Ref. No. SNTI/MAP/SM/58 Rev. No. 00.

STUDY MATERIAL

"Lets us Learn and Lead"

 Pneumatics

Ref. No. SNTI/MAP/SM/58 Rev. No. 00.

STUDY MATERIAL

PRODUCED BY DIRECTED BY APPROVED BY

EMAM GAZALI KHAN PANKAJ KUMAR B. N. SARANGI

Manager (MAP) (Head Improvement Chief (Employees
Initiatives) Training Development)

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 Pneumatics
Foreword

Total productive Maintenance (TPM) is a world-class improvement process which keeps

the production system at its effective best. In recent years we have implemented TPM in
most of the departments of Tata Steel. Among the eight pillars of TPM “Autonomous
Maintenance” is the most important one, and it involves the participation of operators in the
daily routine maintenance of machines. It helps in finding out the smallest fault in the
machine and also tries to solve the problem. In the fourth step of autonomous
maintenance operators have to be trained on machines and their systems for which seven
modules have been proposed. ‘Industrial Pneumatics’ is the second module out of the
seven proposed modules, JIPM consult out Mr Tomoyo Watanabe was of the view that out
operators should have sound knowledge of industrial Pneumatics so TPM is implemented.

Keeping in mind these facts study material on "industrial Pneumatics" has been prepared
in simple language for the operators to understand
easily. The other five modules will be ready shortly.

I am sure that this effort will go a long way in helping the operators to get trained.

B. N. Sarangi
Chief Employees training & Development

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 Pneumatics
PREFACE

Traditionally the maintenance of pneumatics system is the responsibility of

"maintenance group" and its operation is taken care of by the "operation
group". Therefore, maintenance group and operations group personnel have
been trained on maintenance and operation respectively. But, conceptually in
Total Productive Maintenance (TPM) the operator also play on important role
in maintenance of pneumatic systems. Therefore, operators must have a
good knowledge of pneumatic systems. To fulfill this objective, seven
modules on maintenance has been prepared. ‘Industrial Pneumatics’ is the
second module.

In addition to the study material, work bench is also being prepared - this will
help the workers to improve their skill. As soon as the work bench is prepared
we will start training. Other five modules are also being prepared. We have
already started work on hydraulic and lubrication.

We welcome suggestions to improve this study material.

Sarvesh Khanna
Head Technical Education

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CONTENTS

Sl.No. Topics Page

1. Pneumatics: A Brief Introduction 01

2. Safety 02

Method Of Keeping “Pneumatic System’ Without

3. 05
Pressure

4. Fundamental Theory & Introduction To Pneumatics 06

5. Air Preparation 09

6. Drain 11

7. FRL Unit 13

8. Working Element 25

9. Control & Signal Element 26

10. Pneumatic Circuit 30

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1. PNEUMATICS: A BRIEF
INTRODUCTION

Energy Source For Energy Source for Pressure Speed Construction Usage
Generating Safety Conservative Safety Controller Controller Equipment
Equipment After Cooler Flow
Air Air Tank Filter Pressure Control Air Cylinder Machinery
Compressor Regulator Value
Compressed Air is cooled and Compressed Dust particles System Sends oil Reduces Controls Controls the Compressed Machine
air is made moisture is air is collected and moisture pressure is to valves the the speed of the air energy is tools,
ready removed and conserved is removed maintained and sound of direction air converted into construction
as energy within the cylinders exhaust of flow of mechanical industry,
maximum for air energy which transport,
limit lubrication provide motion etc.
to piston

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1.SAFETY AND IMPORTANT DIRECTION

While working on the pneumatic systems the following safety related rules must be
observed.

a) Workplace must be kept clean

b) Any leakage or sound must be attended to immediately.
c) Current, voltage and pressure setting of the compressor must always be
within the prescribed limit.

Needle should be within the green range Needle should be within the green range
Current And Voltage Gauge Pressure Setting

d) Filter and reservoir of F & L unit must be kept clean.

