Norgren Air Preparation Products and Accessories - Fred C

473 Pages·2000·7.96 MB·English

APC-104 Contents
2001
Norgren Air
Preparation Products
and Accessories
Compressed Air Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-0-2
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-1-A
Oil Removal (Coalescing) Filters . . . . . . . . . . . . . . . . . . . . . . . ALE-2-1
Oil Vapor Removal (Adsorbing) Filters. . . . . . . . . . . . . . . . . . . ALE-3-1
Membrane Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-4-1
Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-5-A
Specialty Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-6-1
Manifold Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-7-1
Precision and Instrument Regulators . . . . . . . . . . . . . . . . . . . ALE-8-1
Pilot Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-9-1
Pilot Operated Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-10-1
U.L. Listed Cylinder Gas Regulators for Industrial Use. . . . . ALE-11-1
U.L. Listed Beverage Regulators . . . . . . . . . . . . . . . . . . . . . . ALE-12-1
Filter/Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-13-1
Lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-14-A
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-15-1
Shut-Off and Lockout Valves . . . . . . . . . . . . . . . . . . . . . . . . . ALE-16-1
Stainless Steel Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-17-1
Smooth Start, and Directional Control Valves . . . . . . . . . . . . ALE-18-1
Additional Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-19-1
Filter-Filter Combination Units. . . . . . . . . . . . . . . . . . . . . . . . ALE-20-1
Filter/Regulator-Lubricator Combination Units . . . . . . . . . . . ALE-21-1
Filter-Regulator-Lubricator Combination Units . . . . . . . . . . . ALE-22-1
Filter-Lubricator Combination Units. . . . . . . . . . . . . . . . . . . . ALE-23-1
Modular Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-24-1
Accessories for Filters, Regulators, and Lubricators . . . . . . ALE-25-1
Watson Smith Electronic Products. . . . . . . . . . . . . . . . . . . . . ALE-26-1
Compressed Air Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-27-1
Fittings and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-28-1
Appendix/Technical Information. . . . . . . . . . . . . . . . . . . . . . . ALE-29-1
Part Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALE-29-18
Littleton, CO USA Phone [phone] Fax [phone] ALE-0-1
Compressed Air Systems
Norgren Air Preparation Products: Protecting your
pneumatic system from the hazards of contaminated air.
The air leaving a compressor is hot, dirty, wet and generally at a higher
pressure than the downstream equipment requires. A typical 100 scfm (50
dm3/sec) compressor will push 1200 gallons (4500 liters) of water and 2 gallons
(8 liters) of degraded compressor oil into the system in a year along with
considerable amounts of dirt particles. Before this air can be used it needs to be
treated to remove the contaminants, have its pressure reduced to the right level,
and in many cases have oil added to lubricate downstream equipment.
ALE-0-2 Littleton, CO USA Phone [phone] Fax [phone]
Compressed Air Systems
Build Your System!
These illustrations show three examples of how Norgren (cid:2)
A
Air Preparation Products have been used to design clean, Pilot Operated
safe, and efficient industrial compressed air systems. (Slave) Regulator Modular Excelon System
(cid:127) Lockout Valve
(cid:127) Filter/Regulator
(cid:127) Lubricator
Pressure
Guage
Pilot
Regulator
Lockout
Valve AIR OPERATED TOOLS
➔ (cid:2)
B
COMPRESSED Modular Excelon System
AIR FROM (cid:127) Lockout Valve
RECEIVER (cid:127) Filter/Regulator
(cid:127) Oil Removal Filter
General Oil Removal PAINT SPRAYING
Purpose Air Filter
Filter Dryer
(cid:2)
A
Solenoid
Valve
Bearing
Filter Regulator Lubricator
Lubricator
Lockout Lockout
Valve Valve
Wye Drip Leg
Filter/Regulator MACHINE Drain
LUBRICATION
Reclassifieres CYLINDERS
(cid:2)
B
Filter/Regulator
Oil Removal
Filter Vapor
Removal Filter
ULTRA CLEAN AIR FOR
CRITICAL APPLICATIONS
Lockout
Valve
Drip Leg
Drain
Littleton, CO USA Phone [phone] Fax [phone] ALE-0-3
Compressed Air Systems
Norgren knowledge APPLICATIONS General Pneumatic Circuits:
and products save The following section shows several typical systems eg: directional control valves and cylinders, in
of a generic type and the equipment normally used multi-valve circuits, machine cleaning, air motors
you money for the application. Remember every system should and high speed tools.
be treated on its merits and broken down into several
elements to ensure optimum installation, running A Micro-Fog lubricator is required for the
and maintenance costs are achieved. several varying flow paths to ensure full lubrication.
