Topring Designing an Efficient Compressed Air Network

8/10/2019 Topring Designing an Efficient Compressed Air Network

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DEAD-ENDNETWORK

OCTOPUSNETWORK

A network where each additional line andextension does not necessarily match the

initial configuration is often called anoctopus network. Dead-end networksoften evolve into octopus networks overtime.

The octopus network includes thefollowing anomalies:

Different airline materials

Curves, reductions and enlargementswithout apparent reason

Inconsistent diameters of air lines

Installation done with no knowledgeof pneumatic standards

Predicting what flow and pressure areavailable at any point is virtually

impossible. Air flow fluctuations fromvarying usage of pneumatic equipmentand air tools makes it even more difficultto get the right pressure and flow at anygiven point.

This results in varying pressure and airflow conditions through out the system,creating many problems.

This type of network, while quite common,is the worst possible situation.

In a dead-end network, air flow must besacrificed (quantity of air per minute) inorder to preserve a uniform pressure at thepoint of use. The progressive reduction ofthe central pipe while it moves away fromthe compressor maintains pressure.

However, air tools and equipment mustbe placed along the length of the circuit indecreasing order of consumption (SCFM).

The equipment using the most air flowmust be located near the compressor, andthat using less, further away.

This generates major handling problems,as production processes are not neces-sarily designed this way.

This is not the optimum network design.

CONVENTIONAL

NETWORK

OCTOPUS

NETWORK

The main source of inefficiencies and problemsaffecting compressed air distribution systems isoften the distribution plan of the system itself.

The majority of problems therefore usually occursomewhere between the compressor and theapplication points.

Most systems are usually of either of two types:

Dead-end network

Octopus networkneither of which provides the best results

DESIGNINGANEFFICIENT

COMPRESSEDAIR

DISTRIBUTIONNETWORK

COMPRESSOR

COMPRESSOR

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THE PROBLEM

More than 98% of factories usingcompressed air started out with adead-end network.

Over the years, their systems have cometo resemble a giant octopus whosegrowth reminds us of a monster escapingour control.

At the very least, the dead-end networkthey have has sacrificed air flow in orderto maintain point of use pressure.

A closed loop network allows the airsupply to flow through several lines at atime to any given point on the network.The balance between pressure, air flowand stability of supply is ensured by usinga single diameter for piping. This type ofsystem will also easily accommodate

modifications and can easily supply toolsand equipment with varying supplyrequirements anywhere on the network.

Ball valves permit the isolation of aparticular portion of the air line networkto allow for easy:

Repairs

Connections

Enlargements

Periodic maintenance

The size of each loop does not need to beuniform. The important thing is to have atleast two different supply routes availablesimultaneously for each feeder pipedescending toward a tool or piece ofequipment.

This type of network is the ideal situation

for compressed air distribution systems,providing the balance between flow andpressure required to provide the mostefficient distribution of compressed air.

CLOSED LOOPNETWORK

The equipment locatedat pointAdemonstratesthat the air supply flowsthrough several lines at

a time, providingbalanced pressure andair flow.

OPTIMALNETWORKEFFICIENCY

A well-built closed loop network istherefore most often the ideal situationfor the distribution of compressed air.

In addition to being easy to plan and tomodify when needed, this type ofdistribution system becomes an immensecompressed air reservoir that:

Offers a constant air flow at all times

Guarantees a uniform pressurethrough out

Contributes to the life of thecompressor by limiting functioningtime

Reduces the electrical consumptionof the compressor

THE SOLUTION

The secret to planning an efficient,problem-free distribution network isactually quite simple. The goal is toachieve a balance between flow andpressure to maintain the ideal situation atall points of use, while providing for futureexpansion and remaining flexible in theface of varying compressed air needs.

How is this balance achieved ?

The best solution remains the

CLOSED LOOP NETWORKdesign.

