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A compressor boosts the pressure of a gas, reduces the bulk of it and expands its density without turning it into a liquid. Gardner Denver reciprocating compressors can do this in a number of ways.

A common factor between all compressors is that they all use some type of fuel, such as electricity or gasoline, to power the compression method they utilize. Also, because the compressor increases the pressure on the gas, it also elevates the temperature.

Components of a Gardner Denver Reciprocating Compressor

A reciprocating compressor utilizes pistons to compress air. The compressor has a comparable design to an internal combustion engine and it even looks similar. A central crankshaft drives anywhere from two to six pistons located inside cylinders. It is typically driven by an external motor that can be internal combustion or electric.

Compressing the Gas

As the piston recoils, gas is inserted from a valve located in the compressor. It is injected into the cylinders and is then compressed and discharged either to be used right away by an air-filled machine or stored in compressed air tanks for later use. The gas, however, must be stored or used directly from the compressor so it doesn’t lose its pressurization.

Gardner Denver reciprocating air compressors are widely viewed as being workhorse compressors because of their robust durability.

Industrial reciprocating compressors can operate in more severe-duty environments while offering lower initial costs. Because of their lower maintenance costs, they are great for sporadic duty operation. They operate efficiently at partial loads and save energy in no-load conditions, resulting in higher overall efficiency.

Types of Gardner Denver Reciprocating Compressors

Single acting: On this type, the piston works only in one direction. The other end of the piston is often open or free where no work is performed.

Double acting: As you can tell from its name, it uses both sides to compress the air. These type of compressors have two sets of intake/suction and exhaust/delivery valves on both sides of the piston.

In-line Compressors: Its name explains the design of the compressor. The cylinders are in a straight line when viewed from the top. They are most commonly used compressors where varying pressure is needed.

V-shaped compressors: These are air cooled compressors with parallel valves mounted on each cylinder head which are placed in a V-shape at a 90-degree angle from each other.

For more detailed information regarding Gardner Denver Reciprocating Compressors and to get professional advice on choosing the right type to suit your needs, please call our office today to speak with one of our experts.

Keep in mind that we specialize in a variety of advisory and installation services, all designed to help you get the most out of your equipment.

All Wright Flow Sterilobe pumps in GA - except the SLHS pump - can be fitted with front cover relief valves to protect the pump and seals from over-pressure situations.

The pumps are designed with DIN 24960 L1K seal envelopes allowing proprietary seals to be fitted, and are particularly useful in applications where a site standard seal supplier is specified. EHEDG-certified for CIP cleanability, which means that the Wright Flow SteriLobe pumps in GA can be used under stringent sanitary conditions.

Generous seal access facilitates simple front loading and removal of all seal variations without the need to dismantle the pump head, saving time and money when routine maintenance is required. The cover joint profile improves the hygiene characteristics and cleaning efficiency of the pump.

Enhanced rotor case geometry enables self-draining of the pump without loss of efficiency, saving product and again improving cleaning capabilities. Stainless steel gear case and improved bearing housing finish provide a clean and corrosion-resistant finish, essential in a clean process environment.

Semi-fluid grease charged gear case means no routine maintenance such as checking of oil levels, especially important when a pump is installed in a hard-to-reach situation.

A New Generation of Wright Flow SteriLobe Pumps in GA

In addition to setting the standards in their industry, they have incorporated many new and unique developments to increase the performance envelope and functionality of the product.
In all, there are 17 displacements over 8 frame sizes with nominal discharge pressure capabilities to 15 Bar to provide the ability to more closely meet specific application requirements.

EHEDG and Sanitary/Hygienic Applications Rotors

Universal-Mounting Relief Valves: All pumps may be fitted with front cover and rotor case jackets when required. Jackets are designed to maintain the liquid at pumping temperature.

Pump Sealing Options: SteriLobe is the new benchmark for rotary lobe pumps. Both bi-wing and four-lobe rotors are available with clearances to 150°C, making them suitable for all CIP and SIP conditions. As standard, the rotors are manufactured from 316L stainless steel.

