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RELIABLERELIABLERELIABLE
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
ENVIRONMENT SAFEGUARDCOMPACT TECHNOLOGY
OIL/WATERSEPARATION
PURO-CT
JORC Industrial BVPretoriastraat 28NL-6413 NN HeerlenThe Netherlands
Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79
INDEXChapter Content Page
1 Introductiontocompressorlubrication 2 Additivesanddetergents 2 Compressedaircondensate 3 Whyinstallanoil/waterseparator 3
2 Willanyoil/waterseparatordo? 4 JORC’sguarantee 4 HowisthePURO-CTconstructed? 5 Thehighperformanceelements 5
3 HowdoesthePURO-CTwork? 6 Colouroptions 7
4 PURO-CT-DISTRIBUTOR 8 Explodedview 9
5 Dimensions 10 Capacitychart 11
6 Condensateself-test-kit 12 Instructionmanuals 13
7 Servicepacks&Accessories 14 Samplebottle&Adapters 15
Version2013
OIl/w
atEr sEparatIO
N
Oil/
wat
er s
epar
atio
n
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
ICat
ION Chapter 1
2
CON
DEN
satE
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.
wHy Install an oIl/water seParator?
Condensateisaby-productofaircompressors.Itisamixtureofoilandwaterwithparticlesandhydrocarbonsthathavebeenconcentratedduringthecompressionprocess.
Thismixtureofoilandwaterisclassifiedashazardousindustrialwaste.Environmentallawsandregulationsprohibitthedischargeofuntreatedcompressorcondensateintofoulsewers.
AftertheoilycondensatehasbeenefficientlyremovedfromthecompressedairsystembyareliableJORCdrain,itcannotbedischargeddirectlytothefoulsewerwithoutfirsthavingtheoilcontentreducedtowithinlegaldisposallimits.
Consideringthatcompressorcondensateconsistsofapproximately95%water,itmakesfinancialsensetoseparatetheoilfromthecondensatepriortothewasteisdisposed.
Everyend-userthatoperatesacompressedairsystemshouldhavea(condensate)wastemanagementprogram(ISO14000)inplacenotonlytoabidetolawsandregulationsbuttoalsopracticeecologicalresponsibility.
JORC’sPURO-CToil/waterseparatorsareareliable,effective,efficientandaboveallanenvironmentalsolution.
Fullysynthetic Polyglycolbased Mineraloil Semisynthetic Separatedcondensate
Chapter 1
3
Ma
kE
tHE
rIg
Ht
CHO
ICE
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 Puro-Ct technology is based on these current and evolving developments.
JorC’s guarantee
ThousandsofJORCoil/waterseparatorsareinstalledworldwide.
ThePURO-CTelementsaredesignedandmanufacturedtosuccessfullyseparatecompressorlubricantfromcondensate.
Evenapplicationspecifictailormadeelementsaredesignedandmanufacturedtosuccessfullyoperateinuniquecircumstanceswherebypossibleexternalinfluencesrequiretobeconsidered.
ThereappearstobenoapplicationthatcannotgetresolvedwiththePURO-CTrangeofelementscombinedwithJORC’sin-houseapplicationandproductknowledge.
Chapter 2
4
purO
-Ct kN
Ow
lEDg
E
How Is tHe Puro-Ct ConstruCted?
Therobustinjection-die-castedhousingismadefromPPCmaterialandthedesignisbasedonJORC’sfamiliartwotowerprinciple.
Weapplybrassthreadinsertstoensureasecurepipinginstallationwithoutrunningtheriskofeasydamagingofthethreads,likeyoucanseewhenapplyingplasticthreads.
ThePURO-CTmodelshavetwohighperformanceelementsconsistingofonepoly-propylenefiberelementandoneactivatedcarbonelement.
Thetestvalveandtestbottleoffersimpleroutinesampletakingandthisgiveyouavisualindicationoftheoutputperformance.
HIgH PerformanCe elements
ThecleverlubricantadsorbingelementsofthePURO-CTaredesignedtoperforminthewidestrangeofapplications.
Thechosenelementfibreshavebeenspeciallyselectedandtreatedtomaximiseitssupremeadsorbingperformance.
WehavebeenabletodesignthePURO-CTelementsintoamulti-stageconfiguration,offeringanincreasedfiltrationefficiencyandeasyservicingprocedures.
ErgonomiclawsandlegislationhavebeentakenintoaccountduringtheR&Doftheelements.
Chapter 2
5
HO
w D
OEs
It w
Ork
PrInCIPle workIngs of tHe Puro-Ct
CondensatemaybedischargedintothePURO-CTbyanytypeofcondensatedrain.Thedepressurisingchamberneutralisesthepressure.
