Compressor Fundamentals Overview _ INGERSOLL RAND

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Compressor Fundamentals Overview

Transcript of Compressor Fundamentals Overview _ INGERSOLL RAND

Page 1: Compressor Fundamentals Overview _ INGERSOLL RAND

Compressor Fundamentals

Overview

Page 2: Compressor Fundamentals Overview _ INGERSOLL RAND

Compressor Fundamentals

Why do we compress Air?

In this section, you will learn

• Why do we compress air

• Basic Compressor Operation

• Types of Compressors

• A brief history of compressed air

• Basic operation

Why do we compress air? Compression is undertaken for a variety of reasons. Many processes can only be carried out by compressed gases. Some of these include:

� Transmission of power for pneumatic tools.

� Shot blasting

� Paint Spraying

� Transporting materials

� Conveying

� Air separation, for industrial gases (oxygen, nitrogen).

� Amusement parks

� snow making

� Glass plants

� Blowing

� Etching

� Molding, etc.

Basic Compressor Operation There are various ways to compress air. One of the simplest is by means of a piston in a cylinder. As the piston moves forward in the cylinder it compresses the air into a smaller space, thus raising its pressure. We are all familiar with the bicycle pump, which is typical of this principle.

A reciprocating air compressor utilises the same pumping principle. Air is drawn into a cylinder and compressed by a piston, which is driven by a connecting rod and crankshaft. An air compressor is very similar to the engine in an automobile.

Air enters the compressor through a combination filter and muffler that cleans the air and silences the noise. The clean air passes into the cylinder through an inlet valve, which is opened automatically by differential air pressure. The air is then compressed by the piston and forced through a discharge valve into a storage tank.

Type 30 Air Compressor, circa 1930

Page 3: Compressor Fundamentals Overview _ INGERSOLL RAND

Compressor Fundamentals

Types of Compressors

Types of Compressors There are two general groups of air compressors, positive displacement and continuous flow. Positive Displacement compressors are either Reciprocating or Rotary.

Positive Displacement

These are units in which successive volumes of air are confined within a closed space and elevated to a higher pressure.

Reciprocating

The compressing and displacing element in these units is a piston having a reciprocating motion within a cylinder.

Rotary Compressing and displacement is effected by the positive action of rotating elements

Sliding Vane

Axial vanes slide radially in a rotor eccentrically mounted in a cylindrical casing. Air trapped between vanes is compressed and displaced.

Liquid Piston

Water or other liquid is used as the piston to compress and displace the air.

Straight Lobe

Two straight mating lobed impellers trap air and carry it from intake to discharge. This is no internal compression.

Helical Lobe

Two intermeshing rotors, each with a helical form, compress and displace the air.

Continuous Flow

Ejector

Devices that use a high velocity gas or steam jet to entrain the inflowing air, then convert the velocity of the mixture to pressure in a diffuser.

Dynamic

These are machines in which the rapidly rotating element accelerates the air as it passes through the element, converting the velocity head into pressure, partially in the rotating element and partially in stationary diffusers or blades.

Centrifugal

One or more rotating impellers, usually shrouded on the sides, accelerate the air. Main air flow is radial.

Axial Flow

Air acceleration is obtained by the action of the bladed rotor shrouded on the blade ends. Main air flow is axial.

Mixed Flow

An impeller form combining some characteristics of both the centrifugal and axial types.

Page 4: Compressor Fundamentals Overview _ INGERSOLL RAND

Compressor Fundamentals

A brief history of compressed air 10,000 The first use of compressed air was when ancient man blew on embers to start BC a fire. Thus the first “compressor” was human lungs (capacity 100 1/min,

pressure 0.02-0.08 bar(g)).

The work capability of compressed air was well understood by primitive hunters who used a blowpipe and darts to hunt wild animals.

3000 BC Man began to melt gold, copper, tin and lead found in pure form in nature and later to reduce their oxides.

Temperatures in excess of 1000oC required a more powerful compressor. This again was provided by nature with wind being compressed against a hillside and forced across a ridge.

Egyptian and Sumerian goldsmiths developed a blowpipe to provide a more convenient and reliable means of melting their metals.

The blowpipe is still used today, but is, of course, inadequate in

capacity for volume smelting of metals.

2500 BC Hand bellows, the first mechanical form of compressor, were invented.

1500 BC Foot bellows were invented

1000 BC Bellows were driven by water wheels.

1750 AD John Smeaton’s water driven air blowing cylinder, replaced bellows.

1776 AD John Wilkinson invented a cannon-boring machine. This invention enabled production of large, accurately machined, cast iron cylinders for both blowing machines and steam engines.

