Oil Free Reciprocating Compressor

1
Z Vs Oil Free Recips

Name :Sourajit Mukherjee
Kolkata
2

22.03.2007 Agra Sales Conference , 2007, Oil Free Air
Division

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'
'isc,arges i% on %,e o%,er.
S&ring/loa'e' s)c%ion an' 'isc,arge valves o&en0close a)%o(a%icall$

as %,e &is%on (oves )& an' 'o*n in %,e c$lin'er c,a(#er.
The Oil Free Recip Technology
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A special polymer containing material PTFE (Polytetrafuroethylene) is
used on the piston and on the pressure packing .
Unlike the lubricated recips !here the piston rings foat in a "lm o#
lubricant !hich supports the piston there is no oil "lm to support the
piston in oil #ree recips.
The piston is kept o$ 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 Recip
Technology
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3 No l)#rica%ion reac,es %,e C$lin'er #ore .A longer 'is%ance &iece is )se' %o
se&ara%e %,e cross ,ea' g)i'e fro( %,e c$lin'er .
3 +,is necessi%a%es a longer &is%on ro' on *,ic, a 4collar5 or an oil 'eflec%or is
ins%alle' . +,e collar &reven%s an$ oil (igra%ion along %,e ro' in%o %,e c$lin'er
#ore.
NL Packing
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Quality of air
0.049 mg/cum
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Quality of air What it actually delivers
PSC!"#$%CA" SA&%S'AC&%#N
A 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 al.ays "u+ricated
W!A& %S &!/ 0/A"%& :
.123 PP4 of #il traces in Compressed air produced +y so called Non
lu+ricated Pistons is very common
AN P0##': 4easurement at Sun Pharma5 !oechst
W!A& %& )/"%*/0S:
4any times psychologically #il 'ree Air
PSC!"#$%CA" SA&%S'AC&%#N
A lot. Compressor is supposed to deliver #il free air
W!A& AC&(A"" %S %& )#%N$ :
Pushing #il *apor into Compression Cham+er through loose stuffing +o,
Cran-case is al.ays "u+ricated
W!A& %S &!/ 0/A"%& :
.123 PP4 of #il traces in Compressed air produced +y so called Non
lu+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-
Installation
D)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 .
%nstallation
TIM* +**,*, FOR ISTO+S
I+ST&--&TIO+S
%.RI+/ 0 12 ,&3S
I+ST&--&TIO+ 0 4 ,&3S
II+/ 0 5 ,&3S
*-*%TRI%&- 0 5 ,&3S
TOT&- M&+,&3S
SKI--*, 0 12 ,&3S
.+SKI--*, 0 56 ,&3S
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%nstallation #n site 6o+s
INTERCOOLER
Moisture separator
to 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 at
outlet of Pack
Belt drive results in
5-6% poer loss
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Performance Parameters2 specific po.er
All 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 /' 2(12 &<9=EA'E
'PE9&F&9 P;-E= /> 2) +
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Po.er 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 1
F 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 $ear
8
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Capacity )eration
&LIN$!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(!
8
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Capacity )eration
!4 % "#$%&'() %* M#%*+$#" B,
$#-'P M%)+.%-&+$#$
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4aintenance
More moving parts - More
Maintenance
More moving parts - More
Maintenance
*ASSI%! FO#N$ATION
2
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Reci&roca%ing Co(&ressors = ;ario)s Co(&onen%s
Bearings
rank 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"ting
Rod
0earings
+iston Rod
ross Hea/
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4aintenance S-illed &rained la+our re7uired
Piston Rings nee/s
reg0-ar c1ange
Piston remo2a-
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

over,a)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 <222 hours
Oil has to 'e change# e$ery 1222 hours:
Oil =lter has to 'e change# e$ery 9622 hours
Te>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$ery
A222 hours:
%hecking for o$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 to

