig. 9.1 :
Compressed air receiver, horizontal
9.1.2 Pulsation damping Due to the way they operate, piston compressors generate a
pulsing volume flow. These pressure fluctuations impair the
operation of various consumer devices. Process control and
measuring equipment in particular react to pulsing volume flow
by making errors. The compressed air receiver is used to bal-
ance out these fluctuations in pressure.
This is much less the case with screw compressors because

they generate an almost even volume flow.
140
9.1.3 Condensate collection Compression causes the moisture in the air to form droplets
of water ( condensate ). This water is usually drawn into the
compressed air receiver with the volume flow. This is where
compressed air is stored. Heat is given off to the cooler sur-
rounding by the large surface of the receiver and the com-
pressed air cools down. This causes a large part of the con-
densate to precipitate on the walls of the receiver. The con-
densate collects on the floor of the receiver and is removed by
a suitable condensate collector.
Compressed air receivers that are only emptied at irregular

intervals can be corroded by the condensate. One protection
against corrosion is to galvanise the receiver in a dip-tank. It
is not absolutely essential to galvanise the receiver if the
Fig. 9.2 : condensate is drained regularly. Galvanising is also a useful
Compressed air receiver, standing
option if the condensate contains a high concentration of
aggressive components.
9.1.4 Operation of compressed air Compressed air receivers may only be continuously used for
receivers compressors with intermittent and idling modes. The area of
pressure fluctuation p must not exceed 20 % of the maxi-
mum operating pressure ( max. compressor pressure 10 bar,
p = 2 bar ). If pressure fluctuations are greater, the welding
seams may break as a result of fatigue over the course of
time. The compressed air receiver must then be specially
designed for fluctuating stress.
9.1.5 Installation of compressed air The compressed air receiver should be installed in a cool place
receivers whenever possible. This will cause more condensate to form
inside, which means that less will enter the pneumatic system
and the pre-processing unit.
Compressed air receivers should be installed so that they are

or can be made accessible for periodic inspections, and with
the factory specification plate well visible.
The compressed air receiver should be installed on a suitable

foundation with plenty of space for inspections. It should be
taken into account that the stress on the foundation increases
during pressure testing when the tank is filled with water.
Compressed air receivers must be installed so as not to be a

hazard for the staff or other people. The necessary safety zones
and distances must be observed.
The compressed air receiver and its ancillary equipment must

be protected against mechanical influence from the outside
( e.g., from vehicles ), so that they are not a hazard for people
or equipment.
141
9.1.6 Safety rules for compressed air Compressed air receivers are subject to Directive for pressure
receivers receivers ( DruckbehV ), the technical rules for Pressure re-
ceivers ( TRB ) and the DIN EN rules. These accident preven-
tion rules ( UVV ) are mandatory and must always be followed.
The operator of a compressed air receiver is legally obliged to
keep himself informed about the latest accident prevention rules
at all times.
Special care must be taken to observe the following excerpts

from the rules:
9.1.6.1 Division into test groups Compressed air receivers are divided into test groups as speci-
fied in 8 of pressure receiver rules.
( 1 ) The compressed air receivers are divided into groups

according to their maximum operating pressure p in bar and
the content of the pressure chamber l in litres ( the pressure
content product p l ). If there are several separate pressure
chambers, the product is to be defined separately for each
chamber:
G
ro
u
p
II
G
G
ro
ro
u
u
p
p
IV
III
Operating pressure pop [ bar ]
p
p
p
l=
l=
l=
10
20
20
00
0
G
ro
ro
u
u
p
p
I
II
Content of pressure chamber l [ dm3 ]
Fig. 9.3 : Group I : Compressed air receivers with a maximum oper-

Diagram showing group division of compressed air ating pressure p of no more than 25 bar and a
receivers pressure content product p l of no more than
200.
Group III : Compressed air receivers with a maximum oper-
ating pressure p of no more than 1 bar on which
the pressure content product p l is more than
200 but no greater than 1000
( p > 1 bar and 200 < p l 1000 ).
Group IV : Compressed air receivers with a maximum oper-
ating pressure p of more than 1 bar on which the
pressure content product p l is more than 1000
( p > 1 bar and p l > 1000 ).
142
9.1.6.2 The manufacture of compressed Simple and unfired compressed air receivers with an operat-
air receivers ing pressure of between 0,5 and 30 bar pressure, a pressure
content product p l up to 10 000, ( receivers up to 750 l, 11 bar
or up to 500 l, 16 bar ) and a cylindrical casing with two bases
are manufactured according to EC-Guideline 87/404 EEC. They
have a CE-symbol on the specification plate. They can there-
fore be used throughout the EC without further regard to
national rules.
Compressed air receivers with a pressure content product

p l exceeding 10 000 must be made according to national
rules.
9.1.6.3 Registration and inspection Accident prevention rules state that compressed air receivers
obligations must be inspected at the installation point prior to commis-
sioning ( TRB 531, para. 6 ), and at regular intervals after com-
missioning by an expert or proficient person. Compressed air
receivers must be registered at the technical inspection au-
thority and the receiver certificate presented at the same time.
The first inspection takes place at the factory before the re-
ceiver leaves the works. All receivers are subjected to hydrau-
lic pressure testing with water when the model is registered.
Individual receivers for which no model is registered must be
inspected in the presence of an expert.
9.1.6.4 Expert and proficient persons as Experts as defined in 31 of the German directive for pres-
defined in 31 and 32 of the sure receivers are:
German Directive for Pressure
Receivers Technical inspection authority staff.
Staff of the public material testing institute.
Specialists from the trade association authorised to carry
out inspections.
Proficient people 32 of the German directive for pressure

receivers are those who:
as a result of their training, knowledge and experience

gained through practical activity offer assurance that the
inspection can be properly carried out.
possess the required qualifications.
is not required to follow instructions from others with re-
gard to the inspection.
has suitable inspection equipment available, if necessary.
can verify by documentation that he has attended a state-
organised or state-recognised course to certify that he
meets the requirements set forth in point one.
Evidence of proficiency must be provided to the appropriate
authority on demand.
143
9.1.6.5 Inspection of compressed air The inspection prior to commissioning and periodic inspec-
receivers tions of compressed air receivers are subject to national law.
Inspection prior to commissioning is described in 9 of the
German pressure receiver rules, 10 covers periodic inspec-
tions.
Inspection prior to commissioning 9
( 1 ) A compressed air receiver of Groups III, IV and VII may

only be commissioned after an expert has carried out the ini-
tial inspection and certified that the receiver is in a service-
able condition.
( 2 ) A compressed air receiver of Group I, if used for com-

bustible, caustic or toxic gas, steam or liquid, or of Group II,
may only be commissioned,
1. if the maker has subjected the receiver to a pressure test

and has issued a certificate that it is properly made and
that it meets the appropriate requirements according to
the result of the test, and
2. after a proficient person has inspected the receiver and
certified that it meets the requirements of the inspection.
( 3 ) The initial inspection comprises preliminary inspection,

structural inspection and pressure test. The final inspection
comprises serviceability test, equipment inspection and in-
stallation inspection.
144
Periodic inspections 10
( 1 ) A compressed air receiver of Groups IV and VII must

be inspected by an expert at the intervals specified in para-
graph 4.
( 2 ) A compressed air receiver of Group I, if used for com-

bustible, caustic or toxic gas, steam or liquid, or of Groups II,
III and IV is to be inspected periodically at intervals defined by
the operator based on experience with the mode of operation
and the medium.
( 3 ) Periodic inspections consist of internal inspections and

pressure tests. If the receiver is heated by fire, exhaust emis-
sion or electricity the periodic inspection must also include
external inspections usually carried out on the tank while it is
in operation. Internal inspections according to sentence 1 must
be augmented or replaced by pressure tests or other suitable
tests is the internal inspections can not be performed to the
required extent. Pressure tests according to sentence 1 must
be replaced by non-destructive tests if the pressure tests serve
no useful purpose due to the construction or operating mode
of the tank.
( 4 ) Internal inspections must be carried out on compressed

air tanks of Groups IV and VII every five years, pressure tests
every 10 years, and external tests every 2 years. The authori-
ties responsible may
1. extend these periods if safety is guaranteed by other means,

or
2. shorten them if this is necessary for the safety of staff and
others.
( 10 ) A compressed air receiver of Group IV or VII may only

be used after expiry of the time for periodic inspections if the
inspections have been carried out within the assigned period
and if the expert has certified that according to the results of
the inspection the receiver meets the appropriate requirements.
( 11 ) If the expert finds that the compressed air receiver is

not in a serviceable condition the authority responsible will
pass decision upon application.
145
9.1.6.6 Types of inspection The regular inspections are carried out by experts and profi-
cient people and take place as follows:
Internal inspection ( every 5 years )
The receiver is disconnected from the network and not under

pressure. The inspection aperture is opened and the receiver
thoroughly cleaned from inside. The walls must be metallically
clean. The expert must inspect the internal condition of the
receiver and certify that it is serviceable.
Pressure test ( every 10 years )
The receiver is disconnected from the network and not under

pressure. The fittings must be unscrewed and the connection
openings closed with plugs. The receiver is filled completely
with water and the handpump connected for the pressure test.
The receiver is then brought to operating pressure with the
aid of the handpump and checked for leaks by the expert.
9.1.6.7 Additional excerpts from the Operation of compressed air receivers 13

directive for compressed air
receivers ( 1 ) Persons operating a compressed air receiver are to keep
it in a serviceable condition, to operate it correctly, to keep it
under supervision, to carry out the necessary maintenance
and servicing work in good time and to take the necessary
safety precautions as circumstances demand.
Proof of inspection and list of compressed air receivers

14
( 1 ) Compressed air receivers must bear evidence of the

completed initial inspection.
( 2 ) Persons operating a compressed air receiver of Groups

IV or VII, must keep a logbook or inspection file to record the
results of periodic and extraordinary inspections by experts.
The logbook or inspection file must be submitted with the cer-
tificate of the expert for the initial inspection and final inspec-
tion together with the appropriate documents ( drawing, cer-
tificate for materials and heat treatment ).
146
9.1.7 Fittings on the compressed air The compressed air receiver is not simply a naked steel con-
receiver tainer. It needs a number of fittings to allow it to operate prop-
erly and assure the required safety.
4 1 Pressure switch.
The switch is for controlling the compressor.
6 Non-return valve.
A non-return valve must always be installed in the supply
line from the compressor to the receiver. With piston com-
pressors it prevents compressed air flowing back into the
compressor during breaks in operation. With screw com-
5 pressors the valve is integrated in the system.
Safety valve.
8 The installation of a safety valve on compressed air receiv-
ers is required by law. If the internal pressure of the re-
3 ceiver pN ( network pressure ) rises 10 % ove the nominal
pressure, the safety valve opens and blows out the excess
pressure.
Control flange.
The control flange with aperture is used by the inspection
9 authorities to connect a calibrated manometer for the pres-
sure test.
Manometer.
The manometer shows the internal pressure of the receiver.
Ball shut-off valve.
The ball shut-off valve isolates the receiver from the pneu-
matic system or the compressor.
Condensate drain.
7 2 10 Condensate precipitates inside the receiver and therefore
it requires an appropriate connection for the condensate
collector.
1 = Pressure switch Inspection aperture.
2 = Non-return valve or The inspection aperture can take the form of a socket end
ball shut-off valve or hand-hole flange. It is used to check and clean the in-
3 = Safety valve side of the receiver. The minimum size of the aperture is
4 = Control flange prescribed by law.
5 = Manometer High pressure hose.
6 = Ball shut-off valve The high pressure hose connects the receiver with the com-
7 = Condensate drain pressor. It is used instead of a pipe so as not to transmit
8 = Mounting for fittings vibration from the compressor to the pneumatic system
9 = Inspection aperture and to correct size deviations on connection to the system.
10 = High pressure hose
Fig. 9.4 : The pressure switch, high pressure hose and non-return valve
Compressed air receiver with fittings are not typical fittings for compressed air receivers. But it it is
sensible to have them installed.
147
9.1.7.1 Safety valve The installation of a safety valve on compressed air receivers
is prescribed by law.
If the internal pressure of the receiver pN ( network pressure )

rises to the maximum operating pressure of the tank ( e.g.,
the maximum compressor pressure 10 bar, tank operating pres-
sure 11 bar ), the safety valve must slowly open.
If the system pressure rises to 1.1 times the nominal pressure

( e.g., tank pressure 11 bar, safety valve 12.1 bar ), the safety
valve must open fully and blow off the excess pressure. Care
must be taken that the cross-section of the outlet aperture of
the safety valve is of a size that allows the entire output of all
connected compressors to be blown off without the pressure
in the receiver rising.
When an existing pneumatic system is extended at a later

date the number of compressors increases. An appropriate
upgrading of the safety valve can easily be overlooked when
Fig. 9.5 : this happens. If the safety valve is no longer able to blow off
Safety valve on combined compressed air-oil re- the entire output of the compressors the operating pressure in
ceiver of an oil-injection cooled screw compressor the receiver will rise. This can cause the receiver to explode in
extreme cases.
Safety inspection
The safety valve must be checked every time a compressor

station is extended so as not to have a valve with too low a
capacity.
The mains connection to the receiver must be shut off. The

press switches must then be bridged, so that the compres-
sors can no longer switch off automatically.
Fig. 9.6 :
Diagram symbol for a safety valve
The pressure in the receiver rises until the safety valve switches.
The receiver pressure must not exceed 1.1 times the limit ( e.g.,
receiver pressure 11 bar, safety valve 12.1 bar ). If this does
happen, the safety valve is below par and must be replaced.
148
9.2 The compressed air circuit A central compressed air supply needs a pipeline circuit to
deliver compressed air to the individual devices. The circuit
must meet various conditions in order to guarantee reliable
and economical operation of the devices:
Adequate volume flow.

Each device in the circuit must be supplied with the re-
quired volume flow at all times.
The necessary working pressure.
Each device in the circuit must have the necessary air pres-
sure at all times.
Quality of compressed air.
Each device in the circuit must have compressed air of the
required quality at all times.
Low pressure loss.
The pressure loss in the circuit must be as low as possible
for economic reasons.
Secure operation.
The supply of compressed air should be guaranteed as far
as possible. If lines are damaged, repair and maintenance
work must not put the entire circuit out of use.
Safety rules.
The relevant safety rules must be followed at all times in
order to prevent accidents and the resulting rights of re-
course.
9.2.1 The structure of a compressed air A pipeline circuit is made up of individual sections. This allows
circuit an ideal connection to be made between the compressor and
dependent devices.
9.2.1.1 The main line The main line connects the compressor station with the com-
pressed air treatment and the compressed air receiver. Distri-
Compressed air receiver bution lines are connected to the main line. The main line must
be of a size that allows the entire output of the compressor
station to be delivered now and in the near future, and with the
minimum loss of pressure.
The pressure loss p in the main line should be no higher

than 0.04 bar.
Condensate
drain
Dryer Main line

Compressor
Fig. 9.7 :
Main line of a compressed air circuit
149
9.2.1.2 The distribution line- ring line The distribution lines are laid through the entire operation and
bring compressed air to the devices. They should always take
the form of a ring line wherever possible. This increases the
economy and security of operation of the line as a whole.
Pressure loss p in the distribution lines should be no higher

than 0.03.
3 5
7 Connection line
4
6
Main line
Ring line
1 = Compressor
3 = Compressed air receiver
4 = Condensate drain A ring line forms a closed distribution ring. It is possible to
5 = Safety valve isolate individual sections of the network without interrupting
6 = Compressed air dryer the supply of compressed air to other areas. This provides
7 = Compressed air connections assurance that compressed air will be available for most de-
vices, even when servicing, repairs and extension work is being
Fig. 9.8 : carried out.
Compressed air supply with ring line
If the compressed air is supplied through a distribution ring,
the compressed air has a shorter route to travel than with stub
lines. This means that lower pressure loss p is needed. When
dimensioning the ring line one can calculate with half the flow
pipe length and half the volume flow.
150
9.2.1.3 The distribution line- stub line The distribution lines are laid through the entire operation and
bring compressed air close to the devices. They can also take
the form of a stub line.
The pressure loss p in the distribution lines should be no

3 5 more than 0.03 bar.
7 Connection line
4
6
Main line
Stub line
1 = Screw compressor Stub lines branch off from larger distribution lines or the main
2 = Non-return valve line and end at the consumer device. Outlying consumers can
3 = Compressed air receiver be supplied through stub lines. It is also possible to supply a
4 = Condensate drain complete compressed air system with stub lines. They have
5 = Safety valve the advantage of needing less material than ring lines. But
6 = Compressed air dryer they also have the disadvantage that they must be of larger
7 = Compressed air connections size than ring lines and frequently cause high pressure losses.
Stub lines should always have a non-return valve which can
Fig. 9.9 : isolate them from the system. This makes servicing and repair
Compressed air supply with stub line
work easier.
9.2.1.4 The connection line The connection lines come from the distribution lines. They
supply consumer devices with compressed air. Since the de-
vices operate with different pressures it is normally necessary
to install a service unit with a pressure regulator in front of the
device. The network pressure is reduced to the working pres-
sure of the device by the regulator. Service units comprising
filters, separators, regulators and oilers are not needed if the
compressed air is pre-treated.
The pressure loss p in the connection lines should be no
higher than 0,03 bar.
Note
For industrial applications the recommended pipe size is DN
25 ( 1" ). This size has next to no cost disadvantages com-
pared with smaller sizes and nearly always guarantees a reli-
able supply of compressed air. Consumer devices requiring
up to 1800 l/min can be supplied through line lengths of up to
10 m with hardly any pressure loss.
151
9.2.1.5 Connecting to a collective line with Attention must be paid to the following points when connect-
multiple systems ing several compressors to a common (collective) line.
Compressed air Condensate
5 4 4 3 5 6
1 1
1 3 2 1 2 7
1 = Screw compressor 1 = Screw compressor 5 = Expansion vessel

2 = Water separator 2 = Piston compressor 6 = Vent silencer
3 = Condensate drain 3 = Connection line 7 = Oil-water-separator
4 = Connection line 4 = Collective line
5 = Collective line
Fig. 9.10 :
Collective lines
Compressed air and condensate collective lines
1. Collective line with gradient.

