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Compressed Air Network 1
Compressed Air Network 1
S
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DESIGNING AN EFFICIENT
COMPRESSED AIR
06 DISTRIBUTION NETWORK
07 The main source of inefficiencies and problems
affecting compressed air distribution systems is
often the distribution plan of the system itself.
The majority of problems therefore usually occur
somewhere between the compressor and the
application points.
Most systems are usually of either of two types:
• Dead-end network
• Octopus network
…neither of which provides the best results…
DEAD-END NETWORK
COMPRESSOR
In a dead-end network, air flow must be The equipment using the most air flow
sacrificed (quantity of air per minute) in must be located near the compressor, and
order to preserve a uniform pressure at the that using less, further away.
point of use. The progressive reduction of
This generates major handling problems,
the central pipe while it moves away from
as production processes are not neces-
the compressor maintains pressure.
sarily designed this way.
However, air tools and equipment must
This is not the optimum network design.
be placed along the length of the circuit in
decreasing order of consumption (SCFM).
CONVENTION AL
NET WORK
OCTOPUS NETWORK
A network where each additional line and Predicting what flow and pressure are
COMPRESSOR extension does not necessarily match the available at any point is virtually
initial configuration is often called an impossible. Air flow fluctuations from
“octopus” network. Dead-end networks varying usage of pneumatic equipment
often evolve into octopus networks over and air tools makes it even more difficult
time. to get the right pressure and flow at any
TOPRING
given point.
The octopus network includes the
following anomalies: This results in varying pressure and air
flow conditions through out the system,
• Different airline materials
creating many problems.
• Curves, reductions and enlargements
without apparent reason This type of network, while quite common,
is the worst possible situation.
• Inconsistent diameters of air lines
OCT OPUS • Installation done with no knowledge
NET WORK of pneumatic standards
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THE PROBLEM S
05
More than 98% of factories using At the very least, the dead-end network
compressed air started out with a
dead-end network.
they have has sacrificed air flow in order
to maintain point of use pressure. 06
07
Over the years, their systems have come
to resemble a giant “octopus” whose
growth reminds us of a monster escaping
our control.
THE SOLUTION
A closed loop network allows the air The size of each loop does not need to be
supply to flow through several lines at a uniform. The important thing is to have at
COMPRESSOR
time to any given point on the network. least two different supply routes available
The balance between pressure, air flow simultaneously for each feeder pipe
and stability of supply is ensured by using descending toward a tool or piece of
a single diameter for piping. This type of equipment.
system will also easily accommodate This type of network is the ideal situation
modifications and can easily supply tools for compressed air distribution systems,
and equipment with varying supply providing the balance between flow and
requirements anywhere on the network. pressure required to provide the most
Ball valves permit the isolation of a efficient distribution of compressed air.
particular portion of the air line network
to allow for easy:
• Repairs
• Connections
The equipment located • Enlargements
at point A demonstrates • Periodic maintenance
that the air supply flows
through several lines at
a time, providing
balanced pressure and
air flow.
OPTIMAL NETWORK EFFICIENCY
TOPRING
A well-built closed loop network is • Offers a constant air flow at all times
therefore most often the ideal situation • Guarantees a uniform pressure
for the distribution of compressed air. through out
In addition to being easy to plan and to • Contributes to the life of the
compressor by limiting functioning
modify when needed, this type of
time
distribution system becomes an immense
compressed air reservoir that: • Reduces the electrical consumption
of the compressor
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S
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COMPRESSED AIR DISTRIBUTION SYSTEMS
PROPER SYSTEM DESIGN CAN
INFLUENCE AIR TREATMENT NEEDS
A properly designed system can offer cleaner air of the
appropriate volume and pressure, translating to better tool
performance and worker productivity.
06 SYSTEM DESIGN
07 System design should start with a layout of the
shop or plant. Designate where and what tools will
be used. Determine the placement of the mainline.
