Atlas Copco Engineered Elements

HIGH VALUE AT THE CORE

Oysters may look similar on the outside, but only some

contain a unique and valuable pearl.
At the heart of your compressor, only an Atlas Copco
Engineered Element will offer unrivalled air quality,
reliability and all-round performance.

Superior In Every Detail

At Atlas Copco, we have unrivalled
insight in compression technology, built
up over many decades and driven by
continuous innovation. Resulting from
this unique expertise, an Engineered
Element gives you a best-in-class
compressor element designed for
ultimate energy efficiency and air quality.
Incorporating our latest developments, it
not only restores your compressor’s
original performance, it may actually
enhance it.
 Atlas Copco Engineered Oil Free Elements closely follow the standard design…

We ensure that the key factors in assembling our elements are a mirror of the standard construction and custom-
made improvement to ensure performance stability and longevity in use.

“Don’t waste energy; here is an explanation of why you should check your LP HP elements
performance regularly”

When to exchange a ZR/ZT element ?

Our strategy is to maintain a long-term relationship with our customers and to this end, we will only
exchange Z elements when one of, or a combination of, the following occur.

1. SPM bearing measurements– approaches or exceeds the maximum dBm during load.
2. Intercooler pressure – exceeds the maximum permissible recommendations.
3. Element outlet temperature too high – running in alarm or approaching shutdown.
4. Other technical reasons – e.g. air leaks from seals to atmosphere or causing internal crankcase pressure

We do not exchange based on running time (years or hours) but on the criteria stated above.
This document is property of Atlas Copco and shall not without our permission be altered, copied,

Oil Free Element performance fall off

used for manufacturing or communicated to any other person or company.

Note
GREEN LINE Standard wear for elements running in reference conditions
RED LINE Frequent start stops, high humidity, high temperature, poor environment
CONFIDENTIAL:

HP and LP air seal loss typical of this type of design

Standard Atlas Copco Coating Teflon S

In certain environments, the performance of the standard and

engineered element will suffer in relation to coating wear on
the air seal / oil seal area of the male and female rotor. This can
result in wasted energy over the lifetime of the compressor.
The standard and engineered design of air and oil seals are
different as will be shown here … (Note Solid Oil Seal Design STD)

Leaking air seals becomes progressively worse over time wasting your energy…

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Issue Date: 2020.04.15 Page 2 of 6 Swallowdale Lane, Hemel Hempstead HP2 7EA
 Monitoring the air seal leakage and power input V compressed air output can enable you to make the
best-informed decision when to exchange an oil free element.

Standard Products
ƒ Oil free elements longevity is influenced by extreme operation characteristics (frequent start
stop/ high temp / humidity/ salty environment for example)
ƒ The greatest longevity is maintained when the operation conditions are stable and moderate
humidity and temperatures.

Standard Shaft Seals Engineered Shaft Seals

This document is property of Atlas Copco and shall not without our permission be altered, copied,
used for manufacturing or communicated to any other person or company.

Element losses that can occur over time 40,000 to 80,000 hours *

Item Possible losses

Timing Slip >5%
Rotor Coating Wear >5%
Head Clearance Wear >5%
Inter Rotor Clearance >5%
Seal Leakage >10%

*Dependent on running conditions

Calculation of the possible maximum cost to an end-user when wear is occurring on the air seals,
CONFIDENTIAL:

coating dedication, and timing slip allows us to create the following table based on; 8000hrs/annum, 2 x
worn elements, 0.05€/kW.

ZR / KW L/S Possible Total Losses Cost €/Annum

145 394 30% 17,400
250 726 30% 30,000
450 1257 30% 54,000
750 2075 30% 90,000

‘Driving down the cost of oil free air ‘

Document No.: 9845016501-01 Rev: 1 Atlas Copco’s Systems Hemel Hempstead

Issue Date: 2020.04.15 Page 3 of 6 Swallowdale Lane, Hemel Hempstead HP2 7EA
 Elements Performance Chart

Standard Elements Engineered Elements

Compressor Type Free Air Delivery Free Air Delivery Intercooler Pressure Electricity Current
ZR3 / ZR110 – 8 16.6 m³/min 16.6-17.2 m³/min 1.9-2.4 Bar 185-215 Amps
ZR3 / ZR132 – 8 19.5 m³/min 19.5-20.1 m³/min
ZR3 / ZR160 – 8 22.4 m³/min 22.4-22.8 m³/min
ZR4 / ZR160 – 8 25.1 m³/min 25.1-25.3 m³/min
ZR4 / ZR200 – 8 30.7 m³/min 30.7-32 m³/min 1.9-2.4 Bar 300-365 Amps
ZR4 / ZR250 – 8 38.7 m³/min 38.7-39.5 m³/min
ZR5 / ZR315 – 8 46.4 m³/min 46.4-47.2 m³/min
ZR6 / ZR315 – 8 50.3 m³/min 50.3-51.8 m³/min
ZR6 / ZR400 – 8 61.3 m³/min 61.3-62.5 m³/min 1.9-2.4 Bar 650-720 Amps

The rotor length and diameter are increased on the engineered elements resulting in increased output
aligned with a slight increase in running amps

Special Coating Process

The rotor coating of the engineered elements can perform at 230°C constant running temperatures
This document is property of Atlas Copco and shall not without our permission be altered, copied,

using a more sophisticated coating material than standard elements.

