Types of Air Compressors

Reciprocating, rotary screw and rotary centrifugal air compressors

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The three basic types of air compressors are
reciprocating
rotary screw
rotary centrifugal
These types are further specified by:
the number of compression stages
cooling method (air, water, oil)
drive method (motor, engine, steam, other)
lubrication (oil, Oil-Free where Oil Free means no lubricating oil contacts the compressed air)
packaged or custom-built
Reciprocating Air Compressors
Reciprocating air compressors are positive displacement machines, meaning that they increase the
pressure of the air by reducing its volume. This means they are taking in successive volumes of air
which is confined within a closed space and elevating this air to a higher pressure. The reciprocating
air compressor accomplishes this by a piston within a cylinder as the compressing and displacing
element.
Single-stage and two-stage reciprocating compressors are commercially available.
Single-stage compressors are generally used for pressures in the range of 70 psig to 100
psig.
Two-stage compressors are generally used for higher pressures in the range of 100 psig to
250 psig.
Note that
1 HP ~ 4 CFM at 100 psi
and that 1 to 50 HP are typically for reciprocating units. Compressors 100 hp and above are typically
Rotary Screw or Centrifugal Compressors.
The reciprocating air compressor is single acting when the compressing is accomplished using only
one side of the piston. A compressor using both sides of the piston is considered double acting.
Load reduction is achieved by unloading individual cylinders. Typically this is accomplished by
throttling the suction pressure to the cylinder or bypassing air either within or outside the
compressor. Capacity control is achieved by varying speed in engine-driven units through fuel flow
control.
Reciprocating air compressors are available either as air-cooled or water-cooled in lubricated and
non-lubricated configurations and provide a wide range of pressure and capacity selections.
Rotary Screw Compressors
Rotary air compressors are positive displacement compressors. The most common rotary air
compressor is the single stage helical or spiral lobe oil flooded screw air compressor. These
compressors consist of two rotors within a casing where the rotors compress the air internally. There
are no valves. These units are basically oil cooled (with air cooled or water cooled oil coolers) where
the oil seals the internal clearances.
Since the cooling takes place right inside the compressor, the working parts never experience
extreme operating temperatures. The rotary compressor, therefore, is a continuous duty, air cooled
or water cooled compressor package.
Rotary screw air compressors are easy to maintain and operate. Capacity control for these
compressors is accomplished by variable speed and variable compressor displacement. For the
latter control technique, a slide valve is positioned in the casing. As the compressor capacity is
reduced, the slide valve opens, bypassing a portion of the compressed air back to the suction.
Advantages of the rotary screw compressor include smooth, pulse-free air output
in a compact size with high output volume over a long life.
The oil free rotary screw air compressor utilizes specially designed air ends to compress air without
oil in the compression chamber yielding true oil free air. Oil free rotary screw air compressors are
available air cooled and water cooled and provide the same flexibility as oil flooded rotaries when oil
free air is required.
Centrifugal Compressors
The centrifugal air compressor is a dynamic compressor which depends on transfer of energy from
a rotating impeller to the air.
Centrifugal compressors produce high-pressure discharge by converting angular momentum
imparted by the rotating impeller (dynamic displacement). In order to do this efficiently, centrifugal
compressors rotate at higher speeds than the other types of compressors. These types of
compressors are also designed for higher capacity because flow through the compressor is
continuous.
Adjusting the inlet guide vanes is the most common method to control capacity of a centrifugal
compressor. By closing the guide vanes, volumetric flows and capacity are reduced.
The centrifugal air compressor is an oil free compressor by design. The oil lubricated running gear is
separated from the air by shaft seals and atmospheric vents.






