Know-how for the quality of your compressed air

Issue 1/2014 BEKOWORLD WELCOME TO BEKOWORLD INTERNATIONAL Know-how for the quality of your compressed air With up-to-date information regarding innovative solutions, application examples, product news and background information from BEKO TECHNOLOGIES concerning the subjects of compressed air technology and condensate processing, BEKOWORLD International from now on offers expert knowledge worldwide for the quality of your compressed air. Clear, practical and solution-oriented. This is how BEKO TECHNOLOGIES has informed its customers and experts with BEKOWORLD for twenty years in German speaking countries on all aspects regarding the subject of compressed air technology and condensate processing. The customer magazine, issued four times per annum, provides sound knowledge to its 25,000 readers directly at their workplace and explains how the innovative products and system solutions from BEKO TECHNOLOGIES contribute to more energy efficiency, profitability, and environmental protection. For regular communication with our customers, BEKOWORLD is a very important and successful component, says Heiko Heyn, the sales manager for Europe at BEKO TECHNOLOGIES. In Great Britain, France, and soon in the Netherlands, national issues of BEKOWORLD will also be published. In the new BEKOWORLD International, we would like to provide our specialist knowledge twice a year to all of Volker Fasbender, Sales Manager for non-european countries, and Heiko Heyn, Sales Manager for Europe, from BEKO TECHNOLOGIES. since the increasing requirements on the quality of compressed air are a worldwide trend, as is the desire for more energy efficiency, says Volker Fasbender, the sales manager for non- European countries at BEKO TECHNO- LOGIES. We offer solutions for these tasks, both on the product and system levels. Therefore, Heiko Heyn and Volker Fasbender hope that the new offer a direct benefit to their readers with profound information regarding innovative products and application possibilities. INSIDE THIS ISSUE 2 Frost protection for 6 Modular design dry sprinkler systems for EVERDRY 5 3E technology enhances adsorption dryers our customers throughout the world, BEKOWORLD International will also the performance and 6 BEKO TECHNOenergy efficiency of LOGIES continues BEKOWORLD INTERNATIONAL 1/2014 flanged filters to grow

FIRE CONTROL SOLUTION WITH DRYPOINT M PLUS Frost protection for dry sprinkler systems Compressed air condensate and frost are a dangerous mixture for dry sprinkler systems: freeze-ups and the resulting damage to ball valves and drain pipes in outdoor areas unhinge the fire control and cause costly repairs. The Sprinklerpack from BEKO TECHNOLOGIES offers effective protection. In co-operation with the experts of the plant maintenance department at Daimler AG in the Mercedes-Benz Sindelfingen factory, the system was developed and tested in practice. worst point of the system, water must exit from the sprinkler at the latest after 60 seconds. Compressed air is supplied to the dry ductwork. The operating pressure here is 2 bar and is continuously monitored. At a pressure drop of only 0.2 bar, the fire-brigade will already check the cause for this. At a pressure drop from 0.2 to 0.4 bar, the system will trigger and then: let the water flow! Compressed air condensate as a danger source However, in contrast to what the name implies, dry sprinkler systems are rarely absolutely dry. Typical sources for the introduction of water into the system are breakdown tests of the plant and not to forget condensate from the compressed air. Therefore, the VdS Schadenverhütung GmbH, as an independent institution of the Gesamtverband der Deutschen Versicherungswirtschaft e.v. (Association of German Insurers), recommends the draining of the condensate from the pipes of the dry sprinkler systems to which compressed air was supplied, at least once a year prior to the beginning of the frost period. There is no legal obligation to proceed in this manner in Ger- The application at a glance: the small-size compressor on the left-hand side with the Sprinklerpack mounted on the wall behind, on the right-hand side the dry-valve station of the sprinkler system. Dry sprinkler systems are an important pillar in industrial fire control. The Benz factory in Sindelfingen, Germany burst. The example of the Mercedesprinciple is simple: no water is in the shows how widespread dry sprinkler line between the so-called dry-valve systems are: approximately 20 fire control stations work there according to station and the actual sprinkler head during the state of rest, but compressed air is. This makes dry sprinkler the DSS principle. systems (DSS) the ideal fire control Like all fire control devices, dry sprinkler systems are subject to precise gui- solution for all areas of application prone to frost outdoors, where the delines regarding their planning, setup, and operation. In Germany, a loading zones in front of factory buildings are typical places of application, dry-valve station, for example, must or in cold stores. Here, stagnant water have a maximum pipework volume of in the sprinkler ducts at temperatures 4 m³. With this, an area of up to 600 m² below 0 C could make the ducts can be protected. At the so-called 2 BEKOWORLD INTERNATIONAL 1/2014

many, but there are good reasons to follow this recommendation, as the hazard potential of condensate in DSS pipes is high. Less than a spoonful of condensate is enough during frost periods to make ball valves in the outdoor area burst, explains Thorsten Lenertat, the international Key Account Manager for the systems division at BEKO TECHNOLOGIES, pointing out the possible risks. The drain pipes in outdoor areas are also endangered. They are installed at the lowest point of the sprinkler line and may burst when the condensate that accumulated in them freezes. With this, safe and reliable fire control is no longer ensured. When the frozen condensate unfreezes at varying temperatures, it will flow off of the damaged pipe. Thus, the compressed air can escape to the outside. This leads to a direct pressure drop and the alarm is triggered. And there is still another problem which can result from such frost leaks: puddles form, which will freeze during the next cooling and lead to dangerous ice surfaces a menace that should not be underestimated for the stacker traffic in loading areas in front of factory buildings and for the employees. Compact solution: the Sprinklerpack from BEKO TECHNOLOGIES consists of a CLEARPOINT fine filter with an integrated BEKOMAT condensate drain (left) and a DRYPOINT M PLUS membrane dryer. a result of the required working hours, demonstrates Thorsten Lenertat. And in spite of all preventive measures, frost damage occurs again and again in practice, because, subsequent to the refilling of the lines with compressed air, the compressors also operate during the course of the year to compensate the loss in the system. The Sprinklerpack is installed downstream of the compressor. A downstream pressure reducer then adjusts the compressed air to 2 bar for the dry sprinkler system. This means that the dangerous condensate will always be replenished. Safety with the Sprinklerpack This problem is solved by the Sprinklerpack from BEKO TECHNOLOGIES, which reliably and continuously protects dry sprinkler systems against the In industrial enterprises, the removal of moisture from the lines and the prevention of these types of hazards rank amongst the tasks of the plant maintenance department. The common method is the multiple purging of the lines with compressed air. For this purpose, however, dry sprinkler systems need to be removed from service for up to two days. Depending on the plant size, 300 to 500 litres of compressed air from a small-size compressor are required to fill the network. The expenses for the maintenance and draining of a ductwork quickly reach 800 to 1,100 Euros per system as One of 20 dry-valve stations in the Sindel fingen Daimler factory. They ensure the reliable fire control in all areas prone to frost that need to be covered by the sprinklers. The valves and pipes of the drainage points of dry sprinkler systems are particularly endangered through condensate in the winter. BEKOWORLD INTERNATIONAL 1/2014 3

introduction of water from compressed air. It consists of a DRYPOINT M PLUS membrane dryer and a CLEAR- POINT filter. With this intelligent combination, the system, composed of standard components which have proved themselves time and again, ensures reliably dry sprinkler ducts. First, the CLEARPOINT fine filter purifies the compressed air for the dry sprinkler pipes by removing particles and oil droplets. In this respect, it is of no importance as to whether the compressed air comes from the small-size compressor which was especially installed for the sprinkler valve station or from the works compressed air system. Its integrated BEKOMAT condensate drain with a filter service life management, ensures the cost-effective and reliable discharge of the condensate, as well as the optimum utilization of the filter service life. Subsequently, the compressed air flows through the DRYPOINT M PLUS membrane dryer, which as a protection of the membrane against aerosols and particles contains an additional nano filter unit. DRYPOINT M PLUS compressed air membrane dryer In the DRYPOINT M PLUS compressed air membrane dryer, the air is dried according to the physical principle of the partial vapour pressure compensation of water vapour through diffusion. Two air flows with different moisture contents move in a reverse current through the membrane element, separated only by the membrane wall. The humid compressed air flows in the hollow fibre membranes, and outside the dry purge air flows, which is an atmospherically expanded partial stream of the compressed air. As it is significantly drier than the compressed air, it absorbs the humidity of the com- pressed air through the membrane wall. The compressed air, which is now dry, leaves the membrane element while the humid purge air is released to the environment. By designing the Sprinklerpack for the operating pressure of six to seven bar of the small-size compressor or of the works system, a membrane dryer with a comparatively small size can be chosen, explains Thorsten Lenertat. Only downstream of the membrane dryer, does a pressure reducer regulate the compressed air down to 2 bar for the sprinkler system. Otherwise, the membrane dryer would have to be designed disproportionately large at an operating pressure of only 2 bar. As the experience in the Sindelfingen Mercedes-Benz factory shows, the Sprinklerpack solution reliably provides its service also in the demanding practice of industrial production in the meantime, the initial installation has been in operation for two years already. A fire-control specialist company recently also confirmed the efficiency of the system solution within the scope of maintenance works. The firecontrol engineers reported that since the installation of the Sprinklerpack, consisting of a CLEARPOINT filter and a DRYPOINT M PLUS membrane dryer, humidity could no longer be ascertained in the sprinkler system. Payback period of one year According to Thorsten Lenertat, the Sprinklerpack not only scores through its operational reliability but also through its economic efficiency: The unique investment lies in the range of the annual costs for maintenance and drainage of the sprinkler ducts. In this manner, the purchase already pays off in the second year, through the saved Daimler AG factory Sindelfingen The Sindelfingen factory in the south-west of Germany is the largest production plant of Daimler AG and, at the same time, the centre of competence for the production of upper and luxury class vehicles. Here, the Mercedes-Benz C class limousine, S-, E-, CL- and CLS class, SLS AMG (Coupé and Roadster) and the Maybach are manufactured. In 2011, 484,014 vehicles left the factory. In the adjacent Mercedes-Benz Technology Center, the field of research & development of new Mercedes-Benz models is situated. On the works premises with an extension of just under 3 million m², more than 26,400 people are at work (not including R&D). maintenance costs alone. Under these premises, he is sure to be able to successfully position the Sprinklerpack also in other industrial enterprises and in the relevant fire-control specialist companies. IMPRINT BEKO TECHNOLOGIES GMBH Im Taubental 7, 41468 Neuss, Germany PO Box 100164, 41401 Neuss Phone + 49 (0) 21 31/9 88 0 http://www.beko-technologies.com E-Mail: info@beko-technologies.com Publisher: FORUM Zeitschriften und Spezialmedien GmbH Mandichostraße 18 86504 Merching, Germany Editor: Robert Altmannshofer Phone + 49 (0) 82 33/3 81 129 http://www.forum-zeitschriften.de robert.altmannshofer@forum-zeitschriften.de Photo Credits: BEKO TECHNOLOGIES, abacus - Fotolia.com, Daimler AG BEKOWORLD INTERNATIONAL 1/2014 4

NEW COMPRESSED AIR FLANGED FILTER GENERATION 3E technology enhances the performance and energy efficiency of flanged filters With the new generation of its CLEARPOINT compressed air filter series, the German compressed air product and system provider BEKO TECHNOLOGIES implements the energy-saving 3E filter concept also for flanged filters. 3E stands for Energy Efficient Element. The innovative technology leads to an optimized pressure difference through the enlarged separation surface at a simultaneously enlarged filter cavity. The users can choose whether they want to utilize the flanged filters with a volume flow of 100 per cent at the lowest pressure differences in an energy-optimized manner, or whether they employ them, performance-optimized, for volume flows which are higher by up to 11 per cent with consistently high separation rates and slightly higher pressure differences. condition, an energy optimized pressure difference of between merely 0.05 and 0.2 bar (coarse to ultrafilter) results from it. The filter material consists of a poly-fibre compound with thermally fused borosilicate and polyester fibres. Through the thermal fusing, no disturbing adhesive residues occur between the fibres. Simultaneously, intrinsic particle release, and thus the contamination of the compressed air, is reliably avoided. The oil- and waterrepellent coating of the fibres stands for excellent coalescence properties. Very low pressure differences BEKO TECHNOLOGIES implements the energy-saving 3E filter concept also for the CLEARPOINT flanged filters. With this, the new CLEARPOINT 3E flanged filters offer economic flexibility at a stable separation efficiency to an extent that, until now, was not conceivable in compressed air processing. CLEARPOINT flanged filters are designed for a volume flow from 1,420 m³/h to 31,240 m³/h (energy-optimized), or from 1,580 m³/h to 34,680 m³/h (performance-optimized). Highly efficient filter material The central point of the 3E technology is the employment of a highly efficient new filter material. In a wet-saturated Moreover, through the particularly fine fibre structure, the enlargement of the separation surface by a respectable 450 per cent could be achieved. Parallel to that, the filter cavity was enlarged to 98 per cent. Together with the considerable filter bed depth and a high absorption capacity, this leads to very low pressure differences. The new, energy-optimized 3E technology acts as coarse filter, universal filter, fine filter, ultrafilter and nano filter in the CLEARPOINT versions. 5 BEKOWORLD INTERNATIONAL 1/2014

Modular design for EVERDRY adsorption dryers The special feature of the new EVER- DRY design is the modular concept, which allows for the separation of the adsorber containers from the pipework module, and for the reconnection in just a few steps. Through this structure, even larger plants can be packed in standard sea containers. This drastically reduces the transport and packaging costs and offers optimum protection to the plant during long sea journeys. where it requires only minimum space, and where it is protected against atmospheric influences. However, the modular concept also takes into account maintenance and repair measures: all components are arranged in such a manner that they are easily accessible. This reduces the duration of the maintenance, and the costs. The EVERDRY FRL unit in modular design offers advantages in transport and packaging. Another advantage of the modular concept is, for example, when as a result of the structural conditions, it s necessary to set up the containers outdoors. The pipework module that contains many sensitive components such as measuring devices, valves, and the control, can be installed indoors, BEKO TECHNOLOGIES continues to grow The Indian subsidiary BEKO COMPRESSED AIR TECHNOLOGIES Pvt. Ltd has successfully completed the latest audit for Quality Management System according to ISO 9001:2008. The Indian subsidiary of BEKO TECHNOLOGIES at Hyderabad. The development of the Indian subsidiary BEKO COMPRESSED AIR TECHNOLOGIES Pvt. Ltd is continually progressing. In addition to some infrastructure improvements to access ways and some landscaping, the production building was renovated. Inside the building there are new arrangements for assembly and test stations for the product groups CLEARPOINT high pressure dryers and filters, BEKOMAT and DRYPOINT compressed air dryer range. There are new workplaces for assembly of water separators, which will shortly go into serial production. The new production facility is in full use for CLEARPOINT flanged filters and desiccant dryers, with a new workflow system implemented in the welding, assembly and test area. Beko India has successfully completed the latest audit for Quality Management System according to ISO 9001:2008. The certifying company DNV confirmed the result of the audit. Get in Touch with BEKO TECHNOLOGIES: Europe: Heiko Heyn Head of Sales Europe +49 (0)2131/988 1000 heiko.heyn@beko.de beko@beko.de All other countries: Volker Fasbender Head of Sales Non-European Countries +49 (0)2131/988 1000 volker.fasbender@beko.de beko@beko.de BEKOWORLD INTERNATIONAL 1/2014 6