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Major applications -Oil free Recip
The Oil Free Recip technology
Quality of air
Installation
o!er consu"ption
erfor"ance para"eters
Maintenance
The Z a#$antage
The %o"parati$e e#ge
%o"petition &nalysis - IR
O!nership cost
ay 'ack %alculation
Questions an# #iscussions
Selling Process
AC approach to Competition
Winning points
Q & A.
AGENDA FOR DISCUSSION
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Major applications -Oil free Recip
o!er plant ( neu"atic &sh %on$eying
Ra! "aterial han#ling
Mini )last furnace ( Tap hole #rilling
%he"ical plants
Instru"entation an# electronics
har"a co"panies
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!or" #$ %ra&&ing an' co(&ressing s&ecific vol)(es of gas #e%*een
a &is%on an' a c$lin'er *all. +e #ac" an' for% (o%ion incor&ora%e' #$ a reci&roca%ing
co(&ressor &)lls gas in on %e s)c%ion -or in%a"e s%ro"e an''iscarges i% on %e o%er.
S&ring/loa'e' s)c%ion an' 'iscarge valves o&enclose a)%o(a%icall$
as %e &is%on (oves )& an' 'o*n in %e c$lin'er ca(#er.
The Oil Free Recip Technology
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A special polymer containing material PTFE (Polytetrafuroethylene) is
used on the piston and on the pressure packing .
Unlike the lubricated recips !here the piston rings foat in a "lm o#
lubricant !hich supports the piston there is no oil "lm to support the
piston in oil #ree recips.
The piston is kept o$ the cylinder bore by a guide ring !hich is
re#erred to as the rider ring .
The rider ring is generally o# a lo! #rictional !ear and high temp
resistant material such as polymer or tefon and o# lo! unit loading as
o# the piston !eight .
The Oil Free RecipTechnology
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The Oil Free Recip Technology
No l)#rica%ion reaces %e C$lin'er #ore .A longer 'is%ance &iece is )se' %ose&ara%e %e cross ea' g)i'e fro( %e c$lin'er .
+is necessi%a%es a longer &is%on ro' on *ic a 4collar5 or an oil 'eflec%or isins%alle' . +e collar &reven%s an$ oil (igra%ion along %e ro' in%o %e c$lin'er#ore.
NL Packing
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The Oil Free Recip Technology
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Quality of air
0.049 mg/cum
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Quality of air What it actually delivers
PSC!"#$%CA" SA%S'AC%#NA lot. Compressor is supposed to deliver #il free air
W!A AC(A"" %S % )#%N$ :
Pushing #il *apor into Compression Cham+er through loose stuffing +o,
Cran-case is alays "u+ricatedW!A %S !/ 0/A"% :
.123 PP4 of #il traces in Compressed air produced +y so called Nonlu+ricated Pistons is very common
AN P0##': 4easurement at Sun Pharma5 !oechst
W!A % )/"%*/0S:
4any times psychologically #il 'ree Air
PSC!"#$%CA" SA%S'AC%#NA lot. Compressor is supposed to deliver #il free air
W!A AC(A"" %S % )#%N$ :
Pushing #il *apor into Compression Cham+er through loose stuffing +o,
Cran-case is alays "u+ricatedW!A %S !/ 0/A"% :
.123 PP4 of #il traces in Compressed air produced +y so called Nonlu+ricated Pistons is very common
AN P0##':4easurement at Sun Pharma5 !oechst
W!A % )/"%*/0S:
4any times psychologically #il 'ree Air
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The Oil Free Recip Technology-InstallationD)e %o )ge )n#alance' '$na(ic forces , oil free reci&s re9)ire soli'
ins%alla%ion , involving civil *or" , gro)%ing e%c , *ic no% onl$re9)ires %i(e #)% also a )n acco)n%e' 'rain of (one$ for %e
c)s%o(er .
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The entire installation process #or a oil #ree recip compressor is
nearly % months .
