Compressed Air Compendium PDF

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

1.1.1
The origin of compressed air ................................................ 1
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
Applications for
pneumatics
2.1 The advantages of compressed air ..................................... 14

2.2 Pressure ranges .................................................................... 17
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
Part 3
Compressed air
generators
Examples of specialised applications ................................. 21
3.1 Compressors (Compactors) ................................................. 24

3.1.1
Dynamic compressors ( Turbo-compressors ) .................... 24
3.1.2
Displacement compressors ................................................ 24
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
Table of contents
Chapter
Page
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
Part 4
Control of compressors
Compressor lubricants and coolants .................................. 50
4.1 Pressure definitions .............................................................. 51

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
II
Table of contents
Chapter
Page
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
Compressed air treatment
5.1 Why treatment ? .................................................................... 66

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
III
Table of contents
Chapter
Part 6
Disposal of condensate
Page
6.1 Condensate .......................................................................... 100

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
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
Compressed air
requirement
7.1 Consumption of compressed air by pneumatic devices . 108

7.1.1
Consumption of nozzles ................................................... 108
7.1.1.1 Compressed air consumption of cylindrical nozzles ......... 109
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
Determining the size of the
compressor station
8.1 The type of compressor ...................................................... 125

8.1.1
Screw compressors .......................................................... 125
8.1.2
Piston compressors .......................................................... 125
8.2 Maximum pressure Pmax ..................................................... 126
8.2.1
Factors influencing cutout pressure Pmax ......................... 126
IV
Table of contents
Chapter
Page
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
The pneumatic system
9.1 The compressor air receiver .............................................. 140

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
9.1.6.6
9.1.6.7
9.1.7
Inspection of compressed air receivers ............................ 144

Types of inspection ........................................................... 146
Addtional excerpts from the directive for
compressed air receivers ................................................. 146
Fittings on the compressed air receivers .......................... 147
Table of contents
Chapter
9.1.7.1
Page
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
9.5.5
of pipe by graphics ........................................................... 162
9.5.6
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
Part 10
The installation room
VI
Marking pipelines ................................................................ 168
10.1 Cooling the compressor ..................................................... 169

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
Table of contents
Chapter
Page
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
Heat reclamation
11.1 The heat balance of a compressor station ........................ 188

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
Sound
12.1 The nature of sound ............................................................ 195

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
VII
Table of contents
Chapter
Page
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
Costs of compressed air
13.1 Composition of compressed air costs .............................. 206

13.1.1 Cost factor ratios .............................................................. 206
13.2 Cost-effectiveness calculation for energy costs .............. 207
Part 14
CE-Certification
14.1 Introduction ......................................................................... 208

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
Appendix
VIII
A.1 Symbols ............................................................................... 214

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
Fundamentals of compressed air
1.
Fundamentals of
compressed air
1.1
The history of compressed

air
Compressed air, together with electricity, is the most frequently used carrier of energy in industry and the crafts today.
But whereas we learn to use electricity and electrical appliances 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 compressor 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 reliability of the human compressor is unsurpassed and it costs
nothing to service.
The further development of the lung
Fig. 1.1:
The first compressor - 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
on uplands and the crests of hills. Later, Egyptian and Sumerian
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.
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 manufacturing process. The development can be seen in a wallpainting 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 compressed air

Recognising the properties of compressed
air
Hydraulic organ
Storage and suppression of pulsation
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
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
end.
Fig. 1.5 :
Compressed air to increase energy
Transporting objects through pipes

Pneumatic conveyance
p1
p2
Fig. 1.6 :
Compressed air as a means of transport
Taking up where Heron left off, the French physicist Denis

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
generated at an object inside the pipe. This was recognition of
the advantage of the high work speeds obtainable by using air.
Papin thus laid the foundation stone for pneumatic conveyance.
Pneumatic brakes
Power transmission
As early as around 1810, trains were being powered by

compressed air. In 1869 Westinghouse introduced his pneumatic 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.
Fig. 1.7 :
Pneumatic brakes in a train ca. 1870
This was the first use of a fail-safe system. Brake systems

based on this principle are still used in HGVs today.
Pneumatic post
Conveyance by compressed air
The idea of trains powered by compressed air was not forgotten. 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, atmospheric 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 supplied with compressed air from compressors at both ends of
the tunnel. In both cases the compressed air was transported
over long distances.
Fig. 1.8 :
Pneumatic drills in tunnel construction
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 demonstrated and made known to a wide public as one of the
advantages of compressed air. And from here on, pneumatic
tools of even greater performance and versatility were developed.
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.
Fig. 1.9 :
Compressed air station in Paris 1888
The all-round success of the pneumatic network was underlined by the invention of a clock, the minute hand of which was
moved on every sixty seconds by an impulse from the compressor station. People had not only seen the possibility of
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.
Signal processing
Compressed air for the transmission and processing of signals
Fig. 1.10 :
Four-stage adding device with wall radiation elements
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
electromagnetic radiation from exploding nuclear weapons
gives fluidics a special advantage in several sensitive areas.
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.
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
1.2.2
Symbol
Name
Length
[m]
Metre
Mass
[ kg ]
Kilogramme
Time
[s]
Second
Strength of current
[A]
Ampere
Temperature
[K]
Kelvin
Strength of light
[ cd ]
Candela
Qty of substance
[ mol ]
Mol
Engineering uses measures derived from the basic units. The

following table shows the most frequently used units of measure for compressed air.
Compressed air units
Unit
Formula symbol
Formula symbol
Symbol
Name
Force
[N]
Newton
Pressure
[ Pa ]
[ bar ]
Pascal
Bar
1 bar = 100 000 Pa
Area
[ m2 ]
Square metre
Volume
[ m3 ]
[l]
Cubic metre
Litre
1 m3 = 1 000 l
Speed
[m/s]
Metre per Second
Mass
[ kg ]
[t]
Kilogramme
Tonne
1 t = 1 000 kg
Density
[ kg / m3 ]
Kilogramme per cubic metre
Temperature
[ C ]
Degree Celsius
Work
[J]
Joule
Energy
[W]
Watt
Tension
[V]
Volt
Frequency
[ Hz ]
Hertz
1.3
What is compressed air ?
1.3.1
The composition of air
The air in our environment, the atmosphere, consists of:
78 % Nitrogen
Nitrogen
78 %
21 % Oxygen
Oxygen
21 %
1 % other gases
( e.g.. carbon-dioxide and argon )
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
Pressure energy
Heat
Compressed air can bridge certain distances ( in pipelines ),

be stored ( in compressed air receivers ) and perform work
( decompress ).
Fig. 1.12:
Air compression
1.3.3
How does compressed air behave?
p p
p
p
p
p
The higher the temperature, the greater the movement of air

molecules, and the higher the pressure generated.
p
p
Volume ( V )
p
p
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.
Temperature ( T ) = is increased
Pressure ( p )
T
Fig. 1.13:
Air in a closed container
= constant
= rises
Boyle and Mariotte carried out experiments with enclosed

volumes of gas independently of each other and found the
following interrelationship:
The volume of gas is inversely proportional to pressure.
( Boyle-Mariottes Law )
1.4
Physical fundamentals
The condition of compressed air is determined by the 3

measures of thermal state:
T
= Temperature
= Volume
= Pressure
p V
constant
This means:
Heat
p0 , T0
Volume constant ( isochore )

Pressure and temperature variable
When the temperature is increased and the volume remains
constant, the pressure rises.
p1 , T1
constant volume
isochore compression
p0
p1
T0
T1
Temperature constant ( isotherm )

Pressure and volume variable
p0 , V0
When the volume is reduced and the temperature remains

constant, the pressure rises.
p1 , V1
constant temperature
isotherm compression
Heat
p0 V 0 =
p1 V1 =
constant
Pressure constant ( isobar )

Volume and temperature variable
V0 , T 0
V1 , T 1
constant pressure
isobar compression
When the temperature is increased and the pressure

remains constant, the volume increases.
V0
V1
T0
T1
1.4.1
Temperature
The temperature indicates the heat of a body and is read in C

on thermometers or converted to Kelvin ( K ).
[K]
t [ C ] + 273,15
0C
Fig.1.14:
Showing temperature
1.4.2
Volume V [ l, m3 ]
Volume
Compressed air in expanded state, open air
The volume is determined, for example, by the size of a cylinder. It is measured in l or m 3 and relative to 20 C and
1 bar.
The numbers in our documentation always refers to compressed air in its expanded state.
VCyl =
Volume (V)
d2
h
4
VCyl = Volume
d
= Diameter
h
= Height
[m3]
[m]
[m]
Normal volume VNorm [ Nl, Nm3 ]

Compressed air in expanded state under normal conditions
The normal volume refers to the physical normal state as specified 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
0C
+ 8% =
Volume
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.
0 barabs
8 barabs
When specifying the operating volume the pressure must

always be given, e.g., 1 m 3 at 7 bar means that 1 m 3 expanded (relaxed) air at 7 bar = 8 bar abs. compressed and
only occupies 1/8 of the original volume.
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 ]
pop
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.
Overpressure
pabs
barometric
air pressure
Absolute pressure pabs [ bar ]

The absolute pressure pabs is the sum of the atmospheric
pressure pamb and the over-pressure pop.
pvac
pabs
pamb
Partial
vacuum
= pamb + pop
According to the SI-System pressure is given in Pascal [ Pa ].

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
100 % Vacuum
pamb
pop
pvac
pabs
=
=
=
=
Atmospheric pressure
Over-pressure
Partial vacuum
Absolute pressure
Fig.1.16:
Illlustration of different pressures
10
Pressure =
Area
1 Pascal =
1 Newton
1 m2
1 bar = 10195 mmWH
F
p =
A
1N
1 Pa =
1 m2
[ mm water head ]
1.4.3
Volume flow V [ l/min, m/min., m/h ]
Volume flow
The volume flow describes the volume ( l or m ) per unit of

time ( minute or hour ).
A distinction is made between the working volume flow ( induction rate ) and the volume flow ( output rate ) of a compressor.
Working volume flow

Induction rate
Volume flow
Working volume flow VWor [ l/min, m/min., m/h ]

Induction rate
Output rate
The working volume flow is a calculable quantity on piston

compressors. It is the product of the cylinder size ( piston capacity ), 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
Fig. 1.17:
Working volume flow and volume flow
VWor
A
s
n
c
=
=
=
=
Working volume flow

[ l / min ]
Cylinder area
[ dm2]
Stroke
[ dm]
Number of strokes
[ 1/ min ]
(compressor speed)
= 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
TDC = Top dead centre

BDC = Bottom dead centre
Fig. 1.18:
Cylinder movement
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 temperature it must be re-cooled.
The volume flow is measured according to VDMA 4362,
DIN 1945, ISO 1217 or PN2 CPTC2 and given in l/min, m3/min
or m3/h. The effective volume flow, i.e., the output that can
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 measured.
However, it does not refer to the induction state, but to a theoretical comparative value. With the physical norm state the
theoretical values are:
Volume flow
20C
+ 8% =
Norm volume flow

0C
Fig. 1.19:
Norm volume flow
Temperature= 273,15 K
Pressure
= 1,01325 bar
Air density = 1,294 kg/m3
( 0 C )
( 760 mm HG )
( dry air )
Operating volume flow VOperat [ Ol/min, Om3/min, Om3/h ]

The operating volume flow gives the effective volume flow of
compressed air.
0 barabs
Fig. 1.20:
Operating volume flow
12
8 barabs
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
Om3/h.
1.5
Compressed air in motion
Different laws apply to compressed air in motion than to stationary compressed air.
1.5.1
Flow behaviour
The volume flow is calculated from area and speed.
A1
A2
= A1 v 1
= A2
v2
A1
v2
=
A2
v1
v2
v1
Fig. 1.21:
Flow behaviour
V
=
A 1, A 2 =
v 1, v 2 =
Volume flow
Cross section
Speed
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.
2.1
The advantages of
compressed air
Pneumatics faces increasing competition from mechanical,

hydraulic and electrical appliances on all fronts. But pneumatic
devices have fundamental advantages over the other technologies:
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 stations that can supply points of consumption via ring mains
with a constant working pressure. The energy stored in compressed 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, explosion and electrical hazards. Even in areas where there is a
risk of fire, explosion and extreme weather conditions, pneumatic 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 hydraulic components.
There is no need for regular medium changes, as with hydraulic 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 mechanical 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 pressure 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 adjustable. Both with linear and rotary movement, force, torque and
speeds can be fully adjusted without difficulty by using throttles.
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
Compaction pressure in bar
rotary compressors
High pressure range
Medium pressure range to 15 bar

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

Low pressure range
one-stage screw compressors ( up to 14 bar )

with oil-injection cooling
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 pressure range is the storage of breathing air in diving bottles.
High pressure compressors are used in power stations, rolling 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
Compressed air is used intensively in all sectors of industry,

the crafts, and everyday life. The range of possible applications 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

compressed air
Tensioning and clamping with compressed air is mainly used

in applications involving mechanisation and automation. Pneumatic cylinders or motors fix and position the tools needed for
work processes. This can be done by linear and rotary movement, and also by swivel movement. The energy in the compressed 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 pneumatic 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
Fig. 2.4:
Valveless pneumatic hammer
2.3.4
Spraying with compressed air
Pneumatic drive systems are found in all areas of industry

and the crafts. These can perform rotary and linear movements. 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 changing the volume of the compressed air.
Pneumatic percussion machinery and tools (e.g., pneumatic
hammers) are of great importance in this category. The energy in the compressed air is converted into kinetic energy for
a moving piston. Vibrators and jolting devices belong to this
category.
Pneumatic power is also used by a multitude of valves and
slides, tools, adjustment devices, feed systems and vehicles.
With Spraying applications, the energy of the expanding compressed 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 blasting, shot peening and painting with spray-guns belong to this
category. Concrete and mortar are also applied using this
method.
Fig. 2.5:
Arc-type metal spraying system
If high temperatures are also used, compressed air can be

utilised for applying liquid metals. Arc-type spraying is an example worthy of mention here..
Another application is the atomisation of liquids through spray
nozzles, e.g., for spraying weedkillers and insecticides.
2.3.5
Blowing and flushing with

compressed air
When blowing and flushing the compressed air itself is the

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

compressed air
In pneumatic testing and inspection procedures, the

changes in pressure at the measuring point are used to determine 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

control
All pneumatic applications must be controlled by some means.

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 widespread 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.
Fig. 2.8:
Flow diagram of a BOGE screw compressor, aircooled version with fully-adjustable output control
20
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
high, fluidics can offer an alternative.
2.4
Examples of specialised
applications
The following list will give the reader an idea of the many applications of compressed air in industry, the crafts and everyday 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 applications to be found in the various sectors of the economy.
A list of the typical applications in general mechanical engineering has not been included, since pneumatics touches practically 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
generators
Compressors (compactors)
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 temperature 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
( Turbo-compressors )
Dynamic compressors are for instance turbo-compressors, by

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 reduced and the air compressed by force.
Displacement compressors are to be preferred

for small quantities of medium and high medium pressures.
24
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-oillubricated and oil-lubricated compressors.
Compressors ( compactors )
displacement compressors
Turbo-compressors
Axial compressor
Radial compressor
oscillatory
with crank drive
rotary
without
crank drive
single-shaft
multipleshaft
Rotary vane
compressor
Screw
compressor
Liquid ring
compressor
Rootscompressor
piston
compressor
Plunger
compressor
Crosshead
compressor
Diaphragm
compressor
Free-piston
compressor
25
3.2.1
Standard compressors
Type
Symbol
The table shows the typical areas of work for various standard
types of compressor.
Op. diagram
Pressure range
Volume flow
[ bar ]
[ m3 / h ]
Plunger
compressor
10 ( 1-stage )
35 ( 2-stage )
120
600
Crosshead
compressor
10 ( 1-stage )
35 ( 2-stage )
120
600
Diaphragm
compressor
low
low
Free piston
compressor
26
limited use as
gas generator
Rotary vane
compressor
16
4 500
Liquid ring
compressor
10
Screw
compressor
22
750
Root
compressor
1,6
1 200
Axialcompressor
10
200 000
Radialcompressor
10
200 000
3.2.2
Piston (reciprocating) compressor
Piston compressors draw in air by way of pistons moving up

and down, compress it and then push it out. The processes
control induction and pressure valves.
By arranging several compression stages in series it is possible to generate various pressures, and differing quantities
of air can be generated by using several cylinders.
Fig. 3.1:
Symbol for piston compressor
Plunger compressor
On plunger compressors, the piston is connected directly to
the crankshaft via the con-rod.
Fig. 3.2:
Op. diagram of plunger compressor
Crosshead compressor
The piston is powered by a piston rod and that by the crosshead.
Crosshead
Properties of piston compressors:

Highly efficient.
High pressures.
Fig. 3.3:
Op. diagram of crosshead compressor
27
The piston compressors are differentiated according to the

arrangement of their cylinders:
Vertical cylinders.
No stress on the piston or piston ring through the weight
of the piston.
Small base area.
Fig. 3.4:
V-type plunger compressor
Horizontal cylinders.
Only as multi-cylinder compressor in Boxer construction.
Low forces of gravity. This benefit is only noticeable when
output is greater.
V-, W- or L-type compressors.
Good mechanical balance.
Low space requirement.
Fig. 3.5:
W-type plunger compressor
Fig. 3.6:
Crosshead compressors
Horizontal, L-type, V-type, W-type
28
3.2.3
Diaphragm compressors
The diaphragm compressor belongs to the family of displacement compressors.

An elastic diaphragm causes the compression. Instead of a
piston moving linear between two end positions, the diaphragm
is moved in non-linear vibrations. The diaphragm is attached
to the side and is moved by a con-rod. The stroke of the conrod depends on the elasticity of the diaphragm.
Fig. 3.7:
Symbol for diaphragm compressor
Features:
Large cylinder diameter.
Small stroke.
Economical with low output quantities, low pressures,
and when generating a vacuum.
Fig. 3.8:
Op. diagram of diaphragm compressor
29
3.2.4
Free piston compressor
The free piston compressor belongs to the family of displacement compressors.

It is a compressor with an integrated two-stroke diesel engine.
Compressed air acts on the raised pistons and pushes them
back inside, thereby starting the compressor. The combustion
air thus compressed in the engine cylinder drives the pistons
apart again upon combustion of the injected fuel. The enclosed
air is compressed. After letting out the necessary scavenging
air the greater part of the compacted air is pushed out through
a pressure holding valve. Any remaining air is pushed back in
by the piston for the new cycle. The induction valves draw in
new air again.
Features:
Highly efficient.
b
b
c
d
a
b
c
d
=
=
=
=
Pneum. outlet aperture

Inlet aperture
Fuel injection nozzle
Exhaust aperture
Fig. 3.9:
Op. diagram of free piston compressor
30
Smooth-running.
Simple principle, but seldom used.
In practice, the piston movements need to be synchronised and extensive control equipment fitted.
3.2.5
Rotary vane compressor
The rotary vane compressor ( lamellar or rotary multi-vane compressor) is one of the rotary displacement compressors.
The housing and rotary pistons moving inside form the chamber for inducting and compressing the medium.
A cylindrical rotor on eccentric bearings turns inside a closed
housing.The rotor ( drum) has radial slots along its entire length.
Inside the slots, slides move in a radial direction.
Fig. 3.10:
Symbol for rotary vane compressor
When the rotor reaches a certain speed, the working slide is

pressed outwards against the inner walls of the housing by
centrifugal force. The compression chamber between the rotor and the housing is divided by slides into individual cells
( work chambers).
As a result of the eccentric arrangement of the rotor, the volume increases or decreases during a rotation.
The pressure chambers are lubricated by loss lubrication or
oil injection.
Fig. 3.11:
Op. diagram of rotary vane compressor
By injecting larger quantities of oil into the compression chamber one achieves, in addition to lubrication, a cooling effect
and a sealing of the slides against the inner wall of the housing. The injected oil can be separated from the compound of
oil and air after compression and directed back to the oil circuit.
Features:
Very quiet running.
Pulse-free and even output of air.
Low space requirement and easy to service.
Low efficiency.
High maintenance costs due to wear on the slides.
31
3.2.6
Liquid ring compressor
The liquid ring compressor belongs to the category of rotary

displacement compressors.
The eccentrically borne shaft in the housing with fixed radial
paddle displaces the sealing liquid during rotation. This forms
the liquid ring that seals the spaces between the paddles
against the housing.
The content of the chamber is changed by the rotation of the
shaft, causing air to be inducted, compressed and transported.
Fig. 3.12:
Symbol for liquid ring compressor
The liquid generally used is water.
Features:
Oil-free air ( through oil-free transport medium).
Low sensitivity to soiling and chemicals.
Liquid disperser required because auxiliary liquid is
forced continually into the pressure chamber.
Low degree of efficiency.
a
b
c
d
e
=
=
=
=
=
Paddle wheel
Housing
Inlet aperture
Outlet aperture
Liquid
Fig. 3.13:
Op. diagram of liquid ring compressor
32
3.2.7
Screw compressor
The screw compressor is a rotary displacement compressor.

