2006

Technology Leader in Oil FreeTechnology Leader in Oil FreeSierra Super Duty Oil Free Compressors

Sierra Super Duty2

Sierra Super Duty 50-200hp

Sierra Super Duty3

Sierra Super Duty 50-200hp

Inlet Air

Multi stage heavy dust inlet air filter

• Dry type• High efficiency• 3 micron @ 99.95% efficiency

standard element• Dedicated plenum assures cleanest inlet

air possible

Sierra Super Duty4

Sierra Super Duty 50-200hp

Inlet Valve

Butterfly type valve• Full flow - load/no load• Orifice for makeup air

Load/Unload Control Cylinder• Hydraulic actuation• OL/OL control• Solid mechanical linkage

w/ blow-off valve

Sierra Super Duty5

Sierra Super Duty 50-200hp

First Stage Airend

• Oil-free rotary screw• Air cooled• Timing gears• Cast iron housing

w/UltraCoat coating• Steel rotors w/UltraCoat coating• Compression to 30 PSIG

Sierra Super Duty6

UltraCoat

Solving the Need for Better Oil-freePerformance and Energy SavingsIngersoll-Rand’s exclusive UltraCoat rotor andhousing coating process uses a mechanicaland chemical bond to insure the thinnestcoating with the tightest possible grip

• UltraCoat has proven to be unmatched in its performance

• UltraCoat protects every Sierra airend and now every Nirvana oil-free airend

• UltraCoat rotor and housing coating process uses a mechanical and chemical bond to ensure that the microcoating interlocks with the rotor and casting material

• UltraCoat delivers longer life and 10% energy savings

Sierra Super Duty7

Sierra with UltraCoat

Competitive Coating

Brand X’s Coating Wear

There is a difference

Sierra Ultracoat

Non-Ultracoat design

Ultracoat has no degradation for the most air delivered per inpuUltracoat has no degradation for the most air delivered per input power t power

Time

Sierra Super Duty8

Superior Construction

Discharge Pulsation Dampener• Cast iron elbow• Venturi cast in elbow

Sierra Super Duty9

Robust Piping Design

Piping

• Expansion joints to coolers• Carbon steel air piping -

hot side• Stainless steel air piping -

cold side• Carbon steel oil piping• Flex hose to/from oil cooler• Gearcase breather

Sierra Super Duty10

Intercooler

Intercooler

• Air cooled• Aluminum• 115º F ambient design

Sierra Super Duty11

I/C Safety Valve Moisture Separator

• Cast aluminum• Condensate solenoid valve• Manual drain valve• Isolation valve• Check valve to drain

Moisture Separator

Sierra Super Duty12

Second Stage Airend

• Oil-free rotary screw• Timing gears• Oil in jackets (cooling)• Cast iron housing w/UltraCoat• Stainless steel rotors w/UltraCoat• Compression from 30 PSIG to

discharge PSIG (100, 125 or 150)

Second Stage

Sierra Super Duty13

Second Stage

Discharge Venturi

• Cast iron elbow• Orifice dampens

pulsations

Second Stage Venturi

Sierra Super Duty14

Seal Vents

• SPM (Shock Pulse Monitoring) • Timing gear oil splitter

Seal Vents

Sierra Super Duty15

Discharge Check Valve

• Located on the hot side

Discharge Check Valve

Sierra Super Duty16

Aftercooler

• Air cooled• Aluminum• CTD – 20º F• 115º F ambient design

Aftercooler

Sierra Super Duty17

Solenoid Drain Valves

• Controlled by the Intellisys controller

• Strainer screens keep the orifice clean

Solenoid Drain Valves

Sierra Super Duty18

Manual Drain Valves

• Ball type• .25 inch

Manual Drain Valves

Sierra Super Duty19

Package Ventilation Fan Motor

• Totally enclosed fan cooled (TEFC) motor standard

• .25 inch static pressure allowance

Fan Motor

Sierra Super Duty20

Main Motor

• Totally enclosed fan cooled (TEFC) motor standard

• Class F, B Rise• 115 degF ambient

rated

Main Motor

Sierra Super Duty21

Blowdown Silencer

• Muffler• Vented to atmosphere

outside of the enclosure

Silencer

Sierra Super Duty22

Compression Module

• Two stage• Rotary screw• Oil-free• Jack shaft drive• Cast iron housings• Shaft driven oil pump

Compression Module

Sierra Super Duty23

Bearings & Seals - Each Airend

• (2) 4 point ball bearings- Thrust loads

• (4) roller bearings- Radial loads

• Stainless steel ring seals- Minimizes air leakage

• Labyrinth oil seal- Eliminates oil leaks

• Timing gears• No thrust piston

Bearings and Seals

Sierra Super Duty24

Lube Oil System

• Gear type pump• Relief valve• Thermostatic control valve• Oil cooler• Oil filter• Gearcase vent

Lube Oil System

Sierra Super Duty25

For application in varied locations, NEMA 4 Electrics are a standard

NEMA 4 Electrics

Sierra Super Duty26

IntellisysTM controls it all. Intellisys matches pressure need to compressor operation, monitors compressor health, tells you what maintenance is required.

