Fluid Power Technology

Chapter 16
Conditioning and Distribution of Compressed Air

Controlling Dirt, Moisture, Temperature, and Pressure
Objectives
Compare the various methods used to remove dirt from ambient air entering the compressor and in the final filtering of air distributed to the workstations. Identify the benefits of controlling the temperature of compressed air and the methods used to remove excess heat.
Goodheart-Willcox Co., Inc.
Permission granted to reproduce for educational use only.
Objectives
Describe the problems caused by excess moisture in the compressed air of a pneumatic system. Identify the source of moisture in a pneumatic system and various methods used to remove liquid water from a system. Describe the functions of the pneumatic system receiver and identify construction features of typical designs.
Objectives
Explain the factors that must be considered when establishing the size and location of a receiver for a pneumatic system. Compare the various types of pipe, tubing, and hose used in pneumatic systems. Identify and explain the factors that should be used when selecting a conductor for use in a pneumatic system.
Objectives
Explain the design and construction of the various air distribution systems. Describe the purpose, construction, and operation of the components used for the final preparation of compressed air at a pneumatic system workstation.
Conditioning and Storing Pneumatic System Air

Maximum pneumatic system operating efficiency is achieved when system compressed air is:
Consistently clean Free from moisture At a relatively uniform temperature

Atmospheric air contains dirt under even the best of operating conditions
DeVilbiss Air Power Company


Pneumatic systems need to carefully filter the air taken into the compressor intake to extend the service life of
Compressor Other system components

Correctly designed distribution system
IMI Norgren, Inc. Goodheart-Willcox Co., Inc.
10

Filters used on the intake line of pneumatic compressors may be
Dry element Oil wetted Oil bath
The filter used is based on the type of compressor, atmospheric conditions, and the final use of the compressed air
11

Air at construction sites is dirty
Atlas Copco
12

Painting requires very clean air
DeVilbiss Air Power Company Goodheart-Willcox Co., Inc.
13

The temperature of both the intake and compressed air is important
Temperature changes are reflected in air pressure and volume per the general gas law Temperature influences the ability of air to retain water vapor
14

Air in a pneumatic system may be cooled before, during, or after compression
Intake air temperature usually depends on the location of the compressor air intake Intercoolers and aftercoolers are used to remove heat of compression
15

Intercoolers cool compressed air between the stages of a multiple-stage compressor Aftercoolers cool the air after the air has been compressed Either air or water can be used as the cooling medium in these devices
16

Water vapor in air is referred to as humidity
Essential to our natural environment Can cause problems in a pneumatic system when the temperature of the compressed air drops to the dew point and the vapor condenses into liquid water
17

Free air at 70 Fahrenheit can hold 1.14 pounds of water vapor per 1000 cubic feet By volume, this water is equal to approximately one pint Retention of water vapor in compressed air is based on the volume of air
18

Liquid water in a pneumatic system can:
Wash away lubricants Increase component wear Cause inconsistent system operation Lower the finished quality of products directly using the air in the manufacturing process
19

Liquid water forms in system lines and components whenever the air temperature decreases to the dew point The first step in reducing the liquid water in compressed air is to locate the atmospheric air intake of the compressor in a protected area
20

Condensation of the water vapor in compressed air can occur in:
Aftercooler units Moisture separator System receiver Distribution system
21

Specific air driers can be used in pneumatic systems to remove moisture
Chemical desiccant Refrigeration units Specialized membranes
22

The receiver is the storage unit for compressed air Typically, the receiver is a metal, cylindrical tank with domed ends In addition to air storage, the receiver:
Dampens system pressure pulsations Removes water vapor from system air In smaller systems, serves as the mount for the prime mover and compressor
23

Formulas are available for calculating the volume needed for a receiver These formulas consider:
Cubic feet of free atmospheric air needed per minute Desired cycle time Atmospheric, initial receiver, and final receiver air pressures
24
Air-Distribution System
The air distribution system delivers highpressure, conditioned air from the receiver to workstations with a minimum of pressure drop The type of distribution system depends on the size of the facility and the level of demand for compressed air
25
Four general categories of air distribution systems are used with pneumatic systems
Centralized grid with fixed piping Decentralized grid with fixed piping Loop system with fixed piping Flexible hoses for portable compressor systems
26
Centralized grid has one centralized compressor station and one line network for a facility Decentralized grid has individual compressors in several locations providing air to smaller distribution networks
27
Centralized grid
28
Decentralized grid
29
Loop system has a main line that forms a continuous loop with compressors located at one or more locations This design provides maximum airflow with a minimum of pressure drop between the compressors and the individual workstations
30
Loop system
31
Special attention must given to the setup of a hose air distribution in order to minimize pressure drop
Minimize hose length Reduce the number of couplings Eliminate kinks in the hose
Care must be taken to protect the hoses from abrasion in the work environment
32
Typical hose distribution system
33
Proper sizing of pipe for a fixed air distribution system is difficult Most systems operate under a variety of work conditions:
Multiple workstations Varying actuator loads Intermittent actuator operation
34
Varying loads makes line sizing difficult
35
Sizing is based on:
Rated actuator air consumption Estimate of the time actuators are actually operating Estimate of the percentage of maximum load delivered during actuator operation
36
The pipe in air distribution lines should be installed with a pitch of 1 per 10 of line
Allows liquid water to drain to water traps Water can be remove from traps either manually or with automatic drain devices
37
Drop lines lead from the main air distribution line to the workstations
Should be attached to the top side of the distribution line This prevents water in the distribution lines from entering the workstation lines
38
Proper slope and drop line installation
39
Final Preparation of Air at the Workstation

Final preparation of air at a workstation is accomplished by an FRL unit
Air filter Pressure regulator Lubricator
40

