ADVANCE ENERGY SOLUTIONS

PNEUMSYSSAEP

PNEUMSYS ADVANCE PIPING SOLUTIONS

If you can measure it, you can improve it.

Let’s be coolBreathe cool, fresh and clean airA compressor converts 90% of itspower into heat. The compressorheats up, while a compressor uses lessenergy to compress cold air, 3°C coolerair, already results in 1% energy saving.

Get the complete pictureMeasure, monitor and manage.VPVision monitors your entire compressedair system from supply side to demandside. It becomes the cornerstone of anenergy management system for any plantseeking to sustain the energy efficienciesthey have achieved.

What do you need?Optimize your efficiencyEfficiency, the ratio between compressoroutput and kW input, is the key perfor-mance indicator of choice to optimizemaintenance strategy and costs.

SUPPLY SIDE

Be smartThink of alternative usesDo you really need a compressedair powered tool? Electric toolsmight be a better choice forsome areas in your plant.

Disclaimer: This is a representative drawing. Consult your Compressed Air System Supplier for design specifics. meters are shown without required safety cables and without proper in and out straight piping runs.infographic©2012 www.kennisinbeeld.nl

Create a smooth rideReduce the pressure dropA proper designed piping system allows air toflow smoothly. This results into less pressuredrop. Use angular feed-ins at the main header.Avoid T-pieces and elbows as much as possible.Keep the average velocity in the pipe as low aspossible. Use proper sized filters and driers.

If you can measure it, you can improve it.

Get the complete pictureMeasure, monitor and manage.VPVision monitors your entire compressedair system from supply side to demandside. It becomes the cornerstone of anenergy management system for any plantseeking to sustain the energy efficienciesthey have achieved.

Relax and saveReduce the pressureEvery bar pressure reduction givesan instant win of 7% on yourenergy consumption. Invest inpressure regulators per productionarea, use receivers to reducepressure swings in your network.

Don’t overdo itBe selective with air qualityIf one sub-process needs an extra lowdew point, place the adsorption drierat the entry point of that sub-processonly.

Boost your profitManage your leakage

In general there is 20-40%of leakage in a compressed air

installation. VPVision can be usedas a global leakage management

system and helps you to rank the leakson savings potential. Invest in an ultra-

sound leak detector to find the leaks.

DEMAND SIDE

Air isnt’t free because it’s thereShut of sections or machines when not in useA simple manual or motorized shut off valve can save thousandsof euro’s/dollars. Make sure that the air is not lost through leaks, or throughmachines blowing off in idle position (for example vaccum nozzles o’ air knives).Flow meters help to determine where and when money is lost during standstill of machines.

Disclaimer: This is a representative drawing. Consult your Compressed Air System Supplier for design specifics. meters are shown without required safety cables and without proper in and out straight piping runs.

LUTHRA PNEUMSYS

MeasureUse flow meters to measure and log consumption. We offer insertion probes

for large diameters and in Line flow meters for small diameters up to 2 inch.

VPFlowScope features> Unique 3 in 1 sensor design: flow, pressure, temperature

> Built-in data logger 500,000 points.

> Bi-directional flow measurement

> RS485 (Modbus RTU) all parameters

> Analog 4-20 mA for one parameter

MonitorThe VPFlowTerminal provides instant feedback on your measurements. It

helps you to keep consumption at the lowest possible level.

> Remote Display for Flowmeter

> Add up to 4 analog auxiliary Inputs

> Built-in data logger 2,000,000 points

> 115V / 12 V power supply

> Build in Ethernet connection

ManageWith VPVision, you have a state of the art web-based monitoring solution for

compressed air. From supply to demand side.

> Standardized hardware

> Multiple factories can be interconnected

> Multiple sensors logged in one system

> Data is synchronized in data base

> Readout via PC, IPAD®

38, Madhu Vrinda, Dhuri Industrial Estate,Waliv Fata, Vasai (E), Dist. Thane 401 202Tel.: +91-98211 28362 / 98215 40759Fax : +91-22-2851 4093Email : rl@pneumsys.comVisit us at : www.pneumsys.com

PNEUMSYS specializes in manufacturing pneumatic products and pressure pipeworks

In order to optimize its range designed for transporting industrial fluids under pressure

PNEUMSYS offers piping solutions for the following applications:

• Distribution of compressed air

• Distribution of neutral industrial gases like nitrogen

• Vacuum networks down to - 0,7 bar depression

CORROSION RESISTANT

Aluminum piping and Plastic fittings are neither attacked by atmospheric

agents (humidity, aggressive environment) nor by condensates, which enables

networks to remain sound and airtight throughout their long working lives.

Furthermore, the cleanliness of the air or gas conveyed is maintained.

