2006

Technology Leader in Oil Free

Technology Leader in Oil Free
Sierra Super Duty Oil Free Compressors
Sierra Super Duty 2
Sierra Super Duty 50-200hp
Sierra Super Duty 3
Sierra Super Duty 50-200hp
Inlet Air
Multi stage heavy dust
inlet air filter
Dry type
High efficiency
3 micron @ 99.95% efficiency
standard element
Dedicated plenum assures cleanest inlet
air possible
Sierra Super Duty 4
Sierra Super Duty 50-200hp
Inlet Valve
Butterfly type valve
Full flow - load/no load
Orifice for makeup air
Load/Unload Control Cylinder
Hydraulic actuation
OL/OL control
Solid mechanical linkage
w/ blow-off valve
Sierra Super Duty 5
Sierra Super Duty 50-200hp
First Stage Airend
Oil-free rotary screw
Air cooled
Timing gears
Cast iron housing
w/UltraCoat coating
Steel rotors w/UltraCoat coating
Compression to 30 PSIG
Sierra Super Duty 6
UltraCoat
Solving the Need for Better Oil-free
Performance and Energy Savings
Ingersoll-Rands exclusive UltraCoat rotor and
housing coating process uses a mechanical
and chemical bond to insure the thinnest
coating with the tightest possible grip
UltraCoat has proven to be unmatched
in its performance
UltraCoat protects every Sierra airend and now
every Nirvana oil-free airend
UltraCoat rotor and housing coating process
uses a mechanical and chemical bond to ensure
that the microcoating interlocks with the rotor
and casting material
UltraCoat delivers longer life and 10%
energy savings
Sierra Super Duty 7
Sierra with UltraCoat
Competitive Coating
Brand Xs Coating Wear
There is a difference
Sierra Ultracoat
Non-Ultracoat design
Ultracoat has no degradation for the most air delivered per inpu Ultracoat has no degradation for the most air delivered per input power t power
Time
Sierra Super Duty 8
Superior Construction
Discharge Pulsation Dampener
Cast iron elbow
Venturi cast in elbow
Sierra Super Duty 9
Robust Piping Design
Piping
Expansion joints to coolers
Carbon steel air piping -
hot side
Stainless steel air piping -
cold side
Carbon steel oil piping
Flex hose to/from oil cooler
Gearcase breather
Sierra Super Duty 10
Intercooler
Intercooler
Air cooled
Aluminum
115 F ambient design
Sierra Super Duty 11
I/C Safety Valve
Moisture Separator
Cast aluminum
Condensate solenoid valve
Manual drain valve
Isolation valve
Check valve to drain
Moisture Separator
Sierra Super Duty 12
Second Stage Airend
Oil-free rotary screw
Timing gears
Oil in jackets (cooling)
Cast iron housing w/UltraCoat
Stainless steel rotors w/UltraCoat
Compression from 30 PSIG to
discharge PSIG (100, 125 or 150)
Second Stage
Sierra Super Duty 13
Second Stage
Discharge Venturi
Cast iron elbow
Orifice dampens
pulsations
Second Stage Venturi
Sierra Super Duty 14
Seal Vents
SPM (Shock Pulse Monitoring)
Timing gear oil splitter
Seal Vents
Sierra Super Duty 15
Discharge Check Valve
Located on the hot side
Discharge Check Valve
Sierra Super Duty 16
Aftercooler
Air cooled
Aluminum
CTD 20 F
115 F ambient design
Aftercooler
Sierra Super Duty 17
Solenoid Drain Valves
Controlled by the
Intellisys controller
Strainer screens keep
the orifice clean
Solenoid Drain Valves
Sierra Super Duty 18
Manual Drain
Valves
Ball type
.25 inch
Manual Drain Valves
Sierra Super Duty 19
Package Ventilation Fan
Motor
Totally enclosed fan cooled
(TEFC) motor standard
.25 inch static pressure
allowance
Fan Motor
Sierra Super Duty 20
Main Motor
Totally enclosed fan
cooled (TEFC) motor
standard
Class F, B Rise
115 degF ambient
rated
Main Motor
Sierra Super Duty 21
Blowdown Silencer
Muffler
Vented to atmosphere
outside of the enclosure
Silencer
Sierra Super Duty 22
Compression Module
Two stage
Rotary screw
Oil-free
Jack shaft drive
Cast iron housings
Shaft driven oil pump
Compression Module
Sierra Super Duty 23
Bearings & Seals - Each Airend
(2) 4 point ball bearings
- Thrust loads
(4) roller bearings
- Radial loads
Stainless steel ring seals
- Minimizes air leakage
Labyrinth oil seal
- Eliminates oil leaks
Timing gears
No thrust piston
Bearings and Seals
Sierra Super Duty 24
Lube Oil System
Gear type pump
Relief valve
Thermostatic control valve
Oil cooler
Oil filter
Gearcase vent
Lube Oil System
Sierra Super Duty 25
For
application in
varied
locations,
NEMA 4
Electrics are
a standard
NEMA 4 Electrics
Sierra Super Duty 26
Intellisys
TM
controls it all. Intellisys matches pressure need to
compressor operation, monitors compressor health, tells you
what maintenance is required.
Intellisys SG Controller
Sierra Super Duty 27
UltraCoat rotor
coating
NEMA 4 Electrics
115 F ambient rated
Noble materials
Maximum
performance
Time proven
airend design
Intellisys
Quiet and ambient
compensated
Hi-dust filtration
TEFC Motor
Sierra Super Duty - Summary
Sierra Super Duty 28
Coatings How Important?
Sierra Super Duty 29
Not all coatings are created equal
How does Brand Xs coating wear off?
What happens when Brand Xs coating wears off?
- Performance change (shown earlier)
- Temperature increases
How does Brand Xs airend failure occur?
Coatings Very Important!
Sierra Super Duty 30
Brand X: 2nd Stage Carbon
Steel Surface Exposure
+ Compressed air
+ High humidity
+ High temperature
= CORROSION
Coatings Corrosive atmosphere
Sierra Super Duty 31
Teflon
Brand X: Teflon Coating
Sand blasting extends
rotor surface area
Teflon (paint version)
is applied
- Paint bond created
Heat cured
R
o
t
o
r

