S P PNEUMSYS ADVANCE ENERGY SOLUTIONS

Transcription

1 S AE P ADVANCE ENERGY SOLUTIONS

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3 ADVANCE PIPING SOLUTIONS

4 Let s be cool Breathe cool, fresh and clean air A compressor converts 90% of its power into heat. The compressor heats up, while a compressor uses less energy to compress cold air, 3 C cooler air, already results in 1% energy saving. Get the com Measure, monitor VPVision monitors y air system from supp side. It becomes the energy managemen seeking to sustain th they have achieved. SUPPLY SIDE What do you need? Optimize your efficiency Efficiency, the ratio between compressor output and kw input, is the key performance indicator of choice to optimize maintenance strategy and costs. Create a smooth ride Reduce the pressure drop A proper designed piping system allows air to flow smoothly. This results into less pressure drop. Use angular feed-ins at the main header. Avoid T-pieces and elbows as much as possible. Keep the average velocity in the pipe as low as possible. Use proper sized filters and driers. Be smart Think of alternative uses Do you really need a compressed air powered tool? Electric tools might be a better choice for some areas in your plant. infographic Disclaimer: This is a representative drawing. Consult your Compressed Air System Supplier for design specifics. meters are shown without required safety cables and If you can measure it, yo

5 plete picture r and manage. our entire compressed ply side to demand e cornerstone of an t system for any plant he energy efficiencies. Relax and save Reduce the pressure Every bar pressure reduction gives an instant win of 7% on your energy consumption. Invest in pressure regulators per production area, use receivers to reduce pressure swings in your network. DEMAND SIDE Don t overdo it Be selective with air quality If one sub-process needs an extra low dew point, place the adsorption drier at the entry point of that sub-process only. Boost your profit Manage your leakage In general there is 20-40% of leakage in a compressed air installation. VPVision can be used as a global leakage management system and helps you to rank the leaks on savings potential. Invest in an ultrasound leak detector to find the leaks. Air isnt t free because it s there Shut of sections or machines when not in use A simple manual or motorized shut off valve can save thousands of euro s/dollars. Make sure that the air is not lost through leaks, or through machines blowing off in idle position (for example vaccum nozzles o air knives). Flow meters help to determine where and when money is lost during standstill of machines. d without proper in and out straight piping runs. u can improve it.

6 Measure Use flow meters to measure and log consumption. We offer insertion probes for large diameters and in Line flow meters for small diameters up to 2 inch. VPFlowScope features > Unique 3 in 1 sensor design: flow, pressure, temperature > Built-in data logger 500,000 points. > Bi-directional flow measurement > RS485 (Modbus RTU) all parameters > Analog 4-20 ma for one parameter Monitor The VPFlowTerminal provides instant feedback on your measurements. It helps you to keep consumption at the lowest possible level. > Remote Display for Flowmeter > Add up to 4 analog auxiliary Inputs > Built-in data logger 2,000,000 points > 115V / 12 V power supply > Build in Ethernet connection Manage With VPVision, you have a state of the art web-based monitoring solution for compressed air. From supply to demand side. > Standardized hardware > Multiple factories can be interconnected > Multiple sensors logged in one system > Data is synchronized in data base > Readout via PC, IPAD LUTHRA 38, Madhu Vrinda, Dhuri Industrial Estate, Waliv Fata, Vasai (E), Dist. Thane Tel.: / Fax : rl@pneumsys.com Visit us at :

7 ADVANCE PIPING SYSTEM specializes in manufacturing pneumatic products and pressure pipeworks In order to optimize its range designed for transporting industrial fluids under pressure offers piping solutions for the following applications: Distribution of compressed air Distribution of neutral industrial gases like nitrogen Vacuum networks down to - 0,7 bar depression CORROSION RESISTANT Aluminum piping and Plastic fittings are neither attacked by atmospheric agents (humidity, aggressive environment) nor by condensates, which enables networks to remain sound and airtight throughout their long working lives. Furthermore, the cleanliness of the air or gas conveyed is maintained. RESISTANCE Mechanical: Resistance to static and dynamic pressure. Impact resistance: The system present an excellent ductile behaviour in case of a mechanical impact. Resistance to compressor oils: The components / material feature e x c e l l e n t r e s i s t a n c e t o t h e u s u a l c o m p r e s s o r o i l s ENERGY SAVING/RELIABILITY The smoothness of the pipe s inner surface and its non-corrodability allow for equal cross sections, a better air flow than for metal pipeworks. LIMITS OF USE The system is not compatible with medical air networks, flammable gases or silicon-free applications. WORKING PRESSURE AND TEMPERATURE The 12.5 bar pressure is a maximum operating pressure applicable at pipe wall temperature (fluid + ambient) between -20 C and +25 C. An increase in the temperature causes a reduction in the mechanical strength of the system components which reduced their resistance to pressure. When the fluid or the ambient temperature is higher than 25 C, the Maximum Working Pressure (MWP) must be determined via the graph opposite. 1