The SteriLobe range has cast stainless steel bolt on feet that offer stable and robust support to the pump. Simple relocation of the standard feet enables the pumps to be easily mounted with shafts in the upper or lower position or for ports to be aligned horizontally or vertically.

The Wright Flow SteriLobe pumps in GA are certified to EHEDG cleanliness requirements and in the critical area of the mechanical seal, exceeds the design criteria to make them one of the cleanest standard construction pumps available.

Ideal Industries for Wright Flow SteriLobe Pumps in GA

Personal Care Products: Some personal care products are very sensitive; some, like toothpastes are abrasive, while others, like mascara are very thick and sticky.

Chocolate: Handled badly, the texture and taste of chocolate can easily change, so chocolate needs a quality pump and a certain 'know-how'.

Dairy Cream: Dairy creams require different handling solutions according to the fat content and pumping temperature.

Pet Foods: Pumps are produced with special hardened internals to handle everything from the raw ingredients such as chicken viscera and fats, to the finished gravies and sauces.

Culinary Sauces: Wright Flow handle a wide variety of applications for all the major producers of culinary and cook-in sauces.

Pharmaceutical: Most pharmaceutical applications require cleanliness, FDA conforming materials and full material traceability.

If you would like more information regarding Wright Flow SteriLobe pumps in GA or are looking for a replacement pump on an existing line you can:

1. Talk to one of our applications engineers about how you might improve the performance of your existing system by calling 404-647-0986 or filling out the Pump Quote Request Form.

2. If you know what you need, and when you need it, call us at 404-647-0986 or email us at Sales@pyebarker.com for fast order processing.

FMC Pumps in GA Are Built to Excel

FMC Technologies and its distributors have the resources to deliver turnkey pump systems on a global basis. By combining systems design, engineering, manufacturing, and project management capabilities, FMC pumps in GA are suitable for a complete range of applications, from a simple pump package with motor and skid to a complete pumping system with multiple pumps, controls, valves, and piping.

FMC Technologies provides a complete range of research and development testing using drilling mud, sea water, and other fluids.

As one of the world’s top suppliers of solutions for the global oil and gas industry, they deliver pumps for a complete range of process, transportation, and refining applications.

These world-proven FMC pumps in GA are built to excel in the most demanding services while providing a safe, effective method of pumping hot, corrosive, and/or hazardous fluids at pressures up to 10,000 psi.

Typical applications include:

• Water disposal;
• Secondary recovery;
• Glycol dewatering;
• Amine sweetening;
• Chemical injection;
• Crude transfer.

General Industrial: FMC pumps in GA are ideally suited for a wide variety of industrial services where durability, high efficiency, and versatility are paramount. These pumps are setting new standards for low cost of ownership, long service life, and ease of maintenance in the world’s toughest industrial applications.

Typical applications in this market include:

• Machine tool coolant;
• Mine-dust suppression;
• Mine dewatering;
• Steam boiler feed;
• High-pressure washdown;
• Descaling;
• Fire protection;
• Hydrostatic testing;
• Water jet cutting;
• Slurries.

Reverse Osmosis Water Purification: The high mechanical efficiency of FMC pumps in GA makes them the ideal choice for reverse osmosis systems. The world leader in both commercial and military RO pump technology, FMC Technologies delivers pump solutions for smooth, reliable performance with minimal maintenance requirements.

Sewer Cleaning Pumps: FMC Technologies leads the market into the 21st century with its environmental-friendly pump product. The custom design piston pump products operate at lower rpm’s while incorporating state–of–the–art materials and wear components.

FMC pumps in GA are designed to pump the most abrasive fluids within the industry such as gray water and recycled sewer and storm waters. Their sewer-cleaning pumps continue the tradition of lowering component life cycle cost and total cost of ownership by incorporating longer lasting, increased wear characteristics and run dry capabilities.

