OIL/WATERenvironmental laws and regulations because the modern oils form an emulsion in the condensate which will not separate on gravity. The old-style (gravity separation/weir type)

RELIABLERELIABLERELIABLE

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ENVIRONMENT SAFEGUARDENVIRONMENT SAFEGUARD

OIL/WATERSEPARATION

SEPREMIUM

JORC Industrial BV

Pretoriastraat 28NL-6413 NN HeerlenThe Netherlands

Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79

[email protected]


COMPRESSED

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OIL/WATERSEPARATION

SEPREMIUM

JORC Industrial BV


Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79

[email protected]

INDEXChapter Content Page

1 Introductiontocompressorlubrication 1 Additives&Detergents 1 Compressedaircondensate 2 Whyinstallanoil/waterseparator 2

2 Willanyoil/waterseparatordo? 3 JORC’sguarantee 3 HowistheSEPREMIUMconstructed? 4 Highperformanceelements 4

3 PrincipleworkingsoftheSEPREMIUM 5 SEPREMIUM2 6

4 DISTRIBUTOR 7 Explodedview 8

5 Dimensions 9 Capacitychart 10

6 Condensateself-test-kit 11 Instructionmanuals 12

7 Servicepacks&multi-inletadapter 13 Functionalsamplebottle&elements 14

Version2013

OIl/w

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Informationprovidedherewithisbelievedtobeaccurateandreliable.However,noresponsibilityisassumedforitsuseorforanyinfringementofpatentsorrightsofothers,whichmayresultfromitsuse.Inaddition,JORCreservestherighttoreviseinformationwithoutnoticeandwithoutincurringanyobligation.

JORCIndustrialisaglobalcondensatemanagementspecialistofDutchoriginofferingcondensatedrains,oilwaterseparatorsandairsavingequipmenttodistributors,dealersandOEM’sinmorethan100countries.JORCIndustrialisdedicatedtosettingthestandardinhelpingitscustomersmanagetheircondensatemanagementrequirements.

CONDENsatE MaNagEMENt spECIalIst

IntroduCtIon to ComPressor lubrICants

Compressedairisthefourthenergyutilityafterelectricity,gasandwater.Fewproductionlinesintheworldwouldrunwithoutit.Themajorityofcompressedairisprovidedbyoil-injectedscrewcompressorsandthecompressoroilsplayamajorroleingeneratingcleancompressedairinanenergy-efficientway.Theyaccountforlessthanonepercentofthecostofcompressoroperation;however,therightoilhelpssaveaconsiderablepartofthetotalcost.

Theoilhasthreekeyfunctions:1. Itensuresthattherotorsandrotorbearingsinthecompressorarelubricated;2. Itdissipatestheheatofthecompressionprocess;3.Itformsasealingfilmatthesealedgebetweentherotorandthecompressorcasing.

Twokeyfactorsplayamajorroleincompressedairgeneration:highavailabilityofcleancompressedairandcompressedairgenerationatreasonablecost.Newlydevelopedsyntheticcompressoroilshaveproventheirworthinpractice.Longoillifetime,highefficiencyandaverylowoilcontentinthecompressedaircombinetoreduceoperatingcostsconsiderably.

Forefficientandtrouble-freeproduction,anoilwithlongservicelifeandgoodtemperaturebehaviorwithlowresidualcontentinthecompressedairisrequired.However,thereareconsiderabledifferencesbetweentheperformancesofdifferentcompressoroils.

Awell-formulatedsyntheticproducthasconsiderableadvantagesovermineraloil-basedproductsandparticularlystandsoutforoptimumoxidationprotection,goodadhesionandlowresidueformation.

However there is a consequence, the modern lubricants create an emulsification in the condensate that does not separate fast enough for gravity type separators. a JorC adsorption type separator offers a guaranteed separating solution.

addItIves & detergents

Oiladditivesarevitalfortheproperlubricationandprolongeduseofaircompressoroil.Withoutmanyofthese,theoilwouldbecomecontaminated,breakdown,leakout,ornotproperlyprotectcompressorpartsatalloperatingtemperatures.

