Steel fab­ri­ca­tion plant gets IAS sys­tem in­stalled

DEMM Engineering & Manufacturing - - PNEUMATICS HYDRAULICS -

In­dus­trial Air Sys­tems NZ has in­stalled its Pneutech Alu­minium com­pressed air pip­ing sys­tem into John Jones Steel fab­ri­ca­tion fa­cil­ity in Ti­maru.

With more 4000sq m of work­shop fa­cil­i­ties, John Jones was adding new state-ofthe-art plate cut­ting and drilling equip­ment, which was re­quir­ing more com­pressed air than what was avail­able. Re-siz­ing their ac­tual com­pressed air re­quire­ments was the easy part, with the in­stal­la­tion of a new sin­gle 37 kW VSD com­pres­sor to sup­ply an en­ergy-ef­fi­cient air sup­ply, and cou­pled to fil­tra­tion and re­frig­er­ate dryer for the best in­stru­ment-qual­ity air.

How­ever, it was quickly es­tab­lished that the ex­ist­ing dated and leak­ing gal­vanised air pip­ing sys­tem was not of suf­fi­cient size qual­ity, or lay­out to retic­u­late the new higher qual­ity com­pressed air sup­ply to the var­i­ous work­ing points re­quired.

Fur­ther­more there would be very lit­tle gain from the new com­pressed air plant, un­less the pip­ing sys­tem was also up­graded.

John Jones Steel’s new plant was re­quir­ing con­tam­i­nant­free com­pressed air, both for the safe oper­a­tion of CNC equip­ment, and to pro­duce the high­est qual­ity and most cost ef­fec­tive re­sults. The age­ing gal­vanised pip­ing was found to have in­ter­nal rust­ing, leading to air con­tam­i­na­tion that would have a detri­men­tal ef­fect on plasma cut­ting, while caus­ing pre­ma­ture and costly plant wear.

As with any gal­vanised pip­ing in­stal­la­tion, the sys­tem was also found to be fraught with air leaks, which when added to­gether would be cost­ing many thou­sands of dol­lars ev­ery year in wasted en­ergy.

In­dus­trial Air Sys­tems’ di­rec­tor says: “The air com­pres­sor is re­ally only half the com­pressed air story, the other half lies with the air treat­ment and most im­por­tantly, the air retic­u­la­tion sys­tem.

“Like wa­ter, you can have the largest and best sup­ply in the world right on hand, but un­less it can be piped to where it is re­quired, it is of lit­tle use.”

In­dus­trial Air Sys­tems pro­vided the op­ti­mum so­lu­tion by in­stalling the pre­mium qual­ity Pneutech Alu­minium air pipe sys­tem, with more than 450m of 32mm ring­main, feed­ing 30 20mm drop­pers at each work sta­tion.

The high seis­mic and yet rigid char­ac­ter­is­tics of the ex­truded alu­minium meant that it was very sim­ple to hang, and with no risk of bows or sags, trou­ble­some wa­ter collection points in the air line were elim­i­nated.

The much larger and smooth in­ter­nal bore of the Pneutech Alu Air pip­ing, en­sured higher com­pressed air f lows were achiev­able with the least tur­bu­lence ef­fect, (when com­pared with gal­vanised or poly pip­ing).

This ul­ti­mately leads to large en­ergy sav­ings, as the air com­pres­sor could op­er­ate at a lower pres­sure, in turn us­ing less elec­tric­ity, but for the same air ca­pac­ity.

A com­plete ring­main sys­tem, meant pres­sure and f low con­ti­nu­ity was as­sured at ev­ery work­sta­tion, de­spite an im­bal­anced work­load, while the sim­ple push-lock style fit­ting de­sign, al­lowed for the sys­tem to be quickly and sim­ply al­tered or ex­tended at any time.

The sim­ple ex­pand­ing O-ring de­sign en­sured there were no costly air leaks, while risk of rust cor­ro­sion was com­pletely re­moved.

In­dus­trial Air Sys­tems NZ pre­dicts that the Pneutech vari­able speed com­pres­sor and alu­minium pipe sys­tem, will bring John Jones Steel thou­sands of dol­lars in en­ergy sav­ings ev­ery year.­eren­quiry #D131222

Photo / sup­plied

Pneutech Alu­minium air pipe sys­tem has more than 450m of 32mm ring­main, feed­ing 30 20mm drop­pers at each work sta­tion at John Jones Steel.

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