RESISTANCE

Mechanical: Resistance to static and dynamic pressure.

Impact resistance: The system present an excellent ductile behaviour in case of a mechanical impact.

Resistance to compressor oils: The components / material feature e x c e l l e n t r e s i s t a n c e t o t h e u s u a l c o m p r e s s o r o i l s

ENERGY SAVING/RELIABILITY

The smoothness of the pipe’s inner surface and its non-corrodability allow for equal cross sections, a better air flow than

for metal pipeworks.

LIMITS OF USE

The PNEUMSYS system is not compatible with medical air networks, flammable gases or silicon-free applications.

WORKING PRESSURE AND TEMPERATURE

The 12.5 bar pressure is a maximum operating pressure applicable at pipe wall temperature (fluid + ambient) between -20°C

and +25°C. An increase in the temperature causes a reduction in the mechanical strength of the PNEUMSYS system

components which reduced their resistance to pressure.

When the fluid or the ambient temperature is higher than 25°C, the Maximum Working Pressure (MWP) must be

determined via the graph opposite.

ADVANCE PIPING SYSTEM

PNEUMSYS

1

2

NO CORROSION / RUSTING / SCALING OF FITTINGS

The Fittings are manufactured in Polymer Acetyl

and using Nitrile seals. Acetyl is can withstand

extreme pressures without cracking/ hardening of

the material..

The teeth on the collet being manufactured in

SS316 ensure they grip the pipe even under undue

stress. All fittings are NSF 51 / 61 certified and are

food grade.

WATER TRAP TEE

The UNIQUE water Trap Tee solves the on-going problem of moisture in a compressed air system and provides the easy alternative to the need to install “Swan Necks”.

The ingenious inside arrangement of the fitting allows air to flow, with minimum head loss, from the main to take-off point without allowing water to follow. The moisture is retained in the ring main which can be periodically drained by means of a drain valve.

The Aluminium Pipe is having excellent weather resistant properties.

Aluminum alloy (T6 / 6063) has a strong resistance to corrosion which is a result of an oxide skin that forms as a result of reactions with the atmosphere. This corrosive skin protects aluminum from most chemicals, weathering conditions, and even many acids

Source: : http://www.efunda.com/Materials/alloys/aluminum/aluminum.cfm

NO RUSTING/SCALING OF PIPES

JUST CUT, PUSH & LOCK. ALL YOU NEED IS HANDS

GI pipe / plastic fittings are very cumbersome

to use. Once jointed become tedious /

impossible to disconnect. JG Speedfit pipe

and fittings require no threading / brazing /

soldering or using clumsy sealing / binding

compounds. To insert / remove pipe from

fittings, no tools are required, simply use your

hands.

Pipe Insert givesPipe Insert givessecondary sealsecondary sealPipe Insert givessecondary seal

Main ‘O’ Ring SealMain ‘O’ Ring SealMain ‘O’ Ring Seal

Stainless steelStainless steelteeth gripteeth gripthe pipe.the pipe.

Stainless steelteeth gripthe pipe.

Grips before it sealsGrips before it sealsGrips before it seals

PNEUMSYS

ADVANCE PIPING SYSTEM

3

STRAIGHT ADAPTOR

PART NO. PIPE THREAD OD BSP UG104B 15 3/4PM011514E 15 1/2PM011516E 15 3/4PM011814E 18 ½PM012216E 22 3/4UG104B 25 3/4UG104B 32 11/2 22 1 28 1”

EQUAL ELBOW

PART NO. PIPE OD PM0315E 15PM0318E 18PM0322E 22PM0328E 28UG303B 32

STRAIGHT CONNECTOR

PART NO. PIPE OD

PM0415E 15PM0418E 18PM0422E 22PM0428E 28UG403B 32

EQUAL TEE

PART NO. PIPE OD PM0215E 15PM0218E 18PM0222E 22PM0228E 28UG203B 32

REDUCING TEE

PART NO. PIPE OD TUBE OD ENDS BRANCH

PM3018AE 18 15PM3022AE 22 15UG203B 32 25

STEM ADAPTOR

Converts push fit endto male thread

PART NO. STEM THREAD OD BSP PM051513E 15 3/8PM051514E 15 1/2PM051814E 18 1/2PM052214E 22 1/2PM052216E 22 3/4

END STOP

PART NO. PIPE OD PM4615E 15PM4622E 22

1/2 or 3/4 female thread on the top. Both products have 3 x 1/2” female threads on the side.

ALUMINIUM WALL BOX

PART NO. SIZE JGWALLBOX 1/2 1/2 JGWALLBOX 3/4 3/4

PORTING BLOCK

PART NO.

