Professional Documents
Culture Documents
to air distribution
Omsl_1266_01.indd 1
07-07-11 13.53.03
Introduction
Air tools and compressed air systems are used throughout industry. This
booklet has been produced by Atlas Copco as an aid to understanding the
operation of compressed air systems, to provide the basic information for
the correct design of these systems and to illustrate the drawbacks and
additional costs incurred with a poorly designed system.
It will be of value to engineers and designers concerned with the design,
installation and maintenance of compressed air systems.
Content
Page
1. How can productivity be raised when working with compressed air....................... 4
1.1 Practical examples when grinding, drilling, assembling with screwdrivers,
nutrunners, impact wrenches and pulse tools.......................................................... 5
1.2 What pressure drop is acceptable?..................................................................... 10
2. How to choose airline accessories ............................................................................... 11
2.1 Key questions......................................................................................................... 11
2.2 Typical hose arrangements..................................................................................... 13
2.3 Airline accessories ................................................................................................. 15
Shut off valves, air preparation units, blow protectors, hoses, whip hoses,
spiral hoses, hose reel balancers, swivels, couplings and nipples, hose clamps,
balancers and torque arms .............................................................................. 15 23
3. Installation .................................................................................................................... 24
4. Maintenance.................................................................................................................. 26
4.1 Leakage .................................................................................................................. 26
4.2 Maintenance schedule............................................................................................ 27
5. Safety ............................................................................................................................. 28
6. What is compressed air?.............................................................................................. 30
7. Air distribution ............................................................................................................. 33
8. Actual case: cost savings with ErgoPulse tools ......................................................... 37
9. Relationship between tool pressure and air consumption ....................................... 41
10. Formulas for power cost calculation .........................................................................42
compressor.
The compressor discharge pressure will be
constant at the set level of say 7 or 7.5 bar,
and independent of the system pressure
drop. With low air consumption due to a
low pressure at the tool, the compressor
will operate at the same pressure but for a
longer time for a particular task to be performed. The additional power cost resulting from the high system pressure drop
may be calculated in the following manner:
Grinding
The working cost with a
grinder
6.3
5.8
5.3 bar
Material removal
5.5
4.5
4.0 kg/ hr
Drilling
6.3
5.8 bar
2.0
3.2 sec
6.3
5.8 bar
Maximum torque
248
240 Nm
Time
0.8
0.9 sec
Maximum torque
17.6 Nm16.3 Nm
Rotational speed
Impact wrenches
A) The working cost when
assembling with an impact
wrench with torque control
The torque increases with time on impact
wrenches. Torque levels high above marked torques can be reached. Impact wrenches with torque control, LTS 37, deliver
torque independent of working pressure.
The time to reach the torque increases
with declining pressure. Tests with the
tool show a 12.5% time increase at 0.5 bar
lower air pressure. At an operator cost of
20 Euro per hour and 4 hours of efficient
assembling, this gives 10 Euro unnecessary work every day, (200 Euro per month,
2400 Euro per year).
The compressor costs when
assembling with an impact
wrench with torque control
A LTS 36 HR 13 normally requires 10 l/s
but with 0.5 bar lower pressure the air
consumption is reduced to 92 %*), so
10 l/s x 92% = 9.2 l/s. The working time
for the operator was 12.5 % longer which
gives 112.5% x 4 hours = 4.5 hours
(4 hour and 30 minutes). To compress
1 m3 requires approximately
0.105 kWh
For further information are all formulas
carefully described on page 42.
