*Typical ambient at elevated altitude. For different temperatures and R.H.'s, see formula page.
ACFM CORRECTION DUE TO ALTITUDE Ambient pressure drops as altitude increases, increasing the pressure ratio across the compressor. The increased pressure ratio reduces the volumetric efficiency slightly, reducing the ACFM, as shown in Tables 1. Table 1 is for a single-stage, oil-flooded rotary screw compressor, while
SCFM CORRECTION DUE TO ALTITUDE AND TEMPERATURE EFFECTS The reduced pressure at altitude decreases the density of the inlet air, reducing the amount of "standard air" delivered. In addition, ambient temperature drops as altitude increases. Temperature effects two aspects of a compressor's throughput of air. First, it effects the density of the air at intake, varying the amount of standard air delivered. Secondly, cooler inlet air holds less moisture than standard air does (68 deg. and 36% humidity), and warmer air holds more, effecting the amount of delivered standard air.
ACFM CORRECTION DUE TO ALTITUDE Ambient pressure drops as altitude increases, increasing the pressure ratio across the compressor. The increased pressure ratio reduces the volumetric efficiency slightly, reducing the ACFM, as shown in Table 2. Table 2 is for a two-stage, oil-free rotary screw compressor.
SCFM CORRECTION DUE TO ALTITUDE AND TEMPERATURE EFFECTS The reduced pressure at altitude decreases the density of the inlet air, reducing the amount of "standard air" delivered. In addition, ambient temperature drops as altitude increases. Temperature effects two aspects of a compressor's throughput of air. First, it effects the density of the air at intake, varying the amount of standard air delivered. Secondly, cooler inlet air holds less moisture than standard air does (68 deg. and 36% humidity), and warmer air holds more, effecting the amount of delivered standard air.
Conversion Tables Power Conversions Quantity Unit Quantity/Unit 1.00 HP = 0.746 KW 1.00 HP = 550.00 FT-LBf/SEC 1.00 HP = 42.44 BTU/MIN 1.00 HP/HR = 2547 BTU/HR 1.00 Kilowatt = 1.34102 HP 1.00 Kilowatt = .2843 Ton of REF 1.00 Kilowatt = 3412.1 BTU/HR 1.00 Ton of REF = 12,000 BTU/HR 1.00 BTU/MIN = .017584 KW
Volume Conversions Quantity Unit Quantity/Unit 1.00 Cubic FT = 7.480520 Gallons 1.00 Cubic FT = .028312 Cubic Meters 1.00 Cubic FT = 1,728.00 Cubic Inches 1.00 Cubic FT = 28.3206 Liters 1.00 Gallon = .13368 Cubic Feet 1.00 Gallon = 231.00 Cubic Inches 1.00 Gallon = 3.785 Liters 1.00 Liters = .035310 Cubic Feet 1.00 Cubic Meter = 264.142 Gallons 1.00 Cubic Meter = 1.30795 Cubic Yards
Compressed Air Terminology and Definitions A | B | C | D | E | F | G | H | I | J | K | L | M | N | O | P | Q | R | S | T | U | V | W | X | Y | Z
A Absolute Pressure: The sum of the gauge pressure and the atmospheric pressure (PSIA). (Example: 50 PSIG equals 50 plus atmospheric pressure, 14.7 at sea level, so 50 PSIG is the same as 64.7 PSIA at sea level Absolute Temperature: The temperature of a body referred to the absolute zero, at which point the volume of an ideal gas theoretically becomes zero. On the Fahrenheit scale this is minus 459.67F; on the Celsius scale it is minus 273.15C. Engineering values of minus 460F and minus 273C are used herein. ACFM: Actual Cubic Feet Per Minute. Refers to a volume of air (one cubic foot) at ambient conditions, no matter what those conditions are. Changes in pressure, temperature, and relative humidity do not change these ratings. Therefore, ACFM is a measure of volume, regardless of weight. (see corrections for altitude chart)
After-Coolers: Heat exchangers for cooling air or gas discharged from compressors. They provide the most effective means of removing moisture from compressed air and gases.
Air-cooled compressors: These are machines cooled by atmospheric air circulated around the cylinders or casings. Altitude: The elevation above sea level. Atmospheric Pressure: The pressure of the atmosphere at any location that will decrease as the elevation above sea level increases. Sea level atmospheric pressure is 14.7 PSAI, or 29.92 inches of mercury absolute. At 2500 feet, the pressure is 13.41 PSIA, or 27.32 inches of mercury.
Atmosphere: A pressure measurement obtained by dividing absolute pressure by atmospheric pressure. (Example: 114.7 PSIA/14.7 PSIA equals 7.8 atmospheres.)
Auto Drains: Auto Drains discharge water and oil from collection points within the air system. top B Barometric Pressure: The absolute atmospheric pressure existing at the surface of the earth. It is the weight of a unit column of air above the point of measurement. It varies with altitude and, at any given location, with moisture content and weather. Base plate: A metallic structure on which a compressor or other machine is mounted. Boolean logic: The logic of binary systems, such as control systems in which all operations my be reduced to on/off, open closed, or some similar dichotomous basis. Booster Compressors: Machines designed for compressing air or other gases from an initial pressure, which is above atmospheric pressure, to a higher pressure. Brake Horsepower: The actual horsepower output to the drive motor. top C
Capacity: Capacity of a compressor is the actual volume rate of flow of gas compressed and delivered at conditions of total temperature, total pressure, and composition prevailing at the compressor inlet.
