Compressor Fundamentals

Overview

Compressor Fundamentals

Why do we compress Air?

In this section, you will learn
Why

do we compress air
Basic Compressor Operation
Types of Compressors
A brief history of compressed air
Basic operation

Amusement parks

snow making

Why do we compress air?

Compression is undertaken for a variety of reasons.
Many processes can only be carried out by
compressed gases. Some of these include:

Glass plants

Blowing

Etching

Transmission of power for pneumatic tools.

Molding, etc.

Basic Compressor Operation

Shot blasting

Paint Spraying

Transporting materials

Conveying

Air separation, for industrial gases (oxygen,

nitrogen).

There are various ways to compress air. One of the

simplest is by means of a
piston in a cylinder. As the
piston moves forward in the
cylinder it compresses the air
into a smaller space, thus
raising its pressure. We are all
familiar with the bicycle pump,
which is typical of this principle.
A reciprocating air compressor
utilises the same pumping principle. Air is drawn into
a cylinder and compressed by a piston, which is
driven by a connecting rod and crankshaft. An air
compressor is very similar to the engine in an
automobile.
Air enters the compressor through a combination filter
and muffler that cleans the air and silences the noise.
The clean air passes into the cylinder through an inlet
valve, which is opened automatically by
differential air pressure. The air is then compressed by
the piston and forced
through a discharge valve
into a storage tank.

Type 30 Air Compressor,

circa 1930

Compressor Fundamentals

Types of Compressors
Types of Compressors
There are two general groups of air compressors,
positive displacement and continuous flow. Positive
Displacement compressors are either Reciprocating
or Rotary.

Positive
Displacement

Continuous
Flow

These are units in which successive volumes of air

are confined within a closed space and elevated to a
higher pressure.

Reciprocating
The compressing and displacing element in
these units is a piston having a reciprocating
motion within a cylinder.

Ejector
Devices that use a high velocity gas or steam
jet to entrain the inflowing air, then convert the
velocity of the mixture to pressure in a
diffuser.

Dynamic

Rotary
Compressing and displacement is effected by
the positive action of rotating elements

Sliding Vane
Axial vanes slide radially in a rotor
eccentrically mounted in a cylindrical
casing. Air trapped between vanes is
compressed and displaced.

These are machines in which the rapidly

rotating element accelerates the air as it
passes through the element, converting the
velocity head into pressure, partially in the
rotating element and partially in stationary
diffusers or blades.

Centrifugal
One or more rotating impellers, usually
shrouded on the sides, accelerate the
air. Main air flow is radial.

Liquid Piston
Water or other liquid is used as the piston
to compress and displace the air.

Axial Flow
Air acceleration is obtained by the
action of the bladed rotor shrouded on
the blade ends. Main air flow is axial.

Straight Lobe
Two straight mating lobed impellers trap
air and carry it from intake to discharge.
This is no internal compression.

Helical Lobe
Two intermeshing rotors, each with a
helical form, compress and displace the
air.

Mixed Flow
An impeller form combining some
characteristics of both the centrifugal
and axial types.

Compressor Fundamentals

A brief history of compressed air

10,000
BC

The first use of compressed air was when ancient man blew on embers to start
a fire. Thus the first compressor was human lungs (capacity 100 1/min,
pressure 0.02-0.08 bar(g)).
The work capability of compressed air was well understood by primitive hunters
who used a blowpipe and darts to hunt wild animals.

3000 BC

Man began to melt gold, copper, tin and lead found in pure form in nature and
later to reduce their oxides.
Temperatures in excess of 1000oC required a more powerful compressor. This again was
provided by nature with wind being compressed against a hillside and forced across a ridge.
Egyptian and Sumerian goldsmiths developed a blowpipe to provide a
more convenient and reliable means of melting their metals.
The blowpipe is still used today, but is, of course, inadequate in
capacity for volume smelting of metals.

2500 BC

Hand bellows, the first mechanical form of compressor, were invented.

1500 BC

Foot bellows were invented

1000 BC

Bellows were driven by water wheels.

1750 AD

John Smeatons water driven air blowing cylinder, replaced bellows.

1776 AD

John Wilkinson invented a cannon-boring machine. This invention enabled production of large,
accurately machined, cast iron cylinders for both blowing machines and steam engines.
The first prototype was installed in his machine shop in Wilby, Shropshire, UK. It was limited to a
pressure of about 1 bar(g) by the temperature capability of the leather links controlling the
wooden valves.
The bellows and the early blowing machines were primarily used to supply combustion air for
smelting and to ventilate underground mines. This was necessary because the ore was mined
by setting fire to the face and then cooling it with water to fracture the rock.

