Mike Clarkson
Hiross Zander Division
Marketing & Business
Development Manager
Attention: Contamination!
April 8, 2015
Particulate
Particle contamination in a compressed air system comprises
Atmospheric dirt, micro-organisms, rust and condensate deposits
Much of the contamination is less than 40 millionth of a meter in size
(40 micron) and thus remains hidden from the human eye.
3
Water
4
Oil
5
Why
use microfilters?
Compressing
the problem!
Compressor
Compressor After-Cooler
Compressing
the
contamination
Remaining oil
content after
compressor
plus
Condensate
Compressed Air
plus
Atmospheric
Contamination.
Particulate and
Humidity.
Expansion of the
Compressed air
Particulate
and humidity
from the
atmosphere.
6
Oil
Condensate
The new “GL-Technology”: Lowest energy
requirement at highest validated
performance!
April 8, 2015
Why are we replacing the Zander “GSeries” with the “GL-Series?”
• New international standards
(ISO12500-1) (increased demands
on performance)
• Competitor activity (Filter element
business at risk!)
• Innovation (maintaining marketleadership)
• A new “Marketing-Story “
8
Zander “GL-Filter series”
Development goals
April 8, 2015
What did we want to achieve in the
development of a new compressed
air filter range?
• The highest, validated compressed air quality
• Optimum flow characteristics (energy-loss kept to a minimum)
• A reduction in the operating costs in comparison with the existing
range
• Secure the replacement element business. Remove the threat of
pirate copies or at least make copying unaffordable
• Maintain the key features of the Zander “G-Series” (Taking
account of the customer survey )
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Input from Customer Survey
•
•
•
11
World-wide scope of approvals
All vendors located in Europe, all drawings owned by Zander
BSP-P connections – Improvement on Parker dh Evolution filter range
Input from Customer Survey
•
12
Larger connections sizes – better match to compressor flows and lower
delta p
Input from Customer Survey
•
•
13
Pressure gauges optional, all types still available
Drain connection via ½“ - free flow of liquid
Input from Customer Survey
•
•
•
•
14
No extended servicing space necessary below the bowl
One flow direction: inside-out
Inlet marking on the filter head – clear orientation
No over-tightening of housing thread
Input from Customer Survey
•
•
•
15
ISO 12500-1 performance for standardised oil-loading – catch- up with Parker domnick
hunter Division, Donaldson/Ultrafilter, and Hankison
Outer sock - higher oil loading possible
Captive element design – protection against pirates
Customer Survey - Crucial Points
• Third party ISO-performance certificates
• Variances to assembly dimensions of series G
Cross Port Dims
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Ref
Head Size
Port Size
G02
G03
G05
G07
G09
G11
G12
G13
G14
G17
G18
G19
1
1/4"
3/8"
1/2"
3/4"
1"
1 1/2"
1 1/2"
2"
2 1/2"
2 1/2"
3"
3"
2
3
4
5
Proposed
67
89
89
89
130
130
164
164
164
192
192
192
Mounting Hole Ctrs
Existing Proposed
61
87
87
87
130
130
130
130
164
164
250
250
Red cells highlight values different from the existing product
42
62
62
62
84
84
121
121
121
140
140
140
Existing
34
46
46
46
82
82
82
82
N/A
N/A
N/A
N/A
Customer Survey – Cont.
17
Customer Survey – Cont.
18
Customer Survey – Cont.
19
Customer Survey – Cont.
20
Customer Survey – Cont.
21
Parker Zander “GL-Filter series
Improvement in flow characteristics – Air Flow
Management
April 8, 2015
Improving the air inlet to the filter
element
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•
Where air flows across a sharp
edge, turbulence can occur.
This leads to increased resistance
to flow and an insufficient
distribution of the air flow.
•
The current filter element
design, also true of Zander
The air entering the element is
directed through a sharp 90°
angle. Turbulence, pressure drop,
insufficient distribution of the air
throughout the filter media is the
result.
Such rapid changes in direction
lead to turbulent flow, system
pressure drop and increased
running costs.
Improving the air inlet to the filter
element
•
24
Improvement – rounded corners reduce
turbulence. The air flow however still doesn`t
flow into the element in an even manner.