Capacity (Actual): Quantity of gas actually compressed and delivered to the discharge system at rated speed of the machine and under rated pressure conditions. Actual capacity is usually expressed in cubic feet per minute (cfm) at first stage inlet gas conditions.
Check Valve: A valve that permits flow in one direction only. Clearance: When referring to a reciprocating compressor cylinder is that volume contained in one end of the cylinder which is not swept by the movement of the piston. It includes space between piston and head at the end of the compression stroke, space under the valves, etc., and is expressed as a percentage of the piston displacement per stroke. Clearance may be different for the two ends of a double-acting cylinder. An average is generally used. Clearance pocket: An auxiliary volume that may be opened to the clearance space to increase the clearance, usually temporarily, to reduce the volumetric efficiency of the compressor Coalescing Filter: Removes small particles, dirt, and oil from the compressed air. Compressibility: The factor of a gas or a gas mixture that causes it to differ in volume from that of a perfect gas when each is under the same pressure and temperature conditions. Occasionally it is called deviation. It must be determined experimentally. Compression, adiabatic. This type of compression is effected when no heat is transferred to or from the gas during the compression process Compression, isothermal. isothermal compression is a compression in which the temperature of the gas remains constant. For perfect gases, it is represented by the equation PV is a constant, if the process is reversible, Compression, polytropic. Compression in which the relationship between the pre~ sum and the volume is expressed by the equation Pv is a constant. Compression Efficiency: The ratio of the theoretical work requirement (using a stated process) to the actual work required to be done on the gas for compression and delivery. Expressed as a percentage, compression efficiency accounts for leakage and fluid friction losses, and thermodynamic variations from the theoretical process. Compression Ratio: Ratio of absolute discharge pressure to the absolute intake pressure (CR).
Compressors: Machines designed for compressing air or other gases from an initial intake pressure to a higher discharge pressure.
Constant Speed Control: Unit runs continuously but matches air supply to demand by "loading" or "unloading" the compressor. Critical pressure: The limiting value of saturation pressure as the saturation temperature approaches the critical temperature. Critical temperature: The highest temperature at which well defined liquid and vapor states exist. It is sometimes defined as the highest temperature at which it is possible to liquify a gas by pressure alone. top D
Density: The weight of a given volume of gas, usually expressed in lb/cu ft at specific temperature and pressure. Desiccant Air Dryers: A device that will remove moisture for dew-point requirements to -40 or a -100 degrees F. Dewpoint: The temperature at which the vapour in a space (at a given pressure) will start to condense (form dew). Dewpoint of a gas mixture is the temperature at which the highest boiling point constituent will start to condense. Diaphragm: A stationary element between the stages of a multistage centrifugal compressor, It may include guide vanes for directing the flowing medium to the impeller of the succeeding stage. In conjunction with an adjacent diaphragm, it forms the diffuser surrounding the impeller. Diaphragm routing: A method of removing heat from the flowing medium by circulation of a coolant in passages built into the diaphragm. Diffuser: A stationary passage surrounding an impeller, in which velocity pressure imparted to the flowing' medium by the impeller is converted into static pressure Discharge Pressure: The total gas pressure (static plus velocity) at the discharge flange of the compressor. Velocity pressure usually is considered only with dynamic compressors. Note: Pressure may be expressed as gauge or absolute pressures. psiG plus atmospheric pressure equals psiA. Note that psiG does not define a pressure unless the barometric pressure (atmospheric) is also stated. Discharge Temperature: The temperature existing at the discharge flange of the compressor. Note: In a multistage compressor, the various stages will have different discharge pressures and temperatures. Displacement: Displacement of a compressor is the volume swept out per unit of time; it is usually expressed in cubic feet per minute
Double Acting Compressors: Machines in which compression takes place on both strokes per revolution in each compressing element.
Double Stage Compressors: Machines in which compression from initial to final pressure is completed in two stages. Dry-Bulb Temperature: The ambient gas temperature. Dry Gas: Any gas or gas mixture that contains no water vapour and/or in which all of the constituents are substantially above their respective saturated vapour pressures at the existing temperature. (See Wet Gas). Note: In commercial compressor work, a gas may be considered dry (even though it contains water vapour) if its dewpoint is low at the inlet condition (say minus 50 to minus 60F). Dryer: An integral part of the compressed air system that removes the heat of the compressed air and also removes the moisture from the air due to the heat loss.
