OIL/WATERenvironmental laws and regulations because the modern oils form an emulsion in the...
Transcript of OIL/WATERenvironmental laws and regulations because the modern oils form an emulsion in the...
RELIABLERELIABLERELIABLE
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
ENVIRONMENT SAFEGUARDENVIRONMENT SAFEGUARD
OIL/WATERSEPARATION
SEPREMIUM
JORC Industrial BV
Pretoriastraat 28NL-6413 NN HeerlenThe Netherlands
Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79
RELIABLERELIABLERELIABLE
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
ENVIRONMENT SAFEGUARDENVIRONMENT SAFEGUARD
OIL/WATERSEPARATION
SEPREMIUM
JORC Industrial BV
Pretoriastraat 28NL-6413 NN HeerlenThe Netherlands
Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79
INDEXChapter Content Page
1 Introductiontocompressorlubrication 1 Additives&Detergents 1 Compressedaircondensate 2 Whyinstallanoil/waterseparator 2
2 Willanyoil/waterseparatordo? 3 JORC’sguarantee 3 HowistheSEPREMIUMconstructed? 4 Highperformanceelements 4
3 PrincipleworkingsoftheSEPREMIUM 5 SEPREMIUM2 6
4 DISTRIBUTOR 7 Explodedview 8
5 Dimensions 9 Capacitychart 10
6 Condensateself-test-kit 11 Instructionmanuals 12
7 Servicepacks&multi-inletadapter 13 Functionalsamplebottle&elements 14
Version2013
OIl/w
atEr sEparatIO
N
Oil/
wat
er s
epar
atio
n
Informationprovidedherewithisbelievedtobeaccurateandreliable.However,noresponsibilityisassumedforitsuseorforanyinfringementofpatentsorrightsofothers,whichmayresultfromitsuse.Inaddition,JORCreservestherighttoreviseinformationwithoutnoticeandwithoutincurringanyobligation.
JORCIndustrialisaglobalcondensatemanagementspecialistofDutchoriginofferingcondensatedrains,oilwaterseparatorsandairsavingequipmenttodistributors,dealersandOEM’sinmorethan100countries.JORCIndustrialisdedicatedtosettingthestandardinhelpingitscustomersmanagetheircondensatemanagementrequirements.
CONDENsatE MaNagEMENt spECIalIst
IntroduCtIon to ComPressor lubrICants
Compressedairisthefourthenergyutilityafterelectricity,gasandwater.Fewproductionlinesintheworldwouldrunwithoutit.Themajorityofcompressedairisprovidedbyoil-injectedscrewcompressorsandthecompressoroilsplayamajorroleingeneratingcleancompressedairinanenergy-efficientway.Theyaccountforlessthanonepercentofthecostofcompressoroperation;however,therightoilhelpssaveaconsiderablepartofthetotalcost.
Theoilhasthreekeyfunctions:1. Itensuresthattherotorsandrotorbearingsinthecompressorarelubricated;2. Itdissipatestheheatofthecompressionprocess;3.Itformsasealingfilmatthesealedgebetweentherotorandthecompressorcasing.
Twokeyfactorsplayamajorroleincompressedairgeneration:highavailabilityofcleancompressedairandcompressedairgenerationatreasonablecost.Newlydevelopedsyntheticcompressoroilshaveproventheirworthinpractice.Longoillifetime,highefficiencyandaverylowoilcontentinthecompressedaircombinetoreduceoperatingcostsconsiderably.
Forefficientandtrouble-freeproduction,anoilwithlongservicelifeandgoodtemperaturebehaviorwithlowresidualcontentinthecompressedairisrequired.However,thereareconsiderabledifferencesbetweentheperformancesofdifferentcompressoroils.
Awell-formulatedsyntheticproducthasconsiderableadvantagesovermineraloil-basedproductsandparticularlystandsoutforoptimumoxidationprotection,goodadhesionandlowresidueformation.
However there is a consequence, the modern lubricants create an emulsification in the condensate that does not separate fast enough for gravity type separators. a JorC adsorption type separator offers a guaranteed separating solution.
addItIves & detergents
Oiladditivesarevitalfortheproperlubricationandprolongeduseofaircompressoroil.Withoutmanyofthese,theoilwouldbecomecontaminated,breakdown,leakout,ornotproperlyprotectcompressorpartsatalloperatingtemperatures.