The first prototype was installed in his machine shop in Wilby, Shropshire, UK. It was limited to a pressure of about 1 bar(g) by the temperature capability of the leather links controlling the wooden valves.

The bellows and the early blowing machines were primarily used to supply combustion air for

smelting and to ventilate underground mines. This was necessary because the ore was mined by setting fire to the face and then cooling it with water to fracture the rock.

1800 AD People began to seriously think of compressed air as an energy transmission medium. It had already been found that steam was limited to short distances because it cooled and condensed so quickly.

1820 AD Metallurgical plants were growing in size and it was necessary to supplement installed steam

plants with water power. But, in Wales, a waterfall in the narrow valley could not be used as there

was no adjacent land on which to build a rolling mill.

It was decided to use the water to power blowing machines and to pipe the air to power air motors in the mill about 1000 metres away. Unfortunately on start up, although the blowing machines worked well, the air motors would not turn.

Compressed air technology very nearly ceased before it started.

Eventually it was found that the vitrified clay pipes, which worked well as water conduits, would not

hold air.

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Compressor Fundamentals

A brief history of compressed air 1857 AD Since prehistoric times, man has worked with rock. Mining originated when flint was needed for

stone age tools. When mining progressed from lighting fires to blasting with explosives, it became necessary to drill holes in the rock. This was initially accomplished by hand, using the “hammer and twist” method.

Long distance transmission of compressed air energy began with the building of the Mt. Cenis railway tunnel in the Swiss Alps.

The 13.6km tunnel began in 1857 with manual drilling and would have taken 30 years to

complete. After four years, compressors were installed at both ends to power rock drills. When the

two teams met, there were 7km of distribution line running from each end.

The Mt. Cenis experience caused people to think about building distribution networks to provide compressed air energy to individual businesses.

1860 AD People began to develop mechanical rock drills.

It was shortly after that Ingersoll Rand began (as a result of individual efforts by Simon Ingersoll and the Rand brothers. Once the mechanical rock drill was operational, much work was done to develop reliable sources of motive power.

The air compressor developed quickly from this point

1871 AD

Patent No. 112,254 issued to Simon Ingersoll on 7th March, 1871. This is the date from which we trace Ingersoll Rand's history.

Ingersoll Rand Rock Drill in Kalgoorlie, WA

1888 AD Victor Popp, an Austrian engineer, gained a concession to run a compressed air distribution system through the Paris sewer system.

The plant was commissioned with 1500 kW of compressors feeding 7 km of mains and 50 km of feeder line.

1891 AD By this time, the system which operated at a pressure of 6 bar(g), had grown to a capacity of 18,000 kW (1.8 MW).

One of the major reasons for Popp’s success was a novel pneumatic clock which kept accurate time driven by timed pulses of compressed air. This became a “must have” item and once air was connected to restaurants, factories, shops, physicians surgeries, lawyers offices, etc., it became a simple matter to hook other pneumatic devices into the system.

Inventors in all parts of the work now got busy and many patents were issued. In Paris, for example, air was used for:

• Pneumatic clocks

• Pneumatic despatch systems

• Passenger lifts

• Wine and beer dispensing

• Air motors up to 70 kW to run tools, looms, presses, etc Factory in Paris that made

• Pneumatic drive of DC generators up to 36 kW to light air compressors for Victor

• Restaurants, theatres, hospitals, etc

Many reports concluded that compressed air was the energy transmission medium of the future. They took a very negative attitude to the electric distribution system then also in its infancy. There were others, however; who were equally enthusiastic about the merits of electricity and who dismissed compressed air because of its poor efficiency.

Neither of the two opposing schools of thought were proven totally correct. Compressed air plants kept developing and expanding. Electric transmission systems became the exclusive means of distributing power. Compressed air now serves as an important complement to electricity and it is called the “fourth” utility.

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Compressor Fundamentals

A brief history of compressed air 1902 AD World’s first truly portable compressor built

1903 AD Pneumatic tools added

1913 AD Centrifugal pumps added. First centrifugal compressor built.

1920 AD High temperature pumps aided the thermal cracking of crude oil

1930 AD The T30 compressor introduced

Compressor

1933 AD Two stage air cooled portable developed

1941 AD The boiler circulating pump introduced

1947 AD The first “big drill” built

1948 AD Centrifugal compressors transport natural gas

1950 AD Sliding vane compressors introduced. Quiet pumps for nuclear submarines

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Compressor Fundamentals

A brief history of compressed air 2000 AD IR was first-to-market introducing a true variable speed drive compressor directly driven by

Hybrid/Permanent magnet motor

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Air Solutions

• Air solution and service provider of design, equipment, project management,

maintenance and operations for compressed air systems

• Market leader in prividing customers with air solutions tailored to their

productivity needs.