1800 AD

People began to seriously think of compressed air as an energy transmission medium. It had
already been found that steam was limited to short distances because it cooled and condensed
so quickly.

1820 AD

Metallurgical plants were growing in size and it was necessary to supplement installed steam
plants with water power. But, in Wales, a waterfall in the narrow valley could not be used as there
was no adjacent land on which to build a rolling mill.
It was decided to use the water to power blowing machines and to pipe the air to power air
motors in the mill about 1000 metres away. Unfortunately on start up, although the blowing
machines worked well, the air motors would not turn.
Compressed air technology very nearly ceased before it started.
Eventually it was found that the vitrified clay pipes, which worked well as water conduits, would not
hold air.

Compressor Fundamentals

A brief history of compressed air

1857 AD

Since prehistoric times, man has worked with rock. Mining originated when flint was needed for
stone age tools. When mining progressed from lighting fires to blasting with explosives, it became
necessary to drill holes in the rock. This was initially accomplished by hand, using the hammer and
twist method.
Long distance transmission of compressed air energy began with the building of the Mt. Cenis
railway tunnel in the Swiss Alps.
The 13.6km tunnel began in 1857 with manual drilling and would have taken 30 years to
complete. After four years, compressors were installed at both ends to power rock drills. When the
two teams met, there were 7km of distribution line running from each end.
The Mt. Cenis experience caused people to think about building distribution networks to provide
compressed air energy to individual businesses.

1860 AD

People began to develop mechanical rock drills.

It was shortly after that Ingersoll Rand began (as a result of individual
efforts by Simon Ingersoll and the Rand brothers. Once the mechanical
rock drill was operational, much work was done to develop reliable
sources of motive power.
The air compressor developed quickly from this point
Ingersoll Rand Rock Drill in
Kalgoorlie, WA

1871 AD

Patent No. 112,254 issued to Simon Ingersoll on 7th March, 1871. This
is the date from which we trace Ingersoll Rand's history.

1888 AD

Victor Popp, an Austrian engineer, gained a concession to run a compressed air distribution
system through the Paris sewer system.
The plant was commissioned with 1500 kW of compressors feeding 7 km of mains and 50 km of
feeder line.

1891 AD

By this time, the system which operated at a pressure of 6 bar(g), had grown to a capacity of
18,000 kW (1.8 MW).
One of the major reasons for Popps success was a novel pneumatic clock which kept accurate
time driven by timed pulses of compressed air. This became a must have item and once air was
connected to restaurants, factories, shops, physicians surgeries, lawyers offices, etc., it became a
simple matter to hook other pneumatic devices into the system.
Inventors in all parts of the work now got busy and many
patents were issued. In Paris, for example, air was used for:
Pneumatic clocks
Pneumatic despatch systems
Passenger lifts
Wine and beer dispensing
Air motors up to 70 kW to run tools, looms, presses, etc

Pneumatic drive of DC generators up to 36 kW to light

Restaurants, theatres, hospitals, etc

Factory in Paris that made

air compressors for Victor

Many reports concluded that compressed air was the energy transmission medium of the future.
They took a very negative attitude to the electric distribution system then also in its infancy. There
were others, however; who were equally enthusiastic about the merits of electricity and who
dismissed compressed air because of its poor efficiency.
Neither of the two opposing schools of thought were proven totally correct. Compressed air plants
kept developing and expanding. Electric transmission systems became the exclusive means of
distributing power. Compressed air now serves as an important complement to electricity and it is
called the fourth utility.

Compressor Fundamentals

A brief history of compressed air

1902 AD

Worlds first truly portable compressor built

1903 AD

Pneumatic tools added

1913 AD

Centrifugal pumps added. First centrifugal compressor built.

1920 AD

High temperature pumps aided the thermal cracking of crude oil

1930 AD

The T30 compressor introduced

Compressor
1933 AD

Two stage air cooled portable developed

1941 AD

The boiler circulating pump introduced

1947 AD

The first big drill built

1948 AD

Centrifugal compressors transport natural gas

1950 AD

Sliding vane compressors introduced. Quiet pumps for nuclear submarines

Compressor Fundamentals

A brief history of compressed air

2000 AD

IR was first-to-market introducing a true variable speed drive compressor directly driven by
Hybrid/Permanent magnet motor

Air

Solutions

Air solution and service provider of design, equipment, project management,

maintenance and operations for compressed air systems
Market leader in prividing customers with air solutions tailored to their
productivity needs.

