COMPRESSED AIR AND GAS FILTERS ISO 9001 CERTIFIED

Transcription

1 COMPRESSED AIR AND GAS FILTERS ISO 00 CERTIFIED

2 COMPRESSED AIR AND GAS SYSTEM CONTAMINANTS HOW CONTAMINANTS GET INTO SYSTEMS Air entering a compressor carries a variety of contaminants including water, oil and solid particulate. Lubricated compressors add oil aerosols and vapors and all compressors add solid particulates (wear particles from the compressor itself). Water and hydrocarbon vapors condense into aerosols and liquids when compressed and cooled downstream. The air flow also causes erosion of piping, fittings and inline equipment which will add to the solid particulate contamination. HOW CONTAMINANTS DAMAGE SYSTEMS Water Air systems contain water contaminants in liquid, aerosol and vapor form. These contaminants contribute to corrosion of steel pipes and pressure vessels. In liquid and aerosol form water causes erosion of pipes, fittings and in-line equipment. Both corrosion and erosion produce particulate contaminants, such as pipe scale and wear particles. Oil Oil contaminants can exist in liquid, aerosol and vapor form causing damage similar to the damage caused by water. Oil can also break down under heat and pressure producing acids, varnishes and other corrosive or sticky contaminants. The acids will corrode air system components such as instrumentation, valves and air tools. The varnishes coat surfaces causing a variety of problems: valves stick; air tools and air operated devices operate sluggishly or not at all; they reduce desiccant capacity until minimum performance requirements are not met; they contaminate products and processes; and they contaminate air for breathing applications. Solid Particulate Solid particulate contaminants also cause damage to an air system, such as: eroding internal parts of air tools, motors and other air operated devices; preventing valves from seating properly, thereby causing leakage; contaminating products and processes; plugging orifices or small tubing in instrumentation; and they combine with liquid, oil and water to form a thick sludge that plugs even large orifices and small piping. HOW TO REMOVE CONTAMINANTS The removal of a solid or liquid contaminant from the air stream occurs via one of four filtration mechanisms: diffusion, direct interception, inertial impaction and gravitational settling. See Figure. Diffusion is most effective when particles are less than 0.µm* in diameter. They exhibit a random movement called Brownian motion which is independent of the air flow. This random movement causes the particles to contact and collect on the media fiber s surface. *µm = micron = inches. Page Figure : Filtration Mechanisms Direct Interception captures particles in the 0. to.0µm range. The particle is collected when it passes within / its diameter of a fiber s surface. The interception effectiveness of a filter media is primarily a function of pore structure. The smaller the pores, the greater the effectiveness of the media to intercept particles. Inertial Impaction collects particles.0µm and larger in diameter. Due to their relatively large mass and inertia, these particles tend to remain on their original course thereby contacting and being captured on the fiber s surface. Gravitational Settling is most effective with particles larger than 0µm and low air velocities. Solid particles are captured and retained in the filter media. Liquid aerosols are captured by the media and removed from the air stream via the process of coalescing. Coalescing, by definition, means "to grow or come together into one." It is a continuous process by which small aerosols come in contact with the fibers in the filter media and begin to collect. The collected aerosols travel along the fibers and combine to form liquids. This process continues until the liquids emerge on the downstream surface of the media as droplets. See Figure. These droplets are gravitationally drained to and removed from the sump in the bottom of the coalescing filter housing. Figure : The Coalescing Process

