Natural Gas Engine Drive

Air Compressor Training

Industrial Center, Inc.

Chicago, Illinois
April 9, 1997
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training -1-
 Air Compressor Basics
Presented By:
Allen L. Humphrey
Industrial Marketing Manager
Ingersoll-Rand Company
Portable Compressor Division
Air Compressor Group
Mocksville, North Carolina
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training -2-
 Isn’t all gas
natural!!!
Hi !, I’m an
expert in
Natural Gas !

Gas Company Guy Air Compressor Guy

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training -3-
 I’m an expert in I'm in trouble now,
compressed air,! another guy full of
Hot air, cooled, hot air!!!
and dried

Air Compressor Guy Gas Company Guy

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training -4-
 Outline:
I. Compressed Air Facts

II. Compressed Air Technologies

III. Regulation & Controls

IV. System Location and Arrangement

V. Compressor System Components -
The Basics

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training -5-
 Compressed Air Facts

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training -6-
 Compressed Air Facts

 Most facilities consider compressed

air a utility on par with electricity,
gas, and water
 However, few operating people
know the real operating cost of their
compressed air system

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training -7-
 What is cost per CFM ?
A Good Approximation
 Typical Compressor produces 4 CFM
per 1 Hp
 1 Hp = 0.746/0.9 = 0.829kW
 Therefore, 1 CFM = 0.207kW
 @ 0.06 $/kw-hr, 1 cfm = $0.0124/hr
 10 CFM over 8000 hours costs 10 x
8000 x 0.124 = $ 992.00
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training -8-
 Where are NORMAL savings ?
 Fix System Leaks !!
 Standard plant air system
 8000 hrs per year operation
 Electrical costs = $ 0.06/kWhr
 Plant line pressure = 100 PSIG
 (1) 1/8th inch air leak = 26 CFM
 26 x 8000 x $.0124/hr = $ 2,579.00
 A typical plant can have air leaks = to
20% of total air usage.
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training -9-
 Air Basics

 Three Main Parameters

 1. Pressure
 2.Capacity
 3. Horsepower

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 10 -
 Pressure(PSI) = Pounds per Square inch

 Completely dependent on system,

controls and safety valves
 An unregulated compressor will make
ever increasing pressure until a failure
occurs
 When plant capacity demand exceeds
system capacity(CFM), compressor
discharge pressure will drop

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 11 -
 Pressure - Capacity Relationship

P1 x V1 = P2 x V2
P1= Initial pressure V1= Initial capacity
P2= Final pressure V2= Final capacity
If a system needs more capacity(CFM)
than available, plant pressure drops in
an unsuccessful trade of pressure for
capacity

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 12 -
 The Cost of Pressure

Good Rule of Thumb

Each # (PSI) of system pressure

=
0.5% of system horsepower

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 13 -
 Pressure Cost Example
 100Hp compressor set to discharge at 125
psig to plant system
 Plant system only requires 110 psig
 User resets compressor discharge pressure
to 110 psig ( a 15 psi reduction)
 15 PSI = 7.5 % of Hp = 7.5 Hp
 7.5 x .746/.85 = 6.6kW x 8000 hrs x
$.06/kWhr = $ 3,168.00 (Savings)

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 14 -
 Capacity(Flow) = CFM(ft3per minute)

 Basic measure of true compressor output

 A fixed value in most designs, for a given
model
 Most all capacity measurements are
referred back to inlet conditions. Capacity
varies only slightly with a change in
discharge pressure, for a given model

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 15 -
 Capacity Measurement
 In the pneumatics industry, ALL capacities are
measured referring back to inlet conditions
 Various formulae are used to define
capacity(CFM):
SCFM; ACFM; ICFM; FAD, etc. Require your
vendor to define which and where
 ASME and CAGI-Pneurop have generally
accepted testing standards
 Capacity tolerances may vary from vendor to
vendor. Request definition
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 16 -
 Horsepower
 Typically, electric motor nameplate HP or NG
engine MCHP(Max Continous Hp)
 The work it takes to compress “X” CFM up to
“Y” PSI
 Driver HP is usually fixed. If either CFM or PSI
is increased, the driver may overload, unless
regulation, a speed reduction, or a change in
either CFM or PSI takes place.
 Horsepower tolerances may vary from vendor
to vendor. Request definition
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 17 -
 Air Basics Translations
 Capacity(CFM) does the work; Pressure
effects the rate at which the work is done
 A trending decrease in plant air pressure
typically indicates a requirement for more
capacity(CFM), not pressure
 Increasing or decreasing the existing
compressor discharge pressure will normally
have negligble effect on the compressor
capacity

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 18 -
 II. Compressed Air
Technologies