Dynamic: Machines where air or gas is compressed by the dynamic action of rotating vanes or impellers imparting velocity and pressure to the air or other gases. top E
Efficiency: Any reference to efficiency of a dynamic type compressor must be accompanied by a qualifying statement which identifies the efficiency under consideration, as in the following definitions. Efficiency, compression. Ratio of calculated isentropic work requirement to actual thermodynamic work requirement within the cylinder, the Inner as determined from the cylinder indicator card. Efficiency, isothermal. Ratio of the work calculated on an isothermal basis to the actual work transferred to the gas during compression. Efficiency, mechanical. Ratio of thermodynamic work requirement in the cylinder (a shown by die indicator card) to actual brake horsepower requirement. Efficiency, polytropic. Ratio of the polytropic compression energy transferred to the gas no the actual energy transferred to the gas. Efficiency, volumetric. Ration of actual capacity to displacement, stated as a percentage. Enthalpy: (Heat Content) The sum of the internal and external energies. Entropy: A measure of the unavailability of energy in a substance. top F
Filters: Are devices for separating and removing dust and dirt from air before it enters a compressor. Flange connection: The flange connection (inlet or discharge) is a means of connecting the casing to the inlet or discharge piping by means of bolted rims (flanges).
Free air: Free air is defined as air at atmospheric conditions at any specific location. Because the altitude, barometer, and temperature may vary at different localities and at different times, it follows that this term does not mean air under identical or standard conditions. top G
Gas: While from a physical point of view a gas is one of the three basic phases of matter, and thus air is a gas, a special meaning is assigned in pneumatics practice. The term gas refers to any gas other than air.
Gauge Pressure: The pressure on the gauge measured above atmospheric pressure (PSIG); that is, that measured on a given gauge, not effected by altitude or atmospheric pressure. top H
Head, adiabatic. The energy in four pounds required to compress adiabatically and to deliver one pound of a given gas from one pressure level to another. Head, polytropic. The energy in foot pounds required to compress polytropically and to transfer one pound of a given gas from one pressure level to another. Horsepower, brake: Brake horsepower is the horsepower input to the compressor shaft, or more generally to any driven machine shaft.
Horsepower, theoretical, or ideal: The ideal, or theoretical horsepower of a compressor is defiled as the horsepower required to compress adiabatically the air or gas delivered by the compressor through he specified range of pressures.
Humidity, specific: Specific humidity is the weight of water vapour in an air vapour mixture per pound of dry air
Humidity, relative: The relative humidity of a gas (or air) vapour mixture is the ration of the partial pressure of the vapour to the vapour saturation pressure at the dry bulb temperature of the mixture. top I
Ideal Compression Ratio: In two-stage units, the square root of the total compression ratio is used to size stage compression ratio and balances the load between stages (ICR). Ideal Gas: Follows the perfect gas laws without deviation. Practically, there are no ideal gases, but it is the basis from which calculations are made and corrections applied. Impeller: The part of the totaling element of a dynamic compressor that impacts energy to the flowing medium by means of centrifugal force. It consists of a number of blades mounted so as to rotate with the shaft. Inlet Pressure: The total pressure (static plus velocity) at the inlet flange of the compressor. Velocity pressure is usually considered only with dynamic compressors. (See note under Discharge Pressure). Inlet Temperature: The temperature at the inlet flange of the compressor. Note: In a multistage compressor, the various stages may have different inlet temperatures. Inter-Coolers: These are heat exchangers for removing the heat of compression between stages of a compressor. They usually condense and remove a considerable amount of moisture as well.
Intercooling: This is the removal of heat from the air or gas between stages or stage group. Intercooling degree of. The difference in air or gas temperatures between the inlet of the compressor and the outlet of the intercooler. Intercooling, perfect. Perfect intercooling exists when the temperature of the air leaving the intercoolers equals the temperature of the air at the compressor intake. Isentropic cornpression: An adiabatic compression with an increase in entropy; a reversible-adiabatic compression. top L
Liquid piston: A liquid piston compressor is a rotary compressor in which a vaned rotor revolves in an elliptical casing, with the rotor spaces sealed by a ring of liquid rotating with it inside the casing.
Load factor: This factor is the ration of the average compressor load during a given period of time to the maximum rated load of the compressor. It applies also to air tools, where it is the product of the work factor times the time factor.
Logic Controls: These are control devices the operation of which may be reduced to binary operation such as an on-off, 0-1, or open-closed. They are also referred to as digital controls. top M
Mechanical Efficiency: The ratio, expressed in percent, of the Thermodynamic Work Requirement in the cylinder to the actual shaft horsepower. Mechanical Ratio: Multi-Stage only. The ratio of the displacements of the low pressure and high pressure stages (MR).
Moisture Separators: Devices for collecting and removing moisture precipitated from the air and gas during the process of cooling.
Multi-casing Compressor: When a single motor or turbine drives two or more compressors, each with a separate casing,, the combined unit is called a multi-casing compressor.
Multi-Stage Compressors or Compound Compressors: A machine in which compression from initial to final pressure is completed in two or more distinct steps or stages. top N Normal Air: The term used for average atmospheric air at sea level in a temperate zone where it contains some moisture. It is defined in the ASME Test Code For Displacement Compressors as being at 14.696 psiA, 68F, 36% RH, and weighing 0.075 lb/cu ft. The K value is 1.395. top O
Oil/Water Separator: A device that separates the remaining compressor oil from condensate. top P
Particulate Filter: Removes small particles and dirt from the compressed air. Perfect Intercooling: Is obtained when the gas is cooled to first stage inlet temperature following each stage of compression. Performance Curve: This curve is a plot of expected operating characteristics, e.g., discharge pressure vs. inlet capacity, shaft horsepower vs. inlet capacity.
