US 7014691 B2
An apparatus for treating compressed air from a rail yard compressed air supply pipeline leading from a central air compressor to outlets at remote locations in a rail yard prior to charging air brake lines of trains with compressed air from the pipeline to prevent contaminants such as moisture, entrained atomized oil and/or particulates such as rust from getting into the air brake line of the train. The apparatus includes an air line, an air inlet connector at one end of the air line, an outlet connector at the other end of the air line, and at least one separator device interposed in the air line between the inlet connector and the outlet connector for separating contaminants from a stream of compressed air passing through the apparatus. A test apparatus for testing compressed air for oil contamination and a method of preventing contamination of an air brake line of a train with contaminants from a rail yard compressed air supply pipeline used to charge the air brake lines of trains at remote locations in a rail yard with air from a central compressor system is also disclosed.
1. An apparatus for treating a compressed air stream from a remote compressed air source and delivering the treated air stream to equipment which used the compressed air, said apparatus being portable and comprising an air line, a releasable inlet connector at one end of the air line, a releasable outlet connector at the other end of said air line, and at least one separator device interposed in the air line between the inlet connector and the outlet connector for separating moisture, entrained oil and/or particulate matter from a stream of compressed air passing through said portable apparatus, wherein said separator device comprises a desiccant chamber and a mechanism for cycling the desiccant chamber between an air drying stage and a blow down stage, said cycling mechanism comprising an air driven clock which opens and closes relay valves to switch the desiccant chamber between air drying operation and blow down operation.
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10. A method of preventing contamination of an air brake line of a train with contaminants from a rail yard fixed compressed air supply pipeline used to charge the air brake line of the train at remote locations in a rail yard with air from a central compressor system, said method comprising the steps of connecting the inlet connector of a portable apparatus according to
11. An apparatus for treating a compressed air stream from a remote compressed air source and delivering the treated air stream to equipment which used the compressed air, said apparatus comprising an air line, an inlet connector at one end of the air line, an outlet connector at the other end of said air line, and at least one separator device interposed in the air line between the inlet connector and the outlet connector for separating moisture, entrained oil and/or particulate matter from a stream of compressed air passing through said apparatus, wherein at least one of said inlet connector and said outlet connector is a gladhand connector.
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13. An apparatus for treating a compressed air stream from a remote compressed air source and delivering the treated air stream to equipment which used the compressed air, said apparatus comprising an air line, an inlet connector at one end of the air line, an outlet connector at the other end of said air line, and at least one separator device interposed in the air line between the inlet connector and the outlet connector for separating moisture, entrained oil and/or particulate matter from a stream of compressed air passing through said apparatus, wherein said remote compressed air source is a piping delivery system from an air compressor, and said piping delivery system is a rail yard compressed air supply network for supplying compressed air from a central air compressor to railroad equipment at remote locations in said rail yard.
14. An apparatus for treating a compressed air stream from a remote compressed air source and delivering the treated air stream to equipment which used the compressed air, said apparatus comprising an air line, an inlet connector at one end of the air line, an outlet connector at the other end of said air line, and at least one separator device interposed in the air line between the inlet connector and the outlet connector for separating moisture, entrained oil and/or particulate matter from a stream of compressed air passing through said apparatus, further comprising a shutoff valve in the air line and a branch conduit open to the atmosphere interposed between the inlet connector and said shutoff valve, and a valve on the branch conduit for closing of the branch conduit, whereby by shutting the shutoff valve and opening the valve on the branch conduit, condensate from an air supply line to which the apparatus has been connected can be blown out of the apparatus through said branch line.
15. An apparatus for treating a compressed air stream from a remote compressed air source and delivering the treated air stream to equipment which used the compressed air, said apparatus comprising an air line, an inlet connector at one end of the air line, an outlet connector at the other end of said air line, and at least one separator device interposed in the air line between the inlet connector and the outlet connector for separating moisture, entrained oil and/or particulate matter from a stream of compressed air passing through said apparatus, further comprising a blow down conduit tube connected to the air line of the apparatus through a shut-off valve for purging the apparatus when the shut-off valve is opened.
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18. An apparatus for testing for oil in an air stream, said apparatus comprising in combination a dummy gladhand containing a pressure regulator valve, and an oil content indicator tube with a needle valve.
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The present invention relates to an improved apparatus for cleaning, drying and testing for oil content in air generated from compressors or other sources of flow and delivered through a delivery system where there is a need or desire to remove oil, particulate matter or water droplets and or humidity from a gas stream.
