Featured Articles
Air Oil Separator: What It Does and When to Replace It
What an air oil separator does in a rotary screw compressor, the signs it's clogging, and when to replace the element before oil carries over.
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Air Compressor Safety Relief Valves: What They Do and When to Replace One
What an air compressor safety relief valve does, how to test it, and how to pick the right replacement PSI. The one part you never want to ignore.
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Air Hose Reel Buyer's Guide: Pick the Right Reel and Stop Tripping Over Hose
How to choose an air hose reel: spring-driven vs manual vs motorized, hose length and diameter, mounting, and the features that actually matter.
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Gas Air Compressor Buying Guide: Power Without a Plug
When the jobsite has no power, a gas air compressor keeps your tools running. How to size one, gas vs diesel, and the upkeep to expect.
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Air Compressor Oil: Which Type to Use and How Often to Change It
What air compressor oil to use, why not motor oil, mineral vs synthetic, the ISO grade, and how often to change it by running hours.
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Air Compressor Pressure Switch: How It Works and When to Replace It
How an air compressor pressure switch controls the motor, what cut-in, cut-out, and the unloader do, and the signs it needs replacing.
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How to Choose the Right Air Compressor Hose
Picking an air compressor hose comes down to diameter, length, and material. Here's how to get all three right so your tools get the air they need.
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Rotary Screw vs Piston Air Compressor: Which Is Right for You?
Rotary screw vs piston air compressor: a head-to-head on duty cycle, efficiency, air quality, noise, maintenance, and total cost of ownership to help you choose right.
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How to Choose an Air Compressor Motor (Sizing and Replacing)
Replacing an air compressor motor? Here's how to match horsepower, RPM, frame, and voltage so the new one bolts on and runs right the first time.
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Compressed Air Leak Detection: How to Find and Fix Costly Air Leaks
Up to 30% of compressed air is wasted through leaks. Learn proven compressed air leak detection methods, how to fix the leaks you find, and how fast the savings add up.
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Why Do I Need An Oil Water Separator
Oil spills are not an infrequent guest on news coverages. These spills can be catastrophic to the environment and create long-lasting problems for the flora and fauna in that area. So it should go without saying that any business that uses an air compressor with oil should use an oil water separator to dispose of the oil properly. More specifically, you don’t have a choice but to use one when you discharge oily/ sediment-ridden wastewater into the sewer.
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Ideal Compressed Air Piping Layouts
Finding Your Ideal Layout Compressed air piping is a necessary component of any compressed air system, delivering compressed air where it is needed. A significant concern with compressed air piping is designing an ideal layout for your operation. There is no one-size-fits-all system. Your compressed air piping needs to be able to deliver sufficient volume, at a high quality, and with enough pressure to meet your demands. To adequately meet your compressed air requirements, you must consider multiple factors about your piping. The size, material, and distance of your piping influence the quality of compressed air. Individual aspects of your piping lead to different end results. For example, your piping diameter is dependent on your flow rate, pressure, pressure drop, and total length of the system. To determine your desired pipe diameter, you need an idea of how much air you need to transport. Your compressed air piping system is similar to a highway, and your road needs to be the right size to handle all the traffic. If your compressed air system requires large quantities of air to be transported from the compressors to the point of use, you will need larger piping than systems that require less. Just as busier highways are broader and more complex to handle increased traffic, pipe systems with lots of compressed air need larger diameter pipes. Different Layouts for Different Operations Each case is unique when it comes to compressed air piping requirements. A setup that works for your neighbor in the same industry might not work for your facility. The layout of your facility, the distance from the compressor to your point of use, and other variables that are unique to your operation all determine the type and size of your piping. A good starting point for preparing a layout for your compressed air piping system is the pipe size. Next, you can determine how much of that pipe you will need to get the compressed air to the end of the line. Once you know how much piping you need in the larger sizes, work down to smaller pipes for drops. After you have an idea of the quantity of piping you need, you will need the connections and unions to bring the system together. In optimized systems, energy costs will decrease, equipment failure is less likely, and