Two parallel rotors with differing profiles work in opposite directions inside a housing.
Fig. 3.14:
Symbol of screw compressor
The intake air is compressed in chambers, which continuously

decrease in size due to the rotation of the rotors until the final
pressure is reached, and is then forced out of the discharge
outlet. The chambers are formed by the casing walls and the
meshing helical gears of the rotors.
Oil-free screw compressors

On screw compressors that seal without oil, and with which
the air in the compression chamber does not come into contact with oil, the two rotors are connected by a synchronised
transmission so that the surface profiles do not touch.
Screw compressors with oil-injection cooling

Fig. 3.15:
Op. diagram of screw compressor
On screw compressors with oil-injection cooling only the main

rotor is under power. The secondary rotor turns without contact.
Features:
Small size.
Continuous air production.
Low final compression temperature.
( with oil-injection cooling)
Fig. 3.16:
Section through screw compressor stage
33
3.2.8
Roots compressor
The Roots compressor belongs to the displacement family of

compressors.
Two symmetrically shaped rotary pistons turn in opposite directions inside a cylindrical chamber. They are connected by
a synchronised transmission and operate without contact.
Fig. 3.17:
Symbol of Roots compressor
The air to be compressed is directed from the intake side into

the compressor case. It is enclosed in the chamber between
the wing and case. At the moment in which the piston releases
the edge to the pressure side the gas flows into the discharge
outlet and fills the pressure chamber. When the wing turns
further, the content of the transport chamber is pressed out
against the full counter pressure. Constant compression takes
place. The compressor must always work against the full dynamic pressure.
Features:
No wear on the rotary piston, and therefore no lubrication
is required.
Air contains no oil.
Sensitive to dust and sand.
Fig. 3.18:
Op. diagram of Roots compressor
34
3.2.9
Axial compressor
Axial compressors are flow devices by which the air flows in

alternatingly in an axial direction through a series of rotating
and stationary paddles.
The air is first accelerated and then compressed. The paddle
ducts form randomly expanded channels in which the kinetic
energy generated by circulation of the air delays and is converted into pressure energy.
Fig. 3.19:
Symbol of turbo-compressor
Features:
Uniform output.
No oil content in air.
Sensitive to changes in load and stress.
Minimum output quantities required.
Fig. 3.20:
Op. diagram of axial compressor
35
3.2.10
Radial compressor
Radial compressors are flow devices in which the air is directed to the centre of the rotating running wheel.
The air is moved by centrifugal force against the periphery.
The rise in pressure is caused by the accelerated air being
directed through a diffusor before it reaches the next running
wheel. The kinetic energy (speed energy) converts into static
pressure during this process.
Fig. 3.21:
Symbol of turbo-compressor
Features:
Uniform output.
No oil content in air.
Sensitive to changes in load and stress.
Minimum output quantities required.
Fig. 3.22:
Op. diagram of radial compressor
36
3.3 Piston compressors

3.3.1 General
Piston compressors operate according to the displacement

principle. The piston intakes air through the intake valve during the downwards stroke. It closes at the start of the downwards stroke. The air is compressed and forced out of the
pressure valve. The piston is driven by a crank drive with crankshaft and conrods.
Piston compressors are available with one and several cylinders, and in one and multiple-stage versions.
Multi-cylinder compressors are used for higher outputs, multistage compressors for higher pressures.
Single stage compression

Compression to the final pressure in one piston stroke.
Two stage compression
The air compressed in the cylinder in the first stage ( low pressure stage ) is cooled in the intermediate cooler and then compressed to the final pressure in the second stage ( high pressure cylinder ).
Single action compressors
One compression action with one rotation of the crankshaft.
Fig. 3.23:
BOGE piston compressor
Double action compressors

Two compression actions with one rotation of the crankshaft.
Piston speeds
With compression the compression speed or even the motor
speed is of secondary importance. The most important factor
in assessing wear is the piston speed. So a compressor with
a low speed and large stroke can have a high piston speed.
In contrast, compressors with high speeds and a small stroke
can have low piston speeds. The piston speed, measured in
m/s, is extremely low with BOGE piston compressors. This
means minimal wear.
Intake
Compression
Fig. 3.24:
Principles
37
3.3.2 Suction capacity - output
Suction rate - Output

Stroke volume flow - Volume flow
Suction rate
The suction rate (stroke volume flow) is a calculated size for

piston compressors. It is the product of cylinder capacity, compressor speed (number of strokes ) and the number of intake
cylinders. The stroke volume flow is given in l/min, m3/min and
m3/h.
Suction rate
Volume flow
Output
The output ( free air delivered FAD ) is measured according to

VDMA Unit Sheet 4362, DIN 1945, ISO 1217 or PN2 CPTC2.
The ratio of output to induction rate is the volumetric efficiency
rate.
Fig. 3.25:
Suction rate and free air delivered
Clearance area
The clearance area is a specific dimension located between
the top dead centre of the piston and the bottom edge of the
valve.
The clearance area includes:
Design tolerances
Cavities in the valves and valve seats
Individual design considerations
C = Clearance area
S = Stroke
R = Re-expansion
Fig. 3.26:
Clearance area
38
During the down stroke of the piston the air in the compression expands to atmospheric pressure. Only at this stage and
during the continued downstroke of the piston is air sucked in
from outside.
The difference between the suction rate and the output occurs because during suction the pressure of the air already
drops in the inlet filter, leakages also occur, the air sucked in
heats up and re-expansion occurs in the compression space.
3.3.3 Cooling
Heat is generated in all compression processes. The degree

of heating depends on the final pressure of the compressor.
The higher the final pressure, the higher the compression temperature.
According to safety rules, the final compression temperature
on compressors with oil-lubricated pressure chambers and
single stage compression, a maximum 20 kW motor rating
and maximum 10 bar may be up to 220 C.
With higher pressures and motor ratings a maximum temperature of 200 C is allowed. With multiple stage compression and
pressures of over 10 bar the maximum final compression temperature is 160 C.
Fig. 3.27:
Direction of cooling air on a piston compressor
The greatest part of compression heat must therefore be expelled. High compressed air temperatures can be dangerous
as a small amount of lubrication oil is absorbed into the compressed air during compression, this could be flammable. A
fire in the line or the compressor would be the least danger,
but with higher temperatures the danger of compressed air
explosion is potentially greater because the ratio of oxygen
contained is far greater than atmospheric air.
Each compressor stage therefore has an intercooler and
aftercooler installed in order to cool the compressed air.
The quantity of heat to be removed by cooling depends on the
free air delivered and the pressure. Higher pressure compressors have two, three, or more cylinders. The cylinders are
located in the best position in the air flow of the cooling ventilator wherever possible. In order to intensify heat extraction,
the surfaces of the cylinders and cylinder heads are produced
with generous ribbing. However, the intensive cooling and ribbing of the compressor is not enough to obtain a minimum
compressed air temperature. The compressed air must also
be cooled by an intercooler between the first and second stages
and an the aftercooler behind the second stage. If this cooling
is not sufficient, multi-stage compression is necessary.
Fig. 3.28:
After-cooler as turbulence lamellar cooler
Safety regulation VGB 16 9 for oil-lubricated reciprocating

compressors stipulates that the cooling air temperature must
fall to between 60 C and 80 C after the last compression stage.
It is also beneficial for the consumer to have a low compressor
air outlet temperature, because the cooler compressed air contains less moisture. Apart from this, downstream equipment,
such as the compressor receiver and air treatment components can be designed for low compressed air temperatures
and thus be purchased at less cost. The air outlet temperature
on air-cooled piston compressors is approx. 10 - 15C above
ambient temperature, depending on the quality of the compressor.
39
3.3.4 Coolant
Piston compressors are mainly of the air-cooled variety.

Cold air has the advantage that it is almost everywhere in
unlimited quantities.
The cold air is generated by a ventilator. The ventilator forces
the cold air over the intercooler and aftercooler and over the
compressor.
During compression and cooling stage of the compressed air,
condensate forms inside the cooler. Because of the flow speed
of the compressed air, the condensate is taken out of the
aftercooler by the air, and into the pipe network and compressed air tank.
3.3.5 Control of reciprocating piston

compressors
Piston compressors are normally controlled by pressure

switches. The pressure switches must be located in a calm
area of the compressed air. This is in the compressed air receiver, for example, and not in the pipeline between the compressor and the receiver.
The pressure switch stops the compressor at maximum pressure and switches it back on at 20 % below maximum pressure. The actuation is therefore 8 :10 bar and 12 :15 bar.
A smaller differential is not recommended because the compressor will then cycle too often and the wear on the compressor and the motor increases. The cut-in pressure can be lowered with the cut-out pressure remaining constant. This has
the advantage that the compressor has longer running times
but longer stationary times too. The cut-in pressure may not
be lower than the minimum pressure of the pneumatic network.
Piston compressors do not continue running (running-on) but
switch off immediately after the maximum pressure is reached
(intermittent operation).
Fig. 3.29:
Pressure switch
3.3.6 Advantages of reciprocating piston

compressors
Piston compressors are particularly suitable as peak load machines. The compressor only switches on when there is an
increased demand for compressed air and switches off without run-on time when the maximum pressure is reached, i.e.,
saving approx. 30 % energy consumption in idling mode.
Compression of nearly all technical gases possible

Economical compression of pressures up to 40 bar
Can be used as a booster compressor
Easy control
Economical start-stop-operation ( no idle running time )
40
3.3.7 Components of a piston

compressor
Crank case
Inlet filter
Cooler
Drive motor
Pressure
switch
Safety valve
Condensate
drain
Compressed
air connection
Fig. 3.30:
Layout of a piston compressor
41
3.4 Screw compressors

3.4.1 General
In contrast to the piston compressor, the screw compressor is

a relatively new construction. Although the principle was developed as early as 1878 by Heinrich Krigar in Hannover, the
construction was only perfected after the second world war.
The Swedish company "Svenska Rotor Maskiner" ( SRM ) developed the screw compressor technically to series standard.
Screw compressors operate on the displacement principle.
Two parallel rotors with different profiles work in opposite directions inside a housing.
Fig. 3.31:
Section through a screw compressor stage
3.4.2 Compression process
The intake air is compressed to final pressure in chambers

which continuously decrease in size through the rotation of
the screw rotors. When the final pressure is reached the air is
forced out through the discharge outlet. The compression
chambers are formed by the casing walls and the meshing
helical profiles of the rotors.
Suction side
Pressure side
Intake ( 1 )
Suction side
The air enters through the inlet aperture into the open screw
profiles of the rotors on the intake side.
Pressure side
Compression ( 2 ) + ( 3 )
The air inlet aperture is closed by the continued rotation of the
rotors, the volume reduces and the pressure increases.
Suction side
Oil is injected during this process.

Pressure side
Discharge ( 4 )
Suction side
The compression process is completed. The final pressure is

reached and the discharge begins.
Pressure side
Fig. 3.32:
The compression process in a screw compressor
stage
42
3.4.2 Method of operation
11
10
12
6
2
4
3
7
5
Fig. 3.33:
Sectional diagram of a
BOGE S-series screw compressor
= Intake filter with paper microfilter insert
= Multifunction suction controller
= Oil injection
= Compressor stage
= Oil separator tank
= Spin-on oil separator cartridge
= Minimum pressure valve
= Oil cooler
= Aftercooler parallel to flow of cool air
10 = Oil microfilter
11 = Thermostat valve
12 = Cleaning aperture
BOGE screw compressors draw in atmospheric air through

the cyclonic suction filter 1 fitted with a paper microfilter cartridge and with soiled filter facility. After passing through the
multi-function suction controller 2 the air enters the compressor stage and is compressed 4. Continuously cooled BOGE
long life S46 oil is injected 3 into the compressor stage. The
oil absorbs and removes the heat generated during the compression process which increases in temperature to approx.
85 C. According to EC machinery guidelines the final maximum compression temperature may not exceed 110 C.
A large proportion of the oil is separated from the compressed
air in the combined air/oil separation vessel 5. The residual oil
is removed by the spin-on fine oil separator 6, which removes
the residual oil in the compressed air down to only approx.
1-3 mg/m3.
The compressed air then passes through a minimum pressure valve 7 into the compressed air aftercooler 9 where it is
cooled down to a temperature of only 8 C above ambient and
is then directed through the standard BOGE stop valve into
the compressed air system.
The oil in the oil separator is cooled from 85 C to 55 C in the
amply dimensioned oil cooler 8. It then passes through a replaceable spin-on oil filter 10. A thermostatic valve 11 in the oil
circuit ensures that the oil temperature is ideal in every operating phase.
43
3.4.3 Oil circuit
The oil injected into the compressor stage performs the following functions:
Extraction of compression heat (cooling)
Sealing the gap between the rotors and their housing
Lubricating the bearings
1 = Compressed air/oil separator vessel

The oil is separated from the compressed air by reducing the
air flow velocity in the separator vessel in which the oil collects
System pressure forces this oil out of the separator vessel
into the compressor stage.
Fig. 3.34:
Components of the oil circuit
2 = Thermal bypass valve

The thermal bypass valve directs the oil through the oil cooler
or through a bypass (e.g., in the warm-up stage).The oil is
thus always at its optimum operating temperature.
3 = Oil cooler (air or water)
The oil cooler reduces the oil temperature to optimum conditions prior to injection into the compressor stage.
4 = Oil filter
The oil filter retains impurities from the oil and prevents problems of contamination in the oil circulation system.
5 = Compressor stage
The oil injected in the compressed air is directed back into the
compressed air/oil vessel, where it is separated by gravitational forces.
6 = Scavenging line
The compressor stage draws any residual oil that has collected
in the separator back into the oil circuit via the scavenging
line.
44
3.4.4 Pneumatic circuit
The air sucked into the compressor stage is compressed to

final pressure by the rotors.
1 = Intake filter
The intake filter cleans the air drawn in by the compressor
stage.
3
2 = Suction controller
The suction controller opens (operation mode) or closes (idling
mode and stopped) the intake line, depending on the operating status of the compressor.
3 = Compressor stage
The compressor stage compresses the intake air.
4 = Compressed air/oil vessel
Inside the compressed air/oil vessel the compressed air and
oil are separated by gravity.
5 = Oil separator
The oil separator removes the residual oil from the compressed
air.
Fig. 3.35:
Components of the pneumatic circuit
6 = Minimum pressure valve MPV

This valve opens only when the system pressure has risen to
3.5 bar, which causes a fast build-up of system pressure and
assures lubrication in the start-up and pressure phase of the
compressor. When the compressor is switched off the minimum pressure valve prevents compressed air from flowing
out of the compressor.
7 = Compressed air aftercooler (air cooled)
The compressed air is cooled in the aftercooler. During this
phase, a large proportion of the moisture in the air condenses
out.
8 = Stop valve
The screw compressor can be isolated from the system via
the stop valve located at the outlet of the compressor.
45
3.4.5 Heat reclamation
The oil removes approx 85% of compression heat from screw

compressors with oil injected cooling. When using a heat exchanger the heat can be extracted from the oil and used for
utility or water heating.
The water in the backflow passing through the heat exchanger
is heated to +70 C. The quantity of water heated depends on
the temperature difference.
Fig. 3.36:
Heat exchanger BOGE-DUOTHERM
3.4.6 Intake control
The suction controller controls the intake line of the screw

compressor.
Fully unloaded start-up through closed controllers.

Seals hermetically on idling, stopped and emergency cutout.
Fig. 3.37:
Intake control with ventilation/control valve
3.4.7 Advantages of screw compressors
when compressed air is required on a continuous basis

ideal as a base load machine
economical with 100 % operating availability
46
3.4.8 Components of a screw compressor
Control panel
Intake filter
Oil filter
Compressed air/oil
combi-cooler
Suction controller
Oil separator
Compressor stage
Cabinet air
inlet filter
Drive motor
Compressed air/oil
separator vessel
Fig. 3.38:
Layout of a screw compressor
47
3.5 Components
3.5.1 Drive motor
Drive motors are normally AC motors and mainly operate at a

a speed of 3.000 min-1. The appropriate compressor speed is
obtained by drive belt transmission.
Normal drive motor supply is TEFV (totally enclosed fan vented)
IP 55 class F insulation.
Fig. 3.39:
Drive motor with belt and tensioner
3.5.2 Drive belts
The compressor is driven via drive belt transmission.

Using the BOGE patented GM-drive system on screw compressors, drive belts are practically maintenance-free and have
a calculated design life of up to 25,000 hours.
3.5.3 Belt tensioning
Motors on piston compressors are normally located on a sliding plate for belt tensioning. The plate is fitted with a threaded
central spindle which together with parallel guides ensure accurate alignment of the drive belts across the pulleys.
BOGE screw compressors are equipped with the patented
BOGE-GM-drive system. This take account of different belt
tension forces caused by motor weight, start-up torque and
running torque, and ensures that compressors have constant
belt tension in every operating stage, without the need for
retensioning and alignment on belt change.
Fig. 3.40:
BOGE-GM-drive system
48
3.5.4 Inlet and pressure valves
The tongue valve controls the inlet and outlet of air in the cylinder chamber of the piston compressor.
BOGE-ferax -tongue valves have fewer components than
conventional valves, with friction-free operation, minimal dead
space flow resistance. This means more FAD, higher valve
working life expectancy and practically no carbonised oil deposits on the valves, which can be produced by high compression temperatures.
Fig. 3.41:
BOGE-ferax -Tongue valve
3.5.5 Safety valve
The safety valve must blow off the full output of the compressor at 1.1 times the nominal pressure of the compressed air
tank.
Fig. 3.42:
Safety valve on screw compressor
3.5.6 Intake filter

Dust separator
Paper filter insert
Screw compressors draw in atmospheric air through the air

inlet filter inside the compressor cabinet and through the suction filter with paper microfilter cartridge. The inlet filter separates solid impurities such as dust particles from the intake
air, minimising wear in the compressor and providing the customer with clean compressed air.
In dusty conditions ( e.g., cement works ) paper insert filters
are used. These have a higher separation rate than standard
wet air or foam filtration.
The filter inserts can be cleaned on larger compressors. There
is a possibility to monitor the intake filter for pressure differential, allowing soiled filters to be recognised at an early stage.
Automatic dust extraction

Fig. 3.43:
Intake filter with paper insert
49
3.6 Compressor lubricants and

coolants
Compressor oils are standardised to DIN 51506. No HD (high

density) oils may be used to lubricate compressors. HD oils
tend to emulsify and thus quickly lose their lubricating properties.
Mineral and synthetic oils are allowed. Mineral oils have a useful
life of around 2,000 operating hours under normal operating
conditions. Synthetic oils can be changed at longer intervals.
The oil level of the compressor must be checked regularly.
The first oil change is made after the running-in period (approx.
300 to 500 operating hours).
Compressors must not be operated with too little oil. Even a
short trial run without oil (e.g., to check the direction of rotation) can lead to damage.
The oil filter must be cleaned each time the oil is changed. The
oil filter must be replaced after it has been cleaned for the
second time.
Fir. 3.44:
Oil level check with a dipstick
Compressor oils and the condensate from oil-lubricated compressors may not be discharged into the public drains. They
must be disposed of in an environmentally acceptable manner.
Piston compressors
Synthetic-base oils allow compressor running times of up to
8.000 operating hours.
Screw compressors
Semi-synthetic-base oils allow compressor running times of
up to 9.000 operating hours.
USDA H1 oils must be used if the compressed air comes
into contact with foodstuffs.
50
4.
The aim of control is to minimise energy consumption and
wear and maximise availability.
There are various types of control, depending on the construction type, size and area of application:
the final pressure ( network pressure ).
the inlet pressure.
the generated volume flow.
the absorbed power of the compressor motor.
the climatic conditions of compressor humidity after the
compressor stage.
Controlling the final pressure is the most important of all control tasks.
4.1
Pressure definitions
Network pressure pN [ bar op ]

The network pressure pN is the pressure at the compressor
outlet behind the outlet valve. This is the pressure in the pipeline network.
The network target pressure pNs [ bar op ]
The network target pressure pNs is the minimum pressure that
must be available in the network.
System pressure pS [ bar op ]
The system pressure pS is the pressure inside a screw compressor up to the minimum pressure non-return valve.
Cut-in pressure pmin [ bar op ]
The cut-in pressure pmin is the pressure below which the compressor will cut-in.
The cut-in pressure pmin should be at least 0.5 bar above the
network target pressure pN.
Cut-out pressure pmax [ bar op ]
The cut-out pressure pmax is the pressure above which the
compressor switches off.
The cutout pressure pmax for piston compressors should be
approx. 20 % more than the cut-in pressure ( e.g., cut-in pressure 8 bar, cut-out pressure 10 bar ).
On screw compressors the cut-out pressure pmax should be
0.5 to 1 bar over the cut-in pressure ( e.g., cut-in pressure
9 bar, cut-out pressure 10 bar ).
51
4.2
Operating status
The operating status is the current operating mode of a compressor. The operating status is the basis for compressor control.
4.2.1
Stopped ( L0 )
The compressor is stopped but ready for operation. If compressed air is needed it switches on automatically.
4.2.2
Idle ( L1 )
The compressor is running off load and no air is being compressed (Energy used for compression is saved). If compressed
air is needed it switches to operating mode without delay.
Idle operating mode reduces the motor cycles, thus reducing
wear.
Various techniques are used to control the idle mode:
Circulation switching
The intake line is connected directly to the pressure line. High
pressure losses occur and it is essential that a non-return valve
be installed.
Flowback switching
The intake valves of the compressor are open during the compression process. The air does not compress, it flows back to
the intake side.
The flowback method is suitable for start-up relief, because
the first working stroke is already completely relieved.
Intake line closure
A valve closes the intake line of the compressor. The intake
volume is reduced to zero and there is no air available for
compression. The pressure losses are low.
Pressure line closure
A valve closes the pressure line of the compressor. The compressed air can not be emitted. No volume flow can occur.
52
4.2.3
Part-load
The output of the compressor is adjusted to the relevant compressed air requirement.The energy consumption falls slightly
if the output is lower. The network pressure pN is constant.
There are several methods of varying volume flow. These can
also be combined if necessary:
Speed control
Changing the motor speed also varies the output of the compressor. This occurs mainly with engine-driven compressors.
With electrically-powered compressors speed control is usually accomplished with the aid of a frequency converter.
The output is continuously controlled from 40-100 %.
Emergency chamber control ( piston compressors only )
By increasing the dead space there is a stronger reverse expansion of the compressed air. If several emergency chambers are opened one after the other the output can be reduced in steps. There are also variations by which an emergency chamber can be continuously expanded.
Flowback control ( piston compressors only )
The output of the compressors is reduced by opening the intake valves during the compression stroke. The opening time
of the intake valves determines the amount by which compressed volume flow is reduced.
A part-load control of approx. 25 - 100 % of output is possible.
When the intake valve is open for the full compression stroke
the output drops back to zero.
Intake throttle control
An adjustable throttle in the intake line reduces the intake volume. A pressure servo valve is used for automatic control,
and this is operated at the relevant system pressure. When
the system pressure drops, the valve opens accordingly, the
compressor takes in more air, and the output rises. As soon
as system pressure becomes constant the throttle valve closes
and the compressor operates in idling mode.
The output varies between 0 - 100 %. The electrical power
requirement does not fall below 70 % during this time.
4.2.4
Operating load ( L2 )
The compressor delivers its maximum output and consumes

the maximum energy.
53
4.3
Controlling individual
compressors
Compressor control has two objectives:

Energy-saving and minimisation of wear.
To meet these objectives, the 4 operating modes of compressors are combined in various control methods. The method
used depends on marginal conditions.
4.3.1
Intermittent control
With intermittent control a pressure switch or contact manometer actuates the compressor, depending on network pressure.
The compressor has two operating modes, Operating mode
( L2 ) and Stopped ( L 0 ).
Behaviour of pressure
This arrangement has the best energy consumption of all types

of control. It is recommended when there is a large compressed
air receiver. A large storage volume also reduces the number
of motor cycles.
The network pressure pN rises to the cut-out pressure pmax.
The compressor switches to Stopped ( L0 ).
The network pressure pN drops to cut-in pressure pmin.
The compressor switches Operating mode ( L2 ).
Behaviour of electrical intake
Fig. 4.1 :
Op. diagram of cutout control
4.3.2
Idle mode control
A pressure switch or contact manometer switches the compressor to operating load or idle mode depending on network
pressure.
In Idle mode ( L1 ) the drive motor continues to run, but the
compressor does not produce any compressed air. The electrical power demand falls to approx. 30 % of the operating mode
requirement.
Continuous operation of the drive minimises the number of

motor cycles, which especially with large motors causes increased wear.
Idle operating mode is used in pneumatic systems with relatively small storage volumes, in order not to exceed the maximum switch cycles of the drive motor.
The system pressure pN rises to cut-out pressure pmax.