In the railroad industry, the owners and operators of locomotive and other railroad equipment require or find it operationally desirable to remove as much water vapor, oil, humidity and particulate matter from compressed air as possible, when such air is used to charge and operate the air brake system of the equipment. Additionally, it is desirable to be able to measure the oil content that contaminated the gas stream in order to determine proper maintenance of the compressors and extend the life of air brake equipment of locomotives and cars.
Many railroads utilize dryers and after coolers on their locomotives and yard compressors. For the most part, these dryers and after coolers are very efficient in removing the humidity generated from the process of compressing air; however, they do little to protect the system from oil contamination. Moreover, the presence of oil, will destroy the desiccant's ability to adsorb water vapor. A properly maintained locomotive dryer system with an effective and clean desiccant, is particularly efficient because the system generates air that has been cleaned and dehumidified and deposited directly into the equipment train line through air hose couplings directly between the locomotive air system and each adjoining car.
The yard compressors present a different and unique problem. The yard compressors generate compressed air that, in most instances, is dehumidified with a similar air dryer. The dry air is then delivered to a series of outlets that are located at the head or rear location of various tracks by means of an underground piping system. This piping can be thousands of feet long before reaching the outlet ports for delivery to the train line. This piping is, in many instances, made of steel threaded together with couplings. Subsequently, any breach or loosening of the pipe or couplings will allow groundwater and particulate matter to enter the pipe, thus contaminating the airflow. Even though the air may be dry as it leaves the central compressor, as a practical matter is it virtually impossible to prevent moisture from entering the compressed air through leaks in the piping system between the point of generation and the point of use. Whether this moisture is present in the form of humidity or condenses to liquid water, it is detrimental to the ultimate use. Rust can also be created when these factors are present causing additional problems. Additionally, because the piping is usually below ground surface level, the temperature is significantly below the ambient temperature of the compressed air when it leaves the compressor. A dryer which uses a desiccant for example may reduce the moisture content level to withstand a dew point depression of 20 degrees below ambient. This means that if the air is cooled 20 degrees below its ambient temperature after leaving of the dryer, it will begin to condense and form water droplets. This underground piping system used to deliver air to cars and locomotives is almost universally used in the railroad industry and proves effective means of delivering air to pre-charge trains and cars. It eliminates the time that might otherwise be needed to charge a train line using a locomotive compressor only. However, because of leakage, rust, groundwater and excessive cooling of the air that occurs as a result of the air delivery piping running for hundreds and sometimes thousands of feet under the ground from the compressor, the dryers used on yard compressors at the source are not effective and cannot prevent water seepage into the delivery line. Moreover, if excessive cooling occurs, the dryer is not effective in keeping moisture from entering the train's brake system unless moisture is removed to the point significantly below the ambient moisture level at the source. This is not always possible. Short of removing the compressor to a closer location or replacing old leaking underground piping, there is no practical effective device which is in use to address this problem.
The seriousness of contaminants entering the air brake system cannot be overstated. The presence of oil, rust, particulate matter and excessive moisture cost the U.S. railroad industry up to in excess of $50 to $60 million a year in clean oil test and stencil (CO T. & S.) cost alone. U.S. federal regulations mandate the railroad industry to change out Passenger Locomotive air valves on a 36 month preventative maintenance plan. On the freight side, there are approximately 30,000 locomotives in the United States at an estimated cost of $5000 to $6000 per locomotive this equates to $150 to $180 million. This cost does include all of the other remedial costs associated with this maintenance regulation.
The contaminant problem and the lack of a cost-effective means to address it is a significant factor in the 36 month time interval mandated for CO T.& S. If the industry were able to address this issue by monitoring and reducing the contaminants levels entering into the brake system, the cost would be significantly reduced by providing a longer life expectancy for the air brake valves and justification for increasing the CO T.& S. time interval.
The present invention also relates to an improved apparatus and method for the testing of oil content in a gas stream generated by compressors and has application to the railroad, commuter and trucking industries. For example, in the railroad industry the owners and operators of railroad equipment use compressors to generate air pressure to operate their brake systems. This type of air brake system is also used in the commuter and trucking industries. Many of these compressors utilize air dryers which use a desiccant type filter to remove humidity from the air. If the humidity is not removed from the air, the vapor can condense into water. Additionally, the brake valves which are used to operate the brake system have rubber components that are adversely affected and react to the presence of oil, water and/or other contaminants. The industry has long sought an efficient and cost effective means to monitor the oil content in the compressed air. The presence of oil in the air will reduce the life expectancy of valves and other components, as well as the desiccants which are used to dry the air. Additionally, the presence of oil in the air is an indication that the compressor rings are worn or broken allowing oil lubricants to leak into the air supply.
