EXAIR Products: The Importance of Oil Removal Filters

Oil Removal Filter
Oil Removal Filters

EXAIR’s Intelligent Compressed Air Products have no moving parts and require no maintenance. Most EXAIR products require no direct maintenance, and will continue to require no maintenance if the supplied air is clean. Keeping air clean, in EXAIR’s case, can be done with a simple water/dirt or oil filter separator close to the application of the product – usually within 10 feet. The reason for the filters is that many products have very tight orifices that could get clogged from contaminants such as particulate, condensate, and lubricant.

Oil is commonly present in a compressed air supply, whether that’s intentional or not. Many air compressors are lubricated by a constant supply of oil, inevitably some of this oil ends up in the air supply. As the compressor wears, more oil is permitted to pass and ends up in the distribution system. While this is kept to a minimum with proper maintenance, it is impossible to prevent unless using an oil-free compressor.

Sometimes oil is present in the air supply intentionally. Many pneumatic devices require a precise amount of oil to keep the internal moving parts lubricated. In the case of EXAIR Intelligent Compressed Air Products, we recommend particulate-free, moisture-free, and oil-free air.

EXAIR offers a line of Oil Removal Filters. These coalescing style filters are used to remove very fine water vapor as well as any residual oil. These filters are highly recommended to be installed just prior to dryers that contain a media that would be compromised by lubricant passing through it. Coalescing filters utilize an element typically made up of glass fibers that “coalesce”, or combine, the fine water vapor and oil aerosols until the droplet size becomes large enough that it drops off into the filter bowl. With a coalescing filter, the most common cause of pressure drop increase is due to particulate clogging the element. Because of this, a particulate filter should always be installed just prior to coalescing filters. Check out this video demonstrating an Auto-Drain Filter and Oil-Removal Filter in action:

Without filtration, oil in the air supply will pass through the point of use device and into your product or process. The elimination of this problem is such a simple solution. Don’t neglect your compressed air system and ensure you’re delivering clean, dry, oil-free air to all of your EXAIR Intelligent Compressed Air Products.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

EXAIR Chip Trappers Make Short Work of Coolant Maintenance

“Build a better mousetrap, and the world will beat a path to your door,” words attributed to Ralph Waldo Emerson, means that even if there are established methods of doing something, an improved method will garner success.  It may or may not be true with mousetraps – there are over 4,400 U.S. patents for various designs. The tried-and-true spring loaded bar on a small wood plank seems to still be the most popular by far, however. Likely due to its simplicity, availability, and low cost.

There are also a good many machines on the market to clean & filter machine tool coolant.  Some are made to be permanent attachments to the coolant sump for continuous filtration.  Others are made for portability, and are used to pump out the sump, filter the coolant, and pump it back in.  These can be impressively comprehensive, and that’s often reflected in the knowledge required to operate them, as well as the price tag.

Like anything else, if you need all the “bells and whistles,” I’m sure those machines are worthy every penny.  If you just want clean coolant and you have a few minutes to spare every week or so, look no further than the EXAIR Chip Trapper System.  Here’s how it works:

  • Roll the Chip Trapper to your machine.
  • Pump the coolant out of your sump, stirring it with the pickup wand to get chips & debris sucked up with the coolant.
  • Pump the filtered coolant back in to your sump.
  • If you’ve got another machine tool, roll the Chip Trapper over to it, and repeat.  If not, you’re done.  Unless the Filter Bag’s full, in which case, you’ll want to empty it for the next time.

The vacuum hose (1) is attached to the barbed connection of the Chip Trapper (2). The directional flow control valve on the top of the drum (3) and knob on the pump (4) are set to the “fill” position. The air supply valve is opened to permit compressed air at 80-100 psig (5.5-6.9 BAR) to flow through the pump which pulls the liquid through the hose, then into the reusable filter bag (5). When all liquid is in the drum, the air supply is turned off. The filtered liquid can then be pumped out by setting the directional flow control valve on top of the drum and the knob on the pump to the “empty” position. Once the air supply valve is opened, the air pushes the liquid back through the hose while all solids remain in the reusable filter bag.

There’s no moving parts, and it’s compressed air operated, so there’s nothing to wear out or burn out.  If you keep on top of emptying and cleaning the Filter Bag, the Chip Trapper will operate darn near indefinitely, maintenance free.  Oh, and to explain why I started this blog with the quote I referenced, the folks at Design News Magazine thought it was so innovative, they gave it their “Golden Mousetrap” Award when we rolled them out.  Since then, we’ve incorporated three sizes for 30, 55, and 110 gallon drums.  We also developed a High Lift version that generates 180″ H2O suction lift, for when the standard Chip Trapper‘s 96″ H2O lift isn’t enough.

EXAIR Corporation has a long history of making compressed air products that help a wide variety of industries get the most out of their processes, and the Chip Trapper is one of the most visible, and successful, examples of that.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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How to Manage Condensate in Your Compressed Air System

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.
Good engineering practice calls for point of use filtration and moisture removal, such as that provided by EXAIR Filter Separators.

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.

Russ Bowman
Application Engineer
EXAIR Corporation
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Compressed Air Demand Preventative Maintenance

Preventative maintenance for compressed air demand products is a simple as keeping the compressed air clean and condensate free. It is simple because all it takes is a filter and keeping the filter element clean, just like you do for your home furnace and/or air conditioner.

I received a phone call from a customer that needed replacement elements for EXAIR filters.  They were using four different models of Filter Separators and Oil Removal Filters.  The filters had been in service for one year, and the internal elements needed to be changed.  They requested a quote to replenish the replacement elements that they stocked as a preventative measurement.  What an idea!

Majority of EXAIR products use compressed air for cleaning, cooling, conveying, static elimination, coating and more.  To help keep your EXAIR products running efficiently, it is important to supply them with clean, dry, pressurized air.  EXAIR offers a line of Filter Separators and Oil Removal Filters to supply quality air to your equipment.  In this blog, I will explain the two types of filters that we carry and the maintenance requirements.  The filters and preventative measures 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 utilize a 5-micron filter with a mechanical separation to help remove large amounts of dirt and water.  This type of filter would be considered the minimum requirement for filtration.  Most of the Filter Separators come with an auto-drain to automatically dispense the collection of oil and water.  EXAIR offers a variety of port sizes and flow ranges to meet your pneumatic flow requirement.  For maintenance, the filter elements should be changed once a year or when the pressure drop reaches 10 PSID, whichever comes first.  I created a list in Table 1 showing the correct replacement element kits for each model number.  And for any reason, if the bowl or internal components get damaged, we also have Rebuild Kits as well.  Just remember, the air quality is very important for longevity and functionality for pneumatic products and even for EXAIR products.

The Oil Removal Filters can make your compressed air even cleaner.  They work great at removing very small particles of dirt and oil.  They are made from glass fibers and can remove particles down to 0.01 micron.  They are designed to collect small particles and to coalesce the liquid particles into a large droplet for gravity to remove.  Because of the fine matrix, Oil Removal Filters are not great for bulk separation.  If you have a system with lots of oil and water, I would recommend to use the Filter Separator upstream of the Oil Removal Filter.  As with the Filter Separator, the filter element should be changed once a year or at a pressure drop of 10 PSID.  EXAIR also offers a variety of port sizes and flow ranges.  Table 1 below shows the replacement Element Kits as well as the Rebuild Kits.  If the application requires very clean compressed air, the Oil Removal Filter should be used.

Table 1

By using EXAIR filters, they will clean your compressed air to prevent cross contamination, performance issues, and premature failures.  As an ounce of prevention, you can add the replacement elements in stock and enter them in your preventative maintenance program.  With clean quality air, your pneumatic system and EXAIR products will provide you with effective, long-lasting performance without maintenance downtime.  If you would like to discuss the correct type of filters to use in your application, you can speak with an Application Engineer.  We will be happy to help you.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

What’s The Big Deal About Clean Air?

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.

I covered the importance of compressed air system maintenance in a blog a while back…today, I want to focus on clean air.  And, like the title (hopefully) makes you think, it’s a REALLY big deal.  Consider the effects of the following:

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.

Point of use filtration is key to the performance of your compressed air products, and their effectiveness. Regardless of your application, EXAIR has Filter Separators to meet most any need.

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.

Russ Bowman
Application Engineer
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Oil Removal Filters – Keeping Compressed Air Clean

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.

9005
Example of a 0.03 Micron Coalescing Oil Removal Filter

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.

Brian Bergmann
Application Engineer

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Removing Condensation Is Key To Maintaining Performance

When air is compressed, it is heated to a point that causes the water or moisture  to turn to vapor. As the air begins to cool, the vapors turn to condensation, which can cause performance issues in a compressed air system. Many times this condensation forms in the basic components in the system like a receiver tank, dryer or filter.

Condensation is formed from water vapor in the air

It’s important to remove this condensation from the system before it causes any issues. There are four basic types of condensate drains that can be used to limit or prevent loss of air in the system.

The first method would be to have an operator manually drain the condensation through a drain port or valve. This is the least reliable method though as now it’s the operator’s responsibility to make sure they close the valve so the system doesn’t allow any air to escape which can lead to pressure drops and poor end-use device performance.

Example of a float drain

Secondly, a float or inverted bucket trap system can be used in plants with regular monitoring and maintenance programs in place to ensure proper performance.. These types of drain traps typically require a higher level of maintenance and have the potential to lose air if not operating properly.

An electrically actuated drain valve can be used to automatically drain the condensate at a preset time or interval. Typically these incorporate a solenoid valve  or motorized ball valve with some type of timing control.  These types of systems can be unreliable though as the valve may open without any moisture being present in the line, which can result in air loss or it may not be actuated open long enough for acceptable drain off. With these types of drains, it’s best to use some type of strainer to remove any particulate that could cause adverse performance.

Lastly,  zero air-loss traps utilize a reservoir and a float or level sensor to drain the condensate and maintain a satisfactory level. This type of setup is very reliable but does require the reservoir be drained frequently to keep the system clean and free of debris or contaminants.

If you have any questions or would like to discuss a particular process, contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Condensation image courtesy of Anders Sandberg via creative commons license

Float drain image courtesy of the Compressed Air Challenge