The Innovative Lightweight Ring Main System Introduced to ... · 2.1 Fitting pressure drops Although fittings are smooth inside with the same inside diameter as the tube, they represent

The Innovative Lightweight Ring Main SystemIntroduced to the UK by Tom Parker Ltd

Pneumatic and Hydraulic Specialistswww.tom-parker.co.uk

2www.tom-parker.co.uk www.tom-parker.co.uk

The Easy to Assemble, Economical and Efficient Compressed Air Solution

Tom Parker Ltd has been distributing pneumatic and hydraulic products to the UK fluid power market for over forty years and are renowned as specialists in our field. We have built our reputation by providing a carefully selected, comprehensive range of brands that are innovative, reliable and competitively priced.

One such product range which impressed us enough to add it to our portfolio is the SicoAIR ring main system manufactured by Italian pneumatics brand Sicomat.

On watching a traditional ring main system being installed alongside a SicoAIR compressed air distribution system it is clear to see why the new technology was needed in the first place.

Why choose the SicoAIR ringmain system over conventional methods?

Durability - The SicoAIR ring main system requires a low level of maintenance and is resistant to pressure, fire, UV exposure and corrosion. It is also shock proof.

Ease of use - It is easy to assemble, quick to install and fully adjustable. Whether you need a small installation or to supply air to a large industrial production plant it is equally effective.

Efficiency - The technology used ensures a reduced pressure drop and increased flow rate improving productivity.

Flexibility - It’s simple but effective construction using compression rather than screw-in fittings mean that it is adaptable for a wide range of applications and can be easily moved and re-used.

Lightweight - Due to its aluminium construction this compressed air distribution system is a safe and cost effective alternative to traditional systems that used malleable iron. It is extremely lightweight, easy to carry and transport.

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CERTIFICATION

ASSEMBLY INSTRUCTIONS

12CALCULATING ABSORBTION POINT

13TYPES OF LYRE

14INSTALLATION OF PIPES

19PIPE PREPARATION

20LUBRICATION OF SEAL

21LOCKING FITTINGS

6

8


CERTIFICATION

SicoMat and SicoAir products are TUV tested and certifiedto ensure durability and quality

TUV CERTIFICATION IS WITHOUT qUESTION THE MOST COMPREHENSIVE ANd RIGOROUS TESTING ANY PROdUCT CAN UNdERGO. IT VERIFIES THAT SICOAIR SATISFIES THE STRICTEST PNEUMATIC EUROPEAN REGULATIONS ANd ENSURES SPECIFICATIONS ARE STATEd CORRECTLY


INSTALLATION GUIdE


All of the relative calculations for the assistance of installation in this manual are valid only in conditions with an ambient temperature of between 15°C and 25°C

fig. 1variation from thermal expansion

0°C 50°C

15°C to 25°C

IN THE EVENT THAT THE INSTALLATION IS MAdE AT TEMPERATURES OUTSIdE OF THE RANGE INdICATEd ABOVE, NECESSARY ALTERATIONS MUST BE MAdE

R-RANGE FITTING SIZES dN 20 - 25 - 32 - 40 - 50 - 63

CHAMFER TUBE ENdS BEFORE INSERTING INTO FITTINGS TO AVOId SEAL dAMAGE


The lubrication in addition to facilitating the insertion of the tube into the fitting optimises the operation of the seal reducing damage over time


1. Check that all connection parts are accurately assembled and check the orientation of the clip; if it is incorrectly assembled the tightness of the connection cannot be guaranteed. (See fig. 2)

4. Once the tube has been correctly inserted into the fitting, rotate the coupling ring completely over the antiscrew tooth. To carry out this operation easily it is advisable to use the specially designed Sicoair range of tools.

3. The tube must be pushed into the fitting until the tube will not go any further. This can be checked by marking on the tube the length “L” indicated in the table below, prior to insertion. (See fig. 3)

2. Before inserting the tube into the fitting, rotate the light-blue coupling ring against the antiscrew tooth and no further.

5. Fig. 3 illustrates the tightening force needed for each fitting size (expressed in N/m) in order to guarantee optimal pneumatic and mechanical sealing results.

fig. 2

Coupling Ring

Clip Fitting

Antiscrew

dN 20 25 32 40 50 63N/m 9 ÷ 11 11 ÷ 13 12 ÷ 15 15 ÷ 17 17 ÷ 20 18 ÷ 22

L = mm 45 55 60 58 74 83

fig. 3

6. Fig. 4 illustrates the correct installation. Misalignment of more than 5° from the horizontal line may compromise the tightness of the fittings.

5°5°

85° m

in90

°95

° min

fig. 4



7. Please refer to the specifications indicated in this brochure for compatibility with chemical substances that could be present in the tubes.