JG-L-WSK 5 x ½” Connections

WATER TRAP TEE

PART NO. PIPE OD ENDS

PMTT22E 22

REDUCER

PART NO. STEM PIPE OD OD

PM061512E 15 12PM061815E 18 15PM062215E 22 15PM062218E 22 18PM062815E 28 15PM062822E 28 22PM3215 32 15PM3222 32 22 PM3228 32 28

STOP VALVE

PART NO. SIZE (MM)

15STV 15 22STV 22

PNEUMSYS

4

PIPES & FITTING FOR COMPRESSED AIR

PART NO. STEM COLOUR OD

PM0812R 12 REDPM0815E 15 BLACKPM0818E 18 BLACKPM0822E 22 BLACKPM0828E 28 BLACKUG803E 32 BLACK

PLUG

3 metre straight lengths.

12 to 22mm in packs of 20.

28mm in packs of 10.

Note : PEX Barrier pipes are flexible (upto 22 mm) and can be concealed behind wall.

15 mm pipes are available in coil form and can be directly bent around walls and pillars to reduce connectors

PEX BARRIER PIPE STRAIGHT LENGTH

PART NO. SIZE MM X M

15BPEX-20x3L 15 x 3

22BPEX-20x3L 22 x 3

28BPEX-10 x 3L 28 x 3

ALUMINIUM PIPE

3 metre straight lengths.

15mm to 22mm in packs of 20.

28mm in packs of 10.

6 metre / 4 metre straight lengths are available on request

PART NO. SIZE MM x M

AL-RM1513-3M-20B 15 x 3AL-RM1816-3M-20B 18 x 3AL-RM2220-3M-20B 22 x 3AL-RM2826-4M-10B 28 x 4AL-RM32296 32 x 4AL-RM2523 25 x 3

ACCESSORIESALUMINIUM PIPE CUTTER

PART NO. : ALPC 1528

SIZE : Cuts 15 mm - 32 mm OD Pipe

WINGBACK ELBOW

PART NO. PIPE OD THREAD

PM15WB 15 1/2 BSPPM22WB 22 3/4 BSPUGPWB2516 25 3/4BSP

BRASS STRAIGHT ADAPTOR

PART NO. PIPE OD THREAD MM011504N 15 1/2 BSPTMM012206N 22 3/4 BSPTMM012808N 28 1 BSPT

COMPRESSED AIR FITTINGSBRASS FITTINGSWATER TRAP TEE CONVERTOR

PART NO. SIZE

WTC28 28

COLLET COVERS

PART NO. PIPE OD COLOURS

PM1912E 12 BLACKPM1915E 15 BLACKPM1918E 18 BLACKPM1922E 22 BLACK

PART NO. STEM OD THREAD MM501514N 15 1/2 BSPMM502216N 22 3/4 BSP

FEMALE BRASS STEM ADAPTOR

MALE BRASS STEM ADAPTOR

PART NO. STEM OD THREAD

MM051504N 15 ½ BSPTMM052206N 22 3/4 BSPTMM052818N 28 1 BSPMM052226N 22 3/4 NPTMM052228N 22 1 NPTMM052828N 28 1 NPTMM0532N 32 1 BSPT

PIPE CLIPS AND SPACERS

CLIPPART NO. PIPE OD COLOURS PC15E 15 BLACKPC22E 22 BLACKPC28E 28 BLACK

PNEUMSYS

5

Note : Female adaptors also available of same threads on request.

PART NO. PIPE THREAD OD BSP

QEAL40 40 1 ½”QEAL50 50 2” QEAL63 63 2 ½”

STRAIGHT ADAPTOR

PART NO. PIPE OD

Q4M40 40Q4M50 50Q4M63 63

EQUAL ELBOW

PART NO. PIPE OD

QMA40 40QMA50 50QMA63 63

STRAIGHT CONNECTOR

PART NO. PIPE OD

QBO40 40QBO50 50QBO63 63

END STOP

PART NO. PIPE

QTE40 40QTE50 50QTE63 63

EQUAL TEE

PART NO. PIPE THREAD OD BSP

AL32112E 32 1 ½”AL40114E 40 1 ½”AL502E 50 2” AL63212E 63 2 ½”

STEM ADAPTOR

PART NO. USED PIPE FOR WTC40 SADDLE 40WTC50 SADDLE 50WTC63 SADDLE 63

WATER TRAP TEE CONVERTOR

MODEL SIZE

12MISTRAL ½”34MISTRAL 3/4”1MISTRAL 1”114MISTRAL 1 1/4”112MISTRAL 1 ½”2MISTRAL 2”

BRASS BODY (THREADED) BALL VALVE

PART NO. SIZE LENGTH MM/SM OF PIPE (DIA OF PIPE) (METERS)

AL-RM40376-5M-20B 40MM 5AL-RM5047-5M-20B 50MM 5AL-RM63-6M-20B 63MM 6

ALUMINUM PIPE

PART PORT PORTNO. INLET OUTLET

EQ089.844.048 ½” 4PEQ89.845.048 ½” 5P

PORTING BLOCK (RAILING MOUNTED)

Note : Mounting Rail can be fixed on wall and manifold block position is adjustable.

