Compressed AirQuality Optimisation for Pneumatic Control System

Pressure

Flow rate

Temperature

Force

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Air Management

G. G.Senguttavan Sengu
Works for Festo 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 : info_in@festo.com Ph: 080 - 7833359
Air Management

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What is required for compressed air preparation?

Drying Drying Filtering Filtering Oil Oil removal removal

Compressed Compressed air air quality quality to to DIN DIN ISO ISO 8573 8573 -1 1 Ensure Ensure flow flow Regulate Regulate pressure pressure

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Air Management

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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Air Management

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

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Air Management

What is in air ?
gas nitrogen oxygen carbon dioxide hydrogen argon helium neon crypton xenon volume % 78,08000 20,95000 0,03000 0,01000 0,93000 0,00050 0,00180 0,00010 0,00000 weight % 75,51000 23,01000 0,04000 0,00100 1,28600 0,00007 0,00120 0,00030 0,00004

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Air Management

Average content of dust in air

region average concentration mg/ m3 widespread particle-size m biggest particle m

country - while raining - while dryness big city - residential districts - industrial districts industrial area - workshops - foundry - cement factory - waste from heating

0,05 0,15

0,80 2,00

4,00 25,00

0,40 0,75 3,00 1 to 10 50 to 100 100 to 200 1000 to 15000

7,00 20,00 60,00

60,00 100,00 1000,00

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Air Management

Size of dust in industrial districts

field of dimension m 10 to 30 5 to 10 3 to 5 1 to 3 0,5 to 1 average dimension m 20,00 7,50 4,00 2,00 0,75 pices per m3 x 1000 50 1750 2500 10700 67000 part of weight / vol. % 28 52 11 6 2

80% of the contaminants are less than 2 microns in size Only particle greater then 45 microns can be visible by man

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Air Management

Moisture content 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 water vapour contained in the air) Dew point temperature are between 2 5 degree centigrade

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Air Management

Water content in the air

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Air Management

Effects on pneumatic system Corrosion of components Increased water in air lines Switching operations will be disturbed Reduction in speeds Shorter service life
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Air Management

Possible consequences for system operation and environment

Rust due to condensate

Corroded components

Residue and condensate containing pollutants

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Air Management

Compressed airgeneration & distribution

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Air Management

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 Management

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Air Management

Air Distribution System - Ring Main with Interloops

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Air Management

Selection of suitable material for the pipes considering the following points
Low pressure losses Absence of leaks at joints Corrosion resistant Expansion capability

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Air Management

Nomogram for pipe selection

lenght of tubing [m]

Selection and dimensioning

Pressure

inner diameter of tube [mm]

pressure loss [bar]

air quantity system air pressure [bar]

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Air Management

CQ, PQ PIPING SYSTEM

For PIPING IN FACTORIES For PIPING ON MACHINES

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Air Management

Push-fit piping system for compressed air CQ & PQ

Alu - PIPE Polyamide - PIPE

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

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Air Management

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)
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Air Management

Cost of compressed air leaks

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Air Management

Drying techniques and filter types

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Air Management

Method of drying air

Refrigeration (drying) separation Pressure dew point about +2C

Membrane dryer Atmospheric dew point up to -40

Adsorption dryer Pressure dew point up to -90C

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Air Management

Comparison on different Dryers

Cost of drying compressed air; approx. 10 to 20 % of the cost of producing the compressed air

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Air Management

Membrane dryer
Function principle

Housing cover Exhaust ports for purging air Hollow fibres

Nozzles
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Air Management

LDF - Adsorption dryer

Out put filter for granular dust 1 um (not LFM) Optical indicator

Drying chamber 1

(Molecular sieve) Na AIO!SiO!

Drying chamber 2 Input filter for contaminant 0.01 um (not LFM)

Reversing valve ISO from SA dept. ~2 min switching cycle > 15000 operating hours
Air Management

Auto drain
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Filter types
Cyclone separator Pre-filter Micro filter Active carbon filter Sterile filter

Water, dust "50 m

Water, dust 40 ... 25 m

Water, dust, oil 0.01 m

Odours and flavourings

Bacteria, viruses

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Air Management

Function principle
On-off valve

Adjusting screw for time delay Gradual pressure build-up Electrical on-off valve
Pressure

100%

50%

Time

Manual on-off valve

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Air Management

Lubrication of Air
General use : 1 to 12 drops/1000 lpm of air Use only hydraulic oil, (oil viscosity 32 centistokes at 40C )

Venturi nozzle

Unlubricated air Pressure area Lubricated air

Lubricator LOE
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Air Management

Series overview

Pressure regulator LR / LRS / LRVS

Particle filter LF Filter regulator 40 or 5 m LFR

Fine filter LFMB 1 m

Micro filter Lubricator LOE LFMA 0.01 m

On-off valve HE On-off valve HEE / HEP electrical / pneumatic manual

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Soft start valve HEL (gradual start) Branching module FRM Installation components

Air Management

Service units, D-series

Micro, Mini, Midi, Maxi

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

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 Air Management

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Milestone of Festo Service units

1998 1986 1970 1966 1958 1955

2002

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Air Management

Compressed air preparation at a glance

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 2 3 4 5 6 7 0.1 1 5 15 40 0.1 1 5 8 10 Application Mining Cleaning Welding machines Machine tools Air cylinders Air valves Packaging Storage atmosphere Sensors Foodstuffs Photo process
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-70 -40 -20 3 7 10 not defined

Class 5 5 5 5 5 35 5 2 2 2 1

0.01 0.1 1 5 25 -

Air Management

What means Pneuma tics ?

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

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Air Management

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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Air Management

Take a deep breath

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

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Air Management

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Air Management