Rapidmain Installation Guide 4a - AIR CONTROLS AND ... Installation Guide 4.pdf · Rapidmain Installation Guide Air Controls and Compressors Ltd Trafalgar Court, Waterloo Ind Estate,

Rapidmain Installation Guide

Air Controls and Compressors LtdTrafalgar Court, Waterloo Ind Estate, Widnes Cheshire. UK.

Web: www.accltd.com. Telephone 0151 423 1750.

Aluminium Compressed Air Pipe Work Installation Guide

Ref: Rapidmain installation guide 4b

Index

1. Rapidmain fittings: Assembly and locking torque setting ……………………….…… 3 - 5

2. Calculating compressed air flow ……………………….………………………………..…… 6

4. Design layout for thermal expansion …………………………………….…………………. 7

5. Pipe work fall and further points to consider …………………………………..……….. 8 - 9

6. Pipe work bracket support. Bracket types and their use ……………..……………. 10

7. Take-offs lines (branch lines) and the use of flexible pipe …………………………. 11


Air Controls and Compressors LtdTrafalgar Court, Waterloo Ind Estate, Widnes Cheshire. WA8 OSZ. UK.Web: www.accltd.com. Telephone 0151 423 1750.

* Flow rate calculated over 100 metres Single run line P1@ 8bar

Page 2

Brief SpecificationWorking Pressure - 0.6 to 13 bar (- 8 to 191 PSI)Media Compressed Air and other Neutral GasFlow Range 20 to 63 mm 0.73 to 26.8 M/min (26 to 948 cfm) *Temperature Range -20 to +70 C

We suggest that both the installer and the user of the Rapidmain pipeinstallation carefully read this manual before its use and before carrying out anyinstallation or modification work. Please also refer to the local health andsafety guidelines and accident prevention rules and regulations.

Tightening of locking collars on fittings

Assemble by hand or use our spanner set the correct torque. Black for the body and bluefor the nut: See table B below

Use the depth gauge on the spanner to markthe outside of the pipe: See below.


Rapidmain Installation GuideAluminium Compressed Air Pipe Work Installation

Rapidmain fittings: Assembly and locking torque settings

Page 3

Push the fitting up to the mark on thepipe and then rotate the blue locknutto secure.

Table B

O D 20 25 32 40 50 63Torque 9 -11 11-13 12 - 15 15- 17 17 - 20 18 - 22L = mm 45 55 60 70 85 95


Air Controls and Compressors LtdTrafalgar Court, Waterloo Ind Estate, Widnes Cheshire. WA8 OSZ .UK.Web: www.accltd.com. Telephone 0151 423 1750.

On larger pipe if required use a neutral lubricant or soap.

If you choose to use a vice to clamp the Aluminium pipe when cutting or chamfering leaveclear at least 50mm of pipe to avoid damaging the radius diameter and pipe sealing surface.


Chamfer Pipe


Page 4

____________________________________________________________________________


WARNING: to avoid O-Ring damage, the tube end must be chamfered before insertingthe tube into the fittings.

R-Range of Compressed Air distribution fittings Sizes DN 20 to 63 OD

1.1 Before use check that all the fitting connection parts are correctly assembled. Ensure youcheck the orientation of the locking clip; if this is incorrectly assembled the integrity of theconnection cannot be guaranteed (See Table A).

1.2 Before inserting the tube into the fitting rotate the light-blue coupling ring until a slightmechanical stop is felt and no further.

1.3 The tube must be inserted into the fitting until the tube bottoms. This can be checked bypreviously marking on the tube the length “L” indicated in Table B.

1.4 Once the tube has been correctly inserted into the fitting, rotate the coupling ringcompletely over the first mechanical stop described in Section 1.2 above until fully tight.For best results it is advisable to use the “C” type spanners shown in the catalogue.

1.5 Table B shows the torque (N/m) required for each fitting size to provide the optimummechanical operation and seal.

1.6 Table C illustrates the correct alignment for installation. Misalignment of more than 5o

from the horizontal could compromise the integrity of the fitting seal.

1.7 Please refer to the specifications shown in the present catalogue for pipe and fittingscompatibility with chemical substances that could be present in the compressed air.

1.8 Rapidmain will not be held responsible for any damage caused by improper use of theirproducts and/or non-compliance of the manufacturers assembly instructions here within.

How to calculate an air system pipe size

2.1 Pressure drop through fittingsAlthough fittings are smooth inside and have the same tube internal diameter, theynonetheless cause a resistance to air flow, particularly when tubes change direction as inthe case of elbows, tees, couplings and reduction fittings. Table E refers to pressuredrops caused by fittings. Every fitting or change of direction has an equivalent pipelength of tube indicated in this table.

2.2 Air System pipe sizing Once the compressed air consumption (l/min) and the allowablepressure drop havebeen calculated, refer to Table D to select the correct tube dimension. After havingexamined the plant and considered the changes of direction as well as the pressure dropof fittings you can then refer to Table E to complete and correct previous calculations.


Table A

Page 5

Table C

Table D

Pressure drop for100 m (in bars)

Delivery SRA*

(in l/min)

Outsidediameter of

the tube(mm)

Referentialaxis

Pressure(in bars)

Effe

ctiv

e

Abso

lute

Delivery SRA*

Actual delivery at the effective pressure (P) x absolute pressure (P+1) in bars

Temperature Correction:0 degrees + 273 Air

delivery at 0 degrees C = delivery 15 degrees C x ________________

288*SRA: Standard Reference Atmosphere

Using the Nomogram

The tube diameter can be determined by first finding the flow rate in l/m and the allowablepressure drop.

a. We have chosen the working pressure on the “C” axis. A straight red line has thenbeen drawn connecting the working pressure to the pressure drop value on the “A” axis.

b. Drawing this straight line allows us to locate a point on the “R” referential axis.c. A green line has then been drawn from the referential “R” axis to the value on the

“A” axis which indicates plant delivery in l/min.d. This green line intersects on the “B” axis which shows the suitable tube diameter.