In addition to the services already listed, FMC Technologies is a leading provider of pumping solutions designed for mobile equipment. These FMC pumps in GA feature lightweight, high-performance construction and special designs to allow them to efficiently integrate into the overall equipment package.

If you would like more information regarding FMC pumps in GA or are looking for a replacement pump on an existing line you can:

1. Talk to one of our applications engineers about how you might improve the performance of your existing system by calling 404-647-0986 or filling out the Pump Quote Request Form.

2. If you know what you need, and when you need it, call us at 404-647-0986 or email us at Sales@pyebarker.com for fast order processing.

Recently, I took you through the workings of an internal gear pump. Today I’m going to guide you through the inner workings of an external gear pump.

How do They Work?

External gear pumps use two identical gears rotating against each other to drive fluid from the suction port to the discharge port. Each gear is supported by a shaft with bearings on both sides of the gear. Typically, all four bearings operate in the pumped liquid.

Because the gears are supported on both sides, external gear pumps are often used for high pressure applications. Usually, small external gear pumps operate at 1,750 or 3,450 rpm and larger versions operate at speeds up to 640 rpm.

The design of an external gear pump allows them to be made to closer tolerances than internal gear pumps. The pump is not very forgiving of particulate in the pumped liquid. Since there are clearances at both ends of the gears, there is no end clearance adjustment for wear. When an external gear pump wears, it must be rebuilt or replaced.

External gear pumps handle viscous and watery-type liquids. Thicker liquids require careful setting of the pump speed because gear teeth come out of mesh for a short time, and viscous liquids need more time to fill the spaces between the gear teeth than thinner liquids.

The pump does not perform well under critical suction conditions. Volatile liquids tend to vaporize locally as gear teeth spaces expand rapidly. When the viscosity of pumped liquids rises, torque requirements also rise, and pump shaft strength may not be adequate. We supply torque limit information when it is a factor and advise against external gear pumps for applications when the torque requirements to pump a given liquid are beyond the tolerances of a given pump.

What Do We Use Them For?

We see external gear pumps used to pump fuel oils and lube oils, chemical additives, on hydraulics and low volume transfer applications. It is also common to use an external gear pump for chemical mixing and blending.

Score Card

Abrasives

 

Thin

Liquids

Viscous Liquids Solids Dry Prime Diff. Pressure
How well does an External Gear Pump handle it?

P

G

G

P

A

E

E = Excellent, G = Good, A = Average, P = Poor

Oil Free Air Compressors

I know that we’ve been hearing a lot about oil free air compressors of late. Some of you might be wondering about the hype. I believe they are worth the hype and they can represent incredible value to the right customer.

I suspect that as we move forward and the technology becomes more widespread, the costs will come down and we will see the broader market turn to oil free air.

So I’m going to share the ideal situation to consider an oil free air compressor.

Where I Would Look Long And Hard At Oil Free Air Compressors.

Gardner Denver Oil Free Air Compressors do deliver 100% oil free air. No conventional air compressor can offer that. Once oil is in your compressed air it’s impossible to get it 100% out. No scientist would make that claim and no company would guarantee that their filtration system can clean air from conventional air compressor so that you get 100% oil free air all the time.

It’s just a recipe for legal troubles.

You can make those claims with an oil free air compressor.

ISO-Class 0 air is air that is 100% completely oil free. The best you can get with a conventional compressor is .1 mg/m3 under ideal conditions. I’ll admit it can be good enough but it requires a filtration system.

You don’t need to invest in or maintain an oil removal/filtration system if you use an oil free compressor. There’s a savings and depending on the quality of air you need it can be a big one over the life of a compressor.

Then there is always the risk of a contamination ‘event’ and downstream damage. This can be either from oil in the compressed air contaminating your end product – e.g. pharmaceuticals or food and beverage applications or the oil could damage your equipment that runs on compressed air e.g. pumps and tools.