ROTARY SCREW AIR COMPRESSOR TROUBLESHOOTING AND
REPAIR
You are now at the rotary screw air compressor section of the largest online troubleshooting and
repair guide for air compressors. This section deals with problems with stationary rotary screw air
compressors.
The other sections are reciprocating air compressor troubleshooting and portable air compressor
troubleshooting.
Over the years, I have repaired and did troubleshooting on hundreds of rotary screw air
compressors.
Here is a list of the most frequently asked questions and problems.
Common rotary screw air compressor problems
Compressor will not start
You
press
the start button but nothing happens. Either an electrical problem, or the compressor has
tripped on a safety device.
Check supply power. Check for errors on display. Check emergency stop is out. Check and reset
the overload relay. If it's a new installation, check the phase sequence.
Compressor shuts down on high-temperature
If your compressor trips on over temeprature, it could be any of the following:
Ambient temperature too high or not enough ventilation.
Too low oil level
Wrong type of oil
Dirty oil cooler
Thermostatic valve not not working
Dirt / obstruction in oil lines
Compressor runs but will not load
A screw compressor can run loaded ('pumping air') or unloaded ('idle'). The inlet/loading valve
opens and closes according to air demand. The inlet valve is controlled by a solenoid valve that
supplies control air to the inlet/loading valve.
Check electrical power to solenoid valve
Check solenoid valve coil and solenoid valve operation.
Check working of inlet/loading valve
Low capacity / not enough pressure
First, check that there isn't a very high air demand, or air leak somewhere.
If the capacity of the air compressor is really too low, check the following:
Does the inlet valve fully open
Check differential pressure over oil separator. Replace separator when necessary.
Check if inlet filter is clean
Check and replace compressed air filters (if installed).
Safety valve blows / too high pressure
Compressor does not unload. Check if pressure switch is correctly set and working. Check inlet
valve and loading solenoid for good operation.
If the safety valve is located before the oil separator, check differential pressure of oil separator.
Oil in compressed air
Oil in compressed air can have various causes:
Oil separator old / saturated
Scavenge line plugged
Too high running temperature
Too high oil level
Wrong type of oil used
Minimum pressure valve not working
Water in compressed air
Water is a natural by product of air compression. There will always be water in compressed air,
unless we remove it.
Check the condensate trap for good operation. There should be water coming out every few
minutes. If you open up the manual drain, there should only a little water be coming out.
If you have a compressed air dryer, check the dewpoint.
Compressor overload relay trips
Check the current draw with a current clamp meter.
If the motor draws exeessive current:
Try to turn the compressor by hand. It should be possible to turn it around. It should turn
around smoothly, without any 'hickups' (be sure to completely shut down the air
compressor!).
Check the isolation of the motor windings. Should be in the mage-ohms (you need an
isolation tester / high voltage ohm meter for this).
Check the voltage when the compressor is running. If the voltage drop significantly when the
compressor starts/runs, you have a bad connection somewhere. Check all relays, fuses and
electrical connections.
Check if all phases are present
If the motor draws it's normal current, but still trips on overload, replace the overload relay with anew
one (they are known to sometimes become too sensitive when they get old)
Troubleshoot Your Rotary Screw Compressor Today!

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Rotary screw compressor
From Wikipedia, the free encyclopedia


Rotary screw air compressor internal view


Rotary screw air compressor in a housing for sound attenuation
A rotary screw compressor is a type of gas compressor which uses a rotary type positive
displacement mechanism. They are commonly used to replace piston compressors where large
volumes of high pressure air are needed, either for large industrial applications or to operate high-
power air tools such as jackhammers.
The gas compression process of a rotary screw is a continuous sweeping motion, so there is very
little pulsation or surging of flow, as occurs with piston compressors.
Contents
[hide]
1 Operation
2 Size
3 Applications
o 3.1 Oil-free
o 3.2 Oil-flooded
4 Control schemes
o 4.1 Start/stop
o 4.2 Load/unload
o 4.3 Modulation
o 4.4 Variable displacement
o 4.5 Variable speed
5 Superchargers
o 5.1 Comparative advantages
o 5.2 Related terms
6 See also
7 References
Operation[edit]
Rotary screw compressors use two meshing helical screws, known as rotors, to compress the gas.
In a dry running rotary screw compressor, timing gears ensure that the male and female rotors
maintain precise alignment. In an oil-flooded rotary screw compressor, lubricating oil bridges the
space between the rotors, both providing a hydraulic seal and transferring mechanical energy
between the driving and driven rotor. Gas enters at the suction side and moves through the threads
as the screws rotate. The meshing rotors force the gas through the compressor, and the gas exits at
the end of the screws.
[1][2]

