The Europress gas fittings are already approved for natural gas, but the new “DVGW DG-8531BP0364” certificate for pressfitting Hydrogen GAS applications will shortly be available.

The manufacturer of Europress is among the first ever pressfitting manufacturers to obtain certification for the transportation of mixed gases containing up to 100% hydrogen gas, destined to play a crucial role in a future increasingly oriented towards renewable energy sources and protecting the ecosystem.

This is one of the first pressfitting manufacturers to complete this certification process, which sees the official updating of our renewed DVGW DG-8531BP0364 certificate.

We are now authorised to use the “DVGW H2-Ready”, which certifies that our fittings are suitable for use with natural and hydrogen gas blends, as well as with pure hydrogen.

Towards a sustainable future with hydrogen

Hydrogen is considered to be a most promising solutions for achieving a “zero-emission” future. If produced and used correctly, it can help to significantly reduce greenhouse gas emissions.

• Zero direct emissions: When used as fuel, for example in a fuel cell, the only by-product is water vapour. This renders it a clean alternative to fossil fuels, which release CO2 and other pollutants.
• Production from renewable sources: The true potential of hydrogen lies in its production. If hydrogen is produced through electrolysis (the separation of water into hydrogen and oxygen) with electricity from renewable sources such as solar or wind power, the entire production and use cycles are potentially free of carbon emissions.
• Decarbonisation of industrial sectors that are hard to electrify: Certain industries such as chemicals and heavy-duty transport (by ship or truck) are notoriously difficult to decarbonise with the direct use of electricity. Hydrogen can be used as an alternative fuel, reducing emissions. In steel production, it can substitute coal as a reducing agent, thus cutting emissions. In the chemical industry, it is used to synthesise ammonia and fertiliser, while in the refinery and petrochemical sectors it is used for desulphurisation and refining processes.
• Energy storage: Hydrogen can be used as an energy carrier, allowing for the storage of energy from renewable sources. When there is an excess of energy production from renewable sources, electricity can be used to produce hydrogen via electrolysis, which can then be stored and used when needed.

Despite its potential, the ecologically sustainable use of hydrogen is not without its challenges. Currently, the majority of hydrogen is still produced with natural gas, which generates CO2 emissions. Achieving the full potential for “zero emissions” would require a transition to large-scale hydrogen production from renewable sources.

Using Europress stainless steel pressfittings from Air Energy is a fast, economic & safe way to install gas lines including Hydrogen & Hydrogen blends. Contact Air Energy on 1300 99 55 26 or visit our website www.airenergy.com.au.

Unipipe from Air Energy is an exceptional Aluminium pipe system. Apart from its clean, aesthetically pleasing professional appearance, its performance sets it apart from and above competitors.

Other system fittings use an external nut, but Unipipe utilises a unique internal nut that has much higher pressure rating and resistance to blowing off.

This actual test-to-burst photo shows a high pressure tube split at 535bar without any sign of leakage or failure by the fitting. Other tests at extremes of temperature are equally impressive – at 100℃, standard pipe burst at 202.9 bar with no fitting failure, at minus 30℃ the burst pressure was 243.2 bar; all this considering that most systems operate at 7-8 bar.

This peace of mind, modular, reusabale, lightweight solution enhances every production facility or factory. The pipes are straight and colour coded for standard pressure, high 70bar pressure, oils or vacuum. Installation is straightforward, requiring only simple tools, streamlining the setup process, reducing complexity, and optimizing efficiency from start to finish. Contact the team at Air Energy for more product information.

The Australian Department of Defence has contracted Hanwha Defence Australia to deliver and support 129 locally built REDBACK Infantry Fighting Vehicles for the Australian Army.

Stage 1 of the H-ACE facility was completed to an unrivalled quality standard, over 2 and a half months ahead of schedule! The use of Europress Press fittings from Air Energy saved time and money for the compressed air reticulation throughout the manufacturing area.

Redback is named after the aggressive Australian Redback spider which is capable of hunting and killing creatures much larger than itself. This aggressive nature and ability to hunt and defeat larger prey has been threaded into the DNA of the vehicle’s design.