Where you are looking to replace your air compressors anyway and would like to eliminate the costs or the ‘risk of expense’ associated with maintenance and repairs or product damage, that’s where there could be a big payoff. Cleaning up a disaster could well cost you far more than the oil free compressor would have cost.

If you are looking for a new compressor, the team here at Pye-Barker can guide you through the process. Please call 404-363-6000 or drop us a line sales@pyebarker.com and we will explore a range of options based on your circumstances with you.

We are continuing on with our series of ‘Know Your Pump’ so that you better know your way around the world of Positive Displacement pumps. Today we are looking at Vane Pumps.

How Does A Vane Pump Work?

Vane pumps have a rotor with radial slots, which are positioned off-center in a housing bore. Vanes that fit closely in the rotor slots slide in and out as the rotor turns. Vane action is aided by centrifugal force, hydraulic pressure, or push-rods. Pumping action is caused by the expanding and contracting volumes contained by the rotor, vanes, and housing. Vanes are the main sealing element between the suction and discharge ports and are usually made of a non-metallic composite material. Rotor bushings run in the pumped liquid or are isolated by seals.

A vane pump usually operates between 1,000 rpm and 1,750 rpm. The pumps work well with low-viscosity liquids that easily fill the cavities and provide good suction characteristics.

Speeds must be reduced dramatically for high-viscosity applications to load the area underneath the vanes. These applications require stronger-than-normal vane material.

Because there is no metal-to-metal contact, these pumps are frequently used with low-viscosity non-lubricating liquids such as propane or solvent. This type of pump has better dry priming capability than other PD pumps.

Abrasive applications require the proper selection of vane material and seals. Vane pumps have fixed end clearances on both sides of the rotor and vanes similar to external gear pumps. Once wear occurs, this clearance cannot be adjusted, but some manufacturers supply replaceable or reversible end plates. Casing liners are a low-cost way of restoring pump performance as wear occurs.

What do we use them for?

Vane pumps are designed to handle low viscosity liquids such as LP gas (propane), ammonia, solvents, alcohol, fuel oils, gasoline, and refrigerants. They can be used to pump liquids with viscosities up to 500 cPs / 2,300 SSU.

Vane pumps are able to handle a wide range of fluid temperatures. -25°F and 500°F making them useful in a variety of applications.

Abrasives

 

Thin

Liquids

Viscous Liquids Solids Dry Prime Diff. Pressure
How well does a Vane Pump handle it?

P

E

A

P

G

A

E = Excellent, G = Good, A = Average, P = Poor

3 Root Causes Of Trouble in Compressed Air Systems

Causes Of Trouble in Compressed Air Systems

“There are a thousand hacking at the branches of evil to one who is striking at the root.” Henry David Thoreau

This quote is often how I imagine the army of consultants and experts who offer advice on the improvement of - well anything and compressed air is no exception – acts.

Sure a consultant can come in and do some tests and put together a slick report and make recommendations that aren’t practical or even effective because they are hacking at branches.

If you want results from simple actions, you need to tackle the root cause of your problems – like having a dehydration headache and reaching for an aspirin… No! Drink some water and the headache won’t come back after the aspirin wears off…

Here are my top three root causes of issues with your compressed air system problems.

Root Cause #1 – System Design and Implementation.

This covers both the design of the system and the integration of the components of the system to reach the specified performance. You could write an encyclopaedia of all the wrong ways to design a compressed air system.

Once a system has been built and it is not performing as well as desired then a careful plan to adjust the system is required. This has to be a custom plan. There is no one size fits all solution.

Root Cause #2 – Poor Integration.

Often compressed air systems are not so much designed as built like a child’s Lego project. A big catalogue of bits is opened up and those bits are picked and put together to create the system. Then when the system doesn’t perform more bits are added.

Often times the added components are not properly integrated into the original controls so we see things like idle compressors consuming power, etc. Obviously unless there is complete integration the costs for the system to produce a cubic foot of compressed air will be higher than they need to be.

