When any product / system is designed drawings are made to assist in the production of the designed product. For example if a mechanical part is being machined you may see symbols like these to verify the part is made correctly:
Same with an electrical panel, they use symbols like the ones below to note the type of equipment used in a location.
Then there’s the Piping & Instrumentation Diagram (P&ID)…it depicts an overall view of a system, showing the flow (usually fluid or electricity) through that system’s components, giving the viewer an understanding of the operation, and expected results from said operation.
Some examples of symbols you might find in a compressed air system are:
Air preparation & handling:
Instrumentation and control:
Occasionally, we’re asked if there are standard ANSI or ISO symbols for any of our engineered Intelligent Compressed Air Products…and there aren’t. Perhaps one day they might make the cut, but for now, their standard convention is to choose a shape and call it out by name. It might look something like this:
If you have questions about any of the quiet EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
If you operate an air compressor, you’re drawing water vapor into your compressed air system. Factors like climate control (or lack thereof,) and humidity will dictate how much. If (or more to the point, when) it condenses, it becomes an issue that must be addressed. There are several types of dryer systems to choose from, usually when you buy your compressor…we’ve covered those in a number of blogs. Some of these can leave a little more water vapor than others, but remain popular and effective, when considering the cost, and cost of operation, of the different types.
So, how do you handle the condensate that the dryer doesn’t remove?
Receivers, or storage tanks (like EXAIR Model 9500-60, shown to the right,) are commonly used for several reasons:
By providing an intermediate storage of compressed air close to the point of use, fluctuations across the system won’t adversely affect an application that needs a constant flow and pressure.
This also can keep the air compressor from cycling rapidly, which leads to wear & tear, and additional maintenance headaches.
When fitted with a condensate drain (more on those in a minute,) they can serve as a wet receiver. Condensate collects in the bottom and is manually, or automatically emptied.
Condensate drains, while popularly installed on receivers, are oftentimes found throughout larger systems where the vapor is prone to condense (intercoolers, aftercoolers, filters and dryers) and where the condensation can be particularly problematic (drip legs or adjacent to points of use.) There are a couple of options to choose from, each with their own pros & cons:
Manual drains are self explanatory: they’re ball valves; cycled periodically by operators. Pros: cheap & simple. Cons: easy to blow down too often or for too long, which wastes compressed air. It’s also just as easy to blow down not often enough, or not long enough, which doesn’t solve the condensate problem.
Timer drains are self explanatory too: they cycle when the timer tells them to. Pros: still fairly cheap, and no attention is required. Cons: they’re going to open periodically (per the timer setting) whether there’s condensate or not.
Demand, or “zero loss” drains collect condensate until their reservoir is full, then they discharge the water. Pros: “zero loss” means just that…they only actuate when condensate is present, and they stop before any compressed air gets out. Cons: higher purchase price, more moving parts equals potential maintenance concerns.
The “last line of defense” (literally) is point-of-use condensate removal. This is done with products like EXAIR Automatic Drain Filter Separators. They’re installed close to compressed air operated devices & products, oftentimes just upstream of the pressure regulator and/or flow controls…the particulate filter protects against debris in these devices, and the centrifugal element “spins” any last remaining moisture from the compressed air flow before it gets used.
Efficient and safe use of your compressed air includes maintaining the quality of your compressed air. If you’d like to find out more about how EXAIR Corporation can help you get the most out of your compressed air system, give me a call.
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ISO 8573-1:2010 is the international standard for Air Quality Classes. It lays the ground rules for acceptable levels of pollutants, particulate, moisture, and oil in a compressed air source.
Specification Example: ISO 8573-1:2010 [2:2:1]
This indicates Class 2 for particles, Class 2 for water, and Class 1 for oil.