9 Surface Area Preparation by Phosphatized process

9 Heat cured in oven Creates “Ultra” Large Surface Area
used for manufacturing or communicated to any other person or company.

9 Crevasses for bonding

9 Coating by Organic High Temperature Resin
9 Imbedded PTFE and MoS2 Particles
9 Resin Mechanically Bonds with Crevasses
9 Coating applied by hand

Our Philippian client Ingerand Inc. had to change its standard elements before 20,000 hours year on year!
The cause? High salt and humidity being close to the sea stripped the standard coating prematurely
from the rotors and seals causing air / oil leakage and inefficient running…
Working with our coating provider we found a more resilient solution to this problem and extended the
life of the Z compressor LP and HP elements to over 40,000 hours…

Special Oil Seals

CONFIDENTIAL:

Our oil seal design is an improvement over traditional solid oil

seals design allowing a floating oil seal on the rotor shaft coating
surface.
We have designed an oil seal that provides freedom of
movement of the reverse scroll oil seal design. Being able to
move on the coated surface of the element drive shafts a longer
seal lifetime and less leakage of oil has been proven on our test
elements since 2009.

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Issue Date: 2020.04.15 Page 4 of 6 Swallowdale Lane, Hemel Hempstead HP2 7EA
 A WORLD-CLASS CUSTOM ENGINEERING WORKSHOP

The workshop at Systems Hemel Hempstead, one of Atlas Copco’s six global competence centres that
design and assemble bespoke compressed air and nitrogen generation packages primarily for the oil and gas
industry.
Our world-leading custom built compressors combine custom engineering and industry-leading knowledge to
deliver excellence every time.
The majority of Systems Hemel Hempstead’s end products are modular ‘plug and play’ packaged solutions,
custom built and shipped with all components, such as screw modules, compressors, dryers, filters, air
receivers, nitrogen generators, instrumentation and control systems, on a single base frame for integration
with land-based or offshore process installations.
This document is property of Atlas Copco and shall not without our permission be altered, copied,
used for manufacturing or communicated to any other person or company.

PRE-ENGINEERED SOLUTIONS FOR ALL YOUR NEEDS

In order to provide customers with a more flexible offering for requirements outside the standard product
configuration, pre-engineered solutions are defined.
Atlas Copco recognizes the need to combine the advantage of serial produced compressors with the typical
requirements of the applications for this kind of equipment.
The specifications for oil free compressors frequently require outdoor installation, operation in remote
locations, often exposed to heavy duty conditions.
Atlas Copco is offering pre-engineered kits to simplify the sales process.
The special requests from original equipment manufacturers (OEM’s) for detailed documentation and material
certificates are provided through a simplified order routine.
Deviations on the standard motor selection (request for different brand, oversized motor or motor options)
CONFIDENTIAL:

and tests witnessed by the customer are other services which are supported through the competent
organization behind pre-engineered solutions.

Skid Packaging Compressor House / Modules Complete Compression Systems

Oil-free & Oil-injected Compressors Containerized Packages Sizing and optimization of

Dryers/Nitrogen Generators
Centrifugal Compressors
Vacuum Solutions
Duplex, Plug&Play, Transportable,
Structural skids
Engineered Modules compressors, gas treatment and
Instrument / Plant Air accessories
Modification of any compressor Systems control
Compression system integration in Systems testing
standard shipping containers Complete project management

Document No.: 9845016501-01 Rev: 1 Atlas Copco’s Systems Hemel Hempstead

Issue Date: 2020.04.15 Page 5 of 6 Swallowdale Lane, Hemel Hempstead HP2 7EA
State of the art facilities at

Atlas Copco’s Systems Hemel Hempstead

9845016501-01 Rev: 1 - April 2020 © Atlas Copco ’s Systems Hemel Hempstead- Subject to alteration without prior notice.
COMMITTED TO SUSTAINABLE PRODUCTIVITY
We stand by our responsibilities towards our customers, towards the
environment and the people around us. We make performance stand the test
of time. This is what we call – Sustainable Productivity.

www.atlascopco.com