Hanwha’s vehicle incorporates a suite of advanced protection systems – ranging from an advanced hull built in Tasmania by Elphinstone, a high-quality steel manufactured by Wollongong-based Bisalloy, an advanced armour from Plasan, and Elbit’s active defence systems – to keep Australian soldiers safe in high-intensity combat environments.

The armoured vehicle will be manned by three crew members, including driver, commander and gunner while its rear compartment will accommodate eight dismounted troops.

The turret will be armed with a Bushmaster MK44S 30mm cannon used by the US, UK & NATO, a MAG 58 7.62mm coaxial machine gun, 76mm multi-barrel smoke grenade dischargers and two SPIKE LR2 missile launchers. It can be fitted with an EOS R400S Mk2 HD or R150 remote weapon system and Javelin anti-tank guided missiles.

The turret will be armed with a Bushmaster MK44S 30mm cannon used by the US, UK & NATO, a MAG 58 7.62mm coaxial machine gun, 76mm multi-barrel smoke grenade dischargers and two SPIKE LR2 missile launchers. It can be fitted with an EOS R400S Mk2 HD or R150 remote weapon system and Javelin anti-tank guided missiles.

The manufacturing facility at the Avalon site uses Europress stainless steel tubing and fittings and is tough, rugged and fast to install.

Steels like 316L are called “stainless” because in oxidizing atmospheres (air and water), they form a protective layer on the surface through a phenomenon called “self passivation”. Oxygen from the atmosphere combines with the chromium in the stainless steel to form this passive chromium oxide film that protects from further corrosion.

Stainless steel is not a single alloy, but rather the name applies to a group of iron-based alloys containing a minimum 10.5% chromium. Other elements like nickel and molybdenum are added and the chromium content increased to improve the corrosion resistance and heat resisting properties, enhance mechanical properties, and/or improve fabricating characteristics.  

304 is the basic chromium-nickel austenitic stainless steel and is suitable for a wide range of applications. It is the most readily available in a variety of product forms and is extensively used in commercial and industrial kitchen equipment, cutlery is another well known application. This grade is easy to form and fabricate with excellent resistance to corrosion.  

316 offers more corrosion-resistance through the addition of molybdenum. This grade is desirable where the possibility of severe corrosion exists, such as heavy industrial atmospheres and marine environments.  

316L 316L differs from 316 due to its reduced carbon content, so the chrome present in the alloy has less possibility of combining with the carbon and forming chromium carbides. The free chrome, in other words chrome not combined with carbon, creates the passivating oxide layer, which provides protection against corrosion.

Cleanliness and stainless steel are closely related and, in many applications, each is dependent upon the other in the handling of food, chemicals, pharmaceuticals and in the use of stainless steel as a construction material. Stainless steel provides the degree of corrosion resistance that is necessary to prevent product contamination or surface rusting. However, stainless steel performs best when clean — cleanliness is essential for maximum resistance to corrosion. 

Some form of routine cleaning is necessary to preserve the appearance and integrity of the surface. Stainless steels are easily cleaned by many different methods. They prolong their life with frequent cleaning, and, unlike some other materials, it is impossible to “wear out” stainless steel by excessive cleaning.  

Air Energy recently were contacted by a large abattoir that had replaced most of their existing copper pipework with Europress stainless steel, partly because of corrosion issues with the copper. However rather alarmingly, after a while their SS pipework appeared to be rusting right through and leaking.  

The plant engineers thought it was leaking from inside the pipe right through the pipe wall. 

316 and especially 316L Stainless steel have a high resistance to corrosion, but are suspect to chlorine attack eg high salinity water. Tests on the water supply showed that it was well within acceptable limits.  

Tests and spectroscopic analysis on the composition of the stainless steel proved it complied and was midrange on all specification limits.  

Cutting out a section and examination showed the SS was failing with a deep pit corrosion typical of chlorine attack, but it seemed to be only on the bottom half of the pipework.

