OIL/WATERenvironmental laws and regulations because the modern oils form an emulsion in the...

transcript

RELIABLERELIABLERELIABLE

COMPRESSED

AIR COND

ENSATE M

ANAGEM

ENT AN

ERGY SAVING PROD

COMPRESSED

AIR COND

ENSATE M

ANAGEM

ENT AN

ERGY SAVING PROD

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

info@jorc.nlwww.jorc.eu

COMPRESSED

AIR COND

ENSATE M

ANAGEM

ENT AN

ERGY SAVING PROD

COMPRESSED

AIR COND

ENSATE M

ANAGEM

ENT AN

ERGY SAVING PROD

OIL/WATERSEPARATION

SEPREMIUM

JORC Industrial BV

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

atEr sEparatIO

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

ION Chapter 1

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

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

sEprEMIu

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

PrInCIPle workIngs of tHe sePremIum

CondensatemaybedischargedintotheSEPREMIUMbyanytypeofcondensatedrain.Thedepressurisingchamberneutralisesthepressure.

AscondensateflowsthroughtheSEPREMIUM,theoilisfilteredoutthroughvariousfiltrationelements.

Thefirstoiladsorbingelementhasacleversaturationindicatingfeature,offeringyouavisualelementlifestatusoftheseparatoratadistance.Astheelementsadsorptionlevelincreases,thefirstindicatingelementwillbecomeheavierandslowlysinkdownthetower.Ontopoftheelementthereisanindicatorthatsticksupwhentheelementsarenewandsinksdownwardsasthesaturationlevelsincrease.Oncetheindicatorhascompletelysunkdown,theelementsrequiretobereplacedwithnewones.

Theelementsaredesignedtocombinevarioustypesofadsorptiontechnologiestoachievelessthan10ppmoilresiduevaluesattheoutputstage.

Finalseparationstageincludesspeciallyselectedactivatedcarbontopolishouttheremainingcontaminants.

prEMIuM sEparatION tECHNOlOgy

Chapter 3

sEprEMIu

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

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

sEprEMIu

M - CO

MprEssED

aIr CO

ENsatE sEpa

ratION

eXPloded vIew

TheSEPREMIUMmodels5,10,20and30aredesignedtooperatethesameway.Differencesarephysicalsizingtoaccountforthevariouscompressorcapacitiesandcondensateflows.

AkeyfeatureoftheSEPREMIUMisthesimplicityandeaseofservicing.

Theelementsaredesignedtobereplaced/servicedinatimeefficientway.Theyarealsodesignedtobeaslight-weightaspossible.

BrassthreadsaddtotheprofessionalfinishoftheSEPREMIUM.

AsstandardtheSEPREMIUMpackageincludesaninstallationclothingkitincludingabreathingmask,toprotectyourserviceengineerfromcarbondust,wealsoincludethefunctionalcondensatesamplebottleforroutineinspectionandfinallyastepbystepinstructionmanualtoensureaproperinstallation.

Chapter 4

dImensIons

sePremIum 5

sePremIum 20

sePremIum 2

sePremIum 10

sePremIum 30

dIstrIbutor

Chapter 5

CIty CHa

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

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

INstru

InstruCtIon manuals

Theinstallationisasgoodastheinstructionmanual!

TheinstallationprocedureoftheSEPREMIUMseparatorsisquitestraightforward.NeverthelesswehavedesignedtheinstructionmanualswithstepbysteppicturesofeveryaspectinvolvedingettingyourSEPREMIUMupandrunning.

Chapter 6

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

aCCEssO

funCtIonal samPle bottle

TheJORCoil/waterseparatorsincludeafunctionalsamplebottleforvisualroutineinspectionoftheoutputquality.

Thisvisualinspectionsamplebottleofferstheserviceengineeranindicationoftheoutputperformance.

Thesamplebottlekitispositionedinthetowerlid.

adaPters

Adapter,nipplesandhoseconnectorsappliedonallJORC’sseparatorsarealsoavailableasstandaloneproducts.

rePlaCement elements

Replacementelementsofvirtuallyallcompetitiveoil/waterseparatormodelsareavailable.

TheseareproducedwithJORC’shighqualitynettingsandfillings.

competitiveoil/waterseparatormodels

Chapter 7

COMPRESSED

AIR COND

ENSATE M

ANAGEM

ENT AN

ERGY SAVING PROD

COMPRESSED

AIR COND

ENSATE M

ANAGEM

ENT AN

ERGY SAVING PROD

OIL/WATERSEPARATION

SEPREMIUM

JORC Industrial BV

Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79

OIL/WATERenvironmental laws and regulations because the modern oils form an emulsion in the...

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