Advanced technology, highest reliability, lowest maintenance, highest quaility air,

best energy efficiency

T30 Non-Lubricated Air Compressor

(6.8-18Barg)
T30 Non-Lubricated Air Compressor is one of the patented
products designed and built by Ingersoll Rand. T30 has the
features of low noise, reliable operation and easy
installation. They are widely used in many industries , such
as pharmaceuticals, textile, chemical and garment.

Features

Heavy Cast Iron Design

Higher Reliability
Long Term Durability
Efficient Cooling System
Powder Coat Painting Enhances Antitrust

Single&Two-stage "Standard Package" Air

Compressors(6.8-18Barg)
Ingersoll Rand's Two-stage "Standard Package" air
compressors are designed for the most demanding
applications where a reliable air supply is required. Perfect
for automotive, commercial and industrial applications.
When maximized operating pressure, increased air flow,
and extended duty cycle is required, Ingersoll Rand air
compressor is the choice.

Features

SS Single-stage series
These "SS" series air compressors are the latest design.
Heavy duty single-stage cast iron air compressors is
designed by Ingersoll Rand with high quality for industrial
useage. It is durable and provides non-stop operation. These
twin cylinder block design air compressors have
conservative running speed for prolonged life.
TS Two-stage series
-100% cast iron frame and separate cast cylinders
-Stainless steel finger valve assembly after heat treatment
-Efficient finned intercooler tubes
-Balanced overhung crankshaft
-Rugged one-piece connecting rod
-Centrifugal unloader for no load start
-Factory-filled synthetic lubricants

Features

Infinity 5.5-11 KW
Infinity rotary screw compressors continue the
legacy of the great efficiency, reliability and
high quality. These compressors are simply
designed, easy to control, economical to operate
and convenient to maintain, also can run under
the most extreme ambient conditions. The
exclusive design of cold/hot box and cooling
system make Infinity different. The compressors
are available from 7 to 10 barg and from 0.74 to
1.7 m3/min

Premium Poly-V belt

Provides uniform bearing load and belt wear pattern to
extend the life of belt
High-efficiency blower cools evenly
Saves energy, and produces less noise
Air/ Oil cooler
Discharges heat from the top for greater efficiency
Exclusive hot box/ cool box design
Isolates hot elements from other components to ensure
cooling and extended life
Dual control operation
Provides application flexible and reduced operating cost
Simple user interface and diagnostic indicators
Signal operating status, hours, and faulty warnings to
minimize downtime
Spacious interior design
Permits easy maintenance.

Features

Pegsus15-37 KW
Ingersoll Rand's rotary screw compressors with
innovation and air solution provide customer with
greater profits. The high efficiency integrated
compression module eliminates leaks and pressure
losses to increase effiency and performance.
Exclusive hot box/ cool box design keep the heat
out and the noise in, ensuring the compressors keep
running in the most extreme conditions and still
achieve maximum performance. The options are to
meet all operating conditions for customers, such as
frost protection, high ambient package, power
outage restart and intellisys control option

Whisper Quiet Operation

Oversized, high efficiency cooling air blower.
Provides sound levels as low as 68 dBA
Dual Control Operation
Reliable and effective load/no load control with
automatic stop and restart facility for maximum
flexibility.
Simple Diagnostics
Visual indication of operating status and hours run,
for ease of operation and reduced downtime
Poly-V Belt Drive
Premium drive system applies patented automatic
tensioning to eliminate belt stretch and increase air
output.
Advanced Cooling
A package pre-filter, efficient combination
aftercooler with access to both sides for easy
cleaning and top discharge to simplify ducting.
Generous Serviceability
All key maintenance components have been grouped
to provide ease of serviceability.

Small UP 4-11 KW
Small UP Total Air System integrates the compressors, cycling
dryer,dual filtration pack and controls into an energy reducing
optimized system. Advanced integrated package increase the
reliability and operation time. The compressors are available from 8
to 14.5 barg and from 0.45 to 1.6 m3/min

Features

Whisper Quiet Operation

Oversized, high efficiency motor mount blower. sound levels as 65
dBA
Dual Control Operation
Auto start/stop operation with constant speed control for maximum
flexibility.
Simple Diagnostics
Visual indication of operating status, and hours and fault warnings
for ease of operation and reduced downtime
Poly-V Belt Drive
Premium drive system to minimize belt stretching and increase air
output.
Advanced Cooling
High efficient, oversized combination cooler with roof mount
discharge for ease of ducting.
Generous Serviceability
Spacious design for ease of serviceability.