Trouble shooting investigation by Air Energy ascertained that the worst affected were pipes carrying 84º hot water. At the end of each shift the maintenance team washed down all surfaces with an industrial foaming detergent sanitizer. Once all surfaces were wetted in the area they then washed down with water. 

But what was happening was the hot water evaporated the cleaner before it was washed down. This concentrated the chemical especially on the bottom half of the pipes. The cleaner that was being used had its active ingredient approx. 2000ppm of chlorine!

Europress pressfittings in AISI 316L stainless steel can be used in environments with moderate salinity. They cannot be used to transport saltwater (and seawater) Cupronickel pressfittings must be used for this application.

316 Stainless steel is corrosion resistant but not corrosion proof.

Which is better M-Profile or V-Profile?

There are 2 main systems of press fittings M-Press or V-Press. Most SS suppliers use M-Press so be wary you don’t get stuck with tools that you may not always be able to get compatible fittings. The two profiles are different in shape but in terms of performance there is no difference.

Even the maximum operating pressures and temperatures are the same. Both profiles must meet the same standards, have the same approvals. There is no difference in functionality, fluids pass through pipes and fittings in the same way. Both use the same tools that exert the same forces.

There are multiple manufacturers globally of press fittings more use M, some use V, plus a few other more obscure profiles not needed for this article.

B-Press Tool

Sometimes tradesmen ask can they use their B-Press tools for Stainless Steel? B Press fittings are designed for copper and copper alloy and are quick and easy to install but can only be used for copper. Mostly the Press tools themselves are interchangeable but it is critical that the correct jaws or chains are used, if in doubt check with our Customer Service team

What are the differences?

Historically M-Press was first invented and copyrighted for 50 years, V-press was a later design to get around the copyrights. The choice of one profile or another by installers is entirely discretionary , according to habits and the availability of equipment of one type or another. Nonetheless, at present the manufacture of the EuroPress fittings System range of M profile fittings boasts a greater number of certifications than the more recent V profile range, for which some certifications are in the process of being obtained or are planned for the near future.

Both systems use the same press tools- the integrity of the joint depends on the force applied and the press collar or jaws – all made by the same tool manufacturers.  Both systems must meet the same standards whether Australia’s AS or European DVGW or EN.

The V-profile can be identified by the visible shoulder or extended sleeve on the fitting which is pressed as part of the press operation on either side of the O-ring seat. The M profile has a special toroidal seat for the O ring which is radially pressed for hermetically sealing as well as the geometric deformation of the fitting onto the pipe which guarantees longitudinal and rotary integrity of the joint.

Apart from the the jaws illustrated above M profile also have a more recent development of High pressure ‘chains’. Instead of the scissor action utilised by both jaws above the ‘chains’ are a multisegmented design that wrap around the fitting and press equally on each segment, similar to the larger sizes mechanical action.

With a design life of 50 years and corrosion resistance, stainless steel Press fittings can be relied on to perform long after installation. A secure, permanent joint crimped on both the toroidal seat of the O-ring and on the fitting to pipe interface, ensures the physical connection longitudinally and radially plus the seal integrity.

A Technical Comparison Between M & V Profiles

 

The best plumbing should be neither seen nor heard in the home or office, as it affords us the basic necessities of everyday living.

At Air Energy, we enable the best plumbers to provide the best plumbing with quality aluminium, polymer and stainless steel pipe Australia wide.

Read on to discover how integral well-made plumbing is to your workplace and appreciate the investment that proper pipes can be.

Keeping Clean

Water is an essential and amazing resource for cleaning surfaces and myriads of packaging, components, and ourselves. Without it, harmful bacteria would multiply and render the environment, your friends and colleagues susceptible to sickness. Access to clean water is probably the most important development in all of human civilisation.

The correct design and materials in your plumbing system can reduce maintenance time in emergencies or in any breakdown or modification situation.

Poorly installed pipes can also lead to leaks inside your walls, causing mould and rot to set in. This can lead to negative health effects on inhabitants, not to mention the degradation of assets and poor company culture that can arise from a poorly maintained workplace.