COMPRESSOR


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COMPRESSED AIR DISTRIBUTION SYSTEMS

System design should start with a layout of theshop or plant. Designate where and what tools willbe used. Determine the placement of the mainline.Try to keep the line as short as possible whileproviding access to where tools are used. Try tokeep in mind any future needs or alterations. It ismuch easier to make changes if they are planned for.

Drop supply lines at the point of use or at regularintervals, to minimize hose length. Size the linesappropriately for the equipment to be used.

Each supply line should be installed with at least afilter and regulator. FRLs should be installed at thepoint of use, allowing the air to be prepared properlyfor the application. Designate appropriate supply linesas clean air lines for use with paint guns, blow gunsor tire inflator gauges.

On lines operating air tools, install lubricators toextend tool life.

PROPER SYSTEM DESIGN CANINFLUENCE AIR TREATMENT NEEDS

PROPER SLOPES AND DROPSAs for the slope of network pipes, either for linesrunning along exterior walls or within a building,

there should be a minimum inclination of 1 inchfor every 10 feet of length. This will lead anycondensation toward water evacuation points.

It must be noted that the feeder pipe may performboth functions: air flow and the elimination ofcondensed liquids. Secondary pipes attachedbelow the main pipes should include a ball valveand will help eliminate condensation at their feetby the presence of evacuation valves.

Properly installed pipe minimizes the amount of moistureat the point of use. Piping should slope in the direction ofthe air flow to an accessible moisture drain point

Outlets should be taken from the top of the mainair lines to keep moisture out

Assemble and test for leaks one section at a time to avoidmajor disassembly later

Pipe unions should be installed at regular intervals.This makes future repairs and modifications easier

Sealant should always be used on threads to eliminate air leaks

Tapered threads should not be overtightened as this couldcause the fitting to crack

Air lines should be secured to a solid surface usingpipe clamps

All piping and fittings should be checked regularly to avoidleaks in the system. An air leak will reduce the amount ofair at the tool, causing pressure drop. It will also cause thecompressor to work longer and harder, increasing energyand maintenance costs. See Series 41 for an idea of air leakcosts (Page 185)

PROPER DISTRIBUTION SYSTEM INSTALLATION

A properly designed system can offer cleaner air of the

appropriate volume and pressure, translating to better tool

performance and worker productivity.

SYSTEM DESIGN

Lowest Point of theMain Line

Pre-formed Pipe

Main line slope: 1 inch forevery 10 feet of run (alwaysin the same direction as theair flow)

WaterTrap Tee

Pipe Clip

Ball Valve

Y Strainer

AutomaticDrain


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=1/2 x ABCDA

=ABC

CLOSED LOOP NETWORK

A D

CB

LINEAR/DEAD-END NETWORK

BEFORE EVALUATING TOTAL NETWORK LENGTH

EQUIVALENT LENGTHS FOR VARIOUS FITTINGS (IN LENGTH OF EQUIVALENT TUBE)

In order to calculate an effective length of the total network, fittings used must also be taken into account. Every direction change,cross manifold, T connection or reduction in line size within the network will cause pressure loss equivalent to adding additional linelength.

The table below indicates effective lengths added to the network by each of these restrictions and/or connections.

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 loopandlinear/dead-end. Both are commonly used for compressed air networks.

For a closed loop system, the fact that there are always at least twopaths to any point on the loop means that only half of the total lengthmust be considered when sizing the main air line

For a linear/dead-end system, the total length of line must beconsidered when sizing the main air line

B C

NETWORK TYPES

AEFFECTIVE LENGTH

=ABC

EFFECTIVE LENGTH

Correct sizing of the air line is essentialto maximize the cost effectiveness of thecompressed air distribution system.

Network line size is determined by the

flow capacity required for the tools andequipment to be supplied, as well as bysystem design and length.