overall production efficiency will improve. Changes in your layout can improve the overall efficiency of your piping system, but that requires knowing how to set it up in the most efficient manner possible. Considerations For Your Piping Layout When designing your compressed air piping, there are a few variables that you need to consider before you settle on the products. Each system will require a different level of pressure and airflow. Airflow is impacted by the size of your piping, the material it is made from, and the turns/angles of the piping. Size of Compressed Air Pipe As we mentioned in our highway metaphor, your compressed air piping needs to be capable of transporting the air without pressure drops or blockage. Incorrectly sized pipe will rapidly increase the degradation process and incur steep maintenance costs. Inadequately sized piping, too large or too small, is detrimental to your process. It can also be affected by the size of your compressor. Your compressor will determine the CFM and PSI of the air being introduced into the system. You could have the correct-sized pipe for your needs; your compressor just might not be up to par. Ensure your compressor and pipe are correctly sized to deliver the right air volume at an acceptable pressure. If they are incorrectly sized, problems can be expected. Piping Material Compressed air piping comes in various materials: stainless steel, black iron, aluminum, copper, and PVC, which should never be used. What material works best for your system depends on your required air quality and the capital available to invest in piping. Each material has its pros and cons, with some having more negatives than positives. Different materials come with unique operational preferences as well. Individuals in your shop may be comfortable with stainless steel piping because that is what your system has used for years. Comfort with a material is a valid reason to keep using it; no need to learn a new piping system. Black iron and copper pipes are industry classics for compressed air piping. They are standards for opposite reasons: copper is corrosion-free and easily adaptable to fit your facility, while black iron is implemented for its strong and durable material. Unlike copper, black iron is heavy and susceptible to corrosion. Both materials have good reasons to use them, but their durability and connections make future changes a nightmare. Aluminum is the cream of the crop in terms of compressed air piping material. Like stainless steel, it is resistant to corrosion and degradation. However, aluminum has the same resistance as stainless steel but at a fraction of the total weight. With similar connections made even easier by “plug and play” components, the skills required for stainless steel piping are the same as those for aluminum piping. Pathway of Pipe High-congestion areas or sharp turns cause pressure drops and turbulence. When airflow slows down, the pressure drops along with the CFM. When a sharp turn is present, the air needs to slow down to make it around the corner, just like it would when driving on a highway. Sharp turns slow down the airflow and increase the amount of turbulence. Turbulence occurs when air is forced to slow down as it flows into a bend. As the air slows down, its path changes. Rather than being uniform with a laminar flow, the layers of air will begin to lose their shape. Turbulence is detrimental to the flow of compressed air and increases the likelihood of equipment failures. When it comes to your compressed air By installing gentler bends, you can minimize the turbulence created. Typically, you should minimize the number of 90-degree turns at junctions and use as many 30-degree to 40-degree turns as possible. When using a 90-degree bend, you can expect turbulence and a pressure drop of 3-5 PSI for every turn. Moisture Content Moisture in compressed air is a natural part of the compression process; however, it will deteriorate your system over time. If too much moisture is present in your piping, the inner lining will begin to corrode. As the material corrodes, particles can flake off and gather together. Buildup of particulate matter can completely obstruct airflow, which is precisely why you have filtration and a dryer in place. If you adequately remove moisture and particulate matter from the air, your odds of this occurring are drastically reduced. If you are worried about excess condensation dropping out of the air, moisture separators being installed along the line or near the point of use can provide an additional layer of moisture removal. Future Opportunities When designing a compressed air piping system, it’s easy to tunnel vision on the present. You want to ensure that your equipment and pipe will deliver the desired quantity of air at the correct pressure. When you are so focused on making sure it works now, planning for the future can fall to the back of your mind. But this is precisely when you want to prepare for the future. With plug-and-play connections, adding on to your system is a piece of cake. When it comes time to expand your operations, you can add to your existing equipment rather than rebuilding it entirely. Keeping future expansions in mind while creating a compressed air piping system will make life easier for your future self. Configuring Your Compressed Air Piping Layout People use a few different variations when setting up their compressed air piping. Each network is a little more complicated than the