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CASE HISTORY ARTICLE
Industrial Compressors -Air Intake Filtration
Compressed air, commonly referred to as the fourth utility in the industrial world, is as crucial to the manufacturing process as electric, water and natural gas. Delivering an extremely efficient energy supply, these industrial compressors generate the "plant air" that operates pneumatic equipment and air powered tools. It’s a simple process with a goal of providing more air with less fuel consumption. Compressors enable major industrial manufacturers, like the Checker Motors Corporation (previously known as the Checker Cab Company), in Kalamazoo, Michigan to process their steel auto bumpers and other body components in the heart of automobile capital of the world. These busy compressors often operate a continuous heavy duty cycle 24 hours per day, 365 days per year. Large 200 horsepower industrial air compressor packages, such as the KAESER Model DSD 200 shown here, are designed to run for extended periods of time, in demanding industrial applications. Similar, but smaller portable KAESER units provide compressed air for construction sites and other industrial environments that place them right in the middle of demolition sites, sand blasting, sprinkler irrigation and monument engraving. Particulate contamination is the #1 enemy of industrial compressors. As dirt is being drawn into the air intake louvers of the compressor enclosure cabinet, it clogs the oil cooler and after cooler (2 cell cooling system), fin and tube heat exchangers, pneumatic control valves, electric motor cooling air intakes, centrifugal fans and sensitive electrical controls (like variable speed drive systems). Airflow obstructions in these types of equipment can be a costly expense. Typical maintenance programs of cleaning and setting adjustments are required every 500 operating hours to prevent equipment damage and to allow the systems to run at peak efficiencies. Major annual maintenance of part and fluid replacement is required approximately every 2000 operating hours. Both of which require costly man hours and equipment downtime, which ultimately interferes with industrial processes.
As a solution to protecting the sensitive components inside the compressor
enclosure, TGF Engineering (based in Indiana) recommended the installation of
Permatron's PreVent® Equipment Protection Filters. TGF is an engineering
consulting company who specializes in “engineered solutions” for air side,
equipment protection filtration. Effectively preventing debris from entering the
air inlets, the PreVent filters are made of washable, 3-D polypropylene media,
which draws in and traps airborne particles. The electrostatic media, enhanced
by airflow needs no system modifications or electrical hook-ups. Custom sized
and manufactured to fit any sized air intake, media can be framed with flexible
vinyl binding or rigid galvanized steel frame. Installation options include
grommets, bungee hook cords, velcro hook/loop, magnet stripping or metal clips
affixed to enclosure cabinet. Polymer coated polyester media mesh is available
for high abrasion applications. Filters are easily cleaned by rinsing with water
or using a portable shop vacuum. The black media is UV protected, for indoor or
outdoor use. The media's inherent electrostatic charge won't diminish over time,
providing years of equipment protection. For more information on your custom air
filtration needs, contact sales@permatron.com or 1-800-882-8012. Patent No. US 6,793,715
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Permatron Corporation, 1180 Pratt Avenue, Elk Grove Village, IL 60007Telephone 847-434-1421 FAX 847-434-1429Send mail to
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