THINGS TO CONSIDER:

Pressure drops are totally unrecoverableand waste energy; a drop in pressurefrom 87 to 73 PSI will decrease machineand tool capacity by up to 27%

Energy cost will rise by 10% if pressureis increased by 15 PSI to compensatefor pressure drop

Pipe fittings are responsible for muchof the pressure drop in compressed airsystems

Pipe size should therefore be largeenough to keep pressure drop betweenthe reservoir and the point of use to aminimum

Main line size should never be smallerthan the compressor outlet size

Main line size is determined by total toolconsumption (SCFM) and total effectiveline length

Branch line size should be determinedbased on length and total consumption

of the tools on the branch

Main lines that are too small will causehigh air velocity, thus making waterseparation more difficult

A larger main line is in fact advantageous,acting as a reservoir for the air, reducingthe load on the compressor and providingcapacity for future demand and growth

SIZING A COMPRESSED AIR LINE

INTERNAL DIAMETER OF FITTINGS

15 mm 22 mm 28 mm 40 mm 63 mm

Ball Valve +4" +12" +16" +20" +28"

Reducer +16" +20" +24" +28" +39"

90 Elbow +28" +51" +59" +79" +138"

T Fitting +32" +59" +79" +98" +158"


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NOTE: Equivalent fractional diameters are approximate

LINE SIZING FOR ACLOSED LOOP NETWORKQUICK LINE & AIR LINE

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

1515

22

22

22

22

28

28

28

40

40

40

40

63

63

63

1515

22

22

22

28

28

28

40

40

40

63

63

63

63

63

1515

15

22

22

22

22

28

28

28

28

40

40

40

63

63

1515

15

15

15

22

22

22

22

28

28

40

40

40

40

63

1515

22

22

28

28

40

40

40

40

40

63

63

63

63

1522

22

22

28

28

40

40

40

40

63

63

63

63

63

1522

22

28

28

40

40

40

40

63

63

63

63

63

1522

22

28

28

40

40

40

40

40

63

63

63

63

1522

22

28

28

40

40

40

40

63

63

63

63

1522

22

28

28

40

40

40

40

63

63

63

63

1522

22

28

28

40

40

40

63

63

63

63

63

SCFM

5

10

20

30

40

60

80

100

125

160

200

300

400

500

600

800

1522

28

28

28

40

40

40

63

63

63

63

63

PIPE DIAMETERS

( P)PRESSURE DROP OVER 3 PSIG

TOTAL LENGTH OF LINE (FEET)

TOTALFLOW

REQUIRED

63 mm - 2-1/2"

40 mm - 1-1/2"

28 mm - 1"

22 mm - 3/4"

15 mm - 1/2"

Seepage 78 for

Series 06

25 50 100 200 300 400 500 600 700 800 900 1000


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LINE SIZING FOR ADEAD-END NETWORKQUICK LINE & AIR LINE

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

NOTE: Equivalent fractional diameters are approximate

PIPE DIAMETERS

63 mm - 2-1/2"

40 mm - 1-1/2"

28 mm - 1"

22 mm - 3/4"

15 mm - 1/2"

1515

22

22

22

28

28

40

40

40

40

63

63

63

63

63

1522

22

22

28

28

40

40

40

40

63

63

63

63

63

1515

22

22

22

22

28

28

28

40

40

40

40

63

63

63

1515

15

22

22

22

22

28

28

28

28

40

40

40

63

63

1522

22

28

28

40

40

40

40

63

63

63

63

63

1522

22

28

28

40

40

40

40

63

63

63

63

1522

28

28

40

40

40

40

63

63

63

63

1522

28

28

28

40

40

40

63

63

63

63

63

2222

28

28

40

40

40

63

63

63

63

63

2222

28

28

40

40

40

63

63

63

63

63

2222

28

40

40

40

63

63

63

63

63

63

SCFM

5

10

20

30

40

60

80

100

125

160

200

300

400

500

600

800

2222

28

40

40

40

63

63

63

63

63

( P)PRESSURE DROP OVER 3 PSIG

TOTAL LENGTH OF LINE (FEET)

TOTALFLOW

REQUIRED

Seepage 79 for

Series 06

25 50 100 200 300 400 500 600 700 800 900 1000


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w

w

w

T

O

P

R

I

N

G

c

o

m

40

TOPRING

Series 05AIR LINENylon 46

Series 06Aluminium and Nylon 74

Series 07QUICK LINEAluminium and Brass 58

Series 050607

COMPRESSED AIR

DISTRIBUTION

SYSTEMS


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WHY USETOPRING

COMPRESSED AIRSYSTEMS ?