Piston Displacement: Net volume actually displaced by the compressor piston or rotor at rated machine speed, generally expressed in cubic feet per minute (usually cfm) For multi-stage compressors, the piston or rotor displacement of the first stage only is commonly stated as that of the entire machine. Polytropic Head: An expression used for dynamic compressors to denote the foot-pounds of work required per pound of gas. Positive Displacement: A machine where successive volumes of air or gas are confined within a closed space and pressure is increased as the volume of the closed space is decreased
Pressure (PSI): Pounds-Per-Square-Inch- a rating of Air Pressure in the system. (PSIG) "Gauge" Gauge pressure shows amount of air pressure above ambient
Pressure Discharge: Discharge pressure is the absolute total pressure at the discharge flange of a compressor
Pressure, intake: Intake pressure is the absolute total pressure at the inlet flange of a compressor.
Pressure rise: This is the difference between the discharge pressure and the intake pressure
Pressure static: Static pressure is the pressure measured in a flowing stream (liquid or gas) in such a manner that no effect on the measurement is produced by the velocity of the stream. top R
Rotary Screw Compressors: Machines that use male and female helical rotors to smoothly compress air.
Receivers: Receivers are tanks used for the storage of air discharged from compressors. They serve also to damp discharge line pulsation's.
Reciprocating Compressors: Machines that use a reciprocating motion (piston) to compress air.
Refrigerated Air Dryer: A device that will remove moisture for dew-point requirements no lower than 33-degrees F.
Rotor: The rotor is the rotating element of a machine and, in the case of a compressor, is composed of the impeller (or impellers) and shaft, and may include shaft sleeves and a thrust balancing device.
Rotary Compressors: These are machines in which compression is effected by the positive action of rotating elements. (Capable of 100% Duty)
Rotary Screw: Machines that use male and female helical rotors to smoothly compress air
Rotary, Sliding Vane: Such compressors are machines in which axial vanes slide radially in an eccentrically mounted rotor.
Rotary, two-impeller positive displacement: These are machines in which two mating lobed impellers revolve within a cylinder or casing and are prevented from making contact with each other by timing gears mounted outside the cylinder.
Rotary, liquid-piston compressors: These are machines in which water or other liquids are used, usually in a single rotating element, to displace the air or gas handled. top S
Saturation: Occurs when the vapour is at the dewpoint or saturation temperature corresponding to its partial pressure. A gas is never saturated with a vapour. The space occupied jointly by the gas and vapour may be saturated, however. Saturation (degree of): The ratio of the weight of vapour existing in a given space to the weight that would be present if the space were saturated at the space temperature. Saturated Air-Vapour Mixture: Is one in which the space occupied by the mixture is saturated with water vapour at the mixture temperature. Saturated Vapour Pressure: The pressure existing at a given temperature in a closed vessel containing a liquid and the vapour from that liquid after equilibrium conditions have been reached. It is dependent only on temperature and must be determined experimentally. Saturation Pressure: Another term for Saturated Vapour Pressure. Saturation Temperature: The temperature corresponding to a given saturated vapour pressure for a given vapour. SCFM: Standard Cubic Feet Per Minute. At "standard conditions" (see above) will one standard cubic foot of air actually occupy one cubic foot of volume. Another way to express one standard cubic foot of air is .075 of a pound of air. A standard cubic foot varies in volume as it deviates from standard conditions, but it always weighs .075 of a pound. Therefore, SCFM is a measure of weight, regardless of volume. (see corrections for altitude chart) Seals: Seals are devices used between rotating and stationary parts to separate, and minimize leakage between, areas of unequal pressures.
Single-Acting Compressors: Machines in which compression takes place on one stroke per revolution in each compressing element.