In the railroad industry, as well as in the trucking industry, current methods to detect oil are costly and time-consuming. These methods can require costly modifications to the equipment to attach monitoring devices or idle equipment for extended periods of time while the tests are performed.
Federal regulations relating to air pressure of train lines in the railroad industry are governed by regulations under part 49 CFR 232 and 49 CFR 238 (freight and passenger). FTA safety regulations are covered under 49 CFR 659.31 and reference the manual for development of rail transit safety program plans (A. P. T. A.) Aug. 20, 1999. The Federal regulations relating to the trains air brake pressure requires that the train line may not exceed a 5 pound leak during the test for initial terminal brake. Alternatively, Federal regulations also allows an alternative method of testing that is referred to in the industry as the “air flow method”. Use of this method allows up to 60 cubic feet per minute of leakage.
The present invention addresses these issues and overcomes contaminant problems by providing a cost-effective, easily used, and versatile filtration unit at the end of the delivery line prior to the air being delivered into the train line of cars and locomotives. Its portability allows for its easy and immediate use on various air lines without expensive modification. If the user chooses, it can be temporarily attached by the use of a glad hand or other suitable connector. Attentively, it could be permanently attached to the air line of a piece of equipment such as a locomotive.
The apparatus of the invention comprises a suitable connector at each end for connection to a compressed air source, such as a supply line from a rail yard compressor, and to a train line. A preferred embodiment uses standard railroad gladhand connectors for this purpose. The apparatus of the invention also comprises a replaceable air filter, a cyclonic dirt collector, and/or an air desiccant filter canister. In a preferred embodiment the air desiccant chamber uses an electric relay or air driven clock blow down mechanism for opening and closing directional relay valves. This is used to direct a timed burst of dry air into the train line and then close the airflow to the train line and blow down cycle of the wet desiccant to atmosphere. The train air pressure is protected by a check valve. The vent to atmosphere may, if desired, incorporate a protective air diffusor to prevent possible injury to personnel from vented compressed air. The invention also incorporates the use of the oil indicator connected in line with the air stream to measure oil contaminants levels within the airflow.
The apparatus of the invention is assembled in such a fashion that it may be used according to the specific needs of any given situation. For example, if dew point humidity variables are at a marginal level, the device could be used or made with a desiccant filter designed to run using an air clock mechanism or electrically operated relay. If dew point humidity is not a problem, however water droplets, oil or particulate matter are present in moderate levels, a combination dirt collector/filter may be used in combination with each other. If contamination is only marginal, then a filter or a dirt collector alone may be sufficient to meet a standard. The apparatus of the invention can be constructed to accommodate all three types of filtration or any combination thereof. The invention may be designed to accommodate a single filter feature or combinations thereof. The device may also be designed to accommodate an oil indicator that measures the oil content present in the gas stream.
A blow out conduit and valve may be installed in line upstream of the filter to allow condensation to be blown from the line prior to filtration or testing. The blow down conduit tube can be configured in such a fashion that it can also be used to insert a test probe to test dew point humidity. It may be designed to accommodate a test probe conduit at both ends of the filtration system.
In one preferred aspect the invention comprises a filtration apparatus for use at the end of the piping delivery system of a compressor, to filter a gas streams from particulate matter, oil, water and water vapor, utilizing a gladhand or other suitable connector.
In accordance with another preferred aspect, the invention comprises one or more desiccant filters to remove humidity from a gas streams that is collected beyond the point of generation of compressed air at the end of the piping delivery system. In a particularly preferred embodiment, the apparatus is operated electrically or by use of an air driven clock type mechanism to open and close relay valves mechanically, pneumatically or electrically to cycle the desiccant from dry air to blowdown.
In another aspect the invention comprises a device that utilizes a gladhand for a connector to yard air plant lines or railroad equipment air hoses.
A further aspect of the invention involves a suitable branch tee conduit arranged downstream of the filtration units that will accommodate a probe for measuring the oil content of the air stream utilizing an oil indicator or a meter designed to measure moisture content or particulate matter.
In another aspect the invention includes a pressure gauge and regulator shut off valves to regulate air flow to determine humidity, particulate matter, or oil content upstream or downstream of the filtration system.
Another aspect of the invention involves providing a valve situated at the inlet for blowing condensation from the line before the condensation can enter the filtration system.
