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About Filter, Regulator, Lubricator (FRL) Assemblies

Filter, regulator, lubricator (FRL) assemblies are pre-packaged or modular assemblies of common configurations of air filters, regulators, lubricators, and gauges. Important specifications to consider when searching for filter, regulator, and lubricator assemblies include regulator type, media, performance specifications, adjustment control, connectors or pipe size, body material, features, and environmental parameters. Choices for regulator type for filter, regulator, and lubricator assemblies include general purpose, high pressure, low pressure, differential or bias regulator and pressure reducing regulator. General-purpose regulators are designed for typical industrial use; generally operates only above atmospheric pressure. High-pressure regulators are rated for inlet pressures higher than general purpose; typically over 1000 psi. Lowpressure regulators have special design characteristics for precise control of pressures typically below 15 - 20 psi. A differential or bias regulator maintains a pressure differential between two locations in the system. Pressure-reducing valves are used to provide a sub-circuit with a supply of fluid at a pressure, which is less than the pressure in the main circuit. Media types can be air, fuel or oil, gas, hydraulic fluid, liquid, and steam. Important performance specifications to consider when searching for filter, regulator, and lubricator (FRL) assemblies include regulating (adjustment) range, maximum flow (gas or air), maximum pressure rating, and filter minimum particle size rating. The regulating or adjustment range dictates the limits of adjustment control. The maximum flow specified for a gas or air application is unnecessary to specify if primary application is liquid. The maximum pressure rating refers to the pressure rating for the valve or inlet pressure for the regulator. The filter minimum particle size rating applies to filter, regulator, and lubricator (FRL) assemblies. It is the smallest size particle that will be entrapped by the filter. This rating is an indication of the largest opening in the filter element. Choices for adjustment control for filter, regulator, and lubricator (FRL) assemblies include manual, analog voltage control, analog current control, pneumatic control, and digital interface. Connectors and pipe sizes for FRL assemblies include 1/8 NPT, NPT, 3/8 NPT, NPT, NPT, 1 NPT, 1 NPT, 2 NPT, British standard pipe thread, and metric pipe thread. Body materials can be Acetal, aluminum, brass, bronze, cast iron, steel, stainless steel, and zinc. Common features for FRL assemblies include integral pressure gauge, pressure relief, tamper-proof, and corrosive media. Important environmental parameters to consider include operating temperature.

FILTER
Compressed air is clean, readily available and simple to use, but it can be the most expensive form of energy in your facility. Unregulated or improper pressure settings can result in increased compressed air demand, which results in increased energy consumption. Excessive pressure can also increase equipment wear, resulting in higher maintenance costs and shorter tool life. A rule of thumb states that every 2-psig increase in operating pressure adds an additional 1% to compression energy cost. Point-of-use FRLs (filters, regulators and lubricators) are needed to ensure that every tool or process is receiving a clean, lubricated supply of compressed air at the proper pressure to provide peak performance. Airline filters Reliability is one of the strongest reasons to use compressed air, and proper filtration is the key to maximizing reliability and longevity. Compressed air can carry condensed water, oil carryover from compressors, solid impurities (pipe scale and rust) generated within the pipelines, and wear particles from actuators. These contaminants can cause problems at every point of use, and should be removed by installing suitable filters. Contaminant-particle size is measured in micrometers (m), which each represents one-millionth of a meter or 0.000039 of an inch. Filters are rated according to the minimum particle size that their elements will trap. Although filters rated at 40 to 60 m are adequate for protecting most industrial applications, many point-of-use filters are rated at 5 m. Note that finer ratings increase the pressure drop through the filter, which equates to higher energy cost to compress the air. In addition, finer filters clog more rapidly, also increasing pressure drop. (In other words, while filters finer than necessary do no harm to downstream components, they will have a negative impact on air system operating cost.) Many filter manufacturers will define the expected pressure loss and dirt holding capacity, using curves related to pressure and flow. Therefore, particle-removal filters should be selected based on acceptable pressure drop - and pipe-connection size. A typical pressure drop through such filters would be between 1 and 5 psig. A filter with larger body size will produce less initial pressure loss and provide longer operating life than a smaller size filter with the same removal ratings. The charts in Figure 1 compare pressure drop through several particulate filters that all have identical 5-m removal capacity. Most point-of-use filters claim to remove condensed water, typically via a form of cyclone separator at their inlet end, Figure 2. The water-removal efficiency of such filters is very dependent on the incoming air velocity. Therefore, these filters must be matched to the intended airflow, rather than acceptable pressure drop. If the filter is intended to remove moisture, an integral automatic float-type drain should be provided

