An Invensys company

Condensate Management

Equipment and Accessories for Compressed Air Systems

condensate management - final 16/11/99 4:52 pm Page 2

Intelligent condensate drainsCondensate doesnot appear inconsistentquantities, thisrequires the useof an intelligentdrain to avoidlosing valuablecompressed air.

CompAirBEKOMAT drainsare reliable andefficient,removing condensate from the compressed air systemwherever and whenever it accumulates without loss ofexpensive compressed air.

Oil-WaterSeparatorsCompAir Owamatseparators are simplyinstalled as part of thecompressed air systemand reduce the oilconcentration in thecollected condensate.

By reducing the oilconcentration in the water to a permitted

level, this allows a larger amount of clean water, up to99% of the total condensate, to be discharged safelyinto the environment. This leaves the relatively smallamount of oil to be disposed of legitimately andeconomically.

Emulsion Splitting SystemsWhen air and process gases are compressed, stableemulsions can form due to unfavourable suctionconditions, the type of lubricating oil employed or theparticular design of the compressor. These emulsionscannot be processed with standard oil-waterseparation systems.

The CompAiremulsion splittingplant has beenapplied hundredsof times for thesuccessfulpurification ofcondensateemulsions fromcompressed airsystems.

Compressed AirCondensateTHE PROBLEMThe generation of condensate isunavoidable in the production ofcompressed air. It is often highlycontaminated with oil and dirtparticles and other harmfulsubstances. The removal andtreatment of this condensate isvital to the efficient andeconomical operation of anycompressed air system.

Regulations are becoming morestrict on the disposal ofcondensate, with the dischargeof compressor condensates beingprohibited without suitableprocessing.

THE SOLUTIONSTo handle the problems associatedwith the collection and disposal ofcondensate, CompAir is able tooffer a selection of advanced andreliable products.

condensate management - final 16/11/99 4:53 pm Page 3

Condensate Drains

EconomicalThe Intelligent control avoidsunnecessary loss of compressed air,thus providing considerable energysavings compared with traditionaldrain types.

Reliable functionsThe non-wearing capacitive sensorregisters every type of condensate,including pure oil, so condensatedischarge is no problem even withheavily contaminated condensate.

Easy InstallationThe connection to the compressedair system is simple, because theinlet and outlet of the drain unitare in alignment and discharge canbe arranged either through a hoseor piping.

SafeConstant self-monitoringassures reliability, an LED displayalways indicates the currentoperating state. A functional testcan be carried out at any time bypressing the test button, andpotential free contact makes itpossible to relay fault signals to acontrol centre. All the operatingparts and electronic control aresplash proof and comply with IP65protection rating.

User FriendlyThe electronic system consists of apower unit and a control withaccessible 24 V direct voltage. Afterpulling out the plug in connector,maintenance work on the devicecan be performed without danger.

BEKOMAT 16

BEKOMAT 14

BEKOMAT 12

LED Display

Reliable Sensing

Separate Power supplyand controls for safe

and easy handling

BEKOMAT 13

BEKOMAT 21

condensate management - final 16/11/99 4:53 pm Page 4

Peak Peak dryer Peak filter Peak Temperature Weight Applicationcompressor performance performance operatingperformance pressure

M3/min M3/min M3/min bar min/max 0C kg

BEKOMAT 21 3 6 30 0.8/16 +1/+60 0.7 a,bBEKOMAT 12 4.5 9 45 0.8/16 +1/+60 0.8 aBEKOMAT 12 CO 4.5 9 45 1.2/16 +1/+60 0.8 a,bBEKOMAT 12 CO PN63 4.5 9 45 1.2/63 +1/+60 0.9 a,bBEKOMAT 13 20 40 200 0.8/16 +1/+60 2.0 aBEKOMAT 13 CO PN25 20 40 200 1.2/25 +1/+60 2.2 a,bBEKOMAT 14 90 180 900 0.8/16 +1/+60 2.9 aBEKOMAT 14 CO 90 180 900 1.2/16 +1/+60 2.9 a,bBEKOMAT 16 CO 1000 2000 – 1.2/16 +1/+60 5.9 a,b

Operation

FIG. 1Condensate trickles through theinlet opening and collects in thecontainer (2). The diaphragm valveis closed, since the pilot line (3)and the solenoid valve (4) ensurepressurisation above the valvediaphragm (5). The larger spaceabove the diaphragm results in ahigh closing force, thereby ensuringthe valve seat is leak proof.