Justasimportantareadditivesforoilsusedinsidegearboxes,automatictransmissions,andbearings.Someofthemostimportantadditivesincludethoseusedforviscosityandlubricity,contaminantcontrol,forthecontrolofchemicalbreakdown,andforsealconditioning.

Someadditivespermitlubricantstoperformbetterundersevereconditions,suchasextremepressuresandtemperaturesandhighlevelsofcontamination.

EffICIENt lubrICatION rEquIrEs EffICIENt sEparatION

lubr

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ComPressed aIr Condensate

Duringtheprocessofcompressingair,atmosphericairalongwithwatervapourandatmosphericcontaminants(hydrocarbon,dustparticlesorchemicalvapours),aredrawnintothecompressorintake.Additionally,thecompressionchambersofmostcompressorsrequireoilforlubrication,sealingandcooling.Oncecompressed,theairflowsintoanaftercoolertoremovetheheatofcompression.Astheaircoolsintheaftercooler,waterandhydrocarbonvapourswillcondense.

Additionalcondensationtakesplaceastheairisfurthercooledinthepipingandairdryers.

Environmentalregulationsstrictlyprohibitthedischargeofoilywastesandchemicals,includingthecondensatedrainedfromacompressedairsystem.Becauseoftheserequirements,municipalitiesregulatethedischargeofcompressorcondensatetosurfacewater,wastewatertreatmentfacilities,andsanitarysewers.

Compressorcondensatemustthereforebeeithercollectedortreatedpriortodisposal.Anoil/waterseparatorcanbeusedheretoremovetheoilfromthecondensate.Untreatedcondensatedisposaliscostlyasyourcustomerwillbechargedbyvolume.Asmostoftheuntreatedcondensateiswateritmakesfinancialsensetoseparatethelubricantfromthecondensatebymeansofanoil/waterseparator.

addItIves & detergents

Condensateisaby-productofaircompressors.Itisamixtureofoilandwaterwithparticlesandhydrocarbonsthathavebeenconcentratedduringthecompressionprocess.

Thismixtureofoilandwaterisclassifiedashazardousindustrialwaste.Environmentallawsandregulationsprohibitthedischargeofuntreatedcompressorcondensateintofoulsewers.

AftertheoilycondensatehasbeenefficientlyremovedfromthecompressedairsystembyareliableJORCdrain,itcannotbedischargeddirectlytothefoulsewerwithoutfirsthavingtheoilcontentreducedtowithinlegaldisposallimits.

Consideringthatcompressorcondensateconsistsofapproximately95%water,itmakesfinancialsensetoseparatetheoilfromthecondensatepriortothewasteisdisposed.

Everyend-userthatoperatesacompressedairsystemshouldhavea(condensate)wastemanagementprogram(ISO14000)inplacenotonlytoabidetolawsandregulationsbuttoalsopracticeecologicalresponsibility.

JORC’sSEPREMIUMOil/WaterSeparatorsareareliable,effective,efficientandaboveallanenvironmentalsolution.

Fullysynthetic Polyglycolbased Mineraloil Semisynthetic Separatedcondensate

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wIll any oIl/water seParator do?

Backinthe1980’sthelubricantwasmuchmorebuoyantversuswaterandassuchfloatedtothewatersurfacemuchquickerthancurrentlubricantsdo.Oil/waterseparatorsthatweredevelopedtoworkonthisgravitytypeseparationmighthaveperformedbetterinthedaysprior to the introduction of “commercial internet…”.

Thesedaystheseold-styleoil/waterseparatorssimplydonotperformtocurrentenvironmentallawsandregulationsbecausethemodernoilsformanemulsioninthecondensatewhichwillnotseparateongravity.

Theold-style(gravityseparation/weirtype)separatorswerealsodevelopedbackinthedaywhenergonomic lawswerenotconsidered,ordidnotexist.Forinstance,theweightofthesaturatedelementsexceedcurrentergonomiclawsandregulations.Carryingoutroutineelementreplacementactivitiesthereforcarriesapotentialrisktotheservicingengineer.

