1. 1
Service Industries Ltd Gujrat

2. 2
Pneumatic
Calculations
LSF PU Hall

3. 3
Basic Elements to Calculate :-
 Pressure
1. Required Air Pressure for Components
 Flow Rate
1. Total Air Flow from Compressors
2. Total Air Consumption by machines
 Temperature
1. Ambient Temperature
2. Medium Temperature
 Air Quality
1. Air Efficency(Grade of Filtration)

4. 4
Pneumatic Calculations Include:-
 Air Production Ratio.
 Air Pressure Drop.
 Air Purification Percentage.
 Air Consumption.
 Required Pressure at Different Stages.
 Required Temperature.
 Pneumatic Components Calculations
 Components Function.
 Solution to increase efficiency.

5. 5
Air Production Ratio:-
 No of Compressor Installed = 11
 Make=Comp Air
 Total Air Flow Rate = 43.6 m³/min
4.0 m³/min3.75 m³/min
3.65 m³/min 3.65 m³/min 3.75 m³/min
4.0 m³/min 4.0 m³/min 3.75 m³/min 3.75 m³/min
5.5 m³/min 3.60m³/min

6. 6
Air Pressure Drop:-
 The pressure drop in a piping system can be divided into two parts
1. Major Pressure Losses(Pipe Losses)
2. Minor Pressure Losses(Losses Through Fittings,Valve,etc)
Equation for Major Losses
p1-p2 = f l /D .1/2 ρv²...........(i)
Equation for Minor Losses
p1-p2 = r ∑hL. ………………..(ii)
Where:-
ρ =Density of Fluid (slugs/ft³)
v=Velocity of Fuuid(ft/sec)
f=Frictional Factor
l =Pipe Length
D =Diameter of Pipe(in or ft)
r =Specific Weight(lb/ft³)
hL =Head Loss(ft)
Total Pressure Loss =Major Losses + Minor Losses
Result:-
According to calculation the total Air pressure drop From Compressor to Machine is 11.2 psi
that is approximately equal to 1bar.

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Calculation of Pressure Drop:-
 The Moody friction factor - λ (or f) - is used in the Darcy-Weisbach major
loss equation. The coefficient can be estimated with the diagram below:
 If the flow is transient - 2300 < Re < 4000 - the flow varies between laminar
and turbulent flow and the friction coefiicient is not possible to determine.
The friction factor can usually be interpolated between the laminar value at
Re = 2300 and the turbulent value at Re = 4000.

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9. 9
Air Purification Percentage:-
 Number of Filters used from Compressor to PU Hall
1. 1st in Compressor For (Inlet Air)
2. After Air Storage Tank (Manual Drain)
3. Under Machine(Upto 40µ)
4. Dryer is installed before ISO Tank(100%)
Solution:-
The Air Quality is not good we must Install Dryer after
Compressor and also install Active carbon filter after air
filter mounted on dryer in material tanks.

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Air Consumption:-
 AIR CONSUMPTION
The air consumption data for a cylinder is required to
estimate the compressor capacity. The calculations include
air consumption during forward as well as return stroke. The free air
consumption for forward stroke is calculated as
follows:
 Free air consumption = piston area x (operating pressure +1.013) x
stroke
The free air consumption for return stroke is also calculated
similarly and added to arrive at total free air consumption of
cylinder during one complete cycle.

11. 11
Theoretical Air Consumption:-
 Let
D=Dia of Piston in cm
d=Dia of Piston Rod
L=Stroke Length in cm
P=Pressure in Bar
Free Air Consumption in Liter for forward stroke
C={‫4/ת‬ x D² x (P+1)x L}/1000
Free Air Consumption in Liter for Return Stroke
C={‫4/ת‬ x (D²-d²) x (P+1)x L}/1000

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Pneumatic Components at
Injection Side x 2:-
Pneumatic Cylinders
Air Consumption /per cycle)
 ADVU-63-280-APA-S1 11.60 l/cycle
 ADVU-63-30-APA-S1 1.24 l/cycle
 DNC-50-280-PPV-A 7.08 l/cycle
 ADVU-63-50-PPV-A 2.07 l/cycle
 Linear Drive(40-250) 6.47 l/cycle
 Rotary Cylinder 0.63 l/cycle
Other Equipments
 Air Spray Nozzle
 Pneumatic Valve
 Pressure Switch
 Regulators
 Distributors
 Filters
 Nozzle Opening Cylinders
 Roller Lever Vlves

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Pneumatic Componts
Installed at Rotary Table:-
1.Station 1 x 30 Air Consumption per Cycle
 ADVU-80-250-A-P-A-SA 16.7 l
 DS-80-115-P-SA 7.70 l
 DS-80-115-P-SA 7.70 l
 Base Moving Cylinder(2 Position) D=200 S.L=4 17.35l
2.Main Components of Supply
 Air Storage Tank
 Air Filters
 Ball Valve Drive Unit
 Pressure Gauges
 Solenoid Valves
 Push Buttons
 Pneumatic Fittings
 Pneumatic Pipe
 Pneumatic Valves
 OR Gates
 Reed Switched

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Why Calculating Components
Calculations:-
 As in above slide it is mentioned that what parts are
installed in machine and how much air they consume in
one cycle.
 As per machine design the total air consumed by one
DESMA Machine in one hour is 88m³ at11 second cycle.
 According to these calculation of pneumatic components
we can check that how our machine is consuming air
according to operation) so that we can install better
solution to improve our machine efficiency.

