Sullair Genuine Parts Presentation

CONSUMABLE PARTS PRESENTATION 2008 Customer Care by Sullair
Compressor Filtration
PNEUMATIC TECHNOLOGIES, INC.
MARIO VICENTE D. CANUTO
Sullair Proprietary
Inlet Air Filtration 2008 Customer Care by Sullair
Sullair Proprietary
Question:
Why does an Air Compressor need an Air Filter ?
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Effects of Contamination
• Bearing wear
• Reduced AIR/OIL SEPARATOR ELEMENT life
• Reduced lubricant life
• Added cost!
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Air is not Clean!
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Air is not Clean!
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Air is not Clean!

There are on average 500,000 particles
in 1 ft³ of air at 1 bar.
There are 8 x 500,000 – or 4,000,000 – particles in 1

ft³ of air at 8 bar.
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Types of Contaminants
Solids
• Dust / Dirt
• Pollen / Spores
• Soot / Ash
Liquids
• Aerosols
Gases
• Vapors / H²O
• SO²
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Understanding Inlet Filter Efficiency

Inlet filter efficiency is A “micron” is one-
often stated in terms of a millionth of a meter, or
“micron rating”. .000001 m
The scientific symbol

for a micron is “μm”
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Understanding Inlet Filter Efficiency
•A filter’s “micron rating” means that it will trap all

particles that size or larger
True or False?
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False!
• A “micron rating” is meaningless unless it includes
an efficiency percentage and a test standard
• According to old industry standards, a “nominal” micron

rated filter need only to be 50% efficient,
• An “absolute” micron rated filter need only be 98.7%

efficient
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Sullair Optimalair™ Filters are over 99.99%

Efficient per ISO-5011
•From the previous example, the Optimalair filter

would capture all but 50 particles per ft³
250000
200000 250000
15 0 0 0 0 N o m ina l
A bs o lut e
10 0 0 0 0
O pt im a la ir
50000
6500 50
0
P a rt ic le s do wns t re a m
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What is “Optimalair”
•Sullair Optimalair™ air filters feature a unique

filter media which utilizes nanofiber technology
•Optimalair™ air filters greatly outperform

competitive parts in both efficiency, element life,
and dirt-loading capacity
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What Inspiration!
is “Optimalair”
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“Optimalair” magnified 1100X
Nanofiber layer
Substrate
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Question:
Which of these is more efficient at
capturing dirt?
Most filters become more efficient as they

become loaded
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With conventional media, efficiency starts low and

increases as loading occurs
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Optimalair™ filters have higher initial

efficiency than conventional media
99.99% Efficient per ISO-5011
2 & 5 um particles
2 & 5 um particles
Cellulose Optimalair™
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Side by Side Media Comparison

Cellulose Optimalair™
600x magnification SEM images
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Understanding Filter Life
•Optimalair™ filters will require more frequent

replacement because they capture more dirt.
True or False?
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False!
Optimalair™ filters last longer

than conventional media due to
superior surface loading
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Depth-Loading
Conventional Media
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Effects of Depth-Loading
Conventional Media
– Openings between fibers
become plugged, reducing
open area
– Reduced open area causes
velocities to increase
– Increased velocities raise
Δp and lower compressor
efficiency
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Surface Loading
Optimalair Nanofiber Layer
Conventional
Media serving as
substrate
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Effects of Surface-Loading
– Dirt cakes on the surface
rather than plugging the
internal openings
– When the compressor
unloads, the caked dust can
separate from the surface
web layer
– This process will repeat
many times, extending filter
life
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Surface Loading
Promotes Self-Cleaning
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Sub-Micron Particle
Loading Performance
Nanofibers
loaded with
Sodium Chloride
NaCl
(0.001 - 0.5 µ)
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Initial efficiency by particle size for various

m edia
100
Efficiency (percent
80
removed)
60
40
20
0
0 0.5 1 1.5 2 2.5 3
Particle size (m icro-m eters)
Optimalair
Single media
Sided Nanofiber
Cellulose Media
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A Chinese manufacturing plant tested 5

locally made air cleaners against 5
Sullair air-cleaners with Optimalair
This plant had severe air quality issues
Existing elements needed to be cleaned on

average every 150 hours (alarm) and replaced
every 575 hours
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The first time alarm of former air cleaner