The compressor switches to idle mode ( L1 ).
Fig. 4.2 :
Op. diagram of idle mode control
The network pressure pN drops to cut-in pressure pmin.

The compressor switches to operating mode ( L2 ).
54
4.3.3
Delayed intermittent control
A pressure switch or contact manometer works in conjunction

with a timer and controls the compressor independently of
system pressure.
1.
2.
The compressor goes through the modes of Operating mode

( L2 ), Idle mode ( L1 ) and Stopped ( L0 ). The modes are
linked with each other via the timer tV .
The delayed intermittent control combines the benefits of intermittent control and idling control. It is a middle path with
lower energy consumption than the idling control method.
The delayed intermittent control operates with two switching
variants:
Fig. 4.3
Op. diagram of delayed intermittent control
1st Variant
The system pressure pN has not reached cut-in pressure
pmin after expiry of the time tV.
The compressor switches to stopped ( L0 ).
System pressure pN drops below cut-in pressure pmin.
2nd Variant
System pressure pN reaches cut-in pressure pmin before
expiry of the time tV .
There are 2 possibilities to activate the timer tV :

1. Switching on the compressors ( pmin ) starts the timer tV.
This provides shorter idling times and therefore lower
energy costs as with 2.
2. On reaching the cut-out pressure ( pmax ) the timer tV starts.
55
4.3.4
Part-load control
The volume control of the compressor is adjusted to the respective requirement for compressed air.
The network pressure pN is largely constant due to the variable output control. The fluctuations of pN vary depending on
the method of part-load control used.
The part-load control method is used with systems with small
storage capacities and / or heavy consumption fluctuations. The
number of cycles drops.
Fig. 4.4
Op. diagram of part-load control
4.3.4.1
Infinite output control
In addition to the ARS control unit, BOGE offers an optional

infinite output control for screw compressors with oil injection cooling. This control intervenes in the processes of the
suction control and operates according to the suction throttle
principle.
Characteristic control line for

100%
90%
80%
Economical
zone
Power intake[ % ]
70%
Ideal
characteristic line
60%
Uneconomical
zone
50%
The infinite output control from BOGE is set at the factory to

a production rate of between 50 and 100 % of FAD. If FAD
drops to below 50 %, the compressor is working uneconomically. Depending on the switching cycle the compressor either
switches off or continues on idle mode.
40%
Idling
absorbed
power
30%
20%
10%
0%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90% 100%
Output[ % ] FAD
Fig. 4.5 :
Correlation between FAD and absorbed power when
using infinite output control.
4.3.4.2
Frequency control
The frequency control allows FAD control of between 0%

(idling) and the control range of 40 to 100 % with absorbed
power of between 35 and 110 %. The part-load control is
accomplished by changing the speed of the drive motor, which
is controlled by a frequency converter.
If FAD drops to less than 40 % the compressor is working
uneconomically. Depending on the switching cycle the compressor either switches off or continues in idle mode. The frequency control works most economically with oil-free screw
compressors.
56
4.4.
The ARS control concept

BOGE screw-type compressors and supersilenced piston compressors are equipped with the modern ARS -control concept
( Autotronic, Ratiotronic, Supertronic ).
The ARS-control differs in features and control functions.
ARS is an integrated control and monitoring concept with two
objectives:
Energy-saving and thus a reduction of running costs.
Extending the lifetime of the compressor by allowing only
as little wear as possible.
The ARS-control on screw compressors uses a microcontroller
to obtain the cheapest intermittent operation while taking into
account the max. permissible motor cycles. Piston compressors only use economical intermittent operation.
All programmed data are stored in an EEPROM storage module that can be electronically written to and erased. The stored
information is thus still available in the event of a power failure.
Modular design
The ARS-control comprises standard components that are individually obtainable. Components can also easily be added
at a later date. The controls can therefore be ideally configured
for the individual requirements of the customer. The controls
can be rapidly replaced in the event of failure, thus increasing
the availability of the compressors. There is therefore no need
for time-consuming and costly examination by specialists.
57
4.4.1
Automatic
The Automatic is the control unit for all supersilenced piston
compressors. It offers:
Energy-saving intermittent control via a pressure switch.
Operating status display: Operating mode.
Indicator for op/hrs.
Indicator for NW/pr.
Fig. 4.6 :
The BOGE Automatic for piston compressors
4.4.2
Autotronic
Automatic load-free restart after power failure.

Possibility for connection to a hierarchial control for
several compressors MCS.
The Autotronic is an intelligent control and monitoring unit for

screw and piston compressors. In addition to the features of
Automatic it offers for piston compressors:
convenient and well-arranged operating panel with
7-Segment-display, LEDs and flow plan.
operating mode display.
programmable control.
protection of important program-parameter
by code request.
integrated test mode for all inlets and outlets.
Fig. 4.7 :
The BOGE Autotronic for piston compressors
display of the most important malfunction and warning

messages (partially optional ).
Idling mode ( optional ).
Idling mode hours display ( optional ).
For screw compressors the Autotronic offer the following
additional features :
dynamic full-load/idling control
( delayed intermittent switching ).
automatic selection of the best operating mode.
automatic optimization of motor cycles.
Fig. 4.8 :
The BOGE Autotronic for screw compressors
Standard display of the most important malfunction and

warning messages.
Display and monitoring of final compression temperature.
58
4.4.3
Ratiotronic
The Ratiotronic is an extension of the Autotronic for screw or
piston compressors. It offers the following additional features:
Display of additional malfunction or warning messages
( partially optional ).
Local or remote operation.
External indication of operating data and messages.
Fig. 4.9 :
The BOGE Ratiotronic for piston compressors
Fig. 4.10 :
The BOGE Ratiotronic for screw compressors
4.4.4
Supertronic
The Supertronic is a complex operating and monitoring unit

for screw compressors. In comparison to the other control units
it has comprehensive additional functions:
Well-arranged LCD-display with 4 x 20 characters (digits)
and clear text.
Adjustment of network pressure by keyboard.
Comprehensive display and monitoring of major operating
data.
Fig. 4.11 :
The BOGE Supertronic for screw compressors
Comprehensive compressor monitoring

Malfunction and warning messages shown on the
LCD - display.
Integrated electronic real-time clock for switching on and
off. Operated via keyboard.
All operating parameters can be adjusted via the keyboard.
Access to all functions with a few additional keystrokes.
59
1.1
4.5
Control of several
compressors
For users of compressed air with high, much fluctuating consumption 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 necessary, 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 control 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
Fig. 4.12 :
The BOGE Master Control System 2
MCS 2 controls up to 3 compressors of the same size as

basic load, medium load and peak load. The compressors are
cyclically changed and switched on and off via their own pressure switches. The upgrade to 3 compressors and the greater
cycle difference is the only difference to the MCS 1. The features are otherwise the same.
Minimal cycle difference p = 1,1 bar
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 compressors are controlled by a common pressure sensor on the compressed 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 according to requirement via set intermediate pressure values. The
speed of pressure rise and fall is measured. The compressors switch on and off dynamically.
Fig. 4.14 :
The control offers:

Dynamic pressure control by microcontroller in connection with electronic pressure controllers for a minimum
cut-in difference of 0.5 bar.
( no over-compression energy saving )
Cut-in
pressure
[bar]
Cycle
difference
Time dependent allotment of compressors in rank

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 :
Circuit diagram of the BOGE MCS 3
Time offset allocation of compressors if demanded by

the control unit.
Well arranged LCD-display with 4 x 20 characters and
clear text.
Possibility of checking all inlets and outlets via a testmenu.
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 compressed air receiver.
The basic load with this control unit is normally covered by the
largest compressor or combination of compressors. The smallest compressor takes the peak load. Compressors of the same
size change over in providing the basic load.
The MCS 4 computes compressed air consumption continually from programmed compressor performance data and information from the pressure sensor. It selects the compressor
that most closely matches the requirement.
Fig. 4.16 :
Cut-in
pressure
[bar]
The control offers:

Cycle
difference
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 )
Fig. 4.17 :
Op. diagram of the BOGE MCS 4
three different pressure profiles per day by a timer

programme to adapt the control to differing compressed
air requirement.
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

similar.
The control unit offers:

Adaptation of FAD to the compressed air demand by
infinite output control by the peak load compressor.
Cut-in
pressure
Cycle
difference
Minimal pressure fluctuations in the pneumatic network.

Dynamic pressure control by microcontroller in conjunction 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.
Fig. 4.19 :
Op. diagram for the BOGE MCS 5
Individual allocation of compressors in the load range

groups with even usage of compressors.
Adjustable basic load change cycle.
Independent rotation of compressors in the load range
groups.
control unit.
Well arranged LCD-display with 4 x 20 characters and
clear text output.
Automatic change to pressure switches of individual
compressors in the event of voltage loss.
The individual compressors operate independently
without the MCS 5. They are then controlled by their own
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 compressed 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
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 compressor.
Cut-in
pressure
[bar]
Cycle
difference
Minimum pressure fluctuations in the pneumatic system.

Dynamic pressure control by microcontroller in conjunction with the electronic pressure controller for a minimum
( no over-compression energy saving )
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

range groups with even work rates among the compressors.
Adjustable basic load change cycle.
Independent rotation of compressors in the load range
groups.
control unit.
Well-arranged LCD-display with 4 x 20 characters
and clear text output.
Automatic switchover to the pressure switches of individual compressors in the event of power failure.
The individual compressors work independently without
the MCS 6. They are then controlled by their own pressure 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 additional devices.
The MCS 7 is available in three versions:
Fig. 4.22 :
Cut-in
pressure
[bar]
Version 1
Cycle
difference
Version 1 offers an extended software program of MCS 3. It

uses pressure-dependent control of up to 8 or 12 compressors of the same and/or different size by priorities and timer
programmes.
Version 2
uses pressure-dependent control of up to 8 or 12 compressors of the same and/or different size with infinite output control.
Version 3
Fig. 4.23 :

uses pressure-dependent control of up to 8 or 12 compressors of the same and/or different size with speed frequency
control.
In addition to the basic individual software functions the control offers:
Recording of the operating status of the compressors
and additional components of the compressor station.
Storage of operating, warning and malfunction messages. This makes servicing and repair of the compressor 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.
5.1
Why treatment ?
Modern production equipment needs compressed air. The

many conditions in which it is used range from untreated blowing 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 operation 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 concentration 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 compressed 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 compression
66
Lower pressure loss from leakage and flow resistance.

Lower energy consumption due to lower pressure loss.
Sand blasting
Simple varnishing work
General works air
Conveyance air
Simple spray painting
Sandblasting with higher

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

1-3
Surface treatment
1-3
Medical equipment
3-4
Conveyance air with higher

3-4
Food and luxury

food industry
3-4
Breweries
1-3
Dairies
1-3
Pharmaceuticals industry
1-3
Sterile filter
Active carbon
absorber
Active carbon filter
prefilter
Blowing air
Adsorption dryer
Membrane dryer
Microfilter
Water
Refrigeration dryer
Particle
General air
Prefilter
Oil
DIN ISO 8573-1
Dust separator
Quality
classes
Compressor
Area of application
of compressed air
BOGE recommends the processing described on this page

for the various applications of compressed air.
*)
Planing information
BOGE screw and piston compressors
5.1.2
*) 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 products 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 blockages. 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
Concentration of particles
In our atmosphere there are particles of dirt that are not visible to the naked eye. This chapter contains a general summary of the type, size and concentration of these particles.
Limits
Average values
[ mg/ m ]
[ mg/ m3 ]
5 - 50
15
In the town
10 - 100
30
In an industrial area
20 - 500
100
In large factory plants
50 - 900
200
in atmospheric air
In the country
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 atmosphere. 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 humax [ g /m3 ]
Maximum humidity hu max ( saturation quantity ) means the

maximum quantity of moisture that 1 m air can hold at a certain 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.
Dew point[ C ]
Fig. 5.2 :
Maximum humidity
depending on dew point
hu
hu max
100 %
= relative humidity
[%]
hu
= absolute humidity [ g/m 3 ]
humax = maximale humidity [ g/m 3 ]
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 atmospheric air ( 1 bar abs ) can be cooled without precipitation.
The atmospheric dew point is of minor importance for pneumatic systems.
Pressure dew point [ C ]
The pressure dew point means the temperature to which compressed air can be cooled without precipitation of condensate. The pressure dew point depends on the final compression 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 certain dew points:
max. dew
max. dew
max. dew
max. dew
max. dew
max.
dew
max. dew
point humidity point humidity point humidity point humidity point humidity point humidity point humidity
[ g/ m3 ] [ C ]
[ g/m3 ] [ C ]
[ g/m3] [ C ]
+100 588,208 +76
248,840 +52
90,247 +28
+99
569,071 +75
239,351 +51
+98
550,375 +74
+97
+96
[ C ]
[ g/m3] [ C ]
[ g/m3 ] [ C ]
[ g/m3] [ C ]
[ g/m3]
26,970 +4
6,359 -19
0,960 -43
0,083
86,173 +27
25,524 +3
5,953 -20
0,880 -44
0,075
230,142 +50
82,257 +26
24,143 +2
5,570 -21
0,800 -45
0,067
532,125 +73
221,212 +49
78,491 +25
22,830 +1
5,209 -22
0,730 -46
0,060
514,401 +72
212,648 +48
74,871 +24
21,578
-23
0,660 -47
0,054
-24
0,600 -48
0,048
4,868
+95
497,209 +71
204,286 +47
71,395 +23
20,386
+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
during compression
Air contains water in the form of moisture. Since air can be

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.
Fig. 5.3 :
A wet sponge being squeezed
The following examples illustrate the quantity of condensate

to be expected qc when air is compressed. The example assumes a humid Summer day with 35 C and 80 % atmospheric
humidity.
qc =
V1 humax 1 1
100
6,5 39,286 80
qc = 100
m g / m %
qc =
%
qC
qc =
V2 humax 1 2
100
0,59 39,286 100
100
m g / m %
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
= 35 C
= 35 C
qc
= precipitated condensate
[g]
= 80 %
= 100 %
V1
= Volume at 0 bar-op
[ m3 ]
V2
= Volume at 10 bar-op
[ m 3]
hu max = 39,286 g/ m3
Fig. 5.4 :
Precipitation of condensate during compression
humax 1 = max. humidity at 35 C
[ g/m3 ]
= relative humidity of V 1
[%]
= 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 constant temperature 181,108 g water will precipitate in the
form of condensate.
72
5.2.5
Example
for calculating quantities of
condensate
An example shows the amount of condensate qc that actually

occurs when air is compressed. It is to be noted that the condensate 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
p1
T1
1
humax 1
=1
= 33
= 80
= 35,317
V 1 = 2 720 m/h
bar abs
C
%
g/m
The atmospheric air contains a certain amount of water under

these conditions:
qw = V 1 humax 1 1 /100
g/h = m/h g/m %/%
qw = 2 720 35,317 80/100
^ 76,85 l/h
qW = 76 849,79 g/h =
Compressor
p2
T2
= 11,5
= 40
bar abs
C
2
= 100 %
humax 2 = 50,672 g/m
V1
V 2 =
= 236,5 Bm3/h
P2
During the compression process, the temperature rises above

the pressure dew point of the compressed air, and therefore
no moisture will precipitate. In the aftercooler of the compressor the compressed air is cooled down to T 2 = 40 C. The first
condensate occurs and is taken with the air into the compressed air receiver. The volume flow calms down and the
droplets of water precipitate. A considerable amount of condensate collects there:
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
After this the compressed air is cooled down in the refrigeration compressed air dryer to a temperature corresponding
to a pressure dew point of 3 C. The condensate precipitates
in the dryer and is drained off.
Refrigeration compressed
air dryer
p3
=
T3
=
3
=
humax 3 =
11,5
3
100
5,953
bar abs
C
%
g/m
qc2
V 2 = 236,5 Bm3/h
qc2 = ( V 2 humax 2 ) ( V 2 humax 3 )

qc2 = ( 236,5 50,672 ) ( 236,5 5,953 )
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.
Fig. 5.6 :
Approx. 8 10 l buckets of condensate precipitate in
24 hours
Condensate quantity qc
= qc1 + qc2
= 75441,9 g/h
= 75,4
l/h
With 3-shift operation working at 100 % efficiency the compressor is running 24 hrs. per day. This means, with the basic
assumptions unchanged:
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

Summer day
The quality of compressed air must always remain the same if

the surrounding conditions are unchanged. i.e., the pressure 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.
= 122,6
l/h
With 3-shift operation working at 100 % efficiency the compressor is running 24 hrs. per day. This means, with the basic
assumptions unchanged:
Condensate quantity qcD
= 2 943,3
l/D
The following quantity of condensate will then occur in one

year:
Condensate quantity qcY
74
= 1 071 358 l/Y
5.2.7
Determining the pressure dew

point
The pressure dew point means the temperature to which the

compressed air can be cooled without condensate precipitating. The pressure dew point depends on the final compression pressure. If the pressure drops, the pressure dew point
drops with it.
In
Fina
lcom
pres
sion
pres
sure
Example2
let
te
pe
ra
tu
re
The following diagrams are used to determine the pressure

dew point of the compressed air after compression:
Example1
Relative humidity [ % ]
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

of pressure
When compressed air relaxes (pressure released) the pressure dew point drops. The following table is used to determine
the new pressure dew point and atmospheric dew point after
relaxation:
op
Example1
Ov
erp
res
su
re
[b
arop
max. humidity [ g/m3 ]
Example 2
Atmospheric dew point [ C ]
Example 1
Example 2
Compressed air
Compressed air
pop = 35 bar air pressure
Pressure dew point 10 C
Pressure dew point 20 C
relaxed compressed air
relaxed compressed air
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

DIN ISO 8573-1
The quality classes for compressed air defined in DIN ISO

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 compressed air according to:
Oil content
Definition of the residual quantity of aerosols and hydrocarbons contained in the compressed air.
Particle size and density
Definition of the size and concentration of solid matter particles 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 contains. The pressure dew point changes with the air pressure.
Class
max. oil content
max. residual dust content

particle size
particle density
max. residual water content

res. water
press. dew point
[ mg/ m3]
[ m ]
[ mg/ m3]
[ g/ m3 ]
[ C ]
1
2
0,01
0,1
0,1
1
0,1
1
0,003
0,117
-70
-40
3
4
5
6
1
5
25
5
15
40
5
8
10
0,88
5,953
7,732
9,356
-20
+3
+7
+10
77
5.4
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.
Methods of drying
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
Intake temperature
T0 = 293 K
^ 1 barabs
=
= 0 barop
^ 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, appropriate 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 temperature:
Op. pressure p [ barop ]
8
1,04
Factor f
0,62 0,72 0,81 0,89 0,94
Ambient temperature tA
[ C ]
25
30
1,00
0,92
Factor t
10
11
1,06 1,09
12
14
16
1,1
1,12 1,15 1,17
35
40
43
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
= 10 barop
f = 1,09
tA
= 40 C
t = 0,79
RAd
RAd
= 45 m3/h 1,09 0,79
RAd
RAd
Adjusted through-flow rate
[ m3/h ]
Through-flow rate
[ m3/h ]
Conversion factor for p = 10 barop
Conversion factor for t A = 40 C
38,75 m3/h
With changed operating conditions the dryer has through-flow

rate of 38,75 m 3/h.
79
5.4.2
Condensation
by over-compression
Pressure
dew point
[C]
Operating
pressure
[ barop ]
Volume
flow
[ m3/h ]
approx. -70 Depends on Depends on

C
compressor compressor
With over-compression the air is compressed far beyond the

necessary pressure, and afterwards cooled and relaxed to
operating pressure.
Entry
temperature
[C]
Operating principle
With rising pressure and thus reduced volume the air is able
to hold less water. During pre-compression at high pressure
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 )
p = 1 bar
mK
p = 36 bar
p = 4 bar
Features
Simple process with continuous volume flow.
Fig. 5.7 :
Over-compression with subsequent relaxation
No expensive refrigeration and drying equipment.

