running compressed air for production area

[mechengdude]

My question is on a topic I don't normally deal with:
We are running some compressed air lines in a production area to supply air tools.

For those that do this on a regular basis, any advice or known pitfalls would be helpful to know. In my mind sizing the compressor should be fairly simple based on the number of tools and requirements, psig and CFM. Although again for you guys that do this all the time let me know what I forgot.

Also I am concerned about any OSHA or other regulations I may not be aware of. This is being done in the USA. Are there any requirements for safety values in a compressed air system other than on the tank? Any certain pipe material requirements, etc.

Thanks

 

[budt]

take a look at this web site:

http://www.compressedairchallenge.org/

Bud Trinkel, Fluid Power Consultant
HYDRA-PNEU CONSULTING

 

[TheTick]

Remember drainage points at the low points in the system. These are usually a vertical length of pie at the low points capped with a 90° acting ball valve.

 

[TheTick]

pipe, not pie

 

[berkshire]

mechengdude,

Smaller pipe sizes are often done in copper , with the price of copper what it is today, epoxy coated aluminum pipe is a good alternative, here is a link to one manufacturer.

http://www.raccordsprevost.fr/catalogue/Prevost/en/index.html

They also have pre assembled end fittings.
B.E.

 

[tygerdawg]

I second berkshire. There are some very nifty aluminum extrusion systems out there designed for air supply delivery. The cost, out of the box, appears to be too high. But very little labor is needed to throw it up, to add to it at a later time, or to tear it all down and move it somewhere else in a different configuration. THAT's where the cost savings is.

I vaguely remember that Ingersoll-Rand might have had a system to go along with their compressors. I recommend you look into something like that.

TygerDawg
Blue Technik LLC
Virtuoso Robotics Engineering

http://www.bluetechnik.com

 

[CoryPad]

I third berkshire and second tygerdawg. The TRANSAIR system from Legris is excellent.

Regards,

Cory

Please see FAQ731-376 for tips on how to make the best use of Eng-Tips Fora.

 

[arunmrao]

When you have multiple tools being used at different work stations, line distribution of air is important. Remove all sharp bends and provide drainage points along the lines.This will avoid pressure drop. Always have a pressure regulator moisture trap and a lubricator at each work station.



Chocolates,men,coffee: are somethings liked better rich!!
(noticed in a coffee shop)

 

[IceStationZebra]

From an OSHA standpoint I believe that you can not set the air pressure any higher than the lowest rated tool. The shops I have worked in have dropped the shop air down to 90psi to get around this since people will use the tools at different stations.

Page 14 of the document Bud recommended says "A loop system is generally recommended, with all piping sloped to accessible drop legs and drain points." I have heard the recommendation for a loop before, but I'm not sure why. I suspect it eliminates problems with dead zones and moisture, but it could also do with minimizing pressure drop because air would have two routes.

ISZ

 

[Ross0684]

Mechengdude
Try and create a ring main, that is do not have a blind end to the pipe runs.
Take discharge points off the top of the main line, moisture drains off bottom of main line,
slope main line away from compressor infeed point to drain points
Blow moisture traps drains off regularly or have auto moisture traps
Size the compressor with a decent safety factor for future usage
Good maintenance, correct air leaks if any as they occur.
Ross

 

[SincoTC]

We fitted out our new workshop and renewed all the old metal airlines in our old factory with John Guest Plastic tubing and Speedfit joints and fittings eight years ago. It all came on line without a single leak and has remained so to date. It works fine on vacuum or water too and all you need is a hacksaw and something to deburr the cut. Joints just push fit by hand and can be dismantled just as easily.

http://www.johnguest.com/application_idx.asp

Trevor Clarke. (R & D) Scientific Instruments.Somerset. UK

SW2007x64 SP3.0 Pentium P4 3.6Ghz, 4Gb Ram ATI FireGL V7100 Driver: 8.323.0.0
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[MiketheEngineer]

Remember to use all the same fittings for the tools. I worked for a company where there were multiple fittings for various tools.....

WHAT A NIGHTMARE. Finally fitted all tools with same fittings and solved all kinds of problems.

 

[berkshire]

mechengdude (Mechanical)
One thing nobody else has mentioned yet.
Unless you are in an area of the country where the relative humidity is very low, I would recommend a refrigerated air dryer, if you can afford it.
On days where the relative humidity is high and you have a greater than normal group using air, the compressor tank will get hot and instead of condensing moisture out of the air will dump it down the line where it will then condense out in your air tools.
B.E.

 

[zuccus]

Always put moisture traps at every drop and take the line off the top of the main header even if you have a dryer.

At the drops most people I see put in double block valves with the top one being always open and the one on bottom being the valve you work.

If it is a large distribution header, I would put block valves in at the main branches also.

Zuccus