The Oil Free Recip Technology
%nstallation
TIM* +**,*, FOR ISTO+SI+ST&&TIO+S
%.RI+/ 0 12 ,&3SI+ST&&TIO+ 0 4 ,&3S
II+/ 0 5 ,&3S**%TRI%& 0 5 ,&3S
TOT& M&+,&3SSKI*, 0 12 ,&3S.+SKI*, 0 56 ,&3S
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%nstallation #n site 6o+s
INTERCOOLER
Moisture separatorto be installed
Motor ( to be aligned)
Frame to be levelled
FOUN!TION
(to be "ast)
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Performance Parameters
I#O $%$&
I# ''
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Performance Parameters
Performance
testing
as per ISO1217
Measurement atoutlet of Pack
Belt drive results in
5-6% poer loss
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Performance Parameters2 specific poerAll recips con#orms to test report o# &' * #ollo!ing is the e$ect
Po!er consumption goes up by + due to belt loss.
Po!er consumption goes up by , + due to altitude correction.
-hy
/arometric pressure 0 123 mm o# 4g column
At 1*3 mm .( sea le5el )
Po!er !ill go up by the ratio p%6p2( p,6p% 72)6(p,6p272)
For measuring FA8 at compressor inlet instead o# be#ore
air "lter FA8 is sho!n to be increased by2., +
Pressure drop in a#ter cooler and check 5al5e is around 3. bar. 9onsidering a
normal : + rise #or 5ery 2bar rise in discharge pressure this !ill result in a rise o#
+
As a result total e$ect is 2 + on speci"c po!er
All these are not applicable #or &'; 2%21
Thus to ha5e apple to apple comparison bet!een &'; 2%21 and /' 212 & 2 +
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Poer Consumption
+e 'efor(a%ion in %e ac%)al :/; 'iagra( is ')e %o ;alve
fl)%%er an' valve sla((ing
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Capacity )eration
F 1F 1
F 2
F 2
1. HORIZONTAL FOR!S F1 "ALAN! O#T
2. #N"ALAN!$ %!RTIAL FOR!S A#S! &LIN$!R O%ALIT&'ATIN( ALON(
)ITH TH! PISTON )!I(HT AN$ ALSO AN #N"ALAN!$ O#PL! N!!SSITATIN(
H!A%& FO#N$ATIONS.
+ere is a con%in)o)s 'era%ion of %e ca&aci%$ of a reci& co(&ressor
*i% )se , generall$ i% is < &er $ear
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Capacity )eration
&LIN$!R
PISTON
&LIN$!R O%ALIT& PR!%!NTS R!S#*PTION OF
APAIT& TO ORI(INAL L!%!L L!A$IN( TO
ONTIN#!$ AI L!A+A(!
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Capacity )eration
!4 % "#$&'() * M#*+$#" B,
$#'P M)+&+$#$
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4aintenance
More moving parts - MoreMaintenance
More moving parts - More
Maintenance
*ASSI%! FO#N$ATION
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Reci&roca%ing Co(&ressors = ;ario)s Co(&onen%s
Bearingsrank Assem,-
Packing
Plate alves
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4aintenance
ro'le"s in $al$es "ay inclu#e rapi# !ear of inlet an# #ischarge$al$e
)roken springs or 'roken plates or channel 7'ut not springs8
Val$e seat fracture
Seasonal failure of $al$es
/asket seat failure
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4aintenance
*alve guard
*alve #prings
*alve +lates
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4aintenance
#+RIN,# MO*E '----- TIME# IN ONE !.
/earing parts
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4aintenance
Conne"tingRod
0earings
+iston Rod
ross Hea/
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4aintenance S-illed rained la+our re7uired
Piston Rings nee/sreg0-ar cange
Piston remoa-nee/s ski--e/
manpo3er
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4aintenance effect of Cooling ater
>)ali%$ of cooling *a%er%o #e )se' is ver$ cri%ical
?ar' *a%er circ)la%ion
(a$ lea' %o co(&le%e
'a(age %o %e c$lin'er
liner @ac"e%s .