TOPRINGcompressed air pipingsystems are put together using

non-traditional means, such as

push-in fittings or compression

fittings, as opposed to the usual

threading and welding methods

required by traditional pipe.

These assembly methods speed

up the installation process by as

much as a factor of 4, saving on

installation costs that often include

more labour than materials.

TOPRINGcompressed air distribution

systems are also made of corrosion

proof materials such as Brass,

Aluminium and Thermoplastics.

These modern materials provide great

improvements over traditional

conventional materials, such as Iron,

Galvanized Steel and Copper, by doing

away with the corrosion problems that

plague traditional systems. This ensures

much longer useful life, definite

improvements in flow and reductions

in operating costs.

TOPRINGsystems are also very light,

reducing the time and effort required to

complete installations and reducing

strain on workers.


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Steel tubing is subject to rust and will deteriorate overtime, unlike Aluminium and Nylon, which remainessentially unchanged

NEW TUBINGOR PIPING

TUBING OR PIPINGOVER TIME

ALUMINIUM

NYLON

STEEL

OPERATING COSTS

PRESSURE DROPPressure drop occurs when the air system cannot keep up with

consumption, reducing tool efficiency and therefore reducingproductivity.

Rough, porous Steel (black) and galvanized piping causesresistance to the passage of air and reduces the air flow availablefor supplying tools and applications.

Smooth bore Nylon or Aluminium piping provides better flow andreduced pressure drop, and therefore lower costs.

COMPRESSOR ENERGY CONSUMPTIONTo compensate for the pressure drop that can be caused by rough,porous conventional piping, especially once it is corroded, thecompressor must work harder, using more energy and adding cost.

CORROSION IN AIR PIPING:

RUST

COMPRESSED AIR SYSTEM COSTSAnalyses of compressed air system costs are often limited to theinitial cost of the piping and fittings.

There are many other cost elements beyond these that should be

considered when planning a compressed air system.

Choosing low cost piping and fittings may lower installed costsslightly, but will lead to additional costs over the years of systemoperation that will far surpass any initial savings.

FITTINGS AND PIPING COSTS

Air system decisions should not be made solely based on thepurchase price of the components.

While the cost of AIR LINE, QUICK LINEandSicoAIRcompo-

nents may be higher than traditional black pipe or galvanizedsystems, the savings in installation costs make up the difference.

INSTALLATION COSTS

Labour costs for a TOPRING air distribution system can be aslow as one quarter of the cost of installing a conventional system.

The combination of lightweight materials with easy to usepush-to-connect fittings means that installations can be done inas little as 25% of the time required for comparable black pipe orgalvanised Steel installations.

TOPRING

systems also require less specialized labour, and canoften be installed by the user without outside help.

TOPRING air system components are lightweight andeasy to handle, reducing installation time and costs

TOPRING air system componentsare easy to assemble


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Total cost comparison between the TOPRINGcompressedair distribution systems and conventional systems

OVERALL SYSTEM COSTS ARE THEREFORELOWER WITH TOPRING COMPRESSED AIRDISTRIBUTION SYSTEMSWhile TOPRING air distribution system components maymake up a greater proportion of total initial cost than in aconventional system, total system cost is reduced over thelife of the compressed air system.

