Ingersoll Rand- 1 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Natural Gas Engine DriveAir Compressor Training
Natural Gas Engine DriveAir Compressor Training
Industrial Center, Inc.
Chicago, Illinois
April 9, 1997
Ingersoll Rand- 2 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Allen L. HumphreyIndustrial Marketing Manager
Ingersoll-Rand CompanyPortable Compressor Division
Air Compressor GroupMocksville, North Carolina
Allen L. HumphreyIndustrial Marketing Manager
Ingersoll-Rand CompanyPortable Compressor Division
Air Compressor GroupMocksville, North Carolina
Air Compressor BasicsPresented By:
Ingersoll Rand- 3 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Hi !, I’m an expert in Natural Gas !
Gas Company Guy
Air Compressor Guy
Isn’t all gas natural!!!
Ingersoll Rand- 4 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
I’m an expert in compressed air,! Hot air, cooled, and
dried
Gas Company Guy
Air Compressor Guy
I'm in trouble now, another guy full of hot
air!!!
Ingersoll Rand- 5 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Outline:Outline:
I.I. Compressed Air FactsCompressed Air Facts
II.II. Compressed Air TechnologiesCompressed Air Technologies
III.III. Regulation & ControlsRegulation & Controls
IV.IV. System Location and ArrangementSystem Location and Arrangement
V. Compressor System Components - V. Compressor System Components - The BasicsThe Basics
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Compressed Air FactsCompressed Air Facts
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Compressed Air FactsCompressed Air Facts
Most facilities consider compressed Most facilities consider compressed air a utility on par with electricity, air a utility on par with electricity, gas, and watergas, and water
However, few operating people However, few operating people know the real operating cost of their know the real operating cost of their compressed air systemcompressed air system
Ingersoll Rand- 8 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
What is cost per CFM ?What is cost per CFM ?
A Good ApproximationA Good Approximation Typical Compressor produces 4 CFM Typical Compressor produces 4 CFM
per 1 Hpper 1 Hp 1 Hp = 0.746/0.9 = 0.829kW1 Hp = 0.746/0.9 = 0.829kW Therefore, 1 CFM = 0.207kWTherefore, 1 CFM = 0.207kW @ 0.06 $/kw-hr, 1 cfm = $0.0124/hr@ 0.06 $/kw-hr, 1 cfm = $0.0124/hr 10 CFM over 8000 hours costs 10 x 10 CFM over 8000 hours costs 10 x
8000 x 0.124 = $ 992.008000 x 0.124 = $ 992.00
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Where are NORMAL savings ?Where are NORMAL savings ?
Fix System Leaks !!Fix System Leaks !! Standard plant air systemStandard plant air system
8000 hrs per year operation8000 hrs per year operation Electrical costs = $ 0.06/kWhrElectrical costs = $ 0.06/kWhr Plant line pressure = 100 PSIGPlant line pressure = 100 PSIG
(1) 1/8th inch air leak = 26 CFM(1) 1/8th inch air leak = 26 CFM 26 x 8000 x $.0124/hr = $ 2,579.0026 x 8000 x $.0124/hr = $ 2,579.00 A typical plant can have air leaks = to A typical plant can have air leaks = to
20% of total air usage.20% of total air usage.