• Advanced technology, highest reliability, lowest maintenance, highest quaility air,

best energy efficiency

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T30 Non-Lubricated Air Compressor

(6.8-18Barg) T30 Non-Lubricated Air Compressor is one of the patented

products designed and built by Ingersoll Rand. T30 has the

features of low noise, reliable operation and easy

installation. They are widely used in many industries , such

as pharmaceuticals, textile, chemical and garment.

Features • Heavy Cast Iron Design

• Higher Reliability

• Long Term Durability

• Efficient Cooling System

• Powder Coat Painting Enhances Antitrust

Single&Two-stage "Standard Package" Air

Compressors(6.8-18Barg) Ingersoll Rand's Two-stage "Standard Package" air

compressors are designed for the most demanding

applications where a reliable air supply is required. Perfect

for automotive, commercial and industrial applications.

When maximized operating pressure, increased air flow,

and extended duty cycle is required, Ingersoll Rand air

compressor is the choice.

Features • SS Single-stage series

These "SS" series air compressors are the latest design.

Heavy duty single-stage cast iron air compressors is

designed by Ingersoll Rand with high quality for industrial

useage. It is durable and provides non-stop operation. These

twin cylinder block design air compressors have

conservative running speed for prolonged life.

• TS Two-stage series

-100% cast iron frame and separate cast cylinders

-Stainless steel finger valve assembly after heat treatment

-Efficient finned intercooler tubes

-Balanced overhung crankshaft

-Rugged one-piece connecting rod

-Centrifugal unloader for no load start

-Factory-filled synthetic lubricants

Page 10: Compressor Fundamentals Overview _ INGERSOLL RAND

Infinity 5.5-11 KW Infinity rotary screw compressors continue the

legacy of the great efficiency, reliability and

high quality. These compressors are simply

designed, easy to control, economical to operate

and convenient to maintain, also can run under

the most extreme ambient conditions. The

exclusive design of cold/hot box and cooling

system make Infinity different. The compressors

are available from 7 to 10 barg and from 0.74 to

1.7 m3/min

Features • Premium Poly-V belt

Provides uniform bearing load and belt wear pattern to

extend the life of belt

• High-efficiency blower cools evenly

Saves energy, and produces less noise

• Air/ Oil cooler

Discharges heat from the top for greater efficiency

• Exclusive hot box/ cool box design

Isolates hot elements from other components to ensure

cooling and extended life

• Dual control operation

Provides application flexible and reduced operating cost

• Simple user interface and diagnostic indicators

Signal operating status, hours, and faulty warnings to

minimize downtime

• Spacious interior design

Permits easy maintenance.

Pegsus15-37 KW Ingersoll Rand's rotary screw compressors with

innovation and air solution provide customer with

greater profits. The high efficiency integrated

compression module eliminates leaks and pressure

losses to increase effiency and performance.

Exclusive hot box/ cool box design keep the heat

out and the noise in, ensuring the compressors keep

running in the most extreme conditions and still

achieve maximum performance. The options are to

meet all operating conditions for customers, such as

frost protection, high ambient package, power

outage restart and intellisys control option

Features • Whisper Quiet Operation

Oversized, high efficiency cooling air blower.

Provides sound levels as low as 68 dBA

• Dual Control Operation

Reliable and effective load/no load control with

automatic stop and restart facility for maximum

flexibility.

• Simple Diagnostics

Visual indication of operating status and hours run,

for ease of operation and reduced downtime

• Poly-V Belt Drive

Premium drive system applies patented automatic

tensioning to eliminate belt stretch and increase air

output.

• Advanced Cooling

A package pre-filter, efficient combination

aftercooler with access to both sides for easy

cleaning and top discharge to simplify ducting.

• Generous Serviceability

All key maintenance components have been grouped

to provide ease of serviceability.

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Small UP 4-11 KW Small UP Total Air System integrates the compressors, cycling

dryer,dual filtration pack and controls into an energy reducing

optimized system. Advanced integrated package increase the

reliability and operation time. The compressors are available from 8

to 14.5 barg and from 0.45 to 1.6 m3/min

Features • Whisper Quiet Operation

Oversized, high efficiency motor mount blower. sound levels as 65

dBA

• Dual Control Operation

Auto start/stop operation with constant speed control for maximum

flexibility.

• Simple Diagnostics

Visual indication of operating status, and hours and fault warnings

for ease of operation and reduced downtime

• Poly-V Belt Drive

Premium drive system to minimize belt stretching and increase air

output.

• Advanced Cooling

High efficient, oversized combination cooler with roof mount

discharge for ease of ducting.

• Generous Serviceability

Spacious design for ease of serviceability.

