hydraulics & pneumatics presented by: dr. abootorabi conditioning and distribution of compressed...
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HYDRAULICS & PNEUMATICS
Presented by: Dr. Abootorabi
Conditioning and Distribution of Compressed
Air
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Conditioning and Storing Pneumatic System Air
Maximum pneumatic system operating efficiency is
achieved when system compressed air is:
Consistently clean
Free from moisture
At a relatively uniform temperature
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Conditioning and Storing Pneumatic System Air
Atmospheric air contains dirt under even the best of operating
conditions.
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Conditioning and Storing Pneumatic System Air
Pneumatic systems need to carefully filter the air taken
into the compressor intake to extend the service life of:
Compressor
Other system components
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Conditioning and Storing Pneumatic System Air
Air at construction sites is dirty.
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Conditioning and Storing Pneumatic System Air
Painting requires very clean air.
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Conditioning and Storing Pneumatic System Air
The temperature of both the intake and compressed air
is important:
Temperature changes are reflected in air pressure
and volume per the general gas law
Temperature influences the ability of air to retain
water vapor
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Conditioning and Storing Pneumatic System Air
Air in a pneumatic system may be cooled before,
during, or after compression:
Intake air temperature usually depends on the
location of the compressor air intake
Intercoolers and aftercoolers are used to remove
heat of compression
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Conditioning and Storing Pneumatic System Air
Intercoolers cool compressed air between the stages of a
multiple-stage compressor.
Aftercoolers cool the air after the air has been compressed.
Either air or water can be used as the cooling medium in
these devices.
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Conditioning and Storing Pneumatic System Air
Water vapor in air is referred to as humidity:
Essential to our natural environment
Can cause problems in a pneumatic system when
the temperature of the compressed air drops to the
dew point and the vapor condenses into liquid
water
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Conditioning and Storing Pneumatic System Air
Liquid water in a pneumatic system can:
Wash away lubricants
Increase component wear
Cause inconsistent system operation
Lower the finished quality of products directly
using the air in the manufacturing process
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Conditioning and Storing Pneumatic System Air
Liquid water forms in system lines and components
whenever the air temperature decreases to the dew point.
The first step in reducing the liquid water in compressed air
is to locate the atmospheric air intake of the compressor in
a protected area.
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Conditioning and Storing Pneumatic System Air
Condensation of the water vapor in compressed air can
occur in:
Aftercooler units
Moisture separator
System receiver
Distribution system
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Conditioning and Storing Pneumatic System Air
Specific air dryers can be used in pneumatic systems to
remove moisture:
Chemical desiccant
Refrigeration units
Specialized membranes
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Conditioning and Storing Pneumatic System Air
The receiver is the storage unit for compressed air.
Typically, the receiver is a metal, cylindrical tank with
domed ends.
In addition to air storage, the receiver:
Dampens system pressure pulsations
Removes water vapor from system air
In smaller systems, serves as the mount for the
prime mover and compressor15
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Conditioning and Storing Pneumatic System Air
Formulas are available for calculating the volume needed
for a receiver.
These formulas consider:
Cubic feet of free atmospheric air needed per minute
Desired cycle time
Atmospheric, initial receiver, and final receiver air
pressures
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Air-Distribution System
The air distribution system delivers high-pressure,
conditioned air from the receiver to workstations with a
minimum of pressure drop.
The type of distribution system depends on the size of
the facility and the level of demand for compressed air.
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Air-Distribution System
Four general categories of air distribution systems are
used with pneumatic systems:
Centralized grid with fixed piping
Decentralized grid with fixed piping
Loop system with fixed piping
Flexible hoses for portable compressor systems
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Air-Distribution System
Centralized grid has one centralized compressor station
and one line network for a facility.
Decentralized grid has individual compressors in several
locations providing air to smaller distribution networks.
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Air-Distribution System
Centralized grid:
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Air-Distribution System
Decentralized grid:
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Air-Distribution System
Loop system has a main line that forms a continuous
loop with compressors located at one or more locations.