Let us use the formula for extra power per
day required when working on too low air
tool pressures:
(9.2 l/s x 3.6 m3/h x 4.5 h x 0.105 kWh)
(10 l/s x 3.6 m3/h x 4 h x 0.105 kWh) =
0.53 kWh / day
Torque
Nm
6.3
333
5.8
316
5.3
310
Pulse tool
The working cost for a
pulse tool
Tests performed at Atlas Copco
Tools show that decreased working pressure significantly increases
tightening time and reduces the torque
obtained. Tests were made with an
ErgoPulse 8 XS. The following results
were obtained:
ErgoPulse 8 XS
Pressure
Time
Torque
6.3 bar
6.5 s
48.3 Nm
5.3 bar
10 s
44.3 Nm
4.3 bar
10 s
38.2 Nm
The above figures show that the consequences of too low a working pressure are
longer cycle times and that the torque is
not reached. A simple calculation made
for the cycle times in the best and the
worst cases:
ErgoPulse 8 XS:
worst 10 s
best 6.5 s
difference 3.5 s
LMS37
LUM21
LBB36
LSS53
Reality
In practice many work sites work with
pressures of 3-5 bar which leads to significant wasted energy and productivity. Atlas
Copco can help measure the air supply
pressure with the air tool simulator.
The following calculation could be made
for a small workshop with, for instance, 3
screwdrivers, 2 impact wrenches, 2 drills
and 1 grinder working with 5.8 bar pressure instead of 6.3 bar pressure:
All figures are taken from the cases on the
previous pages.
It is interesting to see that the additional
working cost is always much higher than
the additional compressor energy cost.
The other conclusion is that a working
pressure lower than 6.3 bar is not acceptable. Already at 5.8 bar the additional
working cost and compressor cost are too
high.
Additional
working cost / month
Additional
compressor loss cost / month
3 x LUM 21 SR 14
3 x 200 Euro
3 x 0.15 Euro
2 x LMS 37 HR 13
2 x 0 Euro
2 x 0 Euro
2 x LBB 36 H060
2 x 240 Euro
2 x 2.1 Euro
1 x LSS 53 S085-18
1 x 480 Euro
1 x 6.8 Euro
10 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
distance between the tool and the offtake: the distance between the tool and
the offtake should ideally not be more
than 3-5 meters. Real life shows that in
many cases this is not possible, for
instance at shipyards, where distances
of 20 meters or more are quite common.
11
12 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
13
a main hose together with a short whip hose next to the tool.
This installation is common when working with material removal tools with low
levels of vibrations.
14 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Pa
=1M
Pmax
I FIL
M
25A
1,6MP
Pmax=
L 15
I BA
MID
a
1,6MP
ax=
Pm
I FIL
08B
MIN
MINI up to 12 l/s
MIDI up to 43 l/s (MIDI in combination with
DOSOL can also be used for air flows up to
43 l/s)
MAXI up to 80 l/s
15
16 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Air filters
The filter separates impurities such as
water and solid particles. Not using filters
in combination with air tools leads to
shorter service life, higher maintenance
costs and a lower efficiency. Old air
systems with cool dryers, for instance,
generate a lot of rust and running tools
without installing a filter could damage
the tool in less than a week. Well
maintained air systems supply clean air.
Although the difference might not be
obvious, the tiniest rust flake can damage
a tool. Intermediate air quality will result
in shorter service intervals with higher
costs. For instance, the service cost for an
LBB 45 drill is 60 Euro.
Atlas Copco filters separate up to 98% of
the water when operating within the
design working range. All three types
(MINI, MIDI and MAXI) have a very low
pressure drop.
Filters are usually equipped with a semiautomatic drain. All filters come with a kit
enabling simple conversion from semiautomatic to manual drainage.
Semi-automatic drainage takes place automatically when the pressure in the bowl
17
Air consumption
6.3 bar
100%
7.0
110%
8.0 bar
125%
Lubricators
T-outlets
In some cases there is a need for nonlubricated air from the units. In such cases
a T-outlet is mounted before the lubricator,
which provides a tapping point for clean
air.
18 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Hoses
Blow protector
When a fitting comes loose from a pressurised hose, the hose starts to blow compressed air in an uncontrolled way, whipping around. This can injure people,
damage the work-piece and destroy the
environment. A way to ensure this does
not happen is to use an blow protector.
Normally air hoses must be sized according to air flow, hose size and hose length.