The effectiveness of this mechanism is dependent on precisely fitting clearances between the helical
rotors, and between the rotors and the chamber for sealing of the compression cavities.
Size[edit]
Rotary screw compressors tend to be compact and smooth running with limited vibration and thus do
not require spring suspension. Many rotary screw compressors are, however, mounted using
elastomer vibration isolating mounts to absorb high-frequency vibrations, especially in rotary screw
compressors that operate at high rotational speeds. Rotary screw compressors are produced in
sizes that range from 10 cubic feet per minute to several thousand CFM. Rotary screw compressors
are typically used in applications requiring more airflow than is produced by small reciprocating
compressors but less than is produced by centrifugal compressors.
Applications[edit]
Typically, they are used to supply compressed air for general industrial applications. Trailer mounted
diesel powered units are often seen at construction sites, and are used to power air operated
construction machinery.
Additionally, they are becoming increasingly popular in municipal wastewater treatment facilities, for
their increased efficiency and thus, lower power consumption.
[citation needed]

Oil-free[edit]
In an oil-free compressor, the air is compressed entirely through the action of the screws, without the
assistance of an oil seal. They usually have lower maximum discharge pressure capability as a
result. However, multi-stage oil-free compressors, where the air is compressed by several sets of
screws, can achieve pressures of over 150 psig, and output volume of over 2000 cubic feet (56.634
cubic meters) per minute (measured at 60 C and atmospheric pressure).
Oil-free compressors are used in applications where entrained oil carry-over is not acceptable, such
as medical research and semiconductor manufacturing. However, this does not preclude the need
for filtration as hydrocarbons and other contaminants ingested from the ambient air must also be
removed prior to the point-of-use. Subsequently, air treatment identical to that used for an oil-flooded
screw compressor is frequently still required to ensure a given quality of compressed air.
Oil-flooded[edit]


Diagram of a rotary screw compressor
In an oil-flooded rotary screw compressor, oil is injected into the compression cavities to aid sealing
and provide cooling sink for the gas charge. The oil is separated from the discharge stream, then
cooled, filtered and recycled. The oil captures non-polar particulates from the incoming air,
effectively reducing the particle loading of compressed air particulate filtration. It is usual for some
entrained compressor oil to carry over into the compressed gas stream downstream of the
compressor. In many applications, this is rectified by coalescer/filter vessels.
[3]
In other applications,
this is rectified by the use of receiver tanks that reduce the local velocity of compressed air, allowing
oil to condense and drop out of the air stream to be removed from the compressed air system via
condensate management equipment.
Control schemes[edit]
Among rotary screw compressors, there are multiple control schemes, each with differing
advantages and disadvantages.
Start/stop[edit]
In a start/stop control scheme, compressor controls actuate relays to apply and remove power to the
motor according to compressed air needs.
Load/unload[edit]
In a load/unload control scheme, the compressor remains continuously powered. However, when the
demand for compressed air is satisfied, instead of disconnecting power to the compressor, the inlet
valve is closed, unloading the compressor. This reduces the number of start/stop cycles for electric
motors over a start/stop control scheme in electrically-driven compressors, improving equipment
service life with a minimal change in operating cost. This scheme is utilised by nearly all industrial air
compressor manufacturers. When a load/unload control scheme is combined with a timer to stop the
compressor after a predetermined period of continuously unloaded operation, it is known as a dual-
control or auto-dual scheme.
[4]

Modulation[edit]
Instead of starting and stopping the compressor or actuating the inlet valve between two distinct
positions, a modulation control scheme proportionally adjusts the inlet valve open and closed,
altering the compressor discharge according to demand. While this yields a consistent discharge
pressure over a wide range of demand, power consumption is significantly higher than with a
load/unload scheme, resulting in approximately 70% of full-load power consumption when the
compressor is at a zero-load condition. This control scheme was popularized in industrial air
compressor applications by KOBELCO, Kaeser and Gardner Denver.
[5]