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 19 -
 Compressor Technology
Air Compressors

Positive Displacement Dynamic Displacement

Reciprocating Rotary Screw Centrifugal

Single Acting Double Acting Oil Flooded Oil Free

Single Stage Two Stage

Lower Technology Higher Technology

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 20 -
 Dynamic Displacement

“Performance Curve”
180
Discharge Pressure PSI

160
140
120
100
80
60
40
20
0
0% FL 20% 40% 60% 80% 100% 120%
Percent of Full Load

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 21 -
 Centrifugal Compressors
 Advantages
 Only real option over 600+ Hp
 High air quality- 0 PPM oil carryover
 Moderate to high efficiency
 Longer design life than Rotaries
 Disadvantages
 Higher initial cost
 Fluid cooled only
 Power reduction down to 70% flow
 Constant speed operation
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 22 -
 Positive Displacement
Discharge Pressure PSI
180
“Performance Curve”
160
140
120
100
80
60
40
20
0
0% FL 20% 40% 60% 80% 100% 120%
Percent of Full Load
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 23 -
 Positive Displacement
 Reciprocating or Rotary Screw Designs
 Constant cfm; Variable pressure
 Adaptable to variable speed drive
 Variable speed and unloading provide close
alignment with system demand
 Oil Flooded Rotary Screws--The
design of choice for NGEDAC’s

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 24 -
 Rotary Screw
Oil Flooded- Single Stage
 Advantages

 Low 1st cost; Low maintenance $

 Simple packaged design
 Adaptable to variable speed drive
 Disadvantages
 Somewhat lower efficiency
 Moderate durability - 10 15 years on
average
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 25 -
 Rotary Screw
 Oil Free
 Advantages
 High air quality- 0 PPM oil carryover
 Moderate efficiency
 Packaged design
 Disadvantages
 Higher initial cost
 Higher maintenance cost

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 26 -
 Compressor Selection Criteria

 Evaluated First Cost

 Efficiency
 Controls
 Maintenance
 Cooling
 Air Quality
 Durability

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 27 -
 General Guidelines- First Cost
 Single-stage rotary screw
 Typically lowest first cost
 Greatest market growth, largest
population
 Typically lowest efficiency
 Possible Alternatives
 Two-stage rotary screw
 Oil free rotary screw*

 Centrifugal*

*Dependent on air quality requirements

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 28 -
 General Guidelines- Maintenance
 Capabilities of on site
maintenance personnel ?
Contract maintenance ?
 Oil flooded rotaries typically
require lowest maintenance
 “Air-in-the-box” design enables
on site overhauls of both
compressor system and engine

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 29 -
 General Guidelines- Cooling

 Fluid-Air cooled - less expensive

 Most designs have fluid or fluid-
air cooled design options
available
 Closed evaporative cooling
towers; open towers and external
fluid to air coolers are viable
cooling options
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 30 -
 III. Regulation & Controls

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 31 -
 Regulation/Controls Applications

 Average number of compressors

= 2.5 per facility
 Typical system controls: manual/ none
 Each incremental 1 PSIG of
unnecessary pressure cost 0.5% of
compressor horsepower
 Each electric motor driven compressor
running unloaded = 35-50% of the full
loaded electrical costs
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 32 -
 Regulation Basics
 Do not run compressors unnecessarily
 Evaluate current regulation parameters
 Consider upgrading substandard
controls
 The most efficient operating point is
100% full load.

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 33 -
 Basic Types of Regulation

This information will be covered in

detail later in the seminar
presentation

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 34 -
 IV. System Location and
Arrangement

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 35 -
 Possible Locations
#1
FACILITY

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 36 -
 Outdoors

 Advantages
 Zero floor space
 Zero heat load
 Disadvantages
 Potential weather damage (Freezing,
water, etc.)
 Potential lack of maintenance (Out of
sight, out of mind)

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 37 -
 Possible Locations
#1
FACILITY

#2

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 38 -
 Indoors Centralized

 Advantages
 Protected from elements
 Potentially easier access
 Disadvantages
 Greatest floor space
 Potentially long piping runs

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 39 -
 Possible Locations
#1

FACILITY

#3
#3

#2 #3

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 40 -
 Indoors Decentralized

 Advantages
 Possible to install closest to large air users
 Least amount of pressure drop through air
lines
 Disadvantages
 Highest probability of incorrect regulation
 Potential to spread noise and heat
complaints to broadest number of
employees
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 41 -
 Environmental Factors

 Temperature
 Ventilation
 Conditions
 Atmosphere
 Personnel

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 42 -
 Temperature - Low
 Below 350 F
 Possible control freeze problem
 Possible condensate freeze
problem
 Possible fluid misapplication
 Recommendations
 Heaters
 Heat tracing key elements
 Relocate

