Q&A

After determining the right size for an air compressor, it's crucial to factor in the lifetime operational costs. These costs depend on various elements, including the power efficiency in generating compressed air (kW/m3), demand variability, system pressure settings, service and maintenance expenses over 10 years, and the lifespan of major components like the screw element and electric motor. Controlling the compressor at the minimum needed for plant operation is a smart energy-saving approach. Lowering the discharge pressure by 50kPa can result in approximately 4% energy savings, a significant cost reduction.

It's advisable to select a compressor slightly larger than your immediate needs. Key considerations include the volume of air required, the necessary pressure for your processes, and the intended use of the air. Titan offers assistance in sizing air compressors and ensuring the right fit with the appropriate control system and ancillaries. This can be determined either through a calculated estimate for future needs or by conducting an air audit for current requirements.

Titan is equipped with a dedicated team ready to assist customers in making informed decisions. We possess the necessary tools to conduct an impartial assessment of customer requirements, comprehend the usage of compressed air and ensure accurate equipment selection. With numerous high-profile customers across Australia, we are pleased to offer reference sites and contacts for verification of our product performance and support teams.

A stop-start air compressor operates with a pressure switch that triggers the machine to turn on and off, commonly found in reciprocating (piston) compressors. On the other hand, a constant-run compressor has a motor that runs continuously, while the compressor starts and stops to produce compressed air through a suitable control system that maintains constant motor speed even when the air demand varies. Compressors can be controlled using methods such as constant speed unloading or variable speed drive. Choosing the appropriate control system depends on your specific needs, and it's crucial to seek advice to determine the best fit for your requirements.

The expected lifespan of a screw compressor is determined by the total hours it runs. Several factors influence its longevity, including the quality of materials and components, the fundamental design, operating speed of the screw elements, operating pressure, environmental conditions, and maintenance history. With proper maintenance in line with manufacturer recommendations, it's realistic for a modern screw compressor to achieve this lifespan between bearing changes under normal operating conditions. We have found in our experience that screw compressors can generally last up to 50,000 hours work time and/or up to 10 years depending on the maintenance level completed

The maximum recommended duty cycle for a piston compressor is typically 50-60%. This calculation is derived by dividing the time the compressor is actively running by the total running time. For instance, if the compressor operates for 100 seconds and then is off for 90 seconds, the duty cycle would be 53%.

2-stage rotary screw compressors offer advantages by dividing the compression process into two stages. Unlike single-stage compressors with a high compression ratio, 2-stage compressors reduce internal losses and bearing loads. This design, along with cool oil injection between airends, enhances efficiency. Typically, 2-stage compressors are about 20% more efficient than their single-stage counterparts with equivalent flow rates, making them beneficial for various applications.

For optimal compressor efficiency, the essential equipment includes the air receiver and the air line reticulation system. The air receiver extends load/unload cycles, limiting compressor stop/starts and reducing wear. It's crucial to size the vessel appropriately, aiming for at least 10 litres for every L/sec of compressor discharge capacity. The airline reticulation system transports compressed air with minimal friction losses, preventing pressure drop. Proper sizing and installation, limiting air velocity to under 6m/sec, are key to minimising energy consumption and ensuring cost efficiency.

The recommended air tank size from Titan depends on your process air needs and the compressor's size and design. For instance, a 15kW compressor might be suitable with a 300–500 Litre receiver, while a 200kW compressor could require a 5000 Litre receiver. A general guideline is around 10 litres of storage for every L/sec of compressor discharge. The air receiver is crucial for reducing energy consumption, with larger vessels offering greater energy savings. It also limits load/unload cycles and stop/start cycles, reducing VSD pressure fluctuations. Undersizing your air receiver is not advisable for optimal performance.

Absolutely. If you possess the required skills, we're more than willing to offer guidance for the installation or address any air compressor questions you may have. A successful installation hinges on placing the equipment in a clean, dry, well-ventilated space with ample access for maintenance. The interconnecting pipework should be of suitable material and size for the flow rate and pressure, installed to allow unimpeded access, drainage, and safe servicing. Adequate facilities must be in place for collecting condensate from the compressor, air receiver, filters, and dryer for responsible disposal through trade waste. Alternatively, we can arrange installation through one of our experienced installers, ensuring a leak-free job with minimised pressure loss.

Integrating a second or third compressor into an existing system is feasible through various approaches, depending on your goals and how the air is utilised. If the objective is to have a duty/standby setup, it involves installing the additional unit and adjusting the system to operate one unit while keeping the second as a backup. Another option is a lead/lag arrangement where compressors share the load and alternate to distribute running hours. This can be efficiently managed using a centralised controller.

Yes, spare parts are readily accessible through our network of authorised distributors and service centres. We have strategically located these facilities to ensure that customers can easily obtain the necessary parts to keep their compressors running smoothly. Our commitment to providing accessible spare parts is part of our dedication to customer satisfaction and the longevity of our products.