A still further aspect of the invention is an apparatus containing check valve to protect the train brake pipe pressure immediately after and prior to the air entering the train line.
According to yet another aspect of the invention the apparatus contains a blow down conduit tube and/or a tube which can be used to insert a test probe for determining dew point humidity to measure contamination with oil or particulate matter.
In one preferred embodiment of the invention, the separating device comprises a cyclonic dirt collector having a body and a lid. A similar type is standard in the industry and is used exclusively on railroad equipment between the branch tee of the train line and the pipe portion bracket. It consists of an inlet/outlet lid. The body can be removed from the unit for cleaning. It is designed to direct the airflow in a cyclonic pattern and use centrifugal force to keep particulate matter and moisture that enters the chamber against the walls of the unit while it allows the air to travel up and out leaving the particulate matter and water behind.
In a preferred embodiment, the apparatus of the invention has air valves placed in line with the intake airflow for shutting off or regulating the flow through the air line. The valves also assist in blowing off condensation from the line prior to use. A second shut off valve is employed to shut off the air supply to the filter system when the blow down valve is being utilized to remove excess condensation from the air line.
Preferably the separator device comprises an air filter capable of removing particulate matter while air enters the filter chamber and then passes out of the filter outlet into the air line of the apparatus.
The inlet and outlet connectors of the apparatus may advantageously be standard rail industry gladhands of the type used to couple air lines of individual pieces of rail equipment to each other when the pieces of rail equipment are assembled to form a train.
In one preferred embodiment, the apparatus comprises a combination of a cyclonic dirt collector and an air filter. In another particularly preferred embodiment, the apparatus comprises a combination of a filter for water, oil and particulate matter, a cyclonic dirt collector, and a desiccant filter canister for removing moisture from the stream of compressed air. Alternatively, the apparatus of the invention may comprise a single filter device, which can be used in conjunction with other testing and filtering units. If desired each filter unit, cyclonic dirt separator and desiccant canister could be fitted with its own set of gladhand connectors so that the individual units could be assembled in any combination or sequence as desired in order to provide customized compressed air treatment of the compressed air from a pipeline from a remote source at the point where the compressed air is introduced from the end of the pipeline into the equipment in which the air is used.
The apparatus may also desirably incorporate a branch tee conduit for receiving a probe from a meter used to test humidity, oil content or particulate matter.
The apparatus of the invention may also comprise an air gauge and manual regulator valves used to control airflow and pressure while testing.
In a preferred embodiment, the operation of one or more desiccant filters is controlled by an air driven control mechanism which cycles the operation of the filters between moisture absorption and regeneration or blow down stages. A particularly preferred embodiment comprises a mechanically driven mechanism which opens and closes a wheel type relay valve. Alternatively, an air powered hemispherical gear could be used in combination with a small generator to generate electrical current to electrically operate relay valves and/or heat the air. One particularly preferred apparatus uses an air driven gear mechanism which in turn utilizes a mangle wheel gear to actuate relay valves to change the airflow direction from supply to blow down operation.
An especially preferred embodiment of the apparatus of the invention comprises a combination of a standard gladhand connector for connecting the apparatus to a compressed air source, which may be a plant line, a train line, etc.; a pressure regulating shut off valve to enable the flow channel through the apparatus to be shut off; a conduit tube for insertion of a test probe; an oil indicator to detect the presence of oil in the compressed air; a needle valve to allow airflow into the oil indicator tube; a pressure gauge to determine air pressure in the apparatus and/or supply line; and an automatic/manual blow down valve that allows the removal of oil, water and particulate matter that has been captured by the filter. In this embodiment, the air line of the apparatus leads through a dual chamber desiccant filter which removes humidity from the system. The use of a dual canister desiccant filter makes it possible to keep the equipment supplied with an uninterrupted supply of air and maintain pressure in the equipment air line by cycling alternately between the two canisters. Prior to entry into the desiccant filter, the air line passes through a cyclonic air/dirt separator or dirt collector which uses centrifugal force to keep contaminants from entering the desiccant filter system. An in line check valve is provided to protect the air pressure in the air line of the equipment if pressure is unintentionally lost or intentionally released in the apparatus. The valve may be disposed downstream of the desiccant filter, but it will appreciated by persons skilled in the art that the check valve could be located in any of various places within the apparatus. The apparatus air line is also connected with a blow down conduit test pipe for blowing condensation and/or other contaminants, which may accumulate in the piping system, from the pipe prior to filtration. A shut-off valve is provided on the blow down pipe to close off the blow down conduit during normal operation of the apparatus. The blow down conduit can also be used to insert a test probe, if desired, to determine dew point humidity or the content of particulate matter in the compressed air prior to filtration.