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 43 -
 Temperature - High

 Above 1000 F
 Possible unit shutdown
 Increased engine maintenance
 Possible decreased lubricant life
 Recommendations
 Improved ventilation/relocate
 Higher performance lubricant
 More suitable equipment design

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 44 -
 Ventilation

 Insufficient Ventilation
 Possible unit shutdown
 Increased maintenance
 Possible decreased lubricant life
 Requirements
 Air-cooled
 Water-cooled

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 45 -
 Ventilation - The High Air
Temperature (HAT) Vicious Cycle

Compressor Insufficient
Generates Heat Ventilation
Causes Heat To
Remain Around
Unit

Unit
Temperature
Spirals Upward
This Heat is Ingested By
Engine-Compressor
Increasing Operating
Temperatures
Of Unit
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 46 -
 Miscellaneous Conditions

 Atmosphere
 Personnel

These important subjects will be

covered later in the Seminar

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 47 -
 V. Compressor System
Components-The Basics

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N.G.E.D.A.C. Training - 48 -
 Basic Selection Criteria

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 49 -
 Real World Systems
Design Criteria
 Air Quality required by User

 Moisture content ?

 Oil carryover ?

 Contaminants

 Pressure Drop

 Demand Characteristics

 Energy profile

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 50 -
 Ideal Components For a
Compressed Air System

 Compressor
 Aftercooler
 Wet Receiver
 Pre-Filter
 Dryer
 After Filter
 Dry Receiver
Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand
N.G.E.D.A.C. Training - 51 -
 Ideal Components Layout

“Dry”
After-Cooler Pre-
Receiver
filter

Dryer
Compressor

After-
filter
“Wet”Receiver

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 52 -
 Dryers - Moisture Content
“Rule of Thumb”
Aftercooler 100ºF 80ºF 60ºF

Air Compressor
100% RH 100% RH 100% RH

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.

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 53 -
 After Filter (Recommended)

Purpose
 Reduce oil carryover

Benefit
 Improved air quality

 Improved product quality

 Instrument air applications

 Painting

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 54 -
 Dry Receiver (Recommended)
Purpose
 Provide a reservoir of clean dry air to meet

fluctuating system demands

Benefit
 When sized and installed correctly can

minimize airline pressure fluctuations

 Prevents short term capacity requirements

from overloading cleanup equipment

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 55 -
 Real World Systems
Moisture Content
 Pressure Dewpoint - Temperature

at which water vapor condenses

into liquid in a compressed airline
Rule of thumb:

Select a dewpoint 10-200 F below

the lowest temperature the
compressed airlines will see
 Real World Systems

WARNING:
This applies only to general
industrial application. Specific
applications have specific
dewpoint requirements (i.e.,
paint booths, instruments, etc.)
Contact equipment OEMs
 Real World Systems

“Typical” Real World System

 A 1000 CFM system with

 lowest plant ambient temperature of 600 F

 sensitivity to lubricant
 fairly steady plant demand
 Real World System
After- “Wet”
Cooler Receiver Dryer After-
filter

Compressor

Air Cooled oil coalescing

1000 CFM filter
Compressor
Refrigerated air
1000 gallon dryer with a 400 F
receiver dewpoint
 Real World Systems
Pressure Drop
 Pressure Drop is the cost of air quality

 Every air clean up device will utilize 2-10 PSI

to perform its function
 Air dryers typically 3-5 PSI
 Air filters typically 2-10 PSI (dependent on how
long the element has been in place)

Remember @ 1/2% energy for each PSI,

additional filters may become needlessly
expensive
 Real World Systems

Demand Characteristics
 Receiver size and placement varies

depending on plant demand cycle and

receiver size
 Possible to supply a new intermittent

large air user with a properly sized and

installed receiver tank
 Real World Systems
Typical Compressor Carryover Values:

Reciprocating Compressors
Lubricated 50-100 PPM
Non - Lubricated 0 PPM
Rotary Compressors
Oil Flooded 3-10 PPM
Oil Free 0 PPM
Centrifugal Compressors 0 PPM
 Real World Systems

Oil Content Requirements

 Whether the oil is removed at the

compressor, or at the point of

use, should be determined by
overall plant requirements
 Real World Systems

WARNING:
Although some equipment
may benefit from (or even
require) lubricant in
compressed air, many other
applications (paint booths,
instrumentation) cannot
tolerate it
Again overall system requirements
should dictate system design
 Air Compressor Basics
Thank you for your kind attention

Industrial Center, Inc. / Air Compressor Consortium Ingersoll Rand

N.G.E.D.A.C. Training - 65 -