Root Cause #3 – Ineffective Measurement.

In compressed air systems efficiency is measured by output per unit of power E.g. scfm/kW. It’s useful to know this across the loads the system is likely to experience and in various failure modes.

A compressed air system should be designed around optimizing this number. And a system’s performance should be measured and managed against its initial design. Instead we see companies measure the costs to run parts/components of their system.

We often find with a comprehensive measurement in place, that these savings on individual parts don’t translate into savings for the system as a whole.

Obviously, measurement against a design sometimes is impossible because there was no master design for the compressed air system. In that case, I’d work from current situation and start looking for ways to reduce your output per unit of power consumer.

If your compressed air expenses are climbing (or if you can’t measure them accurately) or you think you need to expand your system, the first thing to do is to take stock of the system as a whole. If you don’t have the necessary expertise in-house, we will audit your compressed air system for you and guide you to getting the performance you need. To get started with a no-obligation discussion call 404-363-6000 or drop us a line sales@pyebarker.com

We’re back for another edition of “Know Your Pumps.” This time we take a look at another member of the positive displacement pump family: lobe pumps.

How Do Lobe Pumps Work?

Lobe pumps are similar to external gear pumps in operation, except the pumping elements or lobes do not make contact. Lobe contact is prevented by external timing gears producing a continuous (non-pulsating) discharge.

Pump shaft support bearings are located in the timing gear case. Since the bearings are out of the pumped liquid, pressure is limited by bearing location and shaft deflection. There is not metal-to-metal contact and wear in abrasive applications is minimal. Use of multiple mechanical seals makes seal construction important.

Lobe pumps are frequently used in food applications, because they handle solids without damaging the pump or the product. Lobe pumps can pump much larger particles than can other positive displacement pumps.

Since the lobes do not make contact, and clearances are not as close as in other PD pumps, this design handles low viscosity liquids with diminished performance. Loading characteristics are not as good as other designs, and suction ability is low. High-viscosity liquids require considerably reduced speeds to achieve satisfactory performance.

Lobe pumps are cleaned by circulating a fluid through them. Cleaning is important when the product cannot remain in the pumps for sanitary reasons or when products of different colors or properties are batched.

What Do We Use Them For?

Lobe pumps are suitable for pumping materials such as polymers, paper coatings, soaps and surfactants, paints and dyes, rubber and adhesives, pharmaceuticals and food applications.

Score Card

Abrasives

 

Thin

Liquids

Viscous Liquids Solids Dry Prime Diff. Pressure
How well does a Lobe Pump handle it?

G

A

E

E

A

G

E = Excellent, G = Good, A = Average, P = Poor

Optimizing Your Compressed Air System

It’s interesting to me that a lot of compressed air systems are allowed to grow organically.

Pumping systems are precisely engineered. Requirements are specified exactly. The system is evaluated on paper, future-proofed. Those designs are evaluated and double checked… Compressed air systems are not specified per se.

Compressed air system components are specified.

A lot of compressed air systems aren’t anywhere near as well engineered. Frankly far too many systems are a built out of a mish-mash of components, often with customization and often there are oversights in integration.

Eli Goldratt wrote a lot of books about using Theory of Constraints in business settings. Initially he was famous for optimizing the production of manufacturing systems. The big mistake he saw in a business was ‘optimizing each step of the process.’ He called it striving for ‘local optima.’

Independently specifying the best compressor, best drying system, best storage tank won’t produce the most overall efficient system.

Ultimately there will be one component that is the constraint on the system and it will determine the overall performance of the system. Kind of like a chain only being as strong as it’s weakest link.

The capacity of your compressed air system will be limited by the ‘weakest link.’

If I was to design a compressed air system from the ground up I would be looking at

Then I’d specify a system based around those criteria.