Try to keep the line as short as possible while
providing access to where tools are used. Try to
keep in mind any future needs or alterations. It is
much easier to make changes if they are planned for.
Drop supply lines at the point of use or at regular
intervals, to minimize hose length. Size the lines
appropriately for the equipment to be used.
Each supply line should be installed with at least a
filter and regulator. FRLs should be installed at the
point of use, allowing the air to be prepared properly
for the application. Designate appropriate supply lines
as clean air lines for use with paint guns, blow guns
or tire inflator gauges.
On lines operating air tools, install lubricators to
extend tool life.
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NETWORK TYPES
Flow capacity is a function of total network length; longer lines require larger diameters to maintain the same flow and minimise
pressure drop.
The type of network used will also have an impact on line size. There are two basic types of network designs: closed loop and
linear/dead-end. Both are commonly used for compressed air networks.
A D A
EFFECTIVE LENGTH EFFECTIVE LENGTH
= 1/2 x ABCDA = ABC
= ABC
B C
B C
For a closed loop system, the fact that there are always at least two For a linear/dead-end system, the total length of line must be
paths to any point on the loop means that only half of the total length considered when sizing the main air line
must be considered when sizing the main air line
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S
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COMPRESSED AIR DISTRIBUTION SYSTEMS
LINE SIZING FOR A
CLOSED LOOP NETWORK
QUICK LINE & AIR LINE
07
PIPE DIAMETERS
63 mm - 2-1/2"
40 mm - 1-1/2"
28 mm - 1"
22 mm - 3/4" See
page 78 for
15 mm - 1/2" Series 06
NOTE: Equivalent fractional diameters are approximate
60 22 22 22 28 28 28 40 40 40 40 40 40
80 22 22 28 28 40 40 40 40 40 40 40 40
100 22 28 28 28 40 40 40 40 40 40 40 40
125 22 28 28 40 40 40 40 40 40 40 63 63
160 28 28 40 40 40 40 40 63 63 63 63 63
200 28 28 40 40 40 63 63 63 63 63 63 63
300 40 40 40 63 63 63 63 63 63 63 63 63
TOPRING
400 40 40 40 63 63 63 63 63 63 63 63 63
500 40 40 63 63 63 63 63 63
600 40 63 63 63 63 63 ( P) PRESSURE DROP OVER 3 PSIG
800 63 63 63 63
• Calculations based on total maximum pressure drop ( P) of no more than 3 PSIG for entire network, at 100 PSIG @ 60 °F
• Total flow required is the sum of all flows for all compressed air powered tools and equipment
• Note that a typical compressor will produce approximately 4 SCFM per HP
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PIPE DIAMETERS
63 mm - 2-1/2"
40 mm - 1-1/2"
28 mm - 1"
22 mm - 3/4" See
page 79 for
15 mm - 1/2" Series 06
NOTE: Equivalent fractional diameters are approximate
60 22 22 28 28 40 40 40 40 40 40 40 40
80 22 28 28 40 40 40 40 40 40 40 63 63
100 28 28 40 40 40 40 40 40 63 63 63 63
125 28 28 40 40 40 40 63 63 63 63 63 63
160 28 40 40 40 63 63 63 63 63 63 63 63
200 28 40 40 63 63 63 63 63 63 63 63 63
300 40 40 63 63 63 63 63 63 63 63 63
TOPRING
400 40 40 63 63 63 63 63
500 40 63 63 63 63
600 63 63 63 63 ( P) PRESSURE DROP OVER 3 PSIG
800 63 63 63
• Calculations based on total maximum pressure drop ( P) of no more than 3 PSIG for entire network, at 100 PSIG @ 60 °F
• Total flow required is the sum of all flows for all compressed air powered tools and equipment
• Note that a typical compressor will produce approximately 4 SCFM per HP
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S eries 05•06•07
COMPRESSED AIR
DISTRIBUTION
SYSTEMS
Series 05
AIR LINE Nylon 46
Series 06
Aluminium and Nylon 74
Series 07
QUICK LINE Aluminium and Brass 58
w w w . T O P R I N G . c o m
TOPRING
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TOPRING
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S
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COMPRESSED AIR DISTRIBUTION SYSTEMS
COMPRESSED AIR SYSTEM COSTS
Analyses of compressed air system costs are often limited to the Choosing low cost piping and fittings may lower installed costs
07
FITTINGS AND PIPING COSTS
Air system decisions should not be made solely based on the
purchase price of the components.