Locally Manufactured Filters
(88290001-466/467)
2000
1500
Hour
1000
500
0
1 2 3 4 5
Machine No
All 5 machines with local air cleaners

showed inlet filter alarms quickly, one in
only 44 hours – average was 375 hours
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After cleaning each element 5 times (not

recommended), the old elements were
no longer serviceable
The service interval of element

(88290001-466/467)
2000
1500
Hours
1000
500
0
1 2 3 4 5
Machine No.
The average life was 575 hours
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All 5 Optimalair units ran over 1500

hours before receiving the first alarm!
The average was 1680 hours
W ithoutalarm running tim e

O ptim alair G 180052
2000
1500
H ours
1000
500
0
1 2 3 4 5 6
M achine N o.
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After 1500 hours
Caked dust captured in the dust ejector

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Inside of the element is clean

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Question:
Is this filter ready for replacement?
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Answer: It depends…. ON THIS!
Inlet Filter
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What should you do when the restriction

gets too high?
Replace the Element!
This is “Condition-Based Maintenance”
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Lube Filtration 2008 Customer Care by Sullair
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FAKE OR WILL FIT AIR FILTER ELEMENTS 2008 Customer Care by Sullair
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Why do we need a lube filter?
To Protect These!
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Filter Head
•Directs oil flow
Bypass Valve
•Opens when restriction exceeds limit – oil is
no longer filtered
Baffle Plate
•Separates clean oil from dirty
Media
•Removes contaminants
•Source of restriction
Can
•Contains and protects media
•Resists bursting
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Beta Rating
5 micron particle
50/2=25
Beta5 = 25
Upstream = Downstream =
50 particles 2 particles
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Efficiency
Efficiency % = [(Beta - 1) ÷ (Beta)]

x 100
Beta 5 µ= 25
Efficiency %:
[(25 - 1) ÷ (25)] x 100 =96% efficient @ 5µ
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Scanning Electron Microscope Scanning Electron Microscope
(Gold Dot Represents

Synthetic Media a 20 micron particle) Cellulose Media
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FAKE FLUID FILTERS 2008 Customer Care by Sullair
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Air-Oil Separation 2008 Customer Care by Sullair
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How Does an AOS Work

• First - coalescing stage
– Fine glass micro-fibers,
coalesce the oil aerosol into
larger drops.
• Second - drain stage

– Coarser polyester fibers,
catch the drops and drain
them to the bottom.
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A 50HP rotary-screw compressor

will
Typical Receiver Vessel
Circulate 50 lpm of lubricant
•This equates to roughly 75,000 ppm oil

challenge to the separation system
•Pre-separation needs to remove 90-95%
•The separator element needs to reduce this
challenge to < 2 ppm
99.997% Efficient!
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What does the inside of the AOS

tank look like?
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Coalescing
High-speed camera recording droplets of compressor fluid

coalescing to form larger droplets
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Service Life
• Measured in service hours to x Δp.
• Affected by
– Contaminant in the air
– Contaminant in the oil
– Air filter efficiency
– Oil filter efficiency
• Better than 8000 hours
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Service Life
• Initial Pressure Drop or P when the separator is
new.
– Normally < 170mbar or 2.5 psid.
• Final P, when the separator must be replaced.
– Normally > 700 mbar or 10 psi.
• Dirt in the air and oil cause the increase.
• Cold starts can cause P surges.
Sullair Proprietary
Sullair Separators Are Superior
Support tube
• Extremely heavy metal No scrim barrier
• Smaller perforation than • Definite media
Genuine element migration
• Higher deltaP, increased • Blocks return line
power consumption strainers
Media construction
• Thin, flat laid or pleated fiber media
• Less surface area,
higher deltaP, higher
Potting compound
Might-fit fluid carryover
• Extremely brittle Metal outer wrap

• Paths for leakage • Use of both x-metal and
• Fluid carryover perforated metal
End Cap Design
• Unknown fluid compatibility
• Inconsistency between
manufacturers
• Poor Pre separation
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Scrim barrier
Pleated media • Blocks media migration
• 3x more surface area • Exclusive to Optimizer
than flat laid
• Multiple layered HEPA
media
• Uniform thickness
and density
• Less pressure drop
• Optimum performance
• Less than 2PPM
• Longer life
Support Screen
• Co-pleated with Micro
Glass media
• Annealed steel construction
Potting compound resists fatigue and flaking
• Sullair tested and
approved
• Compatible with all
fluids
• Secure bonding
End Cap Design
• Correct for optimum
pre-separation
Sullair Proprietary
Question:
When should an AOS be replaced?
Sullair Proprietary
Answer:
It depends….
…on this! …and this!
BHP * 0.746 * PHP * hrs