8 JUST CUT, PUSH & LOCK. ALL YOU NEED IS HANDS ADVANCE PIPING SYSTEM Grips before it seals NO CORROSION / RUSTING / SCALING OF FITTINGS Stainless steel teeth grip the pipe. Pipe Insert gives secondary seal Main O Ring Seal GI pipe / plastic fittings are very cumbersome to use. Once jointed become tedious / impossible to disconnect. JG Speedfit pipe and fittings require no threading / brazing / soldering or using clumsy sealing / binding compounds. To insert / remove pipe from fittings, no tools are required, simply use your hands. The Fittings are manufactured in Polymer Acetyl and using Nitrile seals. Acetyl is can withstand extreme pressures without cracking/ hardening of the material.. The teeth on the collet being manufactured in SS316 ensure they grip the pipe even under undue stress. All fittings are NSF 51 / 61 certified and are food grade. NO RUSTING/SCALING OF PIPES WATER TRAP TEE The Aluminium Pipe is having excellent weather resistant properties. Aluminum alloy (T6 / 6063) has a strong resistance to corrosion which is a result of an oxide skin that forms as a result of reactions with the atmosphere. This corrosive skin protects aluminum from most chemicals, weathering conditions, and even many acids Source: : minum/aluminum.cfm The UNIQUE water Trap Tee solves the on-going problem of moisture in a compressed air system and provides the easy alternative to the need to install Swan Necks. The ingenious inside arrangement of the fitting allows air to flow, with minimum head loss, from the main to take-off point without allowing water to follow. The moisture is retained in the ring main which can be periodically drained by means of a drain valve. 2

9 REDUCER STEM PIPE OD OD STRAIGHT ADAPTOR EQUAL ELBOW PIPE THREAD OD BSP UG104B 15 3/4 PM011514E 15 1/2 PM011516E 15 3/4 PM011814E 18 ½ PM012216E 22 3/4 UG104B 25 3/4 UG104B 32 11/ WATER TRAP TEE PM061512E PM061815E PM062215E PM062218E PM062815E PM062822E PM PM PM PIPE OD ENDS PMTT22E 22 PIPE OD PM0315E 15 PM0318E 18 PM0322E 22 PM0328E 28 UG303B 32 PORTING BLOCK JG-L-WSK 5 x ½ Connections STRAIGHT CONNECTOR PIPE OD PM0415E 15 PM0418E 18 PM0422E 22 PM0428E 28 UG403B 32 ALUMINIUM WALL BOX SIZE JGWALLBOX 1/2 1/2 JGWALLBOX 3/4 3/4 EQUAL TEE REDUCING TEE PIPE OD PM0215E 15 PM0218E 18 PM0222E 22 PM0228E 28 UG203B 32 1/2 or 3/4 female thread on the top. Both products have 3 x 1/2 female threads on the side. END STOP PIPE OD PM4615E 15 PM4622E 22 PIPE OD TUBE OD ENDS BRANCH STOP VALVE PM3018AE PM3022AE UG203B SIZE (MM) 15STV 15 22STV 22 STEM ADAPTOR STEM THREAD OD BSP Converts push fit end to male thread PM051513E 15 3/8 PM051514E 15 1/2 PM051814E 18 1/2 PM052214E 22 1/2 PM052216E 22 3/4 3