Ingersoll Rand- 10 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Air BasicsAir Basics
Three Main ParametersThree Main Parameters 1. Pressure1. Pressure 2.Capacity2.Capacity 3. Horsepower3. Horsepower
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Pressure(PSI) = Pounds per Square inchPressure(PSI) = Pounds per Square inch
Completely dependent on system, Completely dependent on system, controls and safety valvescontrols and safety valves
An unregulated compressor will make An unregulated compressor will make ever increasing pressure until a failure ever increasing pressure until a failure occursoccurs
When plant capacity demand exceeds When plant capacity demand exceeds system capacity(CFM), compressor system capacity(CFM), compressor discharge pressure will dropdischarge pressure will drop
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Pressure - Capacity RelationshipPressure - Capacity Relationship
PP11= Initial pressure = Initial pressure VV11= Initial capacity= Initial capacity
PP11 x V x V11 = P = P22 x V x V22
PP22= Final pressure = Final pressure VV22= Final capacity= Final capacity
If a system needs more capacity(CFM) If a system needs more capacity(CFM) than available, plant pressure than available, plant pressure dropsdrops in in an an unsuccessfulunsuccessful trade of pressure for trade of pressure for capacitycapacity
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
The Cost of PressureThe Cost of Pressure
Good Rule of ThumbGood Rule of Thumb
Each # (PSI) of system pressureEach # (PSI) of system pressure
==
0.5% of system horsepower0.5% of system horsepower
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Pressure Cost ExamplePressure Cost Example
100Hp compressor set to discharge at 125 100Hp compressor set to discharge at 125 psig to plant systempsig to plant system
Plant system only requires 110 psigPlant system only requires 110 psig User resets compressor discharge pressure User resets compressor discharge pressure
to 110 psig ( a 15 psi reduction)to 110 psig ( a 15 psi reduction) 15 PSI = 7.5 % of Hp = 7.5 Hp15 PSI = 7.5 % of Hp = 7.5 Hp 7.5 x .746/.85 = 6.6kW x 8000 hrs x 7.5 x .746/.85 = 6.6kW x 8000 hrs x
$.06/kWhr = $.06/kWhr = $ 3,168.00 (Savings)$ 3,168.00 (Savings)
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Capacity(Flow) = CFM(ft3per minute)Capacity(Flow) = CFM(ft3per minute)
Basic measure of true compressor outputBasic measure of true compressor output A fixed value in most designs, for a given A fixed value in most designs, for a given
modelmodel Most all capacity measurements are Most all capacity measurements are
referred back to inlet conditions. Capacity referred back to inlet conditions. Capacity varies only slightly with a change in varies only slightly with a change in discharge pressure, for a given modeldischarge pressure, for a given model
Ingersoll Rand- 16 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Capacity MeasurementCapacity Measurement
In the pneumatics industry, In the pneumatics industry, ALL ALL capacities are capacities are measured referring back to inlet conditionsmeasured referring back to inlet conditions
Various formulae are used to define Various formulae are used to define capacity(CFM):capacity(CFM):
SCFM; ACFM; ICFM; FAD, etc. Require your SCFM; ACFM; ICFM; FAD, etc. Require your vendor to define which and wherevendor to define which and where
ASME and CAGI-Pneurop have generally ASME and CAGI-Pneurop have generally accepted testing standardsaccepted testing standards
Capacity tolerances may vary from vendor to Capacity tolerances may vary from vendor to vendor. Request definitionvendor. Request definition
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HorsepowerHorsepower
Typically, electric motor nameplate HP or NG Typically, electric motor nameplate HP or NG engine MCHP(Max Continous Hp)engine MCHP(Max Continous Hp)
The work it takes to compress “X” CFM up to The work it takes to compress “X” CFM up to “Y” PSI“Y” PSI
Driver HP is usually fixed. If either CFM or PSI Driver HP is usually fixed. If either CFM or PSI is increased, the driver may overload, unless is increased, the driver may overload, unless regulation, a speed reduction, or a change in regulation, a speed reduction, or a change in either CFM or PSI takes place.either CFM or PSI takes place.