While the cost of AIR LINE, QUICK LINE and SicoAIR compo-
nents may be higher than traditional black pipe or galvanized
systems, the savings in installation costs make up the difference. TOPRING air system components
are easy to assemble
INSTALLATION COSTS
Labour costs for a TOPRING air distribution system can be as
low as one quarter of the cost of installing a conventional system.
The combination of lightweight materials with easy to use
push-to-connect fittings means that installations can be done in
as little as 25% of the time required for comparable black pipe or
galvanised Steel installations.
TOPRING systems also require less specialized labour, and can
often be installed by the user without outside help.
PRESSURE DROP
Pressure drop occurs when the air system cannot keep up with
consumption, reducing tool efficiency and therefore reducing ALUMINIUM
productivity.
Rough, porous Steel (black) and galvanized piping causes
TOPRING
resistance to the passage of air and reduces the air flow available NYLON
for supplying tools and applications.
Smooth bore Nylon or Aluminium piping provides better flow and
reduced pressure drop, and therefore lower costs.
STEEL
RUST
COMPRESSOR ENERGY CONSUMPTION
To compensate for the pressure drop that can be caused by rough,
Steel tubing is subject to rust and will deteriorate over
porous conventional piping, especially once it is corroded, the time, unlike Aluminium and Nylon, which remain
compressor must work harder, using more energy and adding cost. essentially unchanged
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06
interior surfaces pitted after several years of use cause
greater pressure loss and therefore higher operating costs.
This does not happen with TOPRING Nylon or Aluminium
piping, as this corrosion-proof piping will be as good as new
for many years to come.
Traditional piping corrodes and TOPRING piping resists corrosion
07
allows contaminant build-up and stays clean over time
LEAKS
TOPRING compressed air distribution systems use leak-
proof push-to-connect type fittings, eliminating the risk of
leaks from faulty welds or badly sealed threads.
MAINTENANCE COSTS
Maintenance costs for conventional systems will increase
over time as the components deteriorate. TOPRING air
distribution components will not deteriorate.
TOPRING systems remain leak free, eliminating the need
for leak audits to limit compressed air loss.
High quality QUALICOAT paint prevents scratching and,
combined with the absence of corrosion, TOPRING piping
systems do not need to be repainted over time.
TOPRING piping is painted blue for easy identification
OVERALL SYSTEM COSTS ARE THEREFORE Total cost comparison between the TOPRING compressed
LOWER WITH TOPRING COMPRESSED AIR air distribution systems and conventional systems
DISTRIBUTION SYSTEMS TRADITIONAL STEEL OR
COPPER SYSTEMS
While TOPRING air distribution system components may $$$$
make up a greater proportion of total initial cost than in a
conventional system, total system cost is reduced over the TOPRING
life of the compressed air system. Maintenance costs COMPRESSED AIR
DISTRIBUTION SYSTEMS
This is due to the unique advantages of TOPRING systems: $$$$
Maintenance costs
• Lower installation costs
• Fewer leaks Operating costs
Operating costs
TOPRING
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S
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COMPRESSED AIR DISTRIBUTION SYSTEMS
THE IDEAL COMPRESSED AIR DISTRIBUTION SYSTEM
07
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22 mm
15 mm
175
PSI
220
PSI
Actual dimensions
Series 07 QUICK LINE
PIPING 63 mm
FITTINGS
40 63 40 63
TOPRING
220
PSI
45