Justasimportantareadditivesforoilsusedinsidegearboxes,automatictransmissions,andbearings.Someofthemostimportantadditivesincludethoseusedforviscosityandlubricity,contaminantcontrol,forthecontrolofchemicalbreakdown,andforsealconditioning.
Someadditivespermitlubricantstoperformbetterundersevereconditions,suchasextremepressuresandtemperaturesandhighlevelsofcontamination.
EffICIENt lubrICatION rEquIrEs EffICIENt sEparatION
lubr
ICat
ION Chapter 1
1
CON
DEN
satE
ComPressed aIr Condensate
Duringtheprocessofcompressingair,atmosphericairalongwithwatervapourandatmosphericcontaminants(hydrocarbon,dustparticlesorchemicalvapours),aredrawnintothecompressorintake.Additionally,thecompressionchambersofmostcompressorsrequireoilforlubrication,sealingandcooling.Oncecompressed,theairflowsintoanaftercoolertoremovetheheatofcompression.Astheaircoolsintheaftercooler,waterandhydrocarbonvapourswillcondense.
Additionalcondensationtakesplaceastheairisfurthercooledinthepipingandairdryers.
Environmentalregulationsstrictlyprohibitthedischargeofoilywastesandchemicals,includingthecondensatedrainedfromacompressedairsystem.Becauseoftheserequirements,municipalitiesregulatethedischargeofcompressorcondensatetosurfacewater,wastewatertreatmentfacilities,andsanitarysewers.
Compressorcondensatemustthereforebeeithercollectedortreatedpriortodisposal.Anoil/waterseparatorcanbeusedheretoremovetheoilfromthecondensate.Untreatedcondensatedisposaliscostlyasyourcustomerwillbechargedbyvolume.Asmostoftheuntreatedcondensateiswateritmakesfinancialsensetoseparatethelubricantfromthecondensatebymeansofanoil/waterseparator.
addItIves & detergents
Condensateisaby-productofaircompressors.Itisamixtureofoilandwaterwithparticlesandhydrocarbonsthathavebeenconcentratedduringthecompressionprocess.
Thismixtureofoilandwaterisclassifiedashazardousindustrialwaste.Environmentallawsandregulationsprohibitthedischargeofuntreatedcompressorcondensateintofoulsewers.
AftertheoilycondensatehasbeenefficientlyremovedfromthecompressedairsystembyareliableJORCdrain,itcannotbedischargeddirectlytothefoulsewerwithoutfirsthavingtheoilcontentreducedtowithinlegaldisposallimits.
Consideringthatcompressorcondensateconsistsofapproximately95%water,itmakesfinancialsensetoseparatetheoilfromthecondensatepriortothewasteisdisposed.
Everyend-userthatoperatesacompressedairsystemshouldhavea(condensate)wastemanagementprogram(ISO14000)inplacenotonlytoabidetolawsandregulationsbuttoalsopracticeecologicalresponsibility.
JORC’sSEPREMIUMOil/WaterSeparatorsareareliable,effective,efficientandaboveallanenvironmentalsolution.
Fullysynthetic Polyglycolbased Mineraloil Semisynthetic Separatedcondensate
Chapter 1
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Ma
kE
tHE
rIg
Ht
CHO
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wIll any oIl/water seParator do?
Backinthe1980’sthelubricantwasmuchmorebuoyantversuswaterandassuchfloatedtothewatersurfacemuchquickerthancurrentlubricantsdo.Oil/waterseparatorsthatweredevelopedtoworkonthisgravitytypeseparationmighthaveperformedbetterinthedaysprior to the introduction of “commercial internet…”.
Thesedaystheseold-styleoil/waterseparatorssimplydonotperformtocurrentenvironmentallawsandregulationsbecausethemodernoilsformanemulsioninthecondensatewhichwillnotseparateongravity.
Theold-style(gravityseparation/weirtype)separatorswerealsodevelopedbackinthedaywhenergonomic lawswerenotconsidered,ordidnotexist.Forinstance,theweightofthesaturatedelementsexceedcurrentergonomiclawsandregulations.Carryingoutroutineelementreplacementactivitiesthereforcarriesapotentialrisktotheservicingengineer.
Anno2013itiscriticaltounderstandthatmoderndaylubricationsrequiremoderndayoil/waterseparationtechnologysolutions.JORCisconstantlyindirectcontactwithcompressorlubricationmanufacturerstounderstandandfollowthelubricantdevelopmentbasedonthedemandsmadebecompressormanufacturers.
the sePremIum technology is based on these current and evolving developments.