Unigy 5.5-11 KW UNIGY integrates the most advanced air compressor technology.

The human-oriented design and unqiue IntelliDrive system provide

the most efficient compressed air

Features • Whisper Quiet Operation

• Variable speed controlled capacity automatically adjust

compressed air output

• Virtual gear set

Providing flexible power and pressure ranges

• IntelliDrive system

Suitable for multiple electrical supplies

Page 12: Compressor Fundamentals Overview _ INGERSOLL RAND

Nirvana Variable-Speed Drive

Only Ingersoll Rand offers Nirvana variable-speed drive rotary screw compressor, the world's first true

variable-speed drive rotary screw compressor for highest quality of air and the greatest reliablility available

on the market.By matching an innovative modular variable speed inverter with a HYBRID PERMANENT

MAGNET motor,Ingersoll Rand is again first-to-market,this time with a true variable-speed drive air

compressor.

Nirvana has fewer rotating parts than any other rotary air compressors in its class. The Hybrid Permanent

Magnet motor driving the Nirvana raises the standard on compressor reliability to an unequaled level.There

is no motor bearing in HPM motor. Since HPM motor directly drives the compressor,there is no pulley,belt

or coupling to wear out or to replace, and there is nothing to get out of alignment. Equipped with Ingersoll

Rand's time-proven and reliable airend,Nirvana is a highly reliable air compressor.

Features • Premium efficiency IP23 HPM motor

• 96% efficiency rating

• No motor bearing, durable motor life

• Rugged Ingersoll Rand airend with duplex tapered roller bearings

• Aircooled aftercooler with moisture separator

• Integral variable frequency drive, high efficiency

• Variable speed controlled fan motor, save energy

• Factory-fill of SSR UltraCoolant

• IntellisysTM controller featuring

• Infinite on-off control

• Self auditing function

• Low sound level

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R90-160KW Ingersoll Rand contact-cooled,rotary screw

compressors are proven,ruggedly reliable

units that perform to the highedt standards

regardless of industry,application or

environment.Easy to install and continuous-

duty rated for long-term performance,with

our compressors you get what you pay

for,and more

Features • Robust Cast Iron IP54 motor

• Rugged Ingersoll Rand airend with duplex

tapered roller bearings

• No maintenance integral gear drive system

• Air or Water-Cooled aftercooler,high cooling

efficiency

• Integral star delta starter,reduce starting

current

• Factory-fill of UltraCoolant

• IntellisysTM S3 control system featuring

• Language-less control panel with backlit

LCD display

• On-Line/Off-line control with automatic start

& stop

• Real time clock functions, modbus, 3

machine sequence control

• Noise elimination enclosure design

SSR200-250KW Ingersoll Rand contact-cooled,rotary screw

compressors are proven,ruggedly reliable

units that perform to the highest standard

regardless of industry,application,or

environment.Easy to install and continuous-

duty rated for long-term performance,with

our compressors you get what you pay

for,and more.

Features • High efficiency IP23 motor

• Rugged Ingersoll Rand airend with duplex

tapered roller bearings

• No maintenance integral gear drive system

• Air or Water-Cooled aftercooler with

moisture separator

• Integral star delta starter,reduce starting

current

• Factory-fill of SSR UltraCoolant

• Energy saving Intellisys capacity control

system featuring

• Digital inlet control valve

• Upper range modulation

• Low sound enclosure design

Page 14: Compressor Fundamentals Overview _ INGERSOLL RAND

SSR45-75KW Ingersoll Rand contact-cooled,rotary screw compressors are

proven,ruggedly reliable units that perform to the highedt

standards regardless of industry,application,or

environment.Easy to install and continuous-duty rated for

long-term performance,with our compressors you get what

you pay for,and more.

Features • Standard IP55, high efficiency motor

• Rugged Ingersoll Rand airend with duplex tapered

roller bearings

• No maintenance integral gear drive system

• Air or Water-Cooled aftercooler with moisture

separator

• Integral star delta starter,reduce starting current

• Factory-fill of SSR UltraCoolant

• IntellisysTM capacity control system featuring

• Finger-touch control panel

• On-Line/Off-line control with automatic start & stop

• Failure alarm

• Low sound enclosure design

SSR Two Stage 90-350KW Ingersoll Rand contact-cooled,rotary screw compressors are

proven,ruggedly reliable units that perform to the highedt

standards regardless of industry, application, or

environment.Easy to install and continuous-duty rated for

long-term performance,with our compressors you get what

you pay for,and more.