The line must be laid with a gradient of approx. 1.5 - 2 % in
the direction of flow.
2. Connection line from above.
The connection line must be connected to the collective
line from above.
Compressed air collective lines
3. Water separator on longer rising lines.

On longer lines that rise to a collective line a water separa-
tor with automatic drainage must be installed after the com-
pressor in order to catch the water flowing back.
Vent collective lines

Points 1 and 2 also apply when vent lines are brought
together in collective lines.
Vent collective lines must also have an expansion vessel
and vent silencer installed.
152
9.3 Tips for planning pipe systems
9.3.1 General planning tips Compressed air lines should be straight wherever possible.
On corners that can not be avoided, do not use knee and
T -pieces. Long curves and Y-pieces provide better flow con-
ditions and therefore less pressure loss Dp. Abrupt changes
in the diameter of the line should also be avoided due to the
high loss of pressure this causes.
Large pipe systems should be subdivided into several sec-

tions, each of which should be equipped with a non-return
Fig. 9.11 : valve. It is important to be able to isolate parts of the system,
Unfavourable flow conditions: T and knee-piece particularly for inspections, repairs and conversions.
In some situations it may be of benefit to have a second com-

pressor to supply the system from a different point. This short-
ens the distance the compressed air has to travel. As a result,
the pressure loss p is lower.
Fig. 9.12 : Main lines and large distribution lines should be welded with
Favourable flow conditions: Y-tube and curved pipe V-seams. This means there are no sharp edges and points
inside the pipes. There is therefore less resistance in the pipes
and the burden on filters and tools caused by detached parti-
cles of welded metal is reduced.
153
9.3.2 Pipeline without compressed air Compression causes the water in the air to form droplets ( con-
dryer densate ). If the compressed air is not pre-processed by a
compressed air dryer, water must be expected in the entire
pipeline network.
Pipeline with 1.5 - 2 % gradient In this situation there are various guidelines to be followed
when installing the pipeline, in order to prevent damage to
consumer devices.
Temperature gradients.
Where possible, the compressed air lines should be laid
so that the air does not cool down when flowing through.
The air should be heated gradually. If the absolute humid-
ity is constant, the relative humidity will then fall. Conden-
sate will then be unable to form.
Pipelines with gradients.
The pipelines must be laid with a gradient of approx. 1.5 -
2 % in the direction of flow. The condensed water in the
pipeline will then collect at the lowest point of the line.
Vertical main line.
The main line directly behind the compressed air receiver
should rise vertically. The condensate that occurs when
cooling takes place can then flow back into the receiver.
Condensate drain.
wrong Condensate drains must be installed at the lowest points
of the system in order to drain off the condensate.
right
Connection lines.
The connection lines must branch off upwards in the direc-
tion of flow. The pipeline here must be as straight as possi-
ble to avoid unnecessary pressure loss.
Fig. 9.13 : Fittings.
Examples of correctly laid piping A service unit with filter, water separator and pressure re-
duction valve should always be installed. A compressed air
lubricator may also be needed, depending on the applica-
tion.
154
9.3.3 Pipeline system with compressed If there is a compressed air dryer with an appropriate filter
air dryer installed in the system, many of the measures taken against
condensate can be dispensed with.
Pipelines.
The lines can be laid horizontally because there is almost
no water left in the system. The other measures concern-
ing the way the lines are laid are also unnecessary.
Condensate drain.
Condensate drains are only fitted at the filters, the com-
pressed air receiver and the dryer.
Connection lines.
The connection lines can be joined vertically downwards
with T-pieces.
Fittings.
Only pressure reduction valves have to be fitted to the con-
sumer devices. A lubricator may be required, depending
on the application.
This considerably reduces the price of the installation. Some-

times, even the money saved here justifies installing a com-
pressed air dryer.
155
9.4 Pressure loss p Every pneumatic pipeline is resistance for compressed air in
flow. This resistance is internal friction which occurs with the
flow of all liquid and gaseous media. It results from the effect
of force among the molecules( viscosity ) of the flowing me-
dium ad the walls of the pipeline. This is the cause of pressure
loss in pipelines.
9.4.1 Type of flow Quite apart from internal friction, the type of flow inside the
line also affects pressure loss. Air can move in two completely
different ways.
Laminar flow
Laminar flow is even-layered flow. The individual molecules of
vmax the compressed air move in parallel, adjacently flowing layers.
This type of flow has two main properties:
low pressure loss.
low heat transition.
Fig. 9.14 :
Flow and speed development with laminar flow
Turbulent flow
Turbulent flow is whirly and uneven. The axially directed flow
is surrounded by constantly changing additional movement at
vmax all points. The paths of flow all have an effect on each other
and form small whirls. This type of flow has two main proper-
ties:
high pressure loss.
Fig. 9.15 :
high heat transition.
Image of flow and speed with turbulent flow
9.4.2 The Reynolds number Re The type of flow can be defined using the Reynolds number
Re. This gives the criterion for laminar and turbulent flow. The
Reynolds number Re is influenced by various factors:
The kinematic viscosity of the compressed air.

The mean speed of the compressed air.
The inside diameter of the pipe.
The flow in the pipeline remains laminar until what is known
as the critical Reynolds number Recrit is exceeded. It then takes
on the condition of unevenness and turbulence.
Note
The high flow speeds that lead to Recrit being exceeded do not
normally occur in pneumatic networks. The prevailing flow in
pneumatic networks is laminar. Turbulent flow only occurs at
points where there are massive flow disturbances.
The speed of flow in compressed air lines must not exceed
20 m/s, since noise and turbulent flow will otherwise occur.
156
9.4.3 Pressure loss in the pipe system Each change in the line hinders the flow of compressed air
within it. The laminar flow is disturbed and higher pressure
loss results.
Flanged connection
2D-Curve
3D-Curve
Branching off
Reduction
T-Piece
Widening
Leakages
Pressure [ bar ]
Valve
Pressure loss
Fig. 9.16 : Path [ m ]

Pressure loss in a pipeline
The amount of pressure lost is influenced by several compo-

nents and circumstances of the network :
length of pipe.
clear inside diameter of the pipe.
pressure in the pipe network.
branches and bends in the pipe.
narrowing and widening.
valves.
fittings and connections
filters and dryer.
leakage points.
surface quality of the pipelines.
These factors must be taken into account when planning the

system, otherwise increased pressure loss will occur.
157
9.5 Dimensioning pipelines Correct dimensioning of the pipes in a system is of great im-
portance for economical operation. Pipes with too small a di-
ameter cause high losses of pressure. These losses must be
compensated for by high compression in order to guarantee
the performance of consumer devices.
The main factors influencing the ideal inside diameter di of the

pipe are:

Volume flow V.
The maximum throughput of air should be assumed when
determining di . Increased pressure loss has a greater
impact when the requirement for compressed air is at a
maximum.
Effective flow length of pipeline.
The length of the pipeline should be determined as accu-
rately as possible. Fittings and bends are unavoidable in
pipeline systems. When determining the effective flow length
of the pipeline these must be taken into account as an
equivalent section of pipe.
Operating pressure.
When determining di the compressor cut-out pressure pmax
is to be assumed. At maximum pressure the pressure drop
p is also highest.
9.5.1 Maximum pressure drop p The pressure drop p in a pipeline with a maximum pressure
pmax of 8 barop and above should not exceed a certain total
loss by the time it reaches the consumer device :
Pipe system p 0.1 bar

The following values are recommended for the individual sec-
tions of the system:
Main line p 0.04 bar

Distribution line p 0.04 bar
Connection line p 0.03 bar
In pipe systems with lower maximum pressures ( e.g.,

3 barop ) a pressure loss of 0,1 bar is higher in relative terms
than in an 8 barop system. In this case, a different value is
recommended for the system as a whole:
Pipe system p 1,5 % pmax
158
9.5.2 Nominal width of pipelines Medium-weight threaded pipes made of standard structural
Comparison [ DN Inch ] steel ( DIN 17100 ), which are often used for pipe systems,
are made according to the DIN 2440 standard. This standard
prescribes certain graduations of nominal width ( inside diam-
eter di ) and certain designations. For this reason, fittings and
pipes are only available in the corresponding sizes.
The graduations of nominal diameter also apply for other pipe

materials and standardisations.
The standard nominal widths must always adhered to when

dimensioning pipelines. Other nominal widths are only avail-
able if specially made and are disproportionately expensive.
The following table contains standard graduations in DN

( Diameter Nominal ) mm and inches, and the most important
basic data for pipes according to DIN 2440 :
Nominal pipe width Outside Inside Inside Wall

acc. to DIN 2440 diameter diameter cross-section thickness
[Inches ] [ DN ] [ mm ] [ mm ] [ cm2 ] [ mm ]
1/8" 6 10.2 6.2 0.30 2.00

1/4" 8 13.5 8.8 0.61 2.35
3/8" 10 17.2 12.5 1.22 2.35
1/2" 15 21.3 16.0 2.00 2.65
3/4" 20 26.9 21.6 3.67 2.65
1" 25 33.7 27.2 5.82 3.25
1 1/4" 32 42.4 35.9 10.15 3.25
1 1/2" 40 48.3 41.8 13.80 3.25
2" 50 60.3 53.0 22.10 3.65
2 1/2" 65 76.1 68.8 37.20 3.65
3" 80 88.9 80.8 50.70 4.05
4" 100 114.3 105.3 87.00 4.50
5" 125 139.7 130.0 133.50 4.85
6" 150 165.1 155.4 190.00 4.85
159
9.5.3 Equivalent pipe length A major factor in dimensioning the inside diameter of a pipe di
is the pipe length. Pipelines are not only made up of straight
sections of pipe, the flow resistance of which can quickly be
deduced. Installed bends, valves and other fittings consider-
ably increase flow resistance inside the pipeline. This is the
reason that the effective pipe length L must be determined,
taking into account the fittings and bends.
For simplification, the flow resistance values of various fittings

and bends have been converted into equivalent pipe lengths.
The following table gives the equivalent pipe length in depend-

ency on pipe nominal width and the fitting:
Fittings Equivalent Pipe Length [ m ]
Pipe and Fitting Nominal Width [ DN ]

DN 25 DN 40 DN 50 DN 80 DN 100 DN 125 DN 150
Check valve 8 10 15 25 30 50 60
Diaphragm valve 1.2 2.0 3.0 4.5 6 8 10
Gate valve 0.3 0.5 0.7 1.0 1.5 2.0 2.5
Knee bend 90 1.5 2.5 3.5 5 7 10 15
Bend 90 R = d 0.3 0.5 0.6 1.0 1.5 2.0 2.5
Bend 90 R = 2d 0.15 0.25 0.3 0.5 0.8 1.0 1.5
T-Piece 2 3 4 7 10 15 20
Reduction piece D = 2d 0.5 0.7 1.0 2.0 2.5 3.5 4.0
These values must be added to the actual pipe length to ob-

tain the effective pipe length L.
Note
Complete information about fittings and bends are not gener-

ally available at the start of planning a pipeline system. The
effective pipe length L is therefore calculated by multiplying
the straight pipe length by 1.6.
160
9.5.4 Determining the inside diameter d i The following approach formula can be used to dimension
of the pipe by calculation the inside diameter of the pipe. It assumes the maximum
operating pressure p max ( compressor cutout pressure ),

the maximum volume flow V ( required output L B ) and the
effective pipe length L. p is the target pressure loss.

5 1,6 103 V1,85 L
di =
1010 p
pmax
di = Inside diameter of pipeline [m]

V = Total volume flow [ m3/s ]
L = Effective pipe length [m]
p = Target pressure loss [ bar ]
pmax = Compressor cut-out pressure [ barabs ]
Example
The inside pipe diameter d i of a pneumatic connection line

with a target pressure loss p of 0,1 bar is to be determined
using the approach formula. The maximum operating pres-
sure p max ( compressor cutout pressure ) is 8 bar abs . A vol-

ume flow V of 2 m/min will flow through pipeline with an
approximate length of 200 m.

V = 2 m3/min = 0,033 m3/s
L = 200 m 5 1,6 103 0,0331,85 200

di =
1010 0,1 8
p = 0,1 bar
pmax = 8 barabs di = 0,037 m = 37 mm
Nominal width selected: DN 40
The inside diameters of pipes are standardised in certain sizes.

But it is rare to find a standard nominal width that matches the
calculated inside diameter. In such cases the next largest stand-
ard nominal width is taken.
161
9.5.5 Determining the inside diameter The pipe inside diameter di can be determined easier and
of the pipe di by graphics faster with a nomogramme than by calculation. The major in-
fluencing factors are the same with calculation method as with
the graphical method.

Start by reading the intersection of the volume flow V and the
operating pressure pmax. Proceed by following the thick line in
the example in the direction of the arrow.
Pipe length L [ m ]
Volume flow V [ m3/min ]

Pipe inside diameter di [ mm ]
Pressure loss p in the pipeline[ bar ] Operating pressure p max [ barabs ]
Example

Volume flow V = 2 m/min
Effective pipe length L = 200 m
Pressure loss p = 0,1 bar

Operating pressure pmax = 8 barabs
Pipe inside diameter di = app. 38 mm
The nominal width selected for the pipeline is DN 40
162
9.5.6 Determining the inside diameter The third and simplest method of determining the pipe inside
of the pipe di with the aid of a bar diameter di is the bar graph. However, this method is very
graph limited in application. Two conditions must be met for the bar
graph method to be used:
A maximum pressure pmax in the network of 8 barop.

A target pressure loss p of 0,1 bar.
The bar chart is very easy to use:

Take the determined maximum volume flow V and the effec-
tive pipe length and find the respective line or column in the
graph. The resulting intersection indicates the correct pipe
nominal width to meet the requirements.
Example
Pressure loss p = 0,1 bar

Operating pressure pmax = 8 barop
Effective pipe length L = 200 m

Volume flow V = 2000 l/min
The nominal width of the pipe obtained is DN 40
163
9.6 Choosing the material System pipelines are normally made of steel, non-ferrous metal
for pipelines or plastic. They must meet various criteria, which limits the
choice of material for some applications:
Protection against corrosion.