FIG. 2Once the container (2) has filledwith condensate, so that thecapacitive level sensor signals atthe maximum point, the solenoidvalve is energised, closing the pilotsupply line allowing venting of theair above the valve diaphragm. Thediaphragm lifts off the valve seat(7), the pressure in the housingforces the condensate into thedischarge pipe (8). The electronicsystem of the condensate drainnow calculates the discharge ratedown to the minimum point on thesensor and uses this figure todetermine the exact maximumnecessary valve opening time. Thevalve will again be fully closed andleak proof, before any compressedair can escape.

Alarm ModeShould the condensate dischargefail to function properly (blockeddischarge pipe, faulty diaphragm),the device will change to the alarmmode after 60 seconds. In this case,the red LED flashes, a potential free

contact is activated and thesolenoid valve is de-energised.When in alarm mode, the solenoidvalve will open every 4 minutes fora period of 7.5 seconds.

Special ModelsAvailable for:

� Areas with a potentiallyexplosive atmosphere

� Extremely aggressivecondensate

� Low pressure and vacuumconditions

� Discharge during no loadoperation with multi-stagecompressors

a) Oil contaminated condensate, b) oil free, aggressive condensate

Condensate Drains

1

2

2

6

7

8

3

4

5

Technical Specification

Compressor station with

MODEL

condensate management - final 16/11/99 4:54 pm Page 5

Low MaintenanceThe separator only requires oneweekly inspection. When a filterchange is required, as indicated by the simpleturbidity test,the user-friendly designof theseparatormakes it asimple task.

Environmentally SafeMineral oils contained incondensate are very difficult todegrade biologically and impair theoxygen and sludge digestion insewerage plants. The effectivenessof the entire water processingsystem is reduced, resulting inendangering of biological balanceand hazards to human health. TheCompAir separator safeguardsagainst oil leaking into the sewagesystem.

OperationThe oil emulsive condensate entersthe pressure relief chamber of theoil-water separator under pressure.Excess pressure is relieved withoutcreating turbulence in theseparation container. The solidpollutants carried with thecondensate collect in theremovable sediment container.

In the separationcontainer, the oil rises tothe surface and isskimmed off via theadjustable oil overflowinto the overflowprotected oil reservoir.The condensate, thus pre-cleaned now flowsthrough a preliminaryfilter and then through anadsorption filter. Thepreliminary filter bondsthe remaining oil dropletsto it while the adsorptionfilter retains any residueoil.

The CompAir oil-water separatorsystem for dispersed condensatehas been proven for many yearsand continues to be developedfurther. Since it complies with theapplicable regulations, safeprocessing is guaranteed anddischarge of the processed waterinto the sewerage system is possiblewithout any problems.

EconomicThe separator requires no power so there are absolutely no energycosts.

The payback on the system ispossible within a few monthscompared to the alternative ofhaving condensate disposed of by aspecialist company. While this issafe it is expensive and also incursthe additional costs for certifiedcollection tanks, monitoringdevices, and installation work.

Simple InstallationThe oil-water separator comesready to connectand is available in5 sizes, meaningthere is always anappropriate sizeto suit yourapplication. Incase of utilisationin frost hazard areas, a separateheating unit assures problem freeprocessing.

Oil-Water Separators

CompAir Condensate Drains and Oil Water Separator

condensate management - final 16/11/99 4:54 pm Page 6

Selection

In order to achieve an economicalfilter service life, the influencingfactors, such as compressor design,type of compressor oils must betaken into consideration. Oils with ahigh water adsorption capacity areseparated slowly from the water.This requires longer dwell timeswithin the settlement tank. Thefollowing design table will help youto select the type of separatorsuitable for your needs.

The performance data refers to thecompression of air to 7 bar g at anambient temperature of 250C,relative humidity of 65% andcompressor discharge temperatureof 350C. When using oil-waterseparators in warmer climates, thecondensate quantities will be larger,so the values will have to bereduced accordingly.