PART NO. PIPE THREAD OD BSP

PM4015 40 15PM4022 40 22PM5015 50 15PM5022 50 22PMQ328 63 28

REDUCER

PART NO. OD COLOR

UG804E 40 BLACKUG805E 50 BLACKUG806E 63 BLACK

PLUG

PNEUMSYS

PNEUMSYS ADVANCE PIPING SYSTEM

Note : John Guest Fittings are available from 15mm - 32mm size only.

Ref. PIPE OD COLOR

CALE3263 spacer height 20 mm BLACK

CALE3263/4 spacer height 4 mm BLACKHCKC32/8 32 mm BLACKHCKC40/8 40 mm BLACKHCKC50/8 40 mm BLACKHCKC63/8 63 mm BLACK

6

PIPE CLIPS AND SPACERS

Ref. Description

QCLE2040 SIZE 40 MMQCLE50 SIZE 50 MMQCLE63 SIZE 63 MM

40 MM - 63 MM DIA FITTINGS CANNOT BE TIGHTENEDWITHOUT THE ABOVE SPANNERS GENERAL PIPE SPANNERSSHOULD NOT BE USED TO TIGHTEN THESE FITTINGS

SPANNERS

RUBBER LINED CLIPS

Rubber Lined Size

MSTR35 32 mmMSTR42 40 mmMSTR48 50 mmMSTR60 63 mmMSTR90 90 mm

MSTBPF Backplate (Female) M8MSTBPM Backplate (male) M8

ADVANCE PIPING SYSTEM

PNEUMSYS

Ref. Description

KENNEDY ARBOR with SAW CUTTERWITH DCU (drill bit is included in the above)

DCU Spare SAW BELL

DRILLING JIG & CUTTER FOR MAKING HOLE IN PIPE

Ref. Description

DJD32 Drill Hole 32 mmDJD40 Drill Hole 40 mmDJD50 Drill Hole 50 mmDJD63 Drill Hole 63 mmDJDU Drill Hole 32-40-50-63 mm

DRILLING JIG & CUTTER FOR MAKING HOLE IN PIPE

Part No.. Size

15 S BEND 15 MM

S CLAMPS

Part No.. Size

HSV12 1/2"

SHUT OFF VALVE

Part No. Size (BSP)

150 0320 1 1/4" X 1 1/4”150 0575 1 ½" X 1 ½”150 0556 2" X 2”150 0557 2 1/2" X 2 1/2"

UNIVERSAL COUPLING 3 PIECE COUPLING

Part No. Size (BSP)

1557G000404 ½" X ½”1557G000505 3/4" X 3/4”1557G000606 1" X 1”

PART NO. Size

15 U BEND 15 MM

U CLAMPS

SPACER

Ref. Description

QSB3234 Pipe Dia 32 mm X3/4" BSP (F)QSB4034 Pipe Dia 40 mm X3/4" BSP (F)QSB5034 Pipe Dia 50 mm X 3/4" BSP (F)QSBS6350 Pipe Dia 50mm X 1" BSP (F)QSB6334 Pipe Dia 63mm X 3/4" BSP (F)QSBS6363 Pipe Dia 63 mm X 1" BSP (F)

SADDLE CLAMPS

7

Ref. Description

CONE50U Deburring till 50 mm Dia

DEBURRING CONE

Ref. Description

GCMP FOR FIXING TO GIRDERS(SIZE M8) OR BRACKET SUPPORTS (TIE ROD NOT INCLUDED)

GIRDER CLAMP WITH CLIP ADAPTOR

Ref. Description

12MM06M 12 MM OD X 6 MTRS12MM10M 12 MM OD X 10 MTRS.