Horsepower tolerances may vary from vendor Horsepower tolerances may vary from vendor to vendor. Request definitionto vendor. Request definition
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Air Basics TranslationsAir Basics Translations
Capacity(CFM) does the work; Pressure Capacity(CFM) does the work; Pressure effects the rate at which the work is doneeffects the rate at which the work is done
A trending decrease in plant air pressure A trending decrease in plant air pressure typically indicates a requirement for more typically indicates a requirement for more capacity(CFM), not pressurecapacity(CFM), not pressure
Increasing or decreasing the existing Increasing or decreasing the existing compressor discharge pressure will normally compressor discharge pressure will normally have negligble effect on the compressor have negligble effect on the compressor capacitycapacity
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II. Compressed Air Technologies
II. Compressed Air Technologies
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Positive Displacement Dynamic Displacement
CentrifugalRotary ScrewReciprocating
Compressor TechnologyCompressor Technology
Lower TechnologyLower Technology Higher TechnologyHigher Technology
Air Compressors
Oil Flooded Oil Free
Single Stage Two Stage
Single Acting Double Acting
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Dynamic Displacement Dynamic Displacement
020406080
100120140160180
0% FL 20% 40% 60% 80% 100% 120%
Percent of Full Load
Dis
char
ge P
ress
ure
PS
I““Performance Curve”Performance Curve”
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Centrifugal CompressorsCentrifugal Compressors AdvantagesAdvantages
Only real option over 600+ HpOnly real option over 600+ Hp High air quality- 0 PPM oil carryoverHigh air quality- 0 PPM oil carryover Moderate to high efficiencyModerate to high efficiency Longer design life than Rotaries Longer design life than Rotaries
DisadvantagesDisadvantages Higher initial costHigher initial cost Fluid cooled onlyFluid cooled only Power reduction down to 70% flowPower reduction down to 70% flow Constant speed operationConstant speed operation
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Positive DisplacementPositive Displacement
020406080
100120140160180
0% FL 20% 40% 60% 80% 100% 120%
Percent o f Fu ll Load
Dis
char
ge P
ress
ure
PSI
““Performance Curve”Performance Curve”
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Positive DisplacementPositive Displacement
Reciprocating or Rotary Screw DesignsReciprocating or Rotary Screw Designs Constant cfm; Variable pressureConstant cfm; Variable pressure Adaptable to variable speed driveAdaptable to variable speed drive Variable speed and unloading provide close Variable speed and unloading provide close
alignment with system demandalignment with system demand Oil Flooded Rotary ScrewsOil Flooded Rotary Screws--The --The
design of choice for NGEDAC’sdesign of choice for NGEDAC’s
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Rotary ScrewRotary Screw
Oil Flooded- Single StageOil Flooded- Single Stage AdvantagesAdvantages
Low 1st cost; Low maintenance $Low 1st cost; Low maintenance $ Simple packaged designSimple packaged design Adaptable to variable speed driveAdaptable to variable speed drive
DisadvantagesDisadvantages Somewhat lower efficiencySomewhat lower efficiency Moderate durability - 10 15 years on Moderate durability - 10 15 years on
averageaverage
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Rotary ScrewRotary Screw
Oil FreeOil Free AdvantagesAdvantages
High air quality- 0 PPM oil carryoverHigh air quality- 0 PPM oil carryover Moderate efficiencyModerate efficiency Packaged designPackaged design
DisadvantagesDisadvantages Higher initial costHigher initial cost Higher maintenance costHigher maintenance cost
Ingersoll Rand- 27 -
Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Compressor Selection CriteriaCompressor Selection Criteria
Evaluated First CostEvaluated First Cost EfficiencyEfficiency ControlsControls MaintenanceMaintenance CoolingCooling Air QualityAir Quality DurabilityDurability
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
General Guidelines- First CostGeneral Guidelines- First Cost
Single-stage rotary screwSingle-stage rotary screw Typically lowest first costTypically lowest first cost Greatest market growth, largest Greatest market growth, largest
populationpopulation Typically lowest efficiency Typically lowest efficiency
Possible AlternativesPossible Alternatives Two-stage rotary screwTwo-stage rotary screw Oil free rotary screwOil free rotary screw** CentrifugalCentrifugal***Dependent on air quality requirements *Dependent on air quality requirements
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Capabilities of on site Capabilities of on site maintenance personnel ? maintenance personnel ? Contract maintenance ?Contract maintenance ?