planne# 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 rotor
pro=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%
A:
ele(en%
Oil &)(&
!a%er/se&ara%or
B 'rain
F)ll/loa' 0 no/loa'
reg)la%or, #lo*/off
valve B silencer
Silence
r
Oilcooler
Co(&resse'
air o)%le% !a%er in !a%er o)%
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Quality of Air
%S# :1;<23 7uality classes
Quality class )irt Water #il
&ar%icle siCe in (icron concen%ra%ion (g0(D :D: EC concen%ra%ion (g0(D
3 0,8 0,8 /70 0,08
= 3 3 /0 >53
< 1 1 /20 8
? 81 6 < 1
1 0 80 7 21
@ / / 80 /
Reference con'i%ionsF 8 #ar-a. an' 20EC
As &er in%erna%ional s%an'ar's %,e 'ifferen% classes of air are /
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Class 9ero
Clas
s
Concen%ra%ion %o%al oil -aerosol, li9)i', va&or. (g0(
3
> As specified +y the e7uipment user or supplier and
more stringent than class 3
3 A >5>3
= A >53
< A 3
? A 1
ISO 6173 -2008. F +,e s%an'ar' no* s&o"e a#o)% total oil content Baerosol5 li7uid
and vapourC
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$s %o re(ove oil *as 'ele%e'
Re&resen%a%ive sa(&les *ere as"e'
All our 9 series
compressors .ere type
tested for %S# :1;<
Bpart=C : 4easurement of
aerosols and %S# :1;<
part 1 : 4easurement of
oil f)(es an' oil
va&o)rs an' all *ere
fo)n' %o confor( %o
class 405
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Conforming to class D>E2 &(* certification
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Conforming to class D>E2 &(* certification
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9 0otors
All G ro%ors are coa%e' *i%, s&ecial coa%ing
= +eflon la$er allo*s %,ic" la$er coa%ing an' ens)res corrosion
&ro%ec%ion
= +eflon/gra&,i%e allo*s (aHi()( 4r)n/in5, %,)s increasing %,e
efficienc$
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9 /lement )esigned for optimum flo.
+o co(&ress %,e air
All ,ave a 20 lo#e co(#ina%ion
= Fe(ale ro%or ,as 2 fl)%es
= Iale ro%or ,as lo#es
All ,ave an as$((e%ric ro%or &rofile
= Allo*s 'ee&er fl)%e
Iore air 'elivere' 0 lo*er s&ee's

= Je%%er sealing
Aess in%ernal lea"age
Jearings ,ave infini%e life

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Cooling 6ac-ets
/ig cooling ?acket

around the
elements
Possible thanks to lost

#oam casting techni@ue
Allo!s better control o#

the clearances E
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#il Circuit
Gear oil &)(& 'riven #$ (ain s,af% K
Oil fil%er
= ;er$ fine fil%ering L82 M 200 %o &reven% #earing
an' gear 'a(age K
= No &i&ing #e%*een fil%er an' #earings0gears K
Oil cooler
= ;er$ efficien% &la%e ,ea%/eHc,anger
NM al*a$s rig,% oil %e(&era%)re K
= Io)n%e' agains% gear#oH
NM no &i&ing NM no ris" for lea"age K
= :la%e (a%erial is s%ainless s%eel
NM no oil/Co&&er con%ac% NM long oil life%i(e K
GOs ,ave an oil #rea%,er %o avoi' oil f)(es
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#il Circuit
3 ;ir%)al eli(ina%ion of eH%ernal &i&ing
3 S,or%er connec%ions #e%*een co(&onen%s
Possi+ilities for oil5 .ater and air
lea-ages are considera+ly reduced
3 as s%an'ar' no co&&er &i&ing
3no copper F oil contact
no oil 7uality degradation
G oil change only every 3@5>>> hours and
less oil disposal pro+lems
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#ther features
G less parts .ith resonance fre7uency
and structural vi+rations
G minimal internal pressure drop
3 less eH%ernal &i&ing
3 s,or%er connec%ions #e%*een co(&onen%s
re')ce' (ain%enance
an' lo* energ$ cos%
Air &assage cas%e' in %,e af%ercooler
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)rive Arrangement
Io%or
= All (o%ors are ,ig, efficienc$ H
= All (o%ors ,ave ins)la%ion class F K
= Ao* vol%age (o%or
Al*a$s I:11 -+EFC. K
P/Q s%ar%er s%an'ar' incl)'e' K

= Ie'i)( vol%age (o%or
S%an'ar' N I:23 -OD:. 0 O&%ion N I:11 -+EFC.

