IPG Group EMEA
Compressors
Basic Compressed Air Training
Compair products
CompAir Group
A Proud Heritage
BTR
Holman
Invensys
Broom & Wade
BroomWade
Siebe
1801
1872
1898
1904
1912
1913
1920
1952
CompAir
1968
Reavell
UK
Kellogg
USA
Luchard
France
LeRoi
USA
Mahle
Germany
Hydrovane
Mako
Demag
Germany
USA
1969 1971 1972 1979 1985 1995 1996 1999
2002
2004
Our History
Demag, founded as
Pokorny und Wittekind
in 1872,Germany
Broom and Wade founded
in High Wycombe in 1898
Kellogg New York
USA in 1904
Luchard founded in
1912, Paris
Mako, founded in Ocala,
Florida USA in 1952
Over 1,000 years of
combined experience
Leroi Founded in 1913
in Milwaukee, USA
Holman founded in
Cornwall in 1801
Reavell, founded in
Ipswich UK in 1898
Mahle, established in
Stuttgart, Germany in 1920
Hydrovane, created in
Redditch UK in 1952
Our Brands
Compressed Air
to Industry
Quality Air “over the fence”
to Industry
Compressed Air
to Industry
High Pressure Air & Gas
to Industry & Defence
Portable Air
to Construction
Compressed Air
To Industry
High Pressure Breathing Air
for Fire and Dive
The Group
Rotary screw
Vane
Reciprocating Piston
The Pre-CompAir Period
The origins of CompAir can be tracked back to two British companies:
Holman and BroomWade
Holman was founded in 1801 and started out as a boilermaker before
switching over to rock drills and air compressors at the end of the 19th
century
Holman began the production of portable compressors in 1964 for which
Holman is still remembered for today
The Pre-CompAir Period
BroomWade started out as Broom and Wade in 1898 building machinery
for the local woodworking industry before producing their first air
compressor in 1919
Soon after BroomWade built up a reputation for reliable air compressor
and were so successful that BroomWade in some countries became
synonymous with air compressors
1968
BroomWade and Holman merge to create International Compressed Air
Corporation which shortly after changed name to CompAir
1968 Reavell Joins CompAir
Reavell, founded in Ipswich UK in 1898, established in high pressure, marine
and gas markets around the globe
1968 Kellogg Joins CompAir
Kellogg, founded in Rochester, New York USA in 1904
Manufacturer of small reciprocating and rotary screw compressors
1972 Hydrovane Joins CompAir
Hydrovane, created in Redditch UK in 1952, specialised in vane compressor
technology
1979 Mako Joins CompAir
Mako, founded in Ocala, Florida USA in 1952
Specialised in breathing air compressors
1985 Luchard Joins CompAir
Luchard founded in 1912, Paris
Specialised in small reciprocating compressors and high pressure compressors
for the French market
1992 LeRoi Joins CompAir
Founded in 1913 in Milwaukee, Wisconsin USA, moved to Sidney Ohio
in 1960
Manufacturer of industrial and portable compressors
1995 Mahle Joined CompAir
Mahle, established in Stuttgart, Germany in 1920
Specialised in small piston reciprocating compressors
1996 Demag (DLT) Joins CompAir
Demag, founded as Pokorny und Wittekind in 1872, Simmern Germany
Specialised in industrial and portable compressors
2008 Acquisition of CompAir Holdings
Limited
IPG Group EMEA
Compressors
Over 150 years history
--Founded in 1859
--Headquarter in Quincy, Illinois
--Public stock company in New York (GDI)
What Does a Compressor Do?
A compressor is a mechanical device that compresses gas
by increasing the pressure and reducing its volume.
Compressors are used in cars and in refrigeration and
cooling systems.
What Is Air
Air is a Mixture of Gases
NITROGEN
OXYGEN
–
–
–
–
–
–
–
ARGON
HYDROGEN
CARBON DIOXIDE
HELIUM
NEON
KRYPTON
XENON
78.06% by volume
21.0%
0.94%
WHAT IS AIR
Air contains moisture
Air retains moisture when hot
The higher the temperature the more moisture retained in the air
Air contains dust
WHAT IS ?
Ambient Temperature
Pressure
Atmospheric Pressure
Displacement
F.A.D.