Though the standard has detailed standards for maximum particle size, maximum pressure dew point and maximum oil content for different industries and/or environments (see Slide show above) we can generalize a bit and express the levels of air quality like this:
Plant Air – general plant compressed air used for air tools, nozzles etc. Instrument Air – found in laboratories, paint and powder coat booths, used for climate control. Process Air – used in food and pharmaceutical applications, electronics applications. Breathing Air – used for breathing respirators, breathing tanks and hospital air systems.
Achieving the different levels of air quality can be done with 3 basic types of filtration. 1. Particulate – a filter element removes particles larger than the opening in the filter material. Typically done with particles greater than 1 micron. 2. Coalescing – use different methods to capture the particles; 1) direct interception – works like a sieve, 2) Inertial impaction – collision with filter media fibers, 3) Diffusion – particles travel in a spiral motion and are captured in the filter media. 3. Adsorption – the filter element holds the contaminants by molecular adhesion.
The higher the class your air needs to be the more of these filtration methods you will use. Adsorption will remove more and finer particles than a simple particulate filter. And many applications will use a combination of these methods.
EXAIR products, all of which need a source of “clean, dry air” will operate very well utilizing a source of plant air and only a particulate filter. Your process, dictate if you need to supply additional filtration methods for better air quality. For example, an automotive plant using compressed air to blow parts off will not need the kind of filtration a food handling facility will need while blowing a food product off. If you are using a lubricated compressor or have lubricant in your compressed air lines from another source, you will want to use a coalescing oil removal filter.
EXAIR stocks 5 micron particulate filters which are properly sized for each individual product as an option for our customers if they choose. We also stock coalescing oil removal filters for customers who may need to remove oil from the air. Replacement filter elements are also available and should be replaced at least twice a year, depending on the quality of your air.
Remember to ask about filtration if you have any concerns about your air quality. We can assist in sizing up the proper filters to get the air quality we recommend for proper operation and longevity of our products.
When I was seventeen my grandfather took me to a used are dealership and helped me buy my first car. It wasn’t anything special, as it was a 1996 Chevrolet Lumina. It had its fair share of bumps and bruises, but the bones were solid. We took it home and he taught me how to do all the basics, we changed the oil, oil filter, air filter, brakes, pretty much every fluid we could, we changed.
You see my grandfather retired from Ford Motor Company after 50+ years of service. And he always said, “If you treat it right, it will treat you right.”; and I’ve lived by that ever since.
Just like a car, air compressors require regular maintenance to run at peak performance and minimize unscheduled downtime. Inadequate maintenance can have a significant impact on energy consumption via lower compression efficiency, air leakage, or pressure variability. It can also lead to high operating temperatures, poor moisture control, and excessive contamination.
Most problems are minor and can be corrected by simple adjustments, cleaning, part replacement, or the elimination of adverse conditions. This maintenance is very similar to the car maintenance mentioned above, replace filters, fluids, checking cooling systems, check belts and identify any leaks and address.
All equipment in the compressed air system should be maintained in accordance with the manufacturers specifications. Manufacturers provide inspection, maintenance, and service schedules that should be followed strictly. In many cases, it makes sense from efficiency and economic stand-points to maintain equipment more frequently than the intervals recommended by the manufactures, which are primarily designed to protect equipment.
One way to tell if your system is being maintained well and is operating properly is to periodically baseline the system by tracking power, pressure, flow (EXAIR Digital Flowmeter), and temperature. If power use at a given pressure and flow rate goes up, the systems efficiency is degrading.
Types Of Maintenance
Maintaining a compressed air system requires caring for the equipment, paying attention to changes and trends, and responding promptly to maintain operating reliability and efficiency. Types of maintenance include;
Poor Maintenance – Sadly, some plants still operate on the philosophy, “If it isn’t broke, don’t fix it.” Due to the lack of routine preventative maintenance, this practice may result in complete replacement of an expensive air compressor as well as unscheduled and costly production interruptions.
Preventive Maintenance – This type of maintenance can be done by plant personnel or by an outside service provider. Usually, it includes regularly scheduled monitoring of operating conditions. Replacement of air and lubricant filters, lubricant sampling and replacement, minor repairs and adjustments, and an overview of compressor and accessory equipment operation.