This design provides maximum airflow with a minimum
of pressure drop between the compressors and the
individual workstations.
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Air-Distribution System
Loop system:
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Air-Distribution System
Special attention must given to the setup of a hose air
distribution in order to minimize pressure drop:
Minimize hose length
Reduce the number of couplings
Eliminate kinks in the hose
Care must be taken to protect the hoses from abrasion
in the work environment.24
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Air-Distribution System
Typical hose
distribution system:
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DeVilbiss Air Power Company
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Air-Distribution System
Proper sizing of pipe for a fixed air distribution system is
difficult.
Most systems operate under a variety of work conditions:
Multiple workstations
Varying actuator loads
Intermittent actuator operation26
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Air-Distribution System
Sizing is based on:
Rated actuator air consumption
Estimate of the time actuators are actually operating
Estimate of the percentage of maximum load
delivered during actuator operation
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Air-Distribution System
The pipe in air distribution lines should be installed with
a pitch of 1 per 10 of line:
Allows liquid water to drain to water traps
Water can be remove from traps either manually
or with automatic drain devices
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Air-Distribution System
Drop lines lead from the main air distribution line to the
workstations:
Should be attached to the top side of the distribution line
This prevents water in the distribution lines from
entering the workstation lines
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Air-Distribution SystemProper slope and drop line installation:
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Final Preparation of Air at the Workstation
Final preparation of air at a workstation is accomplished
by an FRL unit:
Air filter
Pressure regulator
Lubricator
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Final Preparation of Air at the Workstation
Typical FRL unit:
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Final Preparation of Air at the Workstation
FRL air filter removes:
Airborne dirt remaining in the atmospheric air
compressed in the system
Rust and scale from the interior of the distribution
lines
Liquid water that has condensed in the drop line
Atomized oil from the operating compressor
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Final Preparation of Air at the Workstation
Typical air filter uses centrifugal force and porous filter
material to remove unwanted materials from system air:
Inlet passageway swirls the incoming air, creating a
centrifugal force that separates air and contaminants
Porous filter material traps other undesirable materials
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Final Preparation of Air at the Workstation
Typical FRL air filter:
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IMI Norgren, Inc.
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Final Preparation of Air at the Workstation
FRL filters typically have a
drain.
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Final Preparation of Air at the Workstation
The pressure regulator in an FRL unit reduces system
distribution line pressure to the level needed by
workstation tools and circuit actuators.
This unit is also necessary as air pressure in the
distribution line fluctuates due to varying air demands
and the characteristics of compressor-capacity control.
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Final Preparation of Air at the Workstation
The lubricator in an FRL unit meters oil into pressurized
system air at the workstation.
This provides lubrication for system valves, actuators,
and air-powered tools.
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Final Preparation of Air at the Workstation
Typical FRL lubricator:
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IMI Norgren, Inc.
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Final Preparation of Air at the Workstation
Rapidly moving system air passing through a lubricator
breaks up droplets of oil, forming a mist or fog.
This mist is transported through the workstation lines to
system components.
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Final Preparation of Air at the Workstation
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Final Preparation of Air at the Workstation
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Distribution System Conductors and Fittings
Effectively moving compressed air through a distribution
system requires appropriate conductors and connectors.
Conductors can be classified as:
Rigid
Flexible
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Distribution System Conductors and Fittings
Pipe is the most common rigid conductor.
Hose is the most common flexible conductor.
Conductors must be properly sized and assembled for
compressed air to be transported from the compressor
to actuators with minimal pressure drop.
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Distribution System Conductors and Fittings
Conductors and the associated fittings must be properly sized.
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IMI Norgren, Inc.
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Distribution System Conductors and Fittings
Various types of hose are available:
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Atlas Copco
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Distribution System Conductors and Fittings
Hose selection, application, and maintenance are critical
to assure air distribution with a minimum loss of
pressure:
Hoses should be no larger than necessary
Use a minimum number of fittings
Layout lines to eliminate kinks and reduce the
number of bends
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The end.
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