Compressor Capacity
Relative Humidity
Gauge Pressure
Inter-cooling
After-cooling
Separator
Ambient Temperature
The temperature of the environment where the equipment is working.
Pressure
Pressure = force / area
So what this means is pressure is how much force is exerted over a area of given
size.
Pressure Defined
The bar is defined using the SI unit pascal,
namely: 1 bar ≡ 100,000 Pa. 1 bar is therefore equal to:
100 kPa
1,000,000 dyn/cm2 (baryes)
0.987 atm
14.5038 psi
29.53 inHg
750.06 mmHg
750.06 torr
1×105 N/m2
Atmospheric Pressure
The Absolute Pressure of the atmosphere as measured at the place under
consideration.
Atmospheric Pressure
Defined
An atmosphere (atm) is a unit of measurement equal to the
average air pressure at sea level at a temperature of
15 degrees Celsius
Atmospheric pressure drops as altitude increases.
Aircraft create artificial pressure in the cabin so passengers
remain comfortable while flying.
Displacement
The volume displaced by the compressing element of the first stage
per unit of time.
A method for estimating body composition that makes use of the
volume of space taken up by a body inside a small chamber..
Positive Displacement, A type of compressor that delivers a fixed
volume of air at high pressures. Common types of positive
displacement compressors include piston compressors and rotary
screw compressors.
F.A.D. (free air delivery)
Air at the atmospheric conditions at the inlet point unaffected by
the compressor ; it is usual for the output of an air compressor to
be referred to the stated atmospheric conditions at the inlet.
Measured in CFM (Cubic feet per minute) this is the amount of
compressed air converted back to the
actual inlet (free air) conditions before it was compressed. In other
words, the volume of air, which is
drawn in from the atmosphere by the compressor, then
compressed and delivered at a specific pressure.
Compressor Capacity
The actual volume rate of flow compressed and delivered at the
standard discharge point, at stated inlet conditions, usually
expressed in terms of Free Air Delivered (F.A.D.)
Relative Humidity
The ratio of the amount of water vapour actually contained in a
volume of air at a specific temperature and pressure, to the
maximum amount possible under these conditions ; normally
expressed as a percentage.
Relative humidity is a measure of the water vapour content of the
air at a given temperature. The amount of moisture in the air is
compared with the maximum amount that the air could contain at
the same temperature and expressed as a percentage.
Gauge Pressure
The pressure as measured with reference to atmospheric pressure;
where no other indication is given pressures are expressed in Bar.
Definition: Gauge pressure refers to the pressure of a system
above atmospheric pressure.
Gauge Pressure = Total Pressure - 1 atm.
Gauge Pressure v Absolute Pressure
What are the key differences between Gauge pressure and absolute pressure?
Absolute pressure is zero-referenced against a perfect vacuum, so it is equal to
gauge pressure plus atmospheric pressure.
Gauge pressure is zero-referenced against ambient air pressure, so it is equal to
absolute pressure minus atmospheric pressure. Negative signs are usually
omitted.
Differential pressure is the difference in pressure between two points.
Inter Cooling
The removal of heat from the air between stages of compression.
After cooling
The removal of heat from the air after compression is complete.
Separator
A device which removes liquids from the compressed air.
A machine or device that separates something into its
constituent or distinct elements:
Something that keeps two or more things apart.
Compressed Air Terms
Various terms used to express volume flow rates.
Cubic feet per hour
cfh or ft3/hr
Cubic feet per minute
cfm or ft3/min
Cubic metres per hour m3/hr
Cubic metres per minute
m3/min
Cubic metres per second
m3/sec
Litres per minute
l/min
Litres per second
l/s
Air Flow Definitions
SCFM (Standard) vs. ACFM (Actual) vs. P.D. (Piston Displacement)
In applying air as a utility in a plant, the prime result desired is
Work. Work is known as a force through a
distance. The force in relation to air is the weight of the air, the
weight performing the Work.
Once the weight of air required to perform the work is determine
the required compressor capacity,
stated in terms understandable by all compressor vendors,must
be determined.
Air Flow Definitions
As the weight of air at different altitudes, temperatures and
relative humidity's varies, a common datum
point must be established for continuity in equipment selection.
