CONFIDENTIAL

Doosan Infracore - Portable Power

Compressed Air Fundamentals
Compressor Fundamentals and Safety

• Compressed Air Basics

• I-R Model Designations
• Terms You Need to Know
• Product and Operator Safety

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 Compressed Air

• Air is made up of molecules moving

continuously in random patterns.
• If molecules are placed in a balloon, they
will continuously hit its walls.
• The added effect of all the molecules
hitting against the wall of the balloon is
called pressure.

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Compressed Air

• Molecules inside the balloon hit in all directions, at

speeds so high that we can’t notice any change in size
• Outside the balloon there are also molecules hitting the
outside wall
• The balloon grows as more molecules are placed into
the balloon, making the number of inside hits, larger
than the outside.

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Compressed Air

• Let’s look at the molecule in the

left container……...
• ……..now let’s move the piston
down….
• ……the molecule now hits the
piston more times…...
• THE PRESSURE HAS
INCREASED

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Compressed Air

• If we apply heat without moving

the piston…...…
• …..the speed of the molecules
increases…..
• ….thus increasing the number
of hits against the walls…….
• THE PRESSURE HAS
INCREASED

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 Compressed Air

The compression of gases follows the laws of

physics:

V1 x P1 = V2 x P2
T1 T2

V= Volume, P= Pressure, T= Temperature

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Compressor Basics

There are two basic ways to push air molecules:

- Reciprocating Movement
- Piston and Cylinder

- Rotary Movement
- Fan Blades
- Screws
- Centrifugal Rotors

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Compressor Basics

ADMISSION

COMPRESSION

DISCHARGE

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Compressor Basics

• The compressor airend is a fixed displacement pump which

uses a pair of helical rotors to compress the air.
• As the rotors turn faster more air is sucked into the airend.
• The amount of air that is sucked into the airend is measured
in cubic feet per minute. This is the compressor input rating -
- CFM

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Compressor Basics

• As the air travels through the airend it is compressed between

the rotors. This increases the pressure (PSIG) of the air.
• The air exits the airend when the rated pressure is achieved;
e.g., 100, 125, 150 psig. This is the compressor output rating --
PSIG!

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Compressed Air

• When air molecules move in a particular direction, we can measure the volume of
air (Cubic Feet) that carries these molecules.
• If measure is taken during one minute, we can then express the velocity of this
volume in Cubic Feet per Minute.

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Compressor Basics

• The work required to compress a given amount of air (cubic foot) in a

specific amount of time (minute) to a specified pressure (psig) is measured
in horsepower.

One
Cubic 1.0 Cu. Ft. =
Foot 0.128 Cu.Ft.
@ 100 psig
(7:1 ratio)

185 ICFM = 23.7 ACFM @ 100 PSIG

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Compressor Basics

• For a given amount of horsepower you can attain many different compressor ratings.
- For example, with a 100 bhp engine the following are a few of the possible
airflow/pressure (cfm/psig) combinations:
400/80
375/100
325/125
300/150

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Compressor Basics

Compressor Power

Engine Power Rating

Power (BHP)

Airflow (CFM)
X Y Z
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Compressor Basics

• Engines are rated to produce a certain amount of horsepower

at a specific speed (rpm). As you reduce the speed you
(generally) reduce the horsepower output of the engine. Since
rotor speed is dependent on engine speed…...
…air flow relates to engine speed !

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Compressed Air

• If we move the balloon to a higher altitude, the size of the balloon will increase,
why?

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Effect of Altitude

Sea level High altitude

(more molecules per cubic foot) (less molecules per cubic foot)

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Effect of Altitude and Temperature

ALT. FTS 0 1000 2000 3000 4000 5000 6000 7000 8000 12000 15000

TEMP MTS 0 304.8 609.6 914.4 1219.2 1524 1828.8 2133.6 2438.4 3657.6 4572
0 0
F C

-40 -40 0.805 0.835 0.866 0.898 0.932 0.963 1.004 1.043 1.084 1.266 1.426

-20 -28.9 0.843 0.875 0.907 0.941 0.976 1.009 1.052 1.093 1.136 1.326 1.494

0 -17.8 0.882 0.915 0.949 0.984 1.021 1.055 1.100 1.142 1.187 1.387 1.562

20 -6.7 0.920 0.954 0.990 1.026 1.065 1.101 1.148 1.192 1.239 1.447 1.630

40 4.4 0.958 0.994 1.031 1.069 1.110 1.147 1.196 1.242 1.291 1.507 1.698

60 15.6 0.997 1.034 1.072 1.112 1.154 1.193 1.243 1.292 1.342 1.568 1.766

80 26.7 1.035 1.074 1.114 1.155 1.199 1.239 1.291 1.341 1.394 1.628 1.834

100 37.8 1.074 1.114 1.155 1.198 1.243 1.284 1.339 1.391 1.446 1.689 1.902

120 48.9 1.112 1.154 1.196 1.241 1.288 1.330 1.387 1.441 1.498 1.749 1.970

SCFM x FACTOR = ACFM at altitude and temperature

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Compressor Basics

• Because there are less air molecules per CFM at higher altitude,
horsepower required by the air end decreases with altitude.
• When engines run at high altitude, there are less air molecules available
for the combustion so it is less efficient. Total engine horsepower output
decreases.
• The altitude rating of a compressor is at the point where engine HP
output and airend HP requirement are the same.

