Lesson 16

The PDF report

Everything the lessons have calculated ends in a document someone else reads: the engineer who checks the design, the buyer who orders the parts, the plant manager who pays for the air. This lesson makes the three documents EasyCAS writes — the full report of a design, the one-page air data sheet of a machine, and the audit report with the cost by department.

1. Write the report of the design

   Open lesson14.gf9. The switch reads Design. Choose File → Report (pdf): the command is a submenu that decides how the scheme is drawn in the document.

   Item of the submenu	The scheme picture
   With element IDs on the scheme	every element carries its ID label — the one the item blocks and the problem list of the report refer to
   Without element IDs	the sheet as it looks, for a customer
   Both: the scheme with IDs and without	two pictures, one after the other

   Choose With element IDs on the scheme. If the scheme has not been calculated since it was opened or changed, the program asks first:

   • Yes — calculate now; the report gets the supply requirements, the results and the warnings;
   • No — build it from the input data only, for instance for a parts list of an unfinished scheme; the report then says under its title The scheme was NOT calculated - this report contains input data only;
   • Cancel — nothing.

   Answer Yes. A report of stale numbers is never written: nothing in it would say they are stale. The file is offered next to the scheme as lesson14_report.pdf; when it is written, the program offers to open it.

2. Read it section by section

   The sections come in a fixed order; one that has nothing to say for this scheme is left out.

   Section	What you find for lesson14.gf9
   Scheme summary	the file, the date, the program build; Objects on the scheme 7 element(s); Purchased items 1 position(s); 6 element(s) without a model number are not listed; Calculation: done; Position labels: 5 element(s) share 2 repeated label(s); the composition: Pipe 3, Blowing tube 2, Compressor 1, Connector 1
   Problems (2)	Errors 0, Warnings 0, Recommendations 2: one grouped row 2 × TUBE_BLOWING — A component is recommended for this element for ID12 and ID14, the wrench signs of B1 and B2. It stands near the top, to be read before the figures
   Scheme	the drawing, with the ID labels; captions with references show their values
   Pressure profile	to the consumer with the largest network losses — ID12, B1: ID1 -> ID12: 4 element(s), 55000 mm of pipe, network losses 0.166 bar (limit 0.5 bar), the largest ID9 (P1) 0.103 bar, 62 %; below it the table of the path: P1 0.103, T1 0.016, P2 0.047 bar
   Compressed air supply	one block per source — the rows of COMP: Pout 6.1656 bar, Qn 1637.89 NL/min, Cs 4603.41 € — and the total for the scheme. An accepted compressor selection (lesson 9) would add the machine and its control
   Work cycle	only when at least one consumer has a switching point: the cycle length, the number of elements in the cycle and how many of them switch, the compressor; then the Timing diagram (filled = on) — B1 0:00–0:30, B2 0:20–0:38 — and the Switching events of each consumer. It stands between the supply and the purchased items
   Purchased items	the bill of materials: one line — AIRpipe, 2005_AIRpipe, d-1 in_Equal Tee, 1 pcs — and Total: 1 position(s)
   Elements in detail	a block per item, headed by its ID: catalog data, entered values, results; for B1 and B2 the Possible substitutions — 26 and 30 catalog nozzles of the same blowing force or more, the closest first (EXAIR 1250 for B1, 1230 for B2), the first fifteen printed

   Why is the bill of materials one line long? Only the tee comes from a maker's catalog with a model number. The compressor, the three pipes and the two open pipes are generic elements of lesson 1 — the calculation knows them, a supplier would not. An element without a model number is not listed, and the summary says how many were left out — six here. Items of the same model at the same position are gathered into one line with a quantity; items measured by length are not counted in pieces.

   The item blocks are headed by the ID, not by the model number: two open pipes on one scheme have the same card label Tube_blowing, and the ID is what tells them apart — the reason to keep the IDs on the scheme picture of an engineering report.

   The screenshot of the Work cycle section below is from the report of lesson15.gf9 — the same network with the one-second round of lesson 15: cycle length 0:00:00:01:000, B1 (ID12) on from 100 to 800 ms, B2 (ID14) from 300 to 600 ms. The report of lesson14.gf9 draws its one-minute round the same way.

3. Make the customer's copy

   Choose File → Report (pdf) → Without element IDs and save it as lesson14_report_customer.pdf. The scheme picture is now the sheet as you see it — captions, no labels. The rest of the report still names the items by ID: the IDs identify the items, the picture only stops showing them. Both puts the two pictures one after the other.

4. Write the air data sheet of a machine

   The full report is for the engineer. A machine builder needs one page for the documentation of the machine: what it takes from the plant network. Take the network of lesson 15 — the one with the one-second round — and read it as a cleaning station: COMP is the point where the station is connected to the plant, everything after it is the station. Open lesson15.gf9; it opens in Dynamic mode, and the sheet works in Dynamic as in Design.

   Choose File → Air consumption data sheet (pdf).... The settings window opens:

   Field	Value
   Machine (title of the sheet)	Cleaning station	empty — the file name
   Supply line length (mm)	5000	the hose from the plant network to the machine, 5 m, in the unit of the Length list
   Allowable pressure drop on the supply line (bar)	0.1	at the peak flow
   Compressed air quality, ISO 8573-1	empty	text, for example 1:4:2: the item data hold no air classes. Empty — the sheet says not specified

   The four values are saved in the scheme. The program then calculates by itself — the design, the round point by point, as the cyclogram window does, and the design again so the cards show the steady state — and offers lesson15_air_data_sheet.pdf. The sheet is a design document: in Audit mode the program asks you to switch to Design first.