Features • High efficiency IP23 or IP55motor

• High efficiency 2-stage airend

• No maintenance integral gear drive system

• Air or Water-Cooled aftercooler with moisture

separator

• Integral star delta starter,reduce starting current

• Factory-fill of SSR UltraCoolant

• Energy saving IntellisysTM capacity control system

• Digital inlet control valve

• Upper range modulation

• Low sound enclosure design

Page 15: Compressor Fundamentals Overview _ INGERSOLL RAND

Nirvana Variable-Speed Drive Oil Free Only Ingersoll Rand offers Nirvana Oil-Free,The world's first true variable-speed oil-free compressor for

critical oil-free application requiring the highest quality of air and the greatest reliablility available on the

market.By matching an innovative modular variable speed inverter with a HYBRID PERMANENT

MAGNET motor,IR is again first-to-market,this time with a true variable-speed drive,oil-free air

compressor.

The two-stage Nirvana Oil-Free compressor has fewer rotating parts than any other rotary air compressor in

its class.And the Hybrid Permanent Magnet motor driving the Nirvana Oil-Free raises the standard on

compressor reliability to an unequaled level.There are no motor bearings in the HPM motor.And since the

HPM motor directly drives the compressor,there are no pulleys,belts or couplings to wear out or need

replacing.And there is nothing to get out of alignment.Coupled with IR's time-proven,reliable two-stage oil-

free airend,Nirvana Oil-Free is as reliable as an air compressor can get.

Features

• Premium efficiency IP23 HPM motor

• 97% efficiency rating

• No motor bearings,longer motor life

• Rugged IR oil-free airend with Ultra Coat,high efficiency

• Aircooled aftercooler with moisture separator

• Integral variable frequency drive

• Variable speed controlled fan motor,save energy

• Factory-fill of SSR Ultra Coolant

• IntellisysTM controller featuring

• Infinite on-off control

• Self auditing function

• Low sound level

Page 16: Compressor Fundamentals Overview _ INGERSOLL RAND

Sierra Oil Free 37-300KW

With an Ingersoll Rand oil-free compressor, you don't have to worry about contaminated air, regardless of

the technology you choose. Our oil-free rotary-screw compressor was rigorously tested by TUV Rheinland

—— a global leader in independent testing and assessment services —— and earned ISO8573-1:2001 Class

0certification

Features

• High efficiency IP55 motor

• NEMA1 control cabinet enclosure

• 2-Stage oil-free rotary screw airend,high efficiency and reliable

• High efficiency inlet filter design

• Air or Water-Cooled aftercooler with moisture separator

• Integral star delta starter,reduce staring current

• CMC controller featuring,super advanced function, Provide a list of last 224 events

• Service Scheduling

• Power Outage Restart

• Low sound enclosure design

Page 17: Compressor Fundamentals Overview _ INGERSOLL RAND

Centac CH Single Stage Centrifugal Compressor Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop

class-leading products, but also because we know our customers' industries, the demands placed on

productivity and quality. We are the first to be Class 0 certified by the TUV certification body.

ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most

industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you

need guaranteed pure air for your critical application, then you need Ingersoll Rand!

Features • Simplicity by Design

Ingersoll-Rand Centac blowers have few moving parts, which equate to higher reliability and less

maintenance. This, in turn, keeps your system up and running without unnecessary downtime.

• High Quality Air

Centac blowers are Class 0 certified and deliver 100% inherently oil-free air to your processes. This helps

assure that your product will be manufactured at the highest level of quality with scrap and defects reduction.

• Energy Efficient

With state-of-the-art aerodynamics and a technologically advanced control system, the Centac blower is the

most energy efficient compressor in the industry. It provides cost savings opportunity to the operation.

• Compressor Uptime

Maximizing your production process uptime is always our goal at Ingersoll-Rand. The Centac blower is

designed to minimize maintenance. In addition, Ingersoll-Rand offers preventative maintenance and AirCare

programs to maximize blower uptime. In the event of required maintenance, Ingersoll-Rand offers

unsurpassed local service support.

• Standard Scope of Supply

Complete Tested Package, Built-In Lubrication System, Complete Control, Protection and Diagnostic

System, Mounted Inlet and Bypass Valves, Single Point Flanged Air Connections, Hot Air Discharge (No

Aftercooler).

Page 18: Compressor Fundamentals Overview _ INGERSOLL RAND

Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop

class-leading products, but also because we know our customers’ industries, the demands placed on

productivity and quality. Pay attention that we are the first to be Class 0 certified by the TUV certification

body.

ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most

industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you

need guaranteed pure air for your critical application, then you need Ingersoll Rand!

