Oil Free Reciprocating Compressor

8/12/2019 Oil Free Reciprocating Compressor

1/66


2/66

2 22.03.2007 Agra Sales Conference , 2007, Oil Free Air

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


3/66


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


4/66

22.03.2007 Agra Sales Conference , 2007, Oil Free Air

!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


5/66


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


6/66



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


7/667 22.03.2007 Agra Sales Conference , 2007, Oil Free Air




Quality of air

0.049 mg/cum



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



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 .



The entire installation process #or a oil #ree recip compressor is

nearly % months .


%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



%nstallation #n site 6o+s

INTERCOOLER

Moisture separatorto be installed

Motor ( to be aligned)

Frame to be levelled

FOUN!TION

(to be "ast)



Performance Parameters

I#O $%$&

I# ''



Performance Parameters

Performance

testing

as per ISO1217

Measurement atoutlet of Pack

Belt drive results in

5-6% poer loss



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 +



Poer Consumption

+e 'efor(a%ion in %e ac%)al :/; 'iagra( is ')e %o ;alve

fl)%%er an' valve sla((ing



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



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(!



Capacity )eration

!4 % "#$&'() * M#*+$#" B,

$#'P M)+&+$#$



4aintenance

More moving parts - MoreMaintenance

More moving parts - More

Maintenance

*ASSI%! FO#N$ATION


21/66


Reci&roca%ing Co(&ressors = ;ario)s Co(&onen%s

Bearingsrank Assem,-

Packing

Plate alves


22/66


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


23/66


4aintenance

*alve guard

*alve #prings

*alve +lates


24/66


4aintenance

#+RIN,# MO*E '----- TIME# IN ONE !.

/earing parts


25/66


4aintenance

Conne"tingRod

0earings

+iston Rod

ross Hea/


26/66


4aintenance S-illed rained la+our re7uired

Piston Rings nee/sreg0-ar cange

Piston remoa-nee/s ski--e/

manpo3er


27/66


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$


28/66


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


29/66


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&$


30/66


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


31/66


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)%


32/66


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 /


33/66


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


41/66


#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


42/66


)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


43/66


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


44/66


"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 .


45/66


"oad unload *s 4odulation


46/66


)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 .


47/66


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


48/66


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


49/66



0/C%P P#W/0 C#NS(4P%#N

T4E=E A=E 4;-ECE= A D;T ;F4&88E< P;-E= 9;


50/66



R*%I I+ST&&TIO+

& F;U F;=E=E9T&;< A


51/66



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



52/66



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


53/66


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


54/66


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(


55/66


"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' .


56/66


"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



s)&&l$

NA

Ins%r)(en%a%ion+o a%leas% (a%c a

:C #ase' s$s%e(6100



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



s)&&l$

&otal =1@I1>> >>>>

/,tra investment for scre @1>>

%0 AC%"


57/66


"oo-ing +eyond the offer Commercial aspects

I+STR.M*+T&TIO+ &%%*SSORI*S RI%*

'AFET> CADCE )333


58/66


#nership cost Analysis

Air is #ree but 9ompressedair is


59/66


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%"


60/66


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>>>.>>


61/66


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


62/66


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


63/66


'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 :

.


64/66

6

Questions & )iscussions


65/66


We are committed to your

superior productivity throughinteraction and innovation.


66/66

Documents

Oil Free Reciprocating Compressor