ENGINEERING YOUR SUCCESS.. Best Pneumatic Practices – General Air Cost Facts As much as 25% of air...

ENGINEERING YOUR SUCCESS.

Best Pneumatic Practices –General Air Cost Facts

• As much as 25% of air costs in a plant can be associated to simple leaks

• The higher the operating pressure, the higher the cost – artificial demand

• Compressor efficiency can be as low as 65%, and run continuously in most facilities.

• A combination of smart engineering, zero leakage products, and application of Best Pneumatics Practices still provides a cost effective solution for the motion and control industry

Best Pneumatic Practices –General Air Cost Facts

• Compressed air cost is as much as eight times greater to produce 1 HP of pneumatic energy vs. electrical – For every $1 spent on electricity for compressed air, only about 12¢ comes out as useful work performed.

• As much as 20-30% of air costs in a plant can be associated to simple leaks

• Another 20-30% is inappropriate uses or artificial demand

• Every 2PSI reduction in air pressure equates to 1% of input HP cost reduction in electricity

• 1cfm =1/4HP =.207Kw@$.06/kwh = $110/yr1

1Based on 90% compressor efficiency

Pneumatic Best Practices – Design Consideration

• Sizing and selection of tubing, hose and connectors: Proper sizing of components reduces capital investment and replacement cost. Don’t undersize or grossly oversize!

• Utilize smart air preparation systems that provide adequate flow and PM detection devices (ΔP monitors)

• Specify valve products that provide leak free spool technology and low wattage coils

• Upgrade cylinders that provide repairable rod glands on cylinders, properly sized for 60psi design

• Implement cycle timing controls on blow-off applications to reduce operating cost

• Utilize Economizing Vacuum Generators for air cost reduction

Fluid Connector Technology Best Practices

• Fitting Selection - Type– Push to connect

fittings offer the best total cost of ownership from an assembly standpoint

Note: for reliable, leak-free Operation, it is imperative that the properTubing be used with these fittings!


• Value Statement– Push to connect

fittings can be assembled in 1/5 the time of standard compression fittings. This will result in direct labor savings which drops right to your bottom line


• Fitting Selection – Style– Where ever possible, use straight fittings in

place of 45 or 90 degree elbow fittings to minimize pressure drop

– Example: A straight fitting ¼”NPT by ¼” OD tube at 15 SCFM and 60 psig will have a 2 psi pressure drop

– The equivalent size 90 degree elbow under the same parameters will have nearly twice the pressure drop


• Thread Sealants– Many options exist, TFE tape, “pipe

dope”, Loctite compounds

– All of these sealants rely on the user to properly apply the correct amount

– Improper choice or application of thread sealants can result in system contamination or air leakage

– Select fittings from a supplier having factory applied thread sealants

Best Pneumatic PracticesAir Prep Assemblies - Smart Air Prep Systems

• Drip leg assemblies and value added considerations

• Primary (particulate) filters • Coalescing (oil removal) filters• Pressure drop indicators and

sensors• Regulators • Lubricators

Air Prep Systems - Drip legs

• Provide drip legs with service valves, water trap, and water separator

• Provides for equipment protection at user plant against water and oil contamination

• OEM’s normally do not supply but should consider as value add to customer and minimize damage to equipment in the event of dryer malfunction or failure

Air Prep SystemsFilters

• Primary Filters – Remove water and particles typical 40micron.

5 & 10 micron units may require larger body sizes to meet comparable flow

• Coalescing Filters – Removal of water, aerosols, oils and provide 0.01 micron

filtration protecting system components and premature failure– Filter ratings are in SCFM with coalescing having the lowest

flow rating within body size selection- IMPORTANT: pay close attention to initial pressure drop of filters!

• Undersized or clogged filters create pressure drop reduce flow and increase air and maintenance costs $$$

• Use of PDI visual and electrical sensors provide a solution for preventative maintenance to detect pressure drop as filters clog

Air Prep SystemsSensors

• Pressure switches provide monitoring of operating pressure

• PDI indicators provide pressure drop detection specific to selected filters (dynamic)

• Sensors can be integrated into machine control screen displays as service needed at specific locations or machine shut down

• Smart Air Prep systems provide PM detection for servicing filtration and pressure controls in plants that do not have proactive maintenance programs or resources.

• This adds intelligence to your equipment and adds value in True Cost of Ownership for your customers

Air Prep Systems - Regulators• Regulators reduce pressure at

machine point of use and are rated in SCFM

• Various pressure ranges available for prevention of excessive pressures as user will increase pressure to compensate for pressure drops in filters

• Cost savings opportunities with regulators used on actuators will be discussed later in the presentation

Air Prep Systems- Lubricators• Lubricators only needed for close

tolerance metal to metal devices, i.e., air tools. Use non lube service products for applications that don’t require lubrication.

