1. HYDRAULICS & PNEUMATICS
Conditioning and Distribution of Compressed Air
Presented by: Dr. Abootorabi

2. 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

3. Conditioning and Storing Pneumatic System Air
Atmospheric air contains dirt under even the best of operating conditions.

4. Conditioning and Storing Pneumatic System Air
Pneumatic systems need to carefully filter the air taken into the compressor intake to extend the service life of:
Compressor
Other system components

5. Conditioning and Storing Pneumatic System Air
Air at construction sites is dirty.

6. Conditioning and Storing Pneumatic System Air
Painting requires very clean air.

7. Conditioning and Storing Pneumatic System Air
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

8. Conditioning and Storing Pneumatic System Air
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

9. Conditioning and Storing Pneumatic System Air
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.

10. Conditioning and Storing Pneumatic System Air
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

11. Conditioning and Storing Pneumatic System Air
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

12. Conditioning and Storing Pneumatic System Air
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.

13. Conditioning and Storing Pneumatic System Air
Condensation of the water vapor in compressed air can occur in:
Aftercooler units
Moisture separator
System receiver
Distribution system

14. Conditioning and Storing Pneumatic System Air
Specific air dryers can be used in pneumatic systems to remove moisture:
Chemical desiccant
Refrigeration units
Specialized membranes

15. Conditioning and Storing Pneumatic System Air
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

16. Conditioning and Storing Pneumatic System Air
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

17. Air-Distribution System
The air distribution system delivers high-pressure, 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.

18. Air-Distribution System
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

19. Air-Distribution System
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.

20. Air-Distribution System
Centralized grid:

21. Air-Distribution System
Decentralized grid:

22. Air-Distribution System
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.

23. Air-Distribution System
Loop system:

24. Air-Distribution System
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.

25. Air-Distribution System
Typical hose distribution system:
DeVilbiss Air Power Company

26. Air-Distribution System
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

27. Air-Distribution System
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

28. Air-Distribution System
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

29. Air-Distribution System
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

30. Air-Distribution System
Proper slope and drop line installation:

31. 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

32. Final Preparation of Air at the Workstation
Typical FRL unit:

33. Final Preparation of Air at the Workstation
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

34. Final Preparation of Air at the Workstation
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

35. Final Preparation of Air at the Workstation
Typical FRL air filter:
IMI Norgren, Inc.

36. Final Preparation of Air at the Workstation
FRL filters typically have a drain.

37. Final Preparation of Air at the Workstation
The pressure regulator in an FRL unit reduces system distribution line pressure to the level needed by workstation tools and circuit actuators.
This unit is also necessary as air pressure in the distribution line fluctuates due to varying air demands and the characteristics of compressor-capacity control.

38. Final Preparation of Air at the Workstation
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.

39. Final Preparation of Air at the Workstation
Typical FRL lubricator:
IMI Norgren, Inc.

40. Final Preparation of Air at the Workstation
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.

41. Final Preparation of Air at the Workstation

42. Final Preparation of Air at the Workstation

43. 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

44. Distribution System Conductors and Fittings
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.

45. Distribution System Conductors and Fittings
Conductors and the associated fittings must be properly sized.
IMI Norgren, Inc.

46. Distribution System Conductors and Fittings
Various types of hose are available:
Atlas Copco

47. Distribution System Conductors and Fittings
Hose selection, application, and maintenance are critical to assure air distribution with a minimum loss of pressure:
Hoses should be no larger than necessary
Use a minimum number of fittings
Layout lines to eliminate kinks and reduce the number of bends

48. The end.
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