+is (a$ res)l% in (a@or
overa)ling of %e
c$lin'ers , ca)sing f)r%er
'o*n%i(e an' a 'rain on
(one$
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4aintenance A 8otheration Val$es ha$e to 'e repaire# e$ery 9222 hours:
Springs are to 'e replace# at this ti"e:
ast e;perience sho!s that plates also ha$e to 'e replace# in on packing ring an# !iper rings ha$e to 'e change# e$ery 622 hours
?ear on cross hea#@ crankshaft "ain an# con en# 'earing is to 'e #one e$eryA222 hours:
%hecking for o$ality in 1222 hours
Repeate# #e scaling of cylin#er jackets an# hea# is in$ol$e#
iston rings ha$e to 'e checke# in 9622 hours
,ue to such a lot of la'our in$ol$e# 9 co"pressor in 5 'alance# opppose# "achine!ill ha$e to 'e taken for "aintenance e$ery #ay
&part fro" "aintenance cost of spares non a$aila'ility of co"pressor #ue toplanne# Bunplanne# shut#o!n "ay 'e astrono"ical CCCC
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he 9 advantage #il free scre solution
+e Co(&le%e :ac"age' Sol)%ion
:l)g an' &la$ 'evice
Delivers a#sol)%e oil free air
No fo)n'a%ion re9)ire'
Single &oin% (icro&rocessor
#ase' con%rol = &rogra( %e
&ara(e%ers.Occ)&ies less s&ace
Air Cooler version
Enclose' in a so)n' a#sor&%ion
cano&$
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he oil free scre technology
)uilt aroun# the pro$en oil-free scre!ele"ent
Sta'le positi$e #isplace"ent co"pression
&tlas %opco patente# asy""etrical rotorpro=le
Only < "o$ing parts in co"pression cha"'er+o "etal contact
"ost eDcient geo"etry ( 5 lo'e ( A >ute
Fool proof sealing ( no oil conta"ination
Rolling ele"ent 'earings- operational>e;i'ility
#eli$ers pulsation-free co"presse# air
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9 he actual oil free compressor
Air fil%er Air inle%
Oil fil%er
?:ele(en%
:ele(en%
Oil &)(&
!a%er/se&ara%orB 'rain
F)ll/loa' no/loa'reg)la%or, #lo*/offvalve B silencer
Silencer
Oilcooler
Co(&resse'air o)%le%!a%er in!a%er o)%
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Quality of Air
%S# 1;53
< 1 1 /20 8
? 81 6 < 1
1 0 80 7 21
@ / / 80 /
Reference con'i%ions 8 #ar-a an' 20C
As &er in%erna%ional s%an'ar's %e 'ifferen% classes of air are /
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Class 9ero
Class
Concen%ra%ion %o%al oil -aerosol, li9)i', va&or (g(3
> As specified +y the e7uipment user or supplier and
more stringent than class 3
3 >5>3
= >53
< 3
? 1
ISO 6173 -2008 +e s%an'ar' no* s&o"e a#o)% total oil content Baerosol5 li7uid
and vapour
A s%an'ar' *as in%ro')ce' on (eas)re(en% of oil va&or ISO 6173 &ar% 1
A ne* class -class 0 *as in%ro')ce' %o cover (ore s%ringen% 9)ali%$ re9)ire(en%s
+e cla)se *ic reco((en'e' *a$s %o re(ove oil *as 'ele%e'
Re&resen%a%ive sa(&les *ere as"e'All our 9 series
compressors ere type
tested for %S# 1;>> hours and
less oil disposal pro+lems
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#ther features
G less parts ith resonance fre7uencyand structural vi+rations
G minimal internal pressure drop
less eH%ernal &i&ing
sor%er connec%ions #e%*een co(&onen%s
re')ce' (ain%enancean' lo* energ$ cos%
Air &assage cas%e' in %e af%ercooler
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)rive Arrangemento%or
= All (o%ors are ig efficienc$H
= All (o%ors ave ins)la%ion class FK
= o* vol%age (o%or Al*a$s I:11 -+EFCK P/Q s%ar%er s%an'ar' incl)'e'K
= e'i)( vol%age (o%or S%an'ar' I:23 -OD: O&%ion I:11 -+EFC
K
Gear co)&ling= Re')ces s%ar%/%or9)e %orsional vi#ra%ions
M less s%resson gears an' ele(en%s K
Gears= Drive gears areAGA >83 DIN 1K
= +i(ing gears areAGA >82 DIN K
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9 Controls
= Ele"%roni"on con%roller
Co/engineere' #$ eH&erience' &ar%nersK
"I; is co(&l$ing *i%
= Relevan% E)ro&ean 'irec%ives K
= Relevan% CSA s%an'ar's K
= U 106 K
Co(&le%e con%rol an' (oni%oring K
= &ress)res
= U& %o 80 %e(&era%)res -an' (ore for o&%ions
= All Service &ara(e%ers
In%egra%e' 'esign
= Eas$ relia#le connec%ions K
= Co(()nica%ion *i% conver%ers of (ain 'rive,DID 'r$er, cooling fan H
CC o&%ionor eas$ in%egra%ion in ES illenni)(
s$s%e( H
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"oad No load regulation
All s are aving loa' = no loa' con%rol , no #)%%erfl$ valve %ro%%ling
or (o')la%ing %e s)c%ion .
