01 Compressed Air Fundamentals

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
Company Confidential
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.
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.
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
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
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
Compressor Basics
There are two basic ways to push air molecules:

- Reciprocating Movement
- Piston and Cylinder
- Rotary Movement
- Fan Blades
- Screws
- Centrifugal Rotors
Compressor Basics
ADMISSION
COMPRESSION
DISCHARGE
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
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!
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.
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

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
Compressor Basics
Compressor Power
Engine Power Rating

Power (BHP)
Airflow (CFM)
X Y Z
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 !
Compressed Air
• If we move the balloon to a higher altitude, the size of the balloon will increase,
why?
Effect of Altitude
Sea level High altitude

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

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.
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
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
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
Effect of Moisture in the Air
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)

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
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
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
• Compressor Basics
Portable Products
• Product Nomenclature
- Compressors
- Light Towers
- Air Dryers and Accessories
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]
Portable Air Compressors
Model Designations: CFM

Model Designations: Packaging

W = Whisperized (Meets US EPA Noise Code)
S = Non-Whisperized
Portable Air Compressors
Model Designations: Engine

VHP400WCU / XHP900SCA
CA = Caterpillar
CU = Cummins
IR = Ingersoll-Rand
JD = John Deere
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
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
• Compressor Basics
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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CONFIDENTIAL

Doosan Infracore - Portable Power

• Compressed Air Basics

• Air is made up of molecules moving

• Molecules inside the balloon hit in all directions, at

• Let’s look at the molecule in the

• If we apply heat without moving

The compression of gases follows the laws of

V= Volume, P= Pressure, T= Temperature

There are two basic ways to push air molecules:

• The compressor airend is a fixed displacement pump which

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

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

185 ICFM = 23.7 ACFM @ 100 PSIG

Engine Power Rating

• Engines are rated to produce a certain amount of horsepower

Sea level High altitude

SCFM x FACTOR = ACFM at altitude and temperature

Engine Air End

LINE PRESSURE (PSIG)

1” 50’ 120 2.7 2.1

• All ambient air contains moisture.

Result: More moisture per volume of

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

• Dirt Atmospheric dirt, pipeline dirt, rust, scale

• Oil Oil Aerosol & Oil Vapor

• Water Water Aerosol & Water Vapor

Coalescing Filter Particulate Filters

203 ACFM 203 ACFM 203 ACFM

• I-R Model Designations

• Terms You Need to Know

• Product and Operator Safety

Portable Air Compressors

Model Designations: CFM

P185WIR / XP750WJD / HP915WCU /

Model Designations: Packaging

Portable Air Compressors

Model Designations: Engine

Portable Light Towers

Air Dryers & Accessory Equipment

• I-R Model Designations

• Terms You Need to Know

• Product and Operator Safety

LAT gph B10 Atmosphere

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