16.

8 Valves and accessories

Some of the accessories used in compressed air system are Drain traps, compressed air filters, oil/water
separators, Pressure regulators. These accessories play a major role in maintaining the quality of compressed
air, effective utilisation and enhancing energy efficiency.
16.8.1 Drain valves
Condensate from compressed air is always detrimental to the life of pneumatic equipments. This condensate
should be removed as and when formed at various stages.

Condensation formation takes place at after coolers, air receivers, filters, pipe lines, drop legs etc. The effective
removal of condensate will reduce the moisture load on the air dryers and ensure the quality of air at the user
ends.

Removal of condensate is done by automatic drain valve. In automatic drain valve there is no need for manual
intervention. The automatic drain valves can be classified as follows:

a. Electronic timer based drain valves

b. Condensate sensing drain valves

a. Electronic timer based drain valve:

The drain valve is controlled by an electronic timer. The opening of drain valve is based on the preset timings.
The cycle time of the drain valve opening is adjustable.

The cycle time can be set based on the condensate formation rate.

b. Condensate sensing drain valve:

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In condensate sensing drain valve the operation is based on the level of condensate collected. The condensate
is collected in the drain valve container. There is a probe kept inside that senses the level of condensate. Once

the level of condensate reaches the set value, the controller activates the solenoid valve and discharges the
condensate.

As the level of condensate drops, the probe again senses the lower level and the solenoid valve is shutoff. This
discharges only the condensate and eliminates passing of compressed air through the valves. The condensate
sensing drain valves are more energy efficient since there is no compressed air loss.

16.8.2 Filters
The compressed air treatment for ensuring the quality of compressed air is not only limited to moisture removal.
The other contaminants present in the compressed air such as dust, oil, rust, Bacteria & Viruses etc will lead to
detrimental effects.

Filters are used to remove the contaminants especially dust, oil and moisture. Some of the filter media used is
Ceramics, Sintered Bronze, Boro Silicate glass micro fibre and activated carbon.

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The contaminants and various ways & means of effective removal of those contaminants are explained in detail
below.
 Solids
Solids, i.e., dust is found in compressed air depending on :

 Suction air quality

 Desiccant, activated carbon provided in dryers

 Pipeline rust and scale

It is preferable to remove dust to the extent required at the point of use. Filters should have a low-
pressure drop, as the energy loss across the filter is in the form of pressure drop. A surface filter like
pleated paper, ceramic or sintered bronze filter can be used for dust removal. Pleated paper / cellulose
are best suited, as they offer very low-pressure drop and can handle high dust loads without significant
pressure drop. A pressure drop of 0.3 to 1.0 psi is allowable.
 Oil
Oil from the compressor comes as vapour and liquid aerosol. The vapour cools and becomes liquid in
the line. For most industrial applications only the liquid oil need to be removed and is done by a

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 coalescing filter. Coalescers are depth filters and most energy efficient. E.g. a wet 0.01 micron filters @
99.999% efficiency has a pressure drop of 6 psi, while a 0.01 micron filters @ 99.97% efficiency has a

pressure drop of 3 psi only.

Hence it is recommended to install 99.97 % efficiency, 0.01 micron coalescing filter for industrial
applications.
 Bacteria /Viruses
In food and pharmaceutical plants the intake air must be free from bacteria and

viruses. This can be achieved by heating the compressed air above 180oC then

cooling it to normal temperature. The compressed air can also be passed through

sterile filters, which capture bacteria of sizes 0.3 –2.0 µ and viruses.

 Pressure drop in filters

After the installation of filters, over a period of time the pressure drop across the filters increases. The
increased pressure drop across the filters leads to resetting of compressors at slightly higher pressure
to match with the requirement.

It costs 7% of the total energy for 1 kg/cm2 pressure drop at 7-8 kg/cm2 operating pressure.

This can be higher for higher pressure. Hence,

 The filters have to be sized properly

 The filters have to be replaced when the pressure drop is high.

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 Figure 16.8.1 Pressure drop in filters

It is advisable to change the filters, when the pressure drop reaches 0.5 ksc. A standby filter can also be
arranged to facilitate the changing of filters. Typically a filter element should have a working life of 12 months or
6000 working hrs.

16.8.3 Separators
Moisture is found in liquid as well as in suspended form. Moisture in liquid form is called as condensate and the
moisture in suspended form is called as aerosol.

Aerosol is normally removed using water separators. The common types of water separators are:

 Ceramic cartridge

 Baffle plate

 Demister pad type

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The demister pad type is the most desired and energy efficient water separator, as it is good in removing water
droplets and has a lower pressure drop also.

16.8.4 Pressure Switches

The possibility of lowering the compressor delivery pressure settings should be explored by a careful study of
pressure requirements of various equipment and the pressure drop in the line between compressed air
generation and utilization points.

A reduction in the delivery pressure by 1 bar in a compressor would reduce the power consumption by 6 – 10 %.

Hence, it is suggested to use Pressure switches such that the compressor cuts-in and cuts-out at optimum
levels.

In a battery of compressors, the pressure setting can be adjusted such that only one compressor caters to the
load variation while others operate at full load.
16.8.5 Energy Meter
For individual compressors/ sections, sub meters could be installed to record power consumption. This would
help in identifying any deviations in power consumption and hence record the variation in consumptions..