Industrial Utility Efficiency

Aluminum Pipe Systems: Prevost Corporation


Good Morning. Can you give us some information on your background?

Good morning. Sure, I grew up in Connecticut, graduated from Embry-Riddle Aeronautical University, and went to work for Cessna Aircraft selling airplanes. In the 1980’s I made a decision to move into the industrial marketplace as a Manufacturer’s Representative. In 1997 I went to work for Legris and was fortunate to help bring their innovative Transair aluminum air piping system to market over the next seven years. In 2004, I joined Prevost Corporation and now have full sales and marketing responsibility for the United States and Canada.

    
  Mark McKean of Prevost Corporation    

Can you give us some information about Prevost?

Prevost was established in 1978 with the vision of developing an innovative, new style air coupling. The result was the world’s first push-button quick-disconnect coupling. A few years later Prevost developed a venting-action, push-button, quick-disconnect coupling that became the first safety coupling to pass the ISO 4414 safety standard.

Today Prevost has built a large range of product offerings- in addition to the push-button couplers. Prevost supplies Aluminum Air pipe systems (called ALR), OSHA compliant ergonomic blowguns, FRL’s (filter-regulator-lubricator assemblies), and a large range of hose reels and accessories. We recently won the Innovation award for our Safety Air Fuse which protects against injury or damage from a sudden break in a compressed air line. These products have become the connections of choice for pneumatic tools and air hoses among professional mechanics and technicians throughout the world.

Prevost is truly a global company. Our headquarters is located in Annecy, France. We have sales managers located throughout Europe and other strategic locations worldwide. Our North American Headquarters is in Greenville, South Carolina.

How does Prevost take their products to market?

Prevost has an extensive network of Distributors located throughout North America. In the beginning our focus was heavily influenced by the automotive market. During the past several years we have been moving into industrial markets. Our primary sales channel to the industrial market is with many air compressor distributors who have created opportunities in large manufacturing facilities. We are not limited by industry type, in fact Prevost can be found in almost every industry.

Let’s talk about aluminum pipe systems.

It has always amazed me that a company will pay thousands of dollars for an efficient compressor only to neglect the rest of the air system. Compressed air is expensive and an air system should be efficient from the compressor all the way to the air tool or machine. Have you ever been in a plant on a day when there is no activity?. Listen to the sound of air leaks, that’s the sound of wasted energy, which is wasted dollars. Prevost offers a complete solution from the outlet of the compressor to the tool. We call it “The Perfect Shop”.

I am as passionate about this product today as I was ten years ago. The popularity of aluminum air piping has grown substantially year after year - and I see no end in sight. The market was clearly ready for a new product. In the beginning it was difficult to gain acceptance after years of black iron and copper systems, and even plenty of PVC pipe. The distributors who took the risk back then to introduce aluminum pipe systems have been rewarded many times over.

    
  An aluminum piping system for compressed air.    

What was the spark that ignited the growth of aluminum pipe systems?

I think the spark was and continues to be the education provided by the Compressed Air and Gas Institute (CAGI), air audits, magazines like Compressed Air Best Practices, and the Compressed Air ChallengeÆ. Education has encouraged companies to look at a systems approach to optimizing compressed air operations. This was a huge change from traditional concepts of “adding another compressor” to solve air delivery problems. Generating and maintaining compressed air is typically a company’s second largest energy expense. An efficient air system can pay for itself in less than two years. A good system can also resists corrosion, scale and other debris that damages and reduces the life of expensive components and tools.

What are some of the disadvantages of traditional pipe materials?

Black iron pipe and galvanized pipe have been around forever. The cost of black iron material has increased and over the life of a shop, black iron will cost the owner more due to problems associated with corrosion and leaks. Leaks created due to corrosion can occur as quickly as six months after installation. Corrosion causes a reduction in air pressure thereby increasing energy consumption. Black iron pipe is also heavy requiring several people to install and requires threading machines which creates a mess with cutting fluids and debris.

Copper pipe provides excellent resistance to corrosion, but the material cost of copper has risen sharply over the last two years. It also requires open flame, skilled labor, and extensive labor hours to install. There are no built in condensate prevention devices so a swan neck needs to be sweated in to provide for optimal use. Manifolds are usually crude at best with 90 degree outlets causing the hose to bend sharply-substantially reducing the life of the hose.

Plastic pipe is being used less and less. Poorly designed systems have literally exploded. That’s an obvious safety hazard. Some compressor lubricants can deteriorate pipe glues and cause joint failure. The Plastic Pipe Institute ( PPI ) recommends against using PVC in exposed compressed air systems. The Department of Labor and Industries warned consumers and employers in May 1988 that plastic-polyvinyl- chloride (PVC) pipe cannot be used in compressed air piping systems without risk of explosion. By law, employers must protect their workers by avoiding the use of unapproved PVC pipe in such systems.