Unigy 5.5-11 KW
UNIGY integrates the most advanced air compressor technology.
The human-oriented design and unqiue IntelliDrive system provide
the most efficient compressed air

Features

Whisper Quiet Operation

Variable speed controlled capacity automatically adjust
compressed air output
Virtual gear set
Providing flexible power and pressure ranges
IntelliDrive system
Suitable for multiple electrical supplies

Nirvana Variable-Speed Drive

Only Ingersoll Rand offers Nirvana variable-speed drive rotary screw compressor, the world's first true
variable-speed drive rotary screw compressor for highest quality of air and the greatest reliablility available
on the market.By matching an innovative modular variable speed inverter with a HYBRID PERMANENT
MAGNET motor,Ingersoll Rand is again first-to-market,this time with a true variable-speed drive air
compressor.
Nirvana has fewer rotating parts than any other rotary air compressors in its class. The Hybrid Permanent
Magnet motor driving the Nirvana raises the standard on compressor reliability to an unequaled level.There
is no motor bearing in HPM motor. Since HPM motor directly drives the compressor,there is no pulley,belt
or coupling to wear out or to replace, and there is nothing to get out of alignment. Equipped with Ingersoll
Rand's time-proven and reliable airend,Nirvana is a highly reliable air compressor.

Features

Premium efficiency IP23 HPM motor

96% efficiency rating

No motor bearing, durable motor life

Rugged Ingersoll Rand airend with duplex tapered roller bearings

Aircooled aftercooler with moisture separator

Integral variable frequency drive, high efficiency

Variable speed controlled fan motor, save energy

Factory-fill of SSR UltraCoolant

IntellisysTM controller featuring

Infinite on-off control

Self auditing function

Low sound level

Features

R90-160KW
Ingersoll Rand contact-cooled,rotary screw
compressors are proven,ruggedly reliable
units that perform to the highedt standards
regardless of industry,application or
environment.Easy to install and continuousduty rated for long-term performance,with
our compressors you get what you pay
for,and more

Robust Cast Iron IP54 motor

Rugged Ingersoll Rand airend with duplex
tapered roller bearings
No maintenance integral gear drive system
Air or Water-Cooled aftercooler,high cooling
efficiency
Integral star delta starter,reduce starting
current
Factory-fill of UltraCoolant
IntellisysTM S3 control system featuring
Language-less control panel with backlit
LCD display
On-Line/Off-line control with automatic start
& stop
Real time clock functions, modbus, 3
machine sequence control
Noise elimination enclosure design

Features

High efficiency IP23 motor

Rugged Ingersoll Rand airend with duplex

tapered roller bearings

No maintenance integral gear drive system

Air or Water-Cooled aftercooler with

moisture separator

Integral star delta starter,reduce starting

current

SSR200-250KW
Ingersoll Rand contact-cooled,rotary screw
compressors are proven,ruggedly reliable
units that perform to the highest standard
regardless of industry,application,or
environment.Easy to install and continuousduty rated for long-term performance,with
our compressors you get what you pay
for,and more.

Factory-fill of SSR UltraCoolant

Energy saving Intellisys capacity control

system featuring

Digital inlet control valve

Upper range modulation

Low sound enclosure design

SSR45-75KW
Ingersoll Rand contact-cooled,rotary screw compressors are
proven,ruggedly reliable units that perform to the highedt
standards regardless of industry,application,or
environment.Easy to install and continuous-duty rated for
long-term performance,with our compressors you get what
you pay for,and more.

Features

Standard IP55, high efficiency motor

Rugged Ingersoll Rand airend with duplex tapered
roller bearings
No maintenance integral gear drive system
Air or Water-Cooled aftercooler with moisture
separator
Integral star delta starter,reduce starting current
Factory-fill of SSR UltraCoolant
IntellisysTM capacity control system featuring
Finger-touch control panel
On-Line/Off-line control with automatic start & stop
Failure alarm
Low sound enclosure design

SSR Two Stage 90-350KW

Ingersoll Rand contact-cooled,rotary screw compressors are
proven,ruggedly reliable units that perform to the highedt
standards regardless of industry, application, or
environment.Easy to install and continuous-duty rated for
long-term performance,with our compressors you get what
you pay for,and more.

