Reliable compressed air supply: thyssenkrupp uses stainless steel system

A new thyssenkrupp plant was built in Röhrsdorf near Chemnitz. To manufacture special machines for battery production, it was important to install a reliable system for compressed air and cooling water. The high requirements could be met with our premium stainless steel system NiroSan.

 

16.06.2020

Focus on electromobility

The new building in Röhrsdorf represents a further pillar in the region and for thyssenkrupp System Engineering a very good complement to the electromobility competence center in neighboring Hohenstein-Ernstthal and the Pleißa pilot plant. The production site was built on the 40,000 sq.m. site by property developer VGP Industriebau with German headquarters in Düsseldorf. After completion, the property will be leased to the mechanical engineering company. Depending on requirements, up to 250 employees will be working there. The focus is on environmentally friendly mobility. The international company belongs to thyssenkrupp Industrial Solutions, a systems partner for all key components of the auto body and powertrain process chains.

 

The building

The production hall with a size of about 9,400 m² has been built in a precast concrete construction according to the latest standards. For the heating inside, ceiling radiant panels were installed, which distribute the heat optimally. A total of four Compair compressors generate the compressed air required for production. Two models were used: two speed-controlled L37-RS and two rigid-running L37-10A compressors. To ensure that the plant achieves a long service life, processing technology in the form of four refrigeration dryers with filter technology was installed. The pressure dew point is 3 °C and corresponds to class 4, guaranteeing that the medium is available for the processing procedures in constant quality. The compressed air quality is classified in accordance with the ISO 8573-1 standard - in this case it corresponds:

 

Class 1 for solid particles

Class 4 for humidity (dew point)

Class 1 for oil

A continuous operation of the plant is ensured by compressed air storage tanks. An important aspect concerns the distribution: The system should operate permanently with as little loss as possible. To achieve this, the piping had to be designed without leaks. This was realized and tested by the company druckluft-technik Chemnitz GmbH.

 

Compressed air and cooling water

For production, compressed air and cooling water piping has been laid as ring piping. The size DN 65 was used as the dimension. 30 compressed air connections and 5 cooling water connections were installed in these pipes, each in DN 25. Each connection is secured with a stopcock. These are necessary in order to be able to react to later expansion requests without major interventions in the system. The compressed air lines are not insulated. The system is serviced every 4,000 operating hours, at least once a year. This procedure also includes the inspection of all shut-off and testing devices.

 

Stainless steel system NiroSan

The NiroSan system was used. All stainless steel fittings are made of the materials 1.4404 (stainless steel fittings) and 1.4408 (threaded parts, stainless steel investment casting). The stainless steel material 1.4404 contains at least 2.3% molybdenum and has a lower carbon content than the conventional material 1.4401. It is therefore not only equivalent to this stainless steel, but also convinces with its higher corrosion resistance.

 

The NiroSan press system, the stainless steel pipes as well as the stainless steel fittings are tested according to DVGW worksheets GW 541 and W 534 and approved by DVGW, ÖVGW, SVGW and all renowned European certification bodies. The series is available in all dimensions from 15 to 108 mm, including 64 mm. The maximum operating pressure is 16 bar, the operating temperature for the NiroSan press fittings with EPDM sealing ring is -30 °C to +120 °C.

 

combipress accelerates work processes

Today, speed is of the essence when installing pipes and fittings - together with proper processing. To achieve this at every single step, installers could rely on the advantages of combipress: The processing of pipes and fittings is considerably simplified by the properties of tool compatibility, sliding adhesion and "unpressed leaks", while processing reliability is increased. Existing tools with different original pressing contours (V, M and SA) can be used up to and including 54 mm without any problems. For larger dimensions the original contours SA and M can be used. For the craftsman, this means easier handling and more safety when pressing, because the tool compatibility makes it easier to work with the original contours.