The question of resistance to corrosion is always a prime
consideration unless the compressed air is dried in a pre-
treatment unit. The pipes must not rust through over the
course of time.
Maximum operating temperature.
Some materials lose tensile strength at high temperatures
and become brittle at low temperatures.
Maximum operating pressure.
The maximum operating pressure drops with increasing
thermal stress.
Low pressure loss.
Low pressure loss is obtained by high surface quality on
the inside of the pipe.
Low-cost installation.
Installation prices can be reduced by a multitude of pre-
shaped parts, fast and easy installation and cheap mate-
rial.
9.6.1 Threaded pipes Steel threaded pipes compliant with DIN 2440, DIN 2441 and
DIN 2442 ( medium-weight and heavyweight versions ) are in
widespread use in pneumatic systems. They are used par-
ticularly in small and medium-sized distribution and connec-
tion lines. Threaded pipes are used everywhere where the
demands on the quality of compressed air are not high. They
are available in black and galvanised metal.
Size DN 6 - DN 150
Maximum operating pressure max. 10 - 80 barop
Maximum operating temperature 120 C
Advantages
Threaded pipes are inexpensive and quickly installed. There

are many different and useful shaped parts and fittings to use
with them. The joints can be disconnected and the individual
parts reused.
Disadvantages
Threaded pipes have a high flow resistance and the joints

tend to leak over time. An experienced fitter is needed to in-
stall them. Ungalvanised threaded pipes should not be used
in networks without a dryer, because they corrode.
164
9.6.2 Seamless steel pipes Seamless mild steel pipes compliant with DIN 2448 are chiefly
mainly used in main and distribution lines with medium and
large pipe diameters. They are available in black and galva-
nised finishes.
Sizes 10.2 - 558,8 mm
Maximum operating pressure max. 12.5 - 25 barop
Advantages
Seamless mild steel pipes are available in sizes up to 558,8

mm. They are completely airtight if properly laid. Leakage is
therefore practically zero. The pipes are cheap, and there are
relatively many shaped parts to choose from.
Disadvantages
An experienced fitter is needed to lay seamless, mild steel

pipes because they must be welded and flanged. Ungalva-
nised mild steel pipes should not be used in networks without
a dryer, because they corrode.
9.6.3 Stainless steel pipes Stainless steel pipes compliant with DIN 2462 and DIN 2463
are only used in pneumatic networks requiring the highest
quality. They are also often used in the wet sections of a
conventional system between the compressor and the dryer.
Sizes 6 - 273 mm
Maximum operating pressure max. 80 barop, part. higher
Advantages
Stainless steel pipes are completely corrosion-proof and have

only low flow resistance ( low pressure loss ). They are abso-
lutely airtight if properly laid. Leakage is therefore practically
zero.
Disadvantages
An experienced fitter is needed to lay seamless, stainless steel

pipes because they must be welded and flanged. The pipes
are very expensive and the availability of shaped parts is
limited.
165
9.6.4 Copper pipes Copper pipes conforming to DIN 1786 and DIN 1754 are used
for small and medium pipes as process control lines. The seam-
less pipes are available in hard, semi-hard and soft qualities.
Sizes soft 6 - 22 mm
semi-hard 6 - 54 mm
hard 54 - 131 mm
Maximum operating pressure max. 16 - 140 barop
Advantages
Copper pipes are available in long sections, they can be bent

if the diameter is small, and they are easy to work with. It is
therefore possible to use one piece for longer sections of the
network. This reduces the number of joints. The occurrence of
leaks is also lower.
Copper pipes are corrosion-proof and pressure loss is low

due to the smooth surface of the inside walls.
Disadvantages
An experienced fitter is needed to install copper pipes since

fittings are normally soldered to them. The joints can not be
disconnected.
The material is expensive, but there are many shaped parts to

choose from because copper pipes are also used in the sani-
tary area.
If the lines are longer, the expansion of copper due to heat

must be taken into account. The coefficient of length expan-
sion for copper is greater than that for steel.
If the compressed air contains moisture, particles of copper

may form local galvanic elements in subsequent steel piping,
leading to pitting. Copper vitriol can also arise.
166
9.6.5 Plastic pipes There are plastic pipes as pipe systems from various makers
and in various materials. There are also polyamide pipes for
high pressures and polyethylene pipes for large diameters.
This means that there are plastic pipes with the appropriate
properties for almost every area of application. For this rea-
son it is difficult to generally apply information about sizes,
operating pressures and temperatures.
Advantages
Because plastic pipes do not corrode, there is no need for any

protective surface material. They are up to 80 % lighter than
steel. This simplifies installation and there are fewer demands
placed on the pipefittings.
The inside surface is very smooth. Flow resistance is low ( low

pressure loss ) and deposits such as calcium and rust etc.
have practically no chance to build up. Plastic pipes are usu-
ally harmless from a toxicological and hygienic standpoint.
PVC pipe systems and the like have a large number of shaped
parts and fittings available for them. Installation is very easy.
The pipe sections are fitted together and given an airtight seal
Fig. 9.17: with special adhesive. No special knowledge is necessary for
An assortment of plastic shaped parts and fittings installation. Pressure loss and leakage is generally very low in
plastic piping.
Disadvantages
The low-cost PVC pipe systems have a maximum operating

pressure of only 12.5 bar at 25 C. It must also be carefully
noted that the maximum operating pressure of these plastic
pipes drops heavily if the temperature is increased. For this
reason plastic pipes may not be used in the hot areas of a
compressor station and must be protected from direct sun-
light.
Plastic pipes have large coefficients of linear expansion and

their mechanical stability is not particularly high.
Resistance to certain condensates and types of oil is not al-

ways guaranteed with some plastics. The composition of con-
densates in the network must therefore be checked before-
hand.
Plastic pipes are not made in large quantities for high pres-
sures or large diameters. This makes them expensive and the
number of shaped parts available is limited. An experienced
plastic welder is needed to install these pipes.
167
9.7 Marking pipelines Pipelines must be marked clearly according to the type of
medium they contain according to German law and DIN 2403.
Unambiguous marking also eases correct installation, the plan-
ning of extensions and firefighting.
The marking should indicate possible dangers in order to avert

accidents and physical injury. Appropriate marking also makes
it easier to follow pipelines in a complicated network. For this
reason, the direction of flow of the medium must always be
indicated.
Pipes are marked with ID numbers ( groups ) and colours, both

of which are defined in DIN 2403.
Medium Group Colour Colour number

ID number
Air 3 grey RAL 7001
Water 1 green RAL 6018
Combustible liquids 8 brown RAL 8001
Gas 4/5 yellow RAL 1013
Water steam 2 red RAL 3003
Acids 6 orange RAL 2000
Alkalis 7 violet RAL 4001
Oxygen 0 blue RAL 5015
Colour markings and markings in writing must be applied at

certain points:
In writing at the start of the line.

In writing at the end of the line.
In writing at branches.
Fig. 9.18: In writing where the line passes through a wall.
Marking plates with cleartext
In writing at fittings and distribution points.
In colour by way of rings or continuous paint for the en-
tire length of the line.
Marking plates
Direction of flow.
Colour matches colour code for medium.
Sub-group number ( different line networks ).
Group number of medium.
Fig. 9.19:
Marking plates with ID numbers
168
The Installation Room
10. The Installation Room The installation room of a compressor must satisfy a number
of conditions for correct operation to be assured. When con-
sidering the significance of a well-planned and well-kept in-
stallation room it is important to know that around 2/3 of all
compressor malfunctions are caused by faulty installation, in-
adequate ventilation and a lack of servicing.
The general rules for accident prevention and environmental

protection must also be adhered to.
10.1 Cooling the compressor When designing a compressor station it must be remem-
bered that the compression process inside the compressor
generates a large amount of waste heat. The main principle
100 %
of thermo-dynamics applies, which states that the entire elec-
Electricity trical power intake of the compressor is converted into heat.
intake from the
mains The waste heat must be extracted reliably since there may
9% otherwise be an accumulation of heat in the compressor. If the
Heating
the motor
temperature inside the compressor is too high for too long it
can lead to mechanical damage in the compressor stage and
the drive motor.
The required cooling medium (air or water) can be supplied in

two ways:
4% Air-cooling.
Residual heat
in the com- Air-cooling is the most common cooling method for all types
pressed air of compressor. When it is used, ventilation of the installa-
75 % 13 % tion room is of particular importance. It must be well planned
Oil cooler Compressed air
aftercooler
and implemented. If not, thermal problems with the com-
pressor are bound to occur.
1% Water-cooling.
Heat
radiated off
Water cooling may be necessary in larger compressors if
the heat can not be properly extracted by air-cooling. Wa-
ter-cooling places fewer demands on ventilation inside the
95 % installation room.
of energy intake
is extracted by the
cooling medium
( Water/air ) This chapter deals primarily with the requirements and rules
applying to installation rooms for air-cooled compressors. With
Fig. 10.1 : the exception of information concerning ventilation, the mate-
Heat distribution in a screw-type compressor with oil rial in this chapter can be used equally for water-cooled com-
injection cooling. pressors.
169
10.2 Compressor installation When installing compressors and the other components of a
compressor station there are certain conditions to observe
which, if not complied with, may lead to malfunctions. There
are also certain accident prevention and environmental pro-
tection rules to be followed.
10.2.1 General information regarding The installation room should be clean, free of dust, dry and
the installation room cool. Strong sunlight must not be allowed to enter. The room
should be located on the north side of a building wherever
possible, or in a well-ventilated basement.
There should be no heat-emitting pipes or assemblies in the

installation room of a compressor. If this can not be avoided,
the pipes and assemblies must be adequately insulated.
Easy accessibility and good lighting should be provided for

servicing work and periodic inspections of the compressed air
receivers.
A compressor installation room must always be properly ven-

tilated to prevent the ambient temperature from exceeding the
maximum admissible levels.
Fig. 10.2 :
Compressor station with 2 screw-type compressors,
refrigerant air dryer, compressed air receiver and
oil/water separator.
10.2.2 Admissible ambient temperature Compressors operate ideally at ambient temperatures between
+20 and +25 C. The following ambient temperatures apply
for piston and screw-type compressors :
Minimum + 5 C.
If the temperature falls below + 5 C, pipelines and valves
can ice up. This can cause the compressor to malfunction.
Screw-type compressors switch off automatically if the
temperature is below the minimum admissible compres-
sion temperature.
An additional anti-freeze facility allows ambient tempera-
tures down to -10 C.
Maximum + 40 C.
Maximum + 35 C with sound-insulated piston-type com-
pressors.
If the ambient temperature rises above the maximum level,
the compressed air outlet temperature may exceed the
maximum statutory level. The quality of the compressed
air deteriorates, the components of the compressor are
subjected to more strain, and the servicing intervals are
shorter. Screw-type compressors switch off automatically
if the temperature is above the maximum admissible com-
pression temperature.
170
10.2.3 Fire safety rules for installation The following rules apply for rooms where compressors with
rooms oil injection cooling are to be installed:
The room must have special fire protection if the com-

pressor motor rating is over 40 kW.
Compressors with a motor rating of over 100 kW must
be installed in a separate fire-protected room.
Requirements for fire-protected installation rooms:
The walls, ceilings, floors and doors must be Fire safety

category F30 or better.
No inflammable liquids may be stored in the installation
room.
The floor area around the compressor must not be made
of combustible material.
Leaking oil must not be allowed to spread on the floor.
There must be no inflammable substances within a radius
of at least three metres from the compressor.
No combustible system parts, such as cable lines, may
be laid over the compressor.
10.2.4 Disposal of condensate The inducted air contains water in the form of vapour which
turns into condensate during compression. This condensate
contains oil. It may not be allowed into the public sewage net-
work without being processed.
Always follow the appropriate drainage rules set by the local

authority.
BOGE recommends the WAMAT for processing the conden-

sate. The purified water can be drained into the public sewage
lines. The oil is caught in a catch pan and must then be dis-
posed of in a responsible manner.
171
10.2.5 Compressor installation When installing compressors, the following general points must
instructions be observed, regardless of ventilation:
When installing a compressor or compressed air receiver

a flat industrial floor without foundation will suffice. Special
mountings are not generally needed..
Compressors should always be located on elastic mount-
ings. This stops vibration being transmitted to the floor, and
the compressor noise being carried to other parts of the
building.
The compressor should be connected to fixed lines with a
BOGE high pressure hose of approx. 0.5 m in length. This
prevents vibration from the compressor being transmitted
to the compressed air line and compensates inaccurate
lines.
The compressor must be fitted with paper induction filters
if there is a heavy dust occurrence at the installation point.
This keeps wear on the compressor to a minimum.
Compressor units must never be covered by hoods or clad-
ding. Measures of this type always lead to thermal prob-
lems. An exception to this is the original BOGE sound insu-
lation hood, which is specially designed for each individual
compressor.
10.2.6 The space requirement of a A compressor requires a certain amount of space, and this
compressor depends on the construction and type of compressor con-
cerned. From this arise compressor-specific minimum dis-
tances in all directions.
Air supply possible

The compressor must be installed to allow easy access for
operation and servicing.
Wall mounting possible
Corner For the cooling of a compressor to be assured, there must
inst. be a certain minimum distance between the ventilator or
possible
cooler and the neighbouring wall or other systems. If this is
Compres-
sed air
not provided for, the effect of the ventilator or cooler is much
connection reduced and efficient cooling is no longer guaranteed.
Air
supply When several compressors are installed adjacently the
heated cooling air of one compressor must not be used as
the cooling air of another.
Operating side
The minimum distances to walls and neighbouring equipment

Fig. 10.3 : and machinery can sometimes vary greatly, depending on the
Space requirement plan for a sound-insulated types and versions of the compressors. These are to be taken
screw-type compressor, model S 21 - S 30 from the respective operating instructions.
172
10.2.7 Conditions for installing Certain accident prevention rules must be followed when in-
compressed air receivers stalling compressed air receivers.
Compressed air receivers must be protected from external

damage ( e.g., falling objects ).
The receiver and its equipment must be able to be oper-
ated from a safe location.
Safety areas and distances must be observed.
The receiver must be safe where it stands. It must not move
or tilt by the application of external force. This includes the
additional weight during pressure testing! A reinforced
foundation may be necessary for large compressed air
receivers.
The factory specification plate must be well visible.
Compressed air receivers must have reasonable protec-
tion against corrosion.
Vertical receivers are brought horizontally into the com-
pressor rooms and then set up on their feet. The diagonal
height of the receiver must therefore be taken into account
in the dimensions of the room, otherwise it will be impos-
sible to set up the receiver.
173
10.3 Ventilation of a compressor The most important requirement for operating air-cooled com-

station pressors is an adequate flow of cooling air V c. The waste heat
generated by the compressor must be reliably extracted at all
times. There are three different possibilities for ventilation, de-
pending on the rooms available, and the type and model of
the compressor:
Natural ventilation.
Ventilation through the air inlet and outlet apertures in
the side walls or the ceiling by natural means i.e., without
assistance from a ventilator.
Artificial ventilation.
Ventilation through the air inlet and outlet apertures in
the side walls or the ceiling with the assistance of an outlet
ventilator.
Air inlet and outlet ducts.
Ventilation by means of appropriate ducts, usually with the
assistance of an exhaust ventilator.
With water-cooled compressors the main heat is extracted
by the cooling water. The residual heat ( radiated from the
motor ) must be extracted by cooling air.
10.3.1 Factors influencing the flow of A compressor generates a certain amount of waste heat de-

cooling air of a V c of a compressor pending on its drive rating. On air-cooled compressors this

heat must be extracted by a flow of cooling air Vc.

