Pascal Series K Leak Finder Diagnostic Testing and Simple Data Collection for Equipment Health Program
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CONTENTS
Compressed Air Leak
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Introducing Pascal Series K
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Benefits of Pascal Series K
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Application: Pneumatic Cylinder
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Application: Filter Regulator
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Application: Dust Collector
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Other Applications
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Connect with us!
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Breakthrough Engineering for a Better World Norgren is part of global engineering organisation IMI plc. IMI is at the forefront of delivering the solutions we need in a changing world and is focused on creating tremendous value by solving key industry problems in attractive markets and employing the best. Norgren has a proud history of creating innovative engineering solutions in precise motion control and fluid technology, and we collaborate with our customers across more than 50 countries in critical areas such as Factory Automation, Material Handling, Rail, Energy, Process Control, Life Science and Commercial Vehicles.
From improving speed, productivity, reliability and efficiency of equipment, to generating significant energy and cost savings, or lowering total cost of ownership across many industries, Norgren’s high-quality solutions are designed to help customers pursue progress, achieve new goals and overcome problems. With market-leading industry expertise, we offer the capability, resources, engineering intelligence and global support infrastructure to tackle the largest project demands.
Breakthrough engineering you can count on.
Our world-class portfolio of fluid and motion control products include Norgren, Bimba, Buschjost, FAS, Herion, Kloehn and Maxseal. Supplied either individually or combined into powerful customised solutions to meet customer needs.
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Compressed Air Leak Compressed air is used in almost every industry, including the food, dairy, beverage, brewing, semiconductor, pharmaceutical, biotechnology, chemical, petroleum, oil & gas, offshore and all process industries. It is a vital source of converted energy which can be used as a source of power for pneumatic systems and processes. Yet many compressed air equipment is compromised by wear and poor maintenance practices, which contribute to compressed air contamination and the greatest waste of all – the ever-present leaks. These leaks can be hidden behind machines, at connection points, overhead in fixed pipes, or in cracked pipes or worn hoses.
Leakage is the major source of energy loss in compressed air applications. A typical plant may lose 20% of its compressed air, the waste adds up quickly and can even lead to capital expenses, rework, downtime or quality issues and increased maintenance costs. Fixing the leaks and introducing predictive maintenance can produce substantial savings. While this is a known issue, detecting air leaks has been timeconsuming and difficult until now.
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Introducing Pascal Series K Pascal Series K Leak Finder performs diagnostic tests at the equipment site, and transforms simple data into an effective equipment health program, providing a deeper understanding of system performance. Pascal Series K software with its optimised and modern electronics - pressure and temperature sensor pair - allows the user to collect the pressure profile of the equipment, which can be used to analyse and conclude for improvements across the line. The solution consists of sensors and a monitoring user interface. These modular units can be configured to suit simple or complex applications and allow for future expansion.
SOFTWARE: Collect pressure and temperature data of the machines and analytics module OPERATING PRESSURE RANGE: 0...14 bar RESOLUTION: 0.001 bar ACCURACY: ±20...±40mbar DISPLAY: 10.5 inch PixelSenseTM 1920 x 1280 (220 PPI) resolution display with 10 points multi-touch screen.
Pascal Series K Kit Types The Pascal Series K Basic Kit contains just the basic hardware and software. It is designed for customers that want to monitor a single piece of equipment
The Pascal Series K Expansion User Interface and Expansion Kit - Add-on contains everything that you need to monitor applications.
Basic Kit
Expansion User Interface
Expansion Kit - Add on
Pascal Series K Tablet
Cylinder Analytics Module
Pascal Series K Pressure/ Temperature Sensor Pair
Dust Collector Analytics Module
Compressor Kit - Add-on > Pascal Series K Pressure Dew Point Sensor > Pascal Series K Power Meter > Expansion User Interface - Compressor Module
Pascal Series K Basic User Interface Features > Pressure and Temperature Data with Condition Monitoring
Routine Module
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Benefits of Pascal Series K > Ensure proper air pressure to your pneumatic equipment
This not only extends equipment life, but it also allows equipment to operate at peak efficiency.
> Portable & Durable The durability of Pascal Series K makes it ideal for field work in a wide variety of industrial applications.
> Lower energy costs Numerous Independent studies confirm that industry wastes around 30% of the compressed air it generates, which cost equivalent to £12,000.
> Train the team in a matter of minutes
The Pascal Series K requires only minimal training for effective operation. In addition, the user is instantly notified about the nature of developing faults at the time of measurement, so that you can focus your attention on critical machine issues immediately.
> Embedded Intelligence The ability to perform additional diagnostic tests at the machine site transforms simple data collection into an effective machinery health program. In today’s demanding work environment, it is difficult to find the time to acquire advanced analysis skills. Embedded diagnostics enable even a novice user to conduct sophisticated tests with the touch of a button.
Simple & Reliable
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Applications Pneumatic Cylinder Pascal Series K's User Interface streams pressure data from both sensors every millisecond and temperature data every second providing a deeper understanding of how the system is performing and guiding enhancements to the efficiency of your machine by optimising air usage.
What does Pascal Series K detect? Presence of Cap End Seal Leakage
Presence of Rod End Seal Leakage
» Pressure Leakages would be detected by sensor 1.
» Pressure leakages would be detected by sensor 2
» The Pascal K also has the capability of measuring extent and retract time.
» Leakage at Rod end seal causes slower retraction time and faster extension time.
» As leakage is present at the cap end seal, extension time is slower and retraction time is faster
Presence of Piston Seal Leakage » Pressure leakages would be detected by both sensor 1 and sensor 2. » Leakage at Piston seal causes slower retraction time and slower extension time.