Features

High efficiency IP23 or IP55motor

High efficiency 2-stage airend
No maintenance integral gear drive system
Air or Water-Cooled aftercooler with moisture
separator
Integral star delta starter,reduce starting current
Factory-fill of SSR UltraCoolant
Energy saving IntellisysTM capacity control system
Digital inlet control valve
Upper range modulation
Low sound enclosure design

Nirvana Variable-Speed Drive Oil Free

Only Ingersoll Rand offers Nirvana Oil-Free,The world's first true variable-speed oil-free compressor for
critical oil-free application requiring the highest quality of air and the greatest reliablility available on the
market.By matching an innovative modular variable speed inverter with a HYBRID PERMANENT
MAGNET motor,IR is again first-to-market,this time with a true variable-speed drive,oil-free air
compressor.
The two-stage Nirvana Oil-Free compressor has fewer rotating parts than any other rotary air compressor in
its class.And the Hybrid Permanent Magnet motor driving the Nirvana Oil-Free raises the standard on
compressor reliability to an unequaled level.There are no motor bearings in the HPM motor.And since the
HPM motor directly drives the compressor,there are no pulleys,belts or couplings to wear out or need
replacing.And there is nothing to get out of alignment.Coupled with IR's time-proven,reliable two-stage oilfree airend,Nirvana Oil-Free is as reliable as an air compressor can get.

Features

Premium efficiency IP23 HPM motor

97% efficiency rating

No motor bearingslonger motor life

Rugged IR oil-free airend with Ultra Coat,high efficiency

Aircooled aftercooler with moisture separator

Integral variable frequency drive

Variable speed controlled fan motor,save energy

Factory-fill of SSR Ultra Coolant

IntellisysTM controller featuring

Infinite on-off control

Self auditing function

Low sound level

Sierra Oil Free 37-300KW

With an Ingersoll Rand oil-free compressor, you don't have to worry about contaminated air, regardless of
the technology you choose. Our oil-free rotary-screw compressor was rigorously tested by TUV Rheinland
a global leader in independent testing and assessment services and earned ISO8573-1:2001 Class
0certification

Features

High efficiency IP55 motor

NEMA1 control cabinet enclosure

2-Stage oil-free rotary screw airend,high efficiency and reliable

High efficiency inlet filter design

Air or Water-Cooled aftercooler with moisture separator

Integral star delta starter,reduce staring current

CMC controller featuring,super advanced function, Provide a list of last 224 events

Service Scheduling

Power Outage Restart

Low sound enclosure design

Centac CH Single Stage Centrifugal Compressor

Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop
class-leading products, but also because we know our customers' industries, the demands placed on
productivity and quality. We are the first to be Class 0 certified by the TUV certification body.
ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most
industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you
need guaranteed pure air for your critical application, then you need Ingersoll Rand!

Features

Simplicity by Design
Ingersoll-Rand Centac blowers have few moving parts, which equate to higher reliability and less
maintenance. This, in turn, keeps your system up and running without unnecessary downtime.
High Quality Air
Centac blowers are Class 0 certified and deliver 100% inherently oil-free air to your processes. This helps
assure that your product will be manufactured at the highest level of quality with scrap and defects reduction.
Energy Efficient
With state-of-the-art aerodynamics and a technologically advanced control system, the Centac blower is the
most energy efficient compressor in the industry. It provides cost savings opportunity to the operation.
Compressor Uptime
Maximizing your production process uptime is always our goal at Ingersoll-Rand. The Centac blower is
designed to minimize maintenance. In addition, Ingersoll-Rand offers preventative maintenance and AirCare
programs to maximize blower uptime. In the event of required maintenance, Ingersoll-Rand offers
unsurpassed local service support.
Standard Scope of Supply
Complete Tested Package, Built-In Lubrication System, Complete Control, Protection and Diagnostic
System, Mounted Inlet and Bypass Valves, Single Point Flanged Air Connections, Hot Air Discharge (No
Aftercooler).

Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop
class-leading products, but also because we know our customers industries, the demands placed on
productivity and quality. Pay attention that we are the first to be Class 0 certified by the TUV certification
body.
ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most
industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you
need guaranteed pure air for your critical application, then you need Ingersoll Rand!

