1. ENGINEERING YOUR SUCCESS.

2. 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

3. 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 = $110/yr1
1Based on 90% compressor efficiency

4. 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

5. 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!

6. 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

7. 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 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

8. 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

9. Best Pneumatic Practices Air 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

10. 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

11. Air Prep Systems Filters
Primary Filters
Remove water and particles typical 40micron & 10 micron units may require larger body sizes to meet comparable flow
Coalescing Filters
Removal of water, aerosols, oils and provide 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

12. Air Prep Systems Sensors
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

13. 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

14. 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)

15. Best Pneumatic Practices Directional Control Valves
Proper sizing of valves (Cv)
Solenoid technology – low power consumption
Spool technology – no internal leakage

16. Best Pneumatic Practices – Valve sizing

17. 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

18. Best Pneumatic Practices- Valve Design Air Pilot Solenoid
Uses air pressure to shift spool
Solenoids consume 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 PSI
*Manufacturer’s rating

19. Lapped Spool Technology
Metal to metal spool designed to leak
Spool leakage rate new range from sccm*
Close tolerance matched sets
High replacement cost
Leakage rate 5 million cycles 1,000-5,000sccm*
*Manufacturer’s rating

20. WCS Spool Technology Wear Compensated Spool
Molded nitrile seal prevents leakage and wear
Leakage rate new sccm*
Single slip-in replacement spool
Low replacement cost spool design
Leakage rate 5 million cycles 0-20sccm*
*Manufacturer’s rating

21. 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 compensate This prolongs the life of the valve and prevents air leakage at the spool

22. Leakage Cost of Lapped Spool design
Simple Calculation of Electricity Cost for Valve Leaks in a Plant
Insert your values in the yellow boxes to get the annual cost
Lapped Spool SCCM Leak per Valve
3000
SCCM ( Standard Cubic Centimeters per Minute )
Number of Valves in the Plant
100
Operating Pressure
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

23. Leakage Cost WCS Annual Cost of Leaks $22.59
Simple Calculation of Electricity Cost for Valve Leaks in a Plant
Insert 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
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
$22.59

24. 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

25. 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

26. 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

27. 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

28. $1,558.75 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
Cylinder Rod Diameter
0.625
12.26
Eff. Area
Cycles per minute ( extend and retract )
Number of Actuators in the Plant 1
Extend Pressure 80
PSI
6.44
Comp Factor
Retract Pressure
PSI ( for spring retract cylinders use 0 )
Number of Shifts in a Day ( assuming 8 hour shifts ) 2
Number of Operating Days in a Week 6
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 Electricity with Normal Regulators
$1,558.75

29. $922.17 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
Cylinder Rod Diameter
0.625
12.26
Eff. Area
Cycles per minute ( extend and retract )
Number of Actuators in the Plant 1
Extend Pressure 60
PSI
6.44
Comp Factor
Retract Pressure
PSI ( for spring retract cylinders use 0 )
Number of Shifts in a Day ( assuming 8 hour shifts ) 2
Number of Operating Days in a Week 6
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 Electricity with Normal Regulators
$922.17

30. 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
Cylinder Rod Diameter
0.625
12.26
Eff. Area
Cycles per minute ( extend and retract )
Number of Actuators in the Plant 1
Extend Pressure 60
PSI
5.08
Comp Factor
Retract Pressure 40
PSI ( for spring retract cylinders use 0 )
3.72
Number of Shifts in a Day ( assuming 8 hour shifts ) 2
Number of Operating Days in a Week 6
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 Electricity with Normal Regulators
$922.17
Annual Cost of Electricity with Reverse Flow Regulators
$689.09
Annual Savings
$233.08

31. Best Pneumatic Practices- Air Leakage Rates and Cost ($0
Best Pneumatic Practices- Air Leakage Rates and Cost 8, $.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 1/4” and 3/8” rates)

32. Cost Avoidance from not using open ¼’ Airline to move rivets
Air Cost Savings Example Dial Table Blow Off Application Current 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 $
Savings from shutting air of when not needed + $
Equipment Cost: $
Estimated Cost Avoidance per year for energy: $
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.

33. Air Economizing Vacuum w/ Emergency Stop Function
Vacuum Solutions:
Air Economizing Vacuum
w/ Emergency Stop Function

34. 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???

35. Why Air Economizing ? Sequence: Operation:
Turn on vacuum – 1.5 seconds
Contact & pick up part
Travel time – 30 seconds
Wait/queue for another machine function – 7 seconds
Shut down???
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

36. Vacuum off over 90% of time while part is present = $$$
Why Air Economizing ?
Sequence:
Turn on vacuum – 1.5 seconds
Contact & pick up part
Travel time – 30 seconds
Wait/queue for another machine function – 7 seconds
Shut down???
Operation:
Build vacuum
Sensor detects desired vacuum level & part present
Shuts vacuum generator OFF
Sensor turns generator on when vacuum drops to a preset level
Vacuum off over 90% of time while part is present = $$$

38. 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!

39. 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

40. 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

41. 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

42. 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

43. Thank you for your time! Questions?
PASS
Parker Air Systems Solutions

44. ENGINEERING YOUR SUCCESS.