Single-Stage Compressors: Machines in which compression from initial to final pressure is complete in a single step or stage. Slip: The internal leakage within a rotary compressor. It represents gas at least partially compressed but not delivered. It is determined experimentally and expressed in CFM to be deducted from the displacement to obtain capacity. Slip RPM: The speed required of a rotary compressor to maintain a given discharge pressure, supplying leakage only (zero actual output). The factor must be established by experiment. Specific Gravity The ratio of the density of a given gas to the density of dry air, both measured at the same specified conditions of temperature and pressure, usually 14.696 psiA and 60F. It should also take into account any compressibility deviations from a perfect gas. Specific Heat: (Heat Capacity) The rate of change in enthalpy with temperature. It is commonly measured at constant pressure or at constant volume. The values are different and are known as cp and cv respectively. Specific Humidity: (See Humidity). Specific Volume: The volume of a given weight of gas, usually expressed as cu ft/lb at specific conditions. Standard Air: Measured at 68 degrees F, 14.7 PSIA, and 36% relative humidity (.075lb/ft3 density). This agrees with the Compressed Air and Gas Institute (CAGI). The gas industries uses 60 degrees F, 14.7 PSIA, and dry as conditions for standard air (SCFM). Standard Pressure and Temperature (SPT): Generally is 14.696 psiA and 60F unless specifically stated otherwise. State: (of a system or part thereof) Its condition at an instant of time as described or measured by its properties. Suction Pressure: Absolute static prevailing at the suction of the ejector. Super-Compressibility: A term used with various meanings, most frequently the same as compressibility, although this is not assured. A current ASME Power Test Code uses it as a ratio of gas densities rather than volumes. Therefore it is 1/Z in this case. Super-compressibility should never be used unless its meaning is clarified completely. Compressibility is much to be preferred and is used herein. top T
Temperature rise ratio: This is the ration of the computed isentropic temperature rise to the measured total temperature rise during compression. For a perfect gas, this is equal to the ration of the isentropic enthalpy rise to the actual enthalpy rise.
Torque: Torque is a torsional moment or couple. It usually refers to the driving couple of a machine or motor.
Turbine: A turbine is a prime mover in which a stream of fluid, such as water, steam or gas, provides the impulse to drive a bladed rotor.
Two-Stage Compressors: These are machines in which air or gas is compressed from initial pressure to an intermediate pressure in one or more cylinders or casing. top V
Vacuum Pumps: Machines for compressing air or other gases from an initial pressure that is below atmospheric pressure to a final pressuring that is near atmospheric
Vapour Filters: Are filters designed for the removal of vapours and odours, which still may be present, after the air has passed through the coalescing and/or particulate filters. The activated carbon element attracts residual vapours and binds them to the surface of the activated carbon grain molecules. Vapour Pressure: The pressure exerted by a vapour confined within a given space. The vapour may be the sole occupant of the space, or may be associated with other gases. Volumetric Efficiency: The ratio of the actual inlet capacity (ACFM) to the first stage displacement expressed as a percentage. Volumetric efficiency varies by clearance or blow-by, heating losses, valve losses, and specific gravity of gas being compressed. top W
Water-Cooled Compressors: These are machines cooled by water circulated through jackets surrounding the cylinders or casings. Wet-Bulb Temperature: is used in psychrometry and is the temperature recorded by a thermometer whose bulb has been covered with a wetted wick and whirled on a sling psychrometer. Taken together with the dry-bulb temperature, it permits determination of the relative humidity of the atmosphere. Wet Gas: Any gas or gas mixture in which one or more of the constituents is at its saturated vapour pressure. The constituent at saturation pressure may or may not be water vapour. Work: Energy in transition and is defined in units of Force times Distance. Work cannot be done unless there is movement.
How to Choose the Right Air Compressor Air compressors have been around for well over 100 years and have as many uses as there are tools that use air. One reason for their popularity is because air as a resource is safe, flexible, clean and convenient. These machines have evolved into highly reliable pieces of equipment that are almost indispensable in most of the applications they serve. Compressors can come in a wide variety of different types and sizes. Ultimately, as with any tool, air tools and the compressors that drive them, have to save the user time and money on any given project. Most compressed air tools are more powerful and typically lighter than standard electric tools or battery powered cordless tools. They are used by virtually every industrial sector from aircraft to automobiles to dairy farming to textiles. While there are many types of compressors, they all perform the same function, which is to increase the pressure and reduce the volume of a given gas such as air. The most common type of compressors work by filling a chamber with air and then reducing the chambers volume. These are called positive displacement compressors. They are the most widely available compressors and include reciprocating, rotary screw and rotary vane compressors. Of all the positive displacement compressors, Reciprocating or Piston compressors are the most commonly available on the market and can be found in ranges from fractional to very high horsepower. These compressors are sold world wide by many mass marketers and a large variety of retail outlets. Rotary compressors (Screw and Vane) and the centrifugal compressors are also commonly found but in more of an industrial/commercial environment. Normally they are operated at significantly higher horsepower and flow rates, which makes them more expensive buy and to operate. For more information on rotary compressors please visit our products page at www.trident.on.ca. The following paragraphs contain some very general information on piston compressors that will allow for a more informed decision concerning the type and size of compressor being considered. Single Stage