Ideal Air System Design
Hitachi Air Technology Group is committed to providing cutting-edge air compressors ideal for the most demanding industrial environments. Our design engineers follow rigorous standards to create ideal air system design for compressed air systems that meets compressed air needs of diverse industries.
The following diagram illustrates an optimally installed Hitachi air compressor system with all the air compressor components essential to deliver contaminant free and reliable compressed air. Move your cursor over each component of the air compressor system shown below, to view a brief description of the component and its functioning.
Hitachi Air Technology Group - Ideal Air System Design
Air Compressor is a machine that ingests air at atmospheric pressure, and delivers it at a high pressure and volume relative to the power rating.
Motorized Isolation Valve
The Motorized Isolation Valve, or MIV, is used to protect the air compressor. When the air compressor times out (Auto Restart Mode), the MIV closes the discharge air line to prevent reverse migration of condensate into the air compressor and damage to its internal components.
Three Way Depressurization Valve
An ideal compressor system installation should include a three way depressurization valve with an atmospheric vent. The vent assists in:
- Removing condensate, in case the drain valve is inoperable.
- Releasing the pressurized air build-up inside the air compressor, in order to perform maintenance.
- Testing the air compressor without pressurizing the entire air system.
After air passes through the compressor, the moisture condenses, so it must be removed to improve efficiency and prevent damage to the production equipment downstream. Moisture separators efficiently remove the condensate from compressed air systems, with the help of high speed centrifugal air flow.
Many compressed air systems consist of more than one air compressor. To accurately control such systems, a master control system enables communication among all air compressors from one local control panel with a common pressure reading. This ensures proper shut off and startup of air compressors to save energy for the end user.
"Wet" Air Receiver
An air receiver upstream of the air treatment or a "Wet" air receiver is applied in order to:
- Avoid short cycling of air compressors.
- Promote longevity of the air end and various mechanical components.
- Remove the accumulated moisture.
A drain valve is used to remove condensate that develops in the compressed air system.
Drain valve technologies: Ball Valve, Float, Timed Solenoid, Electric No-Loss, and Pneumatic No-Loss.
Filters are used in the air system to remove contaminates, such as oil, water vapor, particulates, taste, etc.
Types of filters: Coalescing (Removes moisture), Particulate (Removes particles), Activated Charcoal (Removes taste) and Mist Eliminators (Low pressure drop coalescing filters)
Three Valve Bypass
It is highly recommended to add a three valve bypass around the air treatment to prevent compressed air system from losing air pressure, when the air treatment requires maintenance. This enables the facility to bypass compressed air around the air treatment for a short period of time, in order to work on the air treatment without complete manufacturing curtailment
Air Dryers are utilized to remove the condensate in the compressed air, thus protecting the production equipment in the facility.
Types of air dryers: Refrigerated Air Dryers (33-39°F dew point), Desiccant Air Dryers (-40° & -100°F dew point), Membrane Air Dryers, Deliquescent Air Dryers
"Dry" Air Receiver
Air receivers located at the downstream of air treatment, or "dry" air receivers are used to:
- Allocate one common pressure location to multiple air compressors.
- Stabilize the control system readings.
- Provide ample stored energy, or capacitance, to the compressed air system, and assist in lowering compressed air pressure fluctuations.
Constant Pressure Controller
Constant pressure controllers are invaluable to a compressed air system. By creating capacitance, they work like a "firewall" to provide quality and constant pressure to the demand side of a compressed air system. Constant pressure controllers are also helpful in lowering leak load in a compressed air system, and pressure fluctuations in the air compressor. Constant Pressure Controllers are also commonly known as Demand Expanders, Flow Controllers, etc.