10 PIPES & FITTING FOR COMPRESSED AIR PLUG STEM COLOUR OD PEX BARRIER PIPE STRAIGHT LENGTH SIZE MM X M PM0812R 12 RED PM0815E 15 BLACK PM0818E 18 BLACK PM0822E 22 BLACK PM0828E 28 BLACK UG803E 32 BLACK COMPRESSED AIR FITTINGS BRASS FITTINGS WATER TRAP TEE CONVERTOR 15BPEX-20x3L 15 x 3 22BPEX-20x3L 22 x 3 28BPEX-10 x 3L 28 x 3 3 metre straight lengths. 12 to 22mm in packs of mm in packs of 10. Note : PEX Barrier pipes are flexible (upto 22 mm) and can be concealed behind wall. 15 mm pipes are available in coil form and can be directly bent around walls and pillars to reduce connectors SIZE ALUMINIUM PIPE WTC28 28 SIZE MM x M WINGBACK ELBOW BRASS STRAIGHT ADAPTOR PIPE OD THREAD PM15WB 15 1/2 BSP PM22WB 22 3/4 BSP UGPWB /4BSP PIPE OD THREAD MM011504N 15 1/2 BSPT MM012206N 22 3/4 BSPT MM012808N 28 1 BSPT AL-RM1513-3M-20B 15 x 3 AL-RM1816-3M-20B 18 x 3 AL-RM2220-3M-20B 22 x 3 AL-RM2826-4M-10B 28 x 4 AL-RM x 4 AL-RM x 3 3 metre straight lengths. 15mm to 22mm in packs of mm in packs of metre / 4 metre straight lengths are available on request ACCESSORIES ALUMINIUM PIPE CUTTER : ALPC 1528 SIZE : Cuts 15 mm - 32 mm OD Pipe MALE BRASS STEM ADAPTOR FEMALE BRASS STEM ADAPTOR STEM OD THREAD MM051504N 15 ½ BSPT MM052206N 22 3/4 BSPT MM052818N 28 1 BSP MM052226N 22 3/4 NPT MM052228N 22 1 NPT MM052828N 28 1 NPT MM0532N 32 1 BSPT STEM OD THREAD MM501514N 15 1/2 BSP MM502216N 22 3/4 BSP COLLET COVERS PIPE CLIPS AND SPACERS PIPE OD COLOURS PM1912E 12 BLACK PM1915E 15 BLACK PM1918E 18 BLACK PM1922E 22 BLACK CLIP PIPE OD COLOURS PC15E 15 BLACK PC22E 22 BLACK PC28E 28 BLACK 4

11 ADVANCE PIPING SYSTEM STRAIGHT ADAPTOR REDUCER PIPE THREAD OD BSP QEAL ½ QEAL QEAL ½ Note : Female adaptors also available of same threads on request. PIPE THREAD OD BSP PM PM PM PM PMQ EQUAL ELBOW PIPE OD Q4M40 40 Q4M50 50 Q4M63 63 WATER TRAP TEE CONVERTOR USED PIPE FOR WTC40 SADDLE 40 WTC50 SADDLE 50 WTC63 SADDLE 63 STRAIGHT CONNECTOR PORTING BLOCK (RAILING MOUNTED) PIPE OD PART PORT PORT NO. INLET OUTLET QMA40 40 QMA50 50 QMA63 63 EQ ½ 4P EQ ½ 5P Note : Mounting Rail can be fixed on wall and manifold block position is adjustable. END STOP BRASS BODY (THREADED) BALL VALVE PIPE OD QBO40 40 QBO50 50 QBO63 63 MODEL SIZE 12MISTRAL ½ 34MISTRAL 3/4 1MISTRAL 1 114MISTRAL 1 1/4 112MISTRAL 1 ½ 2MISTRAL 2 EQUAL TEE STEM ADAPTOR PIPE PIPE THREAD OD BSP QTE40 40 QTE50 50 QTE63 63 AL32112E 32 1 ½ AL40114E 40 1 ½ AL502E 50 2 AL63212E 63 2 ½ ALUMINUM PIPE PLUG SIZE LENGTH MM/SM OF PIPE (DIA OF PIPE) (METERS) AL-RM M-20B 40MM 5 AL-RM5047-5M-20B 50MM 5 AL-RM63-6M-20B 63MM 6 OD COLOR UG804E 40 BLACK UG805E 50 BLACK UG806E 63 BLACK Note : John Guest Fittings are available from 15mm - 32mm size only. 5