Features • Advanced Centrifugal Technology For Superior Performance

• 100% Oil Free Air

• Next Generation Aerodynamic Design For

-Maximized Efficiency

-Increased Throttle Range For High Efficiency at Part Load

-Enhanced Reliability

• Constant Pressure Control For

-Stable System Pressure

-Smooth Operation

• Simplicity Means Reliability (less Moving Parts)

-1 Bull Gear

-2 to 3 Rotor assemblies

• Well Proven Reliable & Robust Design

-High Reliability and Long Life

-Low Maintenance Requirements

• State-of-the-Art Control System

• Low Operating & Installation Costs

• Low Noise Level (Enclosed) Options

• Worldwide Service and Parts Support

• Largest Centrifugal Installed Base in the World

Page 19: Compressor Fundamentals Overview _ INGERSOLL RAND

C3000 Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop

class-leading products, but also because we know our customers’ industries, the demands placed on

productivity and quality. Pay attention that we are the first to be Class 0 certified by the TUV certification

body.

ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most

industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you

need guaranteed pure air for your critical application, then you need Ingersoll Rand!

Features • Advanced Centrifugal Technology For Superior Performance

• 100% Oil Free Air

• Next Generation Aerodynamic Design For

-Maximized Efficiency

-Increased Throttle Range For High Efficiency at Part Load

-Enhanced Reliability

• Constant Pressure Control For:

-Stable System Pressure

-Smooth Operation

• Simplicity Means Reliability (less Moving Parts)

-1 Bull Gear

-2 to 3 Rotor assemblies

-6 to 8 Bearings per Machine

• Well Proven Reliable & Robust Design:

-High Reliability and Long Life

-Low Maintenance Requirements

• State-of-the-Art Control System

• Low Operating & Installation Costs

• Low Noise Level (Enclosed) Options

• Worldwide Service and Parts Support

• Largest Centrifugal Installed Base in the World

Page 20: Compressor Fundamentals Overview _ INGERSOLL RAND

2ASB Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop

class-leading products, but also because we know our customers' industries, the demands placed on

productivity and quality. We are the first to be Class 0 certified by the TUV certification body.

ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most

industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you

need guaranteed pure air for your critical application, then you need Ingersoll Rand

Features

• Advanced Centrifugal Technology For Superior Performance

• 100% Oil Free Air

• Next Generation Aerodynamic Design For

-Maximized Efficiency

-Increased Throttle Range For High Efficiency at Part Load

-Enhanced Reliability

• Constant Pressure Control For

-Stable System Pressure

-Smooth Operation

• Simplicity Means Reliability (less Moving Parts)

-1 Bull Gear

-2 to 3 Rotor assemblies

-6 to 8 Bearings per Machine

• Well Proven Reliable & Robust Design

-High Reliability and Long Life

-Low Maintenance Requirements

• State-of-the-Art Control System

• Low Operating & Installation Costs

• Low Noise Level (Enclosed) Options

• Worldwide Service and Parts Support

• Largest Centrifugal Installed Base in the World

Page 21: Compressor Fundamentals Overview _ INGERSOLL RAND

PET High Pressure Series

Solutions of Choice An era of choice begins. Ingersoll Rand introduces alternative

solutions to the production challenges of PET bottle blowing.

For the first time, you can choose between different, highly

advanced air compression technologies — which now include the

outstanding performance of four-stage centrifugal and reciprocating

compressors— to select that which best meets the unique

production requirements of your plant.

The reasoning is straightforward. To compete successfully in the

global marketplace, companies like yours must keep production

lines running smoothly and with minimum interruption. Downtime,

whether scheduled or unscheduled, is costly.

So, with a thorough understanding of the dynamics in today's strenuous production environment, Ingersoll

Rand unveils ground-breaking 4-stage centrifugal technology and 4-stage reciprocating technology, for

unmatched reliability and performance. Together with our other highly regarded reciprocating solutions,

these superior technologies from a single source provider offer the PBM Industry:

• Lower life-cycle cost

• Unmatched product durability

• Ability to thrive in punishing environments

• Economical and efficient solutions to maximize productivity

• Numerous configurations to meet any operational need

Centac-C1050 State-of-the-Art Reliability

Specifically designed for demanding PBM applications, the

C750 and C1050 have few moving parts and virtually nothing to

wear out. Valve, ring and packing changes become a thing of the

past. Centac compressors, by design, will run for long

intervals—and since they stay running, you keep producing.

Featuring a noncontact compression cycle, the C750 and C1050

offer unsurpassed air quality, oil-free, with no particles induced

into the air stream. Experience legendary reliability, and the

peace of mind, it brings with the new Centac C750 and C1050

solution.

