Would grade d really make a difference?
Yes. Breathing air at depth changes the effects that contaminants have on your body. Grade D has no spec for hydrocarbons, and Grade E has a rather tight limit; and, there's a narrower limit on O2 percentages.
Here's a good reference.
well, is there anyway to convert or make a grade d filling station to put out grade e air? maybe buy a new filter or something?
There's many factors that affect filtration. Simply dropping in a different filter cartridge is rarely the answer.
The biggest factor, surprisingly, is cubic feet per minute. This governs the dwell time, or, how long the air stays in contact with each layer of the filter. Air that passes through too quickly has insufficent time to allow the media to absorb the contaminants. Hence, filter stacks are rated for a particular filtration grade at a particular CFM. A small filter can become surprisingly efficient at very low CFM rates (say, 2 CFM); a large filter can produce very poor filtration when pushed to double its rated capacity.
I presume you work for a fire department, and this is why you're asking all this, because you'd like to fill your SCUBA cylinders from the SCBA fill station at work.
As a point of reference, our fire department has three mobile SCBA fill apparatus. About 10 years ago they were all updated to produce Grade E air. The filter stacks roughly doubled in size.
There are aftermarket filters you can place in-line with your cylinders as you fill them. It's been a while since I looked them up but they were expensive, in the range of $600 IIRC, and they had amazingly slow CFM rates, (maybe 3 CFM? Can't recall here, sorry) so they were more a PITA than a real help.
Soooo, the short version is if you want Grade E air, then you really need a compressor/filter stack assembly that's designed as a whole to produce that grade.
Probabally not the answer you're looking for, but so be it. For the record, I fill SCBA's at work, and all my SCUBA cylinders at the dive shop.
All the best, James