RECOIL HOSE

Ref. Description

‘L” Shaped Slotted ChannelLMSB6-6 6" X 6”LMSB6-8 6" X 8" LMSB8-12 8" X 12”

STRAIGHT SLOTTED CHANNELSMSB12 12" LONG

METAL SUPPORT BRACKET

Ref. Description

TRM8 M8 X 3 METRES

TIE ROD

Ref. Description

EBAV FOR REMOVING BURRS FROM OUTER DIAMETER OF PIPE

TRIMMER

Ref. Description

SSA FOR SUSPENDING FROM CEILING(SIZE M8) (TIE ROD NOT INCLUDED)

SUSPENDED SUPPORT WITH CLIP ADAPTOR

ADVANCE PIPING SYSTEM

PNEUMSYS

Ref. Description

12FRPL ½" FR + L12FR ½" FR14FRPL 1/4" FR + L14FR ½" FR34FRPL 3/4” FR+L1FRPL 1” FR+L

FILTER / REGULATOR / LUBRICATOR : F/R/L

8

QUICK COUPLER

SPECIFICATION

MATERIAL

WORKING PRESSURE

MAXIMUM PRESSURE

TEMP. RANGE

SIZE

STEEL

215kgf/cm

220 kgf/cm

ZDC-2

210 kgf/cm

215 kgf/cm

-20ºC~+80ºC

1/4” (20 type)

3/8” (30 type)

1/2’(40 type)

Conditions-Fluid : Air Temperature: Room temperature

2000

1000

2Pressure (kg/cm )

0 1 2 3 4 5 6

Pflo

w r

ate

(..

../m

in)

40SP30SP20SP

Variety of connections

Female thread

Male thread

F

M

APPLICATIONS

FEATURES

Pneumatic tools.

Air piping.

Air pressure equipment.

Water piping.

One-way automatic shut-off valve in the socket.

Wide variety provides best choice according to

application.

Hardened important parts are extremely wear

resistant and durable.

Tested 100,000 times, coupler connection is

accurate and reliable.

****

**

*

*

MATERIAL : STEEL

20SHA

30SHA

40SHA

20SHA

30SHA

40SHA

20SHA

30SHA

40SHA

1/4”(PT)

3/8”(PT)

1/2”(PT)

1/4”(PT)

3/8”(PT)

1/2”(PT)

5X8MM

6.5X10MM

8X12MM

20PFA

30PFA

40SHA

20PFA

30PMA

40PMA

20PPA

30PPA

40PPA

1/4”(PT)

3/8”(PT)

1/2”(PT)

1/4”(PT)

3/8”(PT)

1/2”(PT)

5X8MM

6.5X10MM

8X12MM

PNEUMSYS

9

TRIMMING AND CHAMFERING CONE

One side it trims the inside of the pipe, on the other side it chamfers the outside.Ref. CONE 50 U

CHAMFERING TOOL

This tool chamfers pipes outside from Ø 50 to Ø 160.Ref. CHANF160

DRILLING JIG

This is used to hold the pipe in place when trying to drill a hole in it. It is available for specific sizes of pipe in 32mm / 40 mm / 50 mm and 63 mm and also One universal size adaptable from 32 mm - 63 mmRef. DJD32 - 63 and DJDU for Universal size

ARBOR WITH DRILL BIT AND CIRCULAR SAW CUTTER

Used to drill a hole in the pipe. It has to be fixed to the drilling head of a drilling machine and can be inserted in the drilling jig which guides it to give a clean cut in the pipe. Chamfering Tool CHANF160 can be used to remove any burrs from the cut surface. Ref. SAW for Circular Saw cutterRef. KENNIDY for Arbor with Drill bit

PLASTIC SPANNER

The Spanner assists in tightening of the nut for 40mm - 50mm and 63mm Dia fittings by making one last quarter turn to completely ensure fixation of the pipe in the fitting. Ref. QCLE2040 : Size 40 mm DiaRef. QCLE50 : Size 50 mm Dia Ref. QCLE63 : Size 63 mm

PNEUMSYS

CUTTING

• The roller pipe-cutter for plastics

PIPE CUTTER Ø 15 - 28 mmPIPE CUTTER Ø 28 to 63mm

ADVANCE PIPING SYSTEM

10

3. INSTALLING THE SADDLE

Put the saddle in position and tighten each screw in an alternate sequence until both halves are in contact.

SADDLE CLAMP INSTALLATION ONPIPE FOR DROPS

2. TRIMMING

Trim the hole on both sides of the pipe wall and remove the aluminum filings in order to keep the pipework clean.

4. INSTALLING THE WATER TRAP TEE CONVERTOR

The UNIQUE water trap tee convertor solves the on-going problem of moisture in a compressed air system and provides the easy alternative to the need to install “Swan Necks”.The ingenious inside arrangement of the fitting allows air to flow, with minimum head loss, from the main to take-off point without allowing water to follow. The moisture is retained in the ring main which can be periodically drained by means of a drain valve. Ref. WTC32 / 40 / 50 / 63 for insertion in Saddle clamps of sizes 32 mm / 40 mm / 50 mm and 63 mm.