Filter Reservoir

e) While doing any maintenance work on the system, it should be

disconnected from the pressure line.

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 Pneumatics

f) Pressure setting of the pressure regulator should be correct.

Check Pressure
Set pressure here

g) Level of oil in the lubricator should be correct and the flow of the oil
should be just as much as is required.

Inspect Oil Level Regulate Flow Wrong Method

Look here

Look here

h) Keep your fingers and clothes away form actuator.

Wrong Method Correct Method

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 Pneumatics

i) Hose pipe should not be connected with the pressure source in the
beginning.

Wrong Method Correct Method

Can get hurt from open pipe Use both hands to connect pipe

j) Use correct method for opening the hose.

Wrong Method Correct Method

Use both hands

Use one hand

Inclined

The incline of the pipe should be

1:100 so that the drain is easy.

Branching of the pipe should be from

the top.

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 Pneumatics

3) Method for keeping 'Pneumatic Systems without Pressure

in a pneumatic system 3/2 way DC value should be installed after the F & L unit. This will prevent the system from being under
pressure, and prevent any accident on account of compressed air.

System air exhaust through DC valve Flow control valve in Meter-IN position

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4) Fundamental Theory & Introduction to Pneumatics.

In modern industry fluid power systems are in many equipments. In these

systems power is translated into work through use of fluid. Fluid can be either liquid
(For exp, oil and water) or gas (for exp, compressed air, nitrogen or carbon dioxide).

Pneumatics is that branch of science which describes the properties and usage
of gaseous material like air. The word pneumatic is derived from the Greek work
"pneuma" which means breath.

Usage of Pneumatic system

Given below are some of the usages of pneumatic system in industry.

Grinding Automising Mine ventilation

Spray painting Screw Driving Dumper operation
Conveying & Transfer Air Brake Air horn
Rock Drilling Riveting Reaming, etc.
Ladle gear operation Emergency Lancing

Sump pump for taking out water Bin gate operation

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 Pneumatics

Geared Pnematic Motor Pnematic Cylinder

Torque Wrench Pnematic Screw Driver

Units for measuring pressure

Pressure: Unit of Measurement

1 Kgt/cm2 = 14.2 lbf/in2

1 N/m2 or Bar = 14.5 lbf/in2
1 Kgf/cm2 = 0.981 Bar
1 Torr = 1 mm of Hg
Atmospheric Pressure = 14.7 lbf/in2
= 1.0332 kgf/in2
= 760 mm Hg.

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 Pneumatics

One Point Lesson

What is Pneumatics?

Main Components of Pnematic System:

! ! " !

Main points about pneumatics:

Air is compressible, By compressing air energy can be conserved.

In less time frame high speed and output can be achieved.
Design of the system makes things easy.
Power can be transmitted to a long distance. Control from a distance is possible.
With less power to control valve high pressure can be controlled.
From a distance speed, direction and pressure can be easily controlled.
This is a cheap system.
There is no danger of explosion.

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5) Air Preparation (Conditioning)

For correct working of pneumatic system unpolluted or uncontaminated air is

required. Contaminated air affects the different components and system adversely.
Therefore, cleaning of air is very important.

Meaning of Treatment of Air:

To ensure the compressed air which is entering is without dust and moisture.
To control the pressure of the air according to the system requirement.
To ensure the entry of lubricant as mist in the compressed air.

Contaminants enter the system mainly through three sources :-

Built-In: In the newly fabricated systems where during construction dirty components
and pipes are used, contaminants enter the system. These are built-in contaminants.

Generated: The second reason is that dirt gets generated within the system. The
parts which are operating in the system generate dirt particles arising out of friction
among the moving components.

Ingested: This is the third reason for the entry of contaminants in the system. When
a valve or component fails, and it is either repaired or changed at site, then it easy
for the contaminants to enter the system. Contaminants also enter the system
through piston rod.