3 GENERAL AIR FILTERS FILTER MEDIA General Air s Filter Media is a precision matrix of synthetic microfibers designed for maximium efficiency and dirt holding capacity while minimizing pressure drop. Medias utilize all four of the filtration mechanisms discussed earlier. See Figure. In manufacturing the General Air filter media, the proper ratio of various fiber diameters are combined to produce the desired pore size, media thickness and void volume. The media is designed and manufactured to provide a gradient density matrix of microfibers with a tapered pore structure. The result is a pore structure that starts coarser and gets finer making it possible for true depth loading of contaminants into the media. This produces higher dirt holding capacities. The microfiber matrix is secured into a fixed-pore configuration by the introduction of a binder which adheres adjoining fibers together within the media. This fixed-pore configuration gives the media structural stability and ensures that captured solid particulates are not released back into the air/gas stream because of high differential pressure, flow surges, vibration or pressure surges. This is a common occurrence with unbonded or loosely bonded media. General Air media is made from high-quality Borosilicate glass microfibers. The smaller cartridges (all inline housings) are formed into a seamless tubular configuration by a proprietary process. The larger cartridges (X00 housing and above) have cellulose added to the mix to provide increased structural integrity. This allows the media to be pleated, which increases the surface area resulting in a considerably extended cartridge useful life. All General Air medias are highly porous with 0% to % void volume available to hold contaminants. Precisely controlled manufacturing conditions and media formulations ensure reliable performance and exceptional quality in all General Air media. Figure : Scanning electron micrograph of General Air Microfiber Filter Media (00x magnification) The pore size and structure of a media and, therefore, the efficiency of that media is a function of the relative surface area (fiber surface area per unit volume). Relative surface area is a function of the median fiber diameter and fiber packing density. Therefore, combining a larger relative surface area with a smaller pore size produces a higher efficiency. See Figure. STANDARD CARTRIDGE RATINGS & APPLICATIONS FILTER Ratings:.+% Overall oil removal efficiency (including synthetic lubricants)..% DOP efficiency. 0. µm Absolute particulate and aerosol removal. Applications: Prefilter with a regenerative dryer. Prefilter for air tools, valves and other air-operated devices. Prefilter for sophisticated instrumentation, analyzers, etc. Afterfilter with a refrigerated dryer. Rating: FILTER (Activated Carbon Filter) Oil & hydrocarbon vapors down to 0.00 ppm. Applications: Final filter to remove hydrocarbon vapors. Final filter to remove offensive odors. Figure : Variation in permeability and dirt capacity as a function of fiber diameter. FILTER Rating: 0.µm Absolute. Applications: Afterfilter with a regenerative dryer. Prefilter with a refrigerated dryer. Prefilter to a coalescing filter with heavy liquid, aerosol or particulate loadings. Page

4 FEATURE/BENEFIT ANALYSIS GENERAL AIR FILTER SELECTION General Air filters are designed and built for optimum performance incorporating the following features and benefits: Reliable Design Ensures Peace Of Mind. Large relative surface area. Small pore size captures smaller particles. Media s fixed pore configuration maintains its rating even under adverse conditions. Resin binder prevents contamination by the media itself, known as media migration. A non-wicking drain layer on coalescing elements prevents re-entrainment of liquids. Permanent urethane end caps prevent leakage around the element. Fewer Changeouts Give Cost Savings. Highly porous media with 0% - % void volume. Tapered pore structure allows true depth loading capturing times more particulates than surface type filters. Pleated media in all General Air filters increases surface area by - times (X00 Model and above). Coalescing elements have built-in pleated prefilters to remove particulate that would shorten the element's life (X00 Model and above). Low Pressure Drop (Wet or Dry) Results In Lower Compressor Operating Cost. Small median fiber diameter. 0% - % void volume. Quality Construction Gives Reliable Performance Even Under Adverse Operating Conditions. Media s fixed pore configuration ensures that captured solid particulates are retained even with flow or pressure surges, vibration or high differential pressure. Thru-bolt construction ensures cartridge integrity. Many filters rely on sealants and adhesives which can fail when exposed to shock, vibration or pressure surges. Cartridges are constructed with support structures that can handle a psid reverse flow through the cartridge. This reverse flow occurs when there is a sudden loss of pressure upstream. Selecting the proper filter for a specific application is a simple process detailed in Steps through below. Caution: Do not select a filter based on installation pipe size and/or filter connection size. Step - Select the type of General Air filter required for the application (coalescer, odorgard or particulate and standard or inline). Step - Determine the flow (scfm) and pressure (psig) at the point in the system where the filter is to be installed. Step - Find the flow rate chart for the filter type selected. Locate the column for the system pressure. Read down that column until the volume equals or exceeds the system needs. Follow that row all the way to the left to determine the model number of the filter required for the application. Step - Technical data for filters is supplied on dimensional charts. Locate the General Air model number and read the information in that row. Step - Select any accessories that are needed to complete the system. Step - All coalescing filters must have drain valves. Most installations should have automatic drain valves. They can be float type, motor operated ball valve with electronic timer or solid state timer solenoid type. All filter installations benefit from a pressure differential indicator. This indicates the optimum time to replace filter elements. Review the system for delicate downline instrumentation or equipment that would benefit from point-of-use filters. This extra protection could prevent damage to an expensive piece of equipment. Work Under A Wide Range Of Operating Conditions. Elements are compatible with most air/gas streams and contaminants. Elements for high temperature or corrosive applications are available on special order. Elements and housings for custom filtration applications are available on special order. Page