Anno2013itiscriticaltounderstandthatmoderndaylubricationsrequiremoderndayoil/waterseparationtechnologysolutions.JORCisconstantlyindirectcontactwithcompressorlubricationmanufacturerstounderstandandfollowthelubricantdevelopmentbasedonthedemandsmadebecompressormanufacturers.

the sePremIum technology is based on these current and evolving developments.

JorC’s guarantee

ThousandsofJORCoil/waterseparatorsareinstalledworldwide.

TheSEPREMIUMelementsaredesignedandmanufacturedtosuccessfullyseparatecompressorlubricantfromcondensate.

Evenapplicationspecifictailormadeelementsaredesignedandmanufacturedtosuccessfullyoperateinuniquecircumstanceswherebypossibleexternalinfluencesrequiretobeconsidered.

ThereappearstobenoapplicationthatcannotgetresolvedwiththeSEPREMIUMrangeofelementscombinedwithJORC’sin-houseapplicationandproductknowledge.

ParticularlyrelevantfortheGermanmarket,wehavehadtheSEPREMIUMoil/waterseparatortestedtotheDiBtstandards.theSEPREMIUMoil/waterseparatortestedtotheDiBt

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How Is tHe sePremIum ConstruCted?

Therobustrotor-die-castedhousingismadefrompoly-ethylene(PE)materialandthedesignisbasedonJORC’sfamiliartwotowerprinciple.

Weapplybrassthreadinsertstoensureasecurepipinginstallationwithoutrunningtheriskofeasydamagingofthethreads,likeyoucanseewhenapplyingplasticthreads.

TheSEPREMIUMmodelshavethreehighperformanceelementsconsistingoftwopoly-propylenefiberelementsandoneactivatedcarbonelement.

Thereisanelementlifeindicatorofferingyouavisualguidanceastowhentoreplacetheelementswithnewones.

HIgH PerformanCe elements

ThecleverlubricantadsorbingelementsoftheSEPREMIUMaredesignedtoperforminthewidestrangeofapplications.

Thechosenelementfibreshavebeenspeciallyselectedandtreatedtomaximiseitssupremeadsorbingperformance.

WehavebeenabletodesigntheSEPREMIUM’selementsintoamulti-stageconfiguration,offeringanincreasedfiltrationefficiencyandeasyservicingprocedures.

ErgonomiclawsandlegislationhavebeentakenintoaccountduringtheR&Doftheelements.

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CondensatemaybedischargedintotheSEPREMIUMbyanytypeofcondensatedrain.Thedepressurisingchamberneutralisesthepressure.

AscondensateflowsthroughtheSEPREMIUM,theoilisfilteredoutthroughvariousfiltrationelements.

Thefirstoiladsorbingelementhasacleversaturationindicatingfeature,offeringyouavisualelementlifestatusoftheseparatoratadistance.Astheelementsadsorptionlevelincreases,thefirstindicatingelementwillbecomeheavierandslowlysinkdownthetower.Ontopoftheelementthereisanindicatorthatsticksupwhentheelementsarenewandsinksdownwardsasthesaturationlevelsincrease.Oncetheindicatorhascompletelysunkdown,theelementsrequiretobereplacedwithnewones.

Theelementsaredesignedtocombinevarioustypesofadsorptiontechnologiestoachievelessthan10ppmoilresiduevaluesattheoutputstage.

Finalseparationstageincludesspeciallyselectedactivatedcarbontopolishouttheremainingcontaminants.

prEMIuM sEparatION tECHNOlOgy

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ProduCt features

TheSEPREMIUM2isacosteffectivehighperformancesolutionforsmallcompressedairapplications.

TheSEPREMIUM2dropsintoitsholdingbracket(suppliedasstandard).Servicinginvolvesdisconnectingtheinletandoutlet,removingtheseparatorandplacingthenewunitintheholdingbracket.

Therearenoseparatereplacementelementsandassuchservicingisaquickandaboveallacleanprocess.

Brassconnectionsofferaquickcouplinginstallationfeature.

teCHnICal advantages

Theelementcomponentbuild-upoftheSEPREMIUM2ismadeupoutofthesamecomponentsasthelargermodels,offeringhighperformanceseparationofvirtuallyalltypesofcompressorlubricants.