S
u
r
f
a
c
e
Corrosion Susceptible
Sierra Super Duty 32
Corrosion Susceptible
Brand X: Teflon

Coating
Polytetrafluorethylene (PTFE)
- Durable, resists oxidation and
brittleness
Graphite component
- Reduces durability properties
Applied by hand
- Thick coverage
- Uneven coverage
Paint bond is susceptible to
peeling
Sierra Super Duty 33
Brand X: The Coating
2nd stage-
Carbon steel rotors
PTFE coating
- Applied by hand
- Thick & uneven coverage
Paint bond
- Susceptible to peeling
Corrosion Susceptible
Sierra Super Duty 34
Foreign particles
erode
it away
Why Does Brand X Lose Their Coating?
How is the surface lost?
Sierra Super Duty 35
How Does Brand Xs Airend Fail
Lost coating in moisture rich
oxygen laden environment =
rust.
High interstage temperature
- Diminished capacity
- Increased horsepower
Creates high temperature
& accelerates failure
Effects of Corrosion
Sierra Super Duty 36
Compressor operating
temperature approaches
coating design limit
Carbon steel rotor corrosion
2
nd
stage airend element can
actually seize.
Why Does Brand X Lose Their Coating?
Ultimate result of corrosion
Sierra Super Duty 37
UltraCoat- The Process
Surface area preparation
- Carbon steel
- Cast iron
- Stainless steel
Coating applied by robot
Heat cured in oven
Ultracoat Corrosion Inhibitor
Sierra Super Duty 38
Step 1- Surface Preparation
Surface area preparation
- Phosphatized for carbon steel
& cast iron
- Sandblasting for stainless steel
Creates Ultra large surface area
- Crevasses for bonding
Ultracoat -
Corrosion Inhibitor
Sierra Super Duty 39
Step 2- Coating
Organic high temperature resin
Imbedded PTFE and MoS
2
particles
Resin mechanically bonds
with crevasses
Rotor
Surface
Coating
Ultracoat -
Corrosion Inhibitor
Sierra Super Duty 40
UltraCoat Coating
Organic high temperature resin with
imbedded
PTFE and MoS
2
particles
Durable- resists oxidation and brittleness
Applied thin
Mechanical bond = Ultra strength
- UltraCoat must be physically torn off to be
removed
Ultracoat -
Corrosion Inhibitor
Sierra Super Duty 41
Coating Conclusions
UltraCoat is superior because of
Material composition
Metal preparation
- Ultra surface area
Mechanical bonding
Thinner coating
- Yields greatest bonding strength
Ultracoat -
Corrosion Inhibitor
Sierra Super Duty 42
UltraCoat rotor
coating
NEMA 4 Electrics
115 F ambient rated
Noble materials
Maximum
performance
Time proven
airend design
Intellisys
Quiet and ambient
compensated
Hi-dust filtration
TEFC Motor
Sierra Super Duty - Summary