12 ADVANCE PIPING SYSTEM PIPE CLIPS AND SPACERS Ref. PIPE OD COLOR CALE3263 spacer height 20 mm BLACK SPACER CALE3263/4 spacer height 4 mm BLACK HCKC32/8 32 mm BLACK HCKC40/8 40 mm BLACK HCKC50/8 40 mm BLACK HCKC63/8 63 mm BLACK SADDLE CLAMPS Ref. Description QSB3234 Pipe Dia 32 mm X3/4" BSP (F) QSB4034 Pipe Dia 40 mm X3/4" BSP (F) QSB5034 Pipe Dia 50 mm X 3/4" BSP (F) QSBS6350 Pipe Dia 50mm X 1" BSP (F) QSB6334 Pipe Dia 63mm X 3/4" BSP (F) QSBS6363 Pipe Dia 63 mm X 1" BSP (F) DRILLING JIG & CUTTER FOR MAKING HOLE IN PIPE S CLAMPS SHUT OFF VALVE Part No.. Size 15 S BEND 15 MM Part No.. Size Ref. Description HSV12 1/2" DJD32 DJD40 DJD50 DJD63 DJDU Drill Hole 32 mm Drill Hole 40 mm Drill Hole 50 mm Drill Hole 63 mm Drill Hole mm UNIVERSAL COUPLING 3 PIECE COUPLING DRILLING JIG & CUTTER FOR MAKING HOLE IN PIPE Ref. Description KENNEDY ARBOR with SAW CUTTER WITH DCU (drill bit is included in the above) Part No. Size (BSP) /4" X 1 1/ ½" X 1 ½ " X /2" X 2 1/2" DCU Spare SAW BELL Part No. Size (BSP) SPANNERS 1557G ½" X ½ 1557G /4" X 3/4 1557G " X 1 Ref. Description QCLE2040 QCLE50 QCLE63 SIZE 40 MM SIZE 50 MM SIZE 63 MM 40 MM - 63 MM DIA FITTINGS CANNOT BE TIGHTENED WITHOUT THE ABOVE SPANNERS GENERAL PIPE SPANNERS SHOULD NOT BE USED TO TIGHTEN THESE FITTINGS U CLAMPS Size 15 U BEND 15 MM RUBBER LINED CLIPS Rubber Lined MSTR35 MSTR42 MSTR48 MSTR60 MSTR90 Size 32 mm 40 mm 50 mm 63 mm 90 mm MSTBPF Backplate (Female) MSTBPM Backplate (male) M8 M8 6

13 ADVANCE PIPING SYSTEM METAL SUPPORT BRACKET FILTER / REGULATOR / LUBRICATOR : F/R/L Ref. Description L Shaped Slotted Channel LMSB6-6 6" X 6 LMSB6-8 6" X 8" LMSB8-12 8" X 12 STRAIGHT SLOTTED CHANNEL SMSB12 12" LONG Ref. 12FRPL 12FR 14FRPL 14FR 34FRPL 1FRPL Description ½" FR + L ½" FR 1/4" FR + L ½" FR 3/4 FR+L 1 FR+L DEBURRING CONE TRIMMER Ref. Description Ref. Description CONE50U Deburring till 50 mm Dia EBAV FOR REMOVING BURRS FROM OUTER DIAMETER OF PIPE SUSPENDED SUPPORT WITH CLIP ADAPTOR TIE ROD Ref. Description Ref. Description SSA (SIZE M8) FOR SUSPENDING FROM CEILING (TIE ROD NOT INCLUDED) TRM8 M8 X 3 METRES GIRDER CLAMP WITH CLIP ADAPTOR RECOIL HOSE Ref. Description Ref. Description GCMP (SIZE M8) FOR FIXING TO GIRDERS OR BRACKET SUPPORTS (TIE ROD NOT INCLUDED) 12MM06M 12MM10M 12 MM OD X 6 MTRS 12 MM OD X 10 MTRS. 7

14 QUICK COUPLER SPECIFICATION APPLICATIONS MATERIAL WORKING PRESSURE STEEL 2 15kgf/cm ZDC kgf/cm * * * * Pneumatic tools. Air piping. Air pressure equipment. Water piping. MAXIMUM PRESSURE 2 20 kgf/cm 2 15 kgf/cm FEATURES TEMP. RANGE SIZE -20ºC~+80ºC 1/4 (20 type) 3/8 (30 type) 1/2 (40 type) * * * * One-way automatic shut-off valve in the socket. Wide variety provides best choice according to application. Hardened important parts are extremely wear resistant and durable. Tested 100,000 times, coupler connection is accurate and reliable. Variety of connections Conditions-Fluid : Air Temperature: Room temperature Female thread F 2000 Male thread M Pflow rate (.../min) Pressure (kg/cm ) 40SP 30SP 20SP MATERIAL : STEEL 20SHA 1/4 (PT) 20PFA 1/4 (PT) 30SHA 3/8 (PT) 30PFA 3/8 (PT) 40SHA 1/2 (PT) 40SHA 1/2 (PT) 20SHA 1/4 (PT) 20PFA 1/4 (PT) 30SHA 3/8 (PT) 30PMA 3/8 (PT) 40SHA 1/2 (PT) 40PMA 1/2 (PT) 20SHA 5X8MM 20PPA 5X8MM 30SHA 6.5X10MM 30PPA 6.5X10MM 40SHA 8X12MM 40PPA 8X12MM 8