Res)l%
ini()( )nloa' &o*er -20/21 < of f)ll loa' &o*er , res)l%ing in lo*
average &o*er cons)(&%ion a% &ar% loa's .
Reci&s ave %$&icall$ (o')la%ion con%rol , %ro%%ling %e s)c%ion .
+e res)l%s can #e s)#s%an%ia%e' *i% %is c)rve .
Res)l%
;er$ ig )nloa' &o*er cons)(&%ion - 70< of f)ll loa' &o*er ,res)l%ing in iger &o*er cons)(&%ion a% &ar% loa's .
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"oad unload *s 4odulation
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)SS feature
All %e co(&ressors co(es *i% an eH%ra &o*er saving fea%)re of
DSS - Dela$e' Secon' S%o& . !ic f)r%er saves &o*er %o %e %)neof 80< in &rac%ical )se .
+e DSS algori%( (eas)res %e '&'% ra%io of %e co(&resse' air
ne% an' s)%s 'o*n %e val)e 'e&en'ing )&on i%s val)e as &er %e
&revailing con'i%ions a% si%e +is ens)res f)r%er saving of &o*er *en co(&ressor r)ns in
4)nloa' con'i%ion .
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4aintenance free machines
ha5e no maintenance . ;nly the regular consumables are to be
changed at the #ollo!ing #re@uency
333 hr 0 cleaning air "lter
:333 hr 0 replace "lter gearboB breathing
air "lteroil "lter
2*333 hr 0 change oil
2*333 hr 0 counter fo! or clean the coolers
Thus leading to maB uptime and ensuring 233 + reliability o# the
compressed air system and no botheration #or the customer
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he comparative advantages of 9
8. No ca&aci%$ 'era%ion on )sage
0/C%P CAPAC%
CON+INUOUS DE/RA+ION OFCA:ACI+T DUE +O +?E :ROJEOF ;A;E FU++ER
ASO DUE +O O;AI+T:?ENOENON +?ERE IS A
FUR+?ER DERA+ION OFCA:ACI+T
:O!ER CONSU:+ION REAINS+?E SAE
AS A RESU+ S:ECIFIC :O!ERCONSU:+ION IS INCREASED
SC0/W CAPAC%
+?ERE ARE NO ;A;ES IN SCRE!