ILLUSTRATIONS FOR TYPES OF SADDLE DROPS

WHICH CAN BE USED TO PREVENT CONDENSATE

FROM RUNNING DOWN TO THE DROPS

5. SEALING THE TREAD

Roll PTFE tape around the John Guest make 22 mm x 3/4” Or 15 mm x 3/4” BSP Male adaptor, making approx 5 turns following the thread’s direction

1. DRILLING

Mark the brach saddle’s location and drill the pipe with a 19 mm diameter bell saw for saddles with 1/2 “or 3/4” threaded branches.Note : when drilling small pipes, take all precautions to prevent the bell saw from reaching too deep.

PNEUMSYS

Straight Drop Right Angle Drop Flexible Bend Drop

Ė

Ė

Ė

Ė

Ė

1. Threaded Clamp 2. Cover

3. Thread 4. Seal

6. Nut 7. Washer

3

4

6

7

2

1

11

PNEUMSYS

80.020.020.048

80.020.025.068

80.020.032.088

80.020.040.108

80.020.050.128

80.020.063.168

82.020.090.248

Male Adaptor

80.030.020.048

80.030.025.068

80.030.032.088

80.030.040.108

80.030.050.128

80.030.063.168

Female Adaptor

80.040.020

80.040.025

80.040.032

80.040.040

80.040.050

80.040.063

82.040.090

90° Tee

80.010.020

80.010.025

80.010.032

80.010.040

80.010.050

80.010.063

82.010.090

Coupling

Part Number

FITTINGS AND PIPES FOR HIGH PRESSURE APPLICATIONS

Part Number

80.900.020.004

80.900.025.004

80.900.032.004

80.900.040.004

80.900.063.004

80.900.063.004

80.900.090.004

20

25

32

40

50

63

90

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

16 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

16 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

16 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

16 Bars

NP

NP

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

16 Bars

20x1/2”

25x3/4”

32x1”

40x1.1/2”

63x2”

63x2”

90x3”

20x1/2”

25x3/4”

32x1”

40x1.1/4”

50x1.1/2”

63x2”

90x3”

20x20x20

25x25x25

32x32x32

40x40x40

50x50x50

63x63x63

90x90x90

20x20

25x25

32x32

40x40

50x50

63x63

90x90

Ø

4 Mt.

4 Mt.

4 Mt.

4 Mt.

4 Mt.

4 Mt.

6 Mt.

LengthSize

12

PNEUMSYS

80.041.020.048

80.041.025.068

80.041.032.088

80.041.040.108

80.041.050.128

80.041.063.188

82.041.090.248

Female Threaded 90° Tee

Part Number

90° Elbow 80.050.020

80.050.025

80.050.032

80.050.040

80.050.050

80.050.063

82.050.090

NP

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

16 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

16 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

70 Bars

Male Threaded 90° Elbow 80.052.020.048

80.052.025.068

80.052.032.088

80.052.040.108

80.052.050.128

80.052.063.168

Ø

20x1/2”x20

25x3/4”x25

32x1”x32

40x1.1/4”x40

50x1.1/2”x50

63x2”x63

90x3”x90

20x20

25x25

32x32

40x40

50x50

63x63

90x90

20x1/2”

25x3/4”

32x1”

40x1.1/4”

50x1.1/2”

63x2”

FITTINGS AND PIPES FOR HIGH PRESSURE APPLICATIONS

Note : 90mm Dia fittings and pipes are rated to be operational at 16 bar nominal working pressure only.

13

GENERAL

The PNEUMSYS and John Guest system of pipes and fitting are inspected throughout their manufacture and are guaranteed for a use complying with their design within the limit indicated.

During the installation and before putting the PNEUMSYS network into service, it is advisable to make a certain number of checks as with all other materials.

INSPECTION

Visual inspection

During and after installation, the pipes and fitting should be inspected so as to eliminate doubtful elements containing abnormalities such as impacts and deep score caused by unsuitable handling. Before the tests, the whole network will be visually inspected to eliminate any part containing deep cuts or notches, large deformation due to sudden impacts, traces of blow torch burns, etc... Any damaged part should be replaced before putting into service. The aim of the visual inspection is also to ensure that the installation complies with the drawing and hence the correct installation of all the component parts (connection, supports, monitoring and safety mechanisms, etc...)

TEST BEFORE PUTTING INTO SERVICE

When the leak tests have been made, it is advisable, in order to remove all foreign matter, to clean the inside of the network. The test pressure of the circuit will be equal to at least 1.3 times the working pressure with a maximum of 12.5 bar.

The pressure will be kept for 12 hours and the manometers can show a slight pressure drop. IT IS IMPORTANT TO NOTE THAT YOU CANNOT ACHIEVE PRESSURE TIGHTNESS TO 100% in any Pneumatic system as there is bound to be microscopic leakages in any joints which have thread connections.