15 ADVANCE PIPING SYSTEM CUTTING The roller pipe-cutter for plastics PIPE CUTTER PIPE CUTTER Ø mm Ø 28 to 63mm TRIMMING AND CHAMFERING CONE CHAMFERING TOOL One side it trims the inside of the pipe, on the other side it chamfers the outside. Ref. CONE 50 U This tool chamfers pipes outside from Ø 50 to Ø 160. Ref. CHANF160 DRILLING JIG ARBOR WITH DRILL BIT AND CIRCULAR SAW CUTTER This is used to hold the pipe in place when trying to drill a hole in it. It is available for specific sizes of pipe in 32mm / 40 mm / 50 mm and 63 mm and also One universal size adaptable from 32 mm - 63 mm Ref. DJD32-63 and DJDU for Universal size Used to drill a hole in the pipe. It has to be fixed to the drilling head of a drilling machine and can be inserted in the drilling jig which guides it to give a clean cut in the pipe. Chamfering Tool CHANF160 can be used to remove any burrs from the cut surface. Ref. SAW for Circular Saw cutter Ref. KENNIDY for Arbor with Drill bit PLASTIC SPANNER The Spanner assists in tightening of the nut for 40mm - 50mm and 63mm Dia fittings by making one last quarter turn to completely ensure fixation of the pipe in the fitting. Ref. QCLE2040 : Size 40 mm Dia Ref. QCLE50 : Size 50 mm Dia Ref. QCLE63 : Size 63 mm 9

16 SADDLE CLAMP INSTALLATION ON PIPE FOR DROPS 1. DRILLING 2. TRIMMING Mark the brach saddle s location and drill the pipe with a 19 mm diameter bell saw for saddles with 1/2 or 3/4 threaded branches.note : when drilling small pipes, take all precautions to prevent the bell saw from reaching too deep. Trim the hole on both sides of the pipe wall and remove the aluminum filings in order to keep the pipework clean. 3. INSTALLING THE SADDLE 4. INSTALLING THE WATER TRAP TEE CONVERTOR Put the saddle in position and tighten each screw in an alternate sequence until both halves are in contact. 5. SEALING THE TREAD The UNIQUE water trap tee convertor solves the on-going problem of moisture in a compressed air system and provides the easy alternative to the need to install Swan Necks. The ingenious inside arrangement of the fitting allows air to flow, with minimum head loss, from the main to take-off point without allowing water to follow. The moisture is retained in the ring main which can be periodically drained by means of a drain valve. Ref. WTC32 / 40 / 50 / 63 for insertion in Saddle clamps of sizes 32 mm / 40 mm / 50 mm and 63 mm. Roll PTFE tape around the John Guest make 22 mm x 3/4 Or 15 mm x 3/4 BSP Male adaptor, making approx 5 turns following the thread s direction ILLUSTRATIONS FOR TYPES OF SADDLE DROPS WHICH CAN BE USED TO PREVENT CONDENSATE FROM RUNNING DOWN TO THE DROPS 1 3 Ė Ė Ė Ė Ė Straight Drop Right Angle Drop Flexible Bend Drop 2 1. Threaded Clamp 2. Cover 3. Thread 4. Seal 6. Nut 7. Washer 10

17 FITTINGS AND PIPES FOR HIGH PRESSURE APPLICATIONS Part Number Size Length NP Mt Mt Mt Mt Mt Mt Mt. 16 Bars Part Number Ø NP Coupling x x x x x x x90 16 Bars Male Adaptor x1/ x3/ x x1.1/ x x x3 16 Bars Female Adaptor x1/ x3/ x x1.1/ x1.1/ x2 90x3 16 Bars 90 Tee x20x x25x x32x x40x x50x x63x x90x90 16 Bars 11