Typical FRL unit
41

FRL air filter removes:
Airborne dirt remaining in the atmospheric air compressed in the system Rust and scale from the interior of the distribution lines Liquid water that has condensed in the drop line Atomized oil from the operating compressor
42

Typical air filter uses centrifugal force and porous filter material to remove unwanted materials from system air
Inlet passageway swirls the incoming air, creating a centrifugal force that separates air and contaminants Porous filter material traps other undesirable materials
43

Typical FRL air filter
44

FRL filters typically have a drain
45

The pressure regulator in an FRL unit reduces system distribution line pressure to the level needed by workstation tools and circuit actuators Unit is also necessary as air pressure in the distribution line fluctuates due to varying air demands and the characteristics of compressorcapacity control
46

Several regulator designs are available for use in a pneumatic system
Direct-operated regulator Basic, diaphragm-chamber regulator Relieving-type regulator Balanced-poppet valve regulator Pilot-operated regulator
47

Regulators commonly use a flexible diaphragm to sense outlet line pressure and provide the balancing force needed to control airflow through a poppet valve Only sufficient airflow to maintain the selected workstation pressure is allowed to pass through the poppet valve to the outlet port of the regulator
48

Direct-operated pressure regulator
49

Many regulators have a diaphragm-control chamber to separate the regulator side of the diaphragm from direct contact with distribution system air
Sensing orifice connects the control chamber and outlet port This dampens the reaction of the diaphragm, providing more sensitive and efficient workstation pressure control Protects diaphragm from contaminants
50

Diaphragm-chamber regulator
51

Some regulators contain a venting orifice located in the center of the diaphragm
Prevents pressure increase in the outlet port beyond the regulator pressure setting The relieving action automatically bleeds air from the outlet port to the atmosphere This design feature allows the regulator to act like a small relief valve
52

Relieving-type pressure regulator
53

Balanced-poppet valve regulators have a design that subjects both ends of the valve poppet to equal air pressure
Allows the valve to be more accurately positioned Produces better pressure control and improved response to system load variations
54

Balanced-poppet valve pressure regulator
55

Pilot-operated regulators have a sealed pilot-air chamber in place of a control spring and adjustment screw
A second, small, remotely located regulator is used to control air pressure in the pilot-air chamber The air pressure in the pilot-air chamber acts as an air spring to establish the setting of the pilotoperated regulator
56

Pilot-operated pressure regulator
57

Installation of a pilotoperated pressure regulator with a secondary regulator
58

Factors to consider when selecting a system regulator are:
Regulator style Pressure range Airflow range Conductor connection size
59

The lubricator in an FRL unit meters oil into pressurized system air at the workstation This provides lubrication for system valves, actuators, and air-powered tools
60

Typical FRL lubricator
61

Rapidly moving system air passing through a lubricator breaks up droplets of oil, forming a mist or fog This mist is transported through the workstation lines to system components
62
Distribution System Conductors and Fittings

Effectively moving compressed air through a distribution system requires appropriate conductors and connectors Conductors can be classified as
Rigid Flexible
63

Pipe is the most common rigid conductor Hose is the most common flexible conductor Conductors must be properly sized and assembled for compressed air to be transported from the compressor to actuators with minimal pressure drop
64

Conductors and the associated fittings must be properly sized
65

Tables are available that provide data on air pressure loss in standard rigid and flexible conductor sizes using various flow rates
66

Various types of hose are available
Atlas Copco Goodheart-Willcox Co., Inc.
67

Hose selection, application, and maintenance are critical to assure air distribution with a minimum loss of pressure
Hoses should be no longer than necessary Hoses should be no larger than necessary Use a minimum number of fittings Layout lines to eliminate kinks and reduce the number of bends
68

Proper hose selection is important
69
Review Question
Name five materials that may be used to make the element in a dry filter for use in pneumatic systems. A. Paper, B. plastic, C. cloth, D. metal, and E. ceramic.
70
Review Question
_____ is the temperature at which water vapor in the air begins to condense to form liquid water. Dew point
71
Review Question
Name five places where liquid water may form in the pneumatic system.
A. Intercooler, B. aftercooler, C. moisture separator, D. receiver, and E. system distribution lines.
72
Review Question
Name two things that occur when warm, humid, high-pressure air cools in the distribution lines of a pneumatic system. A. The pressure of the air reduces according to the general gas law, and B. liquid water forms when the dew point of the air is reached.
73
Review Question
In addition to air storage, the receiver dampens air _____ caused by compressor operation.
pulsations
74
Review Question
What can be used to supply compressed air to a section of the distribution system that contains equipment using a large volume of air on an intermittent basis without increasing the size of the system? An auxiliary receiver.
75
Review Question
What is the most common rigid conductor for major pneumatic systems?
Pipe.
76
Review Question
Identify two factors that are critical to selecting the actual sizes of the lines used in an air distribution system. A. Anticipated airflow rate through the lines, and B. pressure drop caused by the lines and fittings.
77
Review Question
The _____ compressed-air-distribution system distributes air from a single location to all workstations in a facility. centralized grid
78
Review Question
Why is it necessary to use a pressure regulator in the final air preparation unit at a system workstation?
Air pressure in the distribution lines is higher than what is needed for operation of the workstation actuators. Also, the pressure in the distribution lines varies considerably because of the way the compressor-capacity control system functions.
79

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Chapter 16

Conditioning and Distribution of Compressed Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Permission granted to reproduce for educational use only.

Permission granted to reproduce for educational use only.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

DeVilbiss Air Power Company

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

IMI Norgren, Inc. Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

DeVilbiss Air Power Company Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Permission granted to reproduce for educational use only.

Conditioning and Storing Pneumatic System Air

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only.

Goodheart-Willcox Co., Inc.