Only economical for small output quantities.
Very high energy consumption.
80
5.4.3
Condensation
by refrigeration drying
Pressure
dew point
[C]
Operating
pressure
[ barop ]
to - 2 C
to 210
When the temperature falls, air loses its ability to hold water.
To reduce the moisture content, compressed air can be cooled
down in a refrigeration dryer.
Through- Entry temflow rate perature

[m3/h ]
[C]
11-35 000
to +50 C
Refrigeration drying is a process by which compressed air is

cooled down by a dryer in a heat exchanger. The moisture
contained in the air precipitates in the form of condensate.
The quantity of condensate that precipitates rises with the
difference between the entry and exit temperature of the compressed air.
Operating principle
Dry compressed air

Moist compressed air
1
2
Refrigeration drying runs in two phases. This is done to improve effectiveness and to obtain maximum use of the refrigerant.
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.
2nd Phase
The compressed air flows through a refrigerant/air heat exchanger and cools down almost to freezing point. The precipitated condensate is directed off before re-heating in the first
cooling phase.
Features:
6
4
5
1
2
3
4
5
6
=
=
=
=
=
=
Air/Air heat exchanger

Air/refrigerant heat exchanger
Refrigerant/air heat exchanger
Condensate drain
Refrigerant compressor
Vapour outlet
Highly economical.
Refrigeration drying is the most economical process in
approx. 90 % of all applications.
Separation of impurities.
Almost 100 % of all solid particles and water droplets
larger than 3 m are separated.
Lower pressure loss in the dryer.
The pressure loss p from the dryer is approx. 0,2 bar.
Fig. 5.8 :
Op. diagram of a refrigeration compressed air dryer
81
5.4.4
Diffusion
by membrane drying
Pressure
dew point
[C]
Operating
pressure
[ barop ]
0 to -20 C
5 -12,5
The principle of the membrane dryer is based on the fact that

water penetrates a specially coated hollow fibre 20 000 times
faster than air.
Through- Entry temflow rate perature

[C]
[ m3/h ]
11 - 130
2 to 60 C
The membrane dryer consists of a bundle of thousands of

coated hollow fibre membranes. These hollow fibres are made
of a solid, temperature and pressure-resistant plastic. Their
inside surface is coated with an ultra-thin (less than the length
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
Moist
flushing air
Inside flow
Water
Dry flushing
air
Dry air
Fig. 5.9 :
The principle of a membrane dryer
The moist compressed air flows through the inside of the hollow fibres ( internal flow ). The moisture contained in the air
penetrates through the layer of coating on the hollow fibres
towards the outside. To do this a concentration gradient of
moisture is required between the inside and outside of the
hollow fibres.
A quantity of air for flushing is taken from the main volume
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 flushing air flows around the hollow fibres and provides the necessary concentration gradient of moisture. The flushing air can
escape unfiltered into the open.
Features
Low level of particles in the air.
A filter must always be connected upstream of the membrane dryer, in order to filter out particles up to a size of
0.01 m. If installed directly downstream of the compressor, the filter should be connected to dust separator.
Low pressure loss in the dryer.
The pressure loss p from the dryer is max. 0.2 bar.
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 chemical reaction with a hygroscopic drying agent. Since the absorption properties of the drying agent diminish over time, periodic renewal is necessary.
Pressure
dew point
[C]
Operating
pressure
[ bar op ]
Throughflow rate
[ m3 /h ]
Entry temperature
[C]
Depends on
entry
temperature
to 30 C
There are 3 different types of drying agent. The soluble agents

liquify with increased absorption. The solid and liquid agents
react with the moisture without changing their aggregate status.
Drying agent
Soluble
Liquid
Dehydrated
chalk
Lithium chloride
Sulphuric acid
oversour
magnesium salt
Calcium chloride
Phosphoric acid
Solid
1
Glycerine
Triethylene glycol
Operating principle
1
4
3
During absorption the compressed air flows upwards through

a drying middle bed. During this it gives up some of its moisture to the drying agent. A drain directs the condensate to a
floor tank. The pressure dew point is lowered by 8 - 12 %.
Example
1
2
3
4
=
=
=
=
Screen
Solid drying agent
Cover
Condensate drain
Fig. 5.10 :
Absorption dryer with solid drying agent
Compressed air enters a dryer operating with calcium chloride at a temperature of + 30 C. The pressure dew point
achieved here is between 18 and 22 C.
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 process. 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 without 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 various regeneration processes.
Adsorption material
*)
Properties of Adsorption material *)

Obtainable
press. dew point
Entry
temperature
Regeneration
temperature
Surface
[C]
[C]
[C]
[ m2/g ]
Silicagel ( SiO2 ), raw
- 50
+ 50
120 - 180
500 - 800
Silicagel ( SiO2 ), spherical
-50
+ 50
120 - 180
200 - 300
Activated
Aluminium oxide ( Al2O3 )
- 60
+ 40
175 - 315
230 - 380
Molecular screens
( Na, AlO2, SiO2 )
- 90
+ 140
200 - 350
750 - 800
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 adsorption 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 reason 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

adsorption material :
cold regeneration
internal hot regeneration
external hot regeneration
vacuum regeneration
84
5.4.6.1
Cold regeneration
Pressure
dew point
[C]
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.
Operating Throughpressure flow rate

[ barop ]
[ m/h ]
to - 70 C
4 - 16
4 - 5600
Entry temperature
[C]
to + 60 C
Cold regeneration adsorption dryers operate according to the

pressure alternation process. With this method the desorption
( regeneration ) takes place without additional input of heat. A
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.
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
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 pressure.
Final comp.
pressure
Regeneration
air
4
1
2
3
4
5
6
= Valve block
= Non-return valve
= Perforated cover
= Outlet valve
= Pre-filter
= After-filter
Ratio of regeneration air [ % ]

Press. dew point Press. dew point
[ barabs ]
-25 to - 40 C
- 40 to -100 C
5
7
10
15
20
25,83
17,22
11,49
7,39
5,46
27,14
18,1
12,07
7,77
5,47
These values are physically fixed and it is not possible to

go below them. They are taken from the correlation between air moisture and compressed air pressure relief.
Prefiltration of intake air.
A prefilter removes most of the oil, water droplets and particles of dirt.
Postfiltration of dried compressed air.
Drying material taken with the compressed air from the
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
Pressure
dew point
[C]
to - 40 C

[ barop ]
[ m3/h ]
2 - 16
Entry temperature
[C]
200 - 5600 to + 50 C
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
material. To reverse this process heat must be brought from
outside. If the regeneration temperature of the drying material
is exceeded by heat from outside, the surface energies that
occur outweigh the adhesive forces in the drying material and
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 regeneration 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

4
2
3
5
1st Phase
Drying tank B is slowly heated by the internal heating to the
necessary regeneration temperature. If the regeneration temperature is exceeded, the moisture releases itself from the
adsorption material. Approx. 2 - 3 % of the dried flow of compressed air from the compressor relaxes and at slight pressure 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
6
7
Regeneration
air
1
2
3
4
5
6
7
8
9
=
=
=
=
=
=
=
=
=
Valve block
Non-return valve
Diversion line with perf. cover 1st Phase
Diversion line with perf. cover 2nd Phase
Heating
Stop valve
Outlet valve
Prefilter
After-filter
Fig. 5.14 :
internal hot regeneration
86
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 operating at this point.
Features
Economical with high volume flows.
Simple dryer construction.
Little dried compressed air is required to regenerate the
dryer.
Prefiltration of intake air.
A pre-filter removes most of the oil, water droplets and dirt
particles from the compressed air.
Drying materials taken with the compressed air from the
drying tank must be filtered out of the compressed air.
5.4.6.3
External hot regeneration
Pressure
dew point
[C]
Operating
pressure
[ barop ]
to - 40 C
2 - 16
Though
flow rate
[ m3/h ]
Entry temperature
[C]
500 - 15000 to + 50 C
With hot regeneration the drying and regeneration times are

around 6 - 8 hrs. During the long drying time the moisture
off the moisture.
With external regeneration air is drawn in from the atmosphere by a fan and heated in a heating register. This happens
in three phases:
Fig. 5.15 :
1st Phase
2
Dry compressed air
7
4
5
9
The drying tank B is slowly heated to the necessary regeneration temperature by the flow of hot air. Once the regeneration temperature is reached, the water releases itself from
the Adsorption material. The fan continues to supply hot regeneration air through drying tank B. This flow of regeneration
air takes on the moisture and transports it into the open through
an outlet valve.
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 atmosphere is directed through the drying tank.
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
air
Features
Economical with high volume flows

1
2
3
4
5
6
7
8
9
=
=
=
=
=
=
=
=
=
Bottom valve block

Top valve block
Diversion line with perf. cover 3rd Phase
Heating register
Fan
Stop valve
Non-return valve
Prefilter
After-filter
Higher regeneration temperatures allow a lower pressure

dew point.
Low additional consumption of compressed air.
Only a small part of the regeneration air is taken from
the pneumatic system.
Prefiltration of inlet air.
Fig. 5.16 :
external hot regeneration
87
5.4.6.4
Vacuum regeneration
Pressure
dew point
[C]

[ barop ]
[ m3/h ]
to - 80 C
4 - 16 bar 400 - 7400 to + 40 C
Entry temperature
[C]
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
off the moisture.
Fig. 5.17 :
With vacuum regeneration atmospheric air is drawn with a

partial vacuum into the drying tank. This flow of air heats externally. Vacuum regeneration occurs in two phases.
Dry compressed air
5
6
8
1st Phase
A vacuum pump draws in air from the outside. This flow of air
is heated by a heating register and drawn through the drying
tank. Once the regeneration temperature is reached, the water 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.
2nd Phase
In a cooling phase the operating temperature drops back to

the temperature of the drying tank. For this purpose the heating register is switched off and cold air from the atmosphere is
directed through the drying tank.
Features
Economical with high volume flows
7
Regeneration
air
1

1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
Bottom valve block

Top valve block
Non-return valve
Heating register
Fan
Silencer
Prefilter
After-filter
Fig. 5.18 :
Vacuum regeneration
88
No additional compressed air consumption.

No compressed air is taken from the system for regeneration.
Long utility time of drying agent.
Thermal stress on the drying agent is low.
Energy savings through lower regeneration temperature.
Prefiltration of inlet air.
5.4.7
Arrangement of the refrigeration

compressed air dryer
There are two basic possibilities for arranging a refrigeration

compressed air dryer in a compressor station. It can either be
installed before or after the compressed air receiver. No general decision on this matter is possible because there are
advantages and disadvantages with both constellations.
5.4.7.1
Dryer before the compressed air

receiver
Advantages:
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:
Fig. 5.19 :
Dryer before the compressed air receiver
Large size dryer.

The dryer must be designed for the entire effective output
of installed compressor. The dryer is often over-dimensioned 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 seldom 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

receiver
Advantages:
Favourable dryer size.
The dryer can be sized according to the actual consumption 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 behind 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 concentration 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.
unfiltered
compressed
air ( C1 )
= 100
100
C1 = Concentration of impurities before the filter.
Purified
air (C2 )
C2 = Concentration of impurities after the filter.
Fig. 5.21 :
BOGE Pre-filter, series V
= 99,99 % relevant to 3 m
C1
C2
= Filter separation rate
[%]
The concentration is usually measured in proportion of weight

per unit of volume [ g/m3 ] of compressed air. With weaker concentrations, 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 efficiency of high-performance filters. Measuring the weight proportion per unit of volume with sufficient accuracy would involve a disproportionate amount of effort.
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
0,003
= 99,99 %
100
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.
Devices that measure the pressure difference are installed in
most filters.
Fig. 5.22 :
General filter with p measuring device
If the pressure drop p exceeds the limit, either the filter must
be cleaned or the element replaced.
5.5.1.3 Operating pressure
Pressure [ barop ]
Factor f
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 appropriate conversion factors f.
0,25 0,38 0,5 0,65 0,75 0,88
10
11
12
13
14
1,13 1,25 1,38 1,5 1,63 1,75 1,88
15
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
pop = 10 bar
1,38
R7
R10
R10
= 300 m/h
R10
= 414 m/h
f
1,38
R10
= effective rate at pop = 10 bar

[ m3/h ]
R7
= effective rate at pop = 7 bar

[ m3/h ]
= 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
Pressure Separation
rate
difference
[
%]
p [ bar ]
> 0,05 bar
95 %
Particle
size
[ m ]
Residual oil
content
[ mg/m3]
> 50 m
not influenced
After coming out of the compressor, the compressed air contains water in the form of steam and also droplets of condensate. These droplets are formed during the compression process because the air is no longer able to accommodate it when
its volume is reduced.
This water normally deposits in the storage tank as the compressed air become more inert. From there the condensate is
drained off.
Operating principle
The dust separator operates according to the principle of mass
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
inertia. This causes heavy particles of dirt and water to separate. 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.
Purified air
Compressed
air flowing in
2
3
4
1
2
3
4
=
=
=
=
Vortex insert
Baffle plate
Collection chamber
Condensate drain
The condensate can be drained off automatically or by hand

from the collection chamber and properly disposed of or treated.
Features
Almost complete separation of water droplets.
Heavy particles of dust and dirt filtered out.
The filtering capacity of the dust separator depends on the
flow speed of the air. The higher the flow speed, the more
efficient the filter is. Of course, when the flow speed increases the pressure loss in the separator rises also.
Areas of application
Fig. 5.23 :
Cyclone separator
No compressed air receiver in the pipeline system.

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 downstream of the compressor. It prevents unnecessary transport of water in the pipeline.
Rising lines between the compressed air receiver and the
compressor. The line between the compressor and the receiver 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 downstream of the compressor.
93
5.5.3
Pre-filters
Pressure Separation
difference
rate
p [ bar ]
[%]
Particle
size
[ m ]
Residual oil
content
[ mg/m3]
> 0,03 bar
> 3 m
not influenced
99,99 %
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 dispensed with if the demands on the quality of the compressed
air are low.
Operating principle
Pre-filters operate according to the principle of superficial filtration. They have a purely sifting effect. The pore size determines the size of particle that can be filtered out. The impurities remain only on the outer surface of the filter elements.
Standard materials for filter elements are:
Sintered bronze.
Highly molecular polyethylene.
Fig. 5.24 :
Filtrations mechanism of surface filters
Sintered ceramics.
Bronze or brass wire ( coarse filtration ).
Pleated cellulose paper inserts.
Air flows through the filter from the outside towards the inside. An opposite direction of flow would allow the separated
particles to build up inside the filter element. The growing collection 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
Pressure Separation
difference
rate
p [ bar ]
[%]
Particle
size
[ m ]
Residual oil
content
[ mg/m3]
> 0,1 bar 99,9999 % > 0,01 m
> 0,01
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.
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 system 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
Filter material
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.
There are several advantages in this:
Increased through-flow rate.
Lower energy loss.
Longer service life.
Fig. 5.27 :
Pleated and wound filter material
Air passes through deep-bed filters from the inside towards

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 condensate 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 condensate 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.
Filter medium
Technically oil-free and

clean compressed air
Diffusion.
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

widespread material in high performance filters. It is used as a
material for deep-bed filters. The following are also used:
Metallic fibres.
Fig. 5.29
Mechanisms of deep-bed filtration
Synthetic fibres.
Features
Separation of oil in the liquid phase.
Hydrocarbons are found in two aggregate conditions in compressed 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 temperature 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
Pressure Separation
difference
rate
p [ bar ]
[%]
> 0,02 bar
99,9999
After passing through high-performance filters and dryers, the

technically oil-free compressed air still contains hydrocarbons
and diverse odorous and taste substances.
Particle
size
[ m ]
Residual oil
content
[ mg/m3]
0,01
> 0,005
There are many applications of pneumatics where these residues would lead to disruptions of production, adverse quality
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 series-connected filter ( BOGE-Microfilter Series F ).
Operating principle
The filtration of compressed air by absorption is a purely physical process. The hydrocarbons are bound to the active carbons 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 :
BOGE-Filter combination, Series AF
An active carbon filter with microfilter connected in
series
Features
Pre-filtration.
An active carbon filter must always be connected upstream
from a high-performance filter and a dryer. Unfiltered compressed air destroys the adsorbant and reduces the filtration 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
Pressure Separation
difference
rate
p [ bar ]
[%]
> 0,1 bar
Particle
size
[ m ]
Residual oil
content
[ mg/m3 ]
> 0,003
Pre-filter
After-filter
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.
An active carbon adsorber removes the hydrocarbon vapours
from the compressed air. The residual oil-content can be reduced to 0.003 mg/m. The quality of the compressed air is
better than that required for breathing air by DIN 3188. The
condensated droplets of oil are already removed by the series-connected filter ( BOGE-Microfilter Series F ).
Operating principle
The filtration of compressed air by adsorption is a purely physical process. The hydrocarbons are bound to the active carbons 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
Fig. 5.31 :
Op. plan of a
BOGE active carbon adsorber Type DC
Pre-filtration.
An active carbon filter must always be connected upstream
from a high-performance filter and a dryer. Unfiltered compressed air destroys the adsorbant and reduces the filtration effect.
After-filtration.
For safety reasons a high performance filter should be connected 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
Pressure Separation
difference
rate
p [ bar ]
[%]
> 0,09 bar
Living organisms such as bacteria, bacteriophages and viruses are a big health problem in many areas. Sterile filters
create 100 % sterile and germ-free compressed air.
Particle
size
[ m ]
Residual oil
content
[ mg/m3 ]
0,01
99,9999
Operating principle
The pre-purified flow of air is directed from outside towards
the inside through the filter element. The filter element is composed of two filter stages. The pre-filter retains microorganisms up to a size of 1 m. The second filter stage consists of a
chemically and biologically neutral, three-dimensional microfibre 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 :
BOGE Sterile filter, Series ST
Short sterile contact distances.

A sterile filter should be installed directly on the end consumer device.
Food and luxury food industry.
Pharmaceuticals industry.
Chemicals industry.
Packing industry.
Medical equipment.
99
6.
6.1
Condensate
Condensate consists primarily of the water contained in the

air drawn into the compressor and which forms during compression. 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 content of harmful substances, and for this reason it must be disposed 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 consequences are a hazard to nature and human health.
Distinctions must be made between condensate from different pneumatic systems. The condensate has different properties, depending on environmental conditions and the compressor. 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 compression chamber. The result of this is that oil-lubricated systems 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 discharged 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 marginal 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 compressor.
The summary shows the various construction types according to their method of operation.
Types of condensate drains
Manual
Manual valve
Automatic
Condensate drain
with float control
Condensate drain
with time-dependent
magnetic valve
Condensate drain
with volume
measuring
Electronic measuring
probe
Level float
When selecting condensate drains, regardless of the construction 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 subzero temperatures. The water component of the condensate
will freeze.
101
6.2.1
Condensate drains with manual

valves
The condensate collects in an appropriate tank (vessel). The

servicing or operating staff must check the level of the collection 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

control
Inside the condensate tank there is a float which controls an

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 condensate out. If the level in the tank falls below the minimum, the
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.

2
3
1
2
3
4
=
=
=
=
Inlet line
Outlet line
Drain plug
Vent
Fig. 6.1 :
Condensate drain with float control
102
Susceptible to malfunctions.
The moving parts of the system can solidify, stick or corrode through direct contact with condensate.
Regular servicing required.
As a result of its susceptibility to malfunctions, it does require regular servicing.
No external alarm signal.
Inflexible.
Float valves must be specially adapted for the condition of
the condensate.
6.2.3

time-dependent magnetic valves
The condensate is collected in an appropriate tank. At fixed,

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 compressed 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 possible 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 :
Electromagnetic drain valve
Features
Very reliable operation.
The system operates reliably, even with problematic condensates.
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
1
3
Ni2
Ni1
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
excess pressure in the housing forces the condensate out
through the line to the reprocessing facility.
As soon as the level reaches capacity sensor Ni1, the magnetic valve is electronically closed. The valve diaphragm closes
before compressed air can escape.
5
Features
Very reliable operation.