18 FITTINGS AND PIPES FOR HIGH PRESSURE APPLICATIONS Part Number Ø NP Female Threaded 90 Tee x1/2 x x3/4 x x1 x x1.1/4 x x1.1/2 x x2 x x3 x90 16 Bars 90 Elbow x20 25x25 32x32 40x40 50x50 63x63 90x90 16 Bars Male Threaded 90 Elbow x1/2 25x3/4 32x1 40x1.1/4 50x1.1/2 63x2 Note : 90mm Dia fittings and pipes are rated to be operational at 16 bar nominal working pressure only. 12

19 PIPES & FITTING FOR COMPRESSED AIR GENERAL The and John Guest system of pipes and fitting are inspected throughout their manufacture and are guaranteed for a use complying with their design within the limit indicated. During the installation and before putting the network into service, it is advisable to make a certain number of checks as with all other materials. INSPECTION Visual inspection During and after installation, the pipes and fitting should be inspected so as to eliminate doubtful elements containing abnormalities such as impacts and deep score caused by unsuitable handling. Before the tests, the whole network will be visually inspected to eliminate any part containing deep cuts or notches, large deformation due to sudden impacts, traces of blow torch burns, etc... Any damaged part should be replaced before putting into service. The aim of the visual inspection is also to ensure that the installation complies with the drawing and hence the correct installation of all the component parts (connection, supports, monitoring and safety mechanisms, etc...) TEST BEFORE PUTTING INTO SERVICE When the leak tests have been made, it is advisable, in order to remove all foreign matter, to clean the inside of the network. The test pressure of the circuit will be equal to at least 1.3 times the working pressure with a maximum of 12.5 bar. The pressure will be kept for 12 hours and the manometers can show a slight pressure drop. IT IS IMPORTANT TO NOTE THAT YOU CANNOT ACHIEVE PRESSURE TIGHTNESS TO 100% in any Pneumatic system as there is bound to be microscopic leakages in any joints which have thread connections. The waterproofness of the valves will be checked by closing them, one after the other, and by draining out the pressure downstream each of them. At the end of the tests the normal working pressure should be restored. OPERATING CONDITIONS Whatever the use, the safety mechanisms necessary for the tradition protection of network (regulation pressure reduction and limitation, temperature, regulation and limitation, shut off mechanisms, etc...), should be planned, Installed and kept in perfect working order throughout operation. a) Vibration Vibration can be a source of disorders on both pipework and support; it is highly advisable to install a suitable system preventing vibrations from spreading. It is advisable to install a hydraulic hose connection between the compressor and the fixed piping to eliminate the vibration of the compressor from getting passed on to the piping. b) Sources of heat and UV Being made from thermoplastic material, and John Guest fittings should in no case be installed close to a source of heat causing a rise in temperature greater than its limits of use, nor in places continuously exposed to the sun (ultraviolet rays). If this type of installation proves to be inevitable, a minimum number of precautions must be taken such as a protective screen impermeable to ultraviolet or heat rays. c) Prevention of impacts As with all networks conveying pressurised fluids, pipework systems should be protected against impacts which might occur in passage ways used by handing machinery or suspected loads in movement (use of safety barriers, railings, etc...). 13

20 ADVANCE PIPING SYSTEM GENERAL SPACING SUPPORTS Monoklip Brackets have been especially designed to support systems. The pipe is allowed to move freely inside the bracket as it expands and contracts. To guarantee a constant pipe axis and to accommodate fittings, Monoklip can be fitted with wedges. Ref.: CALE1225 for diameters 20 and 25 mm. CALE3263 for diameters and 63 mm. SPACING BETWEEN MONOKLIPS Pipe diameter Distance between brackets (in meter) Horizontal section (m) Vertical section (m) ,4 1,6 1,8 2,1 2,2 2,9 3 3,1 For fluid temperature reaching 30 C apply 0.9 correction factor and apply 0.8 for temperatures reaching 40 C Note : On Ø 50 & 63 mm, we advise that brackets should be installed as close to the fitting as possible, but without impairing pipe expansion and contraction. CALE (4mm) CALE (20mm) 14