and Two Stage Reciprocating Pumps Reciprocating (Piston) Compressors can be widely found in two primary configurations; Single Stage and Two Stage. Single stage air compressors work by drawing air in and subsequently compressing the air to its final pressure in single piston stroke. Single stage air compressors can attain pressures of up to 150 PSI. Typically, a single stage pump will have a higher CFM (Cubic Feet per Minute) rating than a two stage pump because every cylinder is drawing in air and compressing it with air during every rotation. Two stage air compressors work in a very similar manner with the primary difference being that they compress the air in 2 steps or stages. During the first step or stage, air is drawn in and compressed to an intermediate pressure. After being compressed in the first stage, the air is piped, usually through an intercooler where the air is allowed to cool, to be compressed in the final or second stage. Two stage compressors are normally good for pressures up to 200psi. Two stage pumps are more efficient at higher pressures because the air is cooled between the stages. DCFM, SCFM and ACFM Displaced CFM (DCFM) is a mathematical formula that calculates the bore, stroke and rpm into a CFM figure (Bore x stroke x rpm/2200=DCFM). This figure will always be the highest CFM because this formula does not take into account variables like temperature, atmospheric pressure, humidity, friction and heat dissipation. Another CFM term often used is Standard CFM (SCFM). It defined as the measured flow of free air and converted to a standard set of reference conditions (14.5 PSIA, 68 Degrees F, and 0% relative humidity). Yet another CFM term is Actual CFM (ACFM). AFCM can be determined in a number of different ways. The most common methods include measuring the volume of air that is moved through an orphic plate or measuring pump up times on large compressor tanks and running through a simple calculation. This CFM number takes in effect all the variables and will give the true output of the pump at the current working conditions (i.e. temperature, altitude, humidity, ). Often times, CFM numbers are also shown at various pressures. These numbers can be very useful to help determine if a compressor produces enough CFM for the desired application, but can be confusing when comparing differing pressures or volumes or different compressors. The best way of comparing compressors is through SCFM. Since all the measurements are calculated back to a set of reference standard conditions, it levels the playing field among the multitude of different manufacturers. Electric Motors and Horsepower Compressors are often rated by Horsepower (HP). As simple as this sounds, there are different variations of HP. Some compressor manufacturers rate their air compressors by peak horsepower, also known as brake horsepower. Peak horsepower is the maximum output that a motor can produce while the motor has the start windings engaged. Peak HP can be as much as 5-7 times the rated or running HP. Under normal operating conditions, the start windings are only engaged for a small fraction of a second. Therefore, using peak horsepower as a comparison tool can be somewhat misleading since under normal operating conditions the motor only develops this horsepower during startup. If a motor drive system causes the start winding to remain engaged for a long period of time, the motor will either overheat if it has thermal protection or fail prematurely. Most electric motor manufacturers rate their motors by the horsepower developed after the motor has come up to its designed operating rpms and disengaged the start windings. This is often referred to as running or rated horsepower and is a true indication of the HP a motor can sustain over a long period of time. Some other factors to consider when looking at motors is Duty Cycle and Service Factor. Duty cycle is normally rated as either intermittent or continuous and is defined as the time rating under full load. In other words can the motor run at full load horsepower continuously or only intermittently. The other of the two noteworthy factors is the Service Factor (S.F.) rating of the motor. It is defined as the percentage of rated horsepower at which the motor can safely operate (i.e. 1.15 SF = 115% of rated HP). Higher service factors allow motors to handle more varied conditions without causing motor overheating or premature motor failure. Examples that could cause a motor to run within its Service Factor could be caused by low voltage, higher ambient temperatures, higher startup load etc. Note: Many companies are now eliminating the peak HP reference and instead using SCFM as a more accurate performance indicator. Air Compressor Buying Guidelines Before choosing any compressor to purchase, understanding the compressors uses will ensure that the machine can do the required job. Buying a compressor that is too small will waste valuable time. Buying a compressor that is way too large will waste valuable resources. (See the CFM Usage Chart) It is worth noting that the price of a compressor cannot be based solely on the up front purchase price of the unit. The price of any item should be based on the overall cost over an extended period of time or the life of the unit. Inexpensive units are designed to be disposable, like lighters. The questions that need to be answered are: 1.) What is the maximum required operating pressure? This will determine if a Single Stage or Two Stage compressor will be needed 2.) What is the maximum required CFM usage? Add up all of the air tools that are to be used at the same time. When looking at the compressor, add approximately 30% to the determined CFM number. This will allow for a reasonable buffer against unknown or uncommon compressor usage. Do not simply add up all of the air tools that will be used throughout the work day since this will produce an inflated CFM number and require the purchase of an overly large compressor. 3.) Does the machine need to be portable or stationary? Determine whether or not the unit will need to be moved around your facility or work site regularly or if it will be a stationary unit. This will aid in determining other factors such as size and weight. Higher pressures and volumes will require the unit to be larger in size and heavier in weight since horsepower requirements, pumping systems, chassis construction, electrical components, etc... will have to be larger to accommodate these increases. 