Rapidmain Installation Guide

Transcription

1 Rapidmain Installation Guide Aluminium Compressed Air Pipe Work Installation Guide Trafalgar Court, Waterloo Ind Estate, Widnes Cheshire. UK. Ref: Rapidmain installation guide 4b

2 Index 1. Rapidmain fittings: Assembly and locking torque setting Calculating compressed air flow Design layout for thermal expansion Pipe work fall and further points to consider Pipe work bracket support. Bracket types and their use Take-offs lines (branch lines) and the use of flexible pipe. 11 Brief Specification Working Pressure to 13 bar (- 8 to 191 PSI) Media Compressed Air and other Neutral Gas Flow Range 20 to 63 mm 0.73 to 26.8 M/min (26 to 948 cfm) * Temperature Range -20 to +70 C * Flow rate calculated over 100 metres Single run line P1@ 8bar We suggest that both the installer and the user of the Rapidmain pipe installation carefully read this manual before its use and before carrying out any installation or modification work. Please also refer to the local health and safety guidelines and accident prevention rules and regulations. Page 2

3 Rapidmain Installation Guide Aluminium Compressed Air Pipe Work Installation Rapidmain fittings: Assembly and locking torque settings Tightening of locking collars on fittings Assemble by hand or use our spanner set the correct torque. Black for the body and blue for the nut: See table B below Table B O D Torque L = mm Use the depth gauge on the spanner to mark the outside of the pipe: See below. Push the fitting up to the mark on the pipe and then rotate the blue locknut to secure. Page 3

4 Rapidmain Installation Guide Aluminium Compressed Air Pipe Work Installation Guide Rapidmain fittings: Assembly and locking torque settings Chamfer Pipe If you choose to use a vice to clamp the Aluminium pipe when cutting or chamfering leave clear at least 50mm of pipe to avoid damaging the radius diameter and pipe sealing surface. On larger pipe if required use a neutral lubricant or soap. Trafalgar Court, Waterloo Ind Estate, Widnes Cheshire. WA8 OSZ.UK. Page 4

5 Rapidmain fittings: Assembly and locking torque settings WARNING: to avoid O-Ring damage, the tube end must be chamfered before inserting the 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 you check the orientation of the locking clip; if this is incorrectly assembled the integrity of the connection cannot be guaranteed (See Table A). 1.2 Before inserting the tube into the fitting rotate the light-blue coupling ring until a slight mechanical stop is felt and no further. 1.3 The tube must be inserted into the fitting until the tube bottoms. This can be checked by previously 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 ring completely 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 optimum mechanical operation and seal. 1.6 Table C illustrates the correct alignment for installation. Misalignment of more than 5 o 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 fittings compatibility 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 their products and/or non-compliance of the manufacturers assembly instructions here within. Table A How to calculate an air system pipe size 2.1 Pressure drop through fittings Although fittings are smooth inside and have the same tube internal diameter, they nonetheless cause a resistance to air flow, particularly when tubes change direction as in the case of elbows, tees, couplings and reduction fittings. Table E refers to pressure drops caused by fittings. Every fitting or change of direction has an equivalent pipe length of tube indicated in this table. 2.2 Air System pipe sizing Once the compressed air consumption (l/min) and the allowable pressure drop have been calculated, refer to Table D to select the correct tube dimension. After having examined the plant and considered the changes of direction as well as the pressure drop of fittings you can then refer to Table E to complete and correct previous calculations. Page 5

6 Calculating Compressed air flow Table C Table D Pressure drop for 100 m (in bars) Effective Absolute Pressure (in bars) Delivery SRA * (in l/min) Outside diameter of the tube (mm) Referential axis Delivery SRA * Actual delivery at the effective pressure (P) x absolute pressure (P+1) in bars Temperature Correction: 0 degrees Air delivery at 0 degrees C = delivery 15 degrees C x * SRA: Standard Reference Atmosphere 288 Using the Nomogram The tube diameter can be determined by first finding the flow rate in l/m and the allowable pressure drop. a. We have chosen the working pressure on the C axis. A straight red line has then been 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. Trafalgar Court, Waterloo Ind Estate, Widnes Cheshire. WA8 OSZ.UK. Page 6