Due to the limited adjustment in compressor power consumption relative to compressed air output
capacity, modulation is a generally inefficient method of control when compared to variable speed
drives. However, for applications where it is not readily possible to frequently cease and resume
operation of the compressor (such as when a compressor is driven by an internal combustion engine
and operated without the presence of a compressed air receiver), modulation is suitable.
Variable displacement[edit]
Utilized by compressor companies Quincy Compressor, Kobelco, Gardner Denver, and Sullair,
variable displacement alters the percentage of the screw compressor rotors working to compress air
by allowing air flow to bypass portions of the screws. While this does reduce power consumption
when compared to a modulation control scheme, a load/no load system can be more effective when
large amounts of storage (10 gallons per CFM). If a large amount of storage is not practical, a
variable displacement system can be very effective, especially at greater than 70% of full load.
[6]

One way that variable displacement may be accomplished is via the use of multiple lifting valves on
the suction side of the compressor, each plumbed to a corresponding location on the discharge. In
automotive superchargers, this is analogous to the operation of a bypass valve.
Variable speed[edit]
While an air compressor powered by a variable speed drive can offer the lowest operating energy
cost without any appreciable reduction in service life over a properly maintained load/unload
compressor, the variable frequency power inverter of a variable speed drive typically adds significant
cost to the design of such a compressor, negating its economic benefits if there are limited variations
in demand. However, a variable speed drive provides for a linear relationship between compressor
power consumption and free air delivery. In harsh environments (hot, humid or dusty), variable
speed drives may not be suitable due to the sensitivity of the equipment.
[7]

Superchargers[edit]


Lysholm screws. Note the complex shape of each screw. The screws run at high speed and with closely engineered
tolerances.
The twin-screw type supercharger is a positive displacement type device that operates by pushing
air through a pair of meshing close-tolerance screws similar to a set of worm gears. Twin-screw
superchargers are also known as Lysholm superchargers (orcompressors) after their inventor, Alf
Lysholm.
[8]
Each rotor is radially symmetrical, but laterally asymmetric. By comparison, conventional
"Roots" type blowers have either identical rotors (with straight rotors) or mirror-image rotors (with
helixed rotors). The Whipple-manufactured male rotor has three lobes, the female five lobes. The
Kenne-Bell male rotor has four lobes, the female six lobes. Females in some earlier designs had
four. By comparison, Roots blowers always have the same number of lobes on both rotors, typically
2, 3 or 4. The working area is the inter-lobe volume between the male and female rotors. Its larger
at the intake end, and decreases along the length of the rotors until the exhaust port. This change in
volume is the compression. The intake charge is drawn in at the end of the rotors in the large
clearance between the male and female lobes. At the intake end the male lobe is much smaller than
its female counterpart, but the relative sizes reverse proportions along the lengths of both rotors (the
male becomes larger and the female smaller) until (tangential to the discharge port) the clearance
space between each pair of lobes is much smaller. This reduction in volume causes compression of
the charge before being presented to the output manifold.
Comparative advantages[edit]
The rotary screw compressor has low leakage levels and low parasitic losses vs. Roots type. The
supercharger is typically driven directly from the engine's crankshaft via a belt or gear drive. Unlike
the Roots type supercharger, the twin-screw exhibits internal compression which is the ability of the
device to compress air within the housing as it is moved through the device instead of relying upon
resistance to flow downstream of the discharge to establish an increase of pressure.
[9]