Improving the air inlet to the filter
element – Aerospace Technology!
25
•
Optimum solution – The addition of
deflector-vanes in the air-inlet and a conical
air dispenser at the base of the element
prevent turbulence by maintaining an even
flow distribution at a minimum pressure
drop.
•
Hard to believe, but its true!
Compare a conventional 90° angle and the
savings of up to 75% to be gained from
turbulence-free flow
The optimum combination
•
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Deflector-vanes direct the air flow in
an unrestricted even-manner into the
filter element.
Parker Zander “GL-Filter series”
Filter element construction - Inlet-/Outlet
April 8, 2015
Air inlet – Do away with energy-killers:
Conical “full-flow” filter housing inlet
• Free-flow, turbulence-free
transition of the air
entering the filter element.
No knife-edges.
• The inlet channel to the
filter element (top end-cap)
matches the inlet diameter
of the filter housing.
• The top end-cap seals with
the aid of two o-rings,
above and below the
opening.
28
Air inlet – “Its plain sailing”:
Flow disribution
29
•
“its plain sailing”: Airospace
deflector-vanes enable the air
to flow evenly into the filter
element.
•
“Go with the flow” - Optimum
air distribution throughout the
entire filter element with the
aid of a flow distributor
protruding into the heart of the
element. This unique
construction ensures full
utilisation of the entire surface
area.
No impact on the base of the element!
•
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A conical soft-air disperser at the base
of the filter element prevents turbulence
and directs the flow out through the filter
media in an even manner.
A “successful escape!”
•
31
External air stabilisers,
located on the filter
element top end-cap
ensure the even flow of
compressed air exiting
the filter housing.
Parker Zander “GL-Filter series”
Filter Media
April 8, 2015
The Filter Media – Nano-Technology!
•
High-efficiency filter media
manufactured from borosilicate nanofibres with a voids volume of 96%.
•
A special “oleophobe” coating is
applied to the filter media to actively
repel oil and water.
•
What is nano-technology? Nano
comes from the Greek word “nanos”,
meaning dwarf. 1 Nano =
1m/1.000.000.000. Nano technology
is a particular desigb in atomic and
molecular dimensions. Nano
technology is not a new product, but
a manufacturing technology!
33
Parker Zander incorporates borosilicate nano-fibre technology into it´s current range of filters and into the new GL-filter generation. We termed
this material „borosilicate microfibre“ in the past. The change in name is indicative for the development in analytical methods which make it
possible to establish the presence of nano-fibres in the material previously refered to as micro-fibre. As the technology exists to proove the
presence of such fibres, we now term this filter media „Nano-fibre.“
Large area – greater outcome!
•
Deep-bed pleating techniques result in
4,5 times more effective filtration area
than conventional filter elements –
resulting in increased particulate
retention, reduced space and lower
operating costs
Pleated construction
Zander G-Series
34
Wrapped construction
still seen in many filter elements
in the market (dh & Zander in the past)
Oil-repelling filter media
•
35
The filter media actively repels
oil and water (oleophobic
coating)
Large area – greater outcome!
•
•
The surface area of the filter
media has been optimised using
deep-pleat technology. A
pioneering manufacturing
process representing
considerable technological
advancement.
No “glued seam” – now replaced
by ultra-sound welding.
In contrast, a filterelement from the competition
Quelle: http://www.ultrafilter-elemente.ch/
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Parker Zander “GL-Filter series”
Why change a winning concept?
April 8, 2015
Compressed air must not only be
clean, but also efficient!
As well as the removal of contamination, the economics
of using compressed air filters plays an important role.
Here the requirement is one of minimising costs and
achieving a balance between the compressed air quality
being sought and the amount of energy necessary to
achieve it.
The international standard for compressed
air quality provides a simple, clear system
for the classification of the three main sources
of contamination, namely, water, oil and particulate.