This datum point is known as Standard
Cubic Feet Per Minute. There are several definitions of SCFM.
However, the most commonly used
definition is air at 14.7 PSIA ambient pressure, 15.C ambient
temperature and 0% relative humidity.
Once the SCFM requirement is determined, it is the
responsibility of the compressor supplier to apply
the proper machine selection to perform the required work.
Air Flow Definitions
As compressors are normally rated in Actual Cubic Feet Per Minute capacities
(ACFM), the compressor
vendor must convert the SCFM to ACFM. It should be realized here that in the
air compressor industry,
ACFM is the volume of air in the first stage actually compressed, i.e., in the
case of a positive
displacement machine, the cylinder volume times the volumetric efficiency. In
order to convert SCFM to ACFM,the following calculations must be performed:
ACFM = SCFM x Pstd - (Pvpstd x RHstd) x T10R
P1-(Pvpx RHi) Tstd0R
When SCFM is defined 14.7, 60 dry, this is
shortened to: Pstd X T10R
P1-(Pvp x RH1) Tstd0R
ACFM =14.7PSIA
P1 = Inlet Pressure in PSIA
Pvp = Partial Vapor Pressure of air at P1 &
Ti
RH = Relative Humidity at Site Conditions
T1 = Inlet Temperature 0R = 0F + 460
Tstd = 600F + 460 = 520 0R
Air Flow Definitions
It should be apparent that when SCFM is specified, care should be taken to
assure that all suppliers are quoting on the same basis, that being Standard
Cubic Feet per minute and not Actual Cubic Feet per minute or piston
displacement. Care must also be taken relative to the definition of SCFM.
proper air compressor, the ACFM should be calculated at the highest
ambient temperature and RH the machine will be subjected to, assuring
the required SCFM at all times.
Air Flow Definitions
When selecting an air dryer for the above compressor, the dryer should be
sized to handle the SCFM the selected compressor will supply at the
coldest ambient temperature and lowest RH resulting in the highest SCFM.
When you are working to determine compressed air requirements for
specific locations, you may need to determine the altitude, barometric
pressure, and relative humidity for that location. There are some online
resources to assist you.
SELECTION OF COMPRESSOR PLANT
The following facts need to be established
The required volume of Free Air
Required discharge pressure
Inlet ambient temperature
Relative humidity
Atmospheric pressure
Site conditions
Application
Air quality (lubricated/oil free)
Air consumption(continuos/intermittent)
Prime mover (motor voltage)
The Effect of Pressure
Installations
The compressor should be installed on a level concrete floor, capable of withstanding a
load of 500 kg/m.
A 1 m gap around the machine should generally be allowed for service work / repair work
and to ensure adequate air flow. Similarly a minimum of 1.5 m head room should be
allowed for above the compressor to ensure free vertical air discharge. If space heating is
employed due allowance must be made for ducting.
It is advisable to fit a fullway gate valve in the air delivery pipe between the compressor
and the main distribution pipe work to enable the unit to be isolated for servicing.
Sufficient access should be allowed through doorways for installation of the largest pieces
of plant and lifting equipment.
Suitable lifting gear should be provided capable of handling the heaviest maintenance
weight - usually the motor.
Installations continued
Suitable drainage should be provided for the compressor house.
The compressor should be installed in a cooled but not freezing position.
Electrical isolators must be in a safe and accessible position.
All electrical connections must meet local regulations. If necessary, professional electrical
contractor should be consulted. Adequate electrical cabling and fuses should be
provided.
Safety considerations are paramount. If the compressor can be started remotely or
automatically, warning notices must be displayed and the compressor isolated before
servicing. Similary remote starting equipment should be adequatly displayed with waring
notices to ensure that personnel are clear before starting the equipment.