Predictive Maintenance – Predictive maintenance involves monitoring compressor conditions and trends , including operating parameters such as power use, pressure drops, operating temperatures, and vibration levels. The Right combination of preventive and predictive maintenance generally will minimize repair and maintenance costs.
Proactive Maintenance – If a defect is detected, proactive maintenance involves looking for the cause and determining how to prevent a recurrence.
Unfortunately, even the best maintenance procedures cannot eliminate the possibility of an unexpected breakdown. Provisions should be made for standby equipment to allow maintenance with out interrupting production.
If you would like to discuss improving your compressed air efficiency or any of EXAIR’s engineered solutions, I would enjoy hearing from you…give me a call.
In this blog, I would like to turn your attention to our accessories that support our Intelligent Compressed Air® Products; the Filter Separator and the Oil Removing Filter. EXAIR products use compressed air to coat, conserve, cool, convey and clean. So, to keep our products running properly and efficiently, we need to supply them with clean, pressurized air. If we look at the two types of filters that we offer, we can see how they can play an important part in your compressed air system.
Filter separators are used to remove bulk liquid and contamination from the compressed air stream. They have a 5-micron filter and work very well if you get a slug of liquid in your compressed air system. They use mechanical separation to remove the large particles of dirt and water from the air stream.
Most facilities use some type of compressed air dryer in their system to dry and condition the compressed air. But, if a system failure occurs, then water, oil, and dirt can be pushed into the compressed air lines and perhaps into your EXAIR products.
Even if you have good quality air, it is still important to keep your products protected. I would consider the Filter Separator as a minimum level of protection that should be used.
The Oil Removal Filters are used to keep the compressed air even cleaner yet. They work great at removing very small particles of dirt and oil. The 0.03-micron media of the Oil Removal Filter is designed to “coalesce” the fine liquid particles into large droplets.
Thus, allowing gravity to remove it from the compressed air stream. Some common issues allow for dirt and oil particles to collect in “dead” zones within the air lines. As it piles up and grows, portions can break off and get into the air stream affecting pneumatic devices.
The Oil Removal Filter will be able to help eliminate this long-term problem in your compressed air system. As a note, Oil Removal Filters are not great for bulk separation. If you have a system with lots of water, you should use a Filter Separator in front of the Oil Removal Filter to optimize the filtration.
Now that we went through each type, how do we use them together to get the best supply of compressed air? We always want them to be installed upstream of a Regulator. This is because the velocity is lower at higher pressures.
Lower velocities mean lower pressure drops which is great for supplying the proper amount of compressed air to EXAIR products. If you are using a combination of both filters, the Filter Separator will be upstream of the Oil Removal Filter. The Filter Separator will knock down the large particles and liquid slugs allowing the Oil Removal Filter to remove the smaller droplets and particles.
EXAIR offers a range of sizes to help support our products. They range from ¼” NPT ports up to 1 ½” NPT ports. The size of the ports determines the flow rating for each unit. EXAIR also has Mounting Brackets to mount the filters to walls or frames.
To support each type of filter, we have replacement elements and bowl kits. Since the function of the filter is to remove debris, we recommend to change the filter element once a year or when it reaches 10 PSID pressure drop; whichever comes first.
If we can analyze the compressed air systems, I would like to categorize it into a good and premium quality. For the good quality of compressed air, you can have the compressed air run through the Filter Separator. For the premium quality of compressed air, you can have your compressed air run through the Filter Separator and then through the Oil Removal Filter.
With clean quality air, your EXAIR products will provide you with effective, long-lasting performance without maintenance downtime.
Compressed air isn’t called manufacturing’s “Fourth Utility” (the first three being electricity, water, and natural gas) for nothing. Pneumatic tools are popular because they’re often so much lighter than their electric counterparts. Compressed air can be stored in receiver tanks for use when other power supplies are unavailable or not feasible. Many compressed air operated products can be made to withstand environmental factors (high/low temperature, corrosive elements, atmospheric dust, oil, other contaminants, etc.,) that would make electric devices very expensive, unwieldy, or impractical.