JorC’s guarantee
ThousandsofJORCoil/waterseparatorsareinstalledworldwide.
TheSEPREMIUMelementsaredesignedandmanufacturedtosuccessfullyseparatecompressorlubricantfromcondensate.
Evenapplicationspecifictailormadeelementsaredesignedandmanufacturedtosuccessfullyoperateinuniquecircumstanceswherebypossibleexternalinfluencesrequiretobeconsidered.
ThereappearstobenoapplicationthatcannotgetresolvedwiththeSEPREMIUMrangeofelementscombinedwithJORC’sin-houseapplicationandproductknowledge.
ParticularlyrelevantfortheGermanmarket,wehavehadtheSEPREMIUMoil/waterseparatortestedtotheDiBtstandards.theSEPREMIUMoil/waterseparatortestedtotheDiBt
Chapter 2
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sEprEMIu
M k
NO
wlED
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How Is tHe sePremIum ConstruCted?
Therobustrotor-die-castedhousingismadefrompoly-ethylene(PE)materialandthedesignisbasedonJORC’sfamiliartwotowerprinciple.
Weapplybrassthreadinsertstoensureasecurepipinginstallationwithoutrunningtheriskofeasydamagingofthethreads,likeyoucanseewhenapplyingplasticthreads.
TheSEPREMIUMmodelshavethreehighperformanceelementsconsistingoftwopoly-propylenefiberelementsandoneactivatedcarbonelement.
Thereisanelementlifeindicatorofferingyouavisualguidanceastowhentoreplacetheelementswithnewones.
HIgH PerformanCe elements
ThecleverlubricantadsorbingelementsoftheSEPREMIUMaredesignedtoperforminthewidestrangeofapplications.
Thechosenelementfibreshavebeenspeciallyselectedandtreatedtomaximiseitssupremeadsorbingperformance.
WehavebeenabletodesigntheSEPREMIUM’selementsintoamulti-stageconfiguration,offeringanincreasedfiltrationefficiencyandeasyservicingprocedures.
ErgonomiclawsandlegislationhavebeentakenintoaccountduringtheR&Doftheelements.
Chapter 2
4
HO
w D
OEs
It w
Ork
PrInCIPle workIngs of tHe sePremIum
CondensatemaybedischargedintotheSEPREMIUMbyanytypeofcondensatedrain.Thedepressurisingchamberneutralisesthepressure.
AscondensateflowsthroughtheSEPREMIUM,theoilisfilteredoutthroughvariousfiltrationelements.
Thefirstoiladsorbingelementhasacleversaturationindicatingfeature,offeringyouavisualelementlifestatusoftheseparatoratadistance.Astheelementsadsorptionlevelincreases,thefirstindicatingelementwillbecomeheavierandslowlysinkdownthetower.Ontopoftheelementthereisanindicatorthatsticksupwhentheelementsarenewandsinksdownwardsasthesaturationlevelsincrease.Oncetheindicatorhascompletelysunkdown,theelementsrequiretobereplacedwithnewones.
Theelementsaredesignedtocombinevarioustypesofadsorptiontechnologiestoachievelessthan10ppmoilresiduevaluesattheoutputstage.
Finalseparationstageincludesspeciallyselectedactivatedcarbontopolishouttheremainingcontaminants.
prEMIuM sEparatION tECHNOlOgy
Chapter 3
5
sEprEMIu
M 2
ProduCt features
TheSEPREMIUM2isacosteffectivehighperformancesolutionforsmallcompressedairapplications.
TheSEPREMIUM2dropsintoitsholdingbracket(suppliedasstandard).Servicinginvolvesdisconnectingtheinletandoutlet,removingtheseparatorandplacingthenewunitintheholdingbracket.
Therearenoseparatereplacementelementsandassuchservicingisaquickandaboveallacleanprocess.
Brassconnectionsofferaquickcouplinginstallationfeature.
teCHnICal advantages
Theelementcomponentbuild-upoftheSEPREMIUM2ismadeupoutofthesamecomponentsasthelargermodels,offeringhighperformanceseparationofvirtuallyalltypesofcompressorlubricants.
Thepackagecomescompletewiththeinstallationbracketandrelevantfixings.