Category of Air Treatment :

Clean and dry air helps in reduction in leakage and increase in time between
maintenance of pneumatic system. Atmospheric air contains many faults (smoke,
dust, water, vapour) which makes it necessary to treat the air before usage. Normally
treatment is dirked into three categories which is illustrate through pictures.

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First Category : The inlet filter removes such particles which will harm compressor.

Inlet Filter Absorber Dryer

Thereafter it is necessary to reduce the moisture in the air to dry it. This is normally
done between compressor and receiver, and it is called Primary Air Treatment.
Secondary treatment is done on the basis of local work. Dust and moisture are
removed and fine oil mist is made to enter for the purpose of lubrication.

For secondary treatment FRL unit is

used just before the system.

FLR (Filter, Regulator & Lubricator) Unit : This is called service unit.

F (Filter): Air line filter is such an equipment that it keeps away both the
moisture and solid contaminants.
R (Regulator) : This is a normally opened valve. It converts high inlet pressure into
low outlet pressure. It is a pressure reducing valve which maintains
the outlet pressure at the required level.

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L (Lubricator): Oil along with air serves the purpose of lubrication in different valves
and actuators.

6. Drain (Concentrated Liquid)

1. Drain is a mixture of three things. These are.

a) Moisture (b) Small droplets of oil (c) Fine dust particles and
chips

Moisture

Oil Dirt Particle

2. Different Components of Drain.

a) Moisture: When temperature of the air increases in the compressor, then

moisture in air becomes water.
b) Oil: Dirty oil from compressor mixes with water
c) Dust Particles: Fine dust particles pass through the fitter. These combine with
rust inside the pipe, fine particles generated form friction, seal particles, etc.

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Method for ejecting Drain

Through Drain Separator: When the compressed air comes out of the after-cooler,
then it is made to pass through drain separator where it is separated and drained out
after opening the valve.

Through Drain Separator Wter Ejected Out Through Drain Valve

Drain

Water

Through Receiver Tank: Drain accumulates at the bottom portion of the receiver
tank. It is drained out after opening the valve
Through Receiver Tank Through FRL Unit

Drain Valve

Drain Plug

Drain

Through FLR Unit : Drain accumulates at the bottom of air filter. It is drained out after
opening the valve. This also happens automatically.

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7. FLR Unit : (Filter – Regulator – Lubricator)

Air Filter's Function ;

a) It separates dust particles, moisture, metallic particles, etc.
b) When the air filter does not function properly, then moisture and contaminants
reach lubricator where they mix with oil.
c) When moisture and contaminants reach valves and cylinder, then the rusting
process beings. This spoils "O" ring and packing deteriorate – their capability
reduces.
Points for Inspection
a) When the filter element gets jammed, the pressure gauge of the cylinder will
suddenly indicate low pressure.
b) When the drain level increases in the filter bowl, water flows along with air and
filter’s capability reduces.
c) Filter bowl should be cleaned with kerosene oil or detergent. Petrol or thinner
should not be used.
d) Fitter element should be cleaned once in three months and the inner surface
should be cleaned with compressed air.

Filter Element: Method For Cleaning Made of Sintered Bronze

Air

Dirt

Precaution :
Drain valve can be opened by hand. There is not need to use any tool.

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 Pneumatics

One Point Lesson

Item: Filter – Inspection Items Inspection of Choked Drain

When drain cock is

closed then water
and dirt gets
deposited in filter
bowl

Drain is taken out through

drain cock
ILL Effect ILL Effect
Wear of piston
Wear of valve
spool and 'O' ring

a) Method & Standard for Inspection

While cleaning filter see from outside whether drain has accumulated inside
the bowl or not.

b) Solution (in case of any irregularity)

Loosen the drain cock with hand and water and contaminants will come out.

c) Ill Effects

Moisture mixed with air adversely affects lubrication.