One of the most valuable considerations, though, is that your compressed air system is, by and large, under your control. The type and capacity of your air compressor can be determined by your specific operational needs. The header pressure in your supply lines is based on the applications that your air-operated devices are used for. And the performance & lifespan of every single component in your compressed air system is determined by the care you take in maintaining it.
Debris: solid particulates can enter your air system through the compressor intake, during maintenance, or if lines are undone and remade. If you have moisture in your air (more on that in a minute,) that can promote corrosion inside your pipes, and rust can flake off in there. Almost all of your air operated products have moving parts, tight passages, or both…debris is just plain bad for them. And if you use air for blow off (cleaning, drying, etc.,) keep in mind that anything in your compressed air system will almost certainly get on your product.
Your compressed air system may be equipped with a main filter at the compressor discharge. This is fine, but since there is indeed potential for downstream ingress (as mentioned above,) point-of-use filtration is good engineering practice. EXAIR recommends particulate filtration to 5 microns for most of our products.
Water: moisture is almost always a product of condensation, but it can also be introduced through faulty maintenance, or by failure of the compressor’s drying or cooling systems. Any way it happens, it’s also easy to combat with point-of-use filtration.
EXAIR includes an Automatic Drain Filter Separator in our product kits to address both of these concerns. A particulate filter element traps solids, and a centrifugal element “spins” any moisture out, collecting it in the bowl, which is periodically drained (automatically, as the name implies) by a float.
Oil: many pneumatic tools require oil for proper operation, so, instead of removing it, there’s going to be a dedicated lubricator, putting oil in the air on purpose. Optimally, this will be as close to the tool as possible, because not all of your compressed air loads need oil…especially your blow offs. If, however, a blow off device is installed downstream of a lubricator (perhaps due to convenience or necessity,) you’ll want to do something about that oil. Remember, anything in your system will get blown onto your product.
If this is the case, or you just want to have the cleanest air possible (keep in mind there is no downside to that,) consider an EXAIR Oil Removal Filter. They come in a range of capacities, up to 310 SCFM (8,773 SLPM,) and the coalescing element also offers additional particulate filtration to 0.03 microns.
In closing, here’s a video that shows you, up close and personal, the difference that proper filtration can make:
If you’d like to discuss or debate (spoiler alert: I’ll win) the importance of clean air, and how EXAIR can help, give me a call.
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Compressed air filters help to keep the air clean and condensate free to protect equipment from dust, dirt, pipe scale, oil and water. Even though the compressed air system will typically have a main dryer, additional treatment is often necessary. For this discussion, we will focus on the oil removal process and filter type.
After the compressed air has passed through a particulate filter, the dirt, dust and water droplets have been removed. Oil that is present is much smaller in size, and mostly passes though the particulate filter. The installation of a coalescing filter will provide for the removal of the majority of the fine oil aerosols that remain. The coalescing filter works differently than the particulate filters. The compressed air flows from inside to outside through the coalescing filter media. The term ‘coalesce’ means to ‘come together’ or ‘form one mass.’ The process of coalescing filtration is a continuous process where the small aerosols of oil come in contact with fibers of the filter media. As other aerosols are collected, they will join up and ‘come together’ and grow to become an oil droplet, on the downstream or outside surface of the media. Gravity will then cause the droplet to drain away and fall off the filter element.
Some important information to keep in mind –
Change the filter regularly, not just when the differential pressures exceeds recommended limits, typically 5 PSI
Coalescing filters will remove solids too, at a higher capture rate due to the fine level of filtration, using a pre-filter for solids will extend the life
Oil free compressors do not provide oil free air, as the atmospheric air drawn in for compression contains oil vapors that will cool and condense in the compressed air system.
If you would like to talk about oil removal filters or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.