Prep work – in class for Module 2

1. What is the main function of an air generation and distribution?

2. How does an air generation work?

3. What are the main parts in a compressed air generation? And list the flow path
in order?
4. Draw the ISO symbol for an air compressor.

5. What is the function of a compressed air filter and how does the filtering
process work ?

6. Draw the ISO symbol of an air compressor?

7. What does the cooling and drying unit is used for?

8. A pipe diameter of the air distribution system is selected based on what criteria

9. What is an air Service Unit and what is its function?

10. Name this ISO symbol on your right and what does it do?
Air generation & distribution

Pneumatics – Module 2
 objectives
• Identify the main parts of a pneumatic system.
• Identify the main components of the pneumatic work
station TP 101.
• List the main parts in the compressed air preparation
stage.
• Identify the symbol of air compressor and its function.
• Identify the symbol of air tank and its function.
• Explain the purpose of using the cooling and drying unit.
• Identify the main parts of the air service unit.
• Identify the symbol of air filter and its function.
• Identify the symbol of air pressure regulator and its
function.
• Identify the symbol of lubricator and its function.
• Identify some important pneumatic accessories.
 introduction
The main function of the air generation and
distribution is to provide the system with
compressed air which is dry, clean, and at
the required pressure.
Air is compressed by the air compressor
and delivered to an air distribution system
in the factory. To ensure that the quality of
the air is acceptable, air service unit is
utilized to prepare the air before being
supplied to the control system.
Malfunctions can be considerably reduced in
the system if the compressed air is
correctly prepared.
 Main parts in the compressed air
preparation
Air Air Tank Cooling &
Air Filter
Compressor (Reservoir) Drying Unit

Pressure Air Service Shut off

Piping
Regulator Unit Valve

Air Tubes & Pressure

Manifold
Lubricator Fittings Gauge
 1. AIR COMPRESSOR
•The Air compressor is used to produce the compressed air
for the system by the required volume and pressure.

•The maximum operating pressure should be 800-1000 kPa (8 -

10 bar) but in practice it is recommended to operate at
between 500-600 kPa (5 and 6 bar) for economic and safe use.

•Due to the pressure losses in the distribution system, the

compressor should provide pressure between 650-700 kPa (6.5
and 7) bar.
 2. AIR TANK (RESERVOIR)

* An air reservoir should be fitted to:

1. Store and stabilize the compressed air.
2. Compensate the pressure fluctuation.
3. Cool the air.
 3. AIR FILTER

•Compressed air filter has the job of removing all contaminants

from the compressed air flowing through it as well as water which
has already condensed.

•The compressed air enters the filter bowl through guide slots.
Liquid particles and larger particles of dirt are separated
centrifugally collecting in the lower part of the filter bowl. The
collected condensate must be drained before the level exceeds
the maximum condensate mark, as it will otherwise be re-
entrained in the air stream.
 4. COOLING & DRYING UNIT
As the air comes out from the compressor very hot and humid; The
cooling and drying unit is used to:
1. Condensate the water vapor (humidity) from the compressed air.
2. Reduce the compressed air temperature. (cooling)

•The accumulation of condensate depends largely on the relative air

humidity. The relative air humidity is dependent on the air
temperature and the weather situation.

•To remove the humidity, we use many types of air dryers, the very
common and practical one is by using a cooling unit which cools the
air and at the same time removes the water vapor.
 5. SHUT OFF VALVE

It is used to open and close the compressed air supply

manually.
 6. PIPING
The pipe diameter of the air distribution system should be
selected in such a way that the pressure loss from the
pressurized reservoir to the consuming device ideally does not
exceed approximate 10 kPa (0.1 bar).

Selection
Factors of
the Pipe Piping
Diameter Layout
 SELECTION
FACTORS OF
THE PIPE
DIAMETER

1. Flow rate
2. Line length
3. Permissible pressure loss
4. Operating pressure
5. Number of flow control points
in the line
 PIPING
LAYOUT

PIPE – RUN
The air comes from the
DISTRIBUTION SYSTEM
compressor to the compressed
air supply outlets through a
piping system.

The pipe lines are installed in the direction of flow

with a gradient of 1 to 2% repair. This is
particularly important in the case of branch lines.

Drainage is used to remove the condensed water

from the lines at the Lowest point.

Shut-off valves are used to block sections of

compressed air lines at any stage for maintenance.
 7. AIR SERVICE UNIT

The air service unit is a combination of the following:

1. Compressed air filter (with water separator)
2. Compressed air regulator
3. Compressed air lubricator

The main function of the service unit is to provide the

pneumatic system with a well cleaned, lubricated and regulated
compressed air. (Condition the compressed air).
 8. PRESSURE REGULATOR

(Reduce/regulate the pressure).

The purpose of the regulator is to keep the operating
pressure of the system (secondary pressure) virtually
constant regardless of fluctuations in the line pressure
(primary pressure) and the air consumption.
 9. AIR LUBRICATOR

(Lubricate the moving parts)

•Most moving parts require some type of lubrication.

•Pneumatic components can be lubricated by using an air line

lubricator ,a device for adding lubricating oil in aerosol form
into a compressed air line. The air passing through the
lubricator transports the lubricant to air tools, cylinders or
other air operated equipment.
 10.MAINFOLD (DISTRIBUTOR)

• It is used to provide multi equal pressure outlets.

• Each output port has A check valve (Non return valve).

T- junction
Pressure Source
 11.TUBES & FITTINGS

• Shown below are some types of tubes that are used in

connecting pneumatic circuits.

• Shown below are some important fittings such as T

connections and cross connections.
 12. PRESSURE GAUGE

It used to display the actual amount of the pressure in

two main units PSI and bar.

1 bar= 14.7 PSI

 CLASS ACTIVITY

• Solve the worksheet found

at the end of the module
 FOR FURTHER READING:
• www.Fest-didactic.com
• http://www.eng2all.com/vb/t28932.html
• http://www.logiclab.hu/lesson.php?fe=2
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