last, but that just shows how many different ways there are to achieve your desired results. Linear Air Piping System The simplest way to set up your compressed air piping is also the least efficient use of your compressed air. Linear air piping systems are exactly that, a line with a start and an end. The air starts at the compressor and moves through the system until it reaches the line’s end. As the air moves from the air compressor to the end of the line, the compressed air is being used up. The farther down the line it gets, the more compressed air is consumed. As you get to the end of the line, the total air volume is depleted. There is no issue with enough compressed air for the drops in front, but that story quickly changes as you follow the flow. End-of-the-line equipment is left without compressed air, and as long as the equipment is drawing air, the latter equipment will be dealing with leftovers. Antenna Air Piping System A step above your linear air piping system, antenna air piping systems provide a more equal distribution of the compressed air. With a larger main distribution line going down the center and auxiliary branches for individual supply lines. These systems are made even better when compressed air storage is included on both sides of the main header. This keeps the airflow constant throughout the system. Unlike linear systems, no sections are left without compressed air. A shut-off valve can also be attached to each individual branch to isolate the individual branches. When an area no longer needs air, it can be closed off so the excess air can travel to other parts of the system or back to a storage tank. Closed-Loop Air Piping System It is the most common type of compressed air piping system, and for good reason. With a uniform distribution of compressed air and equal distribution of pressure, closed-loop systems ensure that all points in the system receive the same quality air. This allows everyone to work simultaneously without worrying about enough air reaching the end of the line. When compressed air storage is included in this system, you have even more flexibility to run multiple tools or processes simultaneously. With a main loop, you can keep the airflow centric without investing in oversized pipes. The pipe remains horizontal, and tapping flanges are installed to drop the air down to your desired location. Leaving the main section horizontal makes the installation process more manageable. Satellite Air Piping System Combining the last two layouts, antenna and closed loop, satellite air piping systems consist of one giant loop with secondary or satellite loops coming off of it. This yields the benefits of a closed-loop system for the entire facility and the point-of-use loops. Satellite systems are most often used in more extensive operations. With individual satellites and shut-off valves, you can perform maintenance on one while the others remain operational. Splitting your air into these different satellites gives you more control over the air at points of use. In large-scale operations, air treatment can be adapted to suit the individual loop. This will allow you to use better-proportioned tools in each application, saving you money on equipment that uses less air. Gridded Air Piping System The gridded air piping system is the most elaborate layout for your compressed air system. Rather than extending out to individual closed loops, the entire system is a closed loop. The loop is then “strengthened” by the secondary lines that are included in the loop. These “secondary” lines optimize the efficiency of getting air to the individual drops. Typically, the grid introduces a run of pipe into the middle of your loop. This middle section of pipe will then branch off from the center to rejoin the exterior loop. These branches create smaller loops inside the main one, ensuring identical flow at all points of the compressed air network. By implementing more pathways for the air, you can limit the overall size of your compressed air pipe. Before You Buy Before you build a compressed air piping layout, ensure that you are covering all of your bases. Check that you are using the best material for your operation, achieving the desired airflow at the desired pressure, and that your compressor can fulfill the demand. Get a Air Piping Layout Created For FREE by Warthog Air Compressor Store If you are hesitant to build your own compressed air piping layout, you’re in the right place. Warthog offers complimentary piping layouts and quotes for your compressed air system. In order to get a layout done for your compressed air piping, our technicians require some information about your operation. Facility layout Dimensions are needed for accurate quoting Total Drops Provide ideal locations if possible Pipe Diameter Pipe size gives us a reference point for your system Additional Considerations Compressor is outside, unique requests, anything that the design technician should be aware of. With the right information on your compressed air system, our design technicians can build you a layout with highlights on key installation areas. Alongside the piping layout, you will receive a quote with all the necessary components to bring the diagram to life. Use the below form to submit a request for your compressed air piping layout. If you have a preference from the layouts we discussed prior, feel free to include it on the form. Hand made drawings and notes can also be included for additional reference points.
