UL Listed Coalescer: Safety-Certified Filtration for North American Industrial Systems
Product Introduction
The UL Listed Coalescer is a premium filtration system engineered to meet the rigorous safety and performance standards of Underwriters Laboratories (UL), a global leader in product safety certification. Designed for critical applications in natural gas processing, aviation fuel purification, and hydraulic/lubricant systems, this coalescer ensures reliable separation of water, oil droplets, and particulates while adhering to UL’s strict criteria for hazardous environments.
Certified to UL 508A (Industrial Control Panels), UL 121201 (Explosion-Proof Equipment), and UL 2238 (Fuel Dispensing Systems), the UL Listed Coalescer is the gold standard for industries operating in the U.S., Canada, and Mexico. It combines UL’s trusted safety validation with advanced coalescence technology to mitigate risks of fire, explosion, and equipment failure—protecting assets, personnel, and the environment.
Key Features & Advantages
1. UL Certification: Uncompromising Safety & Compliance
Third-Party Validation: Tested and certified by UL’s independent labs, with full documentation (material traceability, electrical safety reports) for OSHA, NFPA, and EPA compliance.
Hazardous Area Compliance: Meets UL 121201 for Class I, Division 1/2 (gas/vapor) and Class II, Division 1/2 (dust) environments, with explosion-proof (Ex d) and intrinsically safe (Ex i) variants.
Electrical Safety: UL 508A-compliant control panels prevent short circuits or arc flashes in high-risk areas.
2. Ultra-High Separation Efficiency
Beta Ratio (β) > 180,000: Removes 99.999% of droplets ≥0.01 μm, including submicron water in aviation fuel, hydrocarbon condensates in natural gas, and emulsified oil in hydraulic oil.
Multi-Stage Customization: Pre-coalescers (bulk separation) and fine coalescers (ultrafine polishing) optimize flow distribution per UL 2238 for fuel dispensing systems.
3. Robust Construction for Extreme Conditions
Material Durability: 316L stainless steel (UL 1459), carbon steel with UL-approved epoxy coatings, or aluminum alloy (UL 746C) for corrosion resistance in wet or chemical-laden environments.
Pressure & Temperature Tolerance: Rated for 1–400 bar (14.5–5800 psi) and -60°C to +250°C (-76°F to +482°F), with cryogenic variants for LNG (UL 1310) and high-temperature models for refinery off-gases.
4. Energy Efficiency & Cost Savings
Low Pressure Drop (<0.05 bar): Optimized flow paths (per UL 1995) reduce pumping energy costs by 30% compared to non-certified filters.
Extended Lifespan: 36–60 months in industrial settings (vs. 12–24 months for uncertified alternatives), with UL 746B aging resistance testing for UV and chemical exposure.
5. Streamlined Maintenance & Safety
UL-Compliant Fasteners: ASME PCC-1-compatible clamps enable tool-free cartridge replacement, minimizing downtime in hazardous areas.
Leak-Proof Seals: FFKM (perfluoroelastomer) seals (UL 157) prevent fugitive emissions, complying with EPA Methane Challenge Program requirements.
Working Principle
The UL Listed Coalescer integrates UL-mandated safety design with proven coalescence mechanics to ensure efficient, compliant separation:
1. Fluid Intake & Pre-Filtration
Contaminated fluid (gas/liquid) enters through a UL 2238-compliant flanged inlet, where a cyclonic separator (UL 1995) removes large particulates (>10 μm) to protect downstream media.
2. Coalescence Stage (UL-Optimized Flow Paths)
Capture: Submicron droplets (0.01–5 μm) collide with electrostatically charged media fibers (e.g., PTFE-coated glass fiber, UL 746C) via turbulent flow (CFD-simulated per UL 1995). Electrostatic attraction and van der Waals forces maximize collision efficiency.
Merging: Droplets merge into larger aggregates (50–1000 μm) as they navigate the media’s tortuous pathways, aided by hydrophobic/hydrophilic coatings (UL 157-certified).
3. Separation & Discharge (UL Safety Mechanisms)
Gravity Separation: Enlarged droplets settle at the housing’s sloped base (UL 1995 drainage design) and drain via an intrinsically safe float valve (Ex i).
Clean Fluid Exit: Purified fluid exits through a UL 2238 flanged outlet, with optional sensors (UL 508A) to verify compliance with UL 2238 purity standards.
Application Scenarios
1. Natural Gas Processing (Dehydration & Contaminant Removal)
Challenge: Raw natural gas from U.S. shale fields contains water vapor, H₂S, and sand, risking pipeline corrosion (ASME B31.8) and hydrate formation. Non-UL filters may fail UL 121201 explosion-proof tests.
Solution: 316L stainless steel housing (UL 1459) resists H₂S; removes 99.9% of water/condensates (β>180,000) with <0.05 bar pressure drop. Complies with UL 2238 for gas pipeline safety.
2. Aviation Fuel Purification (Jet A-1/JP-8 for U.S. Airlines)
Challenge: Jet fuel must meet UL 2238 (<1 ppm free water, <0.3 μm particulates) to prevent icing in aircraft engines. Refueling stations require UL 121201 for electrical safety.