PHP = kwhr yr
Yr m.e.
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Rule of Thumb:
1 PSI Δp = 0.5% HP
At what point does the loss of efficiency

caused by restriction exceed the price of a
new element?
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Rule of Thumb:
1 PSI Δp = 0.5% HP
BHP * 0.746 * PHP * hrs
PHP = kwhr yr
Yr m.e.
PHP/Yr = cost per year PHP 6,187,355.74
BHP = brake horsepower 200
PHP/kwhr = electricity cost per kilowatt hour 4.45
m.e. = motor efficiency 0.94
hrs/yr = operational hours of the compressor 8760
Sullair Proprietary
Rule of Thumb:
1 PSI Δp = 0.5% HP
PHP/Yr = cost per year PHP 6,187,355,74
• BHP * 0.746 * PHP * hrs
BHP = brake horsepower 200
PHP = kwhr yr
PHP/kwhr = electricity cost per kilowatt hour 4.45
Yr m.e.
m.e. = motor efficiency 0.94
hrs/yr = operational hours of the compressor 8760
3 PSI of added pressure drop across

the AOS = PHP 92,810.34 / yr
Sullair Proprietary
16 6PPM
14
5PPM
12
4PPM
10
8 3PPM
Fluid Ounces
6 2PPM
4
CFM 0 200 400 600 800 1000 1200 1400 1600
Sullair Proprietary
2008 Customer Care by Sullair
Sullair Proprietary
FAKE SEPARATOR ELEMENTS 2008 Customer Care by Sullair
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2008 Customer Care by Sullair
Thank You
Sullair Proprietary

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CONSUMABLE PARTS PRESENTATION 2008 Customer Care by Sullair

PNEUMATIC TECHNOLOGIES, INC.

MARIO VICENTE D. CANUTO

Why does an Air Compressor need an Air Filter ?

Air is not Clean!

Air is not Clean!

Air is not Clean!

There are 8 x 500,000 – or 4,000,000 – particles in 1

Understanding Inlet Filter Efficiency

The scientific symbol

Understanding Inlet Filter Efficiency

•A filter’s “micron rating” means that it will trap all

• According to old industry standards, a “nominal” micron

• An “absolute” micron rated filter need only be 98.7%

Sullair Optimalair™ Filters are over 99.99%

•From the previous example, the Optimalair filter

•Sullair Optimalair™ air filters feature a unique

•Optimalair™ air filters greatly outperform

“Optimalair” magnified 1100X

Most filters become more efficient as they

With conventional media, efficiency starts low and

Optimalair™ filters have higher initial

Side by Side Media Comparison

600x magnification SEM images

Understanding Filter Life

•Optimalair™ filters will require more frequent

Optimalair™ filters last longer

Initial efficiency by particle size for various

A Chinese manufacturing plant tested 5

This plant had severe air quality issues

Existing elements needed to be cleaned on

The first time alarm of former air cleaner

All 5 machines with local air cleaners

After cleaning each element 5 times (not

The service interval of element

The average life was 575 hours

All 5 Optimalair units ran over 1500

W ithoutalarm running tim e

After 1500 hours

Caked dust captured in the dust ejector

Inside of the element is clean

Answer: It depends…. ON THIS!

What should you do when the restriction

Replace the Element!

This is “Condition-Based Maintenance”

Why do we need a lube filter?

Efficiency % = [(Beta - 1) ÷ (Beta)]

Scanning Electron Microscope Scanning Electron Microscope

(Gold Dot Represents

How Does an AOS Work

• Second - drain stage

A 50HP rotary-screw compressor

•This equates to roughly 75,000 ppm oil

What does the inside of the AOS

High-speed camera recording droplets of compressor fluid

Sullair Separators Are Superior

• Extremely brittle Metal outer wrap

BHP * 0.746 * PHP * hrs

At what point does the loss of efficiency

PHP/Yr = cost per year PHP 6,187,355.74

BHP = brake horsepower 200

PHP/kwhr = electricity cost per kilowatt hour 4.45

m.e. = motor efficiency 0.94

hrs/yr = operational hours of the compressor 8760