Thepackagecomescompletewiththeinstallationbracketandrelevantfixings.

CommerCIal benefIts

Anytypeofcondensatedrainmaybeappliedincludingcosteffectivetimerdraincombinationoptions.TheSEPREMIUM2isahighlycompetitivelypricedoil/waterseparatorandoffersanincrediblysmallfootprint.Itislight-weightandsimpletoinstall.

Exchangingtheunitscouldnotbequicker,moresimpleorcleaner!

Clean and easy servICIng ProCedure

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ProduCt features

TheDISTRIBUTORisdesignedtocollectanddistributecondensateintotwotoeightoil/waterseparators.

ThiswayyoucancombinemoreSEPREMIUMunitstomatchupagainstlargercompressorsystems.

AscondensateflowsintotheDISTRIBUTORthedepressurisationtakesplace.Thereonafterthecondensateflowsevenlyintotheconnectedoil/waterseparators.Thiswaytheelementsoftheseparatorsareequallyloadedwithcondensatetotreat.

TheDISTRIBUTORhastwo1”condensateinletsandeight1/2”outlets.

TheDISTRIBUTORissuppliedcompletewithwallbracketsandfixings.Aspiritlevelisalsoincludedtoensurethecorrectinstallation.

ProduCt sPeCIfICatIons

Numberofseparatorsthatcanbehookedup 8Inletconnection 1”(2off )Outletconnection 1/2”(8off )Service/drainingvalve YesOverflowwarningindicator YesHousingmaterial PETotalrecyclable YesHousingcolour Black

Installationkitincluded Yes

suPPlIed wItH all tHe fIXIngs

Completeinstallationkit isincluded

Servicevalve Overflowindicator

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TheSEPREMIUMmodels5,10,20and30aredesignedtooperatethesameway.Differencesarephysicalsizingtoaccountforthevariouscompressorcapacitiesandcondensateflows.

AkeyfeatureoftheSEPREMIUMisthesimplicityandeaseofservicing.

Theelementsaredesignedtobereplaced/servicedinatimeefficientway.Theyarealsodesignedtobeaslight-weightaspossible.

BrassthreadsaddtotheprofessionalfinishoftheSEPREMIUM.

AsstandardtheSEPREMIUMpackageincludesaninstallationclothingkitincludingabreathingmask,toprotectyourserviceengineerfromcarbondust,wealsoincludethefunctionalcondensatesamplebottleforroutineinspectionandfinallyastepbystepinstructionmanualtoensureaproperinstallation.

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dIstrIbutor

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models 2 5 10 20 30

Max.compressorcapacity(m3/min) 2 5 10 20 30*Maximumoiladsorption(litres) 2 5 10 15 25Inletconnections 1/2” 1/2”(2) 1/2”(2) 1/2”(2) 1/2”(2)Outletconnection 1/2” 1” 1” 1” 1”Testvalve no yes yes yes yesServicedrain no no yes yes yesOverflowindicator no yes yes yes yesTargetoutputvalue <10ppm <10ppm <10ppm <10ppm <10ppm

Housingmaterial ABS PE PE PE PETotalrecyclable yes yes yes yes yesHousingcolour Black Black Black Black BlackLidcolour Darkgrey Darkgrey Darkgrey Darkgrey Darkgrey

Minerallubricants yes yes yes yes yesSyntheticlubricants yes yes yes yes yesStabilecondensateemulsions yes yes yes yes yesPolyglycol,Roto-Inject,SigmaMol**yes yes yes yes yes

*ConsultJORCforlargercapacities,seepage7fortheDISTRIBUTORdetails.**ConsultJORCforspecialelementsand/or24/7applications.ConsultJORCforprivatelabelling.

**Roto-inject,UltracoolantandSigmaMolareoilbrandsavailableinmarketforcompressorlubrication.

easy maIntenanCe

TheinitialinstallationoftheJorC sePremIumoil/waterseparatorwillrewardyouwithahighperformingseparationperformance.Thereonafterthemaintainingandservicingoftheoil/waterseparatorisrequired.Heretoowehavedesignedthereplacementoftheelementstobelightandsimple.