Water Usage

When managing any business, the cost of utilities can be a vital part of making or breaking your bottom line. With well installed and designed plumbing, the energy for all piped fluids, including water can be reduced. Also, if the water pressure is optimised, the volume of water you use can be reduced, further cutting your water bill.

As more companies commit to sustainability targets, water usage is increasingly scrutinised. An efficient plumbing system is just one more step you can take to improve your sustainable standing, making your company culture one to be proud of.

Safety Standards

As discussed earlier, leaking pipes can be detrimental to your workplace in more ways than one.

Not only can it cause mould and rot, but any leaks around electrical components can contribute to stray currents or even short circuits and leave you in the dark with a hefty bill to pay for both plumbing and electrical maintenance.

The lights may be the least of your worries – switchboards and data centres can power far more than your ceiling lights. If a leak or stray current were to occur near your company’s dedicated data centre where numerous computers and storage systems are held, there’s no telling how long you could be out of action.

Further on safety, leaks can lead to slips and falls which put your colleagues and your company in danger. To avoid the worst-case scenario of a death or lawsuit, invest in plumbing that keeps everyone safe and well.

The Luxuries of Quality Plumbing

Modern aesthetic and functional plumbing can vastly improve the morale of your workplace as your colleagues recognise the extras afforded by their employer.

Contact Air Energy Today!

To learn more about Air Energy’s plumbing prowess and supply of stainless steel pipes Australia wide, visit our website or contact our team at (03) 9765 5600. Our passionate team of professionals will go above and beyond to ensure that your next build is done right with the proper materials.

Steel is one of the most vital materials in modern day construction.

The alloy raw metal made from two key base components – carbon and iron –  is used across a huge range of applications around the world. There are a number of functional and aesthetic advantages which makes steel the preferred construction material over many other metals.

There are also many ways in which this already dependable alloy metal can be manipulated to be improved further.

For a long time zinc coating either by hot dipping – galvanising, or electrically bonding – electroplating has been used to protect the steel from corrosion.

For example, But now in construction and architectural design industries as well as premium pipework, they use an insurmountable ever-increasing amount of stainless steel pipe Australia wide.

In this blog, we are going to outline the difference between two of these different adaptions manipulations: galvanised and stainless steel.

Galvanised Steel

What makes galvanised steel unique is a thin protective layer of zinc that is applied. This sacrificially protects the steel from oxygen and moisture which ultimately causes rust. Even with a minor scratch through the coating, the surrounding coating will corrode in preference to the steel.

Making steel more rust resistant ultimately improves the overall sturdiness and aesthetic of the steel – making it much safer to use, easier to maintain, and more pleasant to look at.

The process of galvanization simply means adding a zinc coating. The process can be done a few different ways and is relatively simple, which also makes it cheaper. Hot-dipped galvanisation gives a thick, strong coating of molten zinc and is an incredibly simple process as you could imagine. Whereas thermal diffusion galvanising is preferred when working with smaller, more intricately designed pieces of steel. Zinc electroplating is preferred for smaller components as the micron thin coating does not affect the dimensions of the parts like hot-dip galvanising.

While galvanisation does help protect the steel from rust, it is important to note that the zinc coating does wear away eventually – especially in environments that are highly acidic or close to salt water.

Stainless steel

Stainless Steel is made from iron and carbon, with the addition of chromium, and sometimes other elements that offer tremendous corrosion, rust and temperature resistance. The two most utilised are Nickel and molybdenum in varying proportions.

Stainless steel is also easily fabricated, strong, easy to clean, and is visually very appealing. The main difference between stainless and galvanised is that where galvanised simply coats the steel in a protective layer – stainless steel has integral defence against corrosion and rust built into it by the microscopic passive film of chromium oxide on the surface that self heals as the surface oxide layer reconstitutes.

There are more than 100 different grades of stainless steel that are rated on the levels of chromium and other elements added and the application in which they are used. They can be more easily defined into 5 categories:

Austenitic

This is the most commonly used type of stainless steel. It has excellent corrosion and heat resistance with applications made over a wide range of temperatures. It is commonly used in housewares, piping, construction, and architectural facades.