Oil flooded rotaries typically Oil flooded rotaries typically require lowest maintenance require lowest maintenance
““Air-in-the-box” design enables Air-in-the-box” design enables on site overhauls of both on site overhauls of both compressor system and engine compressor system and engine
General Guidelines- MaintenanceGeneral Guidelines- Maintenance
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
General Guidelines- CoolingGeneral Guidelines- Cooling
Fluid-Air cooled - less expensiveFluid-Air cooled - less expensive Most designs have fluid or fluid-air Most designs have fluid or fluid-air
cooled design options availablecooled design options available Closed evaporative cooling towers; Closed evaporative cooling towers;
open towers and external fluid to air open towers and external fluid to air coolers are viable cooling optionscoolers are viable cooling options
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III. Regulation & Controls III. Regulation & Controls
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Regulation/Controls ApplicationsRegulation/Controls Applications
Average number of compressors Average number of compressors = 2.5 per facility= 2.5 per facility
Typical system controls: manual/ noneTypical system controls: manual/ none Each incremental 1 PSIG of Each incremental 1 PSIG of
unnecessary pressure cost 0.5% of unnecessary pressure cost 0.5% of compressor horsepowercompressor horsepower
Each electric motor driven compressor Each electric motor driven compressor running unloaded = 35-50% of the full running unloaded = 35-50% of the full loaded electrical costsloaded electrical costs
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Regulation BasicsRegulation Basics
Do not run compressors unnecessarilyDo not run compressors unnecessarily Evaluate current regulation parametersEvaluate current regulation parameters Consider upgrading substandard Consider upgrading substandard
controlscontrols The most efficient operating point is The most efficient operating point is
100% full load.100% full load.
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Basic Types of RegulationBasic Types of Regulation
This information will be covered in This information will be covered in detail later in the seminar detail later in the seminar presentationpresentation
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IV. System Location and Arrangement
IV. System Location and Arrangement
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Possible LocationsPossible Locations
FACILITYFACILITY
#1#1
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OutdoorsOutdoors
AdvantagesAdvantages Zero floor spaceZero floor space Zero heat loadZero heat load
DisadvantagesDisadvantages Potential weather damage (Freezing, Potential weather damage (Freezing,
water, etc.)water, etc.) Potential lack of maintenance (Out of Potential lack of maintenance (Out of
sight, out of mind)sight, out of mind)
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Possible LocationsPossible Locations
FACILITYFACILITY
#2#2
#1#1
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Indoors CentralizedIndoors Centralized
AdvantagesAdvantages Protected from elementsProtected from elements Potentially easier accessPotentially easier access
DisadvantagesDisadvantages Greatest floor spaceGreatest floor space Potentially long piping runsPotentially long piping runs
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Industrial Center, Inc. / Air Compressor ConsortiumN.G.E.D.A.C. Training
Possible LocationsPossible Locations
FACILITY
#2#2
#1#1
#3#3#3#3
#3#3
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Indoors DecentralizedIndoors Decentralized
AdvantagesAdvantages Possible to install closest to large air usersPossible to install closest to large air users Least amount of pressure drop through air Least amount of pressure drop through air
lineslines DisadvantagesDisadvantages
Highest probability of incorrect regulationHighest probability of incorrect regulation Potential to spread noise and heat complaints Potential to spread noise and heat complaints
to broadest number of employeesto broadest number of employees
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Environmental FactorsEnvironmental Factors
TemperatureTemperature VentilationVentilation ConditionsConditions
AtmosphereAtmosphere PersonnelPersonnel
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Temperature - LowTemperature - Low
Below 35Below 3500
FF Possible control freeze problemPossible control freeze problem Possible condensate freeze Possible condensate freeze
problemproblem Possible fluid misapplicationPossible fluid misapplication
RecommendationsRecommendations HeatersHeaters Heat tracing key elementsHeat tracing key elements RelocateRelocate
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Temperature - HighTemperature - High
Above 100Above 10000
FF Possible unit shutdownPossible unit shutdown Increased engine maintenanceIncreased engine maintenance Possible decreased lubricant lifePossible decreased lubricant life