Compressor Layout
ALTER N ATIVE R EC EIVER POSITION
SAFETY
VALVE
AIR D ELIVER Y
TO R IN G MAIN
ALTER N ATIVE C OMPR ESSOR
OU TLET POSITION S
(D EPEN D S ON MOD EL)
PR ESSU R E
GAU GE
FILTER
ISOLATIN G
VALVE (TYP)
FILTER
AIR
R EC EIVER
SEPAR ATOR
D R YER
D R AIN S
C OMPR ESSOR
VOLUME OF AIR TRANSMITTED THROUGH VARIOUS PIPE DIAMETERS AT 20 ft/sec @ 100psi AT SEA LEVEL
BSP PIPE SIZE
ft 3/min
1/2"
12.71
3/4"
28.21
1"
51.02
1 1/4"
79.0
1 1/2"
114.7
2"
204.4
2 1/2"
314.3
3"
460.0
4"
894.2
5"
1208
6"
1841
8"
3269
150nb
52.13
52131
200nb
92.57
92568
VOLUME OF AIR TRANSMITTED THROUGH VARIOUS PIPE DIAMETERS AT 6m/sec @ 7 bar AT SEA LEVEL
METR IC PIPE SIZE
m3 /min
litres /min
15nb
0.36
360
20nb
0.81
813
25nb
1.44
1445
32nb
2.24
2237
40nb
3.25
3248
50nb
5.79
5788
65nb
8.90
8900
80nb
13.03
13026
100nb
25.32
25321
125nb
34.21
34207
▪ Why Do We Need It?
▪ Compressed Air is often described as the fourth utility, although not as
ubiquitous as electricity, petrol and gas, it plays a fundamental part in the
modern world. The main difference is that users generate their own air and so
have a choice in the way that air is generated.
The importance of compressed air is often over looked, but in reality it plays a
vital part in most modern manufacturing processes and modern civilisation.
Although we may not realize it most products we use today could simply not be
made without compressed air. Compressed air accounts for about 10% of the
global energy used in industry today.
▪ With so many applications in different environments being dependant on
compressed air, the compressors not only have to compress the air to a
specific pressure, at a certain flow, it has to deliver air of the right quality. To
most people, a compressor is all that is required to compress air, but to obtain
the right quality of the compressed air, more equipment is often needed. Filters
and dryers are often needed to remove oil and water before it reaches the
application. CompAir has a range of completely oil-less compressors where air
comes into contact with the process it serves and so the quality is critical, for
example in where a compressor may be used in a food packaging role.
▪
What Happens When We Compress Air?
Compressed Air is clean, safe, simple and efficient. There are no dangerous exhaust fumes of or
other harmful by products when compressed air is used as a utility. It is a non-combustible, nonpolluting utility.
When air at atmospheric pressure is mechanically compressed by a compressor, the transformation of
air at 1 bar (atmospheric pressure) into air at higher pressure (up to 414 bar) is determined by the laws
of thermodynamics. They state that an increase in pressure equals a rise in heat and compressing air
creates a proportional increase in heat. Boyle's law explains that if a volume of a gas (air) halves during
compression, then the pressure is doubled. Charles' law states that the volume of a gas changes in direct
proportion to the temperature. These laws explain that pressure, volume and temperature are
proportional, change one variable and one or two of the others will also change, according to this
equation:
(P1 V1)/ T1 = (P2 V2)/T2
Where P=Pressure V=Volume and T=Temperature of the gas, 1 being an initial state before a change, 2
being final state after a change.
When applying this to a compressor, air volume (or flow) and air pressure can be controlled and
increased to a level that suits the way it is being used. Compressed air is normally used in pressure
ranges from 1 to 414 bar (14 to 6004 PSI) at various flow rates from as little as 0.1m3 (3.5 CFM - cubic
feet per minute) and up.
How to make the most of your system from compressor
Compressing the Air
There are many different types of machines for compressing air reciprocating, rotary-vane, screw and turbine compressors. In this
Information Book we will confine ourselves to reciprocating and
rotary vane compressors: turbine types are normally used only
where extremely large quantities of compressed air are needed,
often at relatively low pressures, and are outside the scope of the
normal industrial installation.
How to make the most of your system from compressor
Compressing the Air
The reciprocating compressor will be familiar to all. It may have one or several stages.
The rotary-vane compressor consists of a rotor, having blades free to slide in radial
slots, rotating off centre in a cylindrical chamber. Rotation causes the blades to be
thrown out by centrifugal force and to sweep the compression chamber. A small amount
of oil is admitted to the chambers to seal and lubricate the blades and to act as an
internal coolant. Again, there may be one or more stages.