to periodically remove accumulated liquids from the filter bowl. Generally, such filters have transparent polycarbonate bowls, which allow easy visual inspection of the sump level. Numerous chemicals can attack this plastic material and it only performs well at pressures below 150 psig and temperatures between 40 and 120 F. A metal bowl may be required when the filter could be subjected to conditions outside those limits, as well as when synthetic compressor lubricants, which often contain chemicals that are harmful to polycarbonate, are present. Most oil entrained in a compressed air stream, as well as some of the condensed water, will be in the form of mists or aerosols that can pass through the openings in standard airline filters. Air for instruments, spray painting, and bulk-material conveying frequently requires the removal of such droplets. Coalescing-type filters, Figure 3, will accomplish this job. Aerosol carryover through such filters is commonly stated as parts per million (ppm) of oil vs. air by weight and will range from 1 to as little as 0.01 ppm. Coalescing filters are often rated to remove aerosols that are substantially smaller than the nominal size of the smallest solid particle that would be captured. Some models offer dual-stage filtration; the first removes solid particulates to protect the coalescing element in the second stage. Because all coalescing filters create a greater restriction to the airflow, pressure losses will be higher than those of conventional compressed air filters. Coalescing filters have an initial (or dry) pressure drop and a working (or saturated) pressure drop, both based on pressure and flow rate. The effective removal efficiency of such filters depends greatly on the air velocity passing through the filter assembly. Therefore, choose a coalescing filter based on acceptable oil carryover, expected airflow rate, and pipe-connection size. A coalescing filter rated at 0.1 ppm will typically have a clean, wetted pressure drop between 2 and 5 psig, while a highefficiency filter rated at 0.01 ppm can cause as much as 10 psig drop once it becomes wetted or fully saturated during service, Figure 4.

Fig. 1. Pressure drop plotted against flow for airline filters with 1/4-in. ports, left, and 1/2in. ports, right.

Fig. 2. Cutaway view of air flow through representative compressed-air point-of-use filter.

Fig. 3. Cutaway view of air flow through typical coalescing compressed-air filter.

Fig. 4. Plots illustrate how pressure drop across coalescing filter increases after element is wetted.

REGULATOR
This regulator also has a safety-type relief valve above the pilot mechanism, which rapidly exhausts any very high overpressure. Pneumatic pressure controls fall in the category of pressure reducing valves, commonly referred to as air line regulators. It is also essential, once a system pressure has been selected to perform a task, that air be supplied at constant pressure to the actuator, regardless of variations in flow and upstream pressure. Thus, it is important to add to a pneumatic system a pressure regulator that:
y y

y y y y

supplies air at constant pressure regardless of flow variation or upstream pressure helps operate the system more economically by minimizing the amount of pressurized air that is wasted. (This happens when the system operates at pressures higher than needed for the job) helps promote safety by operating the actuator at reduced pressure extends component life because operating at higher-than-recommended pressures increases wear rate and reduces equipment life produces readily controlled variable air pressures where needed, and increases operating efficiency

Types of regulators Unbalanced poppet, non-pilot operated - Figure 1 shows the simplest type of unbalanced poppet regulator. Normally, supply pressure enters the regulator and flows around the poppet, which is seated, blocking flow. Turning the adjustment screw to compress the adjustment spring forces the diaphragm down. It pushes the stem down and the poppet uncovers the orifice. As downstream pressure rises, pressure air acts on the underside of the diaphragm, balancing the force exerted by the adjustment spring. The poppet throttles the orifice to restrict flow and produce the desired pressure. As downstream flow demand varies, the regulator automatically repositions the poppet in relation to the orifice. The spring under the poppet ensures that the regulator will close at no-flow. This regulator is non-relieving. Unbalanced poppet, non-pilot operated with diaphragm chamber - The regulator in Figure 2 is larger (and more expensive) than the model in Figure 1. It also has a diaphragm chamber which isolates the diaphragm from the main air flow to help reduce the effects of the abrasive air on the diaphragm.

