Compressed Air Details

7/30/2019 Compressed Air Details

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Air ManagementGS/2004

Compressed Air-

Quality Optimisation for

Pneumatic Control System

Pressure Flow rate Temperature Force


Works forFesto as an Industry Manager

Responsible for :

Industry Segment : Machine Tool,

Material Handling

& Textile Industries

Area of operations : All India

Stationed at Head office : Bangalore

Department : Sales

Contact :

email : [email protected]

Ph: 080 - 7833359

G. SenguttavanG. Sengu


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What is required for compressed airpreparation?

DryingDrying FilteringFiltering Oil removalOil removal

Compressed air quality to DIN ISO 8573 - 1Compressed air quality to DIN ISO 8573 - 1

Ensure flowEnsure flow

Regulate pressureRegulate pressure


Objective criteria for compressed air

preparation Quality

- Water content- Size of airborne particles

- Permissible / required oil content

Quantity

- Minimum / maximum cross sections for the required flow

Pressure

- Minimum / maximum pressure

- Pressure consistancy


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ENVIRONMENTAL

FACTORS Surface of Globe is entirely covered by Air

It is a mixture of gas

Nitrogen approx. 78 %

Oxygen approx. 21 %

Also traces of carbon-di-oxide, argon, hydrogen, neon,

helium, krypton & xenon


gas volume % weight %

nitrogen 78,08000 75,51000

oxygen 20,95000 23,01000

carbon dioxide 0,03000 0,04000

hydrogen 0,01000 0,00100

argon 0,93000 1,28600

helium 0,00050 0,00007

neon 0,00180 0,00120

crypton 0,00010 0,00030

xenon 0,00000 0,00004

What is in air ?


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region average widespread biggestconcent ration part icle-size part icle

mg/ m3 m m

country

- while raining 0,05 0,80 4,00

- while dryness 0,15 2,00 25,00

big city

- residential districts 0,40 7,00 60,00

- industrial districts 0,75 20,00 100,00

industrial area 3,00 60,00 1000,00

- workshops 1 to 10

- foundry 50 to 100

- cement factory 100 to 200

- waste from heating 1000 to 15000

Average content of dust in air


field of average pices part of dimension dimension per m3 weight / vol.

m m x 1000 %

10 to 30 20,00 50 28

5 to 10 7,50 1750 52

3 to 5 4,00 2500 11

1 to 3 2,00 10700 6

0,5 to 1 0,75 67000 2

80% of the contaminants are less than 2 microns in size

Only particle greater then 45 microns can be visible by

man

Size of dust in industrial districts


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Moistu re cont ent of air

Air consists of moisture in the form of water vapour

Higher the air temperature, the greater the quantity of water vapour

As the temperature drops, the water condenses

( Temperature to which air must be cooled to condense watervapour contained in the air)

Dew point temperature are between 2 5 degree centigrade


Water content in the air


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Effects on pneumatic system

Corrosion of components

Increased water in air lines

Switching operations will be disturbed

Reduction in speeds

Shorter service life


Rust due to condensate Corroded components Residue and

condensate

containing pollutants

Possible consequences for system operation and

environment


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Compressed

air-

generation

&

distribution


Compressed air Generation

Air is compressed to approx. 1 / 7 th of its volume by

the air compressor and delivered

Different types of compressors

1.Piston / Reciprocating type

2.Screw type


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Air Distribution System - Ring Main with

Interloops


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Selection of suitable material for the pipes considering

the following points

Low pressure losses

Absence of leaks at joints

Corrosion resistant

Expansion capability


Selection and

dimensioning

Nomogram for pipe selection

air quantity

lenght of tubing [m] inner diameter

of tube [mm]

system airpressure

[bar]

pressure loss [bar]

Pressure


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CQ, PQ PIPING SYSTEM

For PIPING IN FACTORIES

For PIPING ON MACHINES


ush-fit piping system for compressed air CQ & PQ

Alu - PIPE

Polyamide - PIPE

Sizes: 12, 15, 18, 22 & 28 mm


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Advantages of push-fit piping Quick & easy installation