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The Best Parts Of The Rotary Screw Compressor
Now, if you’ve been around compressors for at least a week, you will have heard of a rotary screw air compressor, you know, the one you have if you don’t have a reciprocating compressor. Both of these compressors are positive displacement compressors; the main difference between the compressors is their applications and the way the units are built. Rotary Screw Compressors do not use valves like the reciprocating compressors do to move the air downstream.These compressors have become an industry staple due to their reliability, noise level, and efficiency. Through the use of two motors, pressure is created to compress the air. The simplicity of their design makes these some of the easiest compressors to use and maintain. The standard enclosure features technology to reduce the noise of an air pump that is already much quieter than a reciprocating piston compressor. The way that the rotary screw compressor starts and stops uses less energy than the reciprocating piston would in the same environment.Now how did this machine come about? Is it a modern revelation or a cumulation of time and energy going into making a machine of that caliber? Well you may be surprised to know that the original patent for a “Screw Blower” #4121, was obtained on March 24th, 1878 by a German engineer named Heinrich Krigar. He would then go on to receive two more patents for his 2+2 helical compressor that was capable of making less than 2 psig. So this technology, although nowhere near as refined as it is now, was incredibly groundbreaking.These compressors have come a long way in 145 years from just under 2 PSIG to machines that are powerful enough to power an entire manufacturing facility. So just how far have these compressors come and how do they work now? How Does The Rotary Screw Compressor Work?The main components of these compressors are the male and female rotors. In order to create pressure, these two rotors turn in opposite directions. As the air is moved through the rotors, the space between the individual rotors, as well as the housing for them, is decreased to create compression. Each individual screw component has a built-in pressure ratio that is fixed based on the length and pitch of the screw as well as the shape of the discharge port. These fixed ratios are crucial to making sure the built in pressure ratio is properly adapted to the working pressure.Now that the more technical explanation is out of the way, let’s take a look at the step by step process of how rotary screw compressors create compressed air: Gas is sucked into the compression chamber, which consists of the two screw rotors. As they rotate, the air is isolated in the cavities and moved down the chamber through the rotors. The overall size of the chamber decreases as it moves away from the opening. This process decreases volume and increases the pressure. The pressure builds and the air is condensed. Once the pressure has reached the threshold, the discharge valve will open and move the air into the next step of the process, whether that be dryers, storage, or filtration. The process of compression is streamlined and requires less internal movement of the air in comparison to the reciprocating compressors. The air is pulled in and as it moves through the compression chamber pressure is applied to compress it. No matter the variation, this process remains the same across all rotary screw compressors. These aptly named compressors are known for their consistency and efficiency and they can come in oil lubricated or oil-free.https://youtu.be/qW2RANdPUJ8 Wait What Needs OilRotary Screw compressors are typically divided into two main technologies when it comes to their oil usage: Oil-free and Oil-injected. Both of these options cover all of the needs for rotary screw compressors. If there are high air quality standards, you might need an oil-free, but for everything else the oil-injected is going to work just fine. These two technologies are often referred to as dry and wet screws respectively.The main difference, besides oil content, is how the rotors spin: Oil-Lubricated Screws the male rotor drives the female rotor Oil-Free Screws a timing gear is responsible for ensuring a calculated clearance between the two rotors. Oil-Free Rotary Screw CompressorsThis variant of compressors comes with an asymmetric screw profile to boost energy efficiency and reduce internal leakage. These compressors rely on the timing gear to prevent any contact between the rotors. This results in high-speed compressors with unmatched efficiency that also delivers extremely clean air on demand; however, in order to reach this level of quality the attention to detail needs to be extreme.External gears are the key component for making sure that the screws are synchronized to prevent any unwanted contact between the two. By preventing contact between the rotors and the housing from occurring, there is no need for lubrication to be present on the rotors. This allows the byproduct to be completely oil-free. Without having any oil in the compression chamber, these machines are able to deliver air that is completely oil-free.These units typically work in several stages due to the built-in pressure ratios limiting the components. Through multiple stages and intercooling between them, these compressors can reach higher pressures while still not using oil to help cool the air internally. This helps to limit temperature differences between the air being brought in and the final product. Temperature is important to monitor in oil-free compressors due to the way they heat up rapidly.These compressors do not have the oil in the compression chamber to help reduce the temperature of the air back down to recommended limits. This creates a need that is not present in your standard oil-injected screw. It requires adequate lubrication on bearings and bearing surfaces to ensure reliable and efficient operation. Overall these machines come at the cost of needing more mindful maintenance, but the product these machines create is unlike any other compressed air.Oil-Injected Rotary Screw CompressorsCompletely opposite of the