Condensate Management Condensate Drains Oil Water Separators

Transcription

1 Condensate Management Condensate Drains Oil Water Separators Section 30 Bulletin A-16

2 Condensation is an unavoidable, expensive and ugly byproduct of a compressed air system. It is a mixture of contaminated water, oil, and dirt. It is considered hazardous waste and should be treated and disposed of as such. If allowed to collect anywhere in the distribution system, especially an air receiver, moisture separator or filter bowl, it will overflow into the compressed air system causing damage to equipment and processes. Pneumatech Automatic Condensate Drains provide an affordable way to ensure the positive expulsion of condensate from all collection points. Most air compressors come with a standard, built in aftercooler where more than two thirds of the total condensate is processed and then collected in the moisture separator. Ironically, most factory OEM moisture separators are equipped with the cheapest, most unreliable float drains that money can buy. It is a matter of time before the drain fails, and all of the downstream dryers and filters become overloaded allowing dirty water and oil to overflow into the air distribution system. When the air receiver fills with condensate, storage is significantly reduced causing the compressor to short cycle, increasing maintenance and energy costs. If you have an moisture separator, an immediate change to a Pneumatech drain will save thousands of dollars and render your whole system more efficient. OIL WATER SEPARATORS Going Green means more than just saving energy; it means environmental responsibility. It means providing safe working conditions, respect for future generations ns and being a good corporate citizen. Dumping condensate down the sewer, on the ground or into a lake, river or stream violates several environmental regulations and will eventually result in signifi cant fi nes and penalties. Section 309 of the Federal Water Pollution Control Act provides for penalties and fines up to $25, per day to be assed against a company, and/or company employee responsible for improper condensate disposal. Pneumatech Oil Water Separators protect against costly fi nes and penalties while helping to protect our waterways and wildlife for future generations FEATURES Removes all compressor lubricants Light weight, easy to drain Easy change disposable fi lter elements Convenient replacement fi lter kit with watertight disposal container Simple set up Maintenance Indicator Robust - indifferent to shock and vibrations Pneumatech Oil Water Separators use a patented multi stage fi ltration process that separates contaminants from condensate. The contaminates are trapped in the 1st stage fi lter and polished in the 2nd stage tower leaving only clean water to be drained. Containers for neat and easy disposal of spent fi lters are provided. OWS-200 OWS-750

3 OWS OPERATION SPECIFICATIONS Complete Installation - Includes Dryer, Filters & Air Receiver* Model Cold Climate Mild Climate Hot Climate OWS OWS OWS OWS OWS OWS OWS OWS Untreated condensate enters through the muffl ers into the integral expansion chamber where line pressure is released 2. 2 The depressurized condensate then fl ows into the 1st stage prefi lter where bulk contaminates and oil are trapped in the oliophilic fi lter material 3. 3 The prefi ltered condensate is then directed into the polishing fi lter in the second tower where the remaining contaminates are removed 4. 4 Clean water exits the disposable fi lter through the outlet port and is discharged from the OWS purifi er MAINTENANCE KITS Facilitate Easy Filter Changing Pneumatech Condensate purifi ers employ lightweight, disposable, fi lters. The maintenance kits include: 4 Replacement Filters Water tight buckets for spent elements One year supply of replacement muffl ers and vapor diffusion fi lters Gloves and overall to protect maintenance personnel Complete Installation - Includes Filters & Air Receiver (No Dryer)* Model Cold Climate Mild Climate Hot Climate OWS OWS OWS OWS OWS OWS OWS OWS *Notes: 1. All capacities are based on outlet oil content of 15 ppm. 2. Climate conditions used in the table above are defi ned as follows: Cold conditions ambient temperature 59 F relative humidity 60% Mild conditions ambeint temperature 77 F relative humidity 60% Hot conditions ambient temperature 95 F relative humidity 70% 3. OWS-750 and larger are 3 tower units. 4. For poly-glycol based condensates, the capacity of each unit should be halved. Model Dimensions L W H Weight (lbs) Connections Inlet Outlet OWS /2 (1) 1/2 OWS /2 (2) 1/2 OWS /2 (2) 3/4 OWS /4 (2) 3/4 OWS /4 (2) 3/4 OWS /4 (2) 3/4 OWS /4 (2) 3/4 OWS (2) 3/4 Running Hours Hours run per day Correction factor Multiply the OWS capacity by the appropriate correction factor to adjust for different running hours. Separation performance: For an outlet oil carryover over 10 ppm instead of 15 ppm, multiply the unit capacity by 2/3.

4 NO AIR LOSS DRAINS BENEFITS True "No Air" Loss Design Maximum energy savings Highest Reliability Unaffected by dirt and debris Lowest Maintenance Reduced time and labor costs Fully Automatic Monitors level and function Integrated Alarm With remote detection Sensor Controlled Safe for all condensate types, unparalleled performance Why a No Loss Drain is Needed Air Loss at 100psi Leak Size CFM Passed HP Used Annual Cost ($0.10 per kwh) 1/32" /2 $336 1/16" $1,347 3/32" $2,695 1/8" 26 8 $5,390 1/4" $17,518 HOW IT WORKS - PNL SERIES Empty State Filled State 6 1. Condensate enters side inlet port. 2. Condensate level begins to rise. 33. Condensate level activates sensor. 44. Sensor signals control board. Control board activates solenoid valve. Solenoid valve stops pilot air fl ow to diaphragm. Condensate pushes diaphragm open. 51. Open diaphragm provides condensate discharge path. Condensate discharge begins. Reservoir level begins to fall. Reservoir level drops below sensor. Sensor deactivates solenoid valve. Pilot air closes diaphragm before level drops below discharge port. 61. Condensate discharge completed. Reservoir begins to fi ll and cycle repeats.

