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ME 3012

INTRODUCTION TO PNEUMATIC CONTROL SYSTEMS

INSTRUCTED BY Mr. S.H.C.H. Kumara

NAME COURSE INDEX NO GROUP FEILD DATE OF SUB

Hapuarachchi V.H. B.Sc. Engineering 090170B 04 Mechanical .01.2012

INTRODUCTON Pneumatics systems are being widely used in industrial automation mainly due to its simplicity in installation and maintenance, fast operation, environmental friendliness even in case of leakage, low operational and maintenance costetc. In pneumatic systems compressed air is produced in a compressor and stored in a receiver. From here it is routed to valves which control the direction of fluid flow, flow control valves which control the amount of power produced by the cylinders which converts the potential energy of the compressed air into kinetic energy at the output. EXPERIMENT Introduction to pneumatic control systems OBJECTIVES To be familiar with basic pneumatic components commonly found in the industry To be familiar with the common pneumatic symbols To get a basic knowledge and experience on pneumatic circuit design and simulation To be familiar with real world control circuit design with pneumatics To get an overall idea about compressed air systems

PROCEDURE
A pneumatic control system was designed and simulated using FluidSIM software and made the designed system using actual components. The design considerations of the system were as follow. At the initial position, both cylinders were in the retracted state. Therefore, two limit switches, 1S1 and 2S1 are activated. To start the cycle, both 2S1 and push button valve must be activated. When the cycle starts, piston of C1 advanced slowly and when it came to the position of 1S2, the piston of C2 started advancing. When the piston of C2 reached 2S2, piston C1 retraced quickly back to the initial position of it. When the piston of C1 reaches back to 1S1 position, C2 also retraced back to its initial position. Then the cycle could be repeated with the press of the push button.

2S1 2S2

C2 1S1 1S2

C1

DISCUSSION Different types of compressors and their features Reciprocating compressors Reciprocating air compressors are positive displacement compressors. This means they are taking in successive volumes of air which is confined within a closed space and elevating this air to a higher pressure. The reciprocating air compressor accomplishes this by using a piston within a cylinder as the compressing and displacing element. The reciprocating air compressor is considered single acting when the compressing is accomplished using only one side of the piston. A compressor using both sides of the piston is considered double acting. The reciprocating air compressor uses a number of automatic spring loaded valves in each cylinder that open only when the proper differential pressure exists across the valve. Inlet valves open when the pressure in the cylinder is slightly below the intake pressure. Discharge valves open when the pressure in the cylinder is slightly above the discharge pressure. A compressor is considered to be single stage when the entire compression is accomplished with a single cylinder or a group of cylinders in parallel. Many applications involve conditions beyond the practical capability of a single compression stage.

Advantages
Simple Design Lower initial cost Easy to install Two stage models offer the highest efficiency No oil carryover Large range of horsepower Special machines can reach extremely high pressures

Disadvantages
Higher maintenance cost Many moving parts Potential for vibration problems Foundation may be required depending on size Many are not designed to run at full capacity 100% of the time

Rotary Screw Compressors Rotary air compressors are positive displacement compressors. The most common rotary air compressor is the single stage helical or spiral lobe oil flooded screw air compressor. These compressors consist of two rotors within a casing where the rotors compress the air internally. There are no valves. These units are basically oil cooled (with air cooled or water cooled oil coolers) where the oil seals the internal clearances. Since the cooling takes place right inside the compressor, the working parts never experience extreme operating temperatures. The rotary compressor, therefore, is a continuous duty, air cooled or water cooled compressor package.

Advantages
Simple design Low to medium initial cost Low to medium maintenance cost Two-stage designs provide good efficiency Easy to install Few moving parts Most popular compressor design in plants

Disadvantages
Limited airend life Airends are not field serviceable High rotational speeds Shorter life expectancy than other designs Oil injected designs have oil carryover Single stage designs have lower efficiency Two-stage oil free designs have higher initial cost Difficulty with dirty environments

Centrifugal Compressors The centrifugal air compressor is a dynamic compressor which depends on transfer of energy from a rotating impeller to the air. The rotor accomplishes this by changing the momentum and pressure of the air. This momentum is converted to useful pressure by slowing the air down in a stationary diffuser. The centrifugal air compressor is an oil free compressor by design. The oil lubricated running gear is separated from the air by shaft seals and atmospheric vents. The centrifugal is a continuous duty compressor, with few moving parts, that is particularly suited to high volume applications, especially where oil free air is required. Centrifugal air compressors are water cooled and may be packaged; typically the package includes the after-cooler and all controls.

