Compressed air: what and how it is used

2024 Author: Howard Calhoun | [email protected]. Last modified: 2024-01-02 13:48

Compressed air is an air mass that is contained in a container, while its pressure exceeds atmospheric pressure. It is used in industry in a variety of manufacturing operations. A typical compressed air system is one operating at pressures up to ten bar. In such cases, the air mass is compressed ten times its original volume.

General information

At a pressure of seven bar, compressed air is practically safe to operate. It is able to provide sufficient driving force to the tool as well as an electric feed. This requires less cost. In addition, such a system is characterized by faster response, which in the end can make it much more convenient. However, this will require taking into account the parameters below.

1. The longer the path of the consumer compressor, the more energy is expended.
2. Compressed air is very effective in a large number of similar operations, in suchcase, there is an advantage over electrical installations. After all, it is more efficient to install an air cylinder than an electric motor.
3. Need to constantly monitor for leaks.
4. When using water, domestic gas, etc., we are already accustomed to being economical, but when using this type of energy, many become wasteful, considering it free. It is necessary to constantly improve pneumatic systems in production, for example, in Western Europe, new developments of nozzles are constantly appearing, in which air is consumed much less, while the noise level is significantly reduced.

Compressed air application

Quite often, manufacturers use this type of energy to quickly and efficiently clean equipment from dirt and dust. In addition, compressed air is widely used to blow pipes in boiler rooms. In the woodworking industry, it is used to clean rooms, equipment and even clothes from wood dust. In most countries, standards for the use of this type of energy have already appeared, for example, in Europe it is CUVA, and in the USA it is OSHA. In addition to using it in production operations, tools that work directly on air are widely used - these are screwdrivers, pneumatic drills, wrenches, jackhammers (during equipment installation and construction), spray guns (during major repairs). In addition, compressed air in canisters is now widely used in air guns.

Safety

When using compressed air, the safety precautions below must be followed.

1. Do not direct the jet into the mouth, eyes, nose, ears or other places.
2. You can not treat open wounds with compressed air, because bubbles can form under the skin, if they reach the heart, they will lead to a heart attack, and if they reach the brain, they can provoke a brain hemorrhage. In addition, getting into the wound, air can bring infection into it, which is located in the compressor system or in the pipes.
3. It is forbidden to play around and direct a jet of compressed air at other people.
4. Do not overpressure the compressor system.
5. All elements of the pneumatic installation must be carefully secured to avoid breakage and, as a result, injury.
6. It is forbidden to clean the equipment from dust and dirt in the presence of an open flame and welding. This may cause an explosion due to the presence of dust in suspension.
7. When working with compressed air systems, wear personal protective equipment such as goggles or a mask.
8. It is forbidden to tighten couplings, threaded connections, bolts in assemblies or on pipes under pressure.
9. When installing a pneumatic system, hoses should be fixed in places with the least risk of damage (on ceilings, walls).

Benefits of compressed air

Now consider what arethe benefits of using this type of energy on production lines.

1. Pneumatic tools are characterized by light weight with sufficiently high power.
2. These settings can be used for a long time without overheating.
3. Low system maintenance costs.
4. Pneumatic compressors can be used as a source of energy in fire-hazardous production with explosive and flammable substances (underground tunnels, mines).
5. These tools are suitable for workshops with highly corrosive environments. However, it must be taken into account that the operating temperature of the compressed air exceeds the ambient temperature by ten degrees Celsius. In addition, with an increase in this parameter, the humidity of the air stream will increase in direct proportion.
6. The use of pneumatic systems can significantly simplify the automation of production processes. For example, such as drying, painting and others.
7. Reduces equipment downtime.

Compressed air networks

For optimum operation and high economic efficiency of the installation, the following requirements must be met. In the pneumatic system, losses should be minimized, in addition, the air should come to the consumers dry and clean, this is achieved by installing a special dehumidifier that allows moisture to condense. Also, special attention should be paid to the main pipelines. Proper installation of air ducts is the key to longevityperformance and reduce maintenance costs. By increasing the pressure level in the compressor, a drop in the pipeline can be compensated.

Compressed air consumption calculation

Compressor installations always include so-called receivers (air collectors). Depending on the performance and power of the equipment, the system may contain several receivers. Their main purpose is to smooth out pressure pulsations, in addition, the gas mass is cooled inside the air collector, and this leads to condensate. The calculation of compressed air consists in determining the consumption of the receiver. This is done according to the following formula:

• V=(0.25 x Q_{c x} p_{1 x} T₀)/ (f_max x (p_u-p_l) х T_l), where:

  - V – air receiver volume;

  - Q_c – compressor capacity;

  - p₁ – unit outlet pressure;

  - T_l – maximum temperature;

  - T₀ - compressed air temperature in the receiver_;

  - (p_u -p_l) – set pressure difference between loading and unloading;

  - f_{max – maximum frequency.}