The volume of cooling air Vc is influenced by several factors as
well as the drive rating of the compressor :
Transmission heat
A part of the heat generated is emitted as transmission
heat by the walls enclosing the installation room ( includ-
ing the windows and doors ). The constitution of the walls,
the ceiling, the floor, doors and windows have a consider-

able influence on the flow of cooling air Vc.
Room temperature.
The higher the temperature of the installation room, the
greater the requirement for cooling air.
Temperature gradient.
The greater the difference t between the outside and in-
side temperature, the lower the requirement for cooling air.
Room height and site.
The greater the height and size of the room, the better the
distribution of the generated heat, and the requirement for
cooling air drops accordingly.
174
10.3.2 Definition of the factors influencing To obtain generally applicable values for the flow of cooling

the flow of cooling air V c to and airV c the following outline conditions have been set that influ-

from a compressor ence the volume of cooling air V c.
Room temperature 35 C = 308 K

Temperature gradient t 10 K
Wall thickness 25 cm
The surrounding walls are assumed to be homogenous
brick walls without windows and doors.
Room height and size.
The room height is defined as being lower than 3 m and
the area of the room less than 50 m.
The defined outline conditions above assume the least favour-

able admissible environment for operating the compressor. The

values calculated for the flow of cooling air V c are generally
applicable because conditions in real installation rooms are
normally better.
Thermal problems will not occur if the recommended flow of

cooling air V c for a compressor is assured.
175
10.3.3 General information for ventilation This chapter specifies the most important conditions concern-
of compressor rooms ing air supply and extraction that must be satisfied by the in-
stallation room of one or more air-cooled compressors. They
are based on the requirements set forth in VDMA specifica-
tion sheet 4363 Ventilation of installation rooms for air-cooled
compressors.
Hot air always rises. To allow an effective exchange of heat,

the (inlet) apertures for the supply of cold air must be lo-
cated close to the ground and the (outlet) exhaust aper-
tures must be in the ceiling or in a side wall at the top.
The compressor must be installed next to the air inlet aper-
ture Ain so that it draws fresh air for compression and cool-
ing air for ventilation directly from the inlet aperture Ain.
The compressor must be positioned so that it can not re-
induct its own heated exhaust air..
The inlet apertures or ducts of the compressor must be
Fig. 10.4 :
arranged so that dangerous admixtures ( e.g., explosive or
Arrangement of air inlet and outlet apertures
chemically unstable substances ) can not be inducted.
The exhaust air should flow from the compressor via the
compressed air receiver ( if fitted ) to the outlet aperture
Aout. The assemblies in the installation room should be
Air inlet apertures arranged accordingly.
with roller shutters
Adjustable roller shutters must be installed in the air inlet
apertures Ain. This allows the flow of cold air from the out-
side to be reduced and the temperature should then not
fall below the minimum admissible level in Winter. If this is
not sufficient, the compressor must be equipped with its
own heater. The accessories required can be obtained from
BOGE.
When installing several compressors in one room, care must
be taken that there is no thermal interaction between them.
If one compressor draws in the exhaust air from another
compressor, the system will overheat. The ventilation must
cater for the total cooling-air requirement for all compres-
sors. Ideally, each compressor should have its own air inlet
aperture of a size according to its need.
Air outlet aperture

with ventilator,
if required
Fig. 10.5 :
Installation room with three sound-insulated
compressors
176
10.3.4 Natural ventilation With natural ventilation, the circulation of air is controlled by
an air inlet aperture Ain and an air outlet aperture Aout in the
side walls of the installation room. Heat is exchanged by the
natural circulation of air only, since hot air rises. For adequate
ventilation to be provided, the air inlet aperture must be lo-
cated as far as possible below the air outlet aperture.
Experience shows that this method of ventilation is only suit-

able for compressors with ratings of up to 22 kW. Even smaller
compressors can have ventilation problems, depending on the
conditions in the installation room.

10.3.4.1 Outlet air aperture required An adequate flow of cooling-air V c can only be obtained with
for natural ventilation natural ventilation if the air inlet and outlet apertures are of an
appropriate size.
The figures in the following table are based on VDMA speci-

fication sheet 4363 Ventilation of installation rooms for air-
cooled compressors.

VK
Ain
Aout Drive Required flow of Required ventil-
rating cooling-air ation apertures

P Vc Ain and Aout
[ kW ] [ m/hr ] [ m ]
3,0 1350 0,20

Fig. 10.6 :
Natural ventilation of a compressor installation room 4,0 1800 0,25
with a sound-insulated BOGE screw-type compres- 5,5 2270 0,30
sor 7,5 3025 0,40
11,0 3700 0,50
15,0 4900 0,65
18,5 6000 0,75
22,0 7000 0,90
In principle, the air inlet Ain and outlet apertures Aout should
be of equal size. The cooling air has to pass through both
apertures. But taking into account the installation of roller shut-
ters, grids and the like, the air inlet aperture should be
approx.20 % larger than the air outlet aperture Aout. If this is
not the case, the maximum admissible ambient temperature
may be exceeded..
Note

When defining the flow of cooling-air V c for a compressor sta-
tion, the cooling-air requirement of a cold compressed air dryer
or heat-generating absorption dryer must be included in the
calculations.
177
10.3.5 Artificial ventilation In many cases natural ventilation of the installation room is
insufficient. Due to structural aspects or the high output of the
installed compressor the flow of cooling air is inadequate for
the task. In these cases, the hot air must be extracted with the
VV
aid of a ventilator.
Ain Artificial ventilation increases the flow speed of cooling air
Ventilator inside the installation room and guarantees the required flow
of air by forced ventilation. There are greater reserves when
outside temperatures are high. The inlet air aperture must be
modified to cater for the ventilator output.
The ventilator(s) should, for reasons of economy, be control-

led in several stages by a thermostat. The control depends on
Fig. 10.7 :
the temperature in the installation room. The higher the tem-
Artificial ventilation of a compressor room with a
sound-insulated BOGE screw-type compressor perature rises, the greater the output rate of the ventilator.

10.3.5.1 Required ventilator output with As with natural ventilation, the required flow of cooling air V c is
artificial ventilation derived from the output of the installed compressor. The waste
heat generated by the compressor must be reliably extracted.

The ventilator output V V is approx. 15 % greater than the re-

quired flow of cooling-air V c. This guarantees perfect cooling,
even in high Summer.
The figures in the following table are based on VDMA speci-
fication sheet 4363 Ventilation of installation rooms for air-
cooled compressors.
Drive Required
rating ventilator output

P VV
[ kW ] [ m/hr ]
4.0 1800
5.5 2270
7.5 3025
11.0 3700
15.0 4900
18.5 6000
22.0 7000
30.0 9500
37.0 11000
45.0 14000
55.0 17000
65.0 20000
75.0 23000
90.0 28000
110.0 34000
132.0 40000
160.0 50000
200.0 62000
250.0 70000
178
10.3.5.2 Required inlet air aperture with With artificial ventilation, the exhaust ventilator determines the
artificial ventilation size of the air outlet aperture.
The aperture needed for an exhaust ventilator is normally much

smaller than that required for natural ventilation.
The size of the air inlet aperture Ain depends on the ventilator

output V V and the maximum flow speed vS in the inlet aper-
ture.
It is preferable to calculate with a flow speed of vS = 3 m/s.

However, if structural considerations do not permit the size of
aperture resulting from this calculation, it is also possible to
use a flow speed of vS = 5 m/s.
The minimum size of the air inlet aperture is calculated with

the aid of the following formula:

VV
Ain =
3600 vS
m/hr
m =
3600 s/h m/s
Ain = minimum area of air inlet aperture [ m ]

VV = Ventilator output [ m/h ]
vS = maximum flow speed [ m/s ]
Note
It is to be remembered when choosing exhaust ventilators,

that the flow of cooling-air is subject to the same laws of phys-
ics as the compressed air. Even when cooling-air flows through
ducts and apertures, when flow speed increases the dynamic
pressure p ( pressure loss ) rises. A ventilator can only over-
come dynamic pressure that lies below its defined surface
pressure. If the dynamic pressure is higher than the surface
pressure of the ventilator, no volume flow can occur.
The maximum dynamic pressure is determined from the shape

and size of the air inlet and outlet apertures together with the
respective ducts ( if fitted ). The flow speed must also be taken
into account.
A p = 100 Pa ( 10 mm WH ) can be assumed for simple

apertures without unfavourable diversion (ducting).
179
10.3.5.3 Example of artificial ventilation A screw-type compressor, model S 21, is to be operated to-
of a compressor station gether with a cold compressed air dryer D 27 in a small in-
stallation room. Structural considerations do not allow natural
ventilation. Artificial ventilation with a ventilator is therefore
required.
BOGE screw-type compressor, model S 21

Output V : 2.42 m/min
Motor rating : 15 kW

Cooling-air req. V V1 : 4900 m/hr ( see page 178 )
Cold compressed air dryer, model D 27

Through-flow rate V : 2.66 m/min

Cooling air req. V V2 : 770 m/min ( see data sheet )
The two flows of cooling air must be added together. The re-
sult is the required ventilator output that must be provided in
the installation room.

Ventilator output V Vttl : 5670 m/hr
Fig. 10.8 :
Compressor station with screw-type compressor, The required size of air inlet aperture is calculated using ven-

cooling compressed air dryer, compressed air tilator output V Vttl and the maximum flow speed vS = 3 m/s:
receiver

VVttl
Ain =
3600 vS
5670
Ain =
3600 3
Ain = 0.525 m
Ain = minimum area of air inlet aperture [ m ]

V Vttl = Ventilator output [ m/hr ]
A ventilator with an output of 5670 m/hr must be installed in

the installation room ( The dynamic pressure of the apertures
must be taken into account when choosing the ventilator ).
The air inlet aperture Ain should be at least 0.525 m in size.
180
10.3.6 Circulation of cooling-air The circulation of cooling air through inlet and outlet ducts is
with inlet and outlet ducts an elegant solution to thermal problems in a compressor in-
stallation room.
Duct ventilation is possible with sound-insulated compressors.

The cool air is directed over the compressor and kept together
for extraction. BOGE screw-type compressors are fitted with a
cooling ventilator that generates a surface pressure of approx.
60 Pa ( approx. 6 mm WH ). This means that it can force ex-
haust air through a straight outlet duct of approx. 5 m in length
and with the recommended cross-section.
The ducts can be connected to the apertures in the sound

insulation hood without difficulty. There is normally no need
for an additional exhaust ventilator inside the duct.
The cool-air ducts direct the air out into the open. But they can
also be fitted with flap controls to use the heated air for room
heating in Winter. If the compressor rooms are unheated, it
Fig. 10.9 : may be desirable in Winter to use an air circulation system
Circulation of cooling-air in a BOGE screw-type with part of the heated cooling air being released into the com-
compressor from series S 21 - S 150 pressor room.
10.3.6.1 Air inlet ducts It is also possible in principle to supply cooling air to compres-
sors by way of ducts. However, an air inlet duct reduces the
induction volume flow ( dynamic pressure ) and thus has a
negative effect on the output of the compressor. For this rea-
son, cooling air should only be supplied through ducts in the
following situations:
Unclean environment.
The induction air at the location of the compressor con-
tains a high proportion of dirt, dust, chemical impurities or
it contains too much moisture. Under these conditions
the air supply should be drawn from a cleaner part of the
building.
High ambient temperature.
The temperature at the compressors location is distinctly
higher than that in neighbouring rooms or outside the build-
ing. This is possible if a lot of heat is given off by systems
and machinery in the compressor room.
181
10.3.6.2 Extraction of air through Compressor rooms containing individual units can usually be
a cool-air duct cooled by a appropriately arranged exhaust ventilator or by
natural ventilation. When there are several compressors set
up in one installation room, the use of cool-air ducts is always
recommended.
Ad
Vd
Ain When ducts are fitted, the installation room is not heated as
much by waste heat from the compressor.
The difference in temperature t between the inlet and outlet

air is approx. 20 K. The flow speed in the outlet ducts should
not exceed 6 m/s. The cross section (radius) required for the
duct is therefore much smaller than the wall aperture when
using natural or artificial ventilation.
Fig. 10.10 :
Extraction of air from a compressor room with a
BOGE screw-type compressor, emitting the air into
the open

10.3.6.3 Required flow of cooling-air V d The figures for the required flow of cooling air V d with ducts
and cross-section of duct Ad given in the following table are based on VDMA specification
when using a cool-air duct sheet 4363 Ventilation of installation rooms for air-cooled com-
pressors. An increase in the temperature of the cooling-air of
Dt = 20 K is assumed.
The calculation used to determine the required free cross-

section of the duct Ad are based on a maximum dynamic pres-
sure in the duct of 50 Pa ( 5 mm WH). This corresponds to
approx. 5 m of straight outlet duct, with no bends, tapering or
objects inside, a flow speed of 4 6 m/s.
Drive Required flow of Required

rating cooling-air free cross-
with exhaust duct section for duct

P Vd Ad
[ kW ] [ m/hr ] [ m ]
4.0 800 0.08
5.5 1000 0.10
7.5 1300 0.13
11.0 1700 0.13
15.0 2900 0.15
18.5 4500 0.23
22.0 4500 0.26
30.0 4500 0.33
37.0 6500 0.41
45.0 6500 0.48
55.0 8000 0.59
65.0 8600 0.64
75.0 9200 0.68
90.0 16000 0.85
110.0 16000 1.11
132.0 24400 1.24
160.0 24400 1.61
200.0 27800 2.06
250.0 33600 2.49
182
10.3.6.4 Information concerning ventilation All objects or features inside ducts, such as diversions, filters,
by ducting roller-shutter flaps, curvatures, T-pieces and silencers cause
an increase in flow resistance and thus an obstacle to the flow
of air. If the duct has many such features and is very long, the
size of the recommended free cross-section (radius) of the
duct must be checked by an expert.
There are appropriate fire safety measures prescribed to pre-

vent fire from spreading through ventilation ducts. DIN 4102,
part 6 requires the installation of automatic fire safety flaps
whenever ventilation ducts pass through a wall.
If the duct is long or unfavourably laid, the dynamic pressure

can be over 50 Pa ( 5 mm WH ). In this case there is a risk that
the cooling ventilator of a screw-type compressor can not over-
come the dynamic pressure in the duct. This means that cool-
ing air stops flowing and the entire cooling effort for the com-
pressor collapses. In this case an auxiliary ventilator will have
to be installed.
The air inlet and outlet flaps as well as the ventilators should,
for economical reasons, be controlled by a thermostat in the
installation room.
The cooling-air ducts must never be mounted directly on the

compressor housing. Compensators that remove tension and
stop the transmission of vibration must always be used.
A cooling-air duct with sound-insulation cladding radiates less

heat to the surroundings and also suppresses noise that comes
out of the compressor with the exhaust air.
BOGE generally recommends that the task of installing the

ducts and any associated construction work be given to a spe-
cialist company.
With multiple units, each compressor must have its own air
inlet and outlet duct.
When using a collective duct for multiple units, automatic check

flaps must be used to prevent heated cooling-air flowing over
a compressor that is switched off in the installation room and
heating the inlet air.
183
10.3.6.5 Dimensioning the air inlet aperture The size of the air inlet aperture Ain is dependent on the flow
when using an outlet duct of cooling-air Vd and the maximum flow speed vS in the aper-
ture itself.
It is preferable to calculate with a flow speed of vS = 3 m/s.