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Compressor Basics - Altitude Rating

120
100 Engine HP output

80
Power

60
40
Airend HP demand
20
0
1000 2000 3000 4000 5000 6000 7000
Altitude

Engine Air End

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Pressure Loss

LINE PRESSURE (PSIG)

DIA LGT CFM 60 80 100 120 150 200 300
¾” 50’ 120 9.0 7.4 6.3 5.1 3.9 2.7
140 12.0 9.9 8.4 6.9 5.3 3.6
160 12.7 10.8 8.9 6.8 4.6
180 13.6 11.1 8.5 5.8
200 16.6 13.5 10.4 7.1
220 16.2 12.4 8.4

1” 50’ 120 2.7 2.1

150 4.1 3.2 2.7 2.3
180 5.8 4.6 3.8 3.2 2.6 2.0 1.4
210 7.7 6.1 4.0 4.3 3.5 2.7 1.8
240 7.9 6.5 5.5 4.5 3.5 2.4

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Effect of Moisture in the Air

• All ambient air contains moisture.

• Moisture concentration is low at
compressor intake.
• Moisture concentration is high at
compressor outlet.
• Volume of air is reduced by
compression, but the amount of
moisture remains the same.

Result: More moisture per volume of

compressed air at the compressor outlet
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Effect of Moisture in the Air

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Air Compressor

1600 ICFM
70° F
0 PSIG
Ambient Air
14.5 PSIA
60% RH
8.29 GPH
Air 203 ACFM
Reference Compressor
Moisture in the 190° F
Air Tables. 100 PSIG
114.5 PSIA
100 % RH
8.29 GPH

(These figures are based on 1600 cfm at 100 psig)

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Aftercooler

Water
Separator
Ambient air
temp = 70° F
203 ACFM
84° F
Cooler 203 ACFM 92 PSIG
203 ACFM 85° F 3.9 GPH
190° F 95 PSIG
100 PSIG 8.3 GPH
114.5 PSIA
8.3 GPH
4.4 GPH
• Condenses and removes moisture
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Compressor Basics

Contamination

• Dirt Atmospheric dirt, pipeline dirt, rust, scale

• Oil Oil Aerosol & Oil Vapor

• Water Water Aerosol & Water Vapor

- Compounding the water problem: heat of compression for oil-
flooded, screw compressor is 180 - 200ºF; dry screw is 350 - 390ºF

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Filters - Condition Air

Coalescing Filter Particulate Filters

203 ACFM 203 ACFM 203 ACFM

84° F 83° F 82° F
92 PSIG 89 PSIG 86 PSIG
3.9 GPH 3.5 GPH 3.3 GPH

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Compressor Fundamentals and Safety

• Compressor Basics

• I-R Model Designations

• Terms You Need to Know

• Product and Operator Safety

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Portable Products

• Product Nomenclature
- Compressors
- Light Towers
- Air Dryers and Accessories

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Product Nomenclature
Model Designations: Pressure
P185WIR / XP750WJD / HP915WCU /
VHP400WCU / XHP900SCAT
P = 100 - 124 PSIG [100]
XP = 125 - 149 PSIG [125]
HP = 150 - 174 PSIG [150]
MHP=175 - 199 PSIG
VHP = 200 - 249 PSIG [200]
XHP = 250 + PSIG [300 / 350]

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Product Nomenclature

Portable Air Compressors

Model Designations: CFM

P185WIR / XP750WJD / HP915WCU /

VHP400WCU / XHP900SCAT

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Product Nomenclature

Model Designations: Packaging

P185WIR / XP750WJD / HP915WCU /
VHP400WCU / XHP900SCAT
W = Whisperized (Meets US EPA Noise Code)
S = Non-Whisperized

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Product Nomenclature

Portable Air Compressors

Model Designations: Engine

P185WIR / XP750WJD / HP915WCU /
VHP400WCU / XHP900SCA
CA = Caterpillar
CU = Cummins
IR = Ingersoll-Rand
JD = John Deere

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Product Nomenclature

Portable Light Towers

Model Designations:
L6-4TH / L8-6HPS
L = Light Tower
6 / 8 = Generator Capacity (kW)
4 / 6 = Number of Lamps
HPS = High Pressure Sodium
MH = Metal Halide
TH = Tungsten Halogen

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Product Nomenclature

Air Dryers & Accessory Equipment

Model Designations:
A-165 / AD-85 / AF-1600 / RD1000
A = Air Aftercooler
R = Regenerative
D = Air Dryer
F = Air Filter
85 / 165 / 1600 = Capacity

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Compressor Fundamentals and Safety

• Compressor Basics

• I-R Model Designations

• Terms You Need to Know

• Product and Operator Safety

Company Confidential
 Terms You Need to Know

LAT gph B10 Atmosphere

3 phase PSI Lumen DF2
Unload LRG ACFM micron
µ CFM Foot Candle Dew Point
Minimum Skid Approach psig
Pressure
Sub-base SCFM Cool Box PSIA CO

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