K
Gear co)&ling
= Re')ces s%ar%/%or9)e R %orsional vi#ra%ions
NM less s%ress on gears an' ele(en%s K
Gears
= Drive gears are AGIA >83 0 DIN 1 K
= +i(ing gears are AGIA >82 0 DIN 2 K
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9 Controls
= Ele"%roni"on con%roller
Co/engineere' #$ eH&erience' &ar%ners K
I"I; is co(&l$ing *i%,

= Relevan% E)ro&ean 'irec%ives K
= Relevan% CSA s%an'ar's K
= UA 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$ R relia#le connec%ions K
= Co(()nica%ion *i%, conver%ers of (ain 'rive,
ID0ID 'r$er, cooling fan H
ICC o&%ion or eas$ in%egra%ion in ES Iillenni)(

s$s%e( H

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"oad No load regulation
All G Ss are ,aving loa' = no loa' con%rol , no #)%%erfl$ valve %,ro%%ling

or (o')la%ing %,e s)c%ion .
Res)l%
Iini()( )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 ,ig,er &o*er cons)(&%ion a% &ar% loa's .
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"oad unload *s 4odulation
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)SS feature
3 All %,e G co(&ressors co(es *i%, an eH%ra &o*er saving fea%)re of
DSS - Dela$e' Secon' S%o&. . !,ic, f)r%,er saves &o*er %o %,e %)ne
of 80< in &rac%ical )se .
3 +,e DSS algori%,( (eas)res %,e '&0'% ra%io of %,e co(&resse' air
ne% an' s,)%s 'o*n %,e val)e 'e&en'ing )&on i%s val)e as &er %,e
&revailing con'i%ions a% si%e
3 +,is ens)res f)r%,er saving of &o*er *,en co(&ressor r)ns in
4)nloa' con'i%ion .
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4aintenance free machines
A ha5e no maintenance . ;nly the regular consumables are to be
changed at the #ollo!ing #re@uency
)333 hr 0 cleaning air "lter
:333 hr 0 replace "lter gearboB breathing
air "lter
oil "lter
2*333 hr 0 change oil
2*333 hr 0 counter fo! or clean the coolers
Thus leading to maB uptime and ensuring 233 + reliability o# the
compressed air system and no botheration #or the customer
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&he comparative advantages of 9
8. No ca&aci%$ 'era%ion on )sage
0/C%P CAPAC%&
CON+INUOUS DE/RA+ION OF
CA:ACI+T DUE +O +?E :ROJAEI
OF ;AA;E FAU++ER
AASO DUE +O O;AAI+T
:?ENOIENON +?ERE IS A
FUR+?ER DERA+ION OF
CA:ACI+T
:O!ER CONSUI:+ION REIAINS
+?E SAIE
AS A RESUA+ S:ECIFIC :O!ER
CONSUI:+ION IS INCREASED
SC0/W CAPAC%&
+?ERE ARE NO ;AA;ES IN SCRE!
COI:RESSORS AND ?ENCE NO
;AA;E FAU++ER
AJSOAU+ET NO IE+AA +O IE+AA
CON+AC+ ?ENCE NO DE/RA+ION
OF CA:ACI+T
AS A RESUA+ S:ECIFIC :O!ER
CONSUI:+ION REIAIN +?E
SAIE
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0/C%P P#W/0 C#NS(4P&%#N
T4E=E A=E 4;-ECE= A D;T ;F
4&88E< P;-E= 9;<'UEPT&;<