We know that most systems are already up and running and now many plant managers are having to add capacity or improve air quality or sometimes doing both to their existing compressed air systems. However, when there is no overall system consideration you can end up creating something like Frankenstein’s monster.

For example: if you add a new compressor with a Variable Speed Drive to an existing compressed air system. Say that new compressor runs at 50% speed and power. Say the system’s existing modulating compressor has cut its output and is now running at 20% capacity. That modulating compressor could still be using 75% of its full power load.

The new VSD operated compressor might be able to handle the base load at about 70% capacity and consuming 70% power. Instead, in this example, two compressors are running at 125% of the necessary power.

That’s obviously not optimal.

For a start you’d want is to update the controls for the system so that the VSD compressor handles the base load and the modulating compressor comes on to handle demand over a threshold and it is shut down when demand is below that threshold.

That’s really only the beginning of system optimization.

If your compressed air expenses are climbing (or if you can’t measure them accurately) or you think you need to expand your system, the first thing to do is to take stock of the system as a whole. If you don’t have the necessary expertise in-house, we will audit your compressed air system for you and guide you to getting the performance you need. To get started with a no-obligation discussion call 404-363-6000 or drop us a line sales@pyebarker.com

Sometimes there’s nothing quite like a reminder about the basics of various product categories. So we thought we’d take the time to review some of the major pump categories. Starting with the ever reliable Internal Gear Pump.

How Does Internal Gear Pumps Work?

The crescent internal gear pump has an outer or rotor gear that is generally used to drive the inner or idler gear. The idler gear, which is smaller than the rotor gear, rotates on a stationary pin and operates inside the rotor gear.

The gears create voids as they come out of mesh and liquid flows into the pump. As the gears come back into mesh, volumes are reduced and liquid is forced out the discharge port. Liquid can enter the expanding cavities through the rotor teeth or recessed areas on the head, alongside the teeth. The crescent is integral with the pump head and prevents liquids from flowing to the suction port from the discharge port.

The rotor gear is driven by a shaft supported by anti friction bearings. The idler gear contains a journal bearing rotating on a stationary pin in the pumped liquid. Depending on shaft sealing arrangements, the rotor shaft support bearings may run in pumped liquid. Abrasive liquid can wear out a support bearing.

The speed of internal gear pumps is considered relatively slow compared to centrifugal types. Speeds of up to 1,150rpm are considered common, although some small designs operate up to 3,450 rpm. Because of their ability to operate at low speeds, internal gear pumps are well suited for high-viscosity applications and where suction conditions call for a pump with minimal inlet pressure requirements.

For each revolution of an internal gear pump, the gears have a fairly long time to come out of mesh allowing the spaces between gear teeth to completely fill and not cavitate. Internal gear pumps have successfully pumped liquids with viscosities above 1,320,000 cSt / 6,000,000 SSU and very low viscosity liquids, such as liquid propane and ammonia.

Internal gear pumps are made to close tolerances and are damaged when pumping large solids. These pumps can handle small suspended particulate in abrasive applications, but gradually wear and lose performance. This can be limited for a time by adjusting the pump end clearance (the closeness of the rotor gear to the head of the pump).

What Do We Use It For?

Internal gear pumps have successfully pumped liquids with viscosities above 1,320,000 cSt / 6,000,000 SSU including peanut butter, asphalt, chocolate and adhesives and very low viscosity liquids, such as liquid propane and ammonia.

Score Card

Abrasives

 

Thin

Liquids

Viscous Liquids Solids Dry Prime Diff. Pressure
How well does an Internal  Gear Pump handle it?

G

G

E

P

A

G

E = Excellent, G = Good, A = Average, P = Poor

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Forest Park (Atlanta) Address:
121 Royal Dr.
Forest Park, GA 30297
FAX: (404) 361-8579
Sylvania Address:
452 Industrial Park Rd.
Sylvania, GA 30467
FAX: (912) 564-2636
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524 Mid-Florida Dr., Suite 204
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FAX: (321) 282-6424
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