Features

Advanced Centrifugal Technology For Superior Performance

100% Oil Free Air
Next Generation Aerodynamic Design For
-Maximized Efficiency
-Increased Throttle Range For High Efficiency at Part Load
-Enhanced Reliability
Constant Pressure Control For
-Stable System Pressure
-Smooth Operation
Simplicity Means Reliability (less Moving Parts)
-1 Bull Gear
-2 to 3 Rotor assemblies
Well Proven Reliable & Robust Design
-High Reliability and Long Life
-Low Maintenance Requirements
State-of-the-Art Control System
Low Operating & Installation Costs
Low Noise Level (Enclosed) Options
Worldwide Service and Parts Support
Largest Centrifugal Installed Base in the World

C3000
Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop
class-leading products, but also because we know our customers industries, the demands placed on
productivity and quality. Pay attention that we are the first to be Class 0 certified by the TUV certification
body.
ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most
industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you
need guaranteed pure air for your critical application, then you need Ingersoll Rand!

Features

Advanced Centrifugal Technology For Superior Performance

100% Oil Free Air
Next Generation Aerodynamic Design For
-Maximized Efficiency
-Increased Throttle Range For High Efficiency at Part Load
-Enhanced Reliability
Constant Pressure Control For:
-Stable System Pressure
-Smooth Operation
Simplicity Means Reliability (less Moving Parts)
-1 Bull Gear
-2 to 3 Rotor assemblies
-6 to 8 Bearings per Machine
Well Proven Reliable & Robust Design:
-High Reliability and Long Life
-Low Maintenance Requirements
State-of-the-Art Control System
Low Operating & Installation Costs
Low Noise Level (Enclosed) Options
Worldwide Service and Parts Support
Largest Centrifugal Installed Base in the World

2ASB
Ingersoll Rand is a technology leader in oil-free compressed air technologies not only because we develop
class-leading products, but also because we know our customers' industries, the demands placed on
productivity and quality. We are the first to be Class 0 certified by the TUV certification body.
ISO 8573-1:2001 Class 0 specifies air quality standards for critical manufacturing processes within most
industries. It is the most stringent class covering oil contamination in aerosol, vapor, and liquid forms. If you
need guaranteed pure air for your critical application, then you need Ingersoll Rand

Features
Advanced Centrifugal Technology For Superior Performance
100% Oil Free Air
Next Generation Aerodynamic Design For
-Maximized Efficiency
-Increased Throttle Range For High Efficiency at Part Load
-Enhanced Reliability
Constant Pressure Control For
-Stable System Pressure
-Smooth Operation
Simplicity Means Reliability (less Moving Parts)
-1 Bull Gear
-2 to 3 Rotor assemblies
-6 to 8 Bearings per Machine
Well Proven Reliable & Robust Design
-High Reliability and Long Life
-Low Maintenance Requirements
State-of-the-Art Control System
Low Operating & Installation Costs
Low Noise Level (Enclosed) Options
Worldwide Service and Parts Support
Largest Centrifugal Installed Base in the World

PET
High Pressure Series

Solutions of Choice
An era of choice begins. Ingersoll Rand introduces alternative
solutions to the production challenges of PET bottle blowing.
For the first time, you can choose between different, highly
advanced air compression technologies which now include the
outstanding performance of four-stage centrifugal and reciprocating
compressors to select that which best meets the unique
production requirements of your plant.
The reasoning is straightforward. To compete successfully in the
global marketplace, companies like yours must keep production
lines running smoothly and with minimum interruption. Downtime,
whether scheduled or unscheduled, is costly.
So, with a thorough understanding of the dynamics in today's strenuous production environment, Ingersoll
Rand unveils ground-breaking 4-stage centrifugal technology and 4-stage reciprocating technology, for
unmatched reliability and performance. Together with our other highly regarded reciprocating solutions,
these superior technologies from a single source provider offer the PBM Industry:
Lower life-cycle cost
Unmatched product durability
Ability to thrive in punishing environments
Economical and efficient solutions to maximize productivity
Numerous configurations to meet any operational need

Features

Centac-C1050
State-of-the-Art Reliability
Specifically designed for demanding PBM applications, the
C750 and C1050 have few moving parts and virtually nothing to
wear out. Valve, ring and packing changes become a thing of the
past. Centac compressors, by design, will run for long
intervalsand since they stay running, you keep producing.
Featuring a noncontact compression cycle, the C750 and C1050
offer unsurpassed air quality, oil-free, with no particles induced
into the air stream. Experience legendary reliability, and the
peace of mind, it brings with the new Centac C750 and C1050
solution.