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Required Pressure:-
 Turn Table:-
Main or Compressor------- appro 15bar
Operating Pressure-------- 10bar
Controll Pressure----------- appro 6 bar
Break pressure-------------- app 2 bar
Clamping Unit
Operating Pressure--------- 10 bar
Controll Pressure ----------- 6 bar
Material Tank-----------------Dry Compressed Air app 2 bar
Reaction casting unit-------- operating pressure 10 bar
Controll pressure--------------6 bar

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Required Temperature:-
 Ambient Temperature
The Ambient Temperature is the surrounding
temperature and ambient temperature required
for the installed components are maximum 60-
70°C.
 Medium Temperature
Where as the medium temperature is the
temperature of compressed air and it may not be
more than 45°C.

17. 17
Solutions for Improvement:-
 As per our Calculation our Flow Rate is Complete and
full fill our machines requirements,
 The main problem which we are facing is air leakage that
will not maintain our pressure for that leaked pipe and
fitting should be replaced to save energy
 For Better air quality we should use Air Dryer after
compressors
 To Get 100 % pure air in material tanks we should use
Active Carbon Filter before Dryer.
 For further study we must install flow meter in main air
supply pipe to study in much detail.

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SYSTEM IMPROVEMENT PLAN

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Data Maintaining Solutions:-
Analysis
 Compressed air supply analysis
 Compressed air quality analysis
 Compressed air consumption measurement
 Leakage detection
Planning
 Development of leakage management concept
 Development of condition monitoring concept

Implementation
 Performance of repairs
 Implementation of condition monitoring concept
Maintenance
 Regular leakage detection 3-2-1 and compressed air quality analysis
 Performance of preventive and corrective maintenance 3-2-1
 Training

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Energy analysis of compressed
air production:-
 Measurement of compressor operating times as well as load and idling
times
 Electricity consumption measurement
 Flow measurement/measurement of compressed air consumption
 Pressure level and band width measurement
 Estimation of leakage volume
 Comparison of energy consumption and supplied compressed air volume
 Calculation of current energy costs and potential savings
 The benefits to us:
 Installation of the measuring devices during ongoing operation
 Analysis and interpretation of measurement results.

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Compressed air quality
analysis:-
 Clean compressed air – reliable processes and longer service life
for all pneumatic components
How we can Analyze:-
 Inspection of the decentralized compressed air preparation at its
point of use
 Measurement of residual oil content (up to ISO 8573 Class 2)
 Measurement of pressure dew point (up to ISO 8573 Class 2)
 Analysis of the results and recommendations for improvement
 Documentation of the results
The benefits to us:
 Increased life expectancy for pneumatic components
 Identification of weak points
 Increased process reliability

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Compressed air consumption
analysis:-
 Optimal compressed air provision, reliable cost planning, reliable
processes
How it take parts:
 Determining the static compressed air consumption of machines
when at standstill and when they are running
 Installation and removal of a metering section with standard parts
(fittings, tubing etc.)
 Graphic display of measurement results: either as PDF file or colour
printout
 Analysis of the results and suggestions for improvement
 Documentation of the results
The benefits to us:
 Optimal compressed air supply
 Reliable processes
 Reliable cost planning

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Measure for Energy Savings:-
 Leakage detection and elimination
1. The greatest potential for savings is in the elimination of leaks. That has been
demonstrated by the independent study “Compressed Air Systems in the European
Union” by the Fraunhofer Institute ISI.
 How it take part:
1. Detection of compressed air leaks during operation
2. Inspection of the complete compressed air system, from the compressor to the
pneumatic application
3. Recording and documenting the leaks and the information relevant for repair or
improvement
 The benefits:
1. Reduced compressed air requirements and costs
2. Immediate savings of energy and costs with every leak eliminated
3. Production downtime is usually not required
4. Detailed documentation of the leaks discovered including all data required for
eliminating them

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Benefits
Determine potential savings for compressed air
and save up to 60% of cost the benefits are
given below.
 Reduced operating costs
 Optimal use of compressor output
 Extended service life of components
 High system availability
 Reliable processes
 Energy-efficient and environmentally-friendly system
operation

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Production Supervisor
LSF PU HALL
Employee # S02485