Couplings with a low pressure drop must
be chosen, or the blow protector will not
work properly. Care must be taken in
selecting blow protectors for use with
impact wrenches and pulse tools. The air
flow under load must be increased by 50%
to obtain the design air flow rate or the
fuse will shut off at free running.
Hose recommendations:
Cablair
PVC
Rubair
Turbo
Pliable
Very good
Good
Good
Very good
Flexible
Very good
Good
Very good
Very good
Indoor / outdoor
Indoor
Indoor
In / out
In / out
Spark resistant
Bad
Bad
Good
Good
Rough treatment
Bad
Good
Very good
Very good
19
Max length
5m
10 m
20 m
40 m
03
0.7
05
2.1
0.7
06
2.1
0.7
08
7.5
2.1
0.7
10
13
7.5
2.1
13
21
13
7.5
16
43
21
13
7.5
20
75
43
21
13
25
125
75
43
21
Spiral hoses
A spiral hose together with balancers is
ideal for vertical applications. Spiral hoses
are, due to their shape, very long and thus
have very high pressure drop. To avoid
big losses, choose a short spiral hose.
There are spiral hoses of three materials
available in the Atlas Copco range: nylon,
Pebax and polyurethane. The following
are the significant properties:
Material
Keeps
measurements in
length
Spiral
size
Directly
connected
to tool
Nylon
Best
Big
No
PEBAX
Better
Medium Yes
Polyurethane Good
Small
Yes
20 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Swivels
For screwdrivers, pulse tools, drills or
small die grinders the hose is sometimes
clumsy and in the way when working, for
instance sitting at a workbench. In such
cases a swivel, allowing a certain angle
tolerance between the hose and the tool, is
used. Swivels should not be used in applications where there is a pulling force on
the hose or high levels of vibrations, since
the hose will wear out quickly and start to
leak.
ErgoQIC 08
18 l/s
ErgoQIC 10
47 l/s
QIC 08
11 l/s
Assembly tools
Assembly tools normally have a limited
air consumption and smaller quick couplings are therefore suitable. ErgoQIC 08
and QIC 10 can be used. Big impact
wrenches should be used with bigger size
couplings and a whip hose.
QIC 10
20 l/s
QIC 15
37 l/s
CLAW
290 l/s
21
Hose clamps
Hose clamps are available in three types:
pleated type for hoses with outside diameters of 7-27 mm, screw-strip types for
hoses with outside diameters of 8-65 mm;
and two-part cast iron clamps with a galvanised bolt and nut for hoses with outside diameters of 22-40 mm.
Balancers can provide important ergonomic and safety benefits for the operator.
They provide a constant wire tension that
makes the tool virtually weightless (COL
balancers). Conventional balancers, like
RIL, have a varying spring load and an
adjustable rest position. Balancers which
work on the constant force principle retain
the tool in the position in which it is released. The choice between COL and RIL is
left to the user. If it is important to be able
to leave the tool at a specific height, COL
should be chosen. RIL is cheaper, has a
longer service life and contains fewer
parts.
22 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Torque arms
The gripping force of the human hand is
limited to 500 N for men and 300 N for
women. Therefore it is recommended that
men should not take up more than 4 Nm
torque (2 Nm for women) when working
with a straight tool. A torque arm is useful when working with straight tools with
higher torques. Long working days with a
repeated grip to counter the torque lead to
fatigue and a torque arm is necessary.
Atlas Copco offers a range of arms for
different torque levels. The choice of arm
should be made as follows:
First determine which tool is going to be
used, what torque it will exert, the weight
of the tool, whether it will be straight or
pistol grip and the grip diameter.
23
3. Installation
The picture above shows an air preparation unit with shut off valve, blow protector, a hose, tool and balancer.
The shut off valve can be mounted with
the handle upwards or downwards according to choice. The BAL 1-A handle can
be restricted by the air preparation unit
when mounted upwards so either a
BAL 1, (butterfly handle) should be chosen or the valve should be mounted upside
down.