• Rated in SCFM

• Low oil sensors provide PM detection for empty bowls reducing damage to equipment

• Qualify if needed for capital cost reduction and added leakage potential (reliability)

Best Pneumatic PracticesDirectional Control Valves

• Proper sizing of valves (Cv)

• Solenoid technology – low power consumption

• Spool technology – no internal leakage

Best Pneumatic Practices – Valve sizing

Best Pneumatic Practices –Valve Designs Direct Operated

• Use solenoid power to shift spool armature to spool

• Solenoid consumption as high as 6-8 watt coils*

• Prone to burn out from high heat or stall• Require different coils for each valve size• High cost for coil replacement and time• Shifting speeds slower ~ 45ms• Minimum shifting forces dependent on coil

power• No minimum operating pressure

*Manufacturer’s rating

Best Pneumatic Practices- Valve Design Air Pilot Solenoid

• Uses air pressure to shift spool • Solenoids consume 1.8-2.4 watts*• Burn out reduced to minimum or none• Utilizes common coil in various valve sizes• Lower cost for replacements and labor

time• Shifting speeds faster 18-22ms*• Greater shifting power not dependent on

coil• Minimum operating pressure 20-25 PSI


Lapped Spool Technology

• Metal to metal spool designed to leak • Spool leakage rate new range from 50-300sccm*• Close tolerance matched sets• High replacement cost • Leakage rate 5 million cycles 1,000-5,000sccm*


WCS Spool TechnologyWear Compensated Spool

• Molded nitrile seal prevents leakage and wear

• Leakage rate new 0 - 10sccm*

• Single slip-in replacement spool• Low replacement cost spool design

• Leakage rate 5 million cycles 0-20sccm*


WCS Spool Technology• Seal width is less than spool seal Seal width is less than spool seal

groove. Specially molded nitrile seals groove. Specially molded nitrile seals (Not o-rings)(Not o-rings)

• Under pressure, the seal is forced Under pressure, the seal is forced outward to seal on the valve boreoutward to seal on the valve bore

• The seal is also forced to one side of the The seal is also forced to one side of the groove, to seal against the groove wallgroove, to seal against the groove wall

• During the life of the valve, as seal During the life of the valve, as seal material wears, the seal expands to material wears, the seal expands to compensatecompensateThis prolongs the life of the valve and This prolongs the life of the valve and prevents air leakage at the spoolprevents air leakage at the spool

Leakage Cost of Lapped Spool designSimple Calculation of Electricity Cost for Valve

Leaks in a PlantInsert your values in the yellow boxes to get the annual cost

Lapped Spool SCCM Leak per Valve300

0 SCCM ( Standard Cubic Centimeters per Minute )

Number of Valves in the Plant 100

Operating Pressure 100 PSI

Number of Shifts in a Day ( assuming 8 hour shifts ) 3

For a Lapped Spool use 3 due the fact that they constantly leak

Number of Operating Days in a Week 7

For a Lapped Spool use 7 unless the compressors are shut down during the weekend

Full Cost of Electricity 0.09

$/kWh ( Approximately $0.05 per U.S. Department of Energy 2004, please note that this is only the cost of providing electricity to the plant and it does not take maintenance into account, in order to compensate for maintenance you can estimate around 0.09$/kWh)

Annual Cost of Leaks $2,710.47

Leakage Cost WCSSimple Calculation of Electricity Cost for Valve

Leaks in a PlantInsert your values in the yellow boxes to get the annual cost

WCS SCCM Leak per Valve 25 SCCM ( Standard Cubic Centimeters per Minute )

Number of Valves in the Plant 100

Operating Pressure 100 PSI


For a Lapped Spool use 3 due the fact that they constantly leak


For a Lapped Spool use 7 unless the compressors are shut down during the weekend



Annual Cost of Leaks $22.59

Actuators• Majority of actuators are cylinder devices

• Vast majority of cylinders used in industry

are 4” Bore or smaller

• Valves to operate these cylinders require 1.0 Cv or less

• Majority of cylinders do work in one direction, i.e., on extend stroke

Actuators• Reducing operating pressure provides

huge savings in air cost and maintenance- reduce artificial demand

• Size cylinders at 60PSIG design pressure to provide safety margin and reduce air costs using regulators to reduce pressure

• Upgrading cylinder quality, such as replacing throw away designs with repairable cylinders, will prevent premature failure and air leakage at rod gland.(increased reliability and reduced operating costs)

• Specify repairable cylinders with replaceable rod cartridges on new installations for longer life and fewer leaks

Sandwich Regulators• Advantages

-Pressure control of extend and retract reduces air costs and damage to components and mechanical devices

-Convenient assembly and aesthetically pleasing design

• Disadvantages-Significant flow reduction vs inline reverse flow regulators.- Potentially higher capital cost

Reverse Flow Regulators• Piped between valve and cylinder, provides independent

pressure control for extend and retract• Provides reverse flow at high flow rates without inline reverse

flow check valve• Relieving design saves air and wear on components and

mechanical devices

Reverse FlowReverse FlowNormal OperationNormal Operation

Cost Savings Due to Using Parker's Reverse Flow Regulators

( Assuming Power Stroke On Extend )Insert your values in the yellow boxes to get the annual cost

