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Trace leaks
soap connections locate source of noise leakage spray ultra-sound device
Example: hole diameter: 3 mm air loss: 0.5 m3/min (6 bar gauge) 0.5 m3/min x 60 min/h = 30 m3/h 30 m3/h x 8000 h/year = 240,000 m3/year 240,000 m3/year x 0.02 /m3 =
4,800 /year
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Leakage losses
Hole diameter
Loss kW *)
This small hole (4.5 mm dia.) costs you about 500 every month
1 mm 2 mm 4 mm 6 mm
240.1360.5200.9600.-
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VL =
VL = VR = pI =
pF =
t =
VL =
Kaeser Kompressoren 2000
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VL = VC = t = T =
Leakage volume in m3/min Compressor volumetric flow rate in m3/min Time units during which the compressor ran on load Total time of the measurement procedure
Example:
Volumetric compressor flow rate Compressor time on load Total measurement time V= 3 m3/min t =t1+t2+t3+t4+t5 = 120 sec T= 600 sec
3
2 1
3 x 120
600
Time
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A
Tools, machines and equipment are connected for normal operation (total leakage)
B
The shut-off valves upstream of the connectors of the consumers are closed (air main leakage)
The difference between A and B represents the losses in the pneumatic tools, etc. and their fittings.
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Performance % kW
6.0
100
3.0
5.5
5.0 4.5 4.0
86
74 62 52
2.6
2.2 1.9 1.6
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Pressure drop
The normal working pressure of a pnuematic tool is 6 bar (g). An increase of the pressure in the installation costs money.
Example: V = 30 m3/min demanded at 7 bar (g) 160 kW At 8 bar (g) approximately 6% more power is required, i.e. around 9.4 kW more
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A B
A. B. C. D. E. F. G.
Valve (we recommend ball valves) Filter (separation of water and rust) Regulator (constant working pressure) Lubricator (mostly oil mist lubricators) Quick release couplings (flexibility at the workplace) Hose (length: 3-5 m) Tool balancer (reduction of work effort)
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0.03 bar 0.03 bar 0.04 bar 0.2 bar 0.5 bar 0.8 bar
3
max.
5 1
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Ring Main
dimensioned for half flow rate and half nominal length smaller pipe diameter
Note:
make provision for section isolation add cross lines if p too high
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10
Spur main
Less material requirement
Note:
greater pipe diameter than in ring main extend to ring main if p too high
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11
Choice of materials Environmental conditions (humidity, temperature chemical pollution of the air) Quality of the air (moisture content, oil content, temperature) Costs Expected working life
Kaeser Kompressoren 2000
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12
25
6 3 0,3
125
50 20 1,6
150
60 25 1,9
over 200 m
DN100
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14
over 200 m
to 3,0
to 5,0 to 7,5 to 10,0
2"
2" 2" 2 1/2"
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15
Straight-line graph
for determining inside pipe diameter (steps 1 to 8)
1 2 7 3
Free air delivery m/h - m/min
4 8 6 5
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Condensate drain
Filter, regulator
Condensate drain
Compressor package
Air receiver
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17
Condensate drain
Compressor package
Air receiver
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condensate line
condensate separator
2.5 6 10 16 25
St 35 St 35 St 35 St 35 St 35
2.5 6 10 16 25
2 5 8 13 20
40
64 100
St 35.8
St 35.8 St 35.8
40
64 100
36
50 80
If the temperature increases, the yield point of all materials reduces. DIN sheet 2401 gives information on the relationship between nominal pressure and maximum permissible working pressure for various materials.
Kaeser Kompressoren 2000
Example: An air main designed for 6 bar (g) and subject to a test pressure of 6 bar (g) may only be operated at 5 bar (g) at temperatures above 120 0C.
21
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Metal pipes
Seamless steel pipe Type Material: Size: Pressures: Ends: Pipe connections: Advantages: To be noted:
Black or galvanized to DIN 2448
page 1 of 2
Threaded pipe
Medium weight to DIN 2440 Heavy to DIN 2441 Black or galvanized Seamless St 00 DIN 1629 Welded St 33 DIN 17100 1/8" - 6" 10 - 80 bar (g) Tapered, smooth or threaded Thread, welding Numerous moulded fittings (for screw fittings) Corrosion (partly on galvanized piping too) High flow and friction resistance Leakages after long operating period Time consuming installation because of thread-cutting or welding Installation by experienced fitters
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22
Metal pipes
stainless steel Type: Material: Dimensions: Gauge pressure: Pipe ends: Connections: Advantages: To be noted:
Kaeser Kompressoren 2000 seamless to DIN 2462 welded to DIN 2463 e.g. material no 1.4301, 1.4541, 1.4571 6 - 273 mm
page 2 of 2
copper
soft, in coils, to DIN 1786 hard in straight lengths to DIN 1754/1786 copper 6 - 22 mm soft 6 - 131 mm hard
aluminium
in straight lengths (6m) similar to DIN 1795 alloys seamless, die pressed up to 32 mm up to 15 bar smooth compression fittings smooth interior wall simple assembly no corrosion Oxidation possible if pipe not treated
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according to type up to 80 bar and even higher 16 - 140 bar smooth welded (inert gas) sealed connections no corrosion Laying only by experienced pipe fitter Limited fitting shapes smooth screwed, brazed (Fittings), welded no corrosion smooth interior wall
Laying needs special knowledge Copper sulphate buildup possible
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Polyethylene
10 - 160 mm (DIN 8074) 10 bar plain welding
Reinforced Polyeth.
10 - 160 mm (DIN 16893) up to 20 bar plain screwed / compression fittings
Dimensions:
Working pressure(g) at 20oC: Pipe ends: Pipe joints: Advantages:
16 16--110 110mm mm (DIN (DIN8061/62) 8061/62) 12.5 bar 12.5 bar plain adhesion
No leaks. Fittings and pipes of the same material. Not easily flammable
No leaks. Fittings and pipes of the same material. Not easily flammable
Disadvantages:
Limited size range available at present Higher coefficient of expansion Only normal falmmability available at present Subject to static charging at present Only legal obligation available as warranty at present Some fittings of metal
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3.1
8 bar
Sub-group number
Group number