CO:RESSORS AND ?ENCE NO
;A;E FU++ER
AJSOU+ET NO E+A +O E+A
CON+AC+ ?ENCE NO DE/RA+IONOF CA:ACI+T
AS A RESU+ S:ECIFIC :O!ER
CONSU:+ION REAIN +?E
SAE
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he comparative advantages of 9
0/C%P P#W/0 C#NS(4P%#N
T4E=E A=E 4;-ECE= A D;T ;F4&88E< P;-E= 9;
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he comparative advantages of 9
R*%I I+ST&&TIO+
& F;U F;=E=E9T&;< A
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he comparative advantages of 9
series oil free scre* co(&ressors occ)&ies onl$ 11/ 0 < s&ace as
co(&are' %o reci& co(&ressors
. S&ace Occ)&ie' B Noise level
+e so)n' level of is aro)n' 71 '#-A , *ic is ()c ()c less
%an an average reci& *ic is (ore %an 1 '#-A
he comparative advantages of 9
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he comparative advantages of 9
SR!)2 (!ARS4 "!ARIN(S
TOTAL 15 )!AR IT!*S
R!IPS%!! "!LTS 68RAN+SHAFTS
*AIN "!ARIN(S 698
"I( !N$ "!ARIN(S 698
ONN!TIN( RO$S 698S*ALL !N$ "!ARIN(S 698
ROSS H!A$S 698
)IP!R RIN(S 69 S!TS8
PISTONS 698
PISTON RIN(S 618&LIN$!RS 698
95 %AL%!S 6S#TION:$!LI%!R&8
TOTAL ;; )!AR IT!*S
1. ain%enance
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Competition Analysis
Do)#le Ac%ing JO:S / I?E series
Do)#le %ro* cran"saf% *i% 2 c$lin'ers
Cran" Saf% 'riven gear &)(&s
SG Iron Cross ea'
Die forge' cran" saf% rifle 'rille'Cannel ;alves
Floa%ing #earings
:recision f)ll floa%ing &ac"ing ring
Dis%ance :ieces
:ress)re l)#rica%e'
ecanical l)#rica%or
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Competition Analysis 2%0
IR &)ses %e (o'el of I?E 80 N2 aving a FAD of 7
cf( .
+e #loc" generall$ co(es *i% a 860 ! (o%or .
IR clai(s saf% &o*er as 810 !
Jel% losses are no% 9)o%e' %o %e c)s%o(er *ile 9)o%ing
saf% &o*er .
IR is a% %e en' of %e fra(e sie .
e% )s consi'er an air re9)ire(en% of aro)n' 8000 cf(
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"oo-ing +eyond the offer echnical parameters
Onl$ %e #loc" an' %e (o%or is offere' in %e ini%ial offer .
All o%er accessories are s)&&lie' se&ara%e an' loose an' as a
cos% a''er *ic nee's %o #e &oin%e' o)% an' loa'e' in %e offere'
&rice .
Elec%ro &ne)(a%ic &anel , *i% no ins%r)(en%a%ion an' in%erloc"s,
*ic as also %o #e iglig%e' .
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"oo-ing +eyond the offer Commercial aspectsCo(&ressor Offere' #il free 0ecip %!/ 3> #il free Scre 9& 3@>
)escription Scope of supply Price Scope of supply Price
Jloc" R o%or 8600000 3200000
Af%ercooler *i% (ois%)re se&ar%e'
No% incl)'e' in s%'
sco&e of s)&&l$ , as
%o #e #o)g%
se&ar%a%el$
820000
Incl)'e' in %e &ac"age
as a s%an'ar' sco&e of
s)&&l$
NA
o%or s%ar%er B rela$ e%c
No% incl)'e' in s%'
sco&e of s)&&l$ , as
%o #e #o)g%
se&ar%a%el$
21000
Incl)'e' in %e &ac"age
as a s%an'ar' sco&e of
s)&&l$
NA
Ins%r)(en%a%ion+o a%leas% (a%c a
:C #ase' s$s%e(6100
Incl)'e' in %e &ac"age
as a s%an'ar' sco&e of
s)&&l$
NA
Erec%ion ver$ eav$ 800000 Negligi#le NA
Fo)n'a%ion an' %er civil *or" ,
la#o)r an' o%er over ea'seH%ensive 20000 Negligi#le NA
:i&ing B ;alves )ge 200000
Incl)'e' in %e &ac"age
as a s%an'ar' sco&e of
s)&&l$
&otal =1@I1>> >>>>
/,tra investment for scre @1>>
%0 AC%"
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"oo-ing +eyond the offer Commercial aspects
I+STR.M*+T&TIO+ &%%*SSORI*S RI%*
'AFET> CADCE )333
