Sigma Compressed Air Oil Supervisor
Compressed Air Oil Content Quality to ISO 8573 class 1 and class 0 On-Line Compliance?
Having an oil free compressor does not necessarily mean that your compressed air is oil free as the term “oil-free compressor” refers only to the compression chamber, not the compressor system as a whole, or the resulting compressed air quality.
Contaminants in the compressed air system generally can be attributed to:
The quality of the air drawn into the compressor
The operation of the air compressor
Compressed air storage devices and distribution systems
Keep in mind that most of the millions of particles in normal urban ambient air your compressor sucks in, are below the pore size of the compressor inlet filters.
Hydrocarbon content in ambient air varies from area to area (typically contains between 0.05mg/m3 and 0.5mg/m3 of oil vapor from sources such as car exhausts and industrial processes) but is often sufficient to contaminate the compressed air of your system. Ofcourse, the answer to that, is an air treatment system downstream, but how do you know that your air quality complies with the requirements of oil free air 24hours/day 365 days/year?
Many industrial processes are very sensitive to oil contamination, as this can lead to tremendous risks, downtime, product spoilage & recall, damage the company’s reputation, harmed consumers & product liability, but up to now the only method for measuring the in-pipe oil content involved specialist equipment and a time-consuming laboratory analysis.
OCA-10
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sing a sophisticated measurement technology based on ion exchange, the oil measuring, monitoring and control system provides the user with continuous on-line readings of the actual oil content at any given measurement point within the user’s compressed air system.
The high sensitivity of the system ensures early detection of a filter or compressor malfunction, before a serious damage to the pneumatic machines and/or the products in production.
The product has two parts: the sensor unit which includes an isokinetic probe for horizontal or vertical installation into the pipe (we can also supply a specific purpose manufactured pipe elbow that includes a sensor connection port), and a control/display unit. The display unit offers user-definable alarm limits, and as the measured oil-level increases, so the display reading changes from standard green, through to warning yellow, and finally to flashing red to indicate that the user’s alarm levels are being exceeded. The unit also connects to a building management system for remote monitoring.
The data from the unit can be recorded over a period of time, and the results then imported to commonly available software and converted into clear and concise graph reports.
The unit is available in three versions, each designed for installation at different points in the compressed air line.
The Sigma-OCC series can measure up to 100 mg/Nm3, and is suitable for vertical installation immediately after the compressor and cyclone seperator with level controlled drain.
The Sigma-OCF series is designed to measure the oil content immediately after a condensate-reducing coalescing filter in a vertical installation , and measures down to 0.01 mg/Nm3.
The Sigma-OCA series has the highest sensitivity and is intended for horizontal installation in the most oil-less environment, typically after an activated carbon oil-removal filter. This unit can measure down to 0.001 mg/Nm3
Important Features
- High reliability for compressed air processes
- Round the clock monitoring, 365 days a year
- Early detection of malfunctions
- Prevents consequential damage & maintains production rate
- Easy integration into existing facilities
- Colour changing display for maximum safety
Technical Data
| Sigma-OCC series | downstream of compressor, after cyclone separator with level controlled condensate drain measuring range 0.5 – 100.0 mg/m³ (aerosols) |
| Sigma-OCF series | downstream of refrigeration dryer, behind coalescence filters (staged filtration min. fine and mirco filter) measuring range 0.01 – 20.00 mg/m³ (aerosols) |
| Sigma-OCA series | downstream of refrigeration dryer, behind activated carbon filter / adsorption or catalytic converter with an outlet side dust filter measuring range 0.001 – 1.0 mg/m³ (total ISO 8573.1-C) functional range 0.001 – 9.999 mg/m³ |
| Measuring principle: | ion exchange method |
| Measured quantity: | mg/m³ related to standard conditions 1 bar and 20 °C |
| Sensor connection: | G 3/8“ external thread (coupling with internal thread |
| Isokinetic sampling probes: | T1 for piping DN 20 to DN 50 (¾ to 2 inches)
T2 for piping DN 65 to DN 150 (2 1/2 to 6 inches) |
| Operating temperature: | –20 … +60 °C |
| Operating temperature for electronics: | 0 … +60 °C |
| Operating pressure: | min. 4bar, max. 10 bar (16 bar optional) |
| Analogue output: | 4 … 20 mA |
| Relay output: | 2 changeover contacts, 230 V AC / 5 A |
| Evaluation Electronics and Power supply module:
with or without display Display range: Alarms: |
115…230 VAC, 50/60 Hz
-9999…99999 one LED per alarm |
| Measuring section material(recommended): |
stainless steel 1.4301 or better |
Residual oil content requirements
Quality class 1 according to EN ISO 8573-1 0.01 mg/m³
Limiting value for medical applications EAB 407/1238 0.1 mg/m³
Limiting value for breathing apparatus EN 12021 0.5 mg/m³
Oil-free compressed air applications:
- pharmaceuticals
- medical air
- marine air
- breathable air
- medical engineering
- high tech processes
- high speed trains
- electronics industry
- conveyance of hygroscopic food
Online measuring and monitoring device for oil and pressure dewpoint
600 series (includes S610 S620 S650 models) with ODCA & ODCF versions
The Oil Dew Supervisor is an intelligent compressed air monitoring system which has been developed especially for monitoring residual oil contents (ISO specification) / hydrocarbon concentrations in compressed air systems. The integrated microprocessor control and compact design enable online measurement of the airborne residual oil content (in situ measurement). Therefore, the device serves to protect production processes and machines. A pre- and main alarm are generally set in order to signal when the current values lie outside the chosen tolerance limits. At the same time, the Oil Dew Supervisor can be set to ignore short-time value fluctuations in the plant, so as to prevent false alarms and unnecessary process interruptions. The statutory limit values must of course not be exceeded.The Oil Dew Supervisor can be used for monitoring the maximum permissible total oil content according to ISO 8573-1-Cdownstream of oil-free operating compressors and for guarding against oil breakthrough in the case of oil-injected compressors.
The Oil Dew Supervisor measuring system consists of two main units: the measuring cell with a sampling probe based on the isokinetic principle and the evaluation electronics with display. The measuring cell is connected by cable (max length 200 m) to the evaluation electronics & display unit incorporating the instrument’s operating and display functions.
Measuring range: 0.001 – 1.000 mg/m³ residual oil content (total, according to ISO 8573.1-C) Displayed range: up to 9.999 mg/m³Pressure dew point: -80 to +20°Ctp.
Measuring location: Downstream of dryer and coalescing filters(min. fine and microfilter), downstream of activated carbon filter / activated carbon adsorber or catalytic converter with next-in-line dust filter (and superfine filter)
CONTINUOUS COMPLIANCE VERIFICATION OF COMPRESSED AIR OIL CONTENT QUALITY TO ISO 8573 “CLASS 1 ” & “CLASS 0” ON-LINE.0
A “must” compressed air quality continuous monitoring system for facilities that need clean air without contaminants, at all times and regulatory compliance with ISO 8573:2010 Part 2+5, HTM 02/01 , HEDIS, NCQA accreditation 24/7, GMP-Facility and Manufacturing Excellence.