Similar to cars, air compressors require regular servicing, which can be minor or major based on hours of operation. Regular maintenance includes tasks like changing filters, lubricants, and drive belts. Major services also involve replacing the air/oil separator filter. High-quality lubricants extend service intervals. Various service programs are available, from basic services to fully inclusive programs with fixed annual costs. We're ready to discuss the program that suits your needs.

If the compressor is still operational, keeping it as a backup for servicing or using it for some production tasks could be an option. It can serve as a valuable insurance backup. Alternatively, if it's no longer in use, trading it in may have commercial value for another company. If the unit is no longer operational, Titan can responsibly dispose of it on your behalf. This involves draining fluids, removing contaminated filters and materials, and sending the unit to metal recyclers. Disposal of fluids and filters is then handled through our registered trade waste procedures.

Yes, compressed air can be lethal or cause serious injuries. Directing compressed air onto the skin can lead to an embolism. Inhaling compressed air can rupture the lungs or oesophagus. Blowing compressed air into the ear can rupture eardrums and cause brain damage. It's crucial to avoid directing compressed air at the skin or body orifices to prevent these severe consequences.

Yes, compressed air can penetrate the skin, leading to haemorrhaging and pain. If compressed air enters the body through cuts in the skin, it can form an air bubble (embolism) in the bloodstream, which could be fatal if it reaches the heart or lungs. It is essential to always wear gloves when using compressed air to clean components or perform other tasks.

Compressed air is inherently "wet" because it always contains moisture. This moisture exists as water vapour molecules dispersed among the gas particles, primarily nitrogen and oxygen, in the ambient air. Even in seemingly dry conditions, there is a certain amount of water vapour present. For instance, ambient air at 25°C and 60% relative humidity contains approximately 15.5 grams of moisture per cubic metre.

Yes, it is essential to drain condensate from air receiver tanks regularly, preferably daily. An automatic drain is a convenient solution. In a typical single-day shift (8 hours) at an airflow rate of 1000 m³/h @ 10 Bar with a humidity of 60% @ 30°C, approximately 140 litres of condensate can be produced. Regular draining prevents the accumulation of condensate, maintaining optimal performance and preventing potential issues.

Yes, you can implement automatic draining of water from your receiver tank by installing either an electronically timed drain or a lossless drain. The timed drain opens at set intervals, regardless of condensate presence, while a lossless drain operates only when condensate is detected, avoiding unnecessary loss of air and energy waste.

To remove moisture from an air system, regularly draining air receiver tanks is crucial. Installing a water separator filter helps capture water droplets, and incorporating a refrigerated air dryer further reduces moisture content by cooling the compressed air, ensuring optimal performance and dry air for various applications.

The frequency of changing the oil in a screw compressor should align with the manufacturer's specifications, which can vary based on the type of lubricant used. Intervals may range from as low as 1500 hours to up to 6000 hours. It's important to note that in screw compressors, all the oil mixes with all the air drawn into the compressor. While particulate matter is filtered by the air inlet, aerosols and extremely fine particles get mixed with the lubricant.

The choice of lubricant in a compressor can significantly impact its performance. The two primary types are mineral-based and 100% synthetic-based lubricants. Synthetic lubricants, in particular, offer environmental benefits, as well as advantages for production environments and equipment longevity. They provide lower oil carryover, maintain consistent operating temperatures, and have a typical lifespan of up to 6000 hours between changes. Quality synthetic lubricants, specifically designed for use in screw air compressors, contribute to the longevity of bearings and internal components, making them a preferred choice for enhanced performance and durability.

To eliminate odours from compressed air, which are often caused by small aerosol particles in the air, the installation of a filter containing carbon is an effective solution. The carbon filter works to capture and remove these particles, helping to improve the quality of the compressed air and eliminate any undesirable odours.

You can determine the actual cost of an air leak by using the formula: leakage rate (m3/h) x kW/m3/h x operating hours x $/kWh. For instance, a single 1 mm diameter leak in a compressed air system operating at 6 bar has a nominal flow rate of 4.16 m3/h. If a plant operates 24/7 with a power cost of 30 cents/kW/hr, the cost of that one leak would be over $1,500.00 per annum. It highlights the significant financial impact that air leaks can have on operational costs, underscoring the importance of promptly addressing and fixing any leaks in a compressed air system.

The typical point of failure in a screw compressor pump (element) is often the bearings. In a screw compressor rotary element (pump), the bearings operate in temperatures as high as 100°C and can be affected by contaminants drawn into the compressor through the intake. Generally the element should operate at approximately 85°C. For each degree celcius above this ideal temperature, the life of the oil reduces significantly. When the oil quality is reduced so too is the lifespane of the compressor pump. Low oil temperatures can also harm the screw compressor pump due to the build of of moisture in the oil.

Specifically designed for longevity with extra bearing races to keep the screw rotors from clashing.

Oversized oil coolers to control the running temperature, which in turn keeps the oil in optimum condition for longevity.

Permanent magnet variable speed motors as standard in all Titan's to reduce the power costs by only running at the speed required to match the air demand of your system.

Cost effective air compressors designed to compete against the big brands.