Oil-Water Separators

INSTALLED COMPRESSOR PERFORMANCE IN M3/minScrew and Rotary Compressors with Oil Injection Cooling Piston Compressors

1 and 2 stageLubricating oil grade Turbine oil VDL oil VCL oil Synthetic oil Turbine Oil VDL oil or

synthetic oil

Owamat 1 1.5 1.3 1.0 0.3 - 1.0 0.8 0.3 - 0.6Owamat 2 3.0 2.5 2.0 1.0 - 2 1.5 0.6 - 1.3Owamat 4 7.5 6.3 5.0 2.0 - 5.0 3.8 1.3 - 3.1Owamat 5R 15 12.5 10 5 - 10 7.5 3.1 - 6.3Owamat 6 30 25 20 10 - 20 20 6.3 - 16.7Owamat 8 90 75 60 20 - 60 60 16.7 - 50

Technical Specification

condensate management - final 16/11/99 4:57 pm Page 7

Advanced SeparationTechnology

The CompAir emulsion splittingsystem is the number one choice toguarantee the safe and efficienttreatment of emulsions - be it forsmall or large capacities. Designedfor reliable and low maintenanceoperation, the independent splittingunit in combination with corres-ponding tank components allowsyou to choose the best possibleconfiguration for your particularapplication. The purification ofwaste water using the CompAirtechnique is particularly suitable foroil-emulsions with concentrationsbelow 1%.

The Process

The emulsions are conveyed to theprimary feed tank (2) via thepatented pressure relief chamber(1). Here,preliminary cleaning ofthe waste water takes place bygravitational separation, whichpermits separating the free oil,even with fluctuating feedquantities.

The oil discharge (3) is automaticand the liquid level status ismonitored by the electronic sensorsystem. The specially developedcapacitive electronic monitoringdevice is capable of distinguishingbetween air, oil and emulsion.Consequently, emulsion cannot getinto the oil collector, and free oilcannot enter the reaction chamberof the splitting unit.

The waste water to be treated ispumped by a hose pump into thereaction chamber of the splittingunit. The subsequent waste watertreatment is fully automatic,starting with the addition thesplitting agent. This non-toxic, buthighly effective emulsion powder isstored in a metering unit (4), whichreleases the exact amount ofpowder to be stirred into theemulsion (5).

Splitting and separating of theemulsion are performed in a singlesequence. The separated oil anddirt particles are encapsulated bythe splitting agent and then flowthrough a discharge duct into thefilter bags (6) where they areretained.

The purified water can then besafely discharged into the industrialwater or sewerage network.

Advantages

Compared to with other emulsionsplitting methods, characterised byhigh maintenance and high costs,the CompAir system offers genuineadvantages:

� Easy to use

� Reliable

� Economic operation

� Low maintenance

� Virtually waste free

ESS 12 ESS 13 ESS 14

Hourly capacity l/hr 30 60 90

Associated max. compressor performance m3/min 25 50 75

Reaction tank volume L 12 26

Volume of splitting agent container L 8.5 15

Filter bag volume L 25 60

Weight empty kg 33 51

Input voltage 230V/50-60Hz

Power input VA <100

Pump inlet G 1/2

Water discharge inches 1

Dimensions mm 470 x 410 x 1155 900 x 410 x 1450

Emulsion Splitting Systems

Technical Specification

condensate management - final 16/11/99 4:57 pm Page 8

The Global Player

Complete capability – compressed air to suit all applications

Where our customers areconcerned quality is notjust a word but reality.

From the early planningstage to start-up andafter-sales service, we

can provide the answerswhere compressed air isconcerned – worldwide

Lubricated Compressors

(0.1 to 43 m3/min, 0.75 to 250 kW)

● Single StageScrew Compressors

● Speed RegulatedScrew Compressors

● Piston Compressors

Oil Free Compressors

(0.1 to 43 m3/min,0.75 to 250 kW)

● Two StageScrew Compressors

● Piston Compressors

● Water SealedScrew Compressors

Complete AccessoriesProgramme

● Filters and Dryers

● Cooling Systems

● Heat Recovery

● Condensate Management

● Air Receivers

● Multi Set Controllers

● Compressor Lubricants

Complete Servicefor Compressed AirTechnology

● Engineering of CompleteCompressor Stations

● Computer AssistedDemand Analysis

● Local Service Centres

● Guaranteed PartsAvailability

www.compair.com

CompAir policy is one of continuous improvement and we therefore reserve the right to alter specifications and prices without prior notice. All products are sold subject to the Company's conditions of sale.

Brochure re-order ref: 98700-348E Print ref: AGB/AGB/9.99 Printed in England

An Invensys company

®

condensate management - final 16/11/99 4:50 pm Page 1