However, if structural considerations do not permit the size of
aperture resulting from this calculation, it is also possible to
use a flow speed of vS = 5 m/s.
The minimum size of the air inlet aperture is calculated with

the aid of the following formula:

Vd
Ain =
3600 vS
m/h
m =
3600 s/h m/s
A in = minimum area of outlet aperture [ m ]

Vd = Ventilator output [ m/h ]
184
10.3.6.6 Variations of duct-type

ventilation
The duct directs the hot exhaust air directly into the open. This
Cooling-air method is recommended if there are high temperatures in the
compressor room.
Fig. 10.11 :
Extraction of air into the open using an outlet duct
Cooling-air
Summer operation
The outlet duct directs the hot cooling-air directly into the open.
When temperatures in the installation room are cold, hot ex-
Cooling-air
haust air is added to the cold room air through a circulation
Winter operation flap. The circulatory ventilation prevents the unit from freezing
when outside temperatures are below zero. It is also recom-
mended to have auxiliary heating to prevent a cold compres-
sor from freezing during the start-up phase.
When this method is used, it is necessary to have an air outlet

aperture dimensioned according to the flow of cooling-air in
Fig. 10.12 : addition to the outlet duct itself.
Outlet duct with circulation flap
Cooling-air Cooling-air
Winter operation Summer operation
Inlet air
Fig.10.13 : When the outdoor temperature is cold (in Winter) duct directs
Using hot cooling-air for heating all or some of the heated cooling-air from the compressor into
other rooms in the building in order to heat them. When out-
door temperatures are hotter ( in Summer ) the duct emits the
air directly into the open.
With this configuration, the inlet air is mostly drawn from heated
rooms. This guarantees that the cooling-air is warm enough
when ambient temperatures are low. The compressor then
always operates above the minimum admissible temperature.
Air filters and silencers should be installed in the outlet duct in
order to reduce dust and noise in the rooms heated.
185
10.4 Example installation plans
10.4.1 Installation of a screw-type

compressor: an example
Compressed air receiver

Filter
Compressed air
emission
Outlet air
Oil/water separator
Bypass
Condensate diverter Water Oil
Condensate line
Inlet
air
Operating side HP hose

Screw-type compressor Refrigerant air dryer
Safety distance
acc. to VDE 0100
186
10.4.2 Installation of piston-type

compressor: an example
Compressed air receiver

1000 l
Compressed air
Sub-micro filter
Servicing space emission
F 30 Active carbon
G 3/4
filter A 30
Piston-type compressor
SCL 1160-25
Oil/water separator
Water Refrigerant air dryer

D 12
with Bekomat 2
req. air inlet

aperture 0.4m HP hose Condensate diverter Bekomat 2
Condensate line
Operating side
Servicing space
Safety distance
Servicing space
187
Heat reclamation
11. Heat reclamation Rising energy costs and increasing environmental awareness
led many compressor-users to the view that the enormous
potential of compressor heat must not longer be allowed to
escape unused. They approached the compressor makers who
developed high performance heat reclamation systems. Since
then, the heat given off by compressors has been utilised. It
serves to heat rooms, and to heat utility and heating water.
11.1 The heat balance of a To be able to appreciate the possibilities of heat reclamation
compressor station from compressors it must be taken into account that on the
basis of the first principle of thermodynamics the entire elec-
tricity intake of a compressor is converted into heat. In order
100 %
Electrical to make this heat useful one must know where it occurs and
intake from the what proportion of it can be economically reclaimed for fur-
mains ther use.
9%
Heating The heat is always discharged with the aid of a coolant. This
the motor
coolant contains approx. 95 % of the electrical energy enter-
ing the compressor in the form of heat. Approx. 4 % remains in
the compressed air as residual heat and approx. 1 % is lost to
the atmosphere by radiation.
When drawing up the balance sheet, assumptions should not

4%
Residual heat
be based only on the output from the motor that the compres-
in the com- sor needs to compress the air. The electric motor itself con-
pressed air verts energy into heat. One must also consider the efficiency
75 % 13 % rate of the motor, which according to the drive rating lies
Oil cooler Compressed air
between 80 % and 92 %. This again increases the amount
after-cooler
of heat emitted.
1%
Radiated
heat
95 %
of energy intake
is extracted by the
cooling medium
( water/air )
Fig. 11.1 :
Distribution of heat in a screw compressor with oil
injection cooling
188
Heat reclamation
11.2 Room heating The most obvious use for compressor heat is to heat rooms.
With the simplest method of room heating the compressor is

installed in the room to be heated. This means that the com-
pressor is installed directly in the workshop or storeroom, usu-
ally close to workplaces.
In this case, the only ducts required are those to discharge

hot air into the open during Summer. The heating air does not
require to be transported over long distances.
Of course, there must be adequate cooling for the compres-

sor. Sound insulation is normally required by safety rules.
11.2.1 Room heating through ducting To utilise the heat emitted by a central compressor station the
heated flow of cooling air must be brought through ducts into
6 7 5 6 the rooms to be heated. This is only recommended for larger
compressors since smaller ones do not provide enough us-
5
able heat.
8 The flow of cold air passes over the compressor and drive
motor. The cooling air absorbs the emitted heat and is drawn
into an outlet duct with the aid of a ventilator. In this process
the cooling air normally heats up to + 50 / + 60 C.
One use of compressor heat for room heating requires a si-

lenced compressor with ducted cooling air. BOGE screw com-
pressors are all silenced and fitted with an internal ventilator.
For this reason they can be connected to a ducting system
without difficulty. Non-silenced compressors ( e.g., most pis-
ton compressors ) can not be upgraded later for utilisation of
emitted heat, even if an adjusted sound-insulation hood is
9 2 1 4 3 fitted.
1 = Silenced compressor
2 = Inlet duct
3 = Outlet duct
4 = Additional exhaust ventilator
5 = Control flaps
( thermostatically controlled )
6 = Air outlet duct
( Room heating )
7 = Heat exchanger
8 = Air outlet duct
( into the open for Summer operation )
9 = Air inlet flap
Fig. 11.2 :
Op. diagram of ducting
189
Heat reclamation
11.2.2 Operation of room heating Insulated ducts conduct the warm cooling air of a compressor
or compressors at low outside temperatures into the building.
This heats the respective rooms. If the outside temperatures
are high, a duct directs the cooling air directly into the open.
The flow of cooling air is directed by inlet and control flaps.

These flaps and the ventilators should be controlled by an
adjustable room thermostat which monitors the temperature
in the heated rooms.
Fire safety measures are prescribed to prevent fire spreading

through the ventilation ducts. DIN 4102, Part 6 requires that
self-closing fire safety flaps be installed if the ventilation flaps
pass through a wall.
It is possible to heat exchangers in the ducts. With the aid of

these heat exchangers, water can be heated to a temperature
of approx. + 40 C. This hot water can assist a central heating
system or be used as utility water.
11.2.3 Economy of room heating The installation costs of room heating can be very high in pro-
portion to to energy costs saved. Before installing an expen-
sive system, it should be checked that enough heat is gener-
ated to justify the expense of a ducting system. It should be
taken into account that the flow of hot air inevitably cools down
if it has to travel long distances through a ducting system. The
investment must be in the correct proportion to the heating
costs saved.
The cost savings increase the more the compressor is used.

The more the compressor runs, the more effective the room
heating is.
190
Heat reclamation
11.3 The Duotherm For screw compressors with oil injection cooling there are
heat exchanger special heat reclamation systems for heating utility water or
heating water. . A heat exchanger is installed in the main flow
path of hot oil in the compressor. Utility or heating water is
heated by this hot compressor oil.
The Duotherm heat exchangers operate independently of the

type of compressor cooling because the heat exchanger is
installed as a pre-cooler before the actual air and water cooler.
11.3.1 Duotherm BPT The Duotherm BPT-System is used for heating water or hot
production water. The heart of this system is a plate heat ex-
changer consisting of a number of profiled, stainless steel
plates. The piled plates form a mutually isolated two channel
system. A Special process of hard-soldering connects these
layered plates together. Seals, which have the inherent risk of
leaks, are not required. The resulting heat exchanger works
very effectively and reliably.
Operating principle
The oil heated to approx. + 90 C by the compressor circuit

flows through the plate heat exchanger. The water coming in
Fig. 11.3 :
The heat reclamation system reverse flow through the exchanger is heated up to +70 C.
BOGE-Duotherm BPT The heated quantity of water is independent of the tempera-
ture difference in this process.
Compressed air There is a thermostatic oil control valve before and after the
outlet heat exchanger. Depending on the oil temperature the flow
of oil is either sent through the oil cooler and also the heat
1 2 3 5
9 10 exchanger or through a bypass.
4
Features
8 When the stop valves in the water inlet and outlet are closed
6 Return an enclosed space is formed at the same time. When the
water heats in this space it expands and the pressure rises.
11 An expansion vessel and safety valve must be installed in
order to prevent damage to the plate heat exchanger.
Advance
If the water is very dirty, a dirt pan with a maximum pore
7
6 width of 0.6 mm should be installed in the line.
Flush connections for cleaning the heat exchanger must
1 = Intake filter be fitted.
2 = Suction controller
This heat exchanger is normally integrated in the com-
3 = Compressor stage
pressor cabinet. It can be set up separately or fitted on site
4 = Combined compressed air/oil vessel
later.
5 = Oil separator
6 = Thermostatic oil control valve
7 = Oil cooler
8 = Oil filter
9 = Min. pressure non-return valve
10 = Compressed air aftercooler
11 = Heat exchanger
Fig. 11.4 :
Flow diagram of BOGE-Duotherm BPT
191
Heat reclamation
11.3.2 Duotherm BSW The Duotherm BSW-System is used to heat drinking and util-
ity water. Since other rules apply in the sanitary area, this is a
safety heat exchanger. Two independent circuits are kept apart
by a separation liquid.
The BSW-System is a pipe bundle heat exchanger in which
one pipe is inserted into another without making contact. The
safety area in this double pipe is filled with a non-toxic separa-
Fig. 11.5 : tion liquid. The liquid transmits the heat and in the event of
The heat reclamation system damage it prevents the water from mixing with the oil. The
BOGE-Duotherm BSW drinking water can therefore not be contaminated.
A pressure monitor switches immediately in the event of pipe
breakage. The emitted impulse can be processed elsewhere
( e.g., for an alarm or to shut down the system ).
Compressed air
outlet Operating principle
3 The oil from the compressor circuit heated to approx. + 90 C
1 2 5
9 10 flows through a pipe bundle. The separating liquid transmits
4 the heat to the utility water in the second bundle. The water
coming in reverse flow through the second pipe bundle can be
heated to approx. 55 C. The quantity of water heated depends
8 on the temperature difference. The heated water is subse-
Return
quently directed to a appropriate container ( boiler ) from where
6 it can be transported to the hot water circuit.
12 13
There is a thermostatic oil control valve before and after the
heat exchanger. Depending on the oil temperature the flow of
oil is either sent through the oil cooler and also the heat ex-
11 changer or through a bypass.
Advance
Features
7 6 The pressure monitor must be set to a value that is at least
20 % below the minimum pressure of the media used.
Conditions for use
1 = Intake filter Minimum water pressure 0,5 bar
2 = Suction controller Maximum water pressure 16 bar
3 = Compressor stage Maximum oil pressure 16 bar
4 = Combined compressed air/oil vessel Maximum pressure of separating liquid 10 bar
5 = Oil separator Maximum temperature ( oil and water ) +100 C
6 = Thermostatic oil control valve If the maximum temperature is exceeded, malfunctions will
7 = Oil cooler follow and an alarm will be actuated.
8 = Oil filter
Because of its size, the BSW safety heat exchanger is in-
9 = Min. pressure non-return valve
tegrated in the compressor cabinet. It can also be set up
10 = Compressed air aftercooler
separately or fitted later on site.
11 = Safety heat exchanger
12 = Pressure monitor for aperture
13 = Expansion vessel
Fig. 11.6 :
Flow diagram of BOGE-Duotherm BSW
192
Heat reclamation
11.3.3 How much energy is it possible The Duotherm-System makes available 75 % of the electrical
to save ? power taken into the compressor. This takes in the form of
heat discharged by the compressor oil.
The values given in the table for the quantity of heat and water
have been calculated on the basis of energy retention and the
general laws of heat transfer. They are in principle applicable
for both Duotherm systems. When using a Duotherm BWT
system it is not economical to heat utility water to above + 55 C
because the amount of water heated is too small.
The values given assume continuous compressor operation,

and heat loss is not taken into account because local condi-
tions vary. The calculation of savings for heating costs is based
on conventional oil heating :
Specific heating value H for heating oil 38.0 MJ/l
Price of heating oil 0.40 DM/l
Heating efficiency 75 %
Operating hours 1000 hrs
Drive- Discharged Usable Quantity of water at Cost

rating power quantity of t 25 K t 35 K t 50 K savings
heat 313 338 K 293 328 K 293 343 K at 1000 hrs
[ kW ] [ kW/h ] [ MJ/h ] [ m3/h ] [ m3/h ] [ m3/h ] [ DM ]
11.0 8.9 32.0 0.305 0.217 0.152 449.-

15.0 12.3 44.2 0.420 0.300 0.210 620.-
18.5 14.8 53.2 0.509 0.363 0.255 746.-
22.0 17.7 63.7 0.609 0.435 0.305 894.-
30.0 24.4 87.8 0.835 0.596 0.417 1232.-
37.0 30.3 109.0 1.040 0.743 0.520 1530.-
45.0 37.7 135.7 1.295 0.925 0.647 1905.-
55.0 45.5 163.8 1.565 1.118 0.782 2300.-
65.0 54.9 197.6 1.885 1.346 0.942 2770.-
75.0 63.1 227.1 2.170 1.550 1.085 3187.-
90.0 74.0 266.4 2.545 1.818 1.272 3740.-
110.0 90.0 324.0 3.095 2.210 1.547 4547.-
132.0 110.5 397.0 3.800 2.714 1.900 5570.-
160.0 133.5 480.6 4.590 3.278 2.295 6745.-
200.0 168.3 605.8 5.790 4.136 2.895 8500.-
250,0 208,9 752,0 7,180 5,128 3,590 10550,-
193
Heat reclamation
11.4 Closing remarks concerning Compressors offer enormous possibilities for saving energy
heat reclamation and costs through exploitation of heat emission. However, it is
not wise to attempt to force heat from a small compressor. It is
normally only worth the expense with large screw and piston
compressors and combined systems. The usable energy rises
with the capacity of the compressor.
The investment costs for a heat reclamation system depend

much on local conditions. They must be taken into account
because they are a big influence on the amortisation time of
the system.
A principle decision must be made whether to use the emitted

heat for room heating or for utility and heating water. Remem-
ber that room heating is seldom used in Summer.
Compressor usage is also a major factor. The longer it oper-

ates, the more heat there is, and it is available continuously
and in ample supply.
Before such a system is installed, a needs analysis should

always be made for the heat requirement. This analysis can
then be compared with the average running time of the com-
pressor.
This comparison then allows the true value of the heat recla-
mation system to be seen. It will also show whether reclama-
tion can cover the demand for heating or whether a second
heating system is needed.
194
Sound
12. Sound
12.1 The nature of sound Sound waves are mechanical vibrations of an elastic medium.
Starting from a sound source, a vibrating body, they spread
in solid bodies, liquids and gases in the form of pressure
fluctuations( pressure waves ). The study of sound is called
acoustics.
Vibrating bodies of all aggregate conditions can transmit sound
waves.These are known as sound sources.These can be strings,
rods, plates, columns of air, membranes, machines etc.
If the vibrations are emitted from the ambient air they are known
as airborne sound.
The vibrating bodies, gases and liquids can transmit the vi-
brations to solid objects. In this case they are known as struc-
ture-borne sound.
12.1.1 Sound perception There are the following connections between the vibrations of
airborne sound coming from the vibrations of a sound source
and the human perception of sound:
Amplitude of vibration
The amplitude is the periodic deviation of pressure that oc-
curs in a sound wave.
It corresponds to the impression of loudness perceived by
human beings.
Amplitude (sound pressure )
Tone
Frequency of vibration
The frequency is the number of pressure fluctuations during
a unit of time. It is normally measured in Hz ( vibrations per
second ).
Sinusoidal sound
This corresponds to the impression of tone perceived by hu-
man beings.
Vibration form
Transient noise A distinction is made between different forms of vibration which
cause the different impressions of sound:
Tone.
Time A tone ( pure tone ) is a sinus vibration.
Crack Sinusoidal sound.
This is the superimposition of several tones. Several sinu-
Fig. 12.1 : soidal vibrations superimpose and form a non-sinusoidal
Impressions of sound vibration. The tone with the lowest frequency defines the
overall perception of the sound. The other tones ( top tones )
give the impression of sound colour.
Transient noise.
Transient noise is an irregular vibration. It is a mixture of
very many frequencies or different magnitudes.
Crack.
A crack is a single, short and sharp report.
195
Sound
12.2 Important terminology in acoustics
~
12.2.1 Sound pressure Sound pressure p is the periodic pressure deviation ( over
and under pressure and alternating pressure ) that occurs in
a sound wave. It is measured in Pa ( 10-5 bar ).
In gaseous media sound pressure is superimposed over the

existing gas pressure p. Sound pressure is heavily dependent
on various factors e.g., the sound output of the source, the
spatial circumstances etc.
Sound pressure moves between approx. 2 10-4 Pa with the

ticking of a clock and approx. 65 Pa with the start of an aircraft
in the direct vicinity.
12.2.2 Sound level To be able to handle acoustic sizes better, the value is set in
proportion with a reference size put in a logarithm. The levels
as logarithm of a proportional size are dimensionless. The
designation dB ( Decibel ) is added.
The sound pressure level is set in proportion to the reference

pressure p0 = 2 10-5 Pa and pu in a logarithm. The following
applies for the sound pressure level:
~
p
Lp = 20 lg dB
p0
LP = Sound pressure level [ dB ]

~
p = Sound pressure [ Pa ]
p0 = Reference sound pressure [ 2 10 Pa ]
-5
The other sizes in acoustics are treated in similar fashion.

