ENGINEERING YOUR SUCCESS.

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ENGINEERING YOUR SUCCESS.
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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

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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_at_.06/kwh 110/yr1
• 1Based on 90 compressor efficiency

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Pneumatic Best Practices Design Consideration

• Sizing and selection of tubing, hose and
  connectors Proper sizing of components reduces
  capital investment and replacement cost. Dont
  undersize or grossly oversize!
• Utilize smart air preparation systems that
  provide adequate flow and PM detection devices
  (?P 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

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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 proper Tubing be used with
these fittings!
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Fluid Connector Technology Best Practices

• 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

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Fluid Connector Technology Best Practices

• 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 ¼NPT 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

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Fluid Connector Technology Best Practices

• 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

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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

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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
• OEMs 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

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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

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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

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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

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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 dont
  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)

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Best Pneumatic PracticesDirectional Control
Valves

• Proper sizing of valves (Cv)
• Solenoid technology low power consumption
• Spool technology no internal leakage

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Best Pneumatic Practices Valve sizing
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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

Manufacturers rating
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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

Manufacturers rating
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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

Manufacturers rating
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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

Manufacturers rating
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WCS Spool Technology

• Seal width is less than spool seal groove.
  Specially molded nitrile seals (Not o-rings)
• Under pressure, the seal is forced outward to
  seal on the valve bore
• The seal is also forced to one side of the
  groove, to seal against the groove wall
• During the life of the valve, as seal material
  wears, the seal expands to compensateThis
  prolongs the life of the valve and prevents air
  leakage at the spool

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Leakage Cost of Lapped Spool design
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Leakage Cost WCS
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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

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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

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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

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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

Normal Operation
Reverse Flow
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Best Pneumatic Practices- Air Leakage Rates and
Cost(0.237/MCF _at_ 8,736 Hrs/Year _at_ 100 PSIG _at_
.09 kWh)

• 1/16 Diameter leak 6.5 CFM 800
• 1/8 Diameter leak 26 CFM 3,208
• 1/4 Diameter leak 104 CFM 12,812
• 3/8 Diameter leak 234 CFM 29,113
• (Vacuum and blow off typical _at_ 1/4 and 3/8
  rates)

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Air Cost Savings ExampleDial Table Blow Off
ApplicationCurrent Cost 365 Days Per Year 9,436
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 622.06 Equipment Cost -
837.60 Estimated Cost Avoidance per year for
energy 5446.06
Cost Avoidance from not using open ¼ Airline to
move rivets It will take using the system for
approximately 90 days to recover cost of
equipment due to reduction of compressed air
needed.
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.
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Vacuum Solutions

• Air Economizing Vacuum
• w/ Emergency Stop Function

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Why Air Economizing ?

• Sequence
• Turn on vacuum 1.5 seconds
• Contact pick up part
• Travel time 30 seconds
• Wait/queue for another machine function 7
  seconds
• Shut down???

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Why Air Economizing ?

• Operation
• Build vacuum
• Sensor detects desired vacuum level part
  present
• Shuts vacuum generator OFF
• Sensor turns generator on when vacuum drops to a
  preset level

• Sequence
• Turn on vacuum 1.5 seconds
• Contact pick up part
• Travel time 30 seconds
• Wait/queue for another machine function 7
  seconds
• Shut down???

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Why Air Economizing ?

• Operation
• Build vacuum
• Sensor detects desired vacuum level part
  present
• Shuts vacuum generator OFF
• Sensor turns generator on when vacuum drops to a
  preset level

• Sequence
• Turn on vacuum 1.5 seconds
• Contact pick up part
• Travel time 30 seconds
• Wait/queue for another machine function 7
  seconds
• Shut down???

Vacuum off over 90 of time while part is
present
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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!

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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

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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

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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

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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

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Thank you for your time!Questions?
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ENGINEERING YOUR SUCCESS.