Advanced Centrifugal Technology

For Superior Performance
100% Oil Free Air: No Particles
Generated During the Compression
Process
Simplicity By Design: Only Four
Main Rotating Parts
Low Operating & Installation Costs
Worldwide Service and Parts
Support
Next Generation Aerodynamic
Design
-Maximized Efficiency
-Increased Throttle Range For High
Efficiency at Part Load
-Enhanced Reliability
Constant Pressure Control For
-Stable System Pressure
-Smooth Operation
State-of-the-Art Control System

Recip-Petstar - 4
Four-Stage Atmospheric
When unsurpassed performance and reliability are required, the PETStar-4 line of 4-Stage Reciprocating Air
Compressors answers the challenge. Robustly designed and configured in a horizontally opposed cylinder
configuration, the PETStar-4 arrangement virtually eliminates vibration with a minimal foundation
requirement. By utilizing four stages of compression, the PETStar-4 is capable of providing unsurpassed
compressor efficiency. Lower stage compression ratios reduce the cylinder operating temperatures and
extend the life of valves, rings and packing. To simplify installation, all PETStar-4 units feature a heavy-duty
welded steel subbase and are available with a matching air treatment component package. Whether you
require a compressor for in-line molding or capacity to support a large production operation, there is a
PETStar-4 package to meet your needs.

Features

Nonlubricated 100% Oil Free Water-Cooled Design

Four-Stage Balanced Opposed Layout Eliminates Unwanted Vibration

All Double Acting, Heavy Duty Class 40 Cast Iron Cylinder Construction

16,000 Hour Rated Piston Rings and Packing

Worldwide Service & Parts Support

Sleeve Type Main and Connecting Rod Bearings

Anticorrosion Coating On All System Air Piping

Crankshaft-Driven Main Oil Pump

Large Cast-In Water Jackets For Dimensional Stability Under Extreme Conditions

State-of-the-Art Control System

System Controls
Air System Controller/Air System Manager
The Air System Controller (ASC) provides a window into the compressor room by making the raw data
available to plant operators and managers in formats that are easy to understand plus provide substantial
ENERGY SAVINGS. The ASC utilizes a Machine Interface (HMI) Software specifically designed by
Ingersoll-Rand for Compressed Air Systems.
Benefits
Total System Control - Compressors, Dryers, Cooling Towers, Pumps & Accessories
Energy Management - Stable System
Pressure & Load Sharing
System Benchmarking & Data Management
Enhanced Communications
The Air System Manager (ASM) provides a window into the compressor room by making the raw data
available to plant operators and managers in formats that are easy to understand plus provide substantial
ENERGY SAVINGS. The ASM utilizes an "off-the-shelf" Machine Interface (HMI) Software which is
specifically customized for Compressed Air Systems.

X4I Controller
System control, applied correctly, in mulicompressor installations can dramatically decrease
energy use by ensuring that only the compressors
that are needed are operated while maintaining
system pressure in a single, tight control band. The
X4I uses the base load, base load. trim control
strategy to ensure compressors are managed in this
most efficient manner. Add an Ingersoll Rand
Nirvana 5.5 - 30kW VSD and leverage the advantage
of the most efficient trim control available.

Compressed Air Filter

System Installation & Air Treatment

Compressed Air Filter

Ingersoll Rand Compressed Air Filters are available in four filtration grades.When installed with
refrigeration or desiccant dryers,they will provide clean compressed air to the highest classes as prescribed
by ISO8573.1
Benefits:
Proven to exceed ISO air quality
Quickest,simplest maintenance of any filter design
Built in safety protection
Lowest pressure drop available
Corrosion resistant alocrom treatment
10 year housing guarantee

Features

A Perdect Seal Every Time

Moulded seal cannot be lost or mis-aligned.
Full Flow Inlet
Gives maximum capacity and lowest pressure drop.
Unique Filter Element
Is available in four filtration grades.
Rapid Maintenance
Lift and twist design is quick and easy.
Built In Safety
Simply push for autodrain check and bowl depressuration.
Differential Pressure Indicator
Gives a reminder of filter element life from both sides.
Fixing Clamp
Joins two filters and is a wall mounting bracket in one.
Self Cleaning Drain Screen
Reduces maintenance and increases reliability.