  

A Cost Comparison Between Piping Systems

This is a installation cost comparison between black iron, copper, and aluminum piping systems. The system compared consists of a 300 foot looped header using 1” pipe. The total of 1” pipe compared is 340 feet. There are six (6) _” pipe drops - each being 10 feet long and connected to a double ported outlet.

Proper piping practice used so that condensate does not directly flow down a drop. In the case of black iron and copper, a reducing tee, and two 90 degree elbows are used to create the swan neck. Prevost aluminum pipe uses a single tapping saddle with a built-in condensate retention device.

Labor hour estimates for the installation were obtained from the MCAA Labor Manual as follows: aluminum-20 hours, black iron-63 hours, copper-74 hours. All labor was figured at \$65 per hour. Please note that the cost comparison does not include pipe hangers and threaded rod, as all pipe systems must be hung in the same fashion. Material costs are approximate and are close to list price.

 
 
Piping System Weight* Material Cost Labor Cost Total Cost
Aluminum 4 lbs. $1,822 $1,300 $3,122
Black Iron 35 lbs. $1,196 $4,095 $5,291
Copper 18 lbs. $2,080 $4,810 $6,890
   

 

What are the advantages of aluminum air pipe?

Aluminum offers excellent resistance to corrosion, lower air friction, and offer a full flow design with no restrictions caused by fittings. Aluminum pipe is lightweight, easy to install and requires no open flames, threading machinery or special tools. Adding a drop is a simple operation. Aluminum can be installed by plant personnel in a fraction of the time it takes to install Black Iron or copper and can be easily modified or moved to another location. All of this translates into lower initial costs when you factor in installation, and a safer, cleaner, and efficient system.

Are there other considerations to keep in mind when designing an air piping system?

Absolutely. Be sure your system is properly sized to supply your anticipated air volume demand during peak operation. Plan your system for possible future shop expansion. Here are some tips for a safe and efficient system.

Sizing: Properly size all piping components from the ring-main to each drop. A looped ring-main with a minimum amount of elbows is the most efficient system. Looping the system can cut your pressure drop in half while providing built-in storage for your compressed air. Be sure the pipe is installed with adequate supports to ensure optimum efficiency and safety.

Air Treatment: Don’t skimp here! Make sure your piping system has air treatment components like condensate control, filtration, lubrication (never use lubricators where you will be using compressed air for painting), drains, and pressure regulators.

    
  A Filter-Regulator-Lubricator (FRL).    

What safety features can air connections and hose assemblies have?

Often overlooked, air connections and hose assemblies can dramatically affect safety, productivity, and reduce utility costs from leaks. Selecting “ bubble tight” or “leak free” compressed air products is important. One leaky coupler can cost hundreds of dollars in utility costs each year. Multiply that by the number of connections in your plant, and you can see how investing a little more up front can save you thousands in the long run. Here are some of my recommendations:

Quick Couplings: Specify “venting action” safety quick-couplers at the air source or manifold. This simple choice eliminates “hose whip” reducing personal injuries and damage to equipment or vehicles. “Hose whip” occurs when disconnecting a pressurized air hose. Impact-resistant composite quick couplings with a quick push-button release can make one-handed disconnection much easier than a conventional metal sleeve type.

    
  Increase safety by selecting the proper air connections.    

Specify “bubble tight” push-button non-scratch couplers for use at the air tool. Use HVLP (high volume low pressure) couplers for use in painting areas. This coupler will provide better air flow to the paint gun as well as extend the life of an air tool.

Hose assemblies: In areas where there is a lot of traffic or activity, select self-coiling hoses or retracting hose reels to keep air hoses out from underfoot and provide a safe, efficient work area.

    
  Proper hose assemblies are key to providing a safe, effecient work area.    

Some final thoughts on Aluminum Pipe Systems?

Aluminum pipe systems are here to stay. The growth we have seen in the last ten years has been very impressive. There are thousands of installations worldwide in almost every industry. Companies have begun to take a serious look at Return on Investment (ROI), and with energy costs rising, it only makes sense that your compressed air system be optimized. Adding a compressor which is efficient is only the beginning. The best compressor in the world will keep on running to service air leaks and poorly designed pipe systems. The answer is to complete the optimization by using bubble tight components and good piping practices. The future will bring new and exciting technology and the days of black iron pipe are gone with the Ford Model T.

Thank you Prevost for your insights.

For more information please contact Mark McKean, Prevost Corporation, email: m.mckean@prevostusa.com, tel:800-845-7220, www.prevostusa.com