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Quality requirements - ISO 8573.1
Previous specification
QUALITY CLASS
1
2
3
4
DIRT
CONCENTRATION
Particle size in micron
mg/m³
0,1
0,1
1
1
5
5
15
NOT DEFINED
IS0 8573 : 1991, Part 1 for particle contamination
39
In the 1991 edition, the specification
states a maximum particle size and
a concentration. The 2001 edition
however states a maximum quantity
of particles per cubic-meter. In order
to appreciate the increase in the
demand made on air quality
between these dates, the 1991
particle concentration csn be
converted into the particle quantity.
Quality requirements - ISO 8573.1
QUALITY CLASS
1
2
3
4
EDITION 2001, "X-TIMES" CLEANER THAN IN EDITION 1991
0,1 - 0,5 Micron
1,9 Billion times cleaner than class 1 in 1991
19.000 times cleaner than class 2 in 1991
7.000 times cleaner than class 3 in 1991
This technique shows how much cleaner the 2001
classification is, compared with 1991.
In accordance with this statement, class 1 in the 1991
edition became class 2. In accordance with the 2001
edition it was only possible to achieve class 1 with a
sterile air filter!
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Quality Requirements - ISO
8573.1:2010
Compressed air quality in accordance with
class 1 for particulate means: Per m³ of
compressed air, the particle quantity should
not exceed 20.000 particle in the size range
0,1 to 0,5. (400 particles in the size range 0,5
to 1 micron and 10 particles in the size range
1 to 5 microns).
Particulate
ISO 8573.1:2010
The new edition of ISO 8573.1 establishes considerable higher limits for
particulate contamination. At first glance, this looks like a worstening of the
recommended purity classes!
Classification
Industrial end-users will profit from the new edition of ISO 8573.1. It
establishes more realistically achievable values. It is however advisable to
agree which edition of ISO 8573.1 is being referred to when agreements
are being made!
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Wet Particles
Dry Particles
1
Parker Zander GL_Z & GL_X Filters
Parker Zander GL_Z & GL_X Filters
2
Parker Zander GL_Z Filters
Parker Zander GL_Z Filters
3
Parker Zander GL_Z Filters
Parker Zander GL_Z Filters
4
Parker Zander GL_Z Filters
Parker Zander GL_Z Filters
5
Parker Zander GL_Z Filters
Parker Zander GL_Z Filters
Proof of performance: The bar is high –
but we´re raising it higher!
Quality class performance in terms of oil contamination,
in accordance with ISO 8573.1 makes no statement regarding
the up-stream oil loading entering the filter to arrive at the
downstream performance levels required by the norm.
For a few years now (since 2007), an international specification
governs the inlet oil loading to be achieved and the test equipment
to be adopted, to validate the performance of compressed air filters
in terms of their stated downstream remaining oil content results.
Test methods in accordance with ISO 12500 – Finally a clear statement!
42
Proof of performance: The bar is high –
but we´re raising it higher!
A standardised statement regarding the inlet oil loading exists since 2007.
A basis has been established against which measurements can be made
and validation undertaken.
Source: Brochure: Donalson Ultrafilter
Donaldson Filter 0320
Filter Grade
V-Filter
S-Filter
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Flow Rate m³/h
320
320
Differencial pressure
Measured
Inlet oil
Brochure value
Differential pressure
concentration
Dry mbar Saturated mbar Dry mbar Saturated mbar
mg/m³
110
130
80
115
93
292
40
10
Remaining oil content
brochure value
mg/m³
0,2
0,01
Actual
remaining oil content
mg/m³
7,864
0,008
Proof of performance: The bar is high –
but we´re raising it higher!
Stated remaining oil content values, following a high
performance filter are in actual fact limited in their
meaningfulness. However, where account is taken of the
validated inlet-loading in accordance with ISO 12500-1, it
becomes clear in what range high-performance filters really
do perform.
New GL-Filtration technology delivers what it states and offers
you an independent, validated statement of performance in
accordance with ISO 12500-1.
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Parker Zander “GL-Filter series
Coalescing principle
April 8, 2015
Why filter elements with an external
drainage layer?
Why an external drainage layer again?
The new ISO 12500-1 establishes high levels of
separation duty to be performed. With 40 mg of oil
inlet concentration, performances of 99,95% are
not achievable with filter elements containing a
thin internal drainage layer.