The requirement of high-precision computer-controlled manufacturing techniques makes the screw
type supercharger a more expensive alternative to other forms of available forced induction. With
later technology, manufacturing cost has been lowered while performance increased.
All supercharger types benefit from the use of an intercooler to reduce heat produced during
pumping and compression.
A clear example of the technology applied by the twin-screw in companies
like Ford, Mazda, Mercedes and Mercury Marine can also demonstrate the effectiveness of the twin
screw. While some centrifugal superchargers are consistent and reliable, they typically do not
produce full boost until near peak engine rpm, while positive displacement superchargers such
as Roots type superchargers and twin-screw types offer more immediate boost.
Variable-speed air compressor
From Wikipedia, the free encyclopedia
A variable-speed drive (VSD) air compressor
[1]
is an air compressor that takes advantage
of variable-speed drive technology. This type of compressor uses a special drive to control the
speed (RPM) of the unit, which in turn saves energy compared to a fixed speed equivalent.
The most common form of VSD technology in the air compressor industry is a variable-frequency
drive, which converts the incoming AC power to DC and then back to a quasi-sinusoidal AC power
using an inverter switching circuit. The variable-frequency drive article provides additional
information on electronic speed controls used with various types of AC motors.
Contents
[hide]
1 Benefits
2 Industry
3 See also
4 References
5 External links
Benefits[edit]
The benefits of this technology included reducing power cost, reducing power surges (from starting
AC motors), and delivering a more constant pressure. The down side of this technology is the heavy
expense associated with the drive, and the sensitivity of these drives specifically to heat and
moisture..
Industry[edit]
Typically, a fifth of a factory's electricity bill is attributed to the production of compressed air. The
majority of modern factories are heavily involved in cutting costs, and energy awareness should be a
key concern. For example, 1012% of all power generated in the UK is dedicated to the production
of compressed air, and a portion of this power is wasted energy.
Large electrical cost savings can be achieved by installing a variable speed drive compressor in
place of an existing rotary screw or piston machine. Because of this, many governments, including
the US and UK, are pushing the industries to move towards this technology in hopes of reducing
wasted energy. Governments offer various incentives, such as tax rebates or interest free loans, to
cover the upgrades.
However, variable speed drive compressors are not necessarily appropriate for all industrial
applications. If a variable speed drive compressor operates continuously at full speed, the switching
losses of the frequency converter result in a lower energy efficiency than an otherwise identically
sized fixed speed compressor. Where demand remains constant within 515% of the total free air
delivery flow rate, dual-control compressors configured in a split solution can provide higher
efficiency than a VFD.
A professional air audit is the best way to identify if a VFD compressor is most appropriate for any
given compressed air application.
[2]
These audits are available from various companies that
specialize in the implementation of compressed air equipment, which can determine the most
efficient controls for a compressed air system including variable speed, variable capacity or using
storage and flow controllers.
COMPRESSOR TYPES: DIFFERENT WAYS TO COMPRESS AIR
Buy the right type of compressor, with our informative articles, that teaches you everything about
different air compressor type.
There are a lot of types of compressor to choose from. Choosing the right type of air
compressor for your needs is very important, it will save you a lot of trouble and money in the long
run.
You will learn on this page the advantages and disadvantages of the different kinds of compressors.
Which compressor type is right for you? I can't tell you! It all depends what you use it for! You will
find here a short list with the most popular types of compressors and I will discuss the pros and
cons of each one, including some typical uses.
After reading this page, you should have a fairly good idea what kind of compressor is best for you.
The difference between these compressors is both the PRESSURE and the FLOW (cubic meters
per minute, or cubic feet per minute). Most common pressure is 7 to 8 bars.
Reciprocating piston compressors are most often seen for high-pressure / low flow
applications
(up to 30 bars), while rotary screw compressors are used for continuous applications (high flow,
7 or 8 bar)..
Reciprocating piston compressor
Example of a reciprocating piston compressor.
Photo: Atlas Copco
This compressor type uses a piston, which moves inside a cylinder, to compress the air.
Reciprocating simply means 'moving back-and-forth'. Usually it's a piston that move back-and-forth,
but it can also be a rubber membrane (membrane compressor).
Two sets of valves take care of the air intake and exhaust. Piston compressors are available as
lubricated and oil-free, and most of the time with 2 cylinders in V-shape. Very small piston
compressors use only 1 cylinder.
The piston compressor is nowadays available from 1 HP to about 30 HP.
They are used a LOT for general-purpose applications ('workshop-air'), where the air is used for
hand-tools, cleaning dust, small paint jobs, etc. Together with the rotaryscrew compressor, it's one
of the most used compressor types.
Pros:
Relatively cheap
Easy maintenance (easy to understand the inner working)
Suitable for high pressures
Cons:
Very noisy! You really need to put this type of compressor in a sound-isolating box or in it's
own room.
High outlet temperature of compressed air
High oil content in air piping.
More information about reciprocating compressors.
Rotary screw compressor (oil-injected or oil-free)
Rotary screw compressor element. Photo: Atlas
Copco
Another one of the popular compressor types is the rotary screw compressor. It uses two rotors
(helical screws) to compress the air. The rotors have a very special shape and turn in opposite