Friction in the direction control valve could increase.
Internal leakage could increase.
DC valve and actuator may display unnatural behavior.
Processing could become unnatural and affect adversely the quality of the
product.
With depositions in the flow control valve the flow rate could reduce.
The life and speed of the actuator could reduce.
Water and contaminants could come out through exhaust..

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 Pneumatics

One Point Lesson

Item: Filter – Inspection Item Inspection of Deflector

Size should be correct

There should not be any crack or hole.

ILL-Effect

ILL-Effect of failure of lubrication

a) Method of Inspection & Standard

Remove the bowl to inspect crack or deformation in the deflector.

b) Solution (in case of irregularity or something being wrong)

Change the filter.

c) Ill- Effects
In the absence of sufficient centrifugal force the contaminants will not be
removed.
Large amount of moisture combining with air will affect the lubrication in the
system.

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 Pneumatics

One Point Lesson

Item: Filter – Inspection Item Inspection of Buffel Plate

$ There should not be crack or hole

$
Filter element gets jammed

a) Method of Inspection & Standard

Take out the buffel plate and check whether it is broken or dirty.

b) Solution (in case of irregularity or something being wrong)

In case the buffel plate is in bad condition, change it.
When it is dirty clean it before putting it in place.

c) Ill – Effects
Drain and dirt can remix with air and choke the filter element.
It will affect the lubrication adversely.

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 Pneumatics

One Point Lesson

Item: Filter – Inspection Item Leakage in the pipe joint

Putting soap water at joints

for checking leakage.

Check for
Leakage
here

ILL-Effect

Check for Speed of the actuator can reduce

Leakage here

a) Method of Inspection & Standard

With soap water at the joints check for leakage

b) Solution (in case of irregularity of something being wrong)

If there is leakage even after tightening, then change the seal.

c) Ill – Effects
There can be reduction in pressure.
Actuator operation could be irregular.
The quality and speed of construction can be bad.
There can be breakdown.

17

Inspection points
1. Drain is choking
2. Crack in the fitter
bowel and dirt sticking to Check while cleaning filter
the inner surface
3. condition of deflector
4. Condition of the filter
element
5. Condition of Buffel
Plate
6. Check the filter for its
being vertical
7. Leakage of air from
pipe fittings
Pneumatics
Filter: Normal Inspection Page
Reasons for categorization
Methods of inspection & Inspection Solution
Changing or
Decision Standards Result Detail Stable Semi Stable
unstable
Check while cleaning filter
Open the filter bowl and check
Open the filter element,
inspect, clean and change, if
necessary.
Inspect the fitter bowel after
opening it
Filter should stand upright.
Check by plumbing or any
other means.
Inspect using either water or
soap water bubbles at the joint
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 Pneumatics

One Point Lesson

Item: Pressure Regulator Inspection Item – Checking Pressure
Gauge for ‘0’ Error

In case of no supply of air

the needle should be at 'O'.

a) Method of Inspection & Standard

Stop the supply of air to check whether the needle has returned to "0".

b) Solution (in case of irregularity or something being wrong)

Send the pressure regulator for inspection.

c) Ill – Effects
Wrong information about air pressure
Irregular ups and downs in air pressure
Quality of construction and speed will go down
There can be breakdown.

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 Pneumatics

One Point Lesson

Item: Pressure Regulator Inspection Item – Checking Operating
Range Pressure

Operation pressure
should be within
prescribed range.

a) Method of inspection & Standard

Breakage of glass while cleanings of pressure gauge, bending of needle,
damage to the control area markings, technical details of the pressure gauge
and machine.

b) Solution (in case of irregularity or something being wrong)

Change the pressure gauge
On the basis of technical details mark the control area

c) Ill – Effects
Control can become difficult
Pressure may become erratic
The function of actuator ca become irregular.
Quality and speed may go down
There can be breakdown