The direction of air flow is marked with
arrows on the air preparation units and the
blow protector. The mounting order for air
preparation units is:
FILTERREGULATORLUBRICATOR
which can be seen in the picture above.
The filter and regulator can be replaced by
a filter/regulator combination unit.
When using installations with DIM lubricators it is important to avoid dips in the
hose, (i.e.. a hose loop forming a low
point where the oil could collect). If a low
point is created, the oil will not be used
for lubricating the tool but remain in the
hose.
Air preparation units should be placed
1 1.5 m above the workplace. This is
especially important with a lubricator
DIM. Filter, regulator and DOSOL
injection systems can be placed low for
better water separation.
24 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
If a blow protector is installed with normal hoses the blow protector shall be
installed between coupling and FRL unit
according to the picture above.
25
4. Maintenance
Leakage translates into a loss of air capacity. This means increased utilisation of
the compressor as it works to compensate,
which in turn leads to significantly higher
energy costs.
Remember that a leakage is often
continuous, 24 hours a day!
4.1 Leakage
A well-designed and properly maintained
air distribution system has a leakage of no
more than 5% of the capacity of the installation. Unfortunately, 15-20% leakage is
quite common.
Typical energy
cost per year *
0.3
91 Euro
10
3.1
937 Euro
27
8.3
2510 Euro
10
105
33.0
9979 Euro
4.2 Maintenance
schedule
Regular maintenance should be carried out
on the air system.
Once every day:
Manual drainage filters should be drained every day.
Once per week:
The area closest to the workplace
should be checked for leakage once per
week. Joints between tools and nipples,
in couplings, hoses and air preparation
units should be checked. Lubricators
should be filled with oil.
Every two months:
The whole air system should be checked every two months. First, listen for
leaks after working hours, feel by hand
on suspected areas. A soap and water
solution can be used to detect the exact
point of leakage, (bubbles). Take the
necessary measures to repair the leak.
27
5. Safety
Ball valves: When not working, shut off
the compressed air with the ball valve.
Open all ball valves slowly in order to
discover improperly tightened devices.
Air preparation units: Be aware of solvents which can change the structure of
polycarbonate bowls making them brittle.
When using aggressive solvents special
equipment is required.
Polycarbonate has good chemical resistance to all solvents except chemicals containing acetone, benzene, glycerine, some
hydraulic and synthetic oils, chloroform,
methyl alcohol, carbon tetrachloride (and
similar solvents) carbon disulphide, perchloroethylene, toluene, trichlorethylene,
xylene (nitrocellulose thinner) and acetic
acid.
When closing
3. make sure that the two couplings are
mounted together properly
1. open the valve slowly
28 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
29
30 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Since air is a gas, it is made up of relatively free molecules. When it is squeezed or compressed by gravity, the force
is not only towards earth but in all directions. If air, or any other gas, is compressed further mechanically or by temperature changes, the pressure obtained is
measured as the one bar at sea level plus
the extra pressure.
It is important to distinguish between a =
absolute pressure and g = gauge pressure.
Typically used to measure pressure in an
air distribution system, gauge pressure is
defined as the absolute pressure in the sys-
31
Flow
Flow
Pressure
Pressure drop
Working pressure is generated in the compressor and fed through pipework and
hoses to the user (tool). When transporting
air at pressure, the pressure is reduced by
obstacles such as restrictions, bends, narrow passages etc.) This reduction in pressure is called the pressure drop. Pressure
drop always occurs in the supply of compressed air, and the losses increase if the
supply length is very long or if the supply
system passage is very small.
Definitions:
a) static pressure: is the pressure obtained
in a closed system when no air is used.
b) dynamic pressure at offtake: is the
pressure obtained at the offtake tapping
point from the main line or header
when air is used at a tool or other user.
c) dynamic pressure at FRL-unit: is the
pressure obtained at the FRL unit,
(pressure gauge on regulator) when air
is being used.
d) dynamic pressure at tool inlet: is the
pressure when the tool is in operation,
this pressure needs to be 6.3 bar for
the rated performance.