5. Check the sheet against lessons 14 and 15

   Every figure of the page is one you can work out from the round of lesson 15 — B1 from 100 to 800 ms, B2 from 300 to 600 ms:

   Row	The sheet shows	Where it comes from
   Required inlet pressure, minimum	6.17 bar	the top of the Pout curve: both pipes, 300–600 ms
   Maximum permissible inlet pressure	20.7 bar (ID4)	the Max_pressure of the tee T1, 300 psi — the only item on the path that gives one
   Compressed air quality	—	not specified: the field was left empty
   Reference conditions of normal air	20 °C, 1 bar abs	Input parameters
   Supply line	5000 mm, 0.1 bar	the settings: length, and the drop allowed at peak flow
   Minimum internal diameter	16.1 mm	(0.634 in): 5 m at the peak with no more than 0.1 bar lost
   Recommended nominal size	DN 20	the first size of the series not below 16.1 mm
   Velocity / pressure drop at peak flow	12.1 m/s 0.0355 bar	on DN 20
   First element at the inlet	ID9	P1
   Mean consumption	911 NL/min	1048.25 × 0.7 + 589.64 × 0.3
   Peak consumption	1638 NL/min	1637.89: both at once
   Peak duration	0.3 s	300 – 600 ms
   Peak to mean ratio	1.8	1638 / 911
   Air per cycle	15.2 NL	one second at the mean
   Cycle time	1 s	the Time interval; 3600 cycles per hour
   Continuous base load	0 NL/min	before 100 and after 800 ms nothing blows
   Operating time	1920 h	8 h × 240 days of Input parameters
   Air	104909 Nm³	911 NL/min × 60 × 1920 h, a year
   Specific energy at the required pressure	0.188 kWh/Nm³	the price of a Nm³ at 6.17 bar over the price of a kWh
   Electricity	19688 kWh	a year
   Compressed air cost	2559 €	a year
   CO2	7.88 t	19688 kWh × 400 g/kWh

   Main consumers: B1 (ID12) takes 12.2 NL a round, 80.6 %, and 1048 NL/min at the peak; B2 (ID14) 2.95 NL, 19.4 %, and 590 NL/min. The chart repeats the Qn curve of the cyclogram with the mean as a dashed line, and under it the required source pressure over the round: the sheet and the cyclogram window always agree.

   Check by hand: the money

   The sheet prices all the air at the required inlet pressure, the highest of the round: 0.024 × (6.1656 / 6)^0.603 = 0.02440 €/Nm³ × 104 909 Nm³ = 2559 €, and 2559 / 0.13 = 19 688 kWh. Priced piece by piece at its own Pout, as the cyclogram window of lesson 14 does, the same round would come to about 2552 €. The sheet takes the higher figure on purpose: the plant must hold 6.17 bar at the connection all the time, whether the machine is in its peak or not.

6. Write the audit report with the cost by department

   Open lesson13.gf9 and switch to Scenario → As is (baseline). The mode is Audit. Choose File → Report (pdf) → Without element IDs. In audit mode the report is titled AUDIT REPORT and the scheme picture gets a teal frame. Two sections are new:

   • Audit results, after the pressure profile: the source at both load points, the leaks, the recommendations, the pressure deficits, the measurements of PG, FM and the logger, and the bottlenecks;
   • Compressed air cost by department, because the scheme has zones.

   Row of the department table	Demand, NL/min	Share	Cost a year	Lowest pressure
   Line 1	1095	63.9 %	1 388 €	6.309 bar
   Line 2	618.4	36.1 %	784 €	6.341 bar
   Total	1713	100.0 %	2 172 €	–

   The table also has a Leaks column — 0 for both lines, no leak is drawn in them — and a bar for each share. A row Outside the zones appears only when some demand lies outside every zone; here every consumer is in a line, so there is none. Above the table the section says what the cost of the scheme is and where it comes from: Annual cost of compressed air for the scheme: 2 172 €. It comes from the measured power of the compressor (Audit power). The 2172 € is the Annual cost calibrated by the measured power of lesson 11. The compressor room is a supply zone and has a table of its own, Supply: 1960 NL/min, 6.5 bar, 2 172 €, 100.0 % of the supply. The figures are those of the zone labels of lesson 13, in the same format.

   Now switch to Proposed and make the report again. The title names the scenario, and the file is offered as lesson13_Proposed_report.pdf: a report of a plan can never be mistaken for the report of the plant.

When it does not work

Try this next

• In lesson15.gf9 give B2 the round 800 – 1000 ms, after B1 (lesson 14, step 4) and make the data sheet again: the two pipes never blow together, the peak drops to 1048 NL/min, and the recommended hose with it.
• Set the supply line length to 20000 mm (20 m) and the allowable drop to 0.05 bar: see how far the recommended size goes up.
• In the Problems panel press Send by e-mail...: a message is prepared with the problem list as a PDF attached.

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