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 Pneumatics

Filter : Normal Inspection Page

Methods of inspection & Inspection Solution Classification of Causes

Inspection points
Decision Standards Result Detaiis Stable Semi Stable Changing

Stop the supply of air to see

1. Check the pressure
whether the needle is at "O"
gauge for "O" error.
or not
2. check the glass of Clean the gauge and check
pressure gauge, needle whether the glass is
and pressure range completely transparent or
not, the needle is straight or
not, the minimum and
maximum operating range
markings are risible or not
3. Check for continuous In case of continuous
leakage from the leakage from the exhaust
exhaust check the diaphragm
4. Inspection of pipe Apply soap water to check
joints the leakages at the joints

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 Pneumatics

One Point Lesson

Item: Lubricator Inspection Item – Level of Oil

Fill oil here

Oil should be Wear of piston and valve

between the spool is accelerated.
levels marked.

a) Method of inspection & Standard

Check whether the level of oil is at the centre between the maximum and
minimum level markings

b) Solution (in use of irregularity or something being wrong)

In case oil level is low, then fill with oil till the level of oil is upto the maximum
level marking.
In case oil level is higher them the maximum level, then drain out the excess
oil.
c) Ill – Effects
In case of less oil, the internal friction increases resulting in increase in internal
leakage (inside valve and cylinder) leading to quality and speed going down.
Break down can also result
In case of more oil, instead of oil splitting into small particles, they can jam the
pipe and components thus affecting lubrication adversely.

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 Pneumatics

One Point Lesson

Item: Lubricator Inspection Item – Supply of oil/minute

ILL-Effect

Piston and valve spool

wear is accelerated.

Look here

a) Method of Inspection & Standard

Clean the oil dripper (flow control valve) and check the number of drops mixing
with air per minute.

b) Solution (in case of irregularity or something being wrong)

Set the drip (flow) again as per need.
In case there is no drip, then clean the oil dripper.

c) Ill – Effects
In case of high oil flow (drip) there will be higher friction resulting in higher
temperature
Air leakage can increase affecting the operation of valve and actuator which in
turn will result in speed of operation and quality getting affected.
Lessening of oil drips will result in increase in friction between parts and
increase in internal leakage causing the seals of DC valve and actuator getting
bad.
Operation of valve and actuator can become abnormal resulting in breakdown.

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 Pneumatics

Oil Lubricator : Normal Inspection Page

Methods of inspection & Inspection Solution Classification of Causes

Inspection points
Decision Standards Result Details Stable Semi Stable Changing

1. Inspection of oil While cleaning the oiler and

quality. everyday before starting
work, check whether the oil
level is within the prescribed
twits
2. Deterioration in the
Take out some oil and check
quality of oil and mixing
using filter paper.
of water and dirt
Clean oil dripper and check
3. Quality or rate of drip
whether the flow is as
per minute
required or not.
Put soap water and bubbles
4. Checking the joints
on the joints to find whether
for leakage
there is leakage or not.

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8) Working Element

Working elements are of two types

1. Linear actuator 2. Rotary Actuator (Sump Pump)

Water

Cylinder

LINEAR ACTUATOR
Single Acting Cylinder Double Acting Cylinder
a) Diaphragm type a) Non-cushioned & cushioned type
b) Rolling Diaphragm type b) Tandem cylinder
c) Piston type c) Double ended piston rod cylinder
d) Multi position cylinder
e) Impact cylinder
(f) Rodless cylinder

ROTARY ACTUATOR

Uni-Directional Bi-Directional

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9) Control & Single Elements (Valve)

Different types of valves are control and signal elements, and they are converted into
such type of equipment which can he used to control and regulate.
Defending upon the type of work the available valves have to perform for pneumatic
control, they are classified in four categories.