This is due to the unique advantages of TOPRING systems: Lower installation costs

Fewer leaks

Lower pressure drop and therefore lower compressor costs

No corrosion or deterioration

Lower maintenance costs

TOPRING COMPRESSED AIR DISTRIBUTION

SYSTEMS ARE THEREFORE THE IDEAL CHOICE

TRADITIONAL STEEL ORCOPPER SYSTEMS

Maintenance costs

Maintenance costs

Operating costsOperating costs

Installation costs

Installation costs

Fittings andpiping costs

Fittings andpiping costs

$$$$

$$$

TOPRING

COMPRESSED AIRDISTRIBUTION SYSTEMS

TOPRING piping resists corrosionand stays clean over time

Traditional piping corrodes andallows contaminant build-up

CORROSIONSteel and galvanized steel pipes are affected by rust, andinterior surfaces pitted after several years of use causegreater 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 newfor many years to come.

MAINTENANCE COSTSMaintenance costs for conventional systems will increaseover time as the components deteriorate. TOPRING airdistribution components will not deteriorate.

TOPRING systems remain leak free, eliminating the need

for leak audits to limit compressed air loss.

High quality QUALICOATpaint prevents scratching and,

combined with the absence of corrosion, TOPRING pipingsystems do not need to be repainted over time.

LEAKSTOPRING compressed air distribution systems use leak-

proof push-to-connect type fittings, eliminating the risk ofleaks from faulty welds or badly sealed threads.

Air leaks cost money

TOPRING piping is painted blue for easy identification


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Good quality clean compressed airfor equipment protection The materials used for manufacturingTOPRING pipes and pipe fittingsensure excellent corrosion resistance.This guarantees the life of the productfor many years under normal use

The inside surface of the pipe and pipefittings allows high flow capacities withvery little flow resistance

A complete solution from thecompressor to the workstation

TOPRING compressed air distributionsystems are designed for both primaryand secondary distribution systems,used for compressed air and vacuum,from the smallest workshops to thelargest factories

Tried and tested reliability Not subject to corrosion damage

Compatible with most lubrication oils Excellent mechanical resistance and

pressure handling

Aluminium pipes are able to withstandimpact and shock without danger

Aluminium and Brass components arevirtually flame proof

Significant savings on installation,maintenance and operating costs TOPRING compressed air distribution

systems are easy to install and easy toreconfigure at any time. They are alsoready for immediate pressurization

No need for specialists or specialequipment

Eliminates expensive preparation timerequired for threaded Steel pipe anddrying time for glued plastic systems.Push-in connection provides a strongand permanent seal

Lightweight rigid Aluminium or Nylonpiping is easy to lift and maneuver. Itdoes not require expensive supportstructures

Virtually maintenance free

Leak-free system Designed with reliable O-ring seals,TOPRING compressed air distributionsystems ensure virtually leak-proofoperation

Optimal machine and toolefficiency The full flow design of TOPRING

components, the low friction coefficientof Aluminium/Nylon pipe, and thesealing characteristics of the systemsensure optimal and constant flowthrough out

THE IDEAL COMPRESSED AIR DISTRIBUTION SYSTEM

Maximum flexibility and

modularity TOPRING compressed air distribution

systems can be expanded and moved orreconfigured easily since allcomponents are reusable

Installations that would takedays/weeks with conventional systemsare accomplished in hours

These systems will adapt to everchanging requirements

A wide range of parts are availablefor 5 different piping sizes

FEATURES AND BENEFITS


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28 mm

22 mm

15 mm

63 mm

40 mm

TOPRING

COMPRESSED AIRSYSTEMSARE COMPATIBLE

TOPRING offers several compressedair distribution systems:

Series 05 AIR LINE Series 07 QUICK LINE Series 06 SicoAIR

AIR LINEand QUIK LINEcomponentsare compatible with each other and offerseveral system options for various needs.

Series 05 AIR LINE

Calibrated Nylon

Actual dimensions

S05 AIR LINE& S07 QUICK LINE

Series 05 AIR LINE

Composite Push-In

Series 07 QUICK LINE

Calibrated Aluminium


Calibrated Aluminium


Brass Push-In


Brass Compression

PIPING15 22 28

FITTINGS15 22 28

FITTINGS40 63PIPING40 63

175PSI

220PSI

220PSI

175PSI

175PSI

Actual dimensions


Topring Designing an Efficient Compressed Air Network

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