CommerCIal benefIts
Anytypeofcondensatedrainmaybeappliedincludingcosteffectivetimerdraincombinationoptions.TheSEPREMIUM2isahighlycompetitivelypricedoil/waterseparatorandoffersanincrediblysmallfootprint.Itislight-weightandsimpletoinstall.
Exchangingtheunitscouldnotbequicker,moresimpleorcleaner!
Clean and easy servICIng ProCedure
Chapter 3
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DIs
trIb
utO
r
ProduCt features
TheDISTRIBUTORisdesignedtocollectanddistributecondensateintotwotoeightoil/waterseparators.
ThiswayyoucancombinemoreSEPREMIUMunitstomatchupagainstlargercompressorsystems.
AscondensateflowsintotheDISTRIBUTORthedepressurisationtakesplace.Thereonafterthecondensateflowsevenlyintotheconnectedoil/waterseparators.Thiswaytheelementsoftheseparatorsareequallyloadedwithcondensatetotreat.
TheDISTRIBUTORhastwo1”condensateinletsandeight1/2”outlets.
TheDISTRIBUTORissuppliedcompletewithwallbracketsandfixings.Aspiritlevelisalsoincludedtoensurethecorrectinstallation.
ProduCt sPeCIfICatIons
Numberofseparatorsthatcanbehookedup 8Inletconnection 1”(2off )Outletconnection 1/2”(8off )Service/drainingvalve YesOverflowwarningindicator YesHousingmaterial PETotalrecyclable YesHousingcolour Black
Installationkitincluded Yes
suPPlIed wItH all tHe fIXIngs
Completeinstallationkit isincluded
Servicevalve Overflowindicator
Chapter 4
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sEprEMIu
M - CO
MprEssED
aIr CO
ND
ENsatE sEpa
ratION
eXPloded vIew
TheSEPREMIUMmodels5,10,20and30aredesignedtooperatethesameway.Differencesarephysicalsizingtoaccountforthevariouscompressorcapacitiesandcondensateflows.
AkeyfeatureoftheSEPREMIUMisthesimplicityandeaseofservicing.
Theelementsaredesignedtobereplaced/servicedinatimeefficientway.Theyarealsodesignedtobeaslight-weightaspossible.
BrassthreadsaddtotheprofessionalfinishoftheSEPREMIUM.
AsstandardtheSEPREMIUMpackageincludesaninstallationclothingkitincludingabreathingmask,toprotectyourserviceengineerfromcarbondust,wealsoincludethefunctionalcondensatesamplebottleforroutineinspectionandfinallyastepbystepinstructionmanualtoensureaproperinstallation.
Chapter 4
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sEpr
EMIu
M -
COM
prEs
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aIr
CO
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ENsa
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Epa
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dImensIons
sePremIum 5
sePremIum 20
sePremIum 2
sePremIum 10
sePremIum 30
dIstrIbutor
Chapter 5
9
Capa
CIty CHa
rt
CaPaCIty CHart
models 2 5 10 20 30
Max.compressorcapacity(m3/min) 2 5 10 20 30*Maximumoiladsorption(litres) 2 5 10 15 25Inletconnections 1/2” 1/2”(2) 1/2”(2) 1/2”(2) 1/2”(2)Outletconnection 1/2” 1” 1” 1” 1”Testvalve no yes yes yes yesServicedrain no no yes yes yesOverflowindicator no yes yes yes yesTargetoutputvalue <10ppm <10ppm <10ppm <10ppm <10ppm
Housingmaterial ABS PE PE PE PETotalrecyclable yes yes yes yes yesHousingcolour Black Black Black Black BlackLidcolour Darkgrey Darkgrey Darkgrey Darkgrey Darkgrey
Minerallubricants yes yes yes yes yesSyntheticlubricants yes yes yes yes yesStabilecondensateemulsions yes yes yes yes yesPolyglycol,Roto-Inject,SigmaMol**yes yes yes yes yes
*ConsultJORCforlargercapacities,seepage7fortheDISTRIBUTORdetails.**ConsultJORCforspecialelementsand/or24/7applications.ConsultJORCforprivatelabelling.
**Roto-inject,UltracoolantandSigmaMolareoilbrandsavailableinmarketforcompressorlubrication.
easy maIntenanCe
TheinitialinstallationoftheJorC sePremIumoil/waterseparatorwillrewardyouwithahighperformingseparationperformance.Thereonafterthemaintainingandservicingoftheoil/waterseparatorisrequired.Heretoowehavedesignedthereplacementoftheelementstobelightandsimple.