1. Direction control valve

2. Non-return valve
3. Pressure control valve
4. Flow control valve

Direction control valve: This is used for controlling the direction of air and is mainly
used for commencement and termination. One the basis of direction of air flow,
position and port connection, the valves are 2/2-way, 3/2-way, 4/2-way, 5/2-way, 4/3-
way or 5/3-way. The first number indicates the port while the second shows the
position.
2/2 way Direction control valve:
This has one inlet and one outlet. This is used as shut-off valve. Normally it is either
in closed or open position.
2/2 Way DC Valve 3/2 way DC valve 3/2 way DC valve

%& '

'
'

( '

3/2 way Direction Control Valve : This has one inlet, one outlet and one exhaust
port. This type of value is used for controlling single acting cylinder or to pilot 5/2 way
direction control valve.

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 Pneumatics

5/2 Way Direction Control Valve : This valve is used for controlling double acting
cylinder. It has two exhaust ports, two outlet ports and one pressure port.
5/2-Way Direction Control Valve 5/2-Way Direction Control Valve
( '

' '
&

&
'
' %&
'

Check valve

5/2 way DC valve Check Valve

Check Valve: Normally non-return valve is called check valve. It stops flow of air in
one direction, and allows flow in another direction with minimum loss of pressure.
Settle valve Settle valve

Out let

Inlet Inlet

Shuttle Valve (R-Valve): It has two inlet and one outlet ports. It is used in such
places where cylinder or valve has to be operated from one of the two valves.

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Two Pressure Valve (And Valve): It is mainly used for interlocking, control, safe
guard or monitoring. It has two inlet and one outlet ports. Two input signals must
combine to give one output signal.

Flow Control Valve Two Pressure Valve

( '

Quick Exhaust Valve: This valve is so designed that the air exhausting from the
cylinder is very fast so that the piston speed increases. It is located near the cylinder.
Quick Exhaust Valve Quick Exhaust Valve
!

) %& '

Pressure Limiting Valve (Relief Valve): This valve protects the system when the
pressure exceeds the fixed limit. It is used for exhaust unloading of the compressor.

Pressure Limiting Valve (Relive Valve)

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 Pneumatics

Sequence Valve: It is used in pneumatic control system where operational

sequence is necessary. It is also used in such places where air with sufficient
pressure energy is required for actuator to operate.

Sequence Valve Sequence Valve

Pressure setting is to be done here

Inlet System

Time Delay Valve: Time delay valve has one way flow control valve, small reservoir
and one air operated 3/2 way directional control valve. Variable flow control helps the
air to reach the reservoir and then pressure builds up. Piloting by this air helps the
3/2 way DC valve'
s pressure port to get connected with working port. Pneumatic time
delay valve is used for precise and adjustable time internal.

Time Delay Valve Time Delay Valve

Adjust
flow here Flow control Reservoir 3/2 Way DC
valve
valve

Flow control valve should always be fitted in meter out condition

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 Pneumatics

10) Pneumatic Circuit

Flow Control Valve, if fitted in Meter-IN position, will cause jerk in piston movement i

Flow Control Valve when

fitted in Meter-IN position,
Direction of
flow control
then air enters the cylinder
meter-IN slowly and goes out at
normal flow rate.
Direction
of free
flow

Flow Control Valve, if fitted in Meter-OUT position, will not cause jerk in piston
movement

Flow control valve when

fitted in meter-OUT position,
Direction of then air enters the cylinder at
flow control
Meter-OUT normal flow rate and flows
out slowly

Direction
of free flow

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Please draw a pneumatic circuit fulfilling the following condition :

When one push button operated valve is pressed, then piston should more forward.
When the second push bottom valve is pressed, then the piston should move
backward

l 1.

1.1
II 1.

1.2 1.3
II 1. 1.
3

0.1
IV 0.

1) l Working Element 1.0

2) ll Control Element 1.1

3) lll Signal Element 1.2/1.3

4) lV Air Conditioning Element 0.1

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 Pneumatics

Actual photo of the above pneumatic circuit

Flow Adjustments knob cylinder

Flow control
valve
Meter-IN

Outlet port

5/2-way DC Valve
Pilot port

Pressure port

3/2-way DC Valve

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