No thread cutting & sealing required

Corrosion-free

Electrically non-conducting (PQ-PA)

Aesthetic appearance

Pressure range :

at - 20 deg. C upto 15 bar max

+70 deg. C upto 7 bar max

Vacuum : - 0.95 bar

Liquids: 0 to 10 bar (+1 to +65 deg. C)


Cost of compressed air leaks


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Drying techniques

and

filter types


Refrigeration (drying) separationPressure dew point about +2C

Adsorption dryer

Pressure dew point up to -90C

Membrane dryer

Atmospheric dew

point up to -40

Method of drying air


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Comparison on different Dryers

Cost of drying compressed air;

approx. 10 to 20 % of the cost of prod ucing the

compressed ai r


Function principle

Housing cover

Hollow fibres

Nozzles

Exhaust ports

for purging air

Membrane dryer


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Drying chamber 1

(Molecular sieve)

Na AIO!SiO!

Input filter for

contaminant0.01 um

(not LFM)

Out put filter

for granular dust

1 um (not LFM)

Optical indicator

Drying chamber 2

Reversing valve

ISO from SA dept.

~2 min switching cycle

Auto drain > 15000 operating hours

LDF - Adsorption dryer


Pre-filter

Water, dust

40 ... 25 m

Micro filter

Water, dust, oil

0.01 m

Active carbon

filter

Odours and

flavourings

Water, dust

"50 m

Cyclone separator Sterile filter

Bacteria, viruses

Filter types


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Function principle

On-off valve

100%

50%

Pressure

Time

Gradual pressure build-up

Electrical on-off valve

Manual on-off valve

Adjusting screw for time delay


General use : 1 to 12 drops/1000 lpm of air

Use only hydraulic oil, (oil viscosity 32 centistokes at 40C )

Lubrication of Air

LubricatorLOE

Lubricated air

Venturi nozzle

Unlubricated air

Pressure area


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Filter regulator

LFR

Particle filterLF

40 or 5 mLubricatorLOE

On-off valve HE

manual

Soft start valve HEL

(gradual start)On-off valve HEE / HEP

electrical / pneumaticBranching module FRM

Pressure regulator

LR / LRS / LRVS Fine filter

LFMB

1 m

Micro filter

LFMA

0.01 m

Installation

components

Series overview


Service units, D-seriesMicro, Mini, Midi, Maxi

Connection: G1/8; G1/4; G3/8;

G1/2; G3/4; G1

Grad of filtration: 0,01; 1; 5; 40 m

Pressure range: 0 7/0 12 bar

Condensate drain: manually/automatically

operated

Max. condensate capacity: 80 ml

Temperature range: - 10 + 60 C

Active carbon filter for max. 0,003 mg/m3

residual oil content

Rugged design ready to install Filter/regulators, soft-start valves,

fine/micro-filters, lubricators

Mini G 1/8

Midi G 1/2

Maxi G 1


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1955

1958

1966

1970

1986

1998

Milestone of Festo Service units2002


Sol ids Water content Oil content

Class max. particle size max. particle density max. pressure dew point max. oil concentration

[microns] [mg/m3] [0C] [mg/m3]

1 0.1 0.1 -70 0.01

2 1 1 -40 0.1

3 5 5 -20 1

4 15 8 3 5

5 40 10 7 25

6 - - 10 -

7 - - not defined -

Application Class

Mining 5

Cleaning 5

Welding machines 5

Machine tools 5

Air cylinders 5

Air valves 35

Packaging 5

Storage atmosphere 2

Sensors 2

Foodstuffs 2Photo process 1

Compressed air preparation at a glance


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PNEUMA : means breath in Greek word

Pneumatics is the name given to the branch of physics

which treats

the properties, motions and behavior of air

What means Pneuma tics ?


Advantages of Air & its Applications

An easily generated energy source

Simple storage in air receivers

Simple distribution via factory ring mains

Applications:


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Take a deep breath

Average life time a human being will breath in 285 million liters of air


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Compressed Air Details

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