JORCalsooffersacondensateself-test kitthatallowsyoutoperformcondensateseparatingtests,pleasesee page 11 for details.
TheJorC warnerisanalarmsystemthatsendsSMSmessagestoyourmobilephone,pleasecheckourwebsitehttp://www.jorc.eu/7600main.htm
Chapter 5
10
tEst
kIt
Condensate self-test-kIt
JORCoffersanin-houselaboratorytestkittoanalyseanddeterminethesuccessrateofouroil/waterseparatorspriortosaleand/orinstallation.
Potentialcomplicatedcompressorsystems,i.e.twodifferentcompressorbrandswithdifferentlubricantscouldmakeitdifficulttodeterminewhichelementstouse.Thisself-testkitwillenableyoutodeterminetherightunitandtodemonstrateitseffectivenesstoyourcustomerpriortoinstallation.
Thetestkitconsistsofauniversalkitforalltypesoflubricants,anytypeofcompressoretc.
Thetestisquitesimpletocarryoutandadetailedinstructionmanualisprovided.Aftercarryingoutyourtestweadviseiftailormadeelementsarerequired.
Ifyourcustomerhasafailingoldstyleseparator,thisisanidealtooltoapplytoprovetheSEPREMIUMwillsolvetheproblem.
taIlor made elements
TheSEPREMIUMelementsoffersupremeseparationperformanceinapplicationswhereotherseparatorsarefailingtoseparatethelubricantfromcondensate.
ApplicationswhereyourcustomermighthavetwodifferentcompressormodelsrunningontwodifferenttypesoflubricantformsnoproblemfortheSEPREMIUMseparators.
Whenastabileemulsionflowsthroughtheseparatorwehavelimitedtimetoextractthelubricantfromthecondensate.
AtJORCweareabletomodify/adaptthepolymerfibrestosuitspecificseparatingrequirements.Inshort,weareabletominimisethecontacttimerequiredtoadsorbthelubricant.
Youwillbegivenaspecificpartnumberrelatingtoaspecialseparatingcase.Thiswayyouwillalwaysapplythecorrectelementsintherightapplication.
Chapter 6
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INstru
CtION
Ma
Nu
als
InstruCtIon manuals
Theinstallationisasgoodastheinstructionmanual!
TheinstallationprocedureoftheSEPREMIUMseparatorsisquitestraightforward.NeverthelesswehavedesignedtheinstructionmanualswithstepbysteppicturesofeveryaspectinvolvedingettingyourSEPREMIUMupandrunning.
Chapter 6
12
aCC
EssO
IrEs
sePremIum servICe PaCks
TheSEPREMIUMservicepackincludes:
• threeelements
• plasticwastebagsfor disposingthesaturated elements
• clothingkitcomprisingof amouthmask plasticgloves plasticoverall (aspictured).
multI-Inlet adaPter
TheMulti-inletadapterallowsforuptothreeadditionalcondensateinletoptions.
ThebrassadapterthreadsintothebrassinletoftheSEPREMIUM.
Tosimplifyinstallation,weincludethebrasshoseconnectionnipplesalso.
lIgHt weIgHt elements for
easy servICIng!
Chapter 7
13
aCCEssO
IrEs
funCtIonal samPle bottle
TheJORCoil/waterseparatorsincludeafunctionalsamplebottleforvisualroutineinspectionoftheoutputquality.
Thisvisualinspectionsamplebottleofferstheserviceengineeranindicationoftheoutputperformance.
Thesamplebottlekitispositionedinthetowerlid.
adaPters
Adapter,nipplesandhoseconnectorsappliedonallJORC’sseparatorsarealsoavailableasstandaloneproducts.
rePlaCement elements
Replacementelementsofvirtuallyallcompetitiveoil/waterseparatormodelsareavailable.
TheseareproducedwithJORC’shighqualitynettingsandfillings.
competitiveoil/waterseparatormodels
Chapter 7
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COM
prEs
sED
aIr
CO
ND
ENsa
tE M
aN
ag
EMEN
t a
ND
EN
Egry
sav
INg
prO
Du
Cts
notes
RELIABLERELIABLERELIABLE
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
ENVIRONMENT SAFEGUARDENVIRONMENT SAFEGUARD
OIL/WATERSEPARATION
SEPREMIUM
JORC Industrial BV
Pretoriastraat 28NL-6413 NN HeerlenThe Netherlands
Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79