Advantages
High efficiencies approaching two-stage reciprocating compressors Can reach pressures up to 1200 psi Completely packaged for plant or instrument air up through 500 hp Relative first cost improves as size increases Designed to give lubricant free air Does not require special foundations High initial cost

Disadvantages

Complicated monitoring and control systems Limited capacity control modulation, requiring unloading for reduce capacities High rotational speeds require special bearings and sophisticated vibration and clearance monitoring Specialized maintenance considerations

Rotary sliding vane compressor A sliding (rotary) vane compressor has a solid rotor mounted inside a water jacketed cylinder, similar to that of a jacketed water section of a reciprocating cylinder. The water jacket around the cylinder is used for cooling. The rotor is filled with blades that are free to move in and out of the longitudinal slots in the rotor. Blade configurations range from 8 to 12 blades, depending upon manufacturer and pressure differentials. The blades are forced out against the cylinder wall by centrifugal force, creating individual cells of gas which are compressed as the rotor turns. As it approaches the discharge port, this area is reduced and the gas discharged.

Advantages
Simple design Easy to install Low to medium cost Low maintenance cost Field serviceable airend Long life airend Low rotational speeds Very few moving parts Forgiving to dirty environments

Disadvantages
Oil injected designs have oil carryover Single stage designs have lower efficiency Difficulty with high pressures Oil free designs are unavailable

Operation of filters A pneumatic filter is a type of filter specifically designed for use in a compressed air stream. Filters are devices used to remove contaminants from a stream of liquid or gas. Pneumatic filters remove contaminants, especially solid particulates, from streams of fluid in the form of compressed air. They are frequently used in sequence with secondary filters that trap even smaller particles that escape the primary filters. Filtration for pneumatic systems is handled quite differently. In most industrial pneumatics, compressed air is supplied from a single compressor to a large number of operating systems, as a plant resource, much like light or electricity. Individual filters are used on the separate systems. Sometimes more than one filters per system. Often the filters are found in conjunction with regulators and sometimes lubricators comprising a filter-regulator-lubricator for the system. Operation of lubricators A pneumatic lubricator is set up with the oil on one side of the machine, a narrow chamber in the center and the injection valve on the other side. The movement of the oil from the one side to the other (usually with the help of compressed air), creates the vacuum that pulls the oil through. The speed that the oil is moving renders it into an aerosol, like a mist or a gas, which is then pushed through the machine via pneumatic pressure. The finer the mist of oil, the further it will go and the more of the machine will be oiled throughout the process.

Pneumatic lubricators differ in terms of specifications and features. A regulator lubricator can operate over a range of pressures that are measured in pounds per square inch (psi). The ambient operating temperature for a pneumatic lubrication system is also a range. Modular pneumatic lubricators are designed to be incorporated into existing pneumatic systems. They differ in terms of working pressure, operating temperature, and bowl capacity. Features for pneumatic lubricators include automatic shut-down, warning lights, and dirt stoppers.

Operation of pressure regulators Regulators reduce the pressure of a gas or liquid from a source, such as a cylinder or compressor, to a lower value needed by a device, such as an analyzer. A pressure regulator provides better resolution and control when its inlet and control range pressures closely match the pressure requirements of the fluid handling system. Resolution is the number of handle turns needed to adjust a regulator from its lowest to highest outlet pressure setting. Control is the ability of the regulator to hold a given outlet pressure set point. A pressure regulator is a normally open valve. With a regulator positioned after a receiver tank, air from the receiver can expand (flow) through the valve to a point downstream. As pressure after the regulator rises, it is sensed in an internal pilot passage leading to the underside of the piston. Effect of moisture in compressed air It is critical in the design of compressed air systems that safe moisture level limits be established to protect the systems and processes. Appropriate purification components, such as coalescing filters and desiccant dryers, can then be selected and installed to meet the system requirements. Water droplets are a major cause of erosion. In a compressed air line, water is fluidized to an aerosol mist by the turbulent air flow. The droplets are then propelled downstream at high velocities until they impact on the first obstruction in their path, such as a piping elbow, a valve disc, an orifice plate, or an air motor blade. The resulting repeated impulses produce destructive forces on the solid surfaces that cause erosion. Steps to take Moisture must be reduced in compressed air lines by purification equipment. Liquid water and oil aerosols which cause erosion, oxygen corrosion, biological growth and product contamination can be eliminated by high efficiency coalescing filters. Water vapor, which has similar effects, can be reduced to safe levels by adsorption processes. The degree of dryness required must be determined by an analysis of each individual compressed air system.

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