Acoustics uses almost only levels to indicate sizes.
12.2.3 Sound intensity The sound intensity indicates the sound energy radiated by a
sound source per second. It is a machine-specific size ( emis-
sion size ) and can be influenced by sound insulation meas-
ures among other methods.
Using the sound intensity of a machine, it is possible to calcu-

late the sound pressure level of a certain location, taking into
account the distance, the structural conditions and other sound
sources near to the sound intensity. There is often no need to
carry out extensive measuring.
196
Sound
12.3 Human perception of sound The human ear can normally only hear frequencies from 16 to
20000 Hz . Higher frequencies are described as supersonic,
lower ones as infrasonic. The perceptible sound pressure is
Pain threshold
between 10-5 Pa and 100 Pa, whereby a sound pressure of
100 Pa nearly always leads to the immediate loss of hearing
Sound intensity[ dB ]
in humans.
Audibility range The human sense of hearing does not perceive the various
sound pressures and frequencies with the same intensity. The
audibility range offers a summary of the sound pressure and
frequency ranges perceptible to humans. The bottom limit of
the curve shows the audibility threshold and top curve the
Audibility threshold pain threshold. The largest range of sound pressure percep-
Frequency [ Hz ]
tible to the human ear is at around 1000 Hz.
Fig. 12.2 :
The human hearing range
12.3.1 The sound intensity level Sound pressure is a physical size and can therefore be
measured. The intensity at which a person perceives sound
pressure is a physiological size that depends on the sense of
hearing.
The level of loudness is an empirically determined size. The
perception of loudness has been tested in series of experi-
ments with different people and an average value formed. The
level of loudness is given in Phon.
At 1000 Hz the sound intensity level matches the unassessed
sound pressure level. The sound intensity level can not be
measured with technical instruments. This is why comparative
measurements are very difficult, if not impossible.
12.3.2 Assessed sound level dB ( A ) Acoustic sizes must be adapted to the perception range of the
human ear in a way that they make also technical sense. De-
pending on the frequency, the real sound pressure level is
adjusted with certain values to the sensitivity of the ear. There
are valid international evaluation curves for these adjustment
values.
Some areas of application for different evaluation curves are
given below.
A Evaluation curve for LN = 30 - 60 Phon.

B Evaluation curve for LN = 60 - 90 Phon.
C Evaluation curve for linear audibility range.
D Evaluation curve for aircraft noise.
An evaluated sound level is indicated by having the letter of

the evaluation curve e.g., dB ( A ) suffixed.
The A-evaluation curve is the one primarily used in measuring
the noise of compressors and other machinery. Sound meas-
urement as standardised in DIN 45635 uses A-evaluated sound
pressure levels.
197
Sound
12.3.3 Loudness in comparison The following diagram shows the hearing range of an average
person, which lies between the audibility threshold and the
pain threshold, together with various examples of differing
loudness.
Pain threshold
Sound pressure level [ dB ]
Phon
no
rm
al
au
di
bi
lit
yt
hr
es
ho
ld
Frequency [ Hz ]
The ticking of a clock corresponds to a sound pressure level

of approx. 20 dB ( A ).
Normal conversation at a distance of around 1 m corresponds

to a sound pressure level of approx. 70 dB ( A ).
198
Sound
12.4 Behaviour of sound The dissemination and general behaviour of sound depends
on various factors. It must also be taken into account that the
sound output of a machine ( the sound source ) remains con-
stant.
12.4.1 Distance from the sound source The sound pressure generated from the source always dimin-
ishes with increasing distance. The constant sound output of
a source disseminates over a greater area (dispersion) with
increasing distance. The form of the sound wave plays an
important part in this. Machinery and compressors nearly al-
ways radiate sound energy in the form of a semisphere be-
cause they are normally on a firm base.
The sound pressure level then goes down, with reference to

the 1 m distance value, as shown in the following table:
Distance from the sound source [m] 1 2 5 10 25 50 100
Sound pressure level reduction[ dB ( A ) ] 0 5 12 16 23 28 32
These starting values refer to an unrestricted dissemination

of sound over an open area. A certain amount of reflection
from normal, reverberant ground is taken into account.
Example
An ultra-silenced BOGE screw compressor S 21 is installed

in a large hall. It generates according to DIN 45635 a sound
pressure level of 69 dB ( A ). At a distance of 10 m the sound
pressure generated by the compressor is only around 57 dB
( A ).
12.4.2 Reflection and Absorption A part of the sound is reflected by the walls and other objects.
In rooms, reflection causes a diffuse field of undirected sound
waves. The general level of sound pressure in the room is
increased by reflected sound. This reflected sound is known
as reverberation.
Reverberant materials with smooth surfaces, such as brick

Reflections
walls, reflect a large amount of occurrent sound. The shape of
the surface heavily influences the reflections. If a room is pad-
direct sound ded with specially arranged insulative pyramids the result is
an acoustically dead room without reflection. Rooms of this
type are used to measure sound pressure and the like with
scientific accuracy.
The sound not reflected is absorbed by walls or objects. The

material conducts the absorbed sound further and damps it. It
is usually transmitted back to the air at another point. Materi-
Fig. 12.2 : als with a high elasticity module, such as steel, conduct sound
The dissemination of sound in an enclosed space very well. The damping effect is usually low.
199
Sound
12.4.3 Damping sound Damping is the conversion of sound energy into heat gener-
ated by the friction of particles against each other. The sound
Incident Sound is absorbed in this process. Damping of airborne sound is
sound achieved by porous or fibrous absorption materials with a low
elasticity module and a large area mass ( kg/m ). The extent
to which sound is damped by appropriate materials also
depends on the frequency spectrum of the sound. Some fre-
quencies are affected more and others less.
Reflected
Sound damping by the air depends much on the temperature
Sound and humidity of the air. Under normal conditions it is only per-
ceptible from a distance of 200 m. When humidity is high e.g.,
Absorbed
in fog, the damping effect is greater.
sound
Fig. 12.3 :
Sound insulation (damping) by walls
12.4.5 Dissemination of sound in pipes Special laws apply for the dissemination of sound in pipes and
and ducts ducts. A flowing medium and the reflections in a narrow duct
assist the dissemination of sound. Measures must be taken
against the unrestricted dissemination of sound in ducts, par-
ticularly when the hot outlet air of a compressor is being used
for room heating.
Coming from a silenced compressor, a sound wave is directed

into the air outlet duct. The sound, which here is not affected
by the silencer, continues through the duct system. It proceeds
unimpeded through the ventilation apertures and into the
heated rooms.
There are various measures that can be taken to reduce the

continuation of sound in ducts or pipes:
Linear insulation.
The ducts are lined with strongly absorbent materials. This
reduces the sound energy and the sound pressure level in
the duct.
Absorption insulation.
Fig. 12.4 : A part of the duct is loosely filled with sound absorbent
Absorption silencer with straight elements
material ( e.g., rock wool ). This absorbs a large part of the
sound energy, similar to walls. The great drawback of this
form of insulation lies in its high resistance to flow. Insula-
tion of this type is not recommended in duct systems with-
out a big exhaust ventilator.
200
Sound
12.4.6 Sound pressure level from many If there are several sources of sound in one room, the sound
sound sources pressure level will rise. The more sound energy emitted, the
higher the sound pressure. The perceived intensity of the sound
increases. The correlations are not linear. They depend much
on the structure of the room, the sound pressure levels of the
individual sources and their frequency spectrum. Therefore,
when looking at the correlations, only the two simplest cases
are given here.
The numbers given here should be seen as reference values

only. They may deviate sharply in individual cases because
many influencing factors are not taken into consideration.
12.4.6.1 Several sound sources with the When there are two or more sound sources with the same
same level sound pressure level in a large room, the correlation is rela-
tively simple. The following table shows the increase of the
overall sound pressure level without taking possible reflection
or transient noise into account:
Number of sound sources 2 3 4 5 10 15 20
Increase of sound pressure level [ dB ( A ) ] 3 5 6 7 10 12 13
To obtain the overall sound pressure level the increase in sound

pressure must be added to the sound pressure levels of the
individual sources.
Example
There are three ultra-silenced BOGE screw compressors S 21

in a large hall. Each generates according to DIN 45635 sound
pressure of 69 dB ( A ). The overall sound pressure level is
therefore at 74 dB ( A ) [ 69 + 5 ].
12.4.6.2 Two sound sources with different The total sound pressure of two different sound pressures
levels ( L1 + L2 ) can be determined with the aid of a diagram. When
there are several sound sources with different levels the cor-
relations are very complicated.
The diagram shows by how many Decibels ( L ) the higher of

the two sound levels L1 rises in dependency on the difference
L [ dB ( A )
L 1 + L2 L 1 + L between the two levels( L1 - L2 ).

]
Example
A compressor with a sound pressure according to DIN 45635

L1 - L2 [ dB ( A ) ]
of 69 dB ( A ) and a compressor with a sound pressure of
Fig. 12.5 : 74 dB ( A ) are installed in the same room. The total sound
Sound strengthened by two sources with different pressure in this case is approx. 75.3 dB ( A ).
levels [ 74 - 69 = 5 74 + 1.3 = 75.3 ]
201
Sound
12.5 The effects of noise
150
140
130
120
mechanical
110
damage
100 deafness
90
80
Hearing
70 impairment
Sound pressure level [ dB ( A ) ]
noise deafness
60 damage to inner
vegetative ear, incurable
50 reactions
nervous effects, stress
40 falling work-rate
falling concentration
30
psychic
20
reactions
10 Anger
Irritation
Fig. 12.6 : One form of sound is noise. This is undesired, annoying or

Noise as a health hazard painful sound. Noise has various adverse effects depending
on its sound pressure:
Disturbed concentration
Sound pressure of approx. 70 dB ( A ) disturbs speech
communication.
Sound pressure of 85 dB ( A ) usually leads to a tempo-
rary reduction of hearing after an 8-hour shift. If this acous-
tic stress continues for several years it can cause perma-
nent damage to hearing.
Sound pressure of 110 dB ( A ) leads to a reduction of
hearing in a very short time. If this stress continue for sev-
eral hours it is very likely to result in permanent damage to
hearing.
Sound pressure of 135 dB ( A ) and above causes imme-
diate deafness in most cases.
202
Sound
12.6 Noise protection directives Various safety rules have been devised for workplaces to pre-
vent the negative effects of noise. These rules are intended to
provide long-term protection for staff and to improve general
working conditions.
12.6.1 Safety rules for noise generating The safety rules for noise generating operations prescribe the
operations following measures:
Date 12/1974
Noisy areas of over 90 dB ( A ) must be marked accord-
ingly.
From 85 dB ( A ) staff must be given noise protection gear.
This gear must be worn all the time with sound pressures
above 90 dB ( A ).
Appropriate measures must be taken if noise increases
the risk of accidents.
Regular examinations of staff are prescribed by law if the
sound pressure levels exceed 85 dB ( A ).
New work facilities must comply with the most advanced
noise protection methods.
12.6.2 Safety rules for compressors 12 para.3 Maximum permitted sound pressure 85 dB ( A )
( VBG 16 ) when installed in workrooms. Noise to be meas-
Date 4/1987 ured at the workplace as set forth in DIN 45635.
Remark: The work areas at compressor stations are not

workrooms, even if some of the maintenance
tasks carried out in them require lengthy periods
of time.
12.6.3 National workplace directive The sound pressure level in workrooms should generally be
Date 4/1975 as low as possible ( 15 ). It may not exceed the following
limits:
55 dB ( A ) At the workplace for jobs mainly involving mental

work.
55 dB ( A ) Staff rooms for tea and coffee breaks
70 dB ( A ) For simple or mainly mechanised office jobs.
85 dB ( A ) All other jobs ( production and installation work

and similar activities )
203
Sound
12.6.4 National general administrative These rules define general noise limits for commercial and
rules concerning noise residential areas. This includes noise made by traffic as well
Date 7/1984 as industry.
Place of measurement:
0,5 m in front of the open window of the person most directly

affected by the noise.
Maximum allowed sound level

Area Day Night
6.00 - 22.00 hrs 22.00 - 6.00 hrs
max. dB ( A ) max. dB ( A )
Commercial only 70 70
Mainly
Commercial 65 50
Commercial and
residential 60 45
Mainly residential 55 40
Residential
only 50 35
Med. build. and hospitals 45 35
Homes annexed to
plant buildings 60 45
204
Sound
12.7 Noise measurement When measuring noise at compressors and similar machin-
ery the main method used is the enveloping surface method
of DIN 45635. This norm defines the conditions for measuring
the noise emitted by compressors and machinery to the out-
side air ( noise output ) according to standard methods, thus
making the results comparable.
Noise is mainly measured at compressors and machinery

to find out whether certain requirements are being met. The
results determined are useful for:
Comparing similar machinery.

Comparing different machinery.
Estimating sound levels at a distance.
Checking noise emissions with respect to safety laws.
Planning noise protection measures.
12.8 Silencing on compressors Compressors sometimes emit sound levels of over 85 dB ( A )

when in operation. This can be much higher if there are sev-
eral unsilenced compressors in one room. Since the Work
Safety Act recommends the wearing of protective equipment
from 85 dB ( A ) upwards and prescribes it from 90 dB ( A ), it
is often beneficial to install silenced compressors.
Silenced compressors can be installed close to workplaces.

This avoids the cost of long lines and separate compressor
rooms, and reduces pressure loss in pneumatic lines.
Certain demands are placed on sound-insulation materials:
Not combustibility.
Insensitivity to dust.
Insensitivity to oil.
Fig. 12.7 :
Silenced BOGE screw compressors
The silencing material used for compressors is therefore usu-
ally mineral cotton ( rock wool or fibreglass ) and fluorocarbon-
free, hardly flammable, self-extinguishing foam material, that
is installed in the steel sheet case.
205
Costs of compressed air
13. Costs of compressed air
13.1 Composition of compressed The operating costs for compressed air comprise three fac-
air costs tors:
Servicing and maintenance costs.