Ferritic

This has similar features to common steel, but with better resistance to corrosion, cracking, and heat. It is commonly used in washing machines, boilers and indoor architecture.

Martensitic

A very hard and strong stainless steel, though it is not as resistant to corrosion as austenitic or ferritic grades. It contains approximately 13% chromium and is used to make knives and turbine blades.

Duplex

This steel is a composite of austenitic and ferritic steels, making it both strong and flexible.
Duplex is used in a range of industries including paper, petrochemicals and shipbuilding.

Martensitic or Semi-Austenitic Steels

These steels are made to be extremely strong with the addition of elements such as aluminium, copper or niobium.

Contact Air Energy Today!

Overall, galvanised steel is less expensive than stainless steel. It is also easier to manipulate, but will never be as reliable and desirable as stainless steel.
If you’d like to know more about stainless steel piping, Visit our website or contact our team today at (03) 9765 5600. Our team of passionate professionals will go above and beyond to ensure that your next build is done right with the right materials.

Leaks in compressed air systems are a significant source of energy waste. It takes a lot of time and resources to locate and repair them, especially if the facility has no effective leak management program. The solutions are often reactive. But what if we take a proactive approach to address these costly leaks?

The real cost of compressed air leaks

Air may be free, but the energy required to compress it is not. Compressors are one of the most power-hungry pieces of equipment in a plant, so even a small leak can equate to considerable loss of resources.

In a report, the Air and Mine Equipment Institute Australia calculated the annual cost of leaks. Left unfixed, a single 6.4-diameter leak can cost $3,404 while a 12.7-diameter leak can blow up the loss to $13,619. These numbers can be higher depending on the operation hours and the energy cost per KWH in your location. (these figures are at 1994 pricing  -25 years ago – my table is more up to date) (one hole 12.7 diameter is totally unrealistic, but multiple small holes could add up to this – better to explain this)

Of course, hardly any plant would operate with a 12.7mm hole in their pipework, but multiple small leaks throughout a reasonable size plant could quickly add up to create bleeding compressed air and energy bills.

Compressed air leaks also cause a pressure drop in the system. This decreases the efficiency of the tools that use the air which in turn translates to less production or lower quality of work.

With leaks, compressors tend to cycle more frequently as well. This may shorten the life of almost all equipment in the system, including the compressor unit itself. This leads to an increase in unscheduled downtime and additional repair and maintenance costs for the entire system.

As they cause costly energy waste during production, leaks should be addressed at the front end, either when installing a new compressed air system, rerouting an existing one or upgrading an entire system.

Designing leak solutions on the front end

Leaks can occur at any point along a compressed air line, but they mostly arise in joints and connections. These include pipe joints, valves and even air hose fittings. Before, threaded piping was the only option to join air systems. But this type of connection is slow and tends to leak during operations, especially if poorly installed. Poor thread cuts, uncleaned threads and improperly applied thread sealant can lead to leaks.

If you can assure flawless installation, then threaded piping is still an option to connect pipes. But in recent years, many engineers have begun to recommend press-to-connect or press-fit systems instead.

In press-fit systems, a pipe is cut to size, deburred and marked to specify insertion depth before it is inserted into a coupling, valve or fitting. The pipe will then be pressed using a handheld pressing tool to create a mechanical interlock that ensures a rigid, permanent joint that prevents leakage.

Press-fit systems offer additional benefits, including safe, flame-free installation. Since pipes are pressed onto joints, they also do a better job of standing up to the rigours of plant operations than threaded piping. The thinner wall piping increases flow rates and the smoother bore decreases pressure losses.

Solutions for compressed air leakage shouldn’t be reactive. If you have the chance to address the issue with intelligent design and reliable equipment during installation or rerouting phase, take it. With no or reduced leak issues, you can save energy and keep operational costs down all year round.

If you want to know more about press-fit connections and systems, don’t hesitate to contact us today.