5 AUTOMATIC & TIMER DRAINS BENEFITS 4488 series True No Air loss, Demand Operation Saves Energy. Pneumatic 4488R Pneumatic Operation No Power required, low Profi le Electronic Float, Electronic Timer Precise selection, enhanced performance. BENEFITS 4477/4466 series Simple, Reliable, Affordable Adjustable 1-60 min cycle time Adjustable 1-30 min open time Optimum 7/16 oriface Large Capacity Ideal for Air Receivers and Large Compressors. Stainless Steel Float & Teflon Coated Stem Provide long life and ensure positive operation. Flashing Alarm light Alerts operator of high level. Dry contacts For remote monitoring. SYSTEM DRAIN POINTS Mist Eliminator Dry Receiver Rotary Screw Air Compressor Aftercooler Refrigerated Dryer Intermediate Control Cleaned Condensate Oily Condensate Oil/Water Separator

6 DRAIN FEATURES & SPECIFICATIONS NO AIR LOSS DRAINS Regular and aggressive condensate Alarm function Potential-free contact for alarm Contact for external test Self cleaning function 110 Vac Standard; 24 Vac/dc, 48 Vac, 100 Vac, 110 Vac, 200 Vac, 230 Vac also available No Air Loss Drains PNL Series PNL-200 PNL-450 PNL-1000 PNL-3600 Flow Rate (SCFM) (compressor/dryer/fi lter) 100/200/1, /450/2, /1,000/ 5,000 1,800/3,600/ 18,000 Min. Working Pressure (PSIG) Max. Working Pressure (PSIG) Min - Max Temperature 34 F F 34 F F 34 F F 34 F F Inlet Connection 1 x 1/2" 1 x 1/2" 3 x 1/2" 2 x 1/2" Outlet Connection 1 x 1/4" 1 x 1/4" 1 x 1/2" 1 x 1/2" Outlet (hose di) 3/8" 3/8" 1/2" 1/2" Dimensions W x H (in.) 6.5 x x x x 6.4 Approx. Weight (lbs.) PNL-10K PNL-100K PNL-600 HP PNL-3600 HP Flow Rate (SCFM) (compressor/dryer/fi lter) 5,400/10,800/ 54,000 50,000/100,000/ 500, /600/ 3,000 1,800/3,600/ Min. Working Pressure (PSIG) Max. Working Pressure (PSIG) Min - Max Temperature 34 F F 34 F F 34 F F 34 F F Inlet Connection 3 x 3/4" 2 x 3/4" & 1 x 1" 1 x 1/2" 2 x 1/2" Outlet Connection 1 x 1/2" 1 x 1/2" 1 x 3/8" 1 x 3/8" Outlet (hose di) 1/2" 1/2" 1/2" 1/2" Dimensions W x H (in.) 9.9 x x x x 6.4 Approx. Weight (lbs.)

7 AUTOMATIC & TIMER DRAINS Auto drain without any air loss Electronic solid state control Operates on demand only Stainless float and Teflon coated stem See through resevoir Malfunction indicator flashing light Dry contacts for remote monitoring Self contained and compact design Solid state timer 1 to 60 minute cycle time 1 to 30 second drain time Brass valve body Stainless steel internals 7/16 orifice size Air-Free Automatic Drains 4488 Series 4488-C 4488-AM AM R 4488-RSN 4488-ADMS Operation Float; electronic Float; electronic Float; electronic Float; pneumatic Timer; electronic Reservoir Capacity (oz./cycle) Valve Type Solenoid Solenoid Solenoid Full-ported ball Ball Max. Pressure (PSIG) Fluid Temp. Min - Max 35 F F 35 F F 35 F F 35 F F 35 F F Inlet Connection 1/2" NPT 1/2" NPT (2) 3/4" & 1/2" NPT 3/4" NPT 1/2" NPT Outlet Connection 1/2" NPT 1/4" NPT 1/4" NPT 1/2" NPT 1/2" NPT Electrical 115V-1PH-60HZ 115V-1PH-60HZ 115V-1PH-60HZ 115V-1PH-60HZ Dimensions W x D x H (in.) 5.5 x 8 x x 5.5 x x 8 x x 9 x x 10.5 x Approx. Weight (lbs.) Timer-Operated Drains 4477 Series & 4466 Series 4477-AS 4477-BS 4477-CS 4466 Operation Timer; electronic Timer; electronic Timer; electronic Timer; electronic Reservoir Capacity (oz./cycle) Valve Type Solenoid Solenoid Solenoid Ball Max. Pressure (PSIG) Fluid Temp. Min - Max 35 F F 35 F F 35 F F 35 F F Inlet Connection 1/4" NPT 3/8" NPT 1/2" NPT 3/4" NPT Outlet Connection 1/4" NPT 3/8" NPT 1/2" NPT 3/4" NPT Electrical 115V-1PH-60HZ 115V-1PH-60HZ 115V-1PH-60HZ 115V-1PH-60HZ Dimensions (in.) 1.25 x 6.5 x x 6.5 x x 6.5 x x 8 x 7.5 Approx. Weight (lbs.)

8 Pneumatech th Avenue Kenosha, Wisconsin U.S.A (262) Fax: (262) Distributed by: Pneumatech reserves the right to change or revise specifications and product design in connection with any features of our products. Such changes do not entitle the buyer to corresponding changes, improvements, additions or replacements for equipment previously sold or shipped. Use of this Motor Challenge logo does not imply DOE endorsement. 1106