Features • Advanced Centrifugal Technology

For Superior Performance

• 100% Oil Free Air: No Particles

Generated During the Compression

Process

• Simplicity By Design: Only Four

Main Rotating Parts

• Low Operating & Installation Costs

• Worldwide Service and Parts

Support

• Next Generation Aerodynamic

Design

-Maximized Efficiency

-Increased Throttle Range For High

Efficiency at Part Load

-Enhanced Reliability

• Constant Pressure Control For

-Stable System Pressure

-Smooth Operation

• State-of-the-Art Control System

Page 22: Compressor Fundamentals Overview _ INGERSOLL RAND

Recip-Petstar - 4 Four-Stage Atmospheric

When unsurpassed performance and reliability are required, the PETStar-4 line of 4-Stage Reciprocating Air

Compressors answers the challenge. Robustly designed and configured in a horizontally opposed cylinder

configuration, the PETStar-4 arrangement virtually eliminates vibration with a minimal foundation

requirement. By utilizing four stages of compression, the PETStar-4 is capable of providing unsurpassed

compressor efficiency. Lower stage compression ratios reduce the cylinder operating temperatures and

extend the life of valves, rings and packing. To simplify installation, all PETStar-4 units feature a heavy-duty

welded steel subbase and are available with a matching air treatment component package. Whether you

require a compressor for in-line molding or capacity to support a large production operation, there is a

PETStar-4 package to meet your needs.

Features

• Nonlubricated 100% Oil Free Water-Cooled Design

• Four-Stage Balanced Opposed Layout Eliminates Unwanted Vibration

• All Double Acting, Heavy Duty Class 40 Cast Iron Cylinder Construction

• 16,000 Hour Rated Piston Rings and Packing

• Worldwide Service & Parts Support

• Sleeve Type Main and Connecting Rod Bearings

• Anticorrosion Coating On All System Air Piping

• Crankshaft-Driven Main Oil Pump

• Large Cast-In Water Jackets For Dimensional Stability Under Extreme Conditions

• State-of-the-Art Control System

Page 23: Compressor Fundamentals Overview _ INGERSOLL RAND

System Controls

Air System Controller/Air System Manager The Air System Controller (ASC) provides a window into the compressor room by making the raw data

available to plant operators and managers in formats that are easy to understand plus provide substantial

ENERGY SAVINGS. The ASC utilizes a Machine Interface (HMI) Software specifically designed by

Ingersoll-Rand for Compressed Air Systems.

Benefits

Total System Control - Compressors, Dryers, Cooling Towers, Pumps & Accessories

Energy Management - Stable System

Pressure & Load Sharing

System Benchmarking & Data Management

Enhanced Communications

The Air System Manager (ASM) provides a window into the compressor room by making the raw data

available to plant operators and managers in formats that are easy to understand plus provide substantial

ENERGY SAVINGS. The ASM utilizes an "off-the-shelf" Machine Interface (HMI) Software which is

specifically customized for Compressed Air Systems.

X4I Controller System control, applied correctly, in muli-

compressor installations can dramatically decrease

energy use by ensuring that only the compressors

that are needed are operated while maintaining

system pressure in a single, tight control band. The

X4I uses the “base load, base load…. trim” control

strategy to ensure compressors are managed in this

most efficient manner. Add an Ingersoll Rand

Nirvana 5.5 - 30kW VSD and leverage the advantage

of the most efficient ‘trim control” available.

Page 24: Compressor Fundamentals Overview _ INGERSOLL RAND

Compressed Air Filter System Installation & Air Treatment

Compressed Air Filter Ingersoll Rand Compressed Air Filters are available in four filtration grades.When installed with

refrigeration or desiccant dryers,they will provide clean compressed air to the highest classes as prescribed

by ISO8573.1

Benefits:

Proven to exceed ISO air quality

Quickest,simplest maintenance of any filter design

Built in safety protection

Lowest pressure drop available

Corrosion resistant alocrom treatment

10 year housing guarantee

Features • A Perdect Seal Every Time

Moulded seal cannot be lost or mis-aligned.

• Full Flow Inlet

Gives maximum capacity and lowest pressure drop.

• Unique Filter Element

Is available in four filtration grades.

• Rapid Maintenance

Lift and twist design is quick and easy.

• Built In Safety

Simply push for autodrain check and bowl depressuration.

• Differential Pressure Indicator

Gives a reminder of filter element life from both sides.

• Fixing Clamp

Joins two filters and is a wall mounting bracket in one.

• Self Cleaning Drain Screen

Reduces maintenance and increases reliability.