8. Sicomat and Tom Parker Ltd. will not take responsibility for any damage caused by the incorrect use of their products and/or non-compliance with the instructions indicated by this brochure.

fig. 5 Pressure drop in the tube - Nomogram at 15°C

100 00090 00080 00070 000 0,0260 00050 000

30 000

40 000 0,03

0,04

0,05

0,0620 0000,070,080,090,1

10 0009 000

7 0008 000

6 000

5 000

0,2

3 000

4 000

0,4

0,3

0,60,5

2 000

1 000900

700800

600

10,90,80,7

2

500

400

300

200

100

5

4

3

6

10987

Pressure drop for 100 m (in bars)

Delivery SRA* (in l/min.)

160

110

90

75

63

5040

32

25

20

16

Outside diameter of the tube (mm)

20

109

765

4

3

2

1

8

0

1

2

3

456789

10

20

Referential axis

Pressure (in bars)

delivery SRA*:actual delivery at the effective pressure (P) x absolute pressure (P+1) in bars

Temperature Correction:

air delivery at 0°C = delivery 15C x

*SRA: Standard Reference Atmosphere

0°C + 273288

Using the Nomogram (fig. 5)

The tube diameter can be determined after calculating the delivery in l/m and the allowed pressure drop.

a. Choose the working pressure on axis “C” and draw a line (red in the example) connecting the working pressure to the value on axis “A” to indicate the allowed pressure drop.b. The drawn line will enable you to locate a point on the referential axis “R”.c. Draw a line (green in the example) connecting the point found on the referential axis “R” to the value on axis “A” to indicate the plant delivery in l/min.d. The drawn line connecting the point on axis “R” to the value of the delivery given on axis “A” will intersect axis “B” in a point corresponding to the value of the suitable tube diameter.



2.1 Fitting pressure drops

Although fittings are smooth inside with the same inside diameter as the tube, they represent an obstacle to air flow, particularly when tubes change direction e.g. bends, tee unions and reducers.

Fig. 6 refers to pressure drops caused by fittings. Every fitting or change of direction corresponds to lengths of tube in metres as indicated below.

Tube Outer diameter

Couplings Elbows 90° Tee Unions on a straight line

Tee Unions on a line deviation

Reducers

20 0.15 0.40 0.20 0.60 0.20

25 0.20 0.50 0.30 0.80 0.25

32 0.25 0.60 0.40 1.10 0.35

40 0.30 0.80 0.50 1.40 0.45

50 0.40 0.95 0.70 1.70 0.60

63 0.50 1.25 0.95 2.30 0.75

fig. 6 Equivalent tube lengths of the same diameter (m)

2.2 Network dimensions

Once the compressed air consumption (l/min.) and the sustainable pressure drop have been calculated you can refer to fig. 5 to identify the appropriate tube diameter size.

After examining the plant and considering the changes of direction as well as the presence of tee unions and reducers please refer to fig. 6 to check previous calculations.

did you know you can buy SicoAir from the Tom Parker Ltd online store? Visit www.tom-parker.co.uk or scan the qR code



Please calculate dimensions for projects prior to installation. This is especially important on long lines where tube expansion is caused by thermal changes an absorption point must be calculated to allow for the design to counteract this

DL = DT x 0.02 x LA = DL x 23B = 0.7 x A

GUIdE

A-B = QUOTE (mm)L-L1-L2 = LENGTHS (mt)DL = EXPANSIONS (mm)DT = THERMAL RANGE (°C)M = MOBILE BRACKETF = FIX BRACKET

B dIMENSION IS NOT ESSENTIAL

EXAMPLE L1 = 40 mt L2 = 40 mt dT =50°CDL = DT x 0.02 x L = 50 x 0.02 x 40 = 40 mmA = DL x 23 = 40 x 23 = 920 mmB = 0.7 x A = 0.7 x 920 = 640 mm

CALCULATING ABSORPTION POINT


FLAT LYRE

EXAMPLES OF ABSORBING TUBE EXPANSION

VERTICAL LYRE (TOWARDS CEILING)

VERTICAL LYRE (TOWARDS FLOOR)

GUIdE

A-B = QUOTE (mm)L-L1-L2 = LENGTHS (mt)DL = EXPANSIONS (mm)DT = THERMAL RANGE (°C)M = MOBILE BRACKETF = FIX BRACKET

To avoid condenstate accumulation a vertical lyre must not be used withouta condensate drain

TYPES OF LYRE


All horizontal conduits must have a small inclination (1-2%) to allow drainage of condensate water which can form in the system

1 - 2%

Inclinations should route water into drains (manual or automatic) which should be installed on the system. Place these devices at the lowest points

Pipe Inclination

Pipe Fixing

To allow conduits expansion and to avoid stress points which can compromise the functionality of the system, the conduits must be installed using “fixed monoklips” and “sliding monoklips”