The servicing costs are for the wages of the fitter, spare
parts and consumed materials such as lubrication and cool-
ing oil, air filters, oil filters and the like.
Energy costs.
The energy costs include the costs for electricity and fuel.
These are needed to heat the compressor.
Capital service.
Capital service includes the interest and repayment on the
items invested in ( compressor, pre-processing and pipe-
line ). These are the depreciation and interest costs.
13.1.1 Cost factor ratios The individual factors can vary in size, depending on the hours
of operation per year. With single shift operation this is normally
2000 hrs/yr, 4000 hrs/yr with 2-shift operation, and 7500 hrs/yr
with 3-shift operation.
In determining the cost ratios, calculations are based on elec-

100%
90%
tricity costs of 0,25 DM/kWh and a depreciation period of 5
80% years with an interest rate of 8 % .
70%
60% Cost factors Hours of operation per year
50%
40% 2000 Oh/y 4000 Oh/y 7500 Oh/y
30% [%] [%] [%]
20%
10% Servicing and
0% maintenance 2 2.5 2.7
2000 Bh/J
Oh/Y 4000 Bh/J
Oh/Y 7500 Bh/J
Oh/Y
Energy costs 73 84 87
Capital service 25 13.5 10.3
Servicing and maintenance costs
It is easy to see that energy is the greatest cost factor. The
Energy costs servicing and maintenance costs are more or less negligible,
and the costs for service of capital equipment are hardly a
Capital service major item in the long term. The main criterion in acquiring a
compressor system must therefore be energy consumption.
Fig. 13.1 :
Composition of compressed air costs with differing
There is a breakdown of energy costs on the following page.
operating hours per year
206
Costs of compressed air
13.2 Cost-effectiveness calculation for energy costs
Maker BOGE
Type Screw compressor
Model S21

(1) FAD of complete system ( V ) m3/h 145.2
acc. to PN2 CPTC2
Ambient temperature t = 20 C
Operating pressure bar 8
(2) Electrical power requirement
of compressor kW
of drive belt kW
of transmission kW
of fan kW
of overall system ( Pe ) kW 14.79
(3) Motor efficiency rating ( ) 90
with IP 54 protection
(4) Total intake ( Pi ) kW 16.43
from electricity supply
Pi = Pe ( 2 ) 100 / ( 3 )
(5) Electricity price ( c ) DM/kWh 0.25
(6) Electricity costs per hour DM/h 4.11
C = Pi ( 4 ) c ( 5 )
(7) Costs per m3 compressed air DM/m3 0.0283

CV = C ( 6 ) / V ( 1 )
(8) Costs per year
Compressed air requirement ( AR ) m3/h 122.4
Hours of operation per year Bh 2000
Compressed air requirement per year m3 244800
AR/Y = Oh AR
(9) Total costs per year DM/Year 6926.-
CY = AR/Y ( 8 ) CV ( 7 )
( 10 ) Additional costs per year
The energy cost calculation takes no account of possible idling times.
207
CE-Certification
14. CE-Certification
14.1 Introduction The CE symbol is the technical passport for machinery. Since
1 January 1995 machinery and equipment may no longer be
sold or displayed at exhibitions and fairs inside the EU without
a CE symbol.
This means that machinery and equipment must be compliant

with the EC Directive Machinery and other EC directives,
rules and standards.
The major rules etc. for compressors are:
Machinery directive 89/392/EEC ( from 1.1 1995 )

Fig. 14.1
Low-voltage directive 73/23/EEC ( from 1.1.1997 )
The CE symbol
EMV directive 89/336/EEC ( from 1.1.1996 )
Directive for simple unfired pressure tanks
87/404/EEC
14.1.1 EC Machinery Directive Under the EEC directive the Council Directive for the Align-
ment of Rules of Member States for Machinery ( 89/392/EEC ),
short form: the Machinery Directive, plays a central part.
It does not govern the measures for individual product groups

but sets general safety requirements for the machinery and
equipment in its area of application.
The requirements for safety and health protection for machin-

ery are found in appendix I of the machinery guideline and
form the work base for manufacturers.
In Germany the machinery directive was implemented under

national law by the 9th Directive of the Equipment Safety Act
( Machinery Directive ).
Fig. 14.2
The states of the European Community
14.1.2 Areas of application Machinery, as defined in the directive, is the sum of connected
parts or devices, of which at least one must be movable, and
of actuation devices, control and energy circuits, that are
assembled for a certain application.
Safety features, such as double-handed switching componentry,

are also covered by the guideline. The term Machinery is there-
fore very broadly defined.
A number of expressly specified devices are not covered by

the machinery directive. These include, among others, ma-
chines that are powered solely by human effort.
Electrically powered compressors made by BOGE are there-

fore definitely covered by the machinery directive.
208
CE-Certification
14.2 Introducing machinery to When introducing machinery to the market the following con-
the market ditions must be met:
The CE symbol must be visibly, legibly and permanently

attached to the machinery.
The machinery must be supplied with an EC or Makers
declaration of conformity. By this declaration, the maker
confirms that the machinery is compliant with the safety
requirements and that the prescribed procedures for the
EC declaration of conformity and the EC design inspec-
tion have been observed.
The maker must be in possession of technical documen-
tation for the machinery ( summary plans, certificates and
inspection reports, list of standards complied with and safety
rules ).
The machinery must be supplied with an original set of
operating instructions and operating instructions in the lan-
guage of the country it is used in.
The machinery directive obliges the authorities in EC member

states to monitor machinery marked with the CE symbol by
way of random checks, to ensure that the guideline is com-
plied with.
If it is found that properly used machinery constitutes a dan-

ger to people, domestic animals or property, then measures
are to be taken.
These measures, to be taken by the authorities can be as

follows:
Fines
A ban on further circulation of the machinery.
A recall of all machinery concerned
14.2.1 CE Symbol On signing the EC conformity and makers declaration, the

maker is entitled to affix the CE symbol to the machinery.
The CE symbol consists of the letters CE and if necessary

the name of the body that checked conformity. It must be well
visible, legible and permanently attached. The minimum height
of the letters is 5 mm. This minimum height may be deviated
from with small machinery.
The CE symbol is not a quality or safety symbol. It can be

Fig. 14.3 seen as a market registration sign or a passport. It allows the
The CE Symbol free circulation of goods within the EC single market.
209
CE-Certification
14.2.2 EC Declaration of Conformity The machinery guideline 89/392/EEC states that makers of
machinery and systems must conform in writing that the
machinery they bring into circulation is in line with the basic
safety and health requirements set forth in appendix I of the
guideline.
This written confirmation must be in the same language as

the operating instructions. A copy in the language of the coun-
try where the machinery is used must be included with it.
The EC declaration of conformity must contain the following:
Name and address of the maker ( or person responsible in

the Community ).
Description of the machinery or system ( make, model, se-
rial number etc. )
All relevant rules with which the machinery complies ( all
guidelines that apply for the machinery or system must be
given )
Where to find the harmonised norms, if necessary.
The national technical standards and specifications applied,
if necessary.
Information about signatory ( title, position in company )
Name and address of the accredited inspection and certi-
fication centre that has carried out an inspection, if neces-
sary.
The EC declaration of conformity by BOGE for ready-to-use

compressors is on the following page.
210
CE-Certification
(D) Konformittserklrung gem EG-Richtlinie 89/392/EWG

(I) Dichiarazione di conformit secondo la direttiva CE 89/392/CEE
(GB) Conformity declaration in accordance with EC guideline 89/392/EEC
(F) Certficat de conformit selon la rglementation CE 89/392/CEE
(E) Declaracin de conformidad segn la norma EG 89/392/CEE
(P) Declarao de conformidade segundo as Normas 89/392/CEE
(NL) Conformiteitsverklaring volgens EG-richtlijn 89/392/EEG
(DK) Overensstemmelseserklring i.h.t. EF-Maskindirektiv 89/392/EF
(S) Konformitetsfrklaring enligt EG-riktlinje 89/392/EEC
(N) Konformitetserklring i henhold til EU direktiv 89/392/EF
Wir - Noi - We - Nous - Nosotros - Nos - Wij - Vi - Vi - Vi

B O G E Kompressoren, Lechtermannshof 26, 33739 BIELEFELD
(D) erklren hiermit, da der nachstehende Kompressor in der von (NL) verklaren hiermede, dat de onderstaande compressor inde
uns gelieferten Ausfhrung folgenden einschlgigen door ons geleverde uitvoering aan de toegepaste normen voldoet,
Bestimmungen entspricht, insbesondere: 89/392/EWG speciaal: 89/392/EEG, 73/23/ EEG, 87/404/EEG, 89/336/EEG
Maschinenrichtlinie, 73/23/ EWG Niederspannungsrichtlinie, 87/
404/EWG Richtlinie ber einfache unbefeuerte Druckbehlter, 89/
336/EWG Richtlinie ber elektromagnetische Vertrglichkeit
(I) dichiariamo con la presente che il compressore seguente (DK) erklrer hermed, at flgende kompressor i den af os
nellesecuzione da noi fornita corrisponde alle norme applicate, in leverede udfrelse stemmer overens med de anvendte standarder,
particolare : 89/392/CEE, 73/23/ CEE, 87/404/CEE, 89/336/CEE isr: 89/392/ EF, 73/23/ EF , 87/404/ EF, 89/336/ EF
(GB) hereby declare that the following compressor in the design (S) frklarar hrmed att nedanstende kompressor i av oss
delivered by us meets the standards applied, in particular: 89/392/ levererat utfrande uppfyller de tillmpade normerna, srskilt: 89/
EEC, 73/23/ EEC, 87/404/EEC, 89/336/EEC 392/EEC, 73/23/ EEC, 87/404/EEC, 89/336/EEC
(F) dclarons par la prsente que le compresseur dlivr (N) erklrer hermed at nedenstende kompressor i den utfrelse
mentionn ci-dessous est conforme aux normes, en particulier: 89/ som er levert av oss er overensstemmelse med de anvendte
392/CEE, 73/23/ CEE, 87/404/CEE, 89/336/CEE normer, srlig: 89/392/ EF, 73/23/EF, 87/404/EF, 89/336/ EF
(E) declaramos por la presente que el compresor figurado al final (P) declaramos pela presente, que o compressor, a seguir
en la ejecucin que hemos suministrado cumple las normas mencionado na verso por ns fornecida corresponde s normas
aplicadas, en particular: 89/392/CEE, 73/23/ CEE, 87/404/CEE, aplicadas, em especial: 89/392/CEE, 73/23/ CEE, 87/404/CEE, 89/
89/336/CEE 336/CEE
........................................................................................................................................................................................
Typ/Tipo /Type/Type/ Maschinennr./ N.della maccina/ Machine No.
Tipo/Tipo/ Type/Type/ N de machine/ N de serie/ N da mquina/
Typ/Type Machineno./ Maskin-nr./ Maskinnr./ Maskinnr
(D) Angewendete harmonisierte Normen, insbesondere: prEN 1012 Teil 1 Sicherheitsanforderungen Kompressoren
(I) Norme armonizzate applicate, in particolare: prEN 1012 Teil 1 Sicherheitsanforderungen Kompressoren
(GB) Harmonized standards applied, in particular: EN 292 Teil 1+2 Sicherheit von Maschinen
(F) Normes harmonises appliques, en particulier: EN 294 Sicherheit von Maschinen - Sicherheitsabstnde
(E) Normas armonizadas aplicadas, en particular: EN 60204 Teil 1 Sicherheit von Maschinen - Elektr. Ausrstung
(P) Normas armonizadas aplicadas, em especial: EN 286 Teil 1 Einfache unbefeuerte Druckbehlter
(NL) Toegepaste geharmoniseerde normen, speciaal: EN 50081-1,2 Elektromagnetische Vertrglichkeit - Straussendung
(DK) Anvendte harmoniserede standarder, isr: EN 50082-1,2 Elektromagnetische Vertrglichkeit -Strfestigkeit
(S) Tillmpade harmoniserade normerna, srskilt:
(N) Anvendte harmoniserte normer, srlig:
(D) Angewendete nationale Spezifikationen, insbesondere : Gertesicherheitsgesetz

(I) Specificazioni nationali applicate, in particolare: Verordnungen zum Gertesicherheitsgesetz
(GB) Harmonized standards applied, in particular:
(F) Spcifications nationales appliques, en particulier:
(E) Especificaciones nacionales aplicadas, en particular:
(P) Especificaes nacionais aplicadas, em especial:
(NL) Toegepaste nationale specificaties, speciaal:
(DK) Anvendte nationale specifikationer, isr:
(S) Tillmpade nationella specifikationer, srskilt:
(N) Anvendte nasjonale spesifikasjoner, srlig:
Bielefeld Beutel, Managing director design/development......................................................................
211
CE-Certification
14.2.3 EC Makers Declaration If a machine or machine part or assembly is installed in an-

other machine or a machine part is fitted together with other
machines (parts) to form a machine and this machine or
machine part can not function alone, then this machine ( ma-
chine part, assembly) must be supplied with a declaration from
the maker or person responsible. In this declaration the maker
must state in writing that the machine he is putting into circu-
lation conforms with the basic safety and health requirements
set forth in appendix I of the machinery directive 89/392/EEC.
This written confirmation must be in the same language as

the operating instructions. A copy in the language of the coun-
try where the machinery is used must be included with it.
The EC makers declaration must contain the following:
Name and address of the maker ( or person responsible in

the Community ).
Description of the machinery or system ( make, model,
serial number etc. )
All relevant rules with which the machinery complies ( all
directives that apply for the machinery or system must be
given )
Where to find the harmonised norms, if necessary.
The national technical standards and specifications applied,
if necessary.
Information about signatory ( title, position in company )
Information that commissioning is prohibited until it is es-
tablished that the machine into which this machine it to be
installed is compliant with EC machinery directive 89/392/
EEC.
Name and address of the accredited inspection and certi-
fication centre that has carried out an inspection, if neces-
sary.
The EC makers declaration by BOGE for installed compres-

sors is on the following page.
212
CE-Certification
(D) Herstellererklrung gem EG-Richtlinie 89/392/EWG

(I) Dichiarazione del fabricante secondo la direttiva CE 89/392/CEE
(GB) Manufacturers declaration in accordance with EC guideline 89/392/EEC
(F) Certficat du fournisseur selon la rglementation CE 89/392/CEE
(E) Nota explicativa del fabricante segn la norma EG 89/392/CEE
(P) Declarao de fabrico segundo as Normas 89/392/CEE
(NL) Fabrieksverklaring volgens EG-richtlijn 89/392/EEG
(DK) Fabrikanterklring i.h.t. EF-Maskindirektiv 89/392/EF
(S) Tillverkarfrklaring enligt EG-riktlinje 89/392/EEC
(N) Produsenterklring i henhold til EU direktiv 89/392/EF
Wir - Noi - We - Nous - Nosotros - Nos - Wij - Vi - Vi - Vi