Dryer
System Installation & Air Treatment

TS Refrigerated Air Dryer

A new non-cycling, refrigerated air dryer by Ingersoll Rand, the TS dryer is designed to improve reliability,
productivity and efficiency, protect health and safety and lessen environmental impact. To accomplish this,
the TS dryer incorporates several key technical innovations. Among these innovations are its 3-in -1 heat
exchanger(s), micro-channel condenser, microprocessor and"smart"drain

Features
Reliability and performance
Consistently delivers dry process air with minimal pressure drop. 3-in-1 Heat exchanger integrates the precoller and re-heater,heat exchanger and air/water separation to reduce the opportunity for leaks. High inlet
temperatures to 60 will be accepted with no nuisance shutdowns. Electrostatic-charged panel filter included
on all models for increased package performance.
Productivity
Refrigeration Expansion valve offers more precise control under varying heat loads from the compressed air
and varying ambient temperatures resulting in less risk of product spoilage through dewpoint slippage.
Optimised connection sizes to minimise pressure drop. Intellisys microprocessor indicates component
warnings and if preventative maintenance is needed. Power Out Restart Operation(PPRO) improves
productivity.
Energy Efficiency
"Smart"drain recognises ambient conditions to adjust dwell time and minimise the loss of valuable
compressed air. Energy Saving Efficiency Option to cycle refrigeration compressor is standard.
Health, Safety and the Environment
Design uses environmentally friendly R404A. Less refrigerant is needed with MicroChannel condenser
design.

IRED Heated Desiccant Dryer

Externally heated air dryer adds a heater based on IRED dryer to heat the purge air. It not only benefits the
regeneration effect but also decreases regeneration purge loss.

Features

8 hours standard cycle.

Pressure dew point -40.

Regenerating air capacity:7%.

Pressure lost:0.02Mpa.

Electrical grade:NEMA4 or IP55.

Automatically pressurized to insure the desiccant life is above 6 years.

Reliable types of valve parts, and the usage of the valves is above 1000 thousand times.

Finely designed mufflers reduce the noise below 72dB(A).

Filters, Regulators, Lubricators

System Installation & Air Treatment
Filter/Regulator Combination
The Filter/Regulator combination is designed to be compact
and easy to use and maintain.

Features

Push-pull, non-rising knob allows one-hand adjustment

Balanced valve-type diaphragm regulation assures
positive pressure adjustment
Regulator offers in-line repairability. Valve and
diaphragm can be replaced without removing unit from
line
Automatic drain has 1/8-inch NPT connection for
draining away contaminants
10 PSIG minimum operating pressure

Heavy Duty Filters/Regulators/ Lubricators

Features
Heavy Duty Filters
These ARO Heavy-Duty Series filters extend the life of airoperated equipment while reducing maintenance costs.
These units efficiently remove solid particles from
compressed air lines making them the perfect choice for
large flow applications.
Heavy Duty Regulators
These ARO Heavy-Duty Series regulators provide accurate
and quick response to flow demands and line pressure
changes, giving air-powered equipment the precise air
pressure control needed.
Heavy Duty Lubricators
Extra rugged Heavy-Duty Series lubricators deliver the
reliable lubrication needed for long service life of air line
systems and equipment.

Receiver Tanks
The receiver tank is central to many industrial applications. In
factories using compressed air, the receiver tank helps deliver
stable output of compressed air, serves as a buffer, collects
moisture from cooled air and discharges it out of the system. The
air tank also serves as an air manifold to guarantee air supply in
peak hours. Ingersoll Rand provides air tanks in compliance with
applicable national codes and standards: stainless steel and carbon
steel air tanks; vertical and horizontal air tanks

Intelliflow Controller
Waste of the compressed air from leakage or improper regulation
is a common issue to most compressed air systems. IntelliFlow is
able to reduce the loss via precise control of the operating pressure.
Benefits
SAVE ENERGY: Stabilize demand side pressure at minimum
acceptable level
INCREASE PRODUCTIVITY: Provide consistent repeatable tight
pressure control
ENHANCE RELIABILITY: De-couple supply side from demand
side
INCREASE RELIABILITY: Eliminate rapid cycling of
compressors

SimplAir
SimplAir is a high-performance modular aluminum piping system
that is easy to install and simple to extend or modify. The noncorrosive extruded aluminum provides structural strength and
delivers contaminate-free air in a leak-free piping system. The
smooth bore of SimplAir tubing prevents high-pressure losses and
allows for higher flow rates and performance than that of
conventional piping systems. The positive O-ring seal ensures that
no leaks occur at any stage of the system's life. No air leakage
ensures minimum running costs.