The system operates reliably, even with problematic condensates.
Large cross-section.
Even large impurities and coagulated matter can be discharged without difficulty.
Ni2
Electricity connection required.
Ni1
8
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
Inlet line
Collection tank
Pre-control line
Magnetic valve
Valve diaphragm
Dipstick
Valve seat
Outlet line
Fig. 6.3 :
Condensate drain with electronic volume measurement
104
No pressure loss.
Flexible application.
The system adapts itself automatically to changing operating conditions( e.g., varied condensate viscosity and pressure fluctuations ).
Alarm function.
If there is a malfunction in draining the condensate the
alarm mode is switched after 60 s. The magnetic valve then
opens the valve diaphragm at certain intervals.
External malfunction signal.
A red LED blinks and a potential-free signal is ready.
Wide performance range.
6.2.5
Condensate drains with level floats

for measuring the level
The level of condensate in the pipe drops and after a set time
t the control closes the drain before compressed air can escape. If the condensate level does not reach Contact 1 inside
the time t, the drain is opened at fixed time intervals and reclosed after a set period. This guarantees that the condensate
collection chamber is completely emptied.
3
2
6
1
5
4
The collected condensate is directed into the collection chamber 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 electronic control opens the magnetic valve. The pressure on the
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.
If the condensate level reaches Contact 3, the control actuates the main alarm. The switching intervals and opening times
remain unchanged.
Features
3
Cleaning cycle times.
Even with longer idle times there is no dried condensate.
No pressure loss.
1
2
3
4
5
6
7
=
=
=
=
=
=
=
Collection tank
Level float
Guide
Rising pipe
Valve diaphragm
Magnetic valve
Control line
electricity connection required.
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 content 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-making German organisation ) worksheet A 115 the limit for residual 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 properly 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 discharged 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-compliant treatment.
106
6.3.1
1
Oil-water separators
2
The oil-water separator is suitable for treating condensates

that occur during the operation of screw compressors with
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 chamber of the oil-water separator. There the excess pressure falls
without causing whirling movement in the vessel. The impurities carried with the condensate gather in the removable collector.
7
1
2
3
4
5
6
7
8
9
10
=
=
=
=
=
=
=
=
=
=
10
Condensate inlet
Pressure relief chamber
Impurity tank
Overflow pipe
Level reporter
Pre-filter
Adsorption filter
Water outlet
Oil overflow, height adjustable
Specimen removal valve
Fig. 6.5:
Op. diagram of an oil-water separator
Inside the separation vessel, the oil deposits on the surface

as a result of its lower specific density. Via a height-adjustable
overflow the oil is directed into the oil catch pan and is available for disposal.
The pre-purified condensate flows through a pre-filter that filters out the remaining droplets of oil. After that an adsorption
filter binds the last oil parts of the oil.
Note
All oil-water separation systems are water treatment plants
and must be licensed by law. The oil-water separator should
have a specification inspection symbol. The expensive licensing 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 reference liquid. A change of filter is necessary after the admissible cloudiness is reached.
No separation of oil-water emulsions.
Special reprocessing systems with emulsion-splitting apparatus is required for these stable emulsions.
Fig. 6.6 :
Oil-water separator
107
Compressed air requirement
7.
Compressed air
requirement
The first step in designing a compressor station and the respective pneumatic network is to determine the 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 section 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
air by pneumatic devices
Determining the total consumption of compressed air is often

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 consumption.
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

of cylindrical nozzles
Nozzles with a simple, cylindrical bore ( e.g., blow-out guns )

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 operating pressure and nozzle diameter :
Fig. 7.1 :
Blow-out gun
Nozzle
[ mm ]
Operating pressure [ barop ]

2
0,5
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

of paint spray guns
Paint applied by a spray gun must be even and not drip. The
nozzles of spray guns are therefore designed for an expanding, non-turbulent volume flow with a high exit speed. The consequence 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.
Fig. 7.2 :
Paint spray gun with paint tank
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 compressed air requirement. On many spray guns it is possible to
switch the types of spray.

air consumption of spray paint nozzles depending on operating pressure, nozzle diameter and type of spray :
Nozzle
[ mm ]

Flat and broad spray
3
4
5
6
7
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
Nozzle
[ mm ]

Round spray
3
4
5
6
7
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

of jet nozzles
When spraying, the medium must hit the workpiece with great
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 pressure and nozzle diameter :
Nozzle
[ mm ]

2
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

of cylinders
Compressed air cylinders are especially used in the area of

automation. A distinction is made between two types of cylinder when determining the consumption of compressed air:
The single-action cylinders use compressed air to generate 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
Spab
q = Air consumption( 1 barabs and 20 C )

Fig. 7.3 :
Clamping device with pneumatic cylinder
[ l/min ]
d = Piston diameter
[ dm ]
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 working stroke is 120 mm at 47 work cycles per minute.
112
= 100 mm
^
=
dm
= 130 mm
^
=
1,3 dm
= 7
= 47
= 1
12
= 112
1,3 7 47 1
4
= approx. 336 l/min
barabs
This cylinder consumes approx. 336 Litres of compressed
air per minute.
7.1.3

of tools
Pneumatic tools are among the most frequent consumers of

compressed air in industry and the crafts. They are large numbers of them in almost every environment.
They generally require a working pressure of 6 bar however,
there are versions that use other working pressures, depending on the application and the performance required. In these
cases the consumption of compressed air will differ from the
levels shown in the table.
Fig. 7.4 :
Drive screw powered by compressed air
The following table gives reference values for consumption of

compressed air by a number of pneumatic tools. These values
may vary for individual tools and should be regarded as averages.
Tool
Working pressure 6 barop
Drill
Screw machine
Drive screw
Air consumption
[ l/min ]
Drill up to 4 mm
4 10 mm
10 32 mm
M3
M4 M5
M6 M8
M10 - M24
Angle grinder
Vibration grinder
200
450
180
250
420
200
1000
300
700
/4 Sheet
/3 Sheet
1
/2 Sheet
250
300
400
Belt grinder
Hand grinder
Tacker, tack chuck
300
Collet chucks 6 - 8 mm
8 - 20 mm
200
450
1750
400
300
1500
1000
3000
10
60
113
Device
Working pressure 6 barop
Nailer
Air consumption
[ l/min ]
50
Sash saw ( wood )
114
300
300
Plastic and textile shears
250
350
Metal shears
Chamfer mortiser ( wood and plastic )
Chamfer plane ( phases for welding seams )
400
250
2500
900
400
3000
Rust remover
250
350
Needle rust remover
100
250
Light universal hammer

Rivet, chisel and mortise hammer
Light pick and shaft hammer
Heavy pick and shaft hammer
Pneumatic spade
Drill hammer
150
200
650
900
500
380
700
1500
3000
1500
3000
Stamp hammer( foundries )

Stamp hammer ( concrete and earth )
Vibrator ( inside - outside )
400
750
500
1200
1100
2500
7.2
Determining compressed
air requirement
When determining the compressed air requirement of a pneumatic network, it is not simply a case of adding the consumption values of the individual devices. Other factors that influence 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 figure for the compressed air requirement.
The following formula is used to determine the average usage
rate UR:
UR
TU
TR
100 %
UR = average usage rate

TU = usage time
TR = reference time
[%]
[ min ]
[ min ]
Example
A semiautomatic screwdriver is in use for 25 min in the course
of one hour.
ON
UR =
25
60
UR =
41,6 %
100 %
The usage rate UR of the tool is 41,6 %.
OFF
TU = 25
min
TR = 60
min
Fig. 7.5 :
Average operation time
The average usage rates UR of some widely used pneumatic

devices is given in the following table. The figures are based
on general experience and may deviate sharply in special
cases.
Tool
Drill
Grinding machine
Mortise hammer
Stamp hammer
Forming machine
Blow-out gun
Tooling machine
Average usage rate

30 %
40 %
30 %
15 %
20 %
10 %
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 devices to realistic conditions.
The following table gives the generally recognised values for
the simultaneity factor f:
Fig. 7.6 :
Supplying several consumer devices on a pneumatic
network
Qty. consumer devices
Simultaneity factor f
1
2
3
4
5
1,00
0,94
0,89
0,86
0,83
6
7
8
9
10
0,80
0,77
0,75
0,73
0,71
11
12
13
14
15
16
0,69
0,68
0,67
0,66
0,64
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

requirement
When defining the total compressed air requirement for a pneumatic network the consumer devices are divided into two
groups:
Automatic consumer devices.
General consumer devices.
7.2.3.1
Automatic consumer devices
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.
Working
pressure
[ barop ]
Quantity
Individual
consump.
Q [ Units ] q [ l/min ]
Qq
[ l/min ]
Automatic compressed air cylinders
336
672
Working machinery
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 usage 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
Individual Q q UR / 100
consump.
Q [ Units ] q [ l/min ]
[ l/min ]
Working
pressure
[ barop ]
Usage
rate
UR [ % ]
Quantity
Spray paint guns 1,5 mm
40
180
72
Blow-out guns 1,0 mm
10
65
19,5
Drive screw M10
20
200
120
Drills up to 20 mm
30
700
210
Angle grinders
40
500
400
Total T air consumption of all general consumer devices[ l/min ]

Simultaneity factor f
0,71
Air consumption Tf of general consumer devices
7.2.3.3
Total compressed air consumption
821,5
Tf = f T
[ l/min ]
583,3
The theoretical total compressed air consumption T is the sum

of the consumption of automatic and general devices.
TQ
Tf
982
+ 583,3
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

reserves
Allowances
[%]
Losses
Reserves
Error
5 - 25
10 - 100
5 - 15
Several allowances must be taken into account to bring the

total consumption figure for individual devices to the actual
output requirement of a compressor:
Losses v [ % ]
Losses v through leakage and friction occur in all parts of a
pneumatic system. New systems require an allowance of
approx. 5 % of total FAD to be added for losses. Since leakages and friction losses generally increase when the equipment 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 consumption 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 unnecessarily 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 conditions that are mostly unclear. If a pneumatic system is designed too small and needs to be extended later it will cause
additional costs ( equipment out of action ), and so an allowance 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
LB =
T ( 100 + v + r + e )
100
= 1826 l/min
= 5
1826 ( 100 + 5 + 10 + 15 )
LB =
100
= 10
LB =
= 15
2035 l/min = 2,04 m/min
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 unfavourable 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 additional 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
hole -
at 8 barop
Energy
Cash
[ l/min ]
[ kW ]
[ DM/Y ]
75
0,6
1350
1,5
150
1,3
2900
260
2,0
4300
600
4,4
10200
1100
8,8
20300
1700
13,2
31100
[ mm ]
120
Size
Losses
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
by emptying the receiver
The simplest way of quantifying leakage VL is by emptying the

compressed air receiver.
The supply line to the receiver is plugged . All consumer
devices in the system must be switched off. The receiver pressure 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
VL
V T ( pS p F )
VL
VT = 1000
pS
VL
Volume of leakage
[ l/min ]
pF
VT =
Volume of receiver
[l]
pS
Receiver pressure at start
[ barop ]
pF
Receiver pressure at finish
[ barop ]
Time measured
pS
= 8
bar
pF
= 7
bar
= 2
min
[ 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.
VL
1000 ( 8 7 )
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

working time
The second method of quantifying the volume of leakage VL

is by measuring the operating time of the compressor. This
method can only be used with compressors having intermittent 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 compressor.
The following formula is used to roughly quantify the volume
of leakage : VL
VL
V t 1000
m/min s 1000 l
l/min = -
s m
= 1,65
m/min
t = 30
VL = Volume of leakage
= 180
= Compressor FAD
[ l/min ]
[m3/min ]
t = Total running time of compressor

t = t1 + t2 + t3 + t4 + t5
[s]
[s]
= Measuring time
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 running time t during the measuring time T is 30 s.
VL
1,65 30 1000
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 inevitable in normal pneumatic systems. The additional costs caused
by leakage reduce the cost-effectiveness of the system considerably. 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

compressed air loss
Staff should be instructed to report leaks and damage to the

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 acceptable 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. Bubbles form immediately where there are leaks.
123
7.3.5
Reconstructing a pneumatic
network
If the leakage volume lies clearly above the levels specified in

chapter 7.3.3, reconstruction of the system should be considered.
When reconstructing a pneumatic system the following measures 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.
8.1
The type of compressor
The primary decision when installing a compressor station is

choosing the type of compressor. Screw or piston compressors are the right choice for nearly all applications.
8.1.1
Screw compressors
Screw compressors are particularly suitable for certain applications.

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 excellent as base load machines in composite compressor systems.
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
BOGE screw compressor, Series S
Screw compressors operate economically with final compression 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 also have their special areas of application. They are an ideal supplement to those of the screw compressors.
Piston compressors
Intermittent requirement.
Piston compressors are suitable for fluctuating consumption 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 compressed 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 maximum 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

pressure pmax
The receiver pressure, which fluctuates between pmin and 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:
Fig. 8.3 :
Behaviour of pressure in a compressed air receiver
Normal pneumatic networks

0,1 bar
The network should be designed so that the total pressure
loss p of the entire network does not exceed 0.1 bar.
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
Refrigeration compressed air dryer
Adsorption compressed air dryer with filter
0,6 bar
0,2 bar
0,8 bar
Compressed air treatment by filters and separators.

0,05 bar
Dust separator
0,6 bar
Filters generally
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
Piston compressors
0,5 - 1 bar
pmax - 20 %
Reserves.
Unforeseen pressure loss occurs time and again in pneumatic 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 receiver
Compressed air receivers are tanks used for storing compressed 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 compressed air.
8.3.1
Recommendations for the volume

of compressed air receivers
Determining receiver volume VR is accomplished primarily by

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 compressors it is time to work out the cycle interval, which comprises
the compressor running and idling times. The number of compressor cycles results from this.
8.3.2
Norm series and operating

pressures for sizes of compressed
air receivers
Compressed air receivers are available in sensibly graduated

volume sizes. A standard size should always be chosen to
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 instance, 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
receiver vol. [ l ]
Fig. 8.4 :
Compressed air receiver, standing
18
30
50
80
150
250
350
500
750
1000
1500
2000
3000
5000
Operating pressure up to
11 [ bar ]
16 [ bar ]
36 [ bar ]
127
8.3.3
The ideal capacity of compressed air receiver for a compressor can be defined more precisely with the aid of a formula.
Volumes of compressed air

receivers for compressors
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.
VR
V 60 [ LB/V - ( LB/V ) ]
=
Al ( pmax - pmin )
VR
LB
Fig. 8.5 :
Compressor and compressed air receiver
VR = Volume of compressed air receiver

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

( see chapter 8.4.3 )
[ 1/h ]
pmax = Cut-out pressure of compressor
[ barop ]
pmin = Cut-in pressure of compressor
[ barop ]
Despite taking all influencing factors into account, it is advisable 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 compressed air receiver
Piston compressor
Q 15
VR = --Al p
Screw compressor
Q 5
VR = --Al p

Q
15 or 5
Al
= FAD of compressor
[ m3/min ]
= Constant factor
= Allowed motor cycles / h
( see chapter 8.4.3 )
p = Pressure differential ON/OFF
128
[ m 3]
[ 1/h ]
8.4
Compressor cycle intervals
The cycle interval is an important factor in a pneumatic system. 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 requirement is covered from the volume of air stored in the receiver.
The pressure in the receiver thus drops from the cutout pressure pmax to the cut-in pressure pmin. During this time the compressor does not deliver compressed air.
The following formula is used to determine the compressor
idle time tI:
tI
tI
VR ( pmax - pmin )
LB
= Idle time of compressor

LB
8.4.2
Compressor running times
= Required FAD
[ min ]
[l]
[ l/min ]
pmax =Cut-out pressure of compressor
[ barop ]
[ barop ]
During running time the compressor compensates the pressure 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:
tR
tR
VR ( pmax - pmin )
-L )
(V
B
= Running time of compressor

LB
[ min ]
[l]
= Required FAD
[ l/min ]
= FAD of compressor
[ l/min ]
[ barop ]
[ barop ]
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 ).
A =
60
tI + tR
= Cycle speed
[ 1/h ]
tR
[ min ]
tI
[ min ]
The following table gives the allowed number of cycles for an

electric motor per hour depending on the power rating of the
motor.
130
Motor power rating

[ kW ]
Allowed cycles/ h Al
[ 1/h ]
4 - 7,5
30
11 - 22
30 - 55
65 - 90
110 -160
200 - 250
25
20
15
10
5
8.5
Examples for compressor configuration
8.5.1
Sample calculation for piston

compressors
In chapter 7.2.5 the required FAD of LB = 2035 l/min was

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

pressure pmax
The maximum compressor pressure pmax of the pneumatic

system must now be determined. Starting from the working
pressure of the consumer devices, all components in the pneumatic system must be taken into consideration:
Maximum working pressure in the system
6 barop
Pneumatic network
Pressure loss 0,1 bar
Filters
Refrig.compressed air dryer
Minimum pressure in receiver
6,9 barop
The cut-in pressure pmin must always

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

( cut-out pressure of compressor )
10 bar op
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 compressor.
Vmin =
V min =
V min =
Fig. 8.7 :
BOGE piston compressor, type RM 3650-213
LB
/ 0,6
2035 / 0,6
3392 l/min
The choice is:

Piston compressor Type RM 4150-213
8.5.1.3
Volume of the compressed air

receiver
Max. pressure pmax :
FAD
V :
10
Motor rating
30
3350 l/min
kW
Al
= 20
The volume of the compressed air receiver should be determined 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
132
bar
l/min
VR =
3000 l
8.5.1.4
Compressor cycle interval
After defining the size of the compressed air receiver it is necessary 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
pmax
10
barop
pmin
barop
LB
2035 l/min
VR ( pmax - pmin )
LB
tI
tI
3000 ( 10 - 8 )
=
2035
tI
tI
2,95 min

LB
= Required FAD
[ min ]
[l]
[ l/min ]
[ barop ]
[ barop ]

running time tR:
VR
3000 l
pmax
10
barop
pmin
barop
3650 l/min
LB
2035 l/min
VR ( pmax - pmin )
-L )
(V
B
tR
tR
3000 ( 10 - 8 )
=
( 3350 - 2035 )
tR
tR
4,56 min

LB
[ min ]
[l]
= Required FAD
[ l/min ]
= FAD of compressor
[ l/min ]
[ barop ]
[ barop ]
133
8.5.1.5
tI
tR
Motor cycle rate of compressor
=
=
The motor cycle rate is calculated from the compressor running and idle time and compared with the allowed figure Al.
2,95 min
4,56 min
Motor output rating 22 kW
Al
C =
60
tI + tR
C =
60
2,95 + 4,56
C =
= 25
= Cycles
[ 1/h ]
tR
[ min ]
tI
[ min ]
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 consumption 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

compressors
In chapter 7.2.5 the required FAD of LB = 2,04 m/min was

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

maximum pressure pmax
The maximum compressor pressure pmax of the pneumatic

system must now be determined. Starting from the working
pressure of the consumer devices, all components in the pneumatic 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,
compressed air receiver, refrigeration compressed
air dryer and filter system
Cycle differential of screw compressors
1 bar
The cut-out pressure pmax is at least
7,9 barop
Selected maximum compressor pressure

( cut-out pressure of compressor )
8.5.2.2
Determining compressor size
8 barop
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
FAD
Fig. 8.9 :
BOGE screw compressor
Motor output rate
pmax
bar
2,42 m3/min
15
kW
Al
= 25
135
8.5.2.3
Dimensioning the compressed air

receiver
The volume of the compressed air receiver for screw compressors is calculated with the aid of the following formula.
The usual sizes of standard compressed air receivers should
be taken into account.
= 2,42
m3/min
LB
= 2,04
m3/min
VR
1/h
2,42 60 [ 0,843 - 0,843 ]

VR =
25 ( 9 - 8 )
LB
V 60 [ LB/V - ( LB/V ) ]
=
Al ( pmax - pmin )
/V = 0,843
Al
= 25
pmax = 9
barop
pmin = 8
barop
VR =
0,77 m3
Selected receiver volume:

VR =
VB
Q
Fig. 8.10 :
Compressor and compressed air receiver
0,75 m3
750 l
[ m3 ]
V = FAD of all compressors

[ m3/min ]
[ m3/min ]
LB
= Required FAD
Al
= Allowed motor cycle rate
[ 1/h ]
[ barop ]
[ barop ]
The volume of the compressed air receiver can also be defined according to the BOGE recommendation, compressor
FAD to volume of compressed air receiver VR = V/3.
V = 2,46
8.5.2.4
136
Compressor cycle interval
m3/min
VR =
0,81 m
The cycle intervals and maximum allowed cycle rate of the

motor do not have to be checked with BOGE screw compressors because the microcontroller in the BOGE ARS control
unit does not allow the maximum rate to be exceeded.
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 compressor 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 purchase price, because the system pays for itself quickly if overhead 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 having too many motor cycles.
The ARS control unit aims for intermittent operation with minimum 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 hammers as examples:
Fig. 8.11 :
Hammer screw with pneumatic drive
Effective
pressure
Relative
performance
Relative
air consumption
[%]
[%]
[ bar ]
at
connection
tool
drill
hammer
tool
drill
hammer
7
6
5
4
120
100
77
55
130
100
77
53
115
100
83
64
120
100
77
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.
Fig. 8.13 :
Pneumatic clamp
138
The workpiece falls loose from the clamp while being processed by a machine tool. This can result in the destruction of
the workpiece and may also injure to the machine operator.
8.6.2
Varying working pressure of

consumer devices
If the working pressure of the various consumer devices varies 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 separate 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 second system.
The second system usually amortises itself quickly by reducing operating costs.
8.6.3
Combined compressor systems
For users of compressed air with high, heavily fluctuating consumption, a single, large compressor is not the best solution.
The alternative is to have a combined compressor system consisting of several compressors. Greater operational reliability
and greater economy are the arguments for this option.
One or more compressors cover the continuous basic requirement 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 requirement drops, the compressors are switched back off again,
one after the other.
The configuration of individual compressors ( free air delivered ) in a combined compressor system is individually so
different that no general statement are possible. The configuration depends on the pneumatic behaviour of all consumer
devices connected to the system.
Advantages
Operational reliability.
Operations heavily reliant on compressed air can guarantee 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.
Fig. 8.14 :
Diagram of a combined compressor system
Economy.
Several small compressors are easier to adjust to compressed air consumption than one large compressor. This
fact makes a system of this type more economical. If the
system is only running at half-load, there are no high running costs for a large compressor but low idling costs for
small compressors in readiness in a combined system.
139
9.
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 important 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 pneumatic 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 balance 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
Fig. 9.2 :
Compressed air receiver, standing
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 surrounding by the large surface of the receiver and the compressed air cools down. This causes a large part of the condensate to precipitate on the walls of the receiver. The condensate 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
condensate is drained regularly. Galvanising is also a useful
option if the condensate contains a high concentration of
aggressive components.
9.1.4
Operation of compressed air

receivers
Compressed air receivers may only be continuously used for

compressors with intermittent and idling modes. The area of
pressure fluctuation p must not exceed 20 % of the maximum 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

receivers
The compressed air receiver should be installed in a cool place

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

receivers
Compressed air receivers are subject to Directive for pressure

receivers ( DruckbehV ), the technical rules for Pressure receivers ( TRB ) and the DIN EN rules. These accident prevention 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
Compressed air receivers are divided into test groups as specified in 8 of pressure receiver rules.
Division into test groups
( 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
u
ro
p
II
G
u
ro
u
ro
IV
p
l=
10
00
20
20
l=
l=
u
ro
u
ro
II
Operating pressure pop [ bar ]
III
Content of pressure chamber l [ dm3 ]