JORCalsooffersacondensateself-test kitthatallowsyoutoperformcondensateseparatingtests,pleasesee page 11 for details.

TheJorC warnerisanalarmsystemthatsendsSMSmessagestoyourmobilephone,pleasecheckourwebsitehttp://www.jorc.eu/7600main.htm

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Condensate self-test-kIt

JORCoffersanin-houselaboratorytestkittoanalyseanddeterminethesuccessrateofouroil/waterseparatorspriortosaleand/orinstallation.

Potentialcomplicatedcompressorsystems,i.e.twodifferentcompressorbrandswithdifferentlubricantscouldmakeitdifficulttodeterminewhichelementstouse.Thisself-testkitwillenableyoutodeterminetherightunitandtodemonstrateitseffectivenesstoyourcustomerpriortoinstallation.

Thetestkitconsistsofauniversalkitforalltypesoflubricants,anytypeofcompressoretc.

Thetestisquitesimpletocarryoutandadetailedinstructionmanualisprovided.Aftercarryingoutyourtestweadviseiftailormadeelementsarerequired.

Ifyourcustomerhasafailingoldstyleseparator,thisisanidealtooltoapplytoprovetheSEPREMIUMwillsolvetheproblem.

taIlor made elements

TheSEPREMIUMelementsoffersupremeseparationperformanceinapplicationswhereotherseparatorsarefailingtoseparatethelubricantfromcondensate.

ApplicationswhereyourcustomermighthavetwodifferentcompressormodelsrunningontwodifferenttypesoflubricantformsnoproblemfortheSEPREMIUMseparators.

Whenastabileemulsionflowsthroughtheseparatorwehavelimitedtimetoextractthelubricantfromthecondensate.

AtJORCweareabletomodify/adaptthepolymerfibrestosuitspecificseparatingrequirements.Inshort,weareabletominimisethecontacttimerequiredtoadsorbthelubricant.

Youwillbegivenaspecificpartnumberrelatingtoaspecialseparatingcase.Thiswayyouwillalwaysapplythecorrectelementsintherightapplication.

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InstruCtIon manuals

Theinstallationisasgoodastheinstructionmanual!

TheinstallationprocedureoftheSEPREMIUMseparatorsisquitestraightforward.NeverthelesswehavedesignedtheinstructionmanualswithstepbysteppicturesofeveryaspectinvolvedingettingyourSEPREMIUMupandrunning.

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sePremIum servICe PaCks

TheSEPREMIUMservicepackincludes:

• threeelements

• plasticwastebagsfor disposingthesaturated elements

• clothingkitcomprisingof amouthmask plasticgloves plasticoverall (aspictured).

multI-Inlet adaPter

TheMulti-inletadapterallowsforuptothreeadditionalcondensateinletoptions.

ThebrassadapterthreadsintothebrassinletoftheSEPREMIUM.

Tosimplifyinstallation,weincludethebrasshoseconnectionnipplesalso.

lIgHt weIgHt elements for

easy servICIng!

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funCtIonal samPle bottle

TheJORCoil/waterseparatorsincludeafunctionalsamplebottleforvisualroutineinspectionoftheoutputquality.

Thisvisualinspectionsamplebottleofferstheserviceengineeranindicationoftheoutputperformance.

Thesamplebottlekitispositionedinthetowerlid.

adaPters

Adapter,nipplesandhoseconnectorsappliedonallJORC’sseparatorsarealsoavailableasstandaloneproducts.

rePlaCement elements

Replacementelementsofvirtuallyallcompetitiveoil/waterseparatormodelsareavailable.

TheseareproducedwithJORC’shighqualitynettingsandfillings.

competitiveoil/waterseparatormodels

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COMPRESSED

AIR COND

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ANAGEM

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ERGY SAVING PROD

UCTS


OIL/WATERSEPARATION

SEPREMIUM

JORC Industrial BV


Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79

[email protected]

Documents

OIL/WATERenvironmental laws and regulations because the modern oils form an emulsion in the condensate which will not separate on gravity. The old-style (gravity separation/weir type)