In 1990 and the years to follow, the internal
drainage layer was second to none in comparison
with an external „foam sock.“ (compatibility
problems, low resistance to pulsation).
Furthermore the new „drainage sock“ represents a
new material with oleophobic properties. This is no
longer comparable with the less stable foam from
two decades ago. Since that time materials
technology has made considerable improvements
in performance and reliability.
46
External drainage „sock“, manufactured
from oil and water repelling material
47
•
Liquid repelling material achieves
excellent drainage results.
•
Max. operating temperature 80°C
where an internal float-drain is
installed and 100°C with a manual
drain.
•
Resistent to all mineral and
synthetic compressor oils.
Old, used compressor oil
“No wet feet!”
• No “wet-band” formation, no
etra turbulent-free zone.
Optimum drainage – bottom
end-cap shrouded in drainage
material.
• Traditional filter elements
exhibit a wet-band around the
base.
• 40% more flow through a small
filter element where “wet-band”
formation is prevented.
48
“No wet feet!”
• Cast housing-ribs
compress the lower
part of the filter
element and
encourage liquid
coalescence via
capillary forces.
49
The sum of all features
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Parker Zander “GL-Filter series”
Product variation
April 8, 2015
Optimum fit – no „bottle-necks!“
•
52
GL-series filters have nominal
inlet & outlet connections, which
have been matched to meet
those of the most popular
compressor flow rates.
Mounting two filters of the same size
together?
•
53
The new GL-series maintains the tried
and trusted method of mounting filters
together with the aid of a tie-rod.
Simple filter element replacement?
Clear indication of the filter inlet
avoids confusion
54
•
Simple maintenance and filter
element replacement
•
Clean filter element replacement!
Avoidance of touching the soiled
area of the filter element.
•
Minimum installation height
required to remove filter element
(no tie-rod connection)
•
Space-saving design enables the
installation of the filter in an area
of limited space
The sum of all parts
•
Complete corrosion
resistance – alo-chromed
housings protected with a
tough dry-powder epoxy
coating.
Alo-chrom treatment avoids Un-treated aluminium
corrosion
exhibits corrosion
55
Parker Zander “GL-Filter series”
Putting on the pressure – but not at all cost!
April 8, 2015
Pressure drop costs money!
Pressure resistance
57
•
In order to maintain the required
operating pressure, the resistance to
flow, caused by pressure drop must be
compensated for by increased
compressor performance.
•
Results: increased energy
requirements, premature compressor
wear and an increase in overall cost.
•
Conventional filters build up an
average 200mbar pressure drop, over
and above their initial pressure drop,
during the first year of operation
•
Differential pressure gauges (Optional)
– For the indication of a high,
premature differential pressure.
Assumption: Cost of electricity - 0,1 €/kWh
Compressor end-pressure 8 bar(a)
Avoid experiencing unnecessary pressure drop in
the first place by refraining from the use of old filter
elements!
•
58
Every filter element has a limited
economic lifetime. The dirtholding removal capacity
becomes exhausted and the
materials of construction age –
the result is an increasing
resistance to pressure in the filter.
•
Comparison: Compare the
investment costs of a new filter
element to the energy costs
necessary to compensate for the
resistance to pressure of a dirty
filter element. Its worth changing
in time!
Parker Zander “GL-Filter series”
Options
April 8, 2015
Optional differencial pressure
measurement!
60
Standard float drain and other drain options
61
•
Various drains (Float-drain
installed as standard.)
•
1/2” threaded connection
Parker Zander “GL-Filter series”
Sales-support documentation
April 8, 2015
Sales-support documentation – Brochure and
multi-language operating & maintenance
manual
63
Parker Zander “GL-Filter series”
Technical Data
April 8, 2015
Flow Rates
65
Weighs & Dimensions
66
Product Key
67
This is of value to you: A summary of the
benefits
Investing in compressed air filters to save money can turn out to be a costly mistake. After
all, they should serve to enable the stringent regulations for compressed air quality to be
met, without creating high pressure drop in the system. The resulting additional expenditure
spent on energy considerably increases operating costs. Rely on the merits of the new GLseries – a decision you will not regret.
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Thank you for your attention!
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