P;&<T' D&FE
a) /EDT D;''E'7
T4E'E A99;U<T F;= ( +
b) P;-E= D;'' A' PE= /' 2(12 PA=T
&& -4&94 &' <;T 9;<'&8E=E8
c) P=E''U=E 8=;P &< AFTE= 9;;DE=
<;T 9;<'&8E=E8 -4&94 EEA<'
A<;T4E= ) + &<9=EA'E7
EEA'U=EEE<T A' PE= /'2(12
'PE9&F&9 P;-E= &' 2) + E;=E
SC0/W P#W/0 C#NS(4P&%#N
<; 4&88E< P;-E=
9;<'UEPT&;< P;&<T'
8&=E9T 8=&CE A<8 4E<9E <;
/EDT D;''E'
9APA9&T> A<8 P=E''U=E
EEA'U=E8 AT 9;EP=E'';=
8&'94A=GE &<9DU8&<G
AFTE=9;;DE=' A<8 T4E=E &' <;
&<9=EA'E ;F P;-E=
EEA'U=EEE<T A' PE= 2';2%21
2. :o*er Cons)(&%ion
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R*%I I+ST&--&TIO+
&<'TADDAT&;< 9;<'&'T' ;F
4EAC> F;U<8AT&;< 8UE T;
U</ADA<9E8 F;=9E'
9;'T ;F T4E'E
F;U<8AT&;< &' =' )33 PE=
4 P ;F &<'TADDE8 E;T;=
P;-E=
=E9&P=;9AT&<G
9;EP=E'';=' &<C;DCE A
D;T ;F '&TE A9T&C&T> F;=
E=E9T&;< A<8
9;EE&''&;<&<G (APP=;H
(( 8A>' F;= )33 4P 9;EP)
S%R*? I+ST&--&TIO+
&<'TADDAT&;< 8;E' <;T
=EIU&=E A<> 4EAC>
F;U<8AT&;< A' T4E=E A=E
<; U< /ADA<9E8 F;=9E'.
EA94&<E' 9A< /E PDA9E8
;< A<> DECED FD;;= ECE<
;< T4E 'E9;<8 FD;;=
-&T4;UT P=;/DEE
EA94&<E 9A< /E E=E9TE8
A<8 9;EE&''&;<E8 -&T4&<
A 8A>
3. Ins%alla%ion
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Division
G series oil free scre* co(&ressors occ)&ies onl$ 11/ 20 < s&ace as
co(&are' %o reci& co(&ressors
. S&ace Occ)&ie' B Noise level
+,e so)n' level of G is aro)n' 71 '#-A. , *,ic, is ()c, ()c, less
%,an an average reci& *,ic, is (ore %,an 71 '#-A.
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SR!)
2 (!ARS
4 "!ARIN(S
TOTAL 15 )!AR IT!*S
R!IPS
%!! "!LTS 678
RAN+SHAFTS
*AIN "!ARIN(S 698
"I( !N$ "!ARIN(S 698
ONN!TIN( RO$S 698
S*ALL !N$ "!ARIN(S 698
ROSS H!A$S 698
)IP!R RIN(S 69 S!TS8
PISTONS 698
PISTON RIN(S 6178
&LIN$!RS 698
95 %AL%!S 6S#TION:$!LI%!R&8
TOTAL ;; )!AR IT!*S
1. Iain%enance
1
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Competition Analysis
Do)#le Ac%ing JO:S / I?E series
Do)#le %,ro* cran"s,af% *i%, 2 c$lin'ers
Cran" S,af% 'riven gear &)(&s
SG Iron Cross ,ea'
Die forge' cran" s,af% rifle 'rille'
C,annel ;alves
Floa%ing #earings
:recision f)ll floa%ing &ac"ing ring
Dis%ance :ieces
:ress)re l)#rica%e'
Iec,anical l)#rica%or
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Competition Analysis 2%0
3IR &)s,es %,e (o'el of I?E 80 NA2 ,aving a FAD of 777
cf( .
3+,e #loc" generall$ co(es *i%, a 860 U! (o%or .
3IR clai(s s,af% &o*er as 810 U!
3Jel% losses are no% 9)o%e' %o %,e c)s%o(er *,ile 9)o%ing
s,af% &o*er .
3IR is a% %,e en' of %,e fra(e siCe .
Ae% )s consi'er an air re9)ire(en% of aro)n' 8000 cf(
1
1

Division
"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 ,ig,lig,%e' .
1
2

