Air Quality Guide - PETROS PETROPOULOS AEBE - …

1 ingersoll - rand compressors are not designed, intended or approved for breathing air applications. ingersoll - rand does notapprove specialised equipment for breathing air applications and assumes no responsibility or liability for compressors usedfor breathing air service. Nothing contained on these pages is intended to extend any warranty or representation, expressed or implied, regardingthe product described herein. Any such warranties or other terms and conditions of sale of products shall be in accordancewith ingersoll - rand s standard terms and conditions of sale for such products, which are available upon improvement is a continuing goal at ingersoll - rand . Designs and specifications are subject to change withoutnotice or Than Productivity. SOLUTIONS: Quality GuideCPN 22423941 Printed in the UK 2004 ingersoll -RandAir SolutionsIngersoll- rand European Sales LimitedSwan LaneHindley GreenWigan WN2 4EZ, UKTel: +44 (0) 1942 257171 Fax: +44 (0) 1942 254162 What Influences Your Compressed Air Quality ?

2 Dirt, moisture and oil are everywhere. But they shouldn t be in your compressed air supply. Dust, dirt, pollen, microorganisms, smoke, exhaust emissions and other particulatesMoisture in the form of water vapourOil, unburned hydrocarbons from the ambient air and compressor coolant carryoverCaustic gases such as sulfur oxides, nitrogen oxides and chlorine compoundsThe Results of Contaminated Compressed AirThe problems created by contaminated compressed air in your system can rangefrom annoyance to wreaking havoc on your equipment and your end products. Premature wearing and scoring of surfacesRust and corrosion in tools, piping and equipmentDamaged instrumentsSpoiled paint surfacesIncreased scrap rateUnsafe or unpleasant work environmentGeneral ManufacturingAssemblyConveyingAir Tool UseAdvanced PneumaticsInstrument QualityFood GradeAir CompressorParticulate FilterDryerOil FilterPressure ControllerVapour FilterReceiverOil/WaterSeparatorDrain TrapsThe act of compressing atmospheric air to 7 bar(g) creates an 800% increase in theconcentration of Importance of Air Quality32 AtmosphericCompressed to 7 bar(g)ISO Air Quality ClassesMaintaining air Quality is so important that the International Standards Organisation (ISO) developedsix compressed air Quality classes, as defined by ISO To determine which industry classificationyou require, ask yourself these simple questions.

3 Does compressed air Quality affect my production process and the Quality of my end products?Will poor compressed air Quality decrease my productivity, cost-savings and product Quality standards?What internal and external ambient conditions affect the Quality of my compressed air produced by my system?Removing Particulate ContaminationContaminants Can Destroy a Compressed Air SystemThink of it as a mini dust storm at 7 bar(g). The particulates scattered almost invisibly throughout the ambient air become a concentrated force for damage and destruction of your air-operated tools,equipment and are damaged and products are spoiledScoring and uneven wear patterns ruin tools and instrumentsVolatile, hazardous compounds are producedProduction shuts down, productivity and Quality suffer54 General ManufacturingAssemblyConveyingAir Tool UseAdvanced PneumaticsInstrument QualityFood GradeDual Filters Eliminate Dirt and ProblemsEliminating the sandblast effect of particulates in your compressed air streamgets rid of.

4 Premature wearScored surfacesClogged orificesRuined finishes and instrumentsThe first filterremoves second filter removes smaller precede fine filters with a coarser sensitive or criticalapplications more than oneset of filters may be requiredat the point of use .Compressed Air Quality ISO ParticleWaterOilMaximum number of particles per m3 Pressure(Incl. vapour) micronDewpoint ( C) ,0001, specified10,000500-2014 Not specifiedNot specified1,000355 Not specifiedNot specified20,0007 Not specified6 Not specifiedNot specifiedNot specified10 Not specifiedAir CompressorParticulate FilterDryerOil FilterPressure ControllerVapour FilterReceiverOil/WaterSeparatorDrain TrapsRemoving MoistureWhy Is Relative Humidity Important?Moisture Contamination Has The Following Effects:-Rust and corrosion in the air system pipingInadequate air tool lubricationDamage to labelling, packaging and the finished goodsProductivity losses throughout your operationRefrigerated air dryers are capable of maintaining less than 50% Relative Humidity in mostindustrial plant ambient environments.

5 Processes that require ultra-dry air (ISO Class 1, 2 or 3) will need an advanced solution usingnonrefrigerated dryer vs Ambient Air Temperature102030405010OC7OC3OC25OC76 General ManufacturingAssemblyConveyingAir Tool UseAdvanced PneumaticsInstrument QualityFood GradeHow To Compare Relative Humidity In ISO Standard?ISO classifies a constant Pressure Dewpoint at a specific ambient air temperature (25 C) As illustrated in the graph, when Pressure Dewpoint (PDP) is held constant (represented by the colour curves) and ambient air temperature changes, the Relative Humidity will increase or decreaseWhen a constant Relative Humidity (RH) is maintained, your air system s performance will be consistent and reliableCompressed Air Quality ISO ParticleWaterOilMaximum number of particles per m3 Pressure(Incl. vapour) micronDewpoint ( C) ,0001, specified10,000500-2014 Not specifiedNot specified1,000355 Not specifiedNot specified20,0007 Not specified6 Not specifiedNot specifiedNot specified10 Not specifiedAir CompressorParticulate FilterDryerOil FilterPressure ControllerVapour FilterReceiverOil/WaterSeparatorDrain TrapsRemoving OilOil in Compressed Air Affects Products and the Work EnvironmentOil, unburned hydrocarbons and compressor coolant become highly concentrated during contaminants enter the air flow as entrained droplets and will pass through thecompressed air system into the production process unless they are removedThe built-in air/oil separator on all rotary screw air compressors will remove a portion of the oil,but this is not sufficient for most applicationsOil contamination will cause batch spoilage, poor Quality in finished goods.

6 Unwanted colouring in finished goods and a messy or hazardous work environmentProper Filtration Removes Unwanted Oil from the Air StreamRemoving oil from the compressed air stream provides some real air tool lifeEnsures high Quality of finished goodsNo unwanted odoursSafer workplaceInherent oil-free compressed air can only be achieved by installing an oil-free air , particulate filtration and moisture removal are still first filterremoves largeoil second filterremoves fine ManufacturingAssemblyConveyingAir Tool UseAdvanced PneumaticsInstrument QualityFood GradeThe third filter removes oil vapours, providing odour-free precede fine filters with a coarser sensitive or criticalapplications morethan one set of filtersmay be required atthe point of use .Compressed Air Quality ISO ParticleWaterOilMaximum number of particles per m3 Pressure(Incl.)

7 Vapour) micronDewpoint ( C) ,0001, specified10,000500-2014 Not specifiedNot specified1,000355 Not specifiedNot specified20,0007 Not specified6 Not specifiedNot specifiedNot specified10 Not specifiedAir CompressorParticulate FilterDryerOil FilterPressure ControllerVapour FilterReceiverOil/WaterSeparatorDrain TrapsIR Industry ClassificationsClassIN1 Instrument Grade Air:ISO Class Odour FreeInstrument Grade Air:ISO Class odour freeIN2 Instrument Grade Air:ISO Class Odour FreeInstrument Grade Air:ISO Class odour freeIG4 Industrial Grade Air:ISO Class Odour FreeIndustrial Grade Air: ISO odour freeIG6 Industrial Grade Air:ISO removal of solidparticulates and oil. ISO Class 1 Pressure Dewpoint will bemaintained. Efficient removal of solidparticulates and oil, and oilvapour. ISO Class 1 PressureDewpoint will be maintained. Efficient removal of solidparticulates and oil.

8 ISO Class 2 Pressure Dewpoint will bemaintained. Efficient removal of solidparticulates and oil, and oilvapour. ISO Class 2 PressureDewpoint will be maintained. Efficient removal of solidparticulates and oil. ISO Class 4 Pressure Dewpoint or a 30% (orless) Relative Humidity (RH) willbe maintained. Efficient removal of solidparticulates and oil, and oilvapour. ISO Class 4 PressureDewpoint or a 30% (or less)Relative Humidity (RH) will bemaintained. Efficient removal of solidparticulates and oil. ISO Class 6 Pressure Dewpoint or a 50% (orless) Relative Humidity (RH) willbe ,process, oil and gas,chemical, electronics. Pharmaceutical, foodand beverage, ,process, oil and gas,chemical, electronics. Pharmaceutical, foodand beverage, manufacturing,metal stamping, air tooluse, forging, assembly,painting and and beverage,raw material mixing. Sand blasting, homeuse, s Exclusive Air System Analysis processAirCare.

9 Flexible Maintenance Programs and Constant an understanding of your industry classification requirements, IR canprovide the optimal air treatment equipment for your system. Also with IR sAirCare extended warranty and preventive maintenance program, you llcontinue to enjoy reduced costs and increased can extend the drivetrain or full-package warranty for a five year periodCertified professional technicians will perform routine inspections and diagnostic serviceAn all-inclusive fluid-analysis program monitors compressor lubricants for early detection of problemsVibration analysis and trending can pinpoint an impending component replacementOptional remote monitoring provides 24-hour, seven-day-a-week surveillance of your compressorinstallation for the utmost in peace of mind11 INTELLISURVEY:Automated compressor auditDetailed air profileIdentify fast-track savingsopportunitiesFEASIBILITY STUDY.

10 Analysis by walking aroundInterview operations, finance,managementIdentify potential opportunitiesfrom a supply-side audit or fullsystem auditSUPPLY-SIDE AUDIT:Differentials, signals and set points managementPressure drop managementyields significant energysavingsAir Quality management results in significant productivity improvementsFULL SYSTEM AUDIT:All audit components previously identified, exact match of optimaldemand-side requirements to minimum compressed airconsumptionAir leakage and innapropriateuse of compressed airassessmentPRODUCTIVITYEFFICIENCYRELIA BILITYPRODUCTIVITYEFFICIENCYRELIABILITYC ustomer NeedsISSAFSISSAFSFAFASTARTING POINTSISISFSFSSASAFAFA