32 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
7. Air distribution
In order to separate water from the compressed air, water traps are built into the
system. Pipes are installed with a fall and a
container (water trap) is installed at the
lowest point.
The advantages are many:
when working on the piping system,
only the unit involved has to be cut off;
leakage may be decreased by cutting off
non-running units;
finding a source of leakage is facilitated;
it becomes possible to have the most
important unit supplied with air if the
compressor capacity is insufficient for
the whole system.
33
34 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Typical air line accessories include: a filter combined with a water trap, pressure
regulator, oil fog lubricator or direct lubricator system, hoses and quick couplings.
For a more detailed description, refer to
chapter 1.5, Air line accessories.
Compressed air treatment
All atmospheric air contains water vapour
more at high temperatures and less at
low temperatures. When air is compressed, the concentration of water increases.
For example, a compressor with a working pressure of 7 bar and a capacity of
200 l/s that draws in air at 20C with a
relative humidity of 80% will produce
80 litres of condensed water in the compressed air line during an eight hour working day.
The amount of water in pressurised air
does not present a problem - as long as it
remains in a vapour state. But if it condenses, the result can be corrosion in the
pipes, interference with the lubrication of
air tools, and a constant risk of freezing in
pipes and tools. Thus, water should be
separated as soon as possible - directly
after the compressor and before entering
the air distribution system.
Air receiver
An air receiver stores the air after the
compressor. When the hot compressed air
is cooled in the air receiver the condensation water is collected and separated out
in the bottom of the air receiver. An air
receiver is used in combination with
water traps in the pipes. This is the cheapest way and an old method, which also
gives lowest degree of water separation.
Aftercooler
Uses water or air cooling to cool off the
hot compressed air. An aftercooler removes 6575% of the condensation water.
An aftercooler is used in virtually all
stationary compressor installations, in
modern compressors an aftercooler is
built into the compressor as standard.
Refrigerant dryer
Refrigerant drying means that the compressed air is cooled, whereby a large
amount of the water condenses and can be
separated. After cooling and condensing
the compressed air is reheated to around
room temperature so that condensation
does not form on the outside of the pipe
system. Refrigerant dryers are used with
dew points between +2 to +10C.
35
Adsorption drying
Pipe size
In
Outlet
mm
25
26
1 1/4
32
34
1 1/2
40
50
26
2 1/2
65
34
80
40
100
51
125
74
37
48
Old installation
An Atlas Copco customer had the following installation:
Offtake 1/2
FRL 3/8
Y-piece (3 way)
Brass couplings (2x), Straight Bore 7.2 mm
New installation
Static pressure
8.5 bar
7.1 bar
3.7 bar
Cablair 08 1.5 m.
8.4 bar
8.2 bar
8.0 bar
37
Compressor 2
Compressor 1
55 kW output => 78 kW input
Running 1.89 hours per day at full load 155 l/s output
1.11 hours per day free running
Energy input
78 kW x 2.17 h/day
=169 kWh/day
Energy costs
Energy cost:
38 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
Old cost
New cost
Compressor 1:
23
Compressor 2:
A reduction of air pressure with 1.7 bar means a saving of 23.7 Euro/day.
39
Air consumption
(%)
Action
8.0
125
7.0
111
6.3 bar
100%
6.0
96
5.0
77
4.0
61
3.0
44
Optimal performance!
41
)=
Formula for the extra cost when working on too low air tool
pressures
Extra power in kWh/day X cost /kWh = cost/day
cost/day X working days a month = cost/month
cost/month X number of month = cost/year
42 P O C K E T G U I D E T O A I R D I S T R I B U T I O N
*) See page 41: relationship between tool pressure and air consumption
POCKET GUIDE TO AIR DISTRIBUTION
43
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