Division
"oo-ing +eyond the offer Commercial aspects

Co(&ressor Offere' #il free 0ecip %!/ 3> #il free Scre. 9& 3@>
)escription Scope of supply Price Scope of supply Price
Jloc" R Io%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
Io%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
:AC #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's
eH%ensive 20000 Negligi#le NA
:i&ing B ;alves ,)ge 200000
s)&&l$
&otal =1@I1>> <=>>>>>
/,tra investment for scre. @<>1>>
%0 AC%"
1
7

Division
"oo-ing +eyond the offer Commercial aspects
I +STR.M*+T&TI O+ &%%*SSORI *S RI %*
'AFET> CADCE )333
<=C ,(33
& ';DAT& ;< CADCE7 )69;EP )333
GD;/E CADCE *)33
AUT; 8=A& < T=AP7% <;' 1:33
P=E''U=E 8& AD GAUGE'7) & <94 7 %)33
P=E''U=E '-& T947ADA=E 2%33
P=E''U=E '-& T94 7T=& P 2%33
-ATE= FD;- '-& T94 2(333
)& <94 8& AD GAUGE7: <;' 1%33
TEEP '-& T947ADA=E7 )<;' :)33
TEEP '-& T94 7T=& P7 )<;' :)33
GAUGE /;A=8 2(333
TOT&- I +ST.M*+T&TI O+ F5622
Z %o"pressors
are pro$i#e# !ith
"icroprocessor
'ase# panel @
!here as recips
co"e !ith
tra#itional panel:
&t the least lets
ensure that all the
#isplays @alar"s
an# trips of the ZR
are 'eing
pro$i#e# 'y recip
"anufacturer:
1
6

Division
#.nership cost Analysis
Air is #ree but 9ompressed
air is <;T JJJJJJJJJ
&# !e do the analysis o# o!nership cost KKK
&t mainly consists o#
Po!er consumption cost
Eaintenance cost
&nitial in5estment
:o*er
Iain%enance
Ini%ial inves%(en%
1
7

Division
Po.er Cost Analysis

Compressor #ffered
#il free
0ecip
%!/ 3>
#il free
Scre.
9& 3@>
)escription
FAD -in cf( . 777 726
Io%or a%%ac,e' U! 860 U! 820
S,af% 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 112 ISO 8287
F)r%,er correc%ion of &o*er cons)(e' on A0C of
(eas)ring s%an'ar' IS 112 7< 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. 872.3011112
:ac"age in&)%
-incl)'ing cooling
fan . 871
Ac%)al s&ecific &o*er U*0cf( 0.8726722 U*0cf( 0.86076182
Difference in s&ecific &o*er U*0cf( 0.08288882
Savings in Po.er for #'S for 9& for 3 year
operation 5 considering unit J 0S 1 ;><11>.>@:I
%0 AC%"
2
0

Division
4aintenance Spare parts
S:ARE COS+ FOR 3 TEARS
I+EI 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/ PA0&S C#S& P/0 /A0 #N (S/ #' SC0/WS 0S <5<>5>>>.> .
Savings in 3 year 0s <5<>5>>>.>>F< L 353>5>>>.>>
2
8

Division
0#% calculation
:ara(e%ers Uni% ;al)e
EH%ra inves%(en% (a'e for OFS RS 230100.00
Savings in R)nning on A0C of
8. :o*er Cons)(&%ion for 8 $ear V Rs .1 &er )ni% RS 703110.00
2. Iain%enance for 8 $ear RS 880000.00
+o%al Savings RS 683110.00
:a$ #ac" &erio' - EH%ra inves%(ne%0 %o%al savings. Tears 0.77
:a$ #ac" &erio' - EH%ra inves%(ne%0 %o%al savings. Ion%,s 6.0
2
2

Division
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(&re,ensive (ain%enance

con%rac% for 1 $ears
+o (ee% %,e en' c)s%o(er -in case of a E:C con%rac%or0OEI. an'