4.) What type of drive system is needed? Electric Motor or Gasoline Engine? Knowing the environment that the compressor is to be used in will determine what type of drive system the machine will need. If there is always electrical power available, then the drive system should be an electric motor since they are significantly less expensive to buy and run and require less overall maintenance. If electrical power is not always available then the convenience of a gasoline engine driven compressor will be the way to go. They offer the best in portability and work area flexibility. 5.) What receiver tank size will be needed? The size of the compressor tank, usually measured in gallons, should be determined by the overall type of usage. If the usage is in short quick concentrated bursts, such as an air nailer, then a small tank size can be used. If the unit is to sustain long periods of usage, such as a board sander or impact wrench, a larger tank size will be necessary. Choosing the Correct Compressor Company There are a large number of of air compressors distributors in the world today and any one of them will be more than happy to sell you an air compressor. Before purchasing any unit from any air compressor company, there are several key factors that should be considered: 1. How long has the company been in business? 2. Have you ever heard their name before? 3. Do they offer a full line of compressors? 4. Do they carry parts and accessories for their products? 5. Do they have a good service department? 6. Are they knowledgeable about their product? 7. Are they knowledgeable about air compressors in general? 8. Do they have a reputation for providing quality equipment? 9. How efficient are their compressors? 10. How long is the compressor designed to last? 11. Where is the compressor manufactured? US, Canada, China, Japan, Europe ...etc. 12. What materials are used in the compressors construction? Cast Iron, Steel, Aluminum, Plastic etc. Whatever your compressor need, Trident Compressed air has the compressor to do the job. Backed by a company with over 20 years of experience and one of the largest inventories in the business, we are ready to serve you. Why not call us to discuss your compressor needs and how we can help solve them. Air Tool Description Average CFM @ 90 PSI Angle Disc Grinder - 7" 5-8 Brad Nailer 0.3 Chisel/Hammer 3-11 Cut-Off Tool 4-10 Drill, Reversible or Straight-Line 3-6 Dual Sander 11-13 Framing Nailer 2.2 Grease Gun 4 Hydraulic Riveter 4 Impact Wrench - 3/8" 2.5-3.5 Impact Wrench - 1/2" 4-5 Impact Wrench - 1" 10 Mini Die Grinder 4-6 Needle Scalar 8-16 Nibbler 4 Orbital Sander 6-9 Ratchet - 1/4" 2.5-3.5 Ratchet - 3/8" 4.5-5 Rotational Sander 8-12.5 Shears 8-16 Speed Saw 5
*add 30% to average CFM to get required CFM
Quincy Rotary Screw Sales Manual Useful Formulas
1) Estimating horsepower requirements at pressures other than rated pressure.
In most rotary screw compressors, increasing or decreasing the pressure settings will have similar effects. The rule of thumb is: For every I PSIG change from rated pressure, the brake horsepower required will change 0.5% from the rated BHP. Increase the pressure by 10 PSIG and the BHP will go up 5%. Decrease the pressure by 20 PSIG and the BHP will go down 10%.
2) Estimating volume flow rates at pressures other than rated pressure.
Changes in discharge pressure from the rated pressure of the compressor will result in changes in the overall compression ratio. These compression ratio changes will cause changes in the volumetric efficiency of the compressor that will result in changes in capacity. The rule of thumb is: For every 10 PSIG change from rated discharge pressure, the CFM capacity of the compressor will change 0.4% from the rated capacity. Reducing pressure from 110 PSIG to 100 PSIG will result in a capacity increase offour tenths of one percent. Increasing the pressure by 10 PSIQ will cause a reduction in capacity of about four tenths of one percent.
3) Estimating power costs.
To estimate power costs, you will need to know the following: a) What is the cost per KWH? b) How many hours per year does the compressor run? c) At what capacity will the compressor run or how many hours will the compressor run at various load levels? d) What are the brake horsepower requirements of the compressor at the required load levels? e) What is the motor efficiency?
It is important to use actual CFM requirements to figure the load level of the compressor. Do not base power cost calculations on comments like, About half the time we run at full load and about half the time we run at 70% of full load. Full load for one machine may not be the same as full load for another machine. Always determine the exact air requirement in order to provide the customer with a power cost calculation that approximates his situation.
Motor efficiencies vary from horsepower to horsepower and from manufacturer to manufacturer within horsepower ranges. The only way to accurately figure power costs will be to use the motor efficiency number on the nameplate of the actual motor being used.
With the above information in hand annual power costs can be estimated by using the following formulas: 1) kW = BHP x .746 / Motor Efficiency EXAMPLE Find the kW of a 100 HP, nominal Efficiency motor running at a 95 HP load. KW = 95 x .746 / .93 = 76.2
2) Cost per Hour = KWH x Power Cost in $ EXAMPLE Find the cost per hour to operate the compressor in the above example assuming a cost of 7 cents. Cost Per Hour = 76.2 x 0.07 = $5.334
To find the annual power costs, calculate the cost per hour of operating at the various anticipated load levels and multiply by the anticipated number of hours that the machine will operate at those load levels.
4) Estimating additional capacity required to raise system from one pressure to a higher pressure.
To calculate the additional capacity required you need to know: 1) Current CFM capacity (total) of all compressors feeding the system. 2) Current System Press (PSIG) 3) Desired System Press (PSIG) 4) Ambient absolute press (PSIA) The formula for this calculation is: (Desired absolute system pressure divided by Current Absolute system Press) times Current CFM Capacity equals Actual Capacity required to achieve desired system pressure.
EXAMPLE: What is the additional capacity required to maintain a 100 PSIG system pressure at sea level in a system that now operates at 91 PSIG using 500 cfm?
(Desired Pressure / Current Pressure) x Current Capacity (114.7 / 105.7) x 500 = Actual
Capacity Required 1.085 x 500 = 542.5 cfm
5) Estimating BTU heat rejection of air-cooled rotary screw air compressors.