There is no hard and fast rule about the choice of single or multi-stage compressors. As
a multi-stage machine will use less power to compress a given quantity of air, the power
required being appreciably less as the pressure rises. But a multi-stage compressor can
be more costly to purchase and so there must be an economic balance between the
initial cost and the running cost.
How to make the most of your system from compressor
Compressing the Air
It is therefore usual to find that for simplicity and low initial cost, single stage
compressors are used for small duties and pressures up to about 7 bar, whereas for
pressures above this and for higher duties compressors having two or more stages are
used.
There is also a considerable difference in the air temperature leaving a single or two
stage compressor
The sizing of compressors is outside the scope of this Information Book, but there are a
number of points which should not be forgotten when sizing and choosing a compressor.
One of these points covers the effect of altitude on the volumetric efficiency of a
compressor. Some of the other aspects which should be considered include the
following:
How to make the most of your system from compressor
Compressing the Air
1. Future expansion requirements.
2. Maximum and minimum pressures required in the system.
3. Type of cooling required.
4. Type of compressor.
5. Running cost.
6. Initial cost.
7. Space.
8. Type of control to meet anticipated plant requirement.
9. Protection devices
Compressed Air Explained
The Three Types Of Compressors
Piston Compressors
The piston compressor is one of the earliest compressor designs, but it remains the most versatile
and is still a very efficient compressor. The piston compressor moves a piston forward in a cylinder
via a connecting rod and crankshaft. If only one side of the piston is used for compression, it is
described as single acting. If both sides of the piston, top and underside are employed, it is double
acting.
The versatility of the piston compressors knows virtually no limits. It compresses both air and gases
with very little alterations. The piston compressor is the only design capable of compressing air and
gas to high pressures, such as breathing air applications.
The configuration of a piston compressor can be a single cylinder for low pressure/low volume to a
multi-stage configuration cable of compressing to very high pressure. In these compressors, air is
compressed in stages, increasing the pressure before entering into the next stage to compress the
air into even higher pressure.
Compression capabilities:
CompAir's Piston range operates between 0.75 kW to 420 kW (1hp to 563hp) producing working
pressure at 1.5 bar to 414 bar (21 to 6004psi).
Typical types of applications:
Gas compression (CNG, Nitrogen, Inert gas, Landfill gas), High Pressure (Breathing air for SCUBA
SCBA cylinders, Seismic surveying, Air blast circuit), P.E.T bottling, Engine start, Industrial
Compressed Air Explained
Three Types Of Compressors
Rotary Screw Compressors
The screw compressor is a displacement compressor with pistons in a screw format; this is
the predominant compressor type in use today. The screw compression element main parts
comprise male and female rotors that move towards each other while the volume between
them and the housing decreases. The pressure ratio of a screw is dependent on the length
and profile of the screw and of the form of the discharge port.
The screw element is not equipped with any valves and there are no mechanical forces to
create any imbalance. It can therefore work at high shaft speed and combine a large flow rate
with small exterior dimensions.
Compression capabilities:
CompAir's Rotary Screw range operates between 4kw to 250 kW (5 to 535hp), producing
working pressure at 5 bar to 13 bar (72 to 188psi).
Typical types of applications:
Food Beverage, Brewing, Military, Aerospace, Automotive, Industrial, Electronic,
Manufacturing, Petrochemical, Medical, Hospital, Pharmaceutical, Instrument air
Compressed Air Explained
Three Types Of Compressor
Rotary Vane
The vane compressor is directly driven at very low speed (1450rpm), offering unrivalled
reliability. The rotor, the only continually moving part, has a number of slots machined along its
length into which fit sliding vanes that ride on a film of oil.
The rotor rotates within a cylindrical stator. During rotation, centrifugal force extends the vanes
from their slots, forming individual compression cells. Rotation decreases the cell volume,
increasing the air pressure.
The heat generated by compression is controlled by pressurised oil injection.
The high pressure air is discharged through the outlet port with the remaining traces of oil
removed by the final oil separator.
Compression capabilities:
CompAir's Vane compressors operate between 1.1 kW to 75 kW (1.5 to 100hp), producing
working pressures of 7 to 8 and 10 bar (101 to 145psi).
Typical applications:
OEM, Printing, Pneumatics, Laboratories, Dentistry, Instruments, Machine tools, Packaging,
Robotics
,
Thank You
The End