'isc)ss a#o)% %,e G a'van%ages an' ge% %,e s&ec c,ange' %o OFS.
2
3

Division
'inal Comment 9 Compressor
The !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$es true oil free air @ confor"ing class G2H the "ost stringent class at
present:
*nsures 922I relia'ility @ no #eration of capacity :
lug an# play "achine no reJuire"ent of hea$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 !ater

a$aila'le
-east po!er consu"ption in the range :Kas a loa# no loa# control @!hich
ensures "ini"u" unloa# po!er an# also incorporate# !ith ,SS feature:
Maintenance free "achines @ guarantees "ini"al #o!nti"e :
Microprocessor 'ase# electronikon control !ith all safeties an# protections
+o hi##en cost in$ol$e# :
Occupies least space :
Silent @ lo!est noise le$el :

.
6
4

Questions & )iscussions
2
1

Division
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1

Z Vs Oil Free Recips

o!er plant ( neu"atic &sh %on$eying

Ra! "aterial han#ling

Mini )last furnace ( Tap hole #rilling

Instru"entation an# electronics

!or" #$ %ra&&ing an' co(&ressing s&ecific vol)(es of gas #e%*een

+,e #ac" an' for%, (o%ion incor&ora%e' #$ a reci&roca%ing

S&ring/loa'e' s)c%ion an' 'isc,arge valves o&en0close a)%o(a%icall$

>)ali%$ of cooling *a%er

?ar' *a%er circ)la%ion

+,is (a$ res)l% in (a@or

Val$es ha$e to 'e repaire# e$ery 9222 hours:

Springs are to 'e replace# at this ti"e:

Oil has to 'e change# e$ery 1222 hours:

Oil =lter has to 'e change# e$ery 9622 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

&part fro" "aintenance cost of spares non a$aila'ility of co"pressor #ue to

:l)g an' &la$ 'evice

Delivers a#sol)%e oil free air

Single &oin% (icro&rocessor

Occ)&ies less s&ace

Air Cooler version

Enclose' in a so)n' a#sor&%ion

Iore air 'elivere' 0 lo*er s&ee's

Aess in%ernal lea"age

Jearings ,ave infini%e life

/ig cooling ?acket

Possible thanks to lost

Allo!s better control o#

Al*a$s I:11 -+EFC. K

P/Q s%ar%er s%an'ar' incl)'e' K

S%an'ar' N I:23 -OD:. 0 O&%ion N I:11 -+EFC.

Co/engineere' #$ eH&erience' &ar%ners K

I"I; is co(&l$ing *i%,

Co(&le%e con%rol an' (oni%oring K

ICC o&%ion or eas$ in%egra%ion in ES Iillenni)(

All G Ss are ,aving loa' = no loa' con%rol , no #)%%erfl$ valve %,ro%%ling

Reci&s ,ave %$&icall$ (o')la%ion con%rol , %,ro%%ling %,e s)c%ion .

;er$ ,ig, )nloa' &o*er cons)(&%ion - 70< of f)ll loa' &o*er. ,

Do)#le Ac%ing JO:S / I?E series

Do)#le %,ro* cran"s,af% *i%, 2 c$lin'ers

Cran" S,af% 'riven gear &)(&s

SG Iron Cross ,ea'

Die forge' cran" s,af% rifle 'rille'

:recision f)ll floa%ing &ac"ing ring

Elec%ro &ne)(a%ic &anel , *i%, no ins%r)(en%a%ion an' in%erloc"s,

Po!er consumption cost

+o &)s, %,e FAD %o (ore %,an 8270 cf(

+o as" %,e c)s%o(er %o go for an air coole' )ni%.

+o as" %,e c)s%o(er %o see" for an co(&re,ensive (ain%enance

+o (ee% %,e en' c)s%o(er -in case of a E:C con%rac%or0OEI. an'

&ll the a#$antages of rotary technology o$er recips

The co"plete package# solution in an acoustic enclosure

*nsures 922I relia'ility @ no #eration of capacity :

lug an# play "achine no reJuire"ent of hea$y installation :

&ir coole# co"pressor @ no risk of #a"age !ith the Juality of !ater

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 :

;er$ ,ig, )nloa' &oer cons)(&%ion - 70< of f)ll loa' &oer. ,