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#nership cost Analysis
Air is #ree but 9ompressedair is
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Poer Cost Analysis
Compressor #ffered
#il free
0ecip
%!/ 3>#il free
Scre
9& 3@>
)escription
FAD -in cf( 7 6
o%or a%%ace' U! 860 U! 80
Saf% U! 810 U! 81
Drive Jel% Drive Gear Drive
:o*er loss acco)n%e' in %rans(ission 1< no loss
Correc%e' &o*er fig U! 816 /
:ara(e%ers (eas)re' as &er IS 11 ISO 8287
F)r%er correc%ion of &o*er cons)(e' on AC of
(eas)ring s%an'ar' IS 11 < NA
:o*er re9)ire' for cooling *a%er s$s%e( U! 1 NA
Final correc%e' &o*er fig)re - :ac"age :o*er 8.301111
:ac"age in&)%
-incl)'ing cooling
fan 871
Ac%)al s&ecific &o*er U*cf( 0.862 U*cf( 0.86076182
Difference in s&ecific &o*er U*cf( 0.0888882
Savings in Poer for #'S for 9& for 3 year
opera tion 5 considering unit J 0S 1 ;>.>@:I
%0 AC%"
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4aintenance Spare parts
S:ARE COS+ FOR 3 TEARS
I+E RECI: SCRE!*A"*/S 3>> N.A
P%S#N 0%N$ I@ N.A
W%P/0 0%N$ I@ N.A
$"AN) PACK%N$ 3@ N.A
C"%N)/0 "%N/0S ? N.A
P%S#N ? N.A
C"%N)/0 !/A) 3 S/ N.A
8/A0%N$S 3 S/ N> 0/Q(%0/)
#20%N$F$ASK/S I S/S N# 0/Q(%0/)
A%0 & #%" '%"/0S I S/S = S/S
SA*%N$S %N SPA0/ PA0S C#S P/0 /A0 #N (S/ #' SC0/WS 0S >>.> .
Savings in 3 year 0s >>.>>F< L 353>5>>>.>>
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0#% calculation:ara(e%ers Uni% ;al)e
EH%ra inves%(en% (a'e for OFS RS 30100.00
Savings in R)nning on AC of
8. :o*er Cons)(&%ion for 8 $ear V RS 703110.00
2. ain%enance for 8 $ear RS 880000.00
+o%al Savings RS 683110.00
:a$ #ac" &erio' - EH%ra inves%(ne% Tears 0.77
:a$ #ac" &erio' - EH%ra inves%(ne% on%s 6.0
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Strategy against %0
+o &)s %e FAD %o (ore %an 8270 cf(
+o as" %e c)s%o(er %o go for an air coole' )ni%.
+o 'rive %e 'isc)ssion fro( ini%ial cos% %o life c$cle cos% , consi'ering
%e res&ec%ive a''ers in %e sco&e offere' , ins%alla%ion , &o*er B
(ain%enance .
+o as" %e c)s%o(er %o see" for an co(&reensive (ain%enance
con%rac% for 1 $ears
+o (ee% %e en' c)s%o(er -in case of a E:C con%rac%orOE an'
'isc)ss a#o)% %e a'van%ages an' ge% %e s&ec cange' %o OFS.
C C
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'inal Comment 9 CompressorThe !inning features ( Su""ing up
&ll the a#$antages of rotary technology o$er recips
The co"plete package# solution in an acoustic enclosure
/i$es true oil free air @ confor"ing class G2H the "ost stringent class atpresent:
*nsures 922 relia'ility @ no #eration of capacity :
lug an# play "achine no reJuire"ent of hea$y installation :
,irect #ri$en co"pressor through a gear 'o; @ an# not through 'elts:
&ir coole# co"pressor @ no risk of #a"age !ith the Juality of !atera$aila'le
east po!er consu"ption in the range :as a loa# no loa# control @!hichensures "ini"u" unloa# po!er an# also incorporate# !ith ,SS feature:
Maintenance free "achines @ guarantees "ini"al #o!nti"e :
Microprocessor 'ase# electronikon control !ith all safeties an# protections
+o hi##en cost in$ol$e# :
Occupies least space :
Silent @ lo!est noise le$el :
.
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6
Questions & )iscussions
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We are committed to your
superior productivity throughinteraction and innovation.
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