Fig. 9.3 :
Diagram showing group division of compressed air
receivers
Group I
: Compressed air receivers with a maximum operating pressure p of no more than 25 bar and a
pressure content product p l of no more than
200.
Group III : Compressed air receivers with a maximum operating 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 operating 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

air receivers
Simple and unfired compressed air receivers with an operating 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 therefore 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

obligations
Accident prevention rules state that compressed air receivers

must be inspected at the installation point prior to commissioning ( TRB 531, para. 6 ), and at regular intervals after commissioning by an expert or proficient person. Compressed air
receivers must be registered at the technical inspection authority and the receiver certificate presented at the same time.
The first inspection takes place at the factory before the receiver leaves the works. All receivers are subjected to hydraulic 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

defined in 31 and 32 of the
German Directive for Pressure
Receivers
Experts as defined in 31 of the German directive for pressure receivers are:

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 regard to the inspection.
has suitable inspection equipment available, if necessary.
can verify by documentation that he has attended a stateorganised 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

receivers
The inspection prior to commissioning and periodic inspections 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 inspections.
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 initial inspection and certified that the receiver is in a serviceable condition.
( 2 ) A compressed air receiver of Group I, if used for combustible, 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 installation 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 paragraph 4.
( 2 ) A compressed air receiver of Group I, if used for combustible, 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 emission 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 authorities 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 proficient 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

directive for compressed air
receivers
Operation of compressed air receivers 13

( 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 certificate of the expert for the initial inspection and final inspection together with the appropriate documents ( drawing, certificate for materials and heat treatment ).
146
9.1.7
Fittings on the compressed air

receiver
4
The compressed air receiver is not simply a naked steel container. It needs a number of fittings to allow it to operate properly and assure the required safety.
Pressure switch.
The switch is for controlling the compressor.
Non-return valve.
A non-return valve must always be installed in the supply
line from the compressor to the receiver. With piston compressors it prevents compressed air flowing back into the
compressor during breaks in operation. With screw compressors the valve is integrated in the system.
Safety valve.
The installation of a safety valve on compressed air receivers is required by law. If the internal pressure of the receiver pN ( network pressure ) rises 10 % ove the nominal
pressure, the safety valve opens and blows out the excess
pressure.
8
3
Control flange.
The control flange with aperture is used by the inspection
authorities to connect a calibrated manometer for the pressure 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 pneumatic system or the compressor.
7
1
2
= Pressure switch
= Non-return valve or
ball shut-off valve
3 = Safety valve
4 = Control flange
5 = Manometer
6 = Ball shut-off valve
7 = Condensate drain
8 = Mounting for fittings
9 = Inspection aperture
10 = High pressure hose
Fig. 9.4 :
Compressed air receiver with fittings
10
Condensate drain.
Condensate precipitates inside the receiver and therefore
it requires an appropriate connection for the condensate
collector.
Inspection aperture.
The inspection aperture can take the form of a socket end
or hand-hole flange. It is used to check and clean the inside of the receiver. The minimum size of the aperture is
prescribed by law.
High pressure hose.
The high pressure hose connects the receiver with the compressor. It is used instead of a pipe so as not to transmit
vibration from the compressor to the pneumatic system
and to correct size deviations on connection to the system.
The pressure switch, high pressure hose and non-return valve
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 pressure 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.
Fig. 9.5 :
Safety valve on combined compressed air-oil receiver of an oil-injection cooled screw compressor
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
this happens. If the safety valve is no longer able to blow off
the entire output of the compressors the operating pressure in
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 compressors can no longer switch off automatically.
Fig. 9.6 :
Diagram symbol for a safety valve
148
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.
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 required volume flow at all times.
The necessary working pressure.
Each device in the circuit must have the necessary air pressure 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 recourse.
9.2.1
The structure of a compressed air

circuit
A pipeline circuit is made up of individual sections. This allows

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 compressed air treatment and the compressed air receiver. Distribution 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.
Compressed air receiver
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.
5
7
Connection line
2
4
6
Main line
1
2
3
4
5
6
7
=
=
=
=
=
=
=
Compressor
Non-return valve
Condensate drain
Safety valve
Compressed air dryer
Compressed air connections
Fig. 9.8 :
Compressed air supply with ring line
150
Ring line
A ring line forms a closed distribution ring. It is possible to

isolate individual sections of the network without interrupting
the supply of compressed air to other areas. This provides
assurance that compressed air will be available for most devices, even when servicing, repairs and extension work is being
carried out.
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.
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
more than 0.03 bar.
Connection line
2
4
6
Main line
Stub line
1
2
3
4
5
6
7
=
=
=
=
=
=
=
Screw compressor
Non-return valve
Condensate drain
Safety valve
Compressed air dryer
Compressed air connections
Fig. 9.9 :
Compressed air supply with stub line
9.2.1.4
The connection line
Stub lines branch off from larger distribution lines or the main
line and end at the consumer device. Outlying consumers can
be supplied through stub lines. It is also possible to supply a
complete compressed air system with stub lines. They have
the advantage of needing less material than ring lines. But
they also have the disadvantage that they must be of larger
size than ring lines and frequently cause high pressure losses.
Stub lines should always have a non-return valve which can
isolate them from the system. This makes servicing and repair
work easier.
The connection lines come from the distribution lines. They

supply consumer devices with compressed air. Since the devices 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 pressure 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 compared with smaller sizes and nearly always guarantees a reliable 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

multiple systems
Attention must be paid to the following points when connecting several compressors to a common (collective) line.
Compressed air
5
1
1
2
3
4
5
Condensate
= Screw compressor
= Water separator
= Condensate drain
= Connection line
= Collective line
1
1
2
3
4
= Screw compressor
= Piston compressor
= Connection line
= Collective line
7
5 = Expansion vessel
6 = Vent silencer
7 = Oil-water-separator
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 separator with automatic drainage must be installed after the compressor 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
Fig. 9.11 :
Unfavourable flow conditions: T and knee-piece
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 conditions 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 sections, each of which should be equipped with a non-return
valve. It is important to be able to isolate parts of the system,
particularly for inspections, repairs and conversions.
In some situations it may be of benefit to have a second compressor to supply the system from a different point. This shortens the distance the compressed air has to travel. As a result,
the pressure loss p is lower.
Fig. 9.12 :
Favourable flow conditions: Y-tube and curved pipe
Main lines and large distribution lines should be welded with

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 particles of welded metal is reduced.
153
9.3.2
Pipeline without compressed air

dryer
Compression causes the water in the air to form droplets ( condensate ). 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 humidity is constant, the relative humidity will then fall. Condensate 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.
wrong
right
Fig. 9.13 :
Examples of correctly laid piping
154
Condensate drain.
Condensate drains must be installed at the lowest points
of the system in order to drain off the condensate.
Connection lines.
The connection lines must branch off upwards in the direction of flow. The pipeline here must be as straight as possible to avoid unnecessary pressure loss.
Fittings.
A service unit with filter, water separator and pressure reduction valve should always be installed. A compressed air
lubricator may also be needed, depending on the application.
9.3.3
Pipeline system with compressed

air dryer
If there is a compressed air dryer with an appropriate filter

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 concerning the way the lines are laid are also unnecessary.
Condensate drain.
Condensate drains are only fitted at the filters, the compressed 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 consumer devices. A lubricator may be required, depending
on the application.
This considerably reduces the price of the installation. Sometimes, even the money saved here justifies installing a compressed 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 medium 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
vmax
Laminar flow is even-layered flow. The individual molecules of

the compressed air move in parallel, adjacently flowing layers.
This type of flow has two main properties:
low pressure loss.
Fig. 9.14 :
Flow and speed development with laminar flow
low heat transition.

Turbulent flow
vmax
Turbulent flow is whirly and uneven. The axially directed flow

is surrounded by constantly changing additional movement at
all points. The paths of flow all have an effect on each other
and form small whirls. This type of flow has two main properties:
high pressure loss.
Fig. 9.15 :
Image of flow and speed with turbulent flow
high heat transition.
9.4.2
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 Reynolds number Re
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
Fig. 9.16 :
Pressure loss in a pipeline
Flanged connection
Valve
Pressure loss
Leakages
Branching off
Widening
Reduction
Each change in the line hinders the flow of compressed air

within it. The laminar flow is disturbed and higher pressure
loss results.
T-Piece
3D-Curve
2D-Curve
Pressure loss in the pipe system
Pressure [ bar ]
9.4.3
Path [ m ]
The amount of pressure lost is influenced by several components 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 importance for economical operation. Pipes with too small a diameter 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 accurately 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 sections 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
158
p 1,5 % pmax
9.5.2
Nominal width of pipelines

Comparison [ DN Inch ]
Medium-weight threaded pipes made of standard structural

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 diameter 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 available 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

acc. to DIN 2440
Outside
diameter
Inside
diameter
Inside
cross-section
Wall
thickness
[ DN ]
[ mm ]
[ mm ]
[ cm2 ]
[ mm ]
1/8"
10.2
6.2
0.30
2.00
1/4"
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
[Inches ]
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 considerably 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 dependency on pipe nominal width and the fitting:
Fittings
Equivalent Pipe Length [ m ]
DN 25
Check valve
Pipe and Fitting Nominal Width [ DN ]

DN 40 DN 50 DN 80 DN 100 DN 125 DN 150
10
15
25
30
50
60
Diaphragm valve
1.2
2.0
3.0
4.5
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
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
10
15
20
0.5
0.7
1.0
2.0
2.5
3.5
4.0
T-Piece
Reduction piece D = 2d
These values must be added to the actual pipe length to obtain the effective pipe length L.
Note
Complete information about fittings and bends are not generally 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

of the pipe by calculation
The following approach formula can be used to dimension

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.
di =
1,6 103 V1,85 L
1010 p
pmax
di
= Inside diameter of pipeline
[m]
= Total volume flow
= Effective pipe length
[m]
= Target pressure loss
[ bar ]
[ m3/s ]
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 pressure 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.
m3/min
200
0,1
bar
barabs
pmax =
= 0,033 m3/s
di =
di =
1,6 103 0,0331,85 200
1010 0,1 8
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 standard nominal width is taken.
161
9.5.5
Determining the inside diameter

of the pipe di by graphics
The pipe inside diameter di can be determined easier and

faster with a nomogramme than by calculation. The major influencing 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 inside diameter di [ mm ]
Volume flow V [ m3/min ]
Pipe length L [ m ]
Pressure loss p in the pipeline[ bar ]
Operating pressure p max [ barabs ]
Example
Volume flow
m/min
Effective pipe length
200
Pressure loss
Operating pressure
p =
pmax =
0,1
8
bar
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

of the pipe di with the aid of a bar
graph
The third and simplest method of determining the pipe inside

diameter di is the bar graph. However, this method is very
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 effective 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
Operating pressure
p =
pmax =
0,1
8
Effective pipe length

Volume flow
200 m
2000 l/min
=
=
bar
barop
The nominal width of the pipe obtained is DN 40
163
9.6
Choosing the material

for pipelines
System pipelines are normally made of steel, non-ferrous metal

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 pretreatment 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 preshaped parts, fast and easy installation and cheap material.
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 particularly in small and medium-sized distribution and connection 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
Maximum operating pressure
Maximum operating temperature
DN 6 - DN 150
max. 10 - 80 barop
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 install 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 galvanised finishes.
Sizes
10.2 - 558,8 mm
max. 12.5 - 25 barop
120 C
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. Ungalvanised 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

120 C
Advantages
Stainless steel pipes are completely corrosion-proof and have
only low flow resistance ( low pressure loss ). They are absolutely 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 seamless pipes are available in hard, semi-hard and soft qualities.
Sizes

soft 6 - 22 mm
semi-hard 6 - 54 mm
hard 54 - 131 mm
max. 16 - 140 barop
100 C
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 sanitary area.
If the lines are longer, the expansion of copper due to heat
must be taken into account. The coefficient of length expansion 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 reason 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 usually harmless from a toxicological and hygienic standpoint.
Fig. 9.17:
An assortment of plastic shaped parts and fittings
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
with special adhesive. No special knowledge is necessary for
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 sunlight.
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 always guaranteed with some plastics. The composition of condensates in the network must therefore be checked beforehand.
Plastic pipes are not made in large quantities for high pressures 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
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 planning of extensions and firefighting.
Marking pipelines
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
ID number
Colour
Colour number
Air
grey
RAL 7001
Water
green
RAL 6018
Combustible liquids
brown
RAL 8001
4/5
yellow
RAL 1013
Water steam
red
RAL 3003
Acids
orange
RAL 2000
Alkalis
violet
RAL 4001
Oxygen
blue
RAL 5015
Gas
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:
Marking plates with cleartext
In writing where the line passes through a wall.

In writing at fittings and distribution points.
In colour by way of rings or continuous paint for the entire 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 of a compressor must satisfy a number

of conditions for correct operation to be assured. When considering the significance of a well-planned and well-kept installation room it is important to know that around 2/3 of all
compressor malfunctions are caused by faulty installation, inadequate 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
100 %
Electricity
intake from the
mains
When designing a compressor station it must be remembered that the compression process inside the compressor
generates a large amount of waste heat. The main principle
of thermo-dynamics applies, which states that the entire electrical power intake of the compressor is converted into heat.
The waste heat must be extracted reliably since there may
otherwise be an accumulation of heat in the compressor. If the
temperature inside the compressor is too high for too long it
can lead to mechanical damage in the compressor stage and
the drive motor.
9%
Heating
the motor
The required cooling medium (air or water) can be supplied in

two ways:
4%
Residual heat
in the compressed air
75 %
Oil cooler
13 %
Compressed air
aftercooler
1%
Heat
radiated off
95 %
of energy intake
is extracted by the
cooling medium
( Water/air )
Fig. 10.1 :
Heat distribution in a screw-type compressor with oil
injection cooling.
Air-cooling.
Air-cooling is the most common cooling method for all types
of compressor. When it is used, ventilation of the installation room is of particular importance. It must be well planned
and implemented. If not, thermal problems with the compressor are bound to occur.
Water-cooling.
Water cooling may be necessary in larger compressors if
the heat can not be properly extracted by air-cooling. Water-cooling places fewer demands on ventilation inside the
installation room.
This chapter deals primarily with the requirements and rules

applying to installation rooms for air-cooled compressors. With
the exception of information concerning ventilation, the material in this chapter can be used equally for water-cooled compressors.
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 protection rules to be followed.
10.2.1
General information regarding

the installation room
The installation room should be clean, free of dust, dry and

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 ventilated 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 compression temperature.
An additional anti-freeze facility allows ambient temperatures down to -10 C.
Maximum + 40 C.
Maximum + 35 C with sound-insulated piston-type compressors.
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 compression temperature.
170
10.2.3
Fire safety rules for installation

rooms
The following rules apply for rooms where compressors with

oil injection cooling are to be installed:
The room must have special fire protection if the compressor 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
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 network without being processed.
Always follow the appropriate drainage rules set by the local
authority.
BOGE recommends the WAMAT for processing the condensate. The purified water can be drained into the public sewage
lines. The oil is caught in a catch pan and must then be disposed of in a responsible manner.
171
10.2.5
instructions
When installing compressors, the following general points must

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 mountings. 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 cladding. Measures of this type always lead to thermal problems. An exception to this is the original BOGE sound insulation hood, which is specially designed for each individual
compressor.
10.2.6
A compressor requires a certain amount of space, and this

depends on the construction and type of compressor concerned. From this arise compressor-specific minimum distances in all directions.
The space requirement of a

compressor
The compressor must be installed to allow easy access for

operation and servicing.
Air supply possible

Wall mounting possible
Corner
inst.
possible
Compressed air
connection
Air
supply
For the cooling of a compressor to be assured, there must

be a certain minimum distance between the ventilator or
cooler and the neighbouring wall or other systems. If this is
not provided for, the effect of the ventilator or cooler is much
reduced and efficient cooling is no longer guaranteed.
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
Fig. 10.3 :
Space requirement plan for a sound-insulated
screw-type compressor, model S 21 - S 30
172
The minimum distances to walls and neighbouring equipment

and machinery can sometimes vary greatly, depending on the
types and versions of the compressors. These are to be taken
from the respective operating instructions.
10.2.7
Conditions for installing

compressed air receivers
Certain accident prevention rules must be followed when installing 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 operated 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 protection against corrosion.
Vertical receivers are brought horizontally into the compressor 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 impossible to set up the receiver.
173
10.3
Ventilation of a compressor
station
The most important requirement for operating air-cooled com

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, depending 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
cooling air of a V c of a compressor
A compressor generates a certain amount of waste heat depending 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 ( including 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 inside 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
the flow of cooling air V c to and

from a compressor
To obtain generally applicable values for the flow of cooling
airV c the following outline conditions have been set that influ
ence the volume of cooling air V c.
Room temperature
Temperature gradient t
35 C = 308 K
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 favourable 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

of compressor rooms
This chapter specifies the most important conditions concerning air supply and extraction that must be satisfied by the installation room of one or more air-cooled compressors. They
are based on the requirements set forth in VDMA specification 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 located close to the ground and the (outlet) exhaust apertures must be in the ceiling or in a side wall at the top.
The compressor must be installed next to the air inlet aperture Ain so that it draws fresh air for compression and cooling air for ventilation directly from the inlet aperture Ain.
The compressor must be positioned so that it can not reinduct its own heated exhaust air..
Fig. 10.4 :
Arrangement of air inlet and outlet apertures
Air inlet apertures

with roller shutters
The inlet apertures or ducts of the compressor must be

arranged so that dangerous admixtures ( e.g., explosive or
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
arranged accordingly.
Adjustable roller shutters must be installed in the air inlet
apertures Ain. This allows the flow of cold air from the outside 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 compressors. 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 located as far as possible below the air outlet aperture.
Experience shows that this method of ventilation is only suitable 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

for natural ventilation
An adequate flow of cooling-air V c can only be obtained with

natural ventilation if the air inlet and outlet apertures are of an
appropriate size.
The figures in the following table are based on VDMA specification sheet 4363 Ventilation of installation rooms for aircooled compressors.
VK
Ain
Aout
Drive
rating
P
[ kW ]
Fig. 10.6 :
Natural ventilation of a compressor installation room
with a sound-insulated BOGE screw-type compressor
3,0
4,0
5,5
7,5
11,0
15,0
18,5
22,0
Required flow of
cooling-air
Vc
Required ventilation apertures
[ m/hr ]
[ m ]
1350
1800
2270
3025
3700
4900
6000
7000
0,20
0,25
0,30
0,40
0,50
0,65
0,75
0,90
Ain and Aout
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 shutters, 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 station, 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
VV
Ain
Ventilator
Fig. 10.7 :
Artificial ventilation of a compressor room with a
sound-insulated BOGE screw-type compressor
10.3.5.1 Required ventilator output with

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
aid of a ventilator.
Artificial ventilation increases the flow speed of cooling air
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 controlled in several stages by a thermostat. The control depends on
the temperature in the installation room. The higher the temperature rises, the greater the output rate of the ventilator.
As with natural ventilation, the required flow of cooling air V c is

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 specification sheet 4363 Ventilation of installation rooms for aircooled compressors.
Drive
rating
178
Required
ventilator output
VV
[ kW ]
[ m/hr ]
4.0
5.5
7.5
11.0
15.0
18.5
22.0
30.0
37.0
45.0
55.0
65.0
75.0
90.0
110.0
132.0
160.0
200.0
250.0
1800
2270
3025
3700
4900
6000
7000
9500
11000
14000
17000
20000
23000
28000
34000
40000
50000
62000
70000
10.3.5.2 Required inlet air aperture with

artificial ventilation
With artificial ventilation, the exhaust ventilator determines the

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 aperture.