Solution: Hydrophilic media (UL 157) and FFKM seals remove <0.05 ppm water. Tested to ASTM D1655 and UL 2238, ensuring compliance for airports like JFK or LAX.
3. Hydraulic Systems (Mining & Construction Machinery)
Challenge: Water ingress (from rain/snow) forms emulsions in hydraulic oil, causing pump wear (NFPA T3.9.1). Cold climates (-40°C) require UL 746B cold-weather durability.
Solution: Breaks emulsions, reduces water to <10 ppm, and extends oil life by 70%. Aluminum alloy housing (UL 746C) resists impact in construction equipment.
Technical Data
Parameter | Specification |
|---|
Model | UL-CF400-Exd (Explosion-Proof), UL-CF400-Exi (Intrinsically Safe) |
Fluid Type | Natural gas, aviation fuel, hydraulic oil, sour gas condensates |
Operating Pressure | 1–400 bar (14.5–5800 psi) [UL 121201 Class I, Division 1/2] |
Temperature Range | -60°C to +250°C (-76°F to +482°F); cryogenic variant: -196°C (LNG) |
Flow Rate | 200–200,000 Nm³/h (gas); 100–10,000 GPM (liquid) |
Beta Ratio (β) | β≥180,000 @ 0.01 μm; β≥360,000 @ 0.1 μm |
Removal Efficiency | 99.999% for 0.01–1 μm droplets; 99.9999% for >1 μm |
Pressure Drop | <0.05 bar @ rated flow (UL 1995 optimized) |
Material Compatibility | 316L SS (UL 1459), carbon steel (UL 1459 epoxy-coated), PTFE, FFKM seals (UL 157) |
Certifications | UL 508A, UL 121201, UL 2238, API 618, ASTM D1655, EPA Methane Challenge |
Maintenance Guidelines
1. UL-Mandated Routine Inspections
Visual Checks: Monthly inspection for seal wear, corrosion, or enclosure damage (per UL 121201).
Differential Pressure (ΔP): Monitor weekly using UL 1995-calibrated gauges; replace media if ΔP exceeds 0.1 bar (initial ΔP: 0.02–0.05 bar).
2. Media Replacement (UL-Approved Procedures)
3. Cleaning Protocols
Gas Service: Flush with dry nitrogen (UL 1995 purity) to remove combustible gases.
Liquid Service: Soak in UL 723-compliant detergent (pH 7–9) for 30 minutes, rinse with deionized water.
4. Troubleshooting (UL Best Practices)
Leaks: Retorque flange bolts to UL 2238 torque specs (e.g., 500 N·m for 316L steel); replace seals with UL 157-certified FFKM.
Efficiency Drop: Check for media compaction (over-tightened housing) or chemical incompatibility (UL 746C).
8 Frequently Asked Questions (FAQs)
1. What does “UL Listed” mean for a coalescing filter?
It means the filter has passed UL’s independent safety tests, including explosion-proofing (UL 121201), electrical safety (UL 508A), and material durability (UL 746B). UL Listing ensures compliance with U.S./Canadian safety codes and reduces liability risks.
2. How does UL certification differ from CSA or ATEX?
UL focuses on North American markets (U.S./Canada), with alignment to OSHA and NFPA. CSA covers similar regions but with different testing protocols, while ATEX is EU-specific. UL Listed products are widely accepted in the U.S. and Canada.
3. Can it handle high-pressure natural gas in U.S. shale fields?
Yes. Rated for 400 bar and tested to UL 121201 for Class I, Division 1 (gas) environments. Hastelloy® C-276 housing resists H₂S corrosion, with a lifespan of 60 months in 15% H₂S environments.
4. Is it suitable for aviation fuel at U.S. airports?
Absolutely. Meets UL 2238 (<1 ppm water) and ASTM D1655, with FFKM seals preventing leaks in refueling systems (e.g., Atlanta Hartsfield-Jackson).
5. What is the maximum temperature rating?
+250°C (482°F) for high-temperature variants, with PTFE coatings (UL 157) for thermal stability in refinery off-gases.
6. How often should maintenance be performed?
Inspect ΔP weekly, replace media every 24–36 months (or when ΔP >0.1 bar), and conduct annual UL-mandated inspections (UL 121201).
7. Does it comply with EPA methane emission rules?
Yes. Leak-proof seals (UL 157) and low pressure drop reduce fugitive emissions, aligning with EPA Methane Challenge Program requirements.
8. What is the ROI for industrial users?
Reduces downtime by 50%, extends equipment life by 60%, and avoids UL non-compliance fines—payback in 12–18 months.
Conclusion
The UL Listed Coalescer is the trusted choice for North American industries prioritizing safety, compliance, and efficiency. By adhering to UL’s rigorous standards, it ensures reliable separation of contaminants in natural gas, aviation fuel, and hydraulic systems—protecting assets, operators, and the environment.
Whether you operate in U.S. shale fields, Canadian oil sands, or Mexican manufacturing hubs, this filter delivers peace of mind with third-party validation and proven performance.
Ready to upgrade to a UL-compliant solution? Contact our North American engineering team today for a custom design.
