Title: Study of FRL Unit

Learning Objectives: 1. Understand the need of air preparation unit 2. Understand the construction and working of FRL unit 3. Understand the precautions to be taken for FRL unit 4. Draw the sketches and symbol of FRL unit

Problem Statement: Compressor sucks air from the atmosphere which is not generally clean and contains moisture. Air pressure does not remain constant due to line fluctuations Oil-free air leads to dry friction between certain mating components The individual functions of compressed air preparation, i.e. filtering, regulating and lubricating, can be fulfilled by individual components. These functions have often been combined into one unit, i.e. the service unit. Service units are connected upstream of all pneumatic systems.

Air Filter: Condensed water, contamination and excess oil can lead to wear on the moving parts and seals of pneumatic components. These substances can escape as a result of leakage. Without the use of filters, for exam products to be processed in the food, ple, pharmaceutical or chemical industries could become contaminated and therefore rendered useless. The selection of the correct filter plays an important role in determining the quality and performance of the working system which is to be sup plied with compressed air. One characteristic of compressed-air filters is the pore size. The pore size of the filter element indicates the minimum particle size which can be filtered out of the compressed air. The collected condensate must be drained before the level exceeds the maximum condensate mark otherwise it will be re-introduced in the air stream. Working Principle: The compressed air passes through the filter from left to right and is fed through a baffle plate in the filter bowl. The effect of the baffle plate is that the air is caused to rotate, and the heavier dust particles and water droplets are spun by centrifugal force against the inner wall of the filter bowl. They then run down the wall of the housing and collect in the filter bowl. The air which has been pre-cleaned in this way then passes through the filter element, which filters out the smaller dirt particles. The filter element in this case consists of a highly-porous sintered material. The degree of separation depends on the pore size of the filter element used. Inserts with different pore sizes are available. The usual pore sizes are between 5 microns and 40 microns.

A further important characteristic of compressed-air filters is the degree of separation, or efficiency, which indicates the percentage of particles of a particular size which can be separated out. The efficiency is quoted for a particle size, e.g. efficiency of 99.99% for 5 microns. With micro filters, 99,999% of particles greater than 0.01 m can be filtered. The filtration action of a compressed-air filter is retained, even after long service and with heavy contamination. However, under these conditions, the pressure drop becomes disproportionately high and the filter be comes an energy-waster. In order to recognise the correct time to change the filter element, a vis inspection ual or a measurement of the pressure difference across the filter should be carried out. Depending on the nature of the compressed air available, the air con sumption of the components and the filter size, compressed-air filters require a greater or lesser amount of maintenance work. Maintenance work means the following: Replacing or cleaning the filter element

Draining the condensate

Air Regulator: The compressed air generated by the compressor will fluctuate. the pressure level in the pipe system can adversely affect characteristics of flow control and memory valves. (Changes in

c the switching

characteristics of valves, the running times of cylinders and the timing

A constant pressure level is thus a prerequisite for the trouble-free op eration of a pneumatic control. In order to provide constant pressure conditions, regulators are fitted in a central position in the compressed air network to ensure that there is a constant supply pressure (secon ary pressure) irrespective of the pressure d fluctuations in the main loop (primary pressure). The pressure reducer or pressure regulator is fitted downstream of the compressed air filter and has the task of keeping the operating pressure constant, regardless of pressure fluctuations or air consumption in the system. The air pressure should be matched to indi vidual requirements upstream of each plant section. The system pressure which has proved in practice to be the best eco nomic and technical compromise between compressed-air generation and the efficiency of the components is approximately:600 kPa (6 bar) in the power section and 300 to 400 kPa (4 bar) in the control section.

A higher operating pressure would lead to inefficient energy utilisation and increased wear, whereas a lower operating pressure would lead to poor efficiency, particularly in the power section.

The input pressure (primary pressure) at the pressure regulator must always be

higher than the output pressure (secondary pressure). The pressure is regulated by a diaphragm. The output pressure acts on one side of the diaphragm and a spring acts on the other side. The spring force can be adjusted by means of an adjusting screw. When the output pressure increases for example during cylinder load changes, the diaphragm moves against the spring force causing the outlet cross-sectional area at the valve seat to be reduced or closed en tirely. The centerpiece of the diaphragm then opens and the compressed air can flow to atmosphere through the vent holes in the housing. When the output pressure decreases the spring force opens the valve. Regulation of the preset output pressure is thus a continual opening and closing of the valve seat caused by the flow of air. The operating pres is indicated on a gauge. sure If no air is drawn off on the secondary side, the pressure rises and presses the diaphragm against the compression spring. The outlet cross-sectional area at the vlave seat is reduced or closed and the flow of air is reduced or cut off entirely. The compressed air can continue to flow only when air is drawn off on the secondary side. As a rule the compressed air which is generated should be dry, i.e. free of oil. For some components lubricated air is damaging, for others, it is undesirable, but for power components it may in certain cases be nec essary. Lubrication of the compressed air should therefore always be limited to the plant sections which require lubrication. For this purpose, mist lubricators are fitted to feed the compressed air with specially seected oils. Oils which are introduced into the air l from the compressor are not suitable for the lubrication of control system components.

Air Lubricator:

As a general principle cylinders with heat-resistant seals must not be supplied with lubricated compressed air, since the special grease which forms the original lubrication would be washed out. If systems, which have been operated with lubrication, are converted to un lubricated compressed air, the original lubrication of the valves and cylinders must be renewed, since these may have been flushed out in some instances.

Lubrication of the compressed air by means of mist lubricators may be necessary in certain cases: Where extremely rapid oscillating motions are required

With cylinders of large diameter, lubricators should where possible be installed only directly upstream of the consuming cylinders

The following problems may occur as a result of excessive lubrication: Malfunction of components Increased environmental problems Seizing of components after prolonged downtime

Viaduct Drip chamber Duct Valve restriction

Check valve

Ball seat

Riser

oil

Working Principle: The compressed air passing through the lubricator causes a pressure drop between the oil reservoir and the upper part of the lubricator. The pressure difference is sufficient to force the oil upwards through a duct where it then drips into a nozzle which can be seen through an inspecion glass. Here the oil is atomised and taken up t by the air stream to a greater or lesser extent. A reference value for oil dosage is a quantity of 1 to 10 droplets per cu metre of bic compressed air. The correct metering can be checked as follows: A piece of white cardboard should be held at a distance of aproximately 10 cm from the exhaust port p of the power valve of the cylin which is furthest away from the lubricator. If the der system is then al owed to operate for some time, it should be possible to see only a l pale yellow colour on the cardboard. Dripping oil is a clear sign of over-lubrication.

Up to a few years ago, the general view was that the oil discharged by the compressor could be used as a lubricant for the power components. Now it has been recognised that this is not the case. As the level of heat produced in the compressor is very high, the oil is carbonised and the oil vapour exhausted. This leads to an abrasive action on cylinders and valves, and service is considerably reduced. A further problem is that oil is deposited on the inner walls of the pipes and is eventually absorbed in an uncontrolled way into the air flow. This ''act alone makes controlled and effective distribution impossible. A pipe which has become contaminated in this way can no longer be cleaned without dismantling. A further disadvantage is gumming, which means :nat after a system has been at a standstill for some time (after weeknds and public holidays), lubricated components e do not function correctly.

The following routine service measures are necessary on a regular basis

Compressed air filter:

condensate can be drained usng the drain cock on the sight glass. The filter cartridge i must also be checked for contamination and cleaned or replaced if necessary.

Compressed air regulator:

Compressed air lubricator: