Series 304
WATER AND OIL IN COMPRESSED AIR SYSTEM WATER ACCUMULATION When compressing air, a compressor draws in many other substances including water vapor. The compression process causes this water vapor to condense and accumulate in receivers, tanks and compressed air systems. The most obvious place for this condensate to accumulate is in the compressor tank. In addition to damaging the tank, this condensate will also be entrained in the air flow and be drawn into the compressed air network. Removing this condensate from the compressed air system is vitally important, as even small quantities can have a significantly detrimental effect on downstream equipment. S COMPRESSOR OILS In compressors with lubricated compression chambers, the compressed air unavoidably picks up some oil. The most common examples of these types of compressors are oil-flooded rotary screw machines, lubricated reciprocating, and rotary vane compressors. In most cases, manufacturers of these types of compressors report oil carryover in ppm or parts per million by weight. Fact is a reciprocating compressor does have a higher ppm (parts per million) level of oil carryover then a rotary screw, average ppm of a reciprocating compressor 7-10 ppm and it gets worse as it ages and on the rotary screw 3-5 ppm with oil separation that if maintained regularly will keep it in it s range. In the compressor air business, most people have a difficult time relating to 2 ppm. In the real world, many lubricated compressors run at considerably higher oil carryover levels. In For all these reasons, condensate removal is crucial to any compressed air system. fact, many installations frequently run over 25 ppm. At a concentration of 25 ppm, a typical compressor flowing 100 scfm for 35 hours will introduce 240 ml of oil into the pneumatic system. This oil gets into the flow of air and can mix with water vapor, liquid water and other contaminants to form a thick, viscous substance even more damaging to downstream components. Condensate removal using automatic drains is simple and efficient, but for the disposal of contaminant, a water/oil separator is essential to comply with municipal regulations. DISCHARGING oil contaminated condensate is not only harmful to environment, it is illegal! Quebec Environment Quality Act 20. No one may emit, deposit, issue or discharge or allow the emission, deposit, issuance or discharge into the environment of a contaminant in a greater quantity or concentration than that provided for by regulation of the Government. The same prohibition applies to the emission, deposit, issuance or discharge of any contaminant the presence of which in the environment is prohibited by regulation of the Government or is likely to affect the life, health, safety, welfare or comfort of human beings, or to cause damage to or otherwise impair the quality of the soil, vegetation, wildlife or property. E.Q.A., Chapter 2, a. 20 Source: http://www2.publicationsduquebec.gouv.qc.ca/ dynamicsearch/telecharge.php?type=2&file=/q_2/q2_a.html ENVIRONMENTAL REGULATIONS To meet with environmental regulations for condensate treatment in your location, please refer to your environmental provincial law on the discharge of any contaminant into the natural environment. WARNING A 50 HP compressor will pass about 120 ml of oil in 24 hrs at 10 ppm LITERS OF WATER AFTER 8 HOURS FOR A 25HP COMPRESSOR (100 ) Ambient Air % Humidity Temperature C 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 % 49 84.5 126.8 169.1 211.4 253.7 296.0 338.0 380.0 422.8 43 64.1 95.5 126.8 159.6 190.1 222.3 253.7 286.4 317.8 38 47.7 70.9 94.1 118.7 141.8 166.4 189.6 212.8 237.3 32 35.6 51.8 69.6 87.3 105.0 121.4 139.1 156.8 174.6 27 25.9 38.2 50.5 62.7 76.4 88.6 101.0 113.2 126.8 21 17.7 27.3 35.5 45.0 54.5 61.4 72.3 81.8 90.0 16 12.3 19.1 25.9 32.4 38.2 45.0 50.5.3 64.1 10 9.5 13.6 17.7 21.8 27.3 31.4 35.5 39.6 45.0 4 5.5 9.5 12.3 15.6 17.7 21.8 24.5 27.3 30.0-1 4.1 5.5 8.2 9.5 12.3 13.6 16.4 17.7 20.5-7 2.7 4.1 5.5 6.8 7.7 8.6 9.5 10.9 12.3-12 1.4 2.3 3.2 3.6 4.5 5.5 6.4 6.8 8.2 305
S DISPOSAL OF CONTAMINATED CONDENSATE A typical compressed air system will produce thousands of litres of oily, contaminated condensate every year. For example, a 100 compressor/ refrigeration dryer package, operating in a 25 C, 65% relative humidity for 4 000 hours can produce up to 10 000 litres of condensate. Oil can seriously affect the efficient operation of sewage purification. For this reason, very little oil is permitted in water discharge and rigid legislation exists in most municipalities to protect the environment against this type of contamination. International standards offers a line of water/oil separators that works anywhere, anytime, on virtually any condensate, and with any type of condensate drain. water/oil separators are a simple, economical and environmental solution. These oil/ water separator are installed as part of the compressed air system and reduce the oil concentration in the collected condensate with a larger volume of clean water, up to 99.9% with a relatively small amount of concentrated oil that can be discharged legitimately and economically. Using a specially treated, adsorbent, polypropylene media, water/oil separators efficiently and effectively separate all compressor lubricants without the need for condensate storage tanks, settling chambers, or costly disposal. oil/water separators are the most cost effective and reliable solution to meet environmental regulations for condensate treatment, and ensure your compliance with ISO 14001. Specialized polypropylene media Cost effective, reliable performance such as ISO 14001 also require the compressed air user to comply with local environmental legislation and show use of protective systems and procedures. Traditional solutions for condensate disposal have been to: Collect the condensate and have it trucked away periodically by a waste disposal company. This not only requires storage of the hazardous condensate on site, posing a health and safety risk, it is very costly as disposal charges can be up to several dollars per liter. EFFICIENT ON-SITE DISPOSAL OF CONDENSATE No need for a settling chamber Works with any condensate drain DISPOSAL OF COMPRESSED AIR CONDENSATE COMPRESSOR RECEIVER TANK REFRIGERATED DRYER 10 mg/l = 10 ppm/volume CONDENSATE DRAIN LINE AUTO DRAIN Less than 10 mg/l of oil residue values at the output stage! Use a settling tank to separate the oil and water by gravity, then using carbon to filter the remaining water. Advances in compressor lubricants have made this technology obsolete. Modern compressor lubricants have a specific gravity similar to water, and because of this, they form an emulsified water/oil mixture that cannot be separated by gravity. Activated carbon polishing filter Works on virtually any condensate WATER/OIL SEPARATOR 306
DISPOSABLE WATER/OIL SEPARATOR Simple and cost effective way to meet environmental regulations for condensate disposal. With an advanced polypropylene adsorbent media, it can separate virtually any condensate containing any compressor lubricant discharged from any type of condensate drain, and it does so without the need for a condensate settling tank or storage chamber. The unit is simply mounted to the wall and connected with the inlet and outlet for clean condensate. When the unit is full of oil it must simply be replaced. 70 S Foam depressurization layer separates condensate and compressed air UP TO FEATURES AND BENEFITS Polypropylene media adsorbs compressor oil Carbon polishing media filters out any remaining hydrocarbons Simple replaceable design: the unit must be removed and replaced when it is full of oil Lightweight, yet strong and durable rugged ABS housing No settling chamber: perfect for portable applications Brass inlet and outlet adapter for secure tubing connections Wall mounting kit optional for easy installation with no floor space required Quick and easy to service Fixing brackets included Brass inlet/outlet connection Test kit included 25.5 cm APPLICATIONS Perfect for installations with : Low compressed air flows (up to 70 ) Low condensate flows Portable applications or floor space restrictions Any type of compressor oil Emulsified mixtures Any type of condensate drain EPA discharge regulations MATERIALS ABS Rule of thumb: 1 HP = 4 25 cm 21 cm Mineral and synthetic lubricants applications Polyglycol applications Max flow capacity Max oil adsorption litres I.D. Inlet/Outlet Weight.300.320 70 1.9 1/2 3.6 23 cm The oil adsorbing elements combine various types of adsorption technologies to achieve less than 10 mg/l of oil residue values at the output stage. 307
S WATER/OIL SEPARATOR With an advanced polypropylene adsorbent media and a carbon polisher, it can separate virtually any condensate containing any compressor lubricant discharged from any type of condensate drain, and it does so without the need for a condensate settling chamber or storage tank. A cost effective and reliable solution to meet environmental regulations for condensate disposal. 125 UP TO FEATURES AND BENEFITS No settling chamber or storage tank required: eliminates health and safety concerns Can separate any type of lubricant including modern synthetic lubricants or even emulsified mixtures Can be used with any type of drain including all condensate drains Brass threaded inserts and adapters for secure threaded or tubing connections Foam mesh depressurization chamber with foam exhaust filter slows incoming condensate and cleanly discharges compressed air Three stage of treatment combining two polypropylene elements and carbon polisher for optimum performance Multiple lightweight media bag complying with OSHA lifting requirements Strong and corrosion proof construction and rugged polyethylene housing Wall mounting kit optional for easy to instalation with no floor space required Depressurization chamber Test port & kit included Complete unit APPLICATIONS Perfect for installations with: Portable applications for floor space restrictions Any type of compressor oil Emulsified mixtures Any type of condensate drain EPA discharge regulations Operating cost concerns MATERIALS Polyethylene ELEMENT SERVICE KIT Product No Service kit for.400 Separator.302.410 Separator.322 When it is time to replace the elements, it is important to have in hand a service kit to replace all 3 elements. Service kit includes: 2 polypropylene elements and 1 carbon polisher. 38.5 cm 39.5 cm Mineral and synthetic lubricants applications Polyglycol applications 21 cm Maximum flow capacity The oil adsorbing elements combine various types of adsorption technologies to achieve a less than 10 mg/l of oil residue value at the output stage. Maximum oil adsorption /litre I.D. Inlet/Outlet Weight.302.322 125 3 1/2 8.2 308