Cylinder Bore 4 Inches

12.57 =

Cylinder Area

In ^2

Cylinder Stroke 12 Inches

Cylinder Rod Diameter0.62

5 Inches

12.26 =

Eff. Area

In ^2

Cycles per minute ( extend and retract ) 12

Number of Actuators in the Plant 1

Extend Pressure 80 PSI6.44 = Comp Factor

Retract Pressure 80PSI ( for spring retract cylinders use 0 )

6.44 = Comp Factor





Annual Cost of Electricity with Normal Regulators

$1,558.75



Cylinder Bore 4 Inches

12.57 =

Cylinder Area

In ^2


Cylinder Rod Diameter0.62

5 Inches

12.26 =

Eff. Area

In ^2





6.44 = Comp Factor






$922.17



Cylinder Bore 4 Inches12.57 =

Cylinder

AreaIn ^2


Cylinder Rod Diameter 0.625 Inches12.26 =

Eff. Area

In ^2





3.72 = Comp Factor






$922.17

Annual Cost of Electricity with Reverse Flow Regulators

$689.09

Annual Savings $233.08

Best Pneumatic Practices- Air Leakage Rates and Cost

($0.237/MCF @ 8,736 Hrs/Year @ 100 PSIG @ $.09 kWh)

• 1/16” Diameter leak = 6.5 CFM = $800

• 1/8” Diameter leak = 26 CFM = $3,208



• (Vacuum and blow off typical @ 1/4” and 3/8” rates)

Savings from 60% reduction in air used: ¼’ air line pressure reduced from 100 PSI to 40 PSI minimum needed for the job: Savings from reducing pressure to what is needed $ 5661.60 Savings from shutting air of when not needed + $ 622.06Equipment Cost: - $ 837.60Estimated Cost Avoidance per year for energy: $ 5446.06

This is a projected estimate based on equipment efficiency . It does not take into account the time the air is used while equipment is not in production. System will be designed to turn off air if machine is idle for more than 1 minute (possible that time could be reduced even more). Will automatically restart once production resumes.

Cost Avoidance from not using open ¼’ Airline to move rivetsIt will take using the system for approximately 90 days to recover cost of

equipment due to reduction of compressed air needed.

Air Cost Savings ExampleDial Table Blow Off Application

Current Cost 365 Days Per Year $9,436

Vacuum Solutions:Air Economizing Vacuum

w/ Emergency Stop Function

Why Air Economizing ?

Sequence:

1. Turn on vacuum – 1.5 seconds

2. Contact & pick up part

3. Travel time – 30 seconds

4. Wait/queue for another machine function – 7 seconds

5. Shut down???


Operation:

1. Build vacuum

2. Sensor detects desired vacuum level & part present

3. Shuts vacuum generator OFF

4. Sensor turns generator on when vacuum drops to a preset level

Sequence:





5. Shut down???


Operation:

1. Build vacuum

2. Sensor detects desired vacuum level & part present

3. Shuts vacuum generator OFF

4. Sensor turns generator on when vacuum drops to a preset level

Sequence:





5. Shut down???

Vacuum off over 90% of

time

while part

is present = $$$

The Machine Builders’ (OEM) Opportunity

• Educate your customers before your competitors do.

• By learning more about efficient use of compressed air through better pneumatic designs and component/system selections, you can:– Improve machine efficiency– Reduce air consumption costs– Increase productivity and reliability.

• This can lead to improved competitiveness for you, and less downtime, greater return on investment for your customers!

Cost Of Ownership OEM• Proper sizing of system components optimizes system

efficiency and minimizes component cost

• Reducing required operating pressures saves money on air and maintenance cost

• Utilize valve products with low or no leak design

• Utilize solenoid air pilot and low watt coil designs to reduce electrical cost

• Provide air prep devices with PM devices to protect equipment and provide value add

Cost Of Ownership OEM• Select higher quality repairable actuators that will last longer,

leak less and reduce maintenance costs

• Shut off air on vacuum and blow offs by using Economizing Vacuum Generators and timing systems, saving end user air cost

• Sell value of lower operating cost and better quality (i.e., reliability) to justify any capital cost

• Sell more machines, make more money, reduce service and warranty issues with customers

How can you the OEM capitalize?

• Do side-by-side or on-location comparisons between your equipment/functions vs. your competitors (record the data)

• Use the cost of air calculators shown to you (available from Parker) or create your own to demonstrate the value of your solution vs. competition

• Have a Parker PASS team analyze and make air saving design recommendations

• Document cost or value in use to your customers

Results?• Smarter, more efficient machine designs that

can save significant $$$ for your customers – bring them value!

• Most of these design tips will also result in lower maintenance costs because systems are running on lower pressures (less wear & tear)

• More equipment sales or profitability for OEM Machine builders

Thank you for your time!

Questions?PASSParker Air Systems Solutions

ENGINEERING YOUR SUCCESS.

ENGINEERING YOUR SUCCESS.. Best Pneumatic Practices – General Air Cost Facts As much as 25% of air...

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