Air Controls and Compressors LtdTrafalgar Court, Waterloo Ind Estate, Widnes Cheshire. WA8 OSZ .UK.Web: www.accltd.com. Telephone 0151 423 1750.

Calculating Compressed air flow

Page 6

Introduction

The theoretical calculations and design criteria in thismanual are only relevant where the installationambient temperature is between 15 oC and 25oC.

Attention! Where the installation is outside of therecommended ambient temperatures indicated above,it may be necessary to take corrective action such asthermal insulation of the pipe or the inclusion ofexpansion/contraction loops.

Variation due tothermal expansion

Calculating expansion loop dimensionsOn long straight runs of pipe it may be necessary toinsert expansion loops in the line to prevent damageto the pipe, due to thermal movement (expansion orcontraction) of the pipe.

LegendA-B = Quote (mm)L-L1-L2 = Lengths (mt)DL = Expansions (mm)DT = Thermal range (oC)M = Mobile bracketF = Fix bracket

ExampleL1 = 40 mt L2 = 40 mt DT = 50oCDL = DT x 0.02 x L = 50 x 0.02 x 40 = 40mm A = DL x 23 = 40 x 23 = 920 mmB = 0.7 x A = 0.7 x 920 = 640 mm

DL = DT x 0,02 x LA = DL x 23B = 0.7 x A

“Fixed brackets” hold the pipe firmly while “sliding brackets” allow axial movement.

Examples of Expansion Loops

Vertical layout (Upwards)

Vertical layout (Downwards)

Horizontal



Design layout for thermal expansion

Page 7

Fall of pipes

Where possible horizontal runs should be designed to have a slight fall of (1-2%) in the directionof air flow to encourage drainage and collection of condensate at lower levels or at drop legsbuilt within the air system, from which the condensate can be drained as required.

Install drains at low points where ever possible.

Example

Pipe Fall


Air Controls and Compressors LtdTrafalgar Court, Waterloo Ind Estate, Widnes Cheshire. WA8 OSZ.UK. Web: www.accltd.com. Telephone 0151 423 1750.

Pipe work fall and further points to consider

Page 8

Direction of air flow

To allow for system maintenance, install an adequate quantity of isolation valves in the pipe work.

Ball Valve

Valve

Fixing of Pipes

To allow for thermal movement of the pipe and to avoid stress points, the pipe should be installedand fixed to a secure surface of building, such as a wall, brickwork, roof support (direct or withhanging brackets) or the building framework using suitable “fixed and sliding brackets ” as required.

Fixedbracket

Fixed bracket

Sliding bracket

Fixedbracket



Pipe work fall and further points to consider

Page 9

Bracket and Pipe support centresIt is important to install the pipe work brackets with correct spacing. Always try tosupport the pipe joint with a bracket located within 200 to 500 mm from the pipe joint.Please refer to the diagram below for examples of preferred installation

LegendL = Length (mt)P = Brackets support centre (mt)M = BracketG = Joint

Suggested Maximum Support Centres)DN 20/25 32 40 50 63P (MT) 2.5 3 3.5 4 4.5


Install brackets by each joint to supportthe pipe joint

DL = DT x 0,2 x LB = (2 x R) + DL 1 + DL 2

LegendL1-L2 = Lengths (mt)DL1-DL2 = Expansion (mm)DT = Thermal range (oC)M = BracketR = Radius (mm)A-B = Quotes (mm)

Quote R – A (mm)DN 20 25 32 40 50 63R (mm) 70 85 100 130 160 200A (mm) 370 390 500 560 600 800

Attention!Tables are valid only for stainless steel flexible hoses

type 1REX/INOX/N/321/DN.

For other types refer to the manufacturer’stechnical documentation

An alternative to the “standard” aluminium expansion loop,is to use suitable flexible hose assembly as shown below.



Pipe work bracket support. Bracket types and there use

Page10

DL = DT x 0,2 x LA = DL x Y

LegendA = Quote (mm)L1-L2 = Lengths (mt)DL = Expansion (mm)DT = Thermal range (oC)F = Fixed bracketU = UseY = Calculation factor

Calculation Factor YDN 20 25 32 40 50 63Y 20 20 25 28 33 40

Bends using flexible hose.

Using a flexible hose in corners is alsoacceptable. They can be used for the change ofdirection and at the same time to compensatefor any thermal movement.

L min = 1000 mm

LegendL1-L2 = Lengths (mt)DL1-DL2 = Expansion (mm)M = BracketR = Radius (mm)L = Length of flexible pipe (mm)

Avoid installing flexible hoses with to tight a radius or where thehose is subject to, too much stretch



Take-off lines (branch lines) and the use of flexible pipe

At the end of a pipe run alwaysterminate the pipe and the fitting toan fixed anchored point eg: Wall

Page 11

Pd 20od=0.2 b(3 psi) 6m/secPd 63od=2.5%(3 psi) 12m/sec

Documents

Rapidmain Installation Guide 4a - AIR CONTROLS AND ... Installation Guide 4.pdf · Rapidmain Installation Guide Air Controls and Compressors Ltd Trafalgar Court, Waterloo Ind Estate,