7 Design layout for thermal expansion DL = DT x 0,02 x L A = DL x 23 B = 0.7 x A Variation due to thermal expansion Introduction The theoretical calculations and design criteria in this manual are only relevant where the installation ambient temperature is between 15 o C and 25 o C. Attention! Where the installation is outside of the recommended ambient temperatures indicated above, it may be necessary to take corrective action such as thermal insulation of the pipe or the inclusion of expansion/contraction loops. Calculating expansion loop dimensions On long straight runs of pipe it may be necessary to insert expansion loops in the line to prevent damage to the pipe, due to thermal movement (expansion or contraction) of the pipe. Example L1 = 40 mt L2 = 40 mt DT = 50 o C DL = DT x 0.02 x L = 50 x 0.02 x 40 = 40 mm A = DL x 23 = 40 x 23 = 920 mm B = 0.7 x A = 0.7 x 920 = 640 mm Legend A-B = Quote (mm) L-L1-L2 = Lengths (mt) DL = Expansions (mm) DT = Thermal range ( o C) M = Mobile bracket F = Fix bracket Examples of Expansion Loops Vertical layout (Upwards) Horizontal Vertical layout (Downwards) Fixed brackets hold the pipe firmly while sliding brackets allow axial movement. Page 7

8 Pipe work fall and further points to consider Fall of pipes Where possible horizontal runs should be designed to have a slight fall of (1-2%) in the direction of air flow to encourage drainage and collection of condensate at lower levels or at drop legs built within the air system, from which the condensate can be drained as required. Direction of air flow Install drains at low points where ever possible. Example Pipe Fall Trafalgar Court, Waterloo Ind Estate, Widnes Cheshire. WA8 OSZ. UK. Page 8

9 Pipe work fall and further points to consider To allow for system maintenance, install an adequate quantity of isolation valves in the pipe work. Valve Ball Valve Fixing of Pipes To allow for thermal movement of the pipe and to avoid stress points, the pipe should be installed and fixed to a secure surface of building, such as a wall, brickwork, roof support (direct or with hanging brackets) or the building framework using suitable fixed and sliding brackets as required. Fixed bracket Fixed bracket Sliding bracket Fixed bracket Page 9

10 Rapidmain Installation Guide Aluminium Compressed Air Pipe Work Installation Guide Pipe work bracket support. Bracket types and there use Bracket and Pipe support centres It is important to install the pipe work brackets with correct spacing. Always try to support 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 Install brackets by each joint to support the pipe joint Suggested Maximum Support Centres) DN 20/ P (MT) Legend L = Length (mt) P = Brackets support centre (mt) M = Bracket G = Joint An alternative to the standard aluminium expansion loop, is to use suitable flexible hose assembly as shown below. DL = DT x 0,2 x L B = (2 x R) + DL 1 + DL 2 Legend L1-L2 = Lengths (mt) DL1-DL2 = Expansion (mm) DT = Thermal range ( o C) M = Bracket R = Radius (mm) A-B = Quotes (mm) Quote R A (mm) DN R (mm) A (mm) Attention! Tables are valid only for stainless steel flexible hoses type 1REX/INOX/N/321/DN. For other types refer to the manufacturer s technical documentation Page10

11 Take-off lines (branch lines) and the use of flexible pipe DL = DT x 0,2 x L A = DL x Y Legend A = Quote (mm) L1-L2 = Lengths (mt) DL = Expansion (mm) DT = Thermal range ( o C) F = Fixed bracket U = Use Y = Calculation factor Calculation Factor Y DN Y Bends using flexible hose. Using a flexible hose in corners is also acceptable. They can be used for the change of direction and at the same time to compensate for any thermal movement. L min = 1000 mm At the end of a pipe run always terminate the pipe and the fitting to an fixed anchored point eg: Wall Legend L1-L2 = Lengths (mt) DL1-DL2 = Expansion (mm) M = Bracket R = Radius (mm) L = Length of flexible pipe (mm) Pd 20od=0.2 b(3 psi) 6m/sec Pd 63od=2.5%(3 psi) 12m/sec Avoid installing flexible hoses with to tight a radius or where the hose is subject to, too much stretch Page 11