directions with very little clearance between them.
Air sucked in at one end gets trapped between the rotors, and get pushed to theother side of the
rotors (the pressure-side).
There are two basic types of rotary screw compressors: oil-injected and oil-free.
The oil-injected type is most common, because it has a much lower price-tag than the oil-free one
(which you should only use if your application requires 100% oil-free air).
Pros:
Low noise level . You can just put in in your workshop without wearing ear-protection.
These are the work-horses of the compressors and can supply a large amount of
compressed air.
Good energy-efficiency compared to piston-type compressors
Relatively low end temperature of compressed air
Possible to use energy recovery
Cons:
Purchase price is much higher than piston-type compressors
More complex design, good maintenance very important.
Minimal air use (per day/week) is required to prevent water condensate forming (will create a
lot of problems with rust!)
More information about rotary screw compressors.
Scroll compressor
Inside of a scroll compressor. Photo: Atlas
Copco
I like scroll compressors... they are 'elegant'.. They run smoothly, with almost no noise, no vibrations
and use a clever design principle to compress the air. They are however one of the less seen
compressor types.
How do they work? They compress the air using two spiral elements. 1 is stationary (it doesn't
move), and the other one moves in small eccentric circles inside the other spiral. Air gets trapped
and because of the way the spirals move, gets transported in small air-pockets to the center of the
spiral. It takes about 2.5 turn for the air to reach the pressure output in the center.
I haven't seen too many scroll compressors 'in the wild' (as compared to other compressor types).
Normally they are used in places where a small amount of oil-free and clean compressed air is
needed (for example drinking water-treatment facilities, specialized factories or laboratories, etc).
They don't product a high air flow. If you need a lot of oil-free compressed air, go for an oil-free
rotary screw compressor.
Pros:
Very quiet. Really very quiet!
Compact. A scroll compressor is very small.
Simple design, not so many parts
Low maintenance (hardly any)
Oil-free design
Cons:
Low capacity (flow, liters/minute or cfpm).
Relatively expensive
When the scroll-element fails, there's a very big chance you just have to buy a whole new
element.
The compressed air gets very hot! Much hotter than compared to other types of compressors
More information about scroll compressors.
What kind of compressor is right for you?
It all depends what you use it for! Do you have any specialized needs? Do you need a lot of air, or
just a little bit? Always check your tools, machines and other air-users and calculate how much air
(cfpm = cubic feet per minute, you need.
If you just need a small amount of air (power some tools, operate a small machine), the most
obvious choice would be to buy an oil-lubricated piston-type compressor. Do you need oil-free air?
Use special filters to filter out the oil, or buy an oil-free piston-type compressor (more expensive,
maintenance and repairs will also be more expensive compared to oil lubricated compressors).
Do you need more air? For example, do you use compressed air to sand-blast or operate one or
more machines that use a lot of air, then the obvious choice would be a rotary-screw compressor.
They range from small (5 kW) to very big (1000 or more kW).
The Right Compressor For
You
Reciprocating vs Rotary Screw
This is a common question asked by most people looking for a new air compressor. Either
compressor depends in your application.
If the application requires air all day or has multiple shifts that use air on a consistent basis, then a
rotary screw is probably a better fit for the application due to its ability to run all day every
day. Rotary Screw compressors are thermally controlled through an air cooled oil cooler. Some
rotary screw compressor packages have built in timers that will turn the compressor off if it runs
unloaded for an extended period of time. (Everyone goes to lunch, or it does not get turned off at the
end of the day.)
Reciprocating compressors are best suited for
applications
that require air for shorter durations of timeand might have 15-30-45 minutes before they need
air again. Because a Reciprocating compressor is air cooled, they need to enter an application
with a duty cycle of 70% or less. Either package depends on making sure you purchase a
properly sized compressor for your application. If you have any questions, you can always
contact CAS or one of our local distributors to make sure you have the right unit for your
application.
Noise of Reciprocating vs Rotary Screw
The noise of an air compressor package depends on how it is constructed.. Most rotary screw
compressors sold in the world today are built in sound dampening enclosures. These does not
add to theperformance of the compressor package, all they do is lower the DBA of the compressor
package. Most reciprocating compressors are built open on a tank with no sound proof enclosure,
which is why they sound louder than a rotary screw in a sound dampening enclosure. If you take a
reciprocating compressor and build it in the same enclosure as a rotary screw compressor you will
get a similar DBA reading. At CAS we manufacture a reciprocating compressor muffler that can
lower the DBA of the compressor by up to 10DBA depending on the acoustics or the compressors
environment. This would put the DBA of a CAS reciprocating compressor in the range of 74-82DBA.
At CAS we are one of the few compressor companies to build an open tank mounted rotary screw
compressor while the DBA range is 70-84 depending on the size of the compressor, an enclosed
rotary screw compressor package is between 64-78DBA depending on the size. The enclosure for a
rotary screw compressor is an added expense up front and to the yearly maintenance cost. It takes
longer to service and enclosed rotary screw compressor than an open tank mount version.
At Compressed Air Systems we have several sizing guides to help you pick the right compressor.
Or give us a call and we'll put you in touch with a local distributor who can size a compressor for
your application.