21 ADVANCE PIPING SYSTEM PRESSURE LOSSES AND PIPEWORK SIZE The calculation of pipework dimensions is a direct function of the pressure loss ( p) admitted between start point and end point. Oversized networks will lead to high pressure losses may cause compressors to conserve too much energy. This pressure loss takes into account the total length of pipe, and each fitting s specific influence figured out in equivalent runs of pipe, according t each fitting s shape. EQUIVALENT LENGTH OF PIPE OF THE SAME DIAMETER (in meters) Pipe Coupling Elbow Elbow Tee Tee Reducing Reducing Bends 180 external Ø Unions to branch bush double 90 drop bends short pattern long pattern It is common usage to consider that fitting add up 15% of the total length of pipe. Use the above formula to determine the diameter with an optimised fluid speed of 7m/s: Ø int. = x 10 Q L1 p1 P Aubery equation L1 = Length of pipe + sum of length of the equivalent fitting Note : for a 300 m length circuit if we impose a 0.3 bar p 0.3 x 70 for a 70 m length part p = = 0.07 bar 300 Ø int. = inside diameter (mm) Q = flow (m3/h) L1 = length (m) p1 = pressure loss of the pipework section (bar) P = pressure of the network (bar) technical services will answer your questions. 15

22 ADVANCE PIPING SYSTEM FLOW RATE-PRESSURE LOSSES NETWORK DESIGN ADVICE - Have as many straight sections as possible. - Compressed air speed should be around 7 m/s: indeed, by exceeding this speed, pressure losses increase quickly, and so do energy costs. Nonetheless, a speed inferior to 5 m/s means that the diameter of the pipe is not fully used, which also enables to regulate air consumption peaks thanks to the amount of air stored in the network. - The network needs to be drained easily from its condensates at low point. - Choose accessories and fitting that will causes less pressure losses. - Design a network as simple as possible to have a better balance flow. - Try to have an internal diameter of pipe as constant as possible. Avoid pipe section reductions to limit pressure losses. - Use enough valves to allow for network isolation by section. DRAINING Condensation has no effect on the system, but it can damage production tools. It is important to be able to evacuate condensation and even more if the system does not have a dryer upstream. - Drains can be automatic or manual. - The network requires a slope about 0,7% to 1%, directed toward the drain. - Drains will be located at the lowest points of the circuit or at the end of straight lines BRANCHES In order to avoid the presence of water in downpipes, branches can be done with U bends starting from the upper side of the network. Water trap Tee s are a good alternative to U bends as they are as effective to retain moisture in the ring main. This technique enables condensation and impurities to be evacuated toward the drains without affecting the equipment or the manufacturing process (e.g. low pressure paint pistols..). THE FLOW: PRESSURE OF NETWORK To determine the compressed air network dimensions some data needs to be known precisely: The equipments using compressed air: - quantity, - the pressure recommended by the manufactures, - the volume of air consumed when machines are on, - number of machines working simultaneously. kind of joint used to link the equipment to the compressed air network. Identify the accessories added to the compressed air network (filters...) The pressure of the network at the starting point shall be equal to the pressure of the machine needing the highest pressure added to the system load losses, and to particular accessories pressure losses: filters, quick fitting (some of them may have a pressure loss of 1 bar or more, contact the manufacturer for exact information). Examples: - Pneumatic screwdriver = flow 25 Nm3/h pressure 5 bar - Paint pistol = 14 Nm3/h 4 bar - Sandblaster = 35 Nm3/h 6 bar In order to determine pipework sizes, start with the mains (starting from compressor outlet) and proceed by section. 16

23 ADVANCE PIPING SYSTEM FLOW RATE - PRESSURE LOSSES The table give the pipe outside diameter according to the pressure losses and the flow rate, with a fluid speed about 7m/s. PRESSURE = 7 bar p 0.3 Q cfm Q Flow m3/h L1 = Length (m) pipes length + equal due to the fitting

24 More services from Training centre, analysis of your needs, specification work, adaptation and development of specific fabricated products and daily services are offered to facilitate sales and installation of our products. NETWORK DESIGN Our technical assistance and design service can help optimize network drawing Drawing featuring all Pneumsys articles. Complete bill of materials. Calculations of bracketing... TRAINING CENTRE Our training centre (officially recognized for vocational training) gives installers and decision-makers modular courses about technical installation. INNOVATE AND EXECUTE With support from our experienced engineers, ensures that the solution to any problem is an innovative idea and this is what can be seen at our project installations at various sites in India. Advance Energy Solutions 38, Madhu Vrinda, Dhuri Industrial Estate, Waliv Fata, Vasai (E), Dist. Thane Tel.: / Fax : rl@pneumsys.com Visit us at :