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:
Ain
VV
3600 vS
m/hr
3600 s/h m/s
Ain
VV
= minimum area of air inlet aperture
vS
= maximum flow speed
= Ventilator output
[ m ]
[ m/h ]
[ 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 physics 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 overcome 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

of a compressor station
A screw-type compressor, model S 21, is to be operated together with a cold compressed air dryer D 27 in a small installation 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
Cooling air req. V V2
2.66 m/min
770 m/min
( see data sheet )
The two flows of cooling air must be added together. The result is the required ventilator output that must be provided in
the installation room.
Ventilator output V Vttl

Fig. 10.8 :
Compressor station with screw-type compressor,
cooling compressed air dryer, compressed air
receiver
5670 m/hr
The required size of air inlet aperture is calculated using ven

tilator output V Vttl and the maximum flow speed vS = 3 m/s:
Ain
VVttl
3600 vS
Ain
5670
3600 3
Ain
0.525 m
Ain = minimum area of air inlet aperture

[ m ]
V Vttl = Ventilator output

[ m/hr ]
vS
[ m/s ]
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
with inlet and outlet ducts
The circulation of cooling air through inlet and outlet ducts is

an elegant solution to thermal problems in a compressor installation 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 exhaust 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.
Fig. 10.9 :
Circulation of cooling-air in a BOGE screw-type
compressor from series S 21 - S 150
10.3.6.1 Air inlet ducts
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
may be desirable in Winter to use an air circulation system
with part of the heated cooling air being released into the compressor room.
It is also possible in principle to supply cooling air to compressors 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 reason, cooling air should only be supplied through ducts in the
following situations:
Unclean environment.
The induction air at the location of the compressor contains 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 building. 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

a cool-air duct
Ain
Ad
Vd
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

and cross-section of duct Ad
when using a cool-air duct
Compressor rooms containing individual units can usually be

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.
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.
The figures for the required flow of cooling air V d with ducts
given in the following table are based on VDMA specification
sheet 4363 Ventilation of installation rooms for air-cooled compressors. An increase in the temperature of the cooling-air of
Dt = 20 K is assumed.
The calculation used to determine the required free crosssection of the duct Ad are based on a maximum dynamic pressure 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
rating
P
[ kW ]
4.0
5.5
7.5
11.0
15.0
18.5
22.0
30.0
37.0
45.0
55.0
65.0
75.0
90.0
110.0
132.0
160.0
200.0
250.0
182
Required flow of
cooling-air
with exhaust duct
Vd
[ m/hr ]
800
1000
1300
1700
2900
4500
4500
4500
6500
6500
8000
8600
9200
16000
16000
24400
24400
27800
33600
Required
free crosssection for duct
Ad
[ m ]
0.08
0.10
0.13
0.13
0.15
0.23
0.26
0.33
0.41
0.48
0.59
0.64
0.68
0.85
1.11
1.24
1.61
2.06
2.49
10.3.6.4 Information concerning ventilation

by ducting
All objects or features inside ducts, such as diversions, filters,

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 prevent 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 overcome the dynamic pressure in the duct. This means that cooling air stops flowing and the entire cooling effort for the compressor 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 specialist 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

when using an outlet duct
The size of the air inlet aperture Ain is dependent on the flow
of cooling-air Vd and the maximum flow speed vS in the aperture 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:
184
Ain
Vd
3600 vS
m/h
3600 s/h m/s
A in
Vd
= minimum area of outlet aperture

= Ventilator output
vS
[ m ]
[ m/h ]
[ m/s ]
10.3.6.6 Variations of duct-type

ventilation
The duct directs the hot exhaust air directly into the open. This
method is recommended if there are high temperatures in the
compressor room.
Cooling-air
Fig. 10.11 :
Extraction of air into the open using an outlet duct
Cooling-air
Summer operation
Cooling-air
Winter operation
The outlet duct directs the hot cooling-air directly into the open.
When temperatures in the installation room are cold, hot exhaust air is added to the cold room air through a circulation
flap. The circulatory ventilation prevents the unit from freezing
when outside temperatures are below zero. It is also recommended to have auxiliary heating to prevent a cold compressor 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
addition to the outlet duct itself.
Fig. 10.12 :
Outlet duct with circulation flap
Cooling-air
Winter operation
Cooling-air
Summer operation
Inlet air
Fig.10.13 :
Using hot cooling-air for heating
When the outdoor temperature is cold (in Winter) duct directs

all or some of the heated cooling-air from the compressor into
other rooms in the building in order to heat them. When outdoor 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
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
Safety distance
acc. to VDE 0100
186
Refrigerant air dryer
10.4.2
Installation of piston-type
compressor: an example

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

aperture 0.4m
HP hose
Refrigerant air dryer

D 12
with Bekomat 2
Condensate diverter Bekomat 2
Condensate line
Operating side
Servicing space
Servicing space
Safety distance
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

compressor station
To be able to appreciate the possibilities of heat reclamation

from compressors it must be taken into account that on the
basis of the first principle of thermodynamics the entire electricity intake of a compressor is converted into heat. In order
to make this heat useful one must know where it occurs and
what proportion of it can be economically reclaimed for further use.
100 %
Electrical
intake from the
mains
9%
Heating
the motor
The heat is always discharged with the aid of a coolant. This

coolant contains approx. 95 % of the electrical energy entering 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.
4%
Residual heat
in the compressed air
75 %
Oil cooler
13 %
Compressed air
after-cooler
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
When drawing up the balance sheet, assumptions should not

be based only on the output from the motor that the compressor needs to compress the air. The electric motor itself converts energy into heat. One must also consider the efficiency
rate of the motor, which according to the drive rating lies
between 80 % and 92 %. This again increases the amount
of heat emitted.
Heat reclamation
11.2
The most obvious use for compressor heat is to heat rooms.
Room heating
With the simplest method of room heating the compressor is

installed in the room to be heated. This means that the compressor is installed directly in the workshop or storeroom, usually 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 compressor. Sound insulation is normally required by safety rules.
11.2.1
Room heating through ducting

6
5
8
To utilise the heat emitted by a central compressor station the

heated flow of cooling air must be brought through ducts into
the rooms to be heated. This is only recommended for larger
compressors since smaller ones do not provide enough usable heat.
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.
1
2
3
4
5
=
=
=
=
=
6 =
7 =
8 =
9 =
One use of compressor heat for room heating requires a silenced compressor with ducted cooling air. BOGE screw compressors 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 piston compressors ) can not be upgraded later for utilisation of
emitted heat, even if an adjusted sound-insulation hood is
fitted.
Silenced compressor
Inlet duct
Outlet duct
Additional exhaust ventilator
Control flaps
( thermostatically controlled )
Air outlet duct
( Room heating )
Heat exchanger
Air outlet duct
( into the open for Summer operation )
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 proportion to to energy costs saved. Before installing an expensive system, it should be checked that enough heat is generated 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
For screw compressors with oil injection cooling there are

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 exchanger
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
The Duotherm BPT-System is used for heating water or hot

production water. The heart of this system is a plate heat exchanger 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.
Duotherm BPT
Operating principle
The oil heated to approx. + 90 C by the compressor circuit
flows through the plate heat exchanger. The water coming in
reverse flow through the exchanger is heated up to +70 C.
The heated quantity of water is independent of the temperature difference in this process.
Fig. 11.3 :
The heat reclamation system
BOGE-Duotherm BPT
Compressed air
outlet
1
5
9
10
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
exchanger or through a bypass.
Features
8
6
Return
11
Advance
7
1
2
3
4
5
6
7
8
9
10
11
=
=
=
=
=
=
=
=
=
=
=
Intake filter
Suction controller
Compressor stage
Combined compressed air/oil vessel
Oil separator
Thermostatic oil control valve
Oil cooler
Oil filter
Min. pressure non-return valve
Compressed air aftercooler
Heat exchanger
When the stop valves in the water inlet and outlet are closed
an enclosed space is formed at the same time. When the
water heats in this space it expands and the pressure rises.
An expansion vessel and safety valve must be installed in
order to prevent damage to the plate heat exchanger.
If the water is very dirty, a dirt pan with a maximum pore
width of 0.6 mm should be installed in the line.
Flush connections for cleaning the heat exchanger must
be fitted.
This heat exchanger is normally integrated in the compressor cabinet. It can be set up separately or fitted on site
later.
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 utility 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 separation liquid. The liquid transmits the heat and in the event of
damage it prevents the water from mixing with the oil. The
drinking water can therefore not be contaminated.
Fig. 11.5 :
The heat reclamation system
BOGE-Duotherm BSW
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
3
1
10
8
Return
6
12
13
Advance
1
2
3
4
5
6
7
8
9
10
11
12
13
=
=
=
=
=
=
=
=
=
=
=
=
=
Intake filter
Suction controller
Compressor stage
Combined compressed air/oil vessel
Oil separator
Thermostatic oil control valve
Oil cooler
Oil filter
Min. pressure non-return valve
Compressed air aftercooler
Safety heat exchanger
Pressure monitor for aperture
Expansion vessel
Fig. 11.6 :
Flow diagram of BOGE-Duotherm BSW
192
The oil from the compressor circuit heated to approx. + 90 C

flows through a pipe bundle. The separating liquid transmits
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
on the temperature difference. The heated water is subsequently directed to a appropriate container ( boiler ) from where
it can be transported to the hot water circuit.
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 exchanger or through a bypass.
11
Operating principle
Features
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
Minimum water pressure
0,5 bar
Maximum water pressure
16 bar
Maximum oil pressure
16 bar
Maximum pressure of separating liquid
10 bar
Maximum temperature ( oil and water )
+100 C
If the maximum temperature is exceeded, malfunctions will
follow and an alarm will be actuated.
Because of its size, the BSW safety heat exchanger is integrated in the compressor cabinet. It can also be set up
separately or fitted later on site.
Heat reclamation
11.3.3
How much energy is it possible

to save ?
The Duotherm-System makes available 75 % of the electrical

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 conditions vary. The calculation of savings for heating costs is based
on conventional oil heating :
Driverating
Discharged
power
[ kW ]
[ kW/h ]
Usable
quantity of
heat
[ MJ/h ]
11.0
15.0
18.5
22.0
30.0
37.0
45.0
55.0
65.0
75.0
90.0
110.0
132.0
160.0
200.0
250,0
8.9
12.3
14.8
17.7
24.4
30.3
37.7
45.5
54.9
63.1
74.0
90.0
110.5
133.5
168.3
208,9
32.0
44.2
53.2
63.7
87.8
109.0
135.7
163.8
197.6
227.1
266.4
324.0
397.0
480.6
605.8
752,0
Specific heating value H for heating oil

Price of heating oil
Heating efficiency
Operating hours
Quantity of water at
t 25 K
t 50 K
t 35 K
313 338 K 293 328 K 293 343 K
[ m3/h ]
[ m3/h ]
[ m3/h ]
0.305
0.420
0.509
0.609
0.835
1.040
1.295
1.565
1.885
2.170
2.545
3.095
3.800
4.590
5.790
7,180
0.217
0.300
0.363
0.435
0.596
0.743
0.925
1.118
1.346
1.550
1.818
2.210
2.714
3.278
4.136
5,128
0.152
0.210
0.255
0.305
0.417
0.520
0.647
0.782
0.942
1.085
1.272
1.547
1.900
2.295
2.895
3,590
38.0 MJ/l
0.40 DM/l
75 %
1000 hrs
Cost
savings
at 1000 hrs
[ DM ]
449.620.746.894.1232.1530.1905.2300.2770.3187.3740.4547.5570.6745.8500.10550,-
193
Heat reclamation
11.4
Closing remarks concerning

heat reclamation
Compressors offer enormous possibilities for saving energy

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. Remember that room heating is seldom used in Summer.
Compressor usage is also a major factor. The longer it operates, 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 compressor.
This comparison then allows the true value of the heat reclamation system to be seen. It will also show whether reclamation 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 vibrations to solid objects. In this case they are known as structure-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
Amplitude (sound pressure )
The amplitude is the periodic deviation of pressure that occurs in a sound wave.
It corresponds to the impression of loudness perceived by
human beings.
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 human beings.

Vibration form
Transient noise
A distinction is made between different forms of vibration which

cause the different impressions of sound:
Time
Crack
Fig. 12.1 :
Impressions of sound
Tone.
A tone ( pure tone ) is a sinus vibration.
Sinusoidal sound.
This is the superimposition of several tones. Several sinusoidal vibrations superimpose and form a non-sinusoidal
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:
Lp
LP
~
p
p0
~
p
= 20 lg dB
p0
= Sound pressure level

= Sound pressure
= Reference sound pressure
[ dB ]
[ Pa ]
[ 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 ( emission size ) and can be influenced by sound insulation measures among other methods.
Using the sound intensity of a machine, it is possible to calculate 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
Sound intensity[ dB ]
Pain threshold
Audibility range
Audibility threshold
Frequency [ Hz ]
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
between 10-5 Pa and 100 Pa, whereby a sound pressure of
100 Pa nearly always leads to the immediate loss of hearing
in humans.
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
pain threshold. The largest range of sound pressure perceptible 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 experiments 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. Depending 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 measurement 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.
Sound pressure level [ dB ]
Pain threshold
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 constant.
12.4.1
Distance from the sound source
The sound pressure generated from the source always diminishes 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 always radiate sound energy in the form of a semisphere because 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]
10
25
50
100
Sound pressure level reduction[ dB ( A ) ]
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
Reflections
direct sound
Fig. 12.2 :
The dissemination of sound in an enclosed space
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
walls, reflect a large amount of occurrent sound. The shape of
the surface heavily influences the reflections. If a room is padded 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. Materials with a high elasticity module, such as steel, conduct sound
very well. The damping effect is usually low.
199
Sound
12.4.3
Damping sound
Sound
Incident
sound
Reflected
Sound
Absorbed
sound
Damping is the conversion of sound energy into heat generated by the friction of particles against each other. The sound
is absorbed in this process. Damping of airborne sound is
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 frequencies are affected more and others less.
Sound damping by the air depends much on the temperature
and humidity of the air. Under normal conditions it is only perceptible from a distance of 200 m. When humidity is high e.g.,
in fog, the damping effect is greater.
Fig. 12.3 :
Sound insulation (damping) by walls
12.4.5
Dissemination of sound in pipes

and ducts
Special laws apply for the dissemination of sound in pipes and

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, particularly 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.
Fig. 12.4 :
Absorption silencer with straight elements
200
Absorption insulation.
A part of the duct is loosely filled with sound absorbent
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. Insulation of this type is not recommended in duct systems without a big exhaust ventilator.
Sound
12.4.6
Sound pressure level from many

sound sources
If there are several sources of sound in one room, the sound

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

same level
When there are two or more sound sources with the same
sound pressure level in a large room, the correlation is relatively 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
10
15
20
Increase of sound pressure level [ dB ( A ) ]
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 ].
L [ dB ( A )
]
12.4.6.2 Two sound sources with different

levels
L 1 + L2 L 1 + L
The total sound pressure of two different sound pressures

( L1 + L2 ) can be determined with the aid of a diagram. When
there are several sound sources with different levels the correlations 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
between the two levels( L1 - L2 ).
Example
L1 - L2 [ dB ( A ) ]
Fig. 12.5 :
Sound strengthened by two sources with different
levels
A compressor with a sound pressure according to DIN 45635

of 69 dB ( A ) and a compressor with a sound pressure of
74 dB ( A ) are installed in the same room. The total sound
pressure in this case is approx. 75.3 dB ( A ).
[ 74 - 69 = 5 74 + 1.3 = 75.3 ]
201
Sound
12.5
The effects of noise

150
140
130
120
110
mechanical
damage
100
deafness
90
Sound pressure level [ dB ( A ) ]
80
Hearing
impairment
70
60
vegetative
reactions
50
noise deafness
damage to inner
ear, incurable
nervous effects, stress

falling work-rate
falling concentration
40
30
20
psychic
reactions
10
Anger
Irritation
Fig. 12.6 :
Noise as a health hazard
One form of sound is noise. This is undesired, annoying or

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 temporary reduction of hearing after an 8-hour shift. If this acoustic stress continues for several years it can cause permanent 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 several hours it is very likely to result in permanent damage to
hearing.
Sound pressure of 135 dB ( A ) and above causes immediate deafness in most cases.
202
Sound
12.6
Noise protection directives
Various safety rules have been devised for workplaces to prevent 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

operations
Date 12/1974
The safety rules for noise generating operations prescribe the

following measures:
Noisy areas of over 90 dB ( A ) must be marked accordingly.
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

( VBG 16 )
Date 4/1987
12 para.3 Maximum permitted sound pressure 85 dB ( A )

when installed in workrooms. Noise to be measured at the workplace as set forth in DIN 45635.
Remark:
12.6.3
National workplace directive

Date 4/1975
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.
The sound pressure level in workrooms should generally be

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

rules concerning noise
Date 7/1984
These rules define general noise limits for commercial and

residential areas. This includes noise made by traffic as well
as industry.
Place of measurement:
0,5 m in front of the open window of the person most directly
affected by the noise.
Area
Commercial only
Mainly
Commercial
Commercial and
residential
Mainly residential
Residential
only
Med. build. and hospitals
Homes annexed to
plant buildings
204
Maximum allowed sound level

Day
Night
6.00 - 22.00 hrs 22.00 - 6.00 hrs
max. dB ( A ) max. dB ( A )
70
70
65
50
60
55
45
40
50
45
35
35
60
45
Sound
12.7
Noise measurement
When measuring noise at compressors and similar machinery 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 outside 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 several 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 usually mineral cotton ( rock wool or fibreglass ) and fluorocarbonfree, hardly flammable, self-extinguishing foam material, that
is installed in the steel sheet case.
205
13.
13.1
Composition of compressed
air costs
The operating costs for compressed air comprise three factors:

Servicing and maintenance costs.
The servicing costs are for the wages of the fitter, spare
parts and consumed materials such as lubrication and cooling 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 pipeline ). 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 electricity costs of 0,25 DM/kWh and a depreciation period of 5
years with an interest rate of 8 % .
100%
90%
80%
70%
60%
Cost factors
50%
40%
30%
Hours of operation per year

2000 Oh/y 4000 Oh/y 7500 Oh/y
[%]
[%]
[%]
20%
10%
0%
2000 Bh/J
Oh/Y
4000 Bh/J
Oh/Y
7500 Bh/J
Oh/Y
Servicing and maintenance costs

Energy costs
Capital service
Fig. 13.1 :
Composition of compressed air costs with differing
operating hours per year
206
Servicing and
maintenance
2.5
2.7
Energy costs
73
84
87
Capital service
25
13.5
10.3
It is easy to see that energy is the greatest cost factor. The

servicing and maintenance costs are more or less negligible,
and the costs for service of capital equipment are hardly a
major item in the long term. The main criterion in acquiring a
compressor system must therefore be energy consumption.
There is a breakdown of energy costs on the following page.
13.2
Cost-effectiveness calculation for energy costs

Maker
BOGE
Type
Screw compressor
Model
(1)
FAD of complete system ( V )
S21
m3/h
145.2
bar
acc. to PN2 CPTC2

Ambient temperature t = 20 C
Operating pressure
(2)
(3)
Electrical power requirement

of compressor
kW
of drive belt
kW
of transmission
kW
of fan
kW
of overall system ( Pe )
kW
Motor efficiency rating ( )
14.79
90
with IP 54 protection
(4)
Total intake ( Pi )
kW
16.43
DM/kWh
0.25
DM/h
4.11
DM/m3
0.0283
m3/h
122.4
Hours of operation per year
Bh
2000
Compressed air requirement per year
m3
244800
DM/Year
6926.-
from electricity supply

Pi = Pe ( 2 ) 100 / ( 3 )
(5)
Electricity price ( c )
(6)
Electricity costs per hour

C = Pi ( 4 ) c ( 5 )
(7)
Costs per m3 compressed air
CV = C ( 6 ) / V ( 1 )
(8)
Costs per year

Compressed air requirement ( AR )
AR/Y = Oh AR
(9)
Total costs per year

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:
Fig. 14.1
The CE symbol
Machinery directive
89/392/EEC ( from 1.1 1995 )
Low-voltage directive
73/23/EEC
EMV directive
89/336/EEC ( from 1.1.1996 )
( from 1.1.1997 )
Directive for simple unfired pressure tanks

87/404/EEC
14.1.1
EC Machinery Directive
Under the EEC directive the Council Directive for the Alignment 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 machinery 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
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 therefore very broadly defined.
A number of expressly specified devices are not covered by
the machinery directive. These include, among others, machines that are powered solely by human effort.
Electrically powered compressors made by BOGE are therefore definitely covered by the machinery directive.
208
CE-Certification
14.2
Introducing machinery to
the market
When introducing machinery to the market the following conditions 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 inspection have been observed.
The maker must be in possession of technical documentation 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 language 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 complied with.
If it is found that properly used machinery constitutes a danger 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.
Fig. 14.3
The CE Symbol
The CE symbol is not a quality or safety symbol. It can be

seen as a market registration sign or a passport. It allows the
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 country 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, serial 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 certification centre that has carried out an inspection, if necessary.
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)
(GB)
(F)
(E)
(P)
(NL)
(DK)
(S)
(N)
Dichiarazione di conformit secondo la direttiva CE 89/392/CEE