An aspirator tube connects the diaphragm chamber and the outlet chamber. As flow through the regulator increases, the tube creates a slightly lower-than-outlet pressure in the diaphragm chamber. The power pressure under the diaphragm deflects it downward, forcing the poppet farther away from the orifice. The adjustment spring extends to open the poppet orifice without significantly decreasing outlet pressure. The effect is the same as increasing the adjustment setting and thus reducing droop at higher flow rates. This regulator's much larger diaphragm area produces greater forces and thus displaces the poppet more with a given change in reduced pressure. Larger diaphragms increase regulator response and sensitivity. Balanced poppet, non-pilot operated, with diaphragm chamber - This regulator, Figure 3, has the same general internal construction as the previous type. However, it has a considerably larger orifice to allow for greater flow. In addition, to maintain good stability, the poppet is pressure-balanced. That is, the poppet sees the same reduced pressure on both top and bottom surfaces. Thus, the effects produced by reduced pressure fluctuations cancel out, and sensitivity and response are greatly improved. This very-large-capacity regulator has low droop. With an exactly balanced poppet, the system-pressure/reduced-pressure ratio has no effect because the unbalanced resultant forces on the poppet caused by supply pressure are zero. However, these poppets are generally designed with a slight tendency to close. Therefore, a large increase in supply pressure forces the poppet closer to the orifice, throttling flow. This causes the reduced pressure to drop slightly. Remote controlled, pilot operated, balanced poppet - In some applications, the regulator must be installed where it cannot be easily adjusted. The regulation and pressure setting mechanisms are then separated. A small air pilot line connects the regulator (in the air line at the point of use) to the remote setting mechanism, which can be mounted at any convenient location. The remote setting mechanism is a small regulator that produces a control air signal. The signal is sent to a pilot-operated, balanced-poppet regulator, similar to the previous regulator except that the top is replaced with a short, pressure-tight bonnet to receive the control signal from the small remote setting regulator. Instead of working against a force created by a compressed spring, the pilot-operated regulator works against a force created by air pressure - that is, an air spring. The air spring maintains a constant force on the upper side of the diaphragm of the pilot-operated regulator because the remote setting regulator holds the control signal at constant pressure. Thus, droop in this regulator is small. Internal, pilot-operated, balanced poppet - This regulator also uses the pilot-operated principle to produce a precision regulator. Both the pressure setting regulator and the

pilot-operated regulator are combined in a single housing. The same force-balance principle applies as in the previous regulator. With this regulator, some supply air bleeds into the cavity over the lower diaphragm and escapes through the nozzle. As increased air pressure on the upper diaphragm opens the flexible seat, the pressure above the lower diaphragm drops and causes the poppet to approach the primary orifice, reducing flow, and thus pressure. A bleeding-type relief seat vents through the center of the diaphragm

Fig. 1. Simplest regulator incorporates an adjustment spring (that is, it is not pilotoperated) and an unbalanced poppet. It does not have a separate diaphragm chamber, and it is non-relieving.

Fig. 2. Regulator has an adjustment spring and an unbalanced poppet. It has a separate diaphragm chamber which contains an aspirator tube connecting to the reducedpressure port. It is self-relieving.

Fig. 3. Regulator has a balanced poppet and a separate diaphragm chamber with an aspirator. It is non-pilot operated.

Pressure regulators Once a minimum suitable operating pressure has been determined for any compressed air application, it is essential to supply the air at a constant pressure, regardless of upstream flow and pressure fluctuations. Thus it is critical to install the proper regulator or pressure-reducing valve in the airline. Air regulators are special valves that reduce supply pressure to the level required for efficient operation of downstream pneumatic equipment. A filter to protect the regulator's internal passages from damage should always be installed upstream from it. There are several types of air regulators. The simplest type uses an unbalancedpoppet-style valve. This design incorporates an adjustment spring, does not have a separate diaphragm chamber, and is non-relieving. Turning the adjustment screw compresses the spring, which forces the diaphragm to move, thus pushing a poppet to uncover an orifice. As pressure rises downstream, it acts on the underside of the diaphragm, balancing against the force of the spring. The poppet throttles the orifice opening to restrict flow - and produce the desired downstream pressure. A spring under the poppet assures that the valve closes completely when no flow exists. This is the least expensive type air regulator.

Larger, more expensive regulators, Figure 5, incorporate a separate diaphragm chamber, which has an aspirator tube exposed to the output pressure. Segregating the diaphragm from the main airflow minimizes its abrasive effects and extends the life of the valve. As flow through this regulator increases, the aspirator tube creates a slightly lower pressure in the diaphragm chamber. The diaphragm deflects downward and opens the orifice without significantly reducing the output pressure. The effect is the same as increasing the adjustment setting. Thus, this style regulator has minimal droop (output pressure decay) as supply pressure varies. Figure 6 compares how that variance occurs with a small and a large diaphragm. The larger diaphragms in these regulators improve response and sensitivity. As discharge flow through the regulator is increased over its entire range, output pressure droops, Figure 7. Thus it is important to set the regulator's desired output pressure under normal flow conditions. Another type of regulator incorporates a balanced poppet, but otherwise has the same general construction as the separate diaphragm version. It has a significantly larger orifice to allow for greater airflow. To maintain good stability, the poppet is pressurebalanced. Thus, the effects of output pressure fluctuations cancel out, which improves sensitivity and response, and reduces droop. Finally, precision regulators often employ several isolated diaphragms acting against flapper valves and nozzles in a balancing principle and are normally manufactured in limited flow capacities with smaller connection ports. Selecting the best type of regulator for a specific application first requires a choice among these styles. Mini-regulators are commonly the direct-acting, non-relieving type, while most standard regulators fall within the self-relieving, separate-diaphragmchamber style. The next consideration becomes primary (unregulated supply) pressure versus desired secondary (output) pressure. Finally, desired airflow rate must be selected. Adjusting screws are normally offered in two styles: tamper resistant, locking Tee type or push-lock, plastic knob type. The first is best when a fixed operating pressure will be set once and left alone. The adjustable knob style (quite common on modular FRLs) is the correct choice for general use, where the operating pressure can be easily adjusted without tools. Regulators also are defined by body size (orifice flow rating) and connection size. Although several models may appear to be acceptable for any given airflow and pressure, a larger body size regulator will produce better setting sensitivity and less droop than a smaller body model under the same set of operating conditions. An output pressure gage is essential, although many manufacturers frequently offer it only as an option. (Mounting brackets are another useful option.)