Pressure inlet
Sensor 1
Sensor 2
Quick disconnect coupling
Quick disconnect coupling
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Case Study #1 Leakage detection in construction production line Leakage in production lines is common in manufacturing productions, and results in long-term operating costs and inefficiencies. To prevent this, our customer, a lead in construction supply, started to utilise Pascal Series K to detect any leakage from cylinders installed in their plant. This will also help to test for leakage from any existing cylinders prior to installing them back into the operation line.
Case Study #2 Downtime reduction in packaging line At a manufacturing plant owned by our customer, a robotic palletizer resides at the end of a packaging line. Two pneumatic actuators are used to open and close the end of the arm tool to move cases of oil. As actuators tend to wear down overtime, the gripper does not open fast enough during the packing process and this results in misplaced cases. If this situation is left undetected in time, the palletizer will drop cases creating an oil spill. This would create significant downtime to repair the pallitizer and to clean the oil spill in the plant. To prevent downtime situations in the future, our customer equipped the use of Pascal Series K to monitor the actuators controlling the gripper. By monitoring the stroke time, they can now replace the actuators prior to failure.
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Filter Regulator Compressed air is often wrongly assumed to be a cheap or even ‘free’ source of power. At point of use, compressed air is approximately the same cost as natural gas, that is why it is vital to install the correct equipment to condition and control the air supply.
Proper and genuine compressed air treatment products/ systems are installed to ensure clean compressed air at a quality level as required by the application. The volume of air flow at each stage must always be considered as basis for product selection. Undersized, inappropriate filters, compressed air treatment equipment that cause high pressure drops are a prime reason for high energy and maintenance costs as well as system downtimes.
A well-designed air preparation assembly ensures costs are optimised by keeping leaks to a minimum. Pascal Series K can identify a loss in supply pressure from a Filter Regulator and help determine if the pressure loss is due to clogged filters or insufficient air supplied to the machine.
Sensor 2 Sensor 1
Quick disconnect coupling
Air Inlet
Air Receiver Water Separator
Air Outlet
Distribution System Coalescing Filters Optional Particle Filter Point of Use
Compressor
Condensate Management
Compressed Air Dryer
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Dust Collector In dust-extraction facilities, filter solutions ensure that contaminated air does not get into the atmosphere and pollute the environment. This takes place, for example, by means of the air blasting technique. The filter elements to be cleaned are inflated by a brief but intense pressure surge with the result that dirt and dust particles are released and fall to the floor, from where they are carried away.
To realise an optimum cleaning outcome, the pressure impulse in the filter element must achieve the target value as quickly as possible – the valves therefore must open fully within a few milliseconds. The closing operation requires similarly rapid reaction times. Only if the air impulse achieves the zero value as quickly as possible, it will be possible to avoid any unnecessary air consumption.
Pascal Series K can diagnose the following by differential pressure: 1. Which filter bags are clogged 2. When pulse cycle is behaving abnormally 3. Tells which dust collector valve or filter bag needs attention
Filter House Dust Collector
Differential pressure
» Pascal Series K calculates the difference in pressure and compare it against time (seconds). » Slope of pressure out tells how “sticky” is the dust collector valve, this gives insights for example cracks or holes in the diaphragm.
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Other Applications High-Pressure Leak Test with Pascal Series P The high-pressure leak test can be setup for pressure decay or flow measurement. Differential Pressure leak tests measure the rate of pressure loss between the reference volume and the part volume. Taking curves of the pressure versus time will assist in determining if there is a leak and estimating the actual leak rate. Pascal Series P processing not only offers the earliest warning of developing faults, but it also provides an indication of severity. Measurements can be translated into reliable trends to determine the optimal timing for maintenance. It is quick, reliable, and sensitive enough to detect small leaks.
IO Gateway + Ex d enclosure + electronics
Norgren Dome Loaded Regulator K51
Power Supply
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Your Trustworthy Partner We aim to provide the best engineering and customer support to ensure you get the most out of our solution to fit your applications needs. ENQUIRY Contact us via website, phone, or email to express your interest in Pascal Series K. We will assign the best engineering teams to assist with your enquiry.
CONSULTATION We take the time to listen and understand our customers' needs, and make sure we have the presence on the ground, wherever it is needed. With our dedicated technical experts, we will design to suit your specifications and requirements to run your operations.
DEPLOYMENT Our engineer will assist setting up and delivering Pascal Series K. In addition, we offer on-board workshops to enhance customers' product knowledge to ensure operations with this solution will run smoothly.
OPERATION With Pascal Series K Leak Finder set up, customers can start harnessing the benefits to improve their operational efficiency!
Norgren operates four global centres of technical excellence and a sales and service network in 50 countries, as well as manufacturing capability in Brazil, China, Czech Republic, Germany, India, Mexico UK and the USA.
For further information, scan this QR code or visit www.norgren.com
For information on all Norgren companies visit www.norgren.com Supported by distributors worldwide.
Norgren Pte Ltd JTC Space @ Tuas 16B Tuas Avenue 1 #03-40 Singapore 639534 Tel: +65 6862 1811 Fax: +65 6862 1917
IMI Engineering Sdn. Bhd. 24, Jalan Serendah 26/39, Seksyen 26, 40700, Shah Alam Selangor Malaysia Tel: +60 (3) 5614 2888 Fax: +60 (3) 5614 2889
Norgren Co. Ltd 120/34 Moo.12 Rachadhewa Bandple, Samutprakam 10540 Thailand Tel: +66 (0)2 092 7939 Fax: +66 (0)2 750 3855
Norgren, Bimba, Buschjost, FAS, Herion, Kloehn and Maxseal are registered trademarks of Norgren companies. Due to our policy of continuous development, Norgren reserve the right to change specifications without prior notice. z9817BR en/08/21 Selected Images used under license from Shutterstock.com
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