oil-free model, the oil injected/flooded/lubricated goes by many names for the same process. These machines use oil that has been injected into the compression chamber to lubricate the components, as the male rotor is responsible for driving the female rotor in these machines. Friction is impossible to avoid when one component is responsible for turning another and lubrication is needed to make sure that friction does not wear down the parts.With friction comes heat, and this heat needs to be removed from the air before it goes downstream and potentially causes problems with the equipment. By removing heat from the air stream, the amount of vapor present in the air stream is reduced and minimizes leak potential. Although more oil is being introduced into the compression chamber, the air and equipment benefit greatly from this being introduced.Even with the benefits of compression, it's important to ensure that as much oil has been removed from the air as possible. Compressors often have a centrifugal separator to help remove and reuse the oil. This method does not remove all of the oil, there will be some carry over downstream as the oil passes through in the air. This oil will be removed downstream by passing through filters and a dryer. The oil that's removed from the air is cooled down and recycled back into the chamber to continuously cool the air.Depending on the application, compressed air may undergo more or less filtration than others. This is ultimately determined by the air quality standards and specifications like temperature, CFM, and PSI can all create a difference in your performance. It is important to know what your individual application needs when it comes to determining the details of how your compressor operates. Rotary Compressors Can Run at Whatever Speed You Need With VSDsWhen it comes to rotary screw compressors, they have access to technology that no other compressor can compete with: The Variable Speed Drive (VSD). VSDs can go where no other compressor can, they can match the rate of production to your needs.When it comes down to it: Fixed Speed compressors run at one speed when they are running, they are either on or off Variable Speed Drives run at the speed necessary to fulfill the current demand. Why Would I Want a Fixed Speed?Fixed-Speed compressors when properly sized will deliver when they are needed. These machines run at 100% of their capacity or 0% and no in between. The problem here occurs when the machine is winding down and the motor is not producing air but is still rotating and using energy. This means precious time and money is being wasted whenever the machine is not running at full capacity. So if this machine isn’t as efficient as a VSD why would it be something you would want to invest in?The main differentiator between the two, aside from speed, is the initial cost. VSDs can be a lot more expensive upfront. Fixed Speed compressors can be a valuable asset to your operation if you need a continuous supply of air. IF you just need air consistently, the fixed-speed compressor will be the right fit for you. That being said, you will still be wasting valuable energy and money when the machine is not in use.https://youtu.be/RYMELetN5Ys Should I Use A VSD Rotary Screw Compressor?The VSD currently has a monopoly on energy efficiency. No compressor can compete with the energy savings that come with using a VSD. These compressors can save you anywhere from 35-60% of your total costs of ownership. Although the initial investment may be steeper than a fixed-speed rotary screw compressor, the Variable Speed Drive will end up paying for itself in no time.These machines are the unsung heroes of slow production days, slow second and third shifts, and understaffed periods. Changing operational speed to match need reduces the energy usage during slow periods. So in short, on slow days the VSD will save you more money than any other compressor would.Where Would I Use a Rotary Screw Compressor?With the rotary screw compressor, there are a multitude of different applications that it can be used for. From manufacturing to pharmaceuticals, these compressors can simply get the job done. They are built to handle whatever you throw at them.The Typical Applications for Rotary Screw Compressors: Food and Beverage Manufacturing Painting Automotive Agriculture Food Packaging Construction Energy HVAC Of course this list is not all inclusive of every possible application for a rotary screw compressor. This is in place to give you an idea about whether a screw is right for you. Before You BuyRather than delve into the details, let's go over the benefits to going with a rotary screw compressor. There are five main points we are going to focus on. Energy Efficiency Due to low heat emission and the potential use of a VSD, these machines are more energy efficient than their reciprocating piston counterparts. Long Lifespan A combination of easy maintenance and low heat emissions make this machine the ultimate workhorse. These machines can run full at full power 24/7 and still experience minimal capacity loss. Continuous Air Flow Plan and simple, there is no need for a cooldown period and that allows these machines to keep working and avoid overheating issues. The only time it would take a break is when there is no longer any capacity. Noise Volume With these motors not being in direct contact with each other, it creates a quieter environment around the compressor. Not only is the basic unit quieter, these machines can be made nearly silent with the right add ons. High Capacity Due to 24/7 compression, these compressors can make higher volumes of air than other models of compressors. Now all that’s left is for you to go get your own rotary screw compressor for your own application. These workhorses can be found from the best brands on our website. With access to the latest in VSD technology and compressor technology in general, you won’t be able to find a better machine. All it takes is a few clicks and you can be looking at the best fit machine for your application. Shop with us today. Learn More From Atlas Copco From The Compressed Air Blog From Mark Compressors
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