Page 25: Compressor Fundamentals Overview _ INGERSOLL RAND

Dryer System Installation & Air Treatment

TS Refrigerated Air Dryer

A new non-cycling, refrigerated air dryer by Ingersoll Rand, the TS dryer is designed to improve reliability,

productivity and efficiency, protect health and safety and lessen environmental impact. To accomplish this,

the TS dryer incorporates several key technical innovations. Among these innovations are its 3-in -1 heat

exchanger(s), micro-channel condenser, microprocessor and"smart"drain

Features

• Reliability and performance

Consistently delivers dry process air with minimal pressure drop. 3-in-1 Heat exchanger integrates the pre-

coller and re-heater,heat exchanger and air/water separation to reduce the opportunity for leaks. High inlet

temperatures to 60℃ will be accepted with no nuisance shutdowns. Electrostatic-charged panel filter included

on all models for increased package performance.

• Productivity

Refrigeration Expansion valve offers more precise control under varying heat loads from the compressed air

and varying ambient temperatures resulting in less risk of product spoilage through dewpoint slippage.

Optimised connection sizes to minimise pressure drop. Intellisys microprocessor indicates component

warnings and if preventative maintenance is needed. Power Out Restart Operation(PPRO) improves

productivity.

• Energy Efficiency

"Smart"drain recognises ambient conditions to adjust dwell time and minimise the loss of valuable

compressed air. Energy Saving Efficiency Option to cycle refrigeration compressor is standard.

• Health, Safety and the Environment

Design uses environmentally friendly R404A. Less refrigerant is needed with MicroChannel condenser

design.

Page 26: Compressor Fundamentals Overview _ INGERSOLL RAND

IRED Heated Desiccant Dryer Externally heated air dryer adds a heater based on IRED dryer to heat the purge air. It not only benefits the

regeneration effect but also decreases regeneration purge loss.

Features • 8 hours standard cycle.

• Pressure dew point -40℃.

• Regenerating air capacity:≤7%.

• Pressure lost:≤0.02Mpa.

• Electrical grade:NEMA4 or IP55.

• Automatically pressurized to insure the desiccant life is above 6 years.

• Reliable types of valve parts, and the usage of the valves is above 1000 thousand times.

• Finely designed mufflers reduce the noise below 72dB(A).

Page 27: Compressor Fundamentals Overview _ INGERSOLL RAND

Filters, Regulators, Lubricators System Installation & Air Treatment

Filter/Regulator Combination The Filter/Regulator combination is designed to be compact

and easy to use and maintain.

Features • Push-pull, non-rising knob allows one-hand adjustment

• Balanced valve-type diaphragm regulation assures

positive pressure adjustment

• Regulator offers in-line repairability. Valve and

diaphragm can be replaced without removing unit from

line

• Automatic drain has 1/8-inch NPT connection for

draining away contaminants

• 10 PSIG minimum operating pressure

Heavy Duty Filters/Regulators/ Lubricators

Features

• Heavy Duty Filters

These ARO Heavy-Duty Series filters extend the life of air-

operated equipment while reducing maintenance costs.

These units efficiently remove solid particles from

compressed air lines making them the perfect choice for

large flow applications.

• Heavy Duty Regulators

These ARO Heavy-Duty Series regulators provide accurate

and quick response to flow demands and line pressure

changes, giving air-powered equipment the precise air

pressure control needed.

• Heavy Duty Lubricators

Extra rugged Heavy-Duty Series lubricators deliver the

reliable lubrication needed for long service life of air line

systems and equipment.

Page 28: Compressor Fundamentals Overview _ INGERSOLL RAND

Receiver Tanks

The receiver tank is central to many industrial applications. In

factories using compressed air, the receiver tank helps deliver

stable output of compressed air, serves as a buffer, collects

moisture from cooled air and discharges it out of the system. The

air tank also serves as an air manifold to guarantee air supply in

peak hours. Ingersoll Rand provides air tanks in compliance with

applicable national codes and standards: stainless steel and carbon

steel air tanks; vertical and horizontal air tanks

Intelliflow Controller

Waste of the compressed air from leakage or improper regulation

is a common issue to most compressed air systems. IntelliFlow is

able to reduce the loss via precise control of the operating pressure.

Benefits

SAVE ENERGY: Stabilize demand side pressure at minimum

acceptable level

INCREASE PRODUCTIVITY: Provide consistent repeatable tight

pressure control

ENHANCE RELIABILITY: De-couple supply side from demand

side

INCREASE RELIABILITY: Eliminate rapid cycling of

compressors

SimplAir

SimplAir is a high-performance modular aluminum piping system

that is easy to install and simple to extend or modify. The non-

corrosive extruded aluminum provides structural strength and

delivers contaminate-free air in a leak-free piping system. The

smooth bore of SimplAir tubing prevents high-pressure losses and

allows for higher flow rates and performance than that of

conventional piping systems. The positive O-ring seal ensures that

no leaks occur at any stage of the system's life. No air leakage

ensures minimum running costs.