The waterproofness of the valves will be checked by closing them, one after the other, and by draining out the pressure downstream each of them. At the end of the tests the normal working pressure should be restored.

OPERATING CONDITIONS

Whatever the use, the safety mechanisms necessary for the tradition protection of network (regulation pressure reduction and limitation, temperature, regulation and limitation, shut off mechanisms, etc...), should be planned, Installed and kept in perfect working order throughout operation.

a) Vibration

Vibration can be a source of disorders on both pipework and support; it is highly advisable to install a suitable system preventing vibrations from spreading. It is advisable to install a hydraulic hose connection between the compressor and the fixed piping to eliminate the vibration of the compressor from getting passed on to the piping.

b) Sources of heat and UV

Being made from thermoplastic material, PNEUMSYS and John Guest fittings should in no case be installed close to a source of heat causing a rise in temperature greater than its limits of use, nor in places continuously exposed to the sun (ultraviolet rays). If this type of installation proves to be inevitable, a minimum number of precautions must be taken such as a protective screen impermeable to ultraviolet or heat rays.

c) Prevention of impacts

As with all networks conveying pressurised fluids, PNEUMSYS pipework systems should be protected against impacts which might occur in passage ways used by handing machinery or suspected loads in movement (use of safety barriers, railings, etc...).

PIPES & FITTING FOR COMPRESSED AIR

PNEUMSYS

14

SUPPORTS

Monoklip Brackets have been especially designed to support PNEUMSYS

systems. The pipe is allowed to move freely inside the bracket as it expands

and contracts.

To guarantee a constant pipe axis and to accommodate PNEUMSYS fittings,

Monoklip can be fitted with wedges.

Ref.: “CALE1225” for diameters 20 and 25 mm. “CALE3263” for diameters 32 - 40 - 50 and 63 mm.

®SPACING BETWEEN MONOKLIPS

Pipe diameter

Distance between brackets(in meter)

Horizontal section (m)

Vertical section (m)

1,4 1,6 1,8 2,1

2,2 2,9 3 3,1

32 40 50 63

For fluid temperature reaching 30°C apply 0.9 correction factor and apply 0.8 for temperatures reaching 40°C

Note :

On Ø 50 & 63 mm, we advise that brackets should be installed as close to the fitting as possible, but without

impairing pipe expansion and contraction.

GENERAL SPACING

CALE (4mm)

CALE (20mm)

ADVANCE PIPING SYSTEM

PNEUMSYS

15

The calculation of pipework dimensions is a direct function of the pressure loss (∆p) admitted between start point and

end point. Oversized networks will lead to high pressure losses may cause compressors to conserve too much

energy. This pressure loss takes into account the total length of pipe, and each fitting’s specific influence figured out

in equivalent runs of pipe, according t each fitting’s shape.

PRESSURE LOSSES AND PIPEWORK SIZE

EQUIVALENT LENGTH OF PIPE OF THE SAME DIAMETER (in meters)

Pipe Coupling Elbow Elbow Tee Tee Reducing Reducing Bends 180° external Ø Unions 90° 45° to branch bush double 90° drop bends short pattern long pattern

16 0.10 0.30 0.15 0.10 0.70 0.45 0.20 0.10 0.25

20 0.15 0.40 0.20 0.15 0.85 0.55 0.25 0.15 0.35

25 0.20 0.50 0.25 0.15 1.05 0.70 0.30 0.15 0.55

40 0.30 0.80 0.40 0.25 1.70 1.10 0.45 0.25 -

50 0.40 0.95 0.50 0.35 2.15 1.35 0.60 0.35 -

63 0.50 1.25 0.60 0.45 2.70 1.70 0.75 0.45 -

75 - 1.50 0.75 0.55 3.70 2.40 1.10 0.55 -

90 - 1.85 0.95 0.70 4.55 3.10 1.35 0.75 -

110 - 2.50 1.35 0.95 6.05 3.50 1.55 1.00 -

It is common usage to consider that fitting add up 15% of the total length of pipe.

Use the above formula to determine the diameter with an optimised fluid speed of 7m/s:

-3 2 Ø int. = 10 0.16 x 10 Q L1 5.16

∆p1 PAubery equation

Ø int. = inside diameter (mm)

Q = flow (m3/h)

L1 = length (m)

∆p1 = pressure loss of the pipework section (bar)

P = pressure of the network (bar)

L1 = Length of pipe + sum of length of the equivalent fitting

Note : for a 300 m length circuit if we impose a 0.3 bar ∆p

for a 70 m length part ∆p = = 0.07 bar 0.3 x 70

300

PNEUMSYS technical services will answer your questions.