Compressed air is The applications below are typically (Figure 2)
often wrongly assumed to branches taken off a large works distribution mains
Figure 2.
be a cheap or even ‘free’ and isolating valves are usually placed in front of all
source of power. In fact it branches to permit isolation from the mains to allow
can be 10 times as for maintenance to take place without recourse to
expensive as electricity complete plant shut-down.
by the time all
generation, transmission,
treatment and system
costs are taken into
account. Good air
preparation must
therefore consider the
energy consumption of
the system and air Shut-off valve, filter/reg, Micro-Fog lubricator, soft
treatment equipment. start/dump, relief valve.
The process of air Multiple Simple Applications:
preparation has been at eg: OEM machines.
the core of Norgren’s
business for over 70 It is often a case that with fairly simple
years. The aim of this machines, lubricated air is required for valving and
booklet is to offer pneumatic circuitry and oil-free air for air bearings.
guidance on the correct, To keep costs low two separate lines are
economic and safe unnecessary and a typical arrangement from one air
treatment of compressed supply only can be arranged as shown.
air in industrial Other elements such as pressure switches
applications. Here we can and check valves may be made available within
only provide a brief modular systems. (Figure 3).
summary of the extensive
experience Norgren has Figure 2
as a world leader in FRL
technology.
Shut-off valve, filter/regulator, oil removal filter,
porting block, Micro-Fog lubricator.
ALE-0-4 Littleton, CO USA Phone [phone] Fax [phone]
Compressed Air Systems
Oil-Free Applications: Critical Pressure Control (Instrumentation): Continuous Processes
eg paint spraying, foodstuffs, film processing, eg: precision regulation, fluidic systems, air
powders. gauging, process control. Another facet of Norgren’s Olympian Plus is the
ability to make duplex systems. This is invaluable
These applications need to be free from A typical arrangement is shown, where oil for systems which cannot be shut-down, such as
any water deposits in the downstream system. For aerosols which can prevent fast response of continuous process plant. Two identical air sets are
many installations this will require air drying. The downstream devices, need to be removed. joined together and one may be isolated (and
drying medium (for desiccant or deliquescent Dependant upon air quality drying may not be serviced) whilst the other set is in operation.
dryers) will need protecting from oil to allow it to required. (Figure6) (Figure 8)
work efficiently and the downstream system will
Figure 8.
also need protection from accidental migration of Figure 6.
the material into it. A typical arrangement would be
as figure 26 and in some instances it might be
worth considering an oil vapour removal filter too.
(Figure 4)
Figure 4.
Duplex system: shut-off valve, filter/reg, lubricator,
porting block, oil removal filter and shut-off valve x
2 with manifold block connectors.
Shut-off valve, general purpose filter, oil removal
filter, drier, oil removal filter, precision regulator.
Shut-off valve, general purpose filter, oil removal
Direct Injection Lubrication:
filter, drier, oil removal filter, regulator, relief valve.
eg: conveyor chains.
Heavy Duty Lubrication: The application does not allow for
eg: large slow moving cylinders. ‘fog’type lubrication because of the surrounding
environment and absence of a lubrication chamber.
In such applications large amounts of (Figure 7).
lubricant are required for effective lubrication. Again
a soft start/dump valve is shown but is dependent
Figure 7.
upon the application. (Figure 5).
Figure 5.
Shut-off valve, filter/reg + direct injection
Shut-off valve, filter/reg, Oil-Fog lubricator, lubricator.
soft start/dump valve, relief valve.
Littleton, CO USA Phone [phone] Fax [phone] ALE-0-5

Filter Contents
Filters
General Purpose Filters, Oil
Removal (Coalescing) Filters, Oil
Vapor Removal (Adsorbing)
Filters, and Compressed Air
Membrane Dryers
Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ALE-1-B
Rating Filter Elements and ISO Standard 8573-1 . . . .ALE-1-G
General Purpose Filters . . . . . . . . . . . . . . . . . . . . . . . . . .ALE-1
Oil Removal (Coalescing) Filters . . . . . . . . . . . . . . . . . . .ALE-2
Oil Vapor Removal (Adsorbing) Filters . . . . . . . . . . . . . .ALE-3
Compressed Air Membrane Dryers . . . . . . . . . . . . . . . . .ALE-4
Littleton, CO USA Phone [phone] Fax [phone] ALE-1-A
Filters
1.1 GENERAL OVERVIEW
GENERAL PURPOSE FILTER Three main types of filters exist: The general 1.1.3 How do Vapor removal Filters Work?
purpose filter for water and particles, the coalescing
Service indicator oil removal filter for oil aerosols and the activated Carbon filters are used to remove oil vapors and
(optional) carbon filter for the removal of oil vapors. odors. The activated carbon has a porous structure
The general purpose filter is used for most which results in a large surface area. The oil vapors
Body filter applications and is available from 1/8" to 2" are attracted and adhere to this surface. There is
pipe sizes. Uses are main headers, branch lines, usually a small sintered medium included in an
tools, cylinders, valves and valve circuits, air activated carbon element to prevent the carbon
agitators etc. Oil removal filters are used where very particles from migrating downstream. The carbon
clean, oil-free air is required, such as for the supply filter reduces the maximum oil content of air leaving
Louvre
to fluidic devices, instrumentation, air gauging the filter to 0.003ppm at 70°F, i.e. To ISO 8573 class
Centre post equipment and air bearings. 1.7.1. If protected upstream by general and oil
Activated Carbon filters are used for removal filters life is between 400 and 1000 hours.
Element
systems where the oil vapors in the air are not
Bowl
acceptable; such as instrumentation and paint 1.1.4 Why use a Pre-Filter?
Baffle
Metal bowl
spraying.
sight glass
A pre-filter is simply a general purpose filter placed
1.1.1 How Do General Purpose Filters Work? upstream of a higher grade filter to remove the
Collected
condensate majority of the water and larger particle
(cid:0)y(cid:0)y(cid:0)y The dirt and moisture-laden air enters the inlet port contaminants and thus lengthen the life of the higher
(cid:0)y(cid:0)y(cid:0)y
(cid:0)y(cid:0)y(cid:0)y and is directed into the louvers which centrifugally grade filter element.
(cid:0)(cid:0)yy(cid:0)(cid:0)yy(cid:0)(cid:0)yy Drain separate the entrained liquids and dirt which fall to A 5 micron pre-filter should always be used
(cid:0)y(cid:0)y(cid:0)y
(cid:0)y(cid:0)y(cid:0)y the bottom of the bowl. Near the bottom of the bowl ahead of an oil removal filter.
a baffle creates a quiet zone, preventing the An oil removal (coalescing) filter must be
turbulent air re-entraining the contaminants. The air, used ahead of a vapor removal adsorbing filter.
now free of water droplets and large dirt particles,
COALESCING FILTER passes through the filter element which removes 1.2 AIR QUALITY
small dirt particles. Solid particles eventually plug
Service indicator
the element necessitating replacement. 1.2.1 What is ISO 8573?
(See ALE-1-G for specification)
1.1.2 How Do Oil Removal Filters Work? This is an international standard on air quality. It
Body
covers compressed air for general industrial use.
Air enters the filter and passes through the The air quality is specified using a 3 digit
element from inside to outside, where oil aerosols code expressing the remaining content of a specific
impinge on the borosilicate micro-fibers and are contaminant after the filter (or dryer).
coalesced into larger drops. The drops are carried
Element
through the element until they reach the outer
Outer sock porous sock. The outer sock, because of its cellular 1.2.2 Air Classes for Norgren Filters:
construction, retains these liquids and allows them
Bowl to drain by gravity to the bottom of the bowl. Particulate filters condition compressed air to
Metal bowl Solid partilces are retained in the element different degrees, dependent on the micron rating of
sight glass and cause the pressure drop to slowly increase the filter. The finer filter, 5 µm, will achieve ISO 8573
throught the working life of the element. When the class 3.7. or class 3. Applying a 40 µm filter will
Collected pressure drop across the element reaches 10 psid, result in ISO 8573 class 5.7. or class 5 air.
condensate
the service life indicator on top of the filter will Coalescing filters improve the quality of
(cid:0)y(cid:0)y(cid:0)y
(cid:0)y(cid:0)y(cid:0)y show more red than green and the element should downstream air to ISO 8573 class 1.7.2, the particle
(cid:0)y(cid:0)y(cid:0)y
(cid:0)y(cid:0)y(cid:0)y Drain be replaced. size is reduced down to 0.01µm, with a remaining
(cid:0)y(cid:0)y(cid:0)y oil content of less than 0.01ppm. Coalescing filters
(cid:0)y(cid:0)y(cid:0)y
(cid:0)y(cid:0)y(cid:0)y cannot remove oil which is in the vapor state in the
supply air. One way to remove vapor is to reduce the
temperature of the air flow allowing the vapor to
condense, alternatively remove the vapor chemically
using an activated carbon filter.
ALE-1-B Littleton, CO USA Phone [phone] Fax [phone]
Filters
1.3 PLASTIC BOWLS
1.2.3 What Micron Ratings are Available? 1.2.4 How do Service Life Indicators Work?
Norgren transparent plastic bowls are made from
The standard Norgren general purpose elements are The service life (pressure drop) indicator found on polycarbonate. Some competitors use other
40 and 5 microns, with 40 microns being suitable top of coalescing or general purpose filters is green materials such as Grilamid.
for most industrial applications. Certain industries when the filter is new. As a pressure differential
have 25 or 75 micron as a standard and some develops across the filter element with use, a spring Both these materials are extremely resilient and have
product ranges have these options available. biased red outer sleeve is pushed up. When more an excellent safety record. However these
For a given element size, the smaller the red is visible than green, then the pressure transparent plastics will degrade when subjected to
micron rating the higher the pressure drop across differential across the element is in excess of 10 psi excessive heat, solvents and some chemicals, which
the filter. The service life between cleaning is also (0.7 bar) and the element should be replaced. can lead to crazing and finally bowl failure.
less for the smaller micron filters, as small holes Over the last few years metal bowls and
plug more quickly than bigger holes. 1.2.5 When does the Carbon Pack Indicator Turn guarded plastic bowls have become increasingly
Pink? popular driven by the emergence of guidelines
Figure 1.
recommending the use of guards.
RECOMMENDED FILTRATION LEVELS.
The white ring around the base of the vapor Some organizations have their own internal
Application Typical Quality Classes removal carbon pack turns pink in the presence of standards which call for guarded plastic or metal
Oil Dirt liquid oil. Therefore if the ring turns pink the bowl and the general market trend is away from
Air agitation 1 3 coalescing filter is passing liquid oil and needs plastic bowls in the 1/2” or above port size units.
replacing. If this occurs soon after the filter has This trend is reflected in our latest Excelon 74 and
Air bearings 2 2
been installed then it usually indicates a seal failure Olympian Plus product ranges. Plastic bowls remain
Air gauging 2 2 in the coalescing filter. Remember that visual the most common option for 1/4” and smaller units.
Air motors 4 4 detection is a not a substitute for scheduled Never use polycarbonate bowls at
Brick and glass machines 5 4 maintenance. conditions which exceed the maximum rated
pressure and temperature of 150 psig (10 bar) and
Cleaning of machine parts 3 4
1.2.6 How Long does an Element Last? 125°F (50°C).
Construction 4 5
Certain chemicals, common in some oils
Conveying, granular products 2 4 This depends entirely on the quality of the inlet air. and solvents, can attack polycarbonate and cause
Conveying, powder products 1 3 If it is very poor the elements will need replacing the bowl to burst. If the compressor intake is located
more frequently. in an area containing incompatible vapors, these
Fluidics, power circuits 2 5
In general, air service equipment should contaminants can be drawn into the compressor and
Fluidics, sensors 2 3
be maintained annually. Use, quality of air and conveyed to the bowl in the compressed air. This
Foundry machines 4 5 condition at examination may indicate adjustment can result in bowl failure.
Food and beverages 1 1 of the maintenance interval. Synthetic compressor oils may be drawn in
The following guidelines can be given: from the compressor and can also result in bowl
Hand operated air tools 5 5
General Purpose Replace/maintain annually. The failure.
Machine tools 5 4
Filter: element can lose 15% efficiency If doubt exists as to the compatibility of
Mining 5 5 each time it is cleaned. Elements certain fluids with polycarbonate, please contact
Micro-electronics manufacture 1 1 are low cost, so it is advisable to Applications Engineering.
replace them. Metal bowls should be used where
Packaging and textile machines5 3
Coalescing: Evaluate after 12 months of temperatures exceed 125°F (50°C) and/or pressures
Photographic film processing 1 2
servicing. If the pressure drop exceed 150 psig (10 bar), or when materials are
Pneumatic cylinders 3 5 across the element exceeds 10 present which are incompatible with polycarbonate.
Pneumatic tools 5 4 psig (0.7bar) then the element Maximum rated operating conditions for metal
requires changing. bowls depend on the range; check APC-104.
Pneumatic tools (high speed) 4 3
Activated Carbon Should be changed every 1,000
Process control instruments 2 3
Packs: hours usage or when odor is
Paint spraying 1 1
detected. The life depends
Sand Blasting 4 5 significantly on ambient
Welding macines 5 5 temperature.
General Workshop air 5 4
Littleton, CO USA Phone [phone] Fax [phone] ALE-1-C
Filters
1.4 DRAINS 1.5 PERFORMANCE
1.4.1 Semi Automatic: 1.4.4 Where should a Low Flow Automatic Drain 1.5.1 Performance of General Purpose Filters
be used?
A semi-auto drain is one which operates when the Filters have their flow measured in terms of the
air-line is depressurized eg at the end of a shift. It is In systems where the compressor capacity is pressure drop across them. As the flow increases
a normally open two-way valve which is held closed insufficient to close a number of standard auto then the pressure drop also increases. These
by 7-10 psig (0.7-0.8 bar). When the filter is drains a ‘low flow’ drain is available which requires pressure drops are energy losses in the system.
pressurized, the drain may be operated manually by only 0.5 scfm flow before closing. An ultra low flow A well designed filter not only removes
pushing the tube, which protrudes outside the bowl, auto drain is also available. ‘Low flow’ drains have water and particles efficiently, but also has a low
upwards. less clearance around the valve for expelling pressure drop at a given flow. The flow figures
contaminants, so should only be used where the quoted in Norgren catalogues for general purpose
1.4.2 Automatic: standard unit cannot be used. ‘Low flow’ drains can filters are at a pressure drop of 5 psig (0.3 bar),
be identified by red plastic parts. from a 100 psig (7 bar) inlet pressure.
An automatic drain is a two-way valve, which will 1.4.5 07 Automatic (spitter) Drain: Beware!not all competitors quote their
close when the system is pressurized. The drain flows under the same conditions. If a higher inlet
opens when the float rises due to accumulated liquid When a rapid increase in flow occurs through the pressure is used or a higher pressure drop is quoted
and on depressurization. filter it results in the pressure above the drain’s then the apparent flow will be higher. This does not
diaphragm being less than that below it. This mean it is a better unit , simply that a different point
1.4.3 Where should an Automatic Drain be Used? differential pressure causes the drain to on the curve has been selected. Often the only way
momentarily lift and ‘spit’ out the condensate to compare units is to test them under the same
Automatic Drains should be used where the filter collected underneath the drain. laboratory conditions.
location may make servicing difficult, where filters
may be hidden from view and consequently be 1.5.2 Performance of Coalescing Filters:
overlooked or where equipment is in continual use. 1.4.6 Where should a Drip Leg Drain be Used?
Areas where large quantities of liquid may The maximum flow of an oil removal filter is usually
accumulate over a short period of time should also The drip leg drain is a system protection device. determined by the oil removal efficiency under
be equipped with auto-drain filters. High labor costs Most compressed air distribution systems have saturated conditions. In the catalog there are
for draining a large number of filters manually will varying flows and/or are shut down at the end of a maximum flows quoted ‘to maintain stated oil
generally justify the use of auto-drains. working day. As the system cools, water in the removal characteristics.’ These are the steady state
Machines which have been shut down for a compressed air condenses and collects in the flows which should not be exceeded to guarantee
long period of time, such as over a weekend, can distribution pipe work. This water will run along the that the oil in the outlet air remains below the
draw slugs of water during start-up which can pipe work and settle at the low point(s). On start up 0.01ppm (parts per million) quoted. Cyclic or
overload a filter unless drained immediately. (This of the plant this water can be pushed under pulsating flows will result in oil carry over, as will
situation can normally be handled by a drip leg pressure into the nearest device or process and elevated temperatures.
drain, see.) cause malfunction or damage. If a higher oil carry over is acceptable (or
Norgren float type automatic drains are By running a vertical pipe down from there is no oil in the air-line) then higher flows are
‘normally open’ type drains. During periods when these low points water will flow into the drip leg achievable, and will be determined by the
the air line pressure is shut off, the automatic drain drain where the automatic drain will expel it. ‘acceptable’ pressure drop. For a new (dry) element
will open allowing liquids to drain rather than flood A filter screen within the drip leg drain a flow which gives a pressure drop of less than 5
the air line piping system. When re-pressurizing the prevents particles interfering with the auto-drain psid (0.3 bar) is recommended.
air line, the automatic drain valve will close when operation. A ball valve should be included above
pressure reaches approximately 10 psig (0.7bar). the drip leg drain to allow for maintenance when
This results in a flow through the drain to the system is running.
atmosphere of about 1.77 scfm (0.84dm3/s) until
the valve automatically closes. (See 1.4.4 below.)
ALE-1-D Littleton, CO USA Phone [phone] Fax [phone]