Another aspect of the present invention provides for a test method and a test apparatus which may be used while equipment is idling or in use. Immediate attachment and detachment without modifications to the equipment or loss of use while it is being monitored is extremely important to the industry.
The apparatus of the invention attaches to a train or truck compressed air line via a coupling on the end of the air hose (gladhand). Railroad, computer rail, transit and trucking industries all utilize a similar type gladhand coupling device for coupling air hoses. The same type of arrangement is also used at the end of the yard plant lines delivering compressed air to equipment.
The invention embodies a “dummy” type gladhand with an orifice allowing the attachment of an oil indicator tester which is connected to a needle valve. The dummy connector is then attached to the gladhand of the equipment's train line hose. For example, the locomotive has air hoses on each end of the equipment. The invention allows the attachment to the gladhand hose on each end of the unit which is not in use. After attachment, the air supply is open in order to pressurize the hose. The dummy gladhand retains the air pressure inside the air hose. The needle valve of the oil indicator is then opened to allow air flow into the indicator. The flow of air in the apparatus of the invention is within the leakage limits of federal regulations; the air flow rate is less than 2 SCIM/PS IG (0.08 mL/s/kPa) through the calibrated plastic tube. For the purposes of this invention, an A-4000 oil indicator and needle valve assembly is utilized. The oil indicator tube is treated with a red oil soluble body designed to react with oil by changing color when there is a presence of oil. The time, pressure and color are then calculated by the use of a chart to determine the amount of oil present in the gas stream. The apparatus can be attached and detached simply and without the need to modify the equipment, and the test can be performed while the equipment is idled or in use.
The dummy gladhand may be equipped with a pressure gauge and/or a pressure release valve to enhance calculations and promote safety.
This invention does not require that the train line or compressor be modified with a threaded orifice to accommodate the needle valve indicator for attachment. The attachment is directly to the dummy gladhand for attachment to equipment.
The invention comprises a dummy gladhand designed to fit with standard gladhand connectors used in compressed air lines in the railroad or trucking industry, etc. In the apparatus of the invention, the dummy gladhand is modified to include at least one threaded orifice and a pressure regulator valve for regulating air flow through the at least one orifice. An oil content indicator comprised of a needle valve and a chemically treated tube are attached to an orifice of the dummy gladhand. An air pressure gauge may also be provided to determine the air pressure in the air line. A quick release pressure valve may be provided to enable rapid release of the pressure from the test apparatus.
The dummy gladhand oil tester can be reused repeatedly on different pieces of equipment, and it only requires replacement of the oil indicator tube for each new test.
In accordance with a further aspect of the invention, the invention comprises a method of preventing contamination of an air brake line of a train with contaminants from a rail yard compressed air supply pipeline used to charge the air brake line of the train at remote locations in a rail yard with air from a central compressor system, in which the method comprises the steps of connecting the inlet connector of an apparatus according to the invention as described herein to an outlet of the compressed air supply pipeline, connecting the outlet connector of the apparatus to an inlet to an air brake compressed air line of a train, and charging the air brake compressed air line of the train with compressed air from the compressed air supply pipeline which has been passed through said apparatus to remove contaminants such as moisture, entrained oil droplets and/or particulate matter such as dirt or rust particles therefrom.
The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments shown in the accompanying drawings in which:
The tangential entry of compressed air from line 12 into cyclonic dirt collector 20 is illustrated in
Another possible valve arrangement is shown in
A further arrangement is illustrated in
As an alternative, the air wheel could be used to turn a generator to produce electricity which in turn could be used to operate electrical relays and an electrical timer.
To use the test device, the dummy gladhand is connected to a gladhand connector at the end of an air line containing an air stream to be connected. A bleed stream of air is then discharged through branch tube 87 and oil indicator 81. Oil indicator tube 22, which is lined with a substance which undergoes a color change when contacted by oil, is then observed for an indication of oil contamination in the compressed air stream.
The embodiments described above are, of course, not the only means by which the invention can be realized. Persons skilled in the art could devise the mechanism to operate in numerous ways all of which would be able to accomplish the goal of directing the air flow from supply to blow down and back to supply. The above description is not meant to be limiting and accordingly, the invention should be construed broadly to include any suitable mechanical, pneumatic or electrical means that would accomplish the purposes of the exemplary embodiments described above.