Fig. 5. Cross-sectional view of typical regulator.

Fig. 6. Plots of secondary pressure against supply pressure for regulators with small and large diaphragms illustrate how pressure droop (or decay) varies as supply pressure increases.

Fig. 7. Plots of secondary pressure against supply pressure for regulators with small and large diaphragms illustrate how pressure droop (or decay) increases as flow increases.

LUBRICATOR

The air pressure out of the tank container goes through a on / off valve. Before reaching distribution network, the air must pass "filter units" or filters, which will separate the water / water from the air until the equipment is insulated from the pegaratan / corrosion. Then conditioning to flow through the tool "pressure regulator" / regulator is equipped with "pressure gauge". Air pressure in tank containers are usually higher than the pressure needed. That's why pengaturtekanan tools required,pressure can control the play button controller. For the industry, with the purpose of pneumatic components that could bepreserved, can still be added to one unit of another device that is "lubricator" / lubricator. Unit works eject lubricant lubricants / oils are very subtle in conditioning the pressure

lubricaton downstream Drawing shows the conventional circuit: control valve by mounting lubricant. In the lower drawing, the air flow through the valvelubricates the cylinder. Lubricated when the exhaust valve cylinder. Airline lubricators Many pneumatic system components and almost all pneumatic tools perform better when lubricated with oil. Injecting an oil mist into the air-stream which powers them can continuously lubricate valves, cylinders, and air motors for proper operation and long service life. Locating the lubricator properly in the pipeline is important to ensure that the correct amount of lubrication reaches each device. Too little oil can allow excessive wear and cause premature failure. Excessive oil in the pipeline is wasteful and can become a contaminant in the ambient area as it is carried out of tools and valves by the air exhaust. Intermittent lubrication may be the worst condition of all because the oil film can dry out and form sludge or varnish on the internal surfaces of the equipment. Airline lubricators, Figure 8, meter oil from a reservoir into the moving air-stream. As high-velocity air passes through a venturi, it draws the oil up and through a capillary, then drips it into the air-stream. The moving air breaks up the oil into a mist (small droplets) or fog (larger droplets), which is then carried downstream into the air-powered device. In a typical lubricator, all of the air passes through the venturi during low-flow conditions. Under higher flow conditions, a spring-loaded bypass valve opens to direct the excess flow around the venturi to a point downstream where it rejoins the lubricated flow. A manual adjusting valve sets the oil drip-rate and a sight glass enables the operator to monitor the output. A fill plug provides access to refill the reservoir, which

typically is made from polycarbonate. The same precautions about polycarbonate apply to lubricators as they do to airline filters. Lubricators typically have a larger flow range than an equivalent size regulator or filter, but their pressure drop increases quite rapidly as flow increases, Figure 9. The acceptable pressure loss for a lubricator is normally considered to be 3 to 7 psig. Lubricators are generally selected based on pipe connection size, oil reservoir capacity, and acceptable pressure loss versus flow rate (many manufacturers publish a minimum flow rate at which the venturi will function properly). Remember to account for this added downstream pressure loss when setting the pressure regulator. Set it at desired use pressure plus lubricator loss (drop). Modular or combination units Manufacturers frequently preassemble filters, regulators, and lubricators to form combination units, Figure 10. They are packaged together as common body sizes with common connection port sizes. Interconnections may be via threaded nipples or modular face connectors. The modular connectors allow easy removal of components for servicing or cleaning. In addition, some manufacturers combine filters and regulators in stacked assemblies where the filter head becomes the regulator body. The components share common inlet and outlet connections, which makes the assembly very compact. Such packaged units, whether FR only or FRL complete, are practical choices for most industrial applications. The selection criteria are the same as with any of the individual components, except that the combined pressure and flow performance becomes the only consideration. Note that when critical requirements dictate the use of specialty filters or precision regulators, the assembly probably must be made up of individual

Fig. 8. Cross-section of typical airline lubricator.

Fig. 9. Pressure drop through small and large lubricators rises dramatically as flow increases.