Even though actuators and position sensors are at the forefront of pneumatics evolution, the developments in air preparation are not far behind. Combined Filter-Regulator-Lubricator units are now commonly equipped with pressure sensors, flow meters, and other types of sensors to measure air pressure, flow, contaminants, and everyday usage. By doing so, machine performance can be closely monitored, faults can be identified, and adjustments can be made before any problems arise. It is possible to compare performance parameters from the device with manufacturers’ specs, to determine what factors may be affecting performance and how they can correct.
In addition to choosing the right device for your application, it’s important to conduct regular and appropriate maintenance. Predictive maintenance procedures should be built into your IIoT-enabled devices, so you can ensure that the equipment is performing as it should and thus extend its service life. To install the best possible FRL for your device and to ensure it runs with the least amount of maintenance, here are six considerations:
1. The Operating Environment
It is crucial to consider the operating environment of the FRL unit before selecting it, particularly whether or not it will locate indoors or outdoors. An FRL’s operational components must be construct from appropriate materials and design to withstand their environment, and the first element of this is extremes of temperature and climate. In the case of an outdoor assembly, the range of possible operating temperatures must considere, since extremes of heat or cold will require specific temperature ratings. Saltwater corrosion must tolerate by FRL assemblies use in oil rigs and other marine environments, as well as leak resistance and wear resistance in water treatment plants. A secure seal or mounting within a protective enclosure will require in other extreme environments, such as chemical or caustic operations, clean rooms, food and beverage preparation, and ATEX conditions.
2. Proper Pressure Specification
To determine the specifications of your FRL, you need to know the air-supply pressure of the device, equipment, or plant. The majority of FRL components are design to operate at pressures up to 10 bar in standard sizes and configurations, though some equipment air supplies are rate at up to 17 bar. The equipment or device should specify a high-pressure regulator and filter unit – newer FRL models can even handle pressures up to 20 bars.
3. Lubrication
A lubricator is not require for all pneumatics, although it is more common than not. It is important to properly lubricate your pneumatic valves and cylinders, which act as a detergent in the air system and are built into the FRL assembly. The FRL continuously lubricates the system, washing out any contaminants that might otherwise cause sticking in the valves and cylinders. To remove contaminants otherwise washed out by the lubricant, non-lubricate pneumatics will usually require both coalescing and particulate filters.
4. Lockout and Shutdown Valves
A modular design architecture makes adding lockout valves (high-flow exhaust) and/or shut-off or isolation valves (low-flow exhaust) to an FRLs assembly simple. Installing such devices depends on the application and is usually dictate by the components of the machine. There are two types of lockout valves – quick-exhaust or quick-exhaust with soft-start – that are manually or electrically activated, which ensure that no airflow reaches downstream components. When a mechanical jam or an unsafe operator incursion occurs in a pneumatic system, these vents are commonly require to remove the air from the equipment.
Any routine or emergency maintenance must always performe with live pneumatic systems shut off or isolated. Upstream of the FRL assembly, isolation, or shut-off valves drain potential compress air energy into the atmosphere safely through a back-flow exhaust. Tag-out/lock-out procedures must also follow properly.
5. Air Flow Rate
Airflow rate is one of the most important factors to consider when choosing components for your FRL unit, as the FRL must be properly size according to the machine’s flow rate. A pneumatic component’s response rate is determine by the amount of air require to fill and exhaust it, along with the amount of time it takes for the unit to respond. Most equipment designers find it difficult and time-consuming to accurately calculate the airflow requirements of a pneumatic machine. However, if you do it correctly, your pneumatic devices will be more effective and cost-effective.
Also, engineers match the port side of the FRLs with the port side of the cylinder or valve manifold, and many manufacturers supply FRLs with overlapping port sizes. By using larger series, nominal flow rates can increase significantly, but adjusting pore size within a series can alter flow capacity in a more convenient manner.
6. Filter Replacement
In this area, preventive maintenance is highly recommend, since many users are unaware that pneumatic equipment’s filter elements need to replace at regular intervals. If this is not done on time, inefficient performance and possible machine downtime will result. Modern FRLs have electronic or warning light indicators to raise a maintenance alert, and their modular components make maintenance significantly easier. In older systems, the condition of the filter and lubricator bowls can still monitore by looking for accumulated water and a steady oil supply.
The FRLs of a pneumatic system may be the least prominent feature, but they have a significant impact on its efficiency and productivity. As machines work more efficiently and for longer, experience fewer leaks, and conserve both energy and air, the selection, sizing, and maintenance of FRL components will save money over time.
Also, check Usage and Applications of Pneumatic Control Valve