Piston vs Rotary Screw Compressors: A Short
Comparison for the Collision Market
Michael Camber,
Marketing Services
Manager, Kaeser Compressors, Inc.
Automotive Remanufacturers
Piston compressors are still the most common type of compressor found in the automotive service
industry, which includes gas stations, general service, quick lube shops, tire stores, fleet maintenance
facilities, dealer fixed operations, and collision repair. For most of these facilities, the relatively low air
demand and quality needed make the piston a cost-effective choice. Collision repair shops, however,
typically use much more compressed air and have higher air quality needs than other automotive service
businesses. In these respects, collision repair is similar to manufacturing. In fact, many modern body
shops might be more accurately referred to as automotive remanufacturers.
These days, many body shop owners are finding out they have similar
compressed air needs to larger industrial facilities and that rotary
compressors offer significant operational benefits. Rotary compressors
provide an extremely reliable supply of clean, dry compressed air. This
may not be as critical for general repair, but collision repair stands
apart because the end product is directly affected by air quality. When
deciding between rotary and piston compressors, it is important to
consider duty cycle and performance, energy efficiency, air quality,
maintenance, and installation costs.(Right, collision repair shops are
unique in the automotive service industry because they often need
larger volumes of higher quality air for body work, as shown here, and applying high quality automotive
finishes.)
Duty Cycle and Flow
An important difference between piston and rotary compressors is their
duty cycle. Duty cycle is the percentage of time a compressor may
operate without the risk of overheating and causing excessive wear. A
piston compressor may provide adequate flow for a short period, but its
allowable duty cycle must be considered. Most small piston
compressors have an allowable duty cycle of 60 to 70%. For this
reason, piston compressors are usually oversized to allow the
compressor to periodically shut down and cool off because of the
relatively high operating temperatures. Even with adequate air storage
this can cause capacity problems during peak operating hours. Further,
if the shop expands or business increases, lack of air capacity can become even more of an issue. (Left,
although routine maintenance for piston compressors is inexpensive, they have much higher oil carry-
over and have higher operating temperatures.)
Rotary screw compressors have a 100% allowable duty cycle and operate continuously if the need arises.
This is possible because rotary compressors are fluid cooled. The fluid performs four important functions:
Lubricates the bearings in the pump,
Removes contaminants from the air,
Forms a non-wearing seal between rotors and casing,
Removes the heat generated by compression as part of a thermostatically controlled fluid circuit.
Heat and Moisture
All of these benefits are important, but this
last point is very relevant to the body shop.
Piston compressors operate at internal
temperatures of 300 to 400F, while a rotary
compressor runs at much lower internal
temperatures (between 170 and 200F). Just
as hot summer air holds more humidity,
hotter compressed air can hold more
moisture and requires additional components
to dry and clean it. A rule of thumb is that
every 20 degree (F) increase in temperature doubles air's ability to hold moisture. (Right, duty cycle
comparison between rotary and piston compressors.)
Modern rotary screw compressors now come with built-in aftercoolers designed with ample surface area
and a powerful fan to lower the compressed air's temperature as it exits the compressor. By comparison,
the air exiting a piston compressor is very hot and hard to dry. Even with an aftercooler and a specially
designed high temperature dryer, it is difficult to reach the same dew point as a rotary screw compressor.
Lower operating temperatures make it easier to remove moisture and other contaminants, which is very
beneficial for facilities with expensive tools, paint spray booths, and other moisture-sensitive applications.
Oil Carry-Over
As pistons, cylinders, rings, and valves wear, the piston compressor
delivers less air. A side effect is that more lubricating oil gets past the
rings into the compressed air piping and down to the points of use. This
is often referred to as oil "carry-over." Even new piston compressors