HIFLO WATER/OIL SEPARATORS water/oil separators 175 through 1250 use three stages of treatment to separate difficult condensate. With two specially treated polypropylene elements and a carbon polisher, they provide reliable and cost effective condensate separation performance regardless of the type of lubricant or drains. 1250 UP TO S EACH SEPARATOR INCLUDES 4 The primary, secondary and carbon polisher media bags 4 A sample bottle and sample port for water quality testing to ensure compliance with local environmental regulations 4 A step by step instruction manual for installation and operation ELEMENT LIFE INDICATOR One unique feature of the HIFLO water/oil separators is the element life indicator. This indicator gives instant visual confirmation of the condition of the elements in the separator and when they need to be replaced. When the primary indicator element is new, it floats on top of the condensate in the first tower. As condensate enters the separator over time, the oil becomes trapped within the fibers of the polypropylene media. This additional weight will cause the element to sink. As it sinks the element life indicator begins to lower. When the element is fully saturated with oil, the indicator will be all the way down. This indicates that it is time to replace all three. Indicator is up Element is clean Indicator at half Element is half full Indicator down Replace element Rule of thumb: 1 HP = 4 The oil adsorbing elements combine various types of adsorption technologies to achieve a less than 10 mg/l of oil residue value at the output stage. 309
S HIFLO FEATURES AND BENEFITS No settling chamber or storage tank required: eliminates health and safety concerns. Performance is not affected by movement Can separate any type of lubricant including modern synthetic lubricants or even emulsified mixtures Can be used with any type of drain including all condensate drains Brass threaded inserts and adapters for secure threaded or tubing connections Foam mesh depressurization chamber with foam exhaust filter slows incoming condensate and cleanly discharges compressed air Visual element life indicator provides confident indication of element conditions Overflow warning indicator avoids spill in the event of a blockage Three stage of treatment combining two polypropylene elements and carbon polisher for optimum performance Multiple lightweight media bag: comply with OSHA lifting requirements Corrosion proof construction with strong and rugged polyethylene housing ACCESSORIES Condensate test kit Useful tool to demonstrate the oil adsorbing capabilities of the media and prove it s effectiveness on the condensate at a given application prior to installation. The test can be carried out on site, and the kit includes a detailed step-by-step instruction manual to walk through the simple test procedure. Description.420 Condensate test kit APPLICATIONS Perfect for installations with: High compressed air flows High condensate flows Any type of compressor oil Emulsified mixtures Any type of condensate drain Portable applications Floor space restrictions EPA discharge regulations Brass multiple inlet adaptor Increases inlet connections from two to four MATERIAL Polyethylene 310 Mineral and synthetic lubricants applications Polyglycol applications ELEMENT SERVICE KIT When the indicator is all the way down, it is time to replace all three elements. It is important to always have a service kit to replace all 3 elements (2x polypropylene and 1x carbon media). Max flow capacity Max oil adsorption litres Indicator down Replace element Service kit for separator.402.304.403.306.404.308.406.310.412.324.414.326.416.328.418.330 Dimensions W x H x D cm I.D. Inlet/Outlet Weight.304.324 175 4.9 1/2 10.9 58 x 61 x 19.306.326 350 9.8 1/2 17.7 65 x 75 x 24.308.328 750 15.1 1/2 32.7 78 x 90 x 30.5.310.330 1250 24.9 1/2 48.5 97 x 90 x 38 Description.422 Inlet adaptor
For more information on Water/Oil Separators, see the following brochure at.com Water/Oil Separators Series Efficient on-site disposal of compressed air condensate Discharging oil contaminated condensate is not only harmful to environment, it's illegal! offers a complete range of water/oil separators to meet environmental regulations Visit.com Section «Technical Support» / Air Treatment / Series 311