Heat transfer in rotary screw compressors is dependent on a number of factors concerning efficiencies of lubricant coolers and aftercoolers and the rate of radiant cooling. The only way to arrive at exact heat rejection rates is to actually test the compressor under anticipated operating conditions. Approximate heat rejection rates of rotary screw compressors in standard plant operating conditions for use in designing heat recovery packages or use in sizing additional plant air conditioning requirements can easily be calculated. The rule of thumb is:
The total BTUs per minute of heat rejected by a rotary screw air compressor is equal to the brake horsepower being used times 42.41. A 100 BHP compressor would have a total heat load of 4,241 BTU/minute. Of this total about 8% is rejected as radiant heat. Of the remaining 92% about 85% (78.2% of total) is rejected through the lubricant cooler and about 15% (13.8% of total) is rejected through the aftercooler.
Calculating BHP Requirements For Less Than Full Load Operation
Modulating single (All and two-stage (Ingerso1l-Rand) rotary screw compressors: To calculate the horsepower required to produce an amount of compressed air that is less than the full load capacity of a modulating rotary screw compressor, convert the desired CFM demand level into a percentage of the full load capacity of the compressor. If the demand on a 750 CFM compressor was 600 CFM, the percentage would be 80%. Find the Percent of Capacity in the chart below and note the multiplier next to it. Multiply the drive motor BHP by the number corresponding to the demand percentage. This will give you an estimate of the brake horsepower required to meet the specified air demand. MODULATING Percent of Full Load Capacity Full Load BHP Multiplier Percent of Full Load Capacity Full Load BHP Multiplier Percent of Full Load Capacity Full Load BHP Multiplier 100% 1 80% 0.9577 60% 0.9033 99% 0.9981 79% 0.9554 59% 0.9001 98% 0.9962 78% 0.9529 58% 0.8968 97% 0.9942 77% 0.9505 57% 0.8935 96% 0.9923 76% 0.948 56% 0.8902 95% 0.9903 75% 0.9455 55% 0.8868 94% 0.9883 74% 0.943 54% 0.8833 93% 0.9863 73% 0.9404 53% 0.8798 92% 0.9842 72% 0.9378 52% 0.8762 91% 0.9821 71% 0.9351 51% 0.8725 90% 0.98 70% 0.9324 50% 0.8687 89% 0.9779 69% 0.9297
If, in the above example, the BHP listed for the 750 CFM compressor was 163, then the BHP required at the 600 CFM level (80% of full load) would be 163 x .9577 or 156.1 BHP.
Variable displacement rotary screw compressors with built- in clearance volume (Turn Valve and Spiral Valve: To calculate the horsepower required to produce an amount of air that is less than the full capacity of a variable displacement rotary screw compressor with built-in clearance volumes, follow the preceding example to determine the percentage of full load capacity. Then use the following table to determine the BHP consumed at the desired load level. Percent of Full Load Capacity Full Load BHP Multiplier Percent of Full Load Capacity Full Load BHP Multiplier Percent of Full Load Capacity Full Load BHP Multiplier 100% 1 80% 0.8629 60% 0.7448 98% 0.9853 78% 0.8503 97% 0.9781 77% 0.844 96% 0.9709 76% 0.83 79 95% 0.9638 75% 0.83 17 94% 0.9567 74% 0.8256 93% 0.9497 73% 0.8 195 92% 0.9427 72% 0.8135 91% 0.9358 71% 0.8076 90% 0.9289 70% 0.8016 89% 0.922 1 69% 0.7958 88% 0.9153 68% 0.7899 87% 0.9086 67% 0.7841 86% 0.9019 66% 0.7784 85% 0.8953 65% 0.7727 84% 0.8887 64% 0.767 83% 0.8822 63% 0.7614 82% 0.8757 62% 0.7558 81% 0.8693 61% 0.7503
Variable displacement rotary screw compressors without built-in clearance volume (PowerSync): To calculate the horsepower required to produce an amount of air that is less than the full capacity of a variable displacement rotary screw compressor without built-in clearance volumes, follow the preceding example to determine the percentage of full load capacity. Then use the following table to determine the BHP consumed at the desired load level.
Two-stage rotary screw compressor with variable displacement first stage (Suilair): To calculate the horsepower required to produce an amount of air that is less than the full capacity of a two-stage rotary screw compressor with a variable displacement first stage, follow the preceding example to determine the percentage of full load capacity. Then use the following table to determine the BHP consumed at the desired load level.
Percent of Full Load Capacity Full Load BHP Multiplier Percent of Full Load Capacity Full Load BHP Multiplier Percent of Full Load Capacity Full Load BHP Multiplier 100% 1 80% 0.9154 60% 0.8167 99% 0.996 79% 0.9108 59% 0.8113 98% 0.992 78% 0.9062 58% 0.8058 97% 0.988 77% 0.9016 57% 0.8003 96% 0.984 76% 0.897 56% 0.7947 95% 0.9799 75% 0.8923 55% 0.789 94% 0.9758 74% 0.8875 54% 0.7833 93% 0.9717 73% 0.8828 53% 0.7775