pass several times more oil than rotary compressors. This is highly
undesirable if you are spraying finishes. (Left, rotary screw
compressors have a higher initial purchase price, but can be a long
term cost effective solution.)
With rotary screw compressors, there is little or no change in performance over time because the rotors
do not touch each other or the rotor housing, so they don't wear down. The compressor fluid acts as a
non-wearing sealant. It is captured, filtered, cooled, and recirculated. This greatly extends the life of the
compressor pump and very little lubricant gets downstream.
Energy Efficiency
Energy efficiency may not matter much for a repair or tire shop that intermittently runs a 5-10 hp unit, but
collision repair typically requires more volume. Many shops have compressors as large as 30 hp. At these
sizes, energy efficiency becomes a competitive advantage, especially where electricity is expensive.
Rotary compressors typically deliver more air per unit of input energy
than piston compressors. Piston compressors generally deliver 3-4 cfm
per hp. Rotaries deliver 4-5 cfm per hp. Of course, you pay for kWh
used so it is more practical and accurate to compare efficiencies in
terms of kW and cfm. The Compressed Air and Gas Institute (CAGI)
has created a form for manufacturers to state their energy efficiency for
better "apples-to-apples" comparison. Most manufacturers make the
form available on their websites.
Maintenance
Routine maintenance for piston compressors is simple and inexpensive. Drive belts, inlet air filters, and
lubricating oil should be checked and replaced on a routine schedule. It is also common to add "make-up"
oil due to the oil carry-over, and doing so frequently will slow wear on the machine.
Let there be no mistake: rotary screw compressors have more maintenance points than piston
compressors, including the fluid filter and separator. The routine annual service costs will be higher.
Piston units will, however, eventually wear to the point that they need major service (rebuild) to reverse
the gradual loss of flow and increase in oil carry-over. This expense must be considered in a lifecycle cost
comparison.
Noise Levels and Vibration
Typical shop piston compressors have a well-earned reputation for high noise and vibration that may be
heard and felt throughout the shop. For these reasons, they are often put in separate rooms, in forgotten
corners, or outside - exposed to the elements. Where you put a compressor directly impacts air quality
and compressor life. A hot stuffy room, for example, will increase operating temperature, shorten
compressor life, and make it harder to remove moisture and oil from compressed air. Also, the cost of
building separate rooms or enclosures for the compressor must be considered in an accurate cost
comparison.
Rotary compressors are far quieter and produce far less vibration. They don't need special rooms built
and they don't need to be bolted to the floor to keep them in one place. The sound is low enough to have
a normal conversation near the machine (a convenience and a plus for safety). Being relatively quiet and
vibration free, they offer more flexibility where you put them. This usually results in a placement with
better ventilation, lighting, and service access.
The Real Cost
The main reason cited for selecting piston compressors is often lower purchase price. But the actual cost
comparison really extends beyond the initial transaction. Consider all the facts when setting up a new
shop or retrofitting an existing facility.
Rotary screw compressors do not need to be oversized to compensate for limited duty cycle and are
more efficient that piston models. A 7.5 hp rotary will often do the job of a 10 hp piston. The smaller
horsepower unit will use less electricity and reduce operating costs.
Better compressed air quality creates significant savings in labor, paint, and other materials.
Better compressed air quality will extend air tool and equipment life.
More reliable air compressors keep employees working and productive, not waiting for the compressor to
catch up or be repaired.
Lower heat, noise, and vibration eliminate the need for a separate room or enclosure.
Each of these advantages contributes to the positive ROI for a rotary compressor. Some of them will very
quickly make up the difference in initial price. Think about what you spend on labor and finishing materials
each month. The savings will pay for the investment many times over.

At-a-glance differences between a rotary screw and piston compressor