AscondensateflowsintothePURO-CT,theoilisfilteredoutthroughvariousfiltrationelements.ThePURO-CTusesadsorptionfiltermaterials,insteadofaweir,toremovethebulkoftheoil.ThelifeofthePURO-CTfirststagefiltrationelementisdeterminedbytheamountofoilremoved,notbytheamountofcondensatetreated.ThePURO-CTcarbonelementisutilisedonlyforfinalpurificationpurposesandensuresthatthetargetedvaluesof<10ppmareachieved.
TheprofessionaldesignofthePURO–CTisincrediblycompactandtheelementsarelightweight,maximisingtheergonomicfactorswhencarryingoutroutinemaintenance.Theelementsaredesignedtocombinevarioustypesofadsorptiontechnologiestoachievelessthan10ppmoilresiduevaluesattheoutputstage.
COMpaCt tECHNOlOgy
Chapter 3
6
COlO
ur O
ptION
s
standard Colour
Thestandardcolourcombinationisgreytowersandablacklid.
Colour oPtIons
ThePURO-CTcanbesuppliedinabranded/privatelabelledversion.Colouroptionsofthelidispartofthebrandingfeatures.
Chapter 3
7
purO
-Ct-
DIs
trIb
utO
r
ProduCt features
ThePURO-CT-DISTRIBUTORisdesignedtodistributecondensateintotwoorthreeoil/waterseparators.
ThiswayyoucaneconomicallycombinemorePURO-CTunitstomatchupagainstlargercompressorsystems.
AscondensateflowsintothePURO-CT-DISTRIBUTORcondensateflowsevenlyintotheconnectedoil/waterseparators.Thiswaytheelementsoftheseparatorareequallyloadedwithcondensatetotreat.
ThePURO-CT-DISTRIBUTORhasa1/2”condensateinletandthree1/2”outlets.
ThePURO-CT-DISTRIBUTORissuppliedcompletewiththerequiredfixings.
ProduCt sPeCIfICatIons
Numberofseparatorsthatcanbehookedup 3Inletconnection 1/2”Outletconnection 1/2”(3off )Totalrecyclable YesColour Grey
Installationkitincluded Yes
suPPlIed wItH all tHe fIxIngs
Chapter 4
8
purO
-Ct - EXplO
DED
VIEw
exPloded vIew
ThePURO-CTmodels3,7and15aredesignedtooperatethesameway.Differencesarephysicalsizingtoaccountforthevariouscompressorcapacitiesandcondensateflows.
AkeyfeatureofthePURO-CTisthesimplicityandeaseofservicing.
Theelementsaredesignedtobereplaced/servicedinatimeefficientway.Theyarealsodesignedtobeaslight-weightaspossible.
BrassthreadsaddtotheprofessionalfinishofthePURO-CT.
AsstandardthePURO-CTpackageincludesaninstallationclothingkitincludingabreathingmask,toprotectyourserviceengineerfromcarbondust,wealsoincludethefunctionalcondensatesamplebottleforroutineinspectionandfinallyastepbystepinstructionmanualtoensureaproperinstallation.
Chapter 4
9
purO
-Ct
DIM
ENsI
ON
s
dImensIons
Puro-Ct 3
Puro-Ct 15
Chapter 5
10
Puro-Ct 7
Capa
CIty CHa
rt
CaPaCIty CHart
models Puro-Ct 3 Puro-Ct 7 Puro-Ct 15
Max.compressorcapacity(m3/min) 3 7 15Maximumoiladsorption(litres) 3 7 15Inletconnections 1/2” 1/2” 1/2”Outletconnection 1/2” 1/2” 1/2”Testvalve yes yes yesOverflowindicator yes yes yesTargetoutputvalue <10ppm <10ppm <10ppm
Weight(Packaged)approx 7kgs 11kgs 19kgsPalletquantity 30pieces 20pieces 12pieces
Housingmaterial PPC PPC PPCTotalrecyclable yes yes yesHousingcolour Grey Grey GreyLidcolour Black Black Black
Separationof:Minerallubricants yes yes yesSyntheticlubricants yes yes yesStabilecondensateemulsions yes yes yesPolyglycol,Roto-Inject,SigmaMol**yes yes yes
*ConsultJORCforlargercapacities,seepage9fortheDISTRIBUTORdetails.**ConsultJORCforspecialelementsand/or24/7applications.
ConsultJORCforprivatelabelling.