Intellisys SG Controller

Sierra Super Duty27

UltraCoat rotor coating

NEMA 4 Electrics

115º F ambient rated

Noble materials

Maximum performance

Time proven airend design

Intellisys

Quiet and ambient compensated

Hi-dust filtration

TEFC Motor

Sierra Super Duty - Summary

Sierra Super Duty28

Coatings – How Important?

Sierra Super Duty29

• Not all coatings are created equal– How does Brand X’s coating wear off?– What happens when Brand X’s coating wears off?

- Performance change (shown earlier)- Temperature increases

– How does Brand X’s airend failure occur?

Coatings – Very Important!

Sierra Super Duty30

Brand X: 2nd Stage Carbon Steel Surface Exposure

+ Compressed air+ High humidity+ High temperature

= CORROSION

Coatings – Corrosive atmosphere

Sierra Super Duty31

TeflonBrand X: Teflon Coating

• Sand blasting extends rotor surface area

• Teflon (paint version) is applied- “Paint” bond created

• Heat cured

Rotor S

urface

Corrosion Susceptible

Sierra Super Duty32

Corrosion Susceptible

Brand X: Teflon® Coating

• Polytetrafluorethylene (PTFE)- Durable, resists oxidation and

brittleness

• Graphite component- Reduces durability properties

• Applied by hand- Thick coverage- Uneven coverage

• Paint bond is susceptible to peeling

Sierra Super Duty33

Brand X: The Coating

2nd stage-• Carbon steel rotors• PTFE coating

- Applied by hand- Thick & uneven coverage

• Paint bond- Susceptible to peeling

Corrosion Susceptible

Sierra Super Duty34

• Foreign particles erode it away

Why Does Brand X Lose Their Coating?

How is the surface lost?

Sierra Super Duty35

How Does Brand X’s Airend Fail

• Lost coating in moisture rich oxygen laden environment = rust.

• High interstage temperature- Diminished capacity- Increased horsepower

• Creates high temperature & accelerates failure

Effects of Corrosion

Sierra Super Duty36

• Compressor operating temperature approaches coating design limit

• Carbon steel rotor corrosion• 2nd stage airend element can

actually seize.

Why Does Brand X Lose Their Coating?

Ultimate result of corrosion

Sierra Super Duty37

UltraCoat- The Process

• Surface area preparation- Carbon steel- Cast iron- Stainless steel

• Coating applied by robot• Heat cured in oven

Ultracoat – Corrosion Inhibitor

Sierra Super Duty38

Step 1- Surface Preparation

• Surface area preparation- Phosphatized for carbon steel

& cast iron- Sandblasting for stainless steel

• Creates “Ultra” large surface area- Crevasses for bonding

Ultracoat -Corrosion Inhibitor

Sierra Super Duty39

Step 2- Coating

• Organic high temperature resin• Imbedded PTFE and MoS2

particles• Resin mechanically bonds

with crevasses

Rotor Surface

Coating

Ultracoat -Corrosion Inhibitor

Sierra Super Duty40

UltraCoat Coating

• Organic high temperature resin with imbeddedPTFE and MoS2 particles

• Durable- resists oxidation and brittleness• Applied “thin”• Mechanical bond = “Ultra” strength

- UltraCoat must be physically torn off to be removed

Ultracoat -Corrosion Inhibitor

Sierra Super Duty41

Coating Conclusions

• UltraCoat is superior because of– Material composition– Metal preparation

- Ultra surface area– Mechanical bonding– Thinner coating

- Yields greatest bonding strength

Ultracoat -Corrosion Inhibitor

Sierra Super Duty42

UltraCoat rotor coating

NEMA 4 Electrics

115º F ambient rated

Noble materials

Maximum performance

Time proven airend design

Intellisys

Quiet and ambient compensated

Hi-dust filtrationTEFC Motor

Sierra Super Duty - Summary