FIXEd MONOKLIP

SLIdING MONOKLIP

PIPE HAS SOME GIVE

PIPE DOES NOT HAVE ANY GIVE

“Fixed monoklips” support in a locked position while “sliding monoklips” allow for some axial movement

INSTALLATION OF PIPES


Planning For Maintenance

To facilitate easy maintenance of the system, install ball valves to create sub-systems allowing for localised maintenance operations

BALL VALVE

To ensure fitted pipes are steady it is important to consider the placement of brackets when measuring the dimentions of the installation

Brackets

PITCH

DN 20/25 32 40 50 63

P (MT) 2.5 3 3.5 4 4.5

GUIdE

L = LENGTH (m)P = BRACKETS PITCH (mt)M = BRACKETG = JOINT

To avoid any unwanted defletion close to joints, it is always advisable to place a bracket, even if the pitch does not require it



Slopes and drops

GUIdE

A = QUOTE (mm)L1 - L2 = LENGTHS (mt)DL = EXPANSION (mm)DT = THERMAL RANGE (°C)F = FIXEd BRACKETU = USEY = CALCULATION FACTOR

CALCULATIONS FOR FACTOR “Y”

DN 20 25 32 40 50 63

Y 20 20 25 28 33 40

DL = DT x 0.2 x L A = DL x Y

When installing ball valves into the system, take care to fix the end slope



As an alternative to standard lyre it is possible to use flexible pipe providing that you follow the instructions below

Flexible Pipe

DL = DT x 0.2 x LB = (2 x R) +DL1 +DL2

GUIdE

A-B = QUOTES (mm)L1 - L2 = LENGTHS (mt)DL1 - DL2 = EXPANSION (mm)DT = THERMAL RANGE (°C)M = BRACKETR = RAdIUSY = CALCULATION FACTOR

QUOTE R - A (mm)

DN 20 25 32 40 50 63

R (mm) 70 85 100 130 160 200

A (mm) 370 390 500 560 600 800

THE dATA TABLE ABOVE IS ONLY RELEVANT FOR STAINLESS STEEL FLEXIBLE METALLIC FITTINGS, TYPE 1REX/INOX/N/321/dN. FOR OTHER TYPES, PLEASE REFER TO MANUFACTURERS GUIdE



With a flexible pipe it is possible to manage both change of direction and thermal expansion

Elbow With Flexible Pipe

L min = 1000 mm

GUIdE

L1 - L2 = LENGTHS (mt)DL1 - DL2 = EXPANSION (mm)M = BRACKETR = RADIUS (mm)L = LENGTH OF FLEXIBLE PIPE (mm)

Avoid fitting flexible elbows with either too much or too little hug to the wall



To create the perfect link between pipes it is advisable to cut the pipe at a perpendicular angle, remove any chips and chamfer the edges to safeguard the seal during insertion into the fitting

during cutting and chamfering, try to avoid any damage to the painted surface in the tightening zone (approx. 50mm from the ends of the pipes)

PIPE PREPARATION


The lubrication in addition to facilitating the insertion of the tube into the fitting optimises the operation of the seal reducing damage over time

To facilitate insertion of the tube into the fitting, it is recommended that the outside of the tube and the inner seal of the fitting is lubricated. Where it is requested that the absence of any type of lubricant is used in the system it is still possible to insert the tube into the fitting

Alternatively a neutral or Vaseline lubricant spray can be used

LUBRICATION OF SEAL


To mechanically close the fitting, use SicoAIR spanners with the locking torques indicated below

LOCKING TORQUE (indicative)

DN 20 25 32 40 50 63

F (Nm) 9/11 11/13 12/15 15/17 17/20 18/22

The Blue SicoAIR spanner has a groove to mark the correct position of the fitting on the pipe

FOLLOWING THE INSTALLATION GUIdELINES SET OUT IN THIS BOOKLET ARE ESSENTIAL TO ENSURE A WELL FUNCTIONING SYSTEM. TOM PARKER LTd. ARE AVAILABLE AT ANY TIME FOR CONSULTANCY, qUERIES OR REqUESTS

LOCKING FITTINGS

Basingstoke BranchParker House, Goat LaneBasingstoke, Hampshire, RG21 7qB

T: 01256 330033F: 01256 351888E: [email protected]

More great brands available from Tom Parker Ltd.

Preston Head OfficeMarsh Lane Mill, Marsh LanePreston, Lancashire, PR1 1HY

T: 01772 255109F: 01772 563475E: [email protected]

Introducing NEW core brands:

www.tom-parker.co.uk

Documents

The Innovative Lightweight Ring Main System Introduced to ... · 2.1 Fitting pressure drops Although fittings are smooth inside with the same inside diameter as the tube, they represent