**Roto-inject,UltracoolantandSigmaMolareoilbrandsavailableinthemarketforcompressorlubrication.
easy maIntenanCe
TheinitialinstallationoftheJorC Puro-Ctoil/waterseparatorwillrewardyouwithahighperformingseparationperformance.Thereonafterthemaintainingandservicingoftheoil/waterseparatorisrequired.Thereplacementoftheelementsislightandsimple.
JORCalsooffersacondensateself-test kitthatallowsyoutoperformcondensateseparatingtests,please see page 12 for details.
Chapter 5
11
tEst
kIt
Condensate self-test-kIt
JORCoffersanin-houselaboratorytestkittoanalyseanddeterminethesuccessrateofouroil/waterseparatorspriortosaleand/orinstallation.
Potentialcomplicatedcompressorsystems,i.e.2differentcompressorbrandswithdifferentlubricantscouldmakeitdifficulttodeterminewhichelementstouse.Thisself-testkitwillenableyoutodeterminetherightunitandtodemonstrateitseffectivenesstoyourcustomerpriortoinstallation.
Thetestkitconsistsofauniversalkitforalltypesoflubricants,anytypeofcompressoretc.
Thetestisquitesimpletocarryoutandadetailedinstructionmanualisprovided.Aftercarryingoutyourtestweadviseiftailormadeelementsarerequired.
Ifyourcustomerhasafailingoldstyleseparator,thisisanidealtooltoapplytoprovethePURO-CTwillsolvetheproblem.
taIlor made elements
ThePURO-CTelementsoffersupremeseparationperformanceinapplicationswhereotherseparatorsarefailingtoseparatethelubricantfromcondensate.
ApplicationswhereyourcustomermighthavetwodifferentcompressormodelsrunningontwodifferenttypesoflubricantformsnoproblemforthePURO-CTseparators.
Whenastabileemulsionflowsthroughtheseparatorwehavelimitedtimetoextractthelubricantfromthecondensate.
AtJORCweareabletomodify/adaptthepolymerfibrestosuitspecificseparatingrequirements.Inshort,weareabletominimisethecontacttimerequiredtoadsorbthelubricant.
Youwillbegivenaspecificpartnumberrelatingtoaspecialseparatingcase.Thiswayyouwillalwaysapplythecorrectelementsintherightapplication.
Chapter 6
12
INstru
CtION
Ma
Nu
als
InstruCtIon manuals
Theinstallationisasgoodastheinstructionmanual!
TheinstallationprocedureofthePURO-CTseparatorsisquitestraightforward.NeverthelesswehavedesignedtheinstructionmanualswithstepbysteppicturesofeveryaspectinvolvedingettingyourPURO-CTupandrunning.
Chapter 6
13
aCC
EssO
IrEs
Puro-Ct servICe PaCks
ThePURO-CTservicepackincludes:
•twoelements
•plasticwastebagsfordisposingthesaturated
elements
•clothingkitcomprisingofamouthmaskplasticglovesplasticoverall(aspictured).
multI-Inlet adaPter
TheMulti-inletadapterallowsforuptothreeadditionalcondensateinletoptions.
ThebrassadapterthreadsintothebrassinletofthePURO-CT.
Tosimplifyinstallation,weincludethebrasshoseconnectionnipplesalso.
lIgHt weIgHt elements for
easy servICIng!
Chapter 7
14
aCCEssO
IrEs
funCtIonal samPle bottle
TheJORCoil/waterseparatorsincludeafunctionalsamplebottleforvisualroutineinspectionoftheoutputquality.
Thisvisualinspectionsamplebottleofferstheserviceengineeranindicationoftheoutputperformance.
Thesamplebottlekitispositionedinthetowerlid.
adaPters
Adapter,nipplesandhoseconnectorsappliedonallJORC’sseparatorsarealsoavailableasstandaloneproducts.
rePlaCement elements
Replacementelementsofvirtuallyallcompetitiveoil/waterseparatormodelsareavailable.
TheseareproducedwithJORC’shighqualitynettingsandfillings.
competitiveoil/waterseparatormodels
Chapter 7
15
COM
prEs
sED
aIr
CO
ND
ENsa
tE M
aN
ag
EMEN
t a
ND
EN
Egry
saV
INg
prO
Du
Cts
notes
RELIABLERELIABLERELIABLE
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
COMPRESSED
AIR COND
ENSATE M
ANAGEM
ENT AN
D EN
ERGY SAVING PROD
UCTS
ENVIRONMENT SAFEGUARDCOMPACT TECHNOLOGY
OIL/WATERSEPARATION
PURO-CT
JORC Industrial BVPretoriastraat 28NL-6413 NN HeerlenThe Netherlands
Tel: +31 (0) 45 524 24 27Fax: +31 (0) 45 524 19 79
