Ideal Air System Design Technical Support Library - Air Technology Group

Hitachi Air Technology Group Ideal Air System Design

Below is an illustration of an optimally installed air compressor system with all of the air compressor components required to give an end user contaminant free and reliable compressed air. Please drag the cursor over any component of the air compressor system to see a description of how all of the air compressor components are utilized.

Ideal Air System Design

Constant Pressure Controller
Working like a "firewall", constant pressure controller's are invaluable to a compressed air system, by giving the demand side of a compressed air system, quality, constant pressure, via creation of capacitance. Constant pressure controller's are also very helpful in lowering the leak load in a compressed air system, and lowering the pressure fluctuations on the air compressor. (Also called Demand Expanders, Flow Controllers, etc..)

"Dry" Air Receiver
Air receivers located downstream of air treatment, or "dry" receivers, are used for the following reasons:

Give multiple air compressors one common pressure location
Provides stability to control system readings
Give the compressed air system ample stored energy, or capacitance, and assist in lowering compressed air pressure fluctuations.

Three Valve Bypass
To prevent a compressed air system from losing air pressure when the air treatment requires maintenance, it is highly recommended to add a three valve bypass around the air treatment. This gives the facility the capability of bypassing the compressed air around the air treatment for a short period of time in order to work on the air treatment without full manufacturing curtailment.

Air Piping
Compressed air piping is used to transport the compressed air through the supply side (Compressor Room) of the compressed air system to the demand side (Point of Air Usage)of the compressed air system.

Air Dryers
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 dewpoint), Desiccant Air Dryers (-40° & -100°F dewpoint), Membrane Air Dryers, Deliquescent Air Dryers

Filters
Filters are used in the air system to remove contaminates such as: oil, water vapor, particulates, taste, and etc.

Types of filters: Coalescing (Removes moisture), Particulate (Removes particles), Activated Charcoal (Removes taste) and Mist Eliminators (Low pressure drop coalescing filters)

"Wet" Air Receiver
An air receiver upstream of the air treatment, or "wet" receiver, is applied for a number of reasons:

Avoid short cycling of the air compressors
Promote longevity of the airend and various mechanical component
Remove some accumulated moisture

Master Control Signal Lines
The Master Control Signal Lines allow communication of numerous air compressors and one common pressure reading through a single pressure transducer. Sensing pressure downstream of the air treatment (Dryers, Filters etc) enables a more rapid response to the changes in air demands.

Master Control
Many compressed air systems consist of more than one air compressor. To properly control systems with numerous air compressors, a master control system will allow communications of all air compressors from one local control panel with a common pressure reading. This gives the air compressors the capabilities to properly shut off and start up to save energy for the end customer.

Moisture Separator
After air passes through the compressor, moisture condenses and must be removed to promote efficiency and prevent damage to production equipment downstream. The high speed centrifugal air flow enables moisture separators to efficiently remove the condensate from the compressed air system.

Drain Valve
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.

Three Way Depressurization Valve
Every compressor system installation should include a three way valve with an atmospheric vent. This vent will assist in the following:

Removing condensate, in the case that the drain valve is inoperable
Release the pressurized air inside the air compressor, in order to perform maintenance
Assist with testing the air compressor without pressurizing the complete air system

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 it's internal components.

Air Compressor
A machine that ingests air at atmospheric pressure and delivers air at a higher pressure and volume relative to the power rating.

Technologies of Air Compression: Reciprocating, Rotary Screw, Scroll, Rotary Vane and Centrifugal