RecommendationsRecommendations Improved ventilation/relocateImproved ventilation/relocate Higher performance lubricantHigher performance lubricant More suitable equipment designMore suitable equipment design
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VentilationVentilation
Insufficient VentilationInsufficient Ventilation Possible unit shutdownPossible unit shutdown Increased maintenanceIncreased maintenance Possible decreased lubricant lifePossible decreased lubricant life
RequirementsRequirements Air-cooledAir-cooled Water-cooledWater-cooled
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Insufficient Insufficient Ventilation Ventilation
Causes Heat To Causes Heat To Remain Around Remain Around
UnitUnit
CompressorCompressorGenerates Heat Generates Heat
Ventilation - The High Air Temperature (HAT) Vicious Cycle
Ventilation - The High Air Temperature (HAT) Vicious Cycle
Unit Unit TemperatureTemperature
Spirals UpwardSpirals UpwardThis Heat is Ingested By This Heat is Ingested By
Engine-Compressor Engine-Compressor Increasing Operating Increasing Operating
TemperaturesTemperatures Of Unit Of Unit
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Miscellaneous ConditionsMiscellaneous Conditions
AtmosphereAtmosphere PersonnelPersonnel
These important subjects will be These important subjects will be covered later in the Seminarcovered later in the Seminar
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V. Compressor System V. Compressor System Components-The BasicsComponents-The BasicsV. Compressor System V. Compressor System
Components-The BasicsComponents-The Basics
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Basic Selection CriteriaBasic Selection CriteriaBasic Selection CriteriaBasic Selection Criteria
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Real World SystemsReal World Systems
Design CriteriaDesign Criteria Air Quality required by UserAir Quality required by User
Moisture content ?Moisture content ? Oil carryover ?Oil carryover ? ContaminantsContaminants
Pressure DropPressure Drop Demand CharacteristicsDemand Characteristics Energy profileEnergy profile
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Ideal Components For a Compressed Air System Ideal Components For a Compressed Air System
CompressorCompressor AftercoolerAftercooler Wet ReceiverWet Receiver Pre-FilterPre-Filter DryerDryer After FilterAfter Filter Dry ReceiverDry Receiver
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Ideal Components LayoutIdeal Components Layout
Pre-Pre-filterfilter
“Wet”ReceiverReceiver
CompressorCompressor
After-CoolerAfter-Cooler
DryerDryer
After-After-filterfilter
“Dry” ReceiverReceiver
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Dryers - Moisture ContentDryers - Moisture Content
60ºF60ºF
100% RH100% RH 100% RH100% RH 100% RH100% RH
80ºF80ºF100ºF100ºFAftercooler
Air CompressorAir Compressor
Effect of Compressed Air Temperature on sizing of drying equipment.
A 20º F reduction in temperature condenses 50% of the water vapor in saturated air.(Collect it; trap it; dispose of it)
A 20º F. rise in temperature doubles (200%) the moisture holding capacity of the air.
“Rule of Thumb”
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After Filter (Recommended)After Filter (Recommended)
PurposePurpose Reduce oil carryover Reduce oil carryover
BenefitBenefit Improved air qualityImproved air quality Improved product qualityImproved product quality
Instrument air applicationsInstrument air applications PaintingPainting
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Dry Receiver (Recommended)Dry Receiver (Recommended)
PurposePurpose Provide a reservoir of clean dry air to meet Provide a reservoir of clean dry air to meet
fluctuating system demandsfluctuating system demandsBenefitBenefit When sized and installed correctly can When sized and installed correctly can
minimize airline pressure fluctuationsminimize airline pressure fluctuations Prevents short term capacity requirements Prevents short term capacity requirements
from overloading cleanup equipmentfrom overloading cleanup equipment
Moisture ContentMoisture Content Pressure Dewpoint - Temperature at Pressure Dewpoint - Temperature at
which water vapor condenses into which water vapor condenses into liquid in a compressed airlineliquid in a compressed airline
Select a dewpoint 10-20Select a dewpoint 10-2000
F below the F below the lowest temperature the compressed lowest temperature the compressed airlines will seeairlines will see
Real World SystemsReal World Systems
Rule of thumb:Rule of thumb:
Real World SystemsReal World Systems
This applies only to general industrial This applies only to general industrial application. Specific applications have application. Specific applications have specific specific dewpoint requirements (i.e., dewpoint requirements (i.e., paint booths, instruments, etc.) paint booths, instruments, etc.)