B O G E Kompressoren, Lechtermannshof 26, 33739 BIELEFELD
(D) erklren hiermit, da der nachstehende Kompressor in der von uns (NL) verklaren hiermede, dat de onderstaande compressor in de door ons
gelieferten Ausfhrung zum Einbau in eine Maschine/Zusammenbau mit geleverde uitvoering voor montage in een machine/voor combinatie met
anderen Maschinen bestimmt ist, und da seine Inbetriebnahme solange andere machines bestemd is en dat zijn inbedrijfstelling zolang verboden is,
untersagt ist, bis festgestellt wurde, da die Maschine, in die dieser tot vastgesteld is, dat de machine, waarin deze compressor gemonteerd
Kompressor eingebaut werden soll, den Bestimmungen der EG-Richtlinie moet worden, aan de voorwaarden van de EG-richtlijn 89/392/EEG in de
89/392/EWG i.d.F. 91/368/EWG, 73/23/ EWG Niederspannungsrichtlinie, redactie van 91/368/EEG, 73/23/ EEG, 87/404/EEG, 89/336/EEG voldoet.
87/404/EWG Richtlinie ber einfache unbefeuerte Druckbehlter, 89/336/
EWG Richtlinie ber elektromagnetische Vertrglichkeit entspricht.
(I) dichiariamo con la presente che il compressore seguente (DK) erklrer hermed, at flgende kompressor i den af os leverede
nellesecuzione da noi fornita destinato al montaggio in una macchina / udfrelse er beregnet til indbygning i en maskine/sammenbygning med
allassemblaggio con altre macchine e che la sua messa in esercizio andere maskiner, og at ibrugtagning er forbudt, indtil det er konstateret, at
vietata fintanto che non si sia constatato che la macchina, nella quale deve den maskine, som denne kompressor skal monteres i, stemmer overens
venire montato questo compressore, corrisponde alle disposizioni della med bestemmelserne i EF-Direktiv 89/392/EF, udgave 91/368/EF, 73/23/
direttiva CE 89/392/CEE e seguenti 91/368/CEE, 73/23/ CEE, 87/404/CEE, EF, 87/404/ EF, 89/336/ EF
89/336/CEE
(GB) hereby declare that the following compressor in the design delivered (S) frklarar hrmed att nedanstende kompressor i av oss levererat r
by us is intended for installation in a machine/assembly group in line with avsedd fr montage i en maskin/hopbyggnad med andra maskiner, och at
other machines and that it may not be commissioned until it has been deter- dess igngsttning r frbjuden tills det konstaterats att den maskin, i
mined that the machine in which this compressor is to be installed meets vilken denna kompressor skall monteras, uppfyller bestmmelserna i EG-
the regulations laid down in EC guideline 89/392/EEC continued as 91/368/ riktlinje 89/392/EEC i.d.f. 91/368/EEC, 73/23/ EEC, 87/404/EEC, 89/336/
EEC, 73/23/ EEC, 87/404/EEC, 89/336/EEC EEC
(F) dclarons par la prsente que le compresseur dlivr mentionn ci- (N) erklrer hermed at nedenstende kompressor kompressor i den
dessous est apte tre mont dans une machine ou en combinaison avec utfrelse som er levert av oss er bestemt for installasjon i en maskin/
dautres machines. Sa mise en service nest autorise que lorsquil a t sammenbygning med andre maskiner, og at bruk av dette er forbudt til det
constat que la machine, dans laquelle le compresseur doit tre mont, est er fastsltt at den maskinen som dette kompressor skal bygges inn i er i
conforme aux clauses de la rglementation CE 89/392/CEE, par la suite 91/ overensstemmelse med bestemmelsene i EU-Direktiv 89/392/ EF utgave
368/CEE, 73/23/ CEE, 87/404/CEE, 89/336/CEE 91/368/EF, 73/23/EF, 87/404/EF, 89/336/ EF
(E) declaramos por la presente que el compresor figurado al final en la (P) declaramos pela presente, que o compressor, a seguir mencionado na
ejecucin que hemos suministrado est concebido para el montaje en una verso por ns fornecida, se destina a ser montado numa mquina/
mquina/o montaje conjunto con otras mquinas, y que su puesta en montagem com outras mquinas e que a sua entrada em serviio est
servicio est prohibida hasta que se haya determinado que la mquina en interdita at ser definido que a mquina na qual este compressor deve ser
la que tiene que montarse el compresor cumple el reglamento de la norma instalado, corresponde s prescries das Normas 89/392/CEE na verso
89/392/CEE en continuacin 91/368/CEE, 73/23/ CEE, 87/404/CEE, 89/ 91/368/CEE, 73/23/ CEE, 87/404/CEE, 89/336/CEE
336/CEE
..................................................................................................................................................................................
Typ/Tipo /Type/Type/ Maschinennr./ N.della maccina/ Machine No.
Tipo/Tipo/ Type/Type/ N de machine/ N de serie/ N da mquina/
Typ/Type Machineno./ Maskin-nr./ Maskinnr./ Maskinnr
(D) Angewendete harmonisierte Normen, insbesondere : prEN 1012 Teil 1 Sicherheitsanforderungen Kompressoren
(I) Norme armonizzate applicate, in particolare: EN 292 Teil 1+2 Sicherheit von Maschinen
(GB) Harmonized standards applied, in particular: EN 294 Sicherheit von Maschinen - Sicherheitsabstnde
(F) Normes harmonises appliques: EN 60204 Teil 1 Sicherheit von Maschinen - Elektr. Ausrstung
(E) Normas armonizadas aplicadas, en particular: EN 286 Teil 1 Einfache unbefeuerte Druckbehlter
(P) Normas harmonizadas aplicadas, em especial: EN 50081-1,2 Elektromagnetische Vertrglichkeit - Straussendung
(NL) Toegepaste geharmoniseerde normen, speciaal: EN 50082-1,2 Elektromagnetische Vertrglichkeit -Strfestigkeit
(DK) Anvendte harmoniserede standarder, isr:
(S) Tillmpade anpassade normer, srskilt:
(N) Anvendte harmoniserte normer, srlig:
Bielefeld, Beutel, Managing director design/development................................................................
213
Appendix
A.1 Symbols
A.1.1 Picture symbols defined by The following picture symbols are standardised by DIN 28 004,
DIN 28004 part 3. Only the parts of the norm relevant for compressed air
generation are reproduced here.
These picture symbols are used for standard representation in
flow diagrams for process systems.
Flow diagrams are used for communication among all persons
involved with the development, planning, installation and op-
eration of process systems, and to show the procedure used.
Compressors and pumps
Compressor, general Diaphragm compressor Rotary piston compressor
Liquid ring compressor Reciprocating compressor Roots Compressor
Screw compressor Turbo-Compressor Rotary vane compressor

Rotary Compressor
Filters
Fluid filter, general Liquid filter, general Gas filter, general

Filter apparatus, general Air filter, general
Active carbon filter Gas-sorption filter
214
Appendix
Separators
Separator, general Centrifugal separator, Rotation Gravity separator

separator Deposit chamber
Dust separator
Fittings
Shut-off fitting, general Shut-off through valve Shut-off 3-way valve
Shut-off through cock 3-way cock
Main slide valve Butterfly valve
Non-return fitting, general Non-return through-valve Non-return flap
Fitting with constant setting action Fitting with safety function
Miscellaneous
Dryer, general Condensate drain Vessel/receiver, general
215
Appendix
A.1.2 Symbols for contact units and The following symbols are standardised by ISO 1219 ( 8.78 ).
switching devices as per ISO 1219 Only excerpts from the norm are reproduced here.
The symbols are used to make pneumatic and hydraulic circuit
diagrams for describing the operation of respective controls
and systems.
Energy transformation
Compressor Vacuum pump Pneumatic motor with one direc-

tion of flow
Pneumatic motor with two direc- Single-action cylinder, return stroke Single-action cylinder, return
tions of flow by external power stroke by spring power
Double-action cylinder Double-action cylinder with single- Double-action cylinder with two-
side, non-adjustable damping side, adjustable damping
Non-return valves
Non-return valve without spring Non-return valve with spring Controlled non-return valve
Flow control valves
Throttle valve with constant Throttle valve, adjustable One-way restrictor

restriction
216
Appendix
Direction valves
2/2-Way valve 3/2-Way valve 4/3-Way valve

with shut-off neutral position with open neutral position with shut-off middle position
2/2-Way valve 3/3-Way valve 5/2-Way valve

with open neutral position with shut-off middle position
3/2-Way valve with 4/2-Way valve 4/3-Way valve

shut-off neutral position Middle position Work direction
vented
Pressure valves
Diaphragm non-return valve Pressure relief valve, adjustable Pressure control valve without
drain aperture, adjustable
Throttle valve Emergency valve Pressure control valve with drain

adjustable, manually operated adjustable, with air vent aperture, adjustable
Short description of connections A, B, C Work line R, S, T Drain, vent

P Pneumatic connection X, Y, Z Control lines
217
Appendix
Energy transmission
Compressed air source Work line Control line
Line connection ( fixed ) Line intersection Flexible line
Drain with pipe connection Pressure connection Pressure connection

( closed ) ( with connecting line)
Compressed air receiver Dryer Lubricator
Filter Water separator, hand-operated Water separator, automatic

emptying
Filter with automatic water Cooler Service unit

separator ( simple representation )
218
Appendix
Miscellaneous devices
Pressure measuring device Differential pressure measuring Temperature measuring device

device
Compressed air measuring device Flow measuring device Pressure switch

Ammeter Volumemeter
Flow probe Pressure probe Temperature probe
219
Conversion Table
Length
from x to from x to
mm 0,03937 inch 2,54 mm
m 3,281 foot 0,3048 m
m 1,094 yard 0,914 m
Surface
from x to from x to
mm 1,55 x 10-3 sq.inch 645,16 mm
cm 0,155 sq.inch 6,452 cm
m 10,76 sq.ft. 0,0929 m
Volume
from x to from x to
cm 0,06102 cu.inch 16,388 cm
dm(litre) 0,03531 cu.ft. 28,32 dm(litre)
dm(litre) 0,22 gallon(U.K.) 4,545 dm(litre)
dm(litre) 0,242 gallon(US) 4,132 dm(litre)
m 1,308 cu.yard 0,764 m
Volume flow
from x to from x to
l/min 0,0353 cfm 28,3 l/min
m/min 35,31 cfm 0,0283 m/min
m/h 0,588 cfm 1,7 m/h
Pressure
from x to from x to
bar(abs) 14,5 psia 0,07 bar(abs)
bar(abs) 14,5+Atm. psig 0,07+Atm. bar(abs)
Force
from x to from x to
N 0,2248 pound force(lbf) 4,454 N
kW 1,36 HP 0,736 kW
Temperature
from x to from x to
C (C x 1,8) + 32 F (F -32) / 1,8 C
220
Index
A Pulsation damping 140 D

Safety rules 142
Absorption 83 Set-up 173 Dew point 71
Adsorption 84 Test groups 142 Distribution line 150, 151
Compressed air
Active carbon Adsorber 98 Drive motor 48
requirement 108, 115
ARS 57 Allowances 119 Dryer
Atmospheric humidity 70 Mean operation time 115 Arrangement 89
Simultaneity factor 116 Operating conditions 79
Automatic 58
Compressor 24 Duotherm heat exchanger
Autotronic 58 Cost savings 191
Ambient temperature 170
Duotherm BSW 191, 192
B Cooling air flow VK 174
Cycle interval 129 Dust separator 93
Basic units 6 Diaphragm 29 Dying 78
Blaise Pascal law 3 Free piston 30
Absorption 83
Heat balance 188
Boyle-Mariotte law 7 Liquid ring 32
Adsorption 84
Membrane drying 82
C Lubricant 50
Over-compression 80
Reciprocating piston 27
Refrigerated drying 81
CE-Certification 208 Rotary vane 31
CE-Marking 209 Running time 129 E
Screw 33
Choice of compressor 137 Silencing 205 EC-Machinery directive 208
Collective line 152 Space requirement 172 Expert 143
Stop time 129
Combined compressor
systems 139
Summary 26 F
Notes for installation 172
Compressed air Types of construction 25 Filter
Advantages 14 Compressor installation 170 Active carbon 97
Applications 2, 21 Micro- 95
Compressor layout Operating pressure 92
Composition 7
Piston compressor 131 Pre- 94
Costs 206
Energy costs 207
Screw compressor 135 Pressure loss p 92
Filters 91 Compressors Sterile 99
History 1 Axial 35 Filter mechanisms 96
Impurities 66, 69 Displacement 24 Filter separation rate 91
Loss 120 Dynamic 24
Possible applications 18 Radial 36 Fire safety rules 171
Properties 7 Roots 34 Flow 13, 156
Quality 77 Condensate 100 Fluidics 5
Compressed air consumption Disposal 171 Frequency control 56
Cylinders 112 Condesate drain 101
Cylindrical nozzles 109
Condensate quantity 72 H
Nozzles 108
Spray nozzles 111 Condensate separator Harmful area 38
Spray paint guns 110 Compressed air receiver 141 Heat exchanger 191
Tools 113 Dust separator 93
Total 118
Heat reclamation 188
Condensate treatment 106
Compressed air quality Conformity declaration 210 I
Planning tips 67
Connection line 151 Idling control 54
Compressed air receiver 140
Compressed air storage 140 Control 51 Idling mode ( L1 ) 52
Condensate separation 141 Control unit Infinite output control 56
Determining volume 127 ARS concept 57 Inspection 144, 146
Fittings 147
Cooling air flowVK 174 Inspection, evidence of 146
Inspection 144
Installation 141 Costs Installation room 169
Manufacture 143 Compressed air 206
Compressed air loss 120
Intake filter 49
Norm series 127
221
Index
Intermittent control 54 Piston compressor 37 S

Intermittent control, delayed 55 Area of application 125
Assemblies 41 Safety rules
Isobar 8 Control 40 Compressed air receiver 142
Isochor 8 Cooling 39 Safety valve 49, 148
Isotherm 8 Example installation 187
Screw compressor 42
Pipe inside diameter di
Area of application 125
L Bar diagramme 163 Assemblies 47
Laws Determining by calculation 161 Compression process 42
Determining by graph 162 Example installation 186
Workplace directive 203
Pressure tank directive 142 Pipe length, equivalent 160 Method of operation 43
Noise 204 Pipeline SI-System 6
Safety rules for noise generating Dimensioning 158 Sound 199
operations 203 Marking 168
Safety rules for compressors Sound dissemination 200
Material 164
( VBG 16 ) 203 Nominal width 159 Sound intensity level 196
Leakage 120 Pipeline material 164 Sound level 196
Leakage quantity 123 Copper pipes 166 Assessed, dB ( A ) 197
Determining 121, 122 Plastic pipes 167 Sound perception 195
Loudness 198 Seamless steel pipes 165
Stainless steel pipes 165 Sound pressure 196
level 197
Threaded pipes 164 Stopped/stationary ( L0 ) 52
M Pipe system 149 Stub line 151
Pressure loss p 157 Suction rate 38
Main line 149
with compressed air dryer 155
Maker's declaration 212 without dryer 154 Supertronic 59
MCS 60 Pneumonics 5 Switching symbols 216
Motor cycles Pressure 10 T
Determining 130 Pressure content product 142
Allowed 130 Temperature 9
Pressure definitions 51
Multiple systems 152 Test groups 142
Pressure dew point 71
N Tongue valve 49
Determining 75
on pressure relief 76 Treatment 66
Noise
Safety directives 203 Pressure loss p 156 Types of control 54, 60
Effects 202 Pressure ranges 17 V
Noise measurement 205 Proficient person 143
Norms Vacuum pumps 24
DIN 28004, Part 3 214
Q Ventilators 24
ISO 1219 ( 8.78 ) 216 Quality classes 77 Ventiliation 174
O R Air inlet ducts 181
Artificial 178
WAMAT 107 Ratiotronic 59 Compressor rooms 176
Oil-water separator 107 Cool air duct 182
Refrigeration drying 81 Ducting 181
Operating modes 52 Regeneration 84 Natural 177
Operation mode ( L2 ) 53 Cold 85 Volume 9
Output 38 External hot 87
Volume flow V 11
Internal hot 86
P Vacuum- 88
Reynolds number Re 156
Part-load 53
Ring main 150
Part-load control 56
Room heating 189
Physical fundamentals 8
Economy 190
Picture symbols 214
222

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Table of contents

Contents Chapter Page

Part 1 1.1 The history of compressed air ............................................... 1

Part 2 2.1 The advantages of compressed air ..................................... 14

Part 3 3.1 Compressors (Compactors) ................................................. 24

3.3 Piston compressors .............................................................. 37

Part 4 4.1 Pressure definitions .............................................................. 51

4.5 Control of several compressors .......................................... 60

Part 5 5.1 Why treatment ? .................................................................... 66

Part 6 6.1 Condensate .......................................................................... 100

Part 7 7.1 Consumption of compressed air by pneumatic devices . 108

Part 8 8.1 The type of compressor ...................................................... 125

8.3 Determining the volume of a compressed air receiver ... 127

Part 9 9.1 The compressor air receiver .............................................. 140

9.1.6.5 Inspection of compressed air receivers ............................ 144

9.1.7.1 Safety valve ...................................................................... 148

Part 10 10.1 Cooling the compressor ..................................................... 169

10.3 Ventilation of a compressor station .................................. 174

Part 11 11.1 The heat balance of a compressor station ........................ 188

Part 12 12.1 The nature of sound ............................................................ 195

12.3 Human perception of sound ............................................... 197

Part 13 13.1 Composition of compressed air costs .............................. 206

Part 14 14.1 Introduction ......................................................................... 208

Part 15 A.1 Symbols ............................................................................... 214

Peoples comprehension of compressed air grew parallel to

Many technical applications originate from the earliest days of

The further development of the lung

However, the lung proved to be wholly inadequate when

The first mechanical compressor - the bellows

The first mechanical compressor, the hand-powered bellows,

1.1.2 The first applications of com- Hydraulic organ

Ktesibios used another property of compressed air, stored

Heron, an engineer living in Alexandria in the first century BC,

It was only in the 17th century that a series of learned people

Transporting objects through pipes

Taking up where Heron left off, the French physicist Denis

As early as around 1810, trains were being powered by

This was the first use of a fail-safe system. Brake systems

The idea of trains powered by compressed air was not forgot-

Pneumatic post networks soon sprung up in Berlin, New York

When in 1871 the breakthrough in the tunnel was achieved,

The experience gained using networks of pneumatic lines and

The all-round success of the pneumatic network was under-

The pneumatic network in Paris is unique to this day, and is still

Basic unit Formula symbol Symbol Name

Length l [m] Metre

Time t [s] Second

Strength of current I [A] Ampere

Temperature T [K] Kelvin

Strength of light I [ cd ] Candela

Qty of substance n [ mol ] Mol

Unit Formula symbol Symbol Name

Force F [N] Newton

Area A [ m2 ] Square metre

Volume V [ m3 ] Cubic metre

Speed v [m/s] Metre per Second

Density [ kg / m3 ] Kilogramme per cubic metre

Temperature T [ C ] Degree Celsius

Work W [J] Joule