Conformity declaration in accordance with EC guideline 89/392/EEC
Certficat de conformit selon la rglementation CE 89/392/CEE
Declaracin de conformidad segn la norma EG 89/392/CEE
Declarao de conformidade segundo as Normas 89/392/CEE
Conformiteitsverklaring volgens EG-richtlijn 89/392/EEG
Overensstemmelseserklring i.h.t. EF-Maskindirektiv 89/392/EF
Konformitetsfrklaring enligt EG-riktlinje 89/392/EEC
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
uns gelieferten Ausfhrung folgenden einschlgigen
Bestimmungen entspricht, insbesondere: 89/392/EWG
Maschinenrichtlinie, 73/23/ EWG Niederspannungsrichtlinie, 87/
404/EWG Richtlinie ber einfache unbefeuerte Druckbehlter, 89/
336/EWG Richtlinie ber elektromagnetische Vertrglichkeit
(NL) verklaren hiermede, dat de onderstaande compressor inde

door ons geleverde uitvoering aan de toegepaste normen voldoet,
speciaal: 89/392/EEG, 73/23/ EEG, 87/404/EEG, 89/336/EEG
(I) dichiariamo con la presente che il compressore seguente

nellesecuzione da noi fornita corrisponde alle norme applicate, in
particolare : 89/392/CEE, 73/23/ CEE, 87/404/CEE, 89/336/CEE
(DK) erklrer hermed, at flgende kompressor i den af os

leverede udfrelse stemmer overens med de anvendte standarder,
isr: 89/392/ EF, 73/23/ EF , 87/404/ EF, 89/336/ EF
(GB) hereby declare that the following compressor in the design

delivered by us meets the standards applied, in particular: 89/392/
EEC, 73/23/ EEC, 87/404/EEC, 89/336/EEC
(S) frklarar hrmed att nedanstende kompressor i av oss

levererat utfrande uppfyller de tillmpade normerna, srskilt: 89/
392/EEC, 73/23/ EEC, 87/404/EEC, 89/336/EEC
(F) dclarons par la prsente que le compresseur dlivr

mentionn ci-dessous est conforme aux normes, en particulier: 89/
392/CEE, 73/23/ CEE, 87/404/CEE, 89/336/CEE
(N) erklrer hermed at nedenstende kompressor i den utfrelse

som er levert av oss er overensstemmelse med de anvendte
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

en la ejecucin que hemos suministrado cumple las normas
aplicadas, en particular: 89/392/CEE, 73/23/ CEE, 87/404/CEE,
89/336/CEE
(P) declaramos pela presente, que o compressor, a seguir

mencionado na verso por ns fornecida corresponde s normas
aplicadas, em especial: 89/392/CEE, 73/23/ CEE, 87/404/CEE, 89/
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)
(I)
(GB)
(F)
(E)
(P)
(NL)
(DK)
(S)
(N)
Angewendete harmonisierte Normen, insbesondere:

Norme armonizzate applicate, in particolare:
Harmonized standards applied, in particular:
Normes harmonises appliques, en particulier:
Normas armonizadas aplicadas, en particular:
Normas armonizadas aplicadas, em especial:
Toegepaste geharmoniseerde normen, speciaal:
Anvendte harmoniserede standarder, isr:
Tillmpade harmoniserade normerna, srskilt:
Anvendte harmoniserte normer, srlig:
(D)
(I)
(GB)
(F)
(E)
(P)
(NL)
(DK)
(S)
(N)
Angewendete nationale Spezifikationen, insbesondere :

Specificazioni nationali applicate, in particolare:
Spcifications nationales appliques, en particulier:
Especificaciones nacionales aplicadas, en particular:
Especificaes nacionais aplicadas, em especial:
Toegepaste nationale specificaties, speciaal:
Anvendte nationale specifikationer, isr:
Tillmpade nationella specifikationer, srskilt:
Anvendte nasjonale spesifikasjoner, srlig:
Bielefeld
prEN 1012 Teil 1

prEN 1012 Teil 1
EN 292 Teil 1+2
EN 294
EN 60204 Teil 1
EN 286 Teil 1
EN 50081-1,2
EN 50082-1,2
Sicherheitsanforderungen Kompressoren
Sicherheit von Maschinen
Sicherheit von Maschinen - Sicherheitsabstnde
Sicherheit von Maschinen - Elektr. Ausrstung
Einfache unbefeuerte Druckbehlter
Elektromagnetische Vertrglichkeit - Straussendung
Elektromagnetische Vertrglichkeit -Strfestigkeit
Gertesicherheitsgesetz
Verordnungen zum Gertesicherheitsgesetz
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 another 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 ( machine 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 circulation 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 country 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 established 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 certification centre that has carried out an inspection, if necessary.
The EC makers declaration by BOGE for installed compressors is on the following page.
212
CE-Certification
(D) Herstellererklrung gem EG-Richtlinie 89/392/EWG

(I)
(GB)
(F)
(E)
(P)
(NL)
(DK)
(S)
(N)
Dichiarazione del fabricante secondo la direttiva CE 89/392/CEE

Manufacturers declaration in accordance with EC guideline 89/392/EEC
Certficat du fournisseur selon la rglementation CE 89/392/CEE
Nota explicativa del fabricante segn la norma EG 89/392/CEE
Declarao de fabrico segundo as Normas 89/392/CEE
Fabrieksverklaring volgens EG-richtlijn 89/392/EEG
Fabrikanterklring i.h.t. EF-Maskindirektiv 89/392/EF
Tillverkarfrklaring enligt EG-riktlinje 89/392/EEC
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
gelieferten Ausfhrung zum Einbau in eine Maschine/Zusammenbau mit
anderen Maschinen bestimmt ist, und da seine Inbetriebnahme solange
untersagt ist, bis festgestellt wurde, da die Maschine, in die dieser
Kompressor eingebaut werden soll, den Bestimmungen der EG-Richtlinie
89/392/EWG i.d.F. 91/368/EWG, 73/23/ EWG Niederspannungsrichtlinie,
87/404/EWG Richtlinie ber einfache unbefeuerte Druckbehlter, 89/336/
EWG Richtlinie ber elektromagnetische Vertrglichkeit entspricht.
(NL) verklaren hiermede, dat de onderstaande compressor in de door ons

geleverde uitvoering voor montage in een machine/voor combinatie met
andere machines bestemd is en dat zijn inbedrijfstelling zolang verboden is,
tot vastgesteld is, dat de machine, waarin deze compressor gemonteerd
moet worden, aan de voorwaarden van de EG-richtlijn 89/392/EEG in de
redactie van 91/368/EEG, 73/23/ EEG, 87/404/EEG, 89/336/EEG voldoet.
(I) dichiariamo con la presente che il compressore seguente

nellesecuzione da noi fornita destinato al montaggio in una macchina /
allassemblaggio con altre macchine e che la sua messa in esercizio
vietata fintanto che non si sia constatato che la macchina, nella quale deve
venire montato questo compressore, corrisponde alle disposizioni della
direttiva CE 89/392/CEE e seguenti 91/368/CEE, 73/23/ CEE, 87/404/CEE,
89/336/CEE
(DK) erklrer hermed, at flgende kompressor i den af os leverede

udfrelse er beregnet til indbygning i en maskine/sammenbygning med
andere maskiner, og at ibrugtagning er forbudt, indtil det er konstateret, at
den maskine, som denne kompressor skal monteres i, stemmer overens
med bestemmelserne i EF-Direktiv 89/392/EF, udgave 91/368/EF, 73/23/
EF, 87/404/ EF, 89/336/ EF
(GB) hereby declare that the following compressor in the design delivered
by us is intended for installation in a machine/assembly group in line with
other machines and that it may not be commissioned until it has been determined that the machine in which this compressor is to be installed meets
the regulations laid down in EC guideline 89/392/EEC continued as 91/368/
EEC, 73/23/ EEC, 87/404/EEC, 89/336/EEC
(S) frklarar hrmed att nedanstende kompressor i av oss levererat r

avsedd fr montage i en maskin/hopbyggnad med andra maskiner, och at
dess igngsttning r frbjuden tills det konstaterats att den maskin, i
vilken denna kompressor skall monteras, uppfyller bestmmelserna i EGriktlinje 89/392/EEC i.d.f. 91/368/EEC, 73/23/ EEC, 87/404/EEC, 89/336/
EEC
(F) dclarons par la prsente que le compresseur dlivr mentionn cidessous est apte tre mont dans une machine ou en combinaison avec
dautres machines. Sa mise en service nest autorise que lorsquil a t
constat que la machine, dans laquelle le compresseur doit tre mont, est
conforme aux clauses de la rglementation CE 89/392/CEE, par la suite 91/
368/CEE, 73/23/ CEE, 87/404/CEE, 89/336/CEE
(N) erklrer hermed at nedenstende kompressor kompressor i den

utfrelse som er levert av oss er bestemt for installasjon i en maskin/
sammenbygning med andre maskiner, og at bruk av dette er forbudt til det
er fastsltt at den maskinen som dette kompressor skal bygges inn i er i
overensstemmelse med bestemmelsene i EU-Direktiv 89/392/ EF utgave
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

ejecucin que hemos suministrado est concebido para el montaje en una
mquina/o montaje conjunto con otras mquinas, y que su puesta en
servicio est prohibida hasta que se haya determinado que la mquina en
la que tiene que montarse el compresor cumple el reglamento de la norma
89/392/CEE en continuacin 91/368/CEE, 73/23/ CEE, 87/404/CEE, 89/
336/CEE
(P) declaramos pela presente, que o compressor, a seguir mencionado na

verso por ns fornecida, se destina a ser montado numa mquina/
montagem com outras mquinas e que a sua entrada em serviio est
interdita at ser definido que a mquina na qual este compressor deve ser
instalado, corresponde s prescries das Normas 89/392/CEE na verso
91/368/CEE, 73/23/ CEE, 87/404/CEE, 89/336/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)
(I)
(GB)
(F)
(E)
(P)
(NL)
(DK)
(S)
(N)
Angewendete harmonisierte Normen, insbesondere :

Norme armonizzate applicate, in particolare:
Normes harmonises appliques:
Normas armonizadas aplicadas, en particular:
Normas harmonizadas aplicadas, em especial:
Toegepaste geharmoniseerde normen, speciaal:
Anvendte harmoniserede standarder, isr:
Tillmpade anpassade normer, srskilt:
Anvendte harmoniserte normer, srlig:
Bielefeld,
prEN 1012 Teil 1

EN 292 Teil 1+2
EN 294
EN 60204 Teil 1
EN 286 Teil 1
EN 50081-1,2
EN 50082-1,2
Sicherheit von Maschinen
Sicherheit von Maschinen - Sicherheitsabstnde
Sicherheit von Maschinen - Elektr. Ausrstung
Einfache unbefeuerte Druckbehlter
Elektromagnetische Vertrglichkeit - Straussendung
Elektromagnetische Vertrglichkeit -Strfestigkeit
Beutel, Managing director design/development................................................................
213
Appendix
A.1
Symbols
A.1.1
Picture symbols defined by

DIN 28004
The following picture symbols are standardised by DIN 28 004,

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 operation 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

Filter apparatus, general
214
Liquid filter, general
Gas filter, general

Air filter, general
Active carbon filter
Gas-sorption filter
Appendix
Separators
Separator, general
Centrifugal separator, Rotation

separator
Dust separator
Gravity separator
Deposit chamber
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
Fitting with constant setting action
Fitting with safety function
Non-return flap
Miscellaneous
Dryer, general
Condensate drain
Vessel/receiver, general
215
Appendix
A.1.2
Symbols for contact units and

switching devices as per ISO 1219
The following symbols are standardised by ISO 1219 ( 8.78 ).

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 direction of flow
Pneumatic motor with two directions of flow
Single-action cylinder, return stroke

by external power
Single-action cylinder, return

stroke by spring power
Double-action cylinder
Double-action cylinder with singleside, non-adjustable damping
Double-action cylinder with twoside, 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

restriction
216
Throttle valve, adjustable
One-way restrictor
Appendix
Direction valves
2/2-Way valve
with shut-off neutral position
3/2-Way valve
with open neutral position
4/3-Way valve
with shut-off middle position
2/2-Way valve
with open neutral position
3/3-Way valve
with shut-off middle position
5/2-Way valve
3/2-Way valve with

shut-off neutral position
4/2-Way valve
4/3-Way valve
Middle position Work direction
vented
Pressure valves
Diaphragm non-return valve
Pressure relief valve, adjustable
Pressure control valve without

drain aperture, adjustable
Throttle valve
adjustable, manually operated
Emergency valve
adjustable, with air vent
Pressure control valve with drain

aperture, adjustable
Short description of connections
A, B, C
P
R, S, T
X, Y, Z
Work line
Pneumatic connection
Drain, vent
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
( closed )
Pressure connection
( with connecting line)
Dryer
Lubricator
Filter
Water separator, hand-operated
Water separator, automatic

emptying
Filter with automatic water

separator
Cooler
Service unit
( simple representation )
218
Appendix
Miscellaneous devices
Pressure measuring device
Differential pressure measuring

device
Temperature measuring device
Compressed air measuring device

Ammeter
Flow measuring device

Volumemeter
Pressure switch
Flow probe
Pressure probe
Temperature probe
219
Conversion Table
Length
from
to from
to
mm
m
m
0,03937
3,281
1,094
inch
foot
yard
2,54
0,3048
0,914
mm
m
m
to from
to
Surface
from
mm
cm
m
1,55 x 10-3
0,155
10,76
sq.inch
sq.inch
sq.ft.
645,16
6,452
0,0929
mm
cm
m
Volume
from
to from
cm
dm(litre)
dm(litre)
dm(litre)
m
0,06102
0,03531
0,22
0,242
1,308
cu.inch
cu.ft.
gallon(U.K.)
gallon(US)
cu.yard
to from
x
16,388
28,32
4,545
4,132
0,764
to
cm
dm(litre)
dm(litre)
dm(litre)
m
Volume flow
from
l/min
m/min
m/h
0,0353
35,31
0,588
cfm
cfm
cfm
x
28,3
0,0283
1,7
to
l/min
m/min
m/h
Pressure
from
bar(abs)
bar(abs)
x
14,5
14,5+Atm.
to from
to
psia
psig
0,07
0,07+Atm.
bar(abs)
bar(abs)
Force
from
to from
to
N
kW
0,2248
1,36
pound force(lbf)
HP
4,454
0,736
N
kW
from
to from
to
(C x 1,8) + 32
(F -32) / 1,8
Temperature
220
Index
A
Absorption
Adsorption
Active carbon Adsorber
ARS
Atmospheric humidity
Automatic
Autotronic
83
84
98
57
70
58
58
B
Basic units
Blaise Pascal law
Boyle-Mariotte law
6
3
7
C
CE-Certification
CE-Marking
Choice of compressor
Collective line
Combined compressor
systems
Compressed air
Advantages
Applications
Composition
Costs
Energy costs
Filters
History
Impurities
Loss
Possible applications
Properties
Quality
208
209
137
152
139
14
2, 21
7
206
207
91
1
66, 69
120
18
7
77

Cylinders
Cylindrical nozzles
Nozzles
Spray nozzles
Spray paint guns
Tools
Total
Compressed air
requirement
Allowances
Mean operation time
Simultaneity factor
Compressor
Ambient temperature
Cooling air flow VK

Cycle interval
Diaphragm
Free piston
Heat balance
Liquid ring
Lubricant
Reciprocating piston
Rotary vane
Running time
Screw
Silencing
Space requirement
Stop time
Summary
Notes for installation
Types of construction
112
109
108
111
110
113
118
67
140
Compressed air storage

Condensate separation
Determining volume
Fittings
Inspection
Installation
Manufacture
Norm series
140
141
127
147
144
141
143
127
140
142
173
142
108, 115
119
115
116
24
170
174
129
29
30
188
32
50
27
31
129
33
205
172
129
26
172
25
Compressor layout
170
Piston compressor
Screw compressor
131
135
Compressors
Axial
Displacement
Dynamic
Radial
Roots
Condensate
Disposal
Compressed air quality

Planning tips
Pulsation damping
Safety rules
Set-up
Test groups
Condesate drain
Condensate quantity
Condensate separator
Dust separator
Condensate treatment
Conformity declaration
Connection line
Control
Control unit
ARS concept
Cooling air flowVK

Costs
Compressed air
Compressed air loss
35
24
24
36
34
100
171
101
72
141
93
106
210
151
51
57
174
206
120
D
Dew point
Distribution line
Drive motor
Dryer
71
150, 151
48
Arrangement
Operating conditions
89
79
Duotherm heat exchanger

Cost savings
Duotherm BSW
Dust separator
Dying
191
191, 192
93
78
Absorption
Adsorption
Membrane drying
Over-compression
Refrigerated drying
83
84
82
80
81
E
EC-Machinery directive
Expert
208
143
F
Filter
Active carbon
MicroOperating pressure
PrePressure loss p
Sterile
97
95
92
94
92
99
Filter mechanisms
Filter separation rate
Fire safety rules
Flow
Fluidics
Frequency control
96
91
171
13, 156
5
56
H
Harmful area
Heat exchanger
Heat reclamation
38
191
188
I
Idling control
Idling mode ( L1 )
Inspection
Inspection, evidence of
Installation room
Intake filter
54
52
56
144, 146
146
169
49
221
Index
Intermittent control
Intermittent control, delayed
Isobar
Isochor
Isotherm
54
55
8
8
8
Laws
Workplace directive
203
Pressure tank directive
142
Noise
204
Safety rules for noise generating
operations
203
Safety rules for compressors
( VBG 16 )
203
Determining
120
123
121, 122
Loudness
198
level
197
M
Main line
Maker's declaration
MCS
Motor cycles
Area of application
Assemblies
Control
Cooling
Example installation
Bar diagramme
Determining by calculation
Determining by graph
Pipe length, equivalent

Pipeline
Dimensioning
Marking
Material
Nominal width
149
212
60
130
130
Multiple systems
152
Pipeline material
Copper pipes
Plastic pipes
Seamless steel pipes
Stainless steel pipes
Threaded pipes
Safety directives
Effects
203
202
Noise measurement
Norms
205
DIN 28004, Part 3

ISO 1219 ( 8.78 )
214
216
Pneumonics
Pressure
Pressure content product
Pressure definitions
Pressure dew point
Pressure loss p
Pressure ranges
Proficient person
160
164
166
167
165
165
164
157
155
154
5
10
142
51
71
75
76
156
17
143
Q
Quality classes
77
R
107
107
52
53
38
222
163
161
162
149
Pressure loss p
with compressed air dryer
without dryer
Determining
on pressure relief
Noise
Part-load
Part-load control
Physical fundamentals
Picture symbols
125
41
40
39
187
158
168
164
159
Pipe system
Determining
Allowed
WAMAT
Oil-water separator
Operating modes
Operation mode ( L2 )
Output
37
Pipe inside diameter di
Leakage
Leakage quantity
Piston compressor
53
56
8
214
Ratiotronic
Refrigeration drying
Regeneration
Cold
External hot
Internal hot
Vacuum-
Reynolds number Re
Ring main
Room heating
Economy
59
81
84
85
87
86
88
156
150
189
190
S
Safety rules
Safety valve
Screw compressor
Area of application
Assemblies
Compression process
Example installation
Method of operation
SI-System
Sound
Sound dissemination
Sound intensity level
Sound level
Assessed, dB ( A )
Sound perception
Sound pressure
Stopped/stationary ( L0 )
Stub line
Suction rate
Supertronic
Switching symbols
142
49, 148
42
125
47
42
186
43
6
199
200
196
196
197
195
196
52
151
38
59
216
T
Temperature
Test groups
Tongue valve
Treatment
Types of control
9
142
49
66
54, 60
V
Vacuum pumps
Ventilators
Ventiliation
Air inlet ducts
Artificial
Compressor rooms
Cool air duct
Ducting
Natural
Volume
Volume flow V
24
24
174
181
178
176
182
181
177
9
11

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What are some common applications of compressed air mentioned?

Table of contents

1.1 The history of compressed air ............................................... 1

2.1 The advantages of compressed air ..................................... 14

Examples of specialised applications ................................. 21

3.1 Compressors (Compactors) ................................................. 24

3.3 Piston compressors .............................................................. 37

Compressor lubricants and coolants .................................. 50

4.1 Pressure definitions .............................................................. 51

4.5 Control of several compressors .......................................... 60

5.1 Why treatment ? .................................................................... 66

6.1 Condensate .......................................................................... 100

7.1 Consumption of compressed air by pneumatic devices . 108

8.1 The type of compressor ...................................................... 125

8.3 Determining the volume of a compressed air receiver ... 127

9.1 The compressor air receiver .............................................. 140

Inspection of compressed air receivers ............................ 144

9.2 The compressed air circuit ................................................. 149

Marking pipelines ................................................................ 168

10.1 Cooling the compressor ..................................................... 169

10.3 Ventilation of a compressor station .................................. 174

cooling air of a Vc of a compressors ................................. 174

of cooling air Vc to and from a compressor ..................... 175

10.3.6.3 Required flow of cooling-air Vd and cross-section

11.1 The heat balance of a compressor station ........................ 188

12.1 The nature of sound ............................................................ 195

12.3 Human perception of sound ............................................... 197

13.1 Composition of compressed air costs .............................. 206

14.1 Introduction ......................................................................... 208

A.1 Symbols ............................................................................... 214

Fundamentals of compressed air

The history of compressed

The origin of compressed air

The first compressor - the lung

The further development of the lung

However, the lung proved to be wholly inadequate when

Fundamentals of compressed air

The first mechanical compressor - the bellows

The first applications of compressed air

The first deliberate exploitation of energy in the air is handed

Ktesibios used another property of compressed air, stored

Heron, an engineer living in Alexandria in the first century BC,

Fundamentals of compressed air

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

Fundamentals of compressed air

When in 1871 the breakthrough in the tunnel was achieved,

The experience gained using networks of pneumatic lines and

Fundamentals of compressed air

Fundamentals of compressed air

Units and formula symbols

The SI-units ( Systme International d'Units ) were agreed

The basic units are defined independent units of measure