WARNINGWARNING::
Contact equipment OEMsContact equipment OEMs
Real World SystemsReal World Systems
““Typical” Real World SystemTypical” Real World System A 1000 CFM system withA 1000 CFM system with
lowest plant ambient temperature of 60lowest plant ambient temperature of 6000
FF sensitivity to lubricant sensitivity to lubricant fairly steady plant demandfairly steady plant demand
After-After-filterfilter
Real World SystemReal World System
1000 CFM 1000 CFM CompressorCompressor
Air CooledAir Cooled
1000 gallon1000 gallonreceiverreceiver
Refrigerated airRefrigerated airdryer with a 40dryer with a 4000 F F dewpointdewpoint
oil coalescingoil coalescingfilterfilter
““Wet”Wet”ReceiverReceiver
CompressorCompressor
After-After-CoolerCooler DryerDryer
Real World SystemsReal World Systems
Pressure DropPressure Drop Pressure Drop is the cost of air quality Pressure Drop is the cost of air quality
Every air clean up device will utilize 2-10 PSI Every air clean up device will utilize 2-10 PSI to perform its functionto perform its function
Air dryers typically 3-5 PSIAir dryers typically 3-5 PSI Air filters typically 2-10 PSI (dependent on how Air filters typically 2-10 PSI (dependent on how
long the element has been in place)long the element has been in place)
Remember @ 1/2% energy for each PSI, Remember @ 1/2% energy for each PSI, additional filters may become needlessly additional filters may become needlessly expensiveexpensive
Real World SystemsReal World Systems
Demand CharacteristicsDemand Characteristics Receiver size and placement varies Receiver size and placement varies
depending on plant demand cycle and depending on plant demand cycle and receiver sizereceiver size
Possible to supply a new intermittent Possible to supply a new intermittent large air user with a properly sized and large air user with a properly sized and installed receiver tankinstalled receiver tank
Real World SystemsReal World Systems
Typical Compressor Carryover Values:Typical Compressor Carryover Values:
Reciprocating CompressorsReciprocating CompressorsLubricatedLubricated 50-100 PPM50-100 PPMNon - LubricatedNon - Lubricated 0 PPM 0 PPM
Rotary CompressorsRotary Compressors Oil Flooded 3-10 PPM3-10 PPMOil FreeOil Free 0 PPM0 PPM
Centrifugal CompressorsCentrifugal Compressors 0 PPM0 PPM
Real World SystemsReal World Systems
Oil Content RequirementsOil Content Requirements Whether the oil is removed at the Whether the oil is removed at the
compressor, or at the point of compressor, or at the point of use, should be determined by use, should be determined by overall plant requirementsoverall plant requirements
WARNINGWARNING::
Real World SystemsReal World Systems
Although some equipment may Although some equipment may benefit from (or even require) benefit from (or even require) lubricant in compressed air, lubricant in compressed air, many other applications (paint many other applications (paint booths, instrumentation) booths, instrumentation) cannot tolerate itcannot tolerate it
Again overall system requirements Again overall system requirements should dictate system designshould dictate system design
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Air Compressor BasicsAir Compressor Basics
Thank you for your kind attentionThank you for your kind attention