5 RECOMMENDED FLOW RATES (SCFM) FOR FILTERS BASED ON PRESSURE Standard Coalescing and Odorgard : Coalescing Odorgard OPERATING PRESSURES (PSIG) C O 0 0 C O C O C 0 O C 0 O 0 CX 00 OX CX 0 OX CX 00 OX CX 00 OX CX 00 OX CX 00 OX CX 00 OX CX 00 OX CX 00 OX CX 000 OX CX 000 OX CX 000 OX Standard Particulate : Particulate OPERATING PRESSURES (PSIG) P P 0 P 0 00 P 0 00 P PX PX PX PX PX PX PX PX PX PX PX PX Inline Coalescing, Odorgard and Particulate : Coalescing Odorgard Particulate OPERATING PRESSURES (PSIG) C O P C 0 O 0 P C O P C O P C 0 O 0 P C 0 O 0 P C 00 O 00 P C 00 O 00 P C 0 O 0 P C O P Page

6 E A MIN. CLEAR C B PORT F ( P PORT) F (VENT PORT) G H D DIA. F ( P PORT) F (DRAIN PORT) MODELS X00 X00 A PORT F (DRAIN PORT) MODELS X00 X000 B MODEL 0 0 X00 X0 X00 MODEL X00 X00 X00 X00 X00 X00 X000 X000 X000 SIZE/TYPE SIZE/TYPE " FLG. " FLG. " FLG. " FLG. " FLG. 0" FLG. " FLG. " FLG. " FLG. STANDARD HOUSING DATA STANDARD ASSEMBLY DATA DIMENSIONS (IN.) A B C D E F 0 PRESS. (PSIG) TEMP. (F) WEIGHT (LBS.) 0 DIMENSIONS (IN.) A B C D E F WEIGHT (LBS.) OF ELEMENTS OF ELEMENTS ELEMENT TYPE PART MAX. SCFM 00 PSIG ,000 0,00,,00 ELEMENT TYPE PART MAX. SCFM,00,0,00,000,00,000,0,00,0,00,0,00,000,00,000,00,0,00,00,0,00,00,0,00,00 0,0,00 DESCRIPTION OF DESCRIPTION OF INITIAL PSID STANDARD ASME HOUSING DATA STANDARD ASME ASSEMBLY DATA G H 0 COMMENT: Models X00 - X000 above are rated for 0 psig max. pressure and F max. temperature PSIG HEAD MATERIALS INITIAL PSID SHELL & NOZZLES HEAD MATERIALS ZINC ZINC ZINC ALUMINUM ALUMINUM BOWL ALUMINUM HOUSING PART HOUSING PART ,,,, Page

7 NOTES: MODEL SIZE/TYPE " " FLG. " FLG. " FLG. " FLG. " FLG. " FLG. " FLG. 0" FLG. 0" FLG. 0 DIMENSIONS (IN.) A B C D E F ASME HOUSING DATA ASME ASSEMBLY DATA PRESS. (PSIG) TEMP. (F) 00 WEIGHT (LBS.) OF ELEMENTS ELEMENT TYPE PART MAX. SCFM PSIG 0,,,0,0,0,00,0, MATERIALS DESCRIPTION OF INITIAL PSID SHELL & NOZZLES HEADS HOUSING PART Filter Model Numbers X00 thru X000 are ASME stamped (rated as applicable) for 0 psig maximum pressure and O F maximum temperature. Description of connections for filter types is as follows: Coalescing = Flow from inside to outside of cartridge ("A" port to "B" port) Particulate = Flow from outside to inside of cartridge ("B" port to "A" port) Odorgard = Flow from outside to inside of cartridge ("B" port to " A" port) Connections on Filter Model Numbers. thru should be made only as indicated on housing, i.e. "IN" to "OUT" regardless of element type.. Initial psid at maximum conditions for elements is. psid clean/dry,. psid wet. Page

8 Manufacturers of quality products since PSB INDUSTRIES INC. General Air Division 0 West th Street Erie, PA 0 USA Phone: -- Toll Free: 00-- Fax: -- psb@genair.net Printed in U.S.A. Form No. 0-SBG, PDF-/0 Your Contact Is: