Maintenance Technology May 2016 - (Page 34)
FLUID HANDLING
Don't Ignore
Compressed Air Filters
COMPRESSED AIR FILTERS are often-forgotten
items that can affect the quality of your air supply
and-surprisingly-the efficiency of your overall
system. You can't afford to overlook them.
Air compressors ingest atmospheric air from the
compressor room, pass it through an inlet filter, and
compress it to a space about 1/7th the original size.
This process generates large amounts of heat that must
be removed by some type of cooler. When this is done,
moisture is squeezed and condensed out of the air
and mostly eliminated by a water separator. While it's
inside the compressor, though, the air also picks up
small amounts of the equipment's lubricant. Any dust
in the air as it passed the inlet filter remains, but in a
denser form due to the reduction in volume.
Water, lubricant, and dust particles that
aren't filtered out before they reach the
air dryer will travel to points unknown
throughout the system. Among other
things, such contaminants could then
ruin your product or clog the internal
pneumatic circuits of expensive production equipment. That's why compressed
air filtration is so important.
Fortunately, there are many different
types and styles of filtering solutions in the marketplace, ranging from very
coarse elements that remove large particles to very fine ones that remove tiny
dust particles and minute traces of lubricant and water. Unfortunately, all
filters present a restriction to the flow of air that leads to the development of
pressure differential.
Pressure differential consumes energy in compressed air systems. About
1% of additional power is required for every 2 psi higher compressordischarge pressure. Thus, filters need to be chosen wisely. Note, too, that
there's usually a balance between the need for clean air and the cost of
compressor operation. In general, the finer your filtering, the higher your
energy costs.
That said, who chooses your filters and why? Frequently it's the
compressor supplier-who might have somewhat of a vested interest in
supplying your operations with filter elements for years to come. Often, you'll
find a train of multiple filters installed in a compressor room, from coarse to
fine, sometimes in multiple groups before and after the air dryer. These types
of units can represent the biggest pressure differential in a plant.
Ron Marshall
Compressed Air Challenge (CAC)
Contaminants, among other
things, that aren't filtered from
your compressed air system could
clog internal pneumatic circuits of
expensive production equipment.
Tips to reduce your filtering costs:
■ Investigate your air-quality requirements
and filter only to the level you really need.
■ Realize that a filter is removing something,
which must eventually be removed. If
that "something" is liquid, an airless drain
should be used. If it's a solid, you must
regularly replace the filter element to keep
an excessive pressure differential from
developing.
■ Keep in mind that some filters lead to
higher levels of pressure differential
than others. Where possible, use misteliminator-type or oversized filters to
reduce pressure loss.
■ Measure the pressure loss across filters
with accurate installed gauges. MT
For more information on compressed air topics and related training through the Compressed Air Challenge (CAC),
visit compressedairchallenge.org, or contact Ron Marshall directly at ronm@marshallcac.com.
34 |
MAINTENANCE TECHNOLOGY
MAY 2016
http://www.compressedairchallenge.org
Table of Contents for the Digital Edition of Maintenance Technology May 2016
Editorial
Uptime
On The Floor
A 40% Production Boost From Reliability
Beck Helps Women Excel In Engineering
Unleash Your Plant's Hidden Potential
Right-Size Your Maintenance Organization
Respect The Cornerstones of Manual Grease Lubrication
Motor Connection Advice
Maximize Millennial Workers
Compressed Air Filtration
Pneumatic Tubing & Hose Specs
Products
Showcase
Ad Index
Final Thought
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