Ingersoll Rand - 1 - Industrial Center, Inc. / Air Compressor Consortium N.G.E.D.A.C. Training...

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 -


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 -


Hi !, I’m an expert in Natural Gas !

Gas Company Guy

Air Compressor Guy

Isn’t all gas natural!!!

Ingersoll Rand- 4 -


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 -


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

Ingersoll Rand- 6 -


Compressed Air FactsCompressed Air Facts

Ingersoll Rand- 7 -


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 -


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

Ingersoll Rand- 9 -


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 -


Air BasicsAir Basics

Three Main ParametersThree Main Parameters 1. Pressure1. Pressure 2.Capacity2.Capacity 3. Horsepower3. Horsepower



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



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



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



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)



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



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



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



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



II. Compressed Air Technologies

II. Compressed Air Technologies



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



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”



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



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”



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



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



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



Compressor Selection CriteriaCompressor Selection Criteria

Evaluated First CostEvaluated First Cost EfficiencyEfficiency ControlsControls MaintenanceMaintenance CoolingCooling Air QualityAir Quality DurabilityDurability



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



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



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



III. Regulation & Controls III. Regulation & Controls



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



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.



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



IV. System Location and Arrangement

IV. System Location and Arrangement



Possible LocationsPossible Locations

FACILITYFACILITY

#1#1



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)




FACILITYFACILITY

#2#2

#1#1



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




FACILITY

#2#2

#1#1

#3#3#3#3

#3#3



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



Environmental FactorsEnvironmental Factors

TemperatureTemperature VentilationVentilation ConditionsConditions

AtmosphereAtmosphere PersonnelPersonnel



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



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



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



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



Miscellaneous ConditionsMiscellaneous Conditions

AtmosphereAtmosphere PersonnelPersonnel

These important subjects will be These important subjects will be covered later in the Seminarcovered later in the Seminar



V. Compressor System V. Compressor System Components-The BasicsComponents-The BasicsV. Compressor System V. Compressor System

Components-The BasicsComponents-The Basics



Basic Selection CriteriaBasic Selection CriteriaBasic Selection CriteriaBasic Selection Criteria



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



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



Ideal Components LayoutIdeal Components Layout

Pre-Pre-filterfilter

“Wet”ReceiverReceiver

CompressorCompressor

After-CoolerAfter-Cooler

DryerDryer

After-After-filterfilter

“Dry” ReceiverReceiver



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”



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



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


Rule of thumb:Rule of thumb:


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


““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


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


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


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


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::


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



Air Compressor BasicsAir Compressor Basics

Thank you for your kind attentionThank you for your kind attention

Ingersoll Rand - 1 - Industrial Center, Inc. / Air Compressor Consortium N.G.E.D.A.C. Training...

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Transcript of Ingersoll Rand - 1 - Industrial Center, Inc. / Air Compressor Consortium N.G.E.D.A.C. Training...