PNEUMSYS

ADVANCE PIPING SYSTEM

16

NETWORK DESIGN ADVICE

- Have as many straight sections as possible.

- Compressed air speed should be around 7 m/s: indeed, by exceeding this speed, pressure losses increase quickly, and so do energy costs.

Nonetheless, a speed inferior to 5 m/s means that the diameter of the pipe is not fully used, which also enables to regulate air consumption peaks thanks to the amount of air stored in the network.

- The network needs to be drained easily from its condensates at low point.

- Choose accessories and fitting that will causes less pressure losses.

- Design a network as simple as possible to have a better balance flow.

- Try to have an internal diameter of pipe as constant as possible. Avoid pipe section reductions to limit pressure losses.

- Use enough valves to allow for network isolation by section.

DRAINING

Condensation has no effect on the PNEUMSYS system, but it can damage production tools. It is important to be able to

evacuate condensation and even more if the system does not have a dryer upstream.

- Drains can be automatic or manual.

- The network requires a slope about 0,7% to 1%, directed toward the drain.

- Drains will be located at the lowest points of the circuit or at the end of straight lines

BRANCHES

In order to avoid the presence of water in downpipes, branches can be done with U bends starting from the upper side of the

network. Water trap Tee’s are a good alternative to U bends as they are as effective to retain moisture in the ring main.

This technique enables condensation and impurities to be evacuated toward the drains without affecting the equipment or

the manufacturing process (e.g. low pressure paint pistols..).

THE FLOW: PRESSURE OF NETWORK

To determine the compressed air network dimensions some data needs to be known precisely:

• The equipments using compressed air:

- quantity,

- the pressure recommended by the manufactures,

- the volume of air consumed when machines are on,

- number of machines working simultaneously.

• kind of joint used to link the equipment to the compressed air network.

• Identify the accessories added to the compressed air network (filters...) The pressure of the network at the starting point shall be equal to the pressure of the machine needing the highest

pressure added to the PNEUMSYS system load losses, and to particular accessories pressure losses: filters, quick

fitting (some of them may have a pressure loss of 1 bar or more, contact the manufacturer for exact information).

Examples:

- Pneumatic screwdriver = flow 25 Nm3/h pressure 5 bar

- Paint pistol = “ 14 Nm3/h “ 4 bar

- Sandblaster = “ 35 Nm3/h “ 6 bar

In order to determine pipework sizes, start with the mains (starting from compressor outlet) and proceed by section.

FLOW RATE-PRESSURE LOSSES

PNEUMSYS

ADVANCE PIPING SYSTEM

17

PRESSURE = 7 bar

The table give the pipe outside diameter according to the pressure losses and the flow rate, with a fluid speed about 7m/s.

FLOW RATE - PRESSURE LOSSES

∆p ≤ 0.3

L1 = Length (m)pipes length + equal due to the fitting

25

50 75

100

200

300

400

500

600

700

800

900

QFlow m3/h

15

15 22

22 28

32 40

50 50

50 50

63

15

22 28

28 28

40 40

50 50

63 63

63

15

22 28

28 28

40 40

50 50

63 63

63

18

22 28

28 32

40 50

50 63

63 63

63

22

22 28

28

32 40

50 50

63 63

63

63

22

22 28

28 32

40 50

50 63

63 63

63

22

28 28

28 32

40 50

50 63

63 63

63

22

28 28

28 40

50 50

50 63

63 63

-

10 25 50 75 100 125 150 200

Qcfm

15

30 45

60

115

175

235

300

350

415

470

530

PNEUMSYS

ADVANCE PIPING SYSTEM

TRAINING CENTREOur training centre (officially recognized for vocational training) gives installers and decision-makers modular

courses about technical installation.

NETWORK DESIGNOur technical assistance and design service can help optimize network drawing

• Drawing featuring all Pneumsys articles.

• Complete bill of materials.

• Calculations of bracketing...

More services from PNEUMSYSTraining centre, analysis of your needs, specification work, adaptation and development of specific fabricated products and daily services are offered to facilitate sales and installation of our products.

INNOVATE AND EXECUTEWith support from our experienced engineers, PNEUMSYS ensures that the solution to any problem is an innovative idea and this is what can be seen at our project installations at various sites in India.

PNEUMSYS Advance Energy Solutions38, Madhu Vrinda, Dhuri Industrial Estate, Waliv Fata, Vasai (E),

Dist. Thane 401 202 • Tel.: +91-98211 28362 / 98215 40759Fax : +91-22-2851 4093 • Email : rl@pneumsys.com

Visit us at : www.pneumsysenergy.com