1600--Compressor_PMB Vendor - Rick Miles - NCI

Slide 1: 

NCI Information Systems, Inc. 811 Park Drive Warner Robins, GA 31088 rmiles@nciinc.com Phone: (478) 975-0744 Fax: (478) 975-0756 New Technology Air Compressor Rick Miles, Ph.D. David Ellicks, Materials Engineer Air Force Corrosion Prevention & Control Office

Purpose: 

Purpose Develop & Field Test More Efficient Air Compressors That Can Be Used In Military Applications

Outline: 

Outline Advantages of New Technology Phase I Compressor Phase II Compressor Applications of Future Technology Phase III Performance Parameters Summary

Traditional Compressor: 

Traditional Compressor Large footprints and extremely heavy Must be oriented in a particular direction Usually requires a surge tank Requires lubrication Requires significant filtration to provide breathable air

Resonance Compressor: 

Resonance Compressor Linear Simplicity and Reliability High Force for Low Cost Control and Variable Capacity Smooth Start-Up and Low In-Rush Current Clean and Contamination Free Oil-free and Flexible Orientation

Advantages: 

Advantages Reliability and Maintainability Performance Environmental/Safety Aspects Applications

Reliability & Maintainability: 

Reliability & Maintainability Doesn’t experience total system failure Modular replacement Capability degrades but total loss of use avoided Ease of maintenance Filter replacement Minimum repair time for modules No maintenance checks Doesn’t require back up compressors

Reliability & Maintainability: 

Reliability & Maintainability No extensive filtration requiring maintenance upkeep Typical filter system cost to produce breathable air When CO is a concern: $11,000 When water vapor & particulate but not CO is a concern: $2,900 Filter change frequency can vary. Typical is 30 and 180 days 1 Filter changed at 30 days costs $50 2 Filters changed at 180 days costs $320 Annual cost is $1240

Reliability & Maintainability: 

Reliability & Maintainability No special facility requirements Requires only a covered facility No external refrigeration units required An additional system that won’t be required and have to be maintained

Performance: 

Performance Variable Output Most compressors in the military are used at 40% capacity 80% of the time Dual Capability Breathable air source Shop air Energy Consumption

Environmental/Safety Aspects: 

Environmental/Safety Aspects Eliminates need for refrigeration unit No CFC utilization OSHA requirements and certification

Compressor Development History: 

Compressor Development History High Frequency Low Displacement Diaphragm Pump ERD Mechanical and Acoustic Resonance Diaphragm Drive Mechanical and Pneumatic Resonance Diaphragm Drive Mechanical and Acoustic Resonance

Prototype Development: 

Prototype Development 1 st Generation Prototype: (9 CFM, 15 PSI) Delivered December 2001 2 nd Generation Prototype: (25 CFM, 90 PSI) To Be Delivered March 2003 3 rd Generation Prototype: (100 CFM, 125 PSI), To Be Delivered April 2004

Compressor Modules: 

Compressor Modules Pump Piston & Diaphragm Assembly VR Motor

Compressor Modules: 

Compressor Modules AG-1250-475 (x3) 1.25” center lamination width 4.75” piston diameter 18 lbs 7.25” overall diameter 6” overall length Max pressure of 30 psig Max flow of 6 cfm Flow of 3.5 cfm @ 15 psig

Final 1st Generation Status: 

Final 1 st Generation Status Unit Target ModAir Flow @ 15 psig cfm 7.5-12 9 Weight lbs <100 86 Volume ft 3 <2.5 2.4 Noise dB A <70 89 Voltage V AC 115 115 Max Current A rms <30 15 Max Power watts 1300

ModAir Compressor: 

ModAir Compressor 27.25” 14” Compressor module Inlet filter Controller Cooling fan Service Hose Pressure transducer Display Set Pressure Knob Power switch Handle 11”

2nd Generation Targets: 

2 nd Generation Targets Unit Targets 3 Performance scfm @ psig 25 @ 90 Weight 1 lbs 1350 Volume 1 ft^3 50 Noise dBA 85 Voltage VAC 208 3 Phase Current 2 Arms 120 Power 2 HP 14 Reliability hrs. 2000 Tank not included Compressors and controller only, does not include approx 1/2HP for fans and pump As requested in July 2002

2nd Generation Work Plan: 

2 nd Generation Work Plan Phase 1 Module Design & Reliability Phase 4 Field Testing Phase 3 Robust Design Reliability Phase 2 System Design & Integration

ShopAir System Requirements: 

ShopAir System Requirements Controller with LCD display screen that displays pressure reading Oil free pump assembly with no lubrication or rotating parts Variable output operation Field serviceable 3/8” diameter 5’ hose between quick disconnect connections 3/8” quick disconnect connections to hook up paint gun to compressor Ability to work with a surge tank of at least 80 gallons capacity User adjustable pressure from 60 to 90 psi

Breathable Air Source: 

Breathable Air Source Must follow guidelines of T.O. 42B-1-22 Satisfies guidelines for OSHA Grade D Breathable Air Source CGA D, NFPA 1500 (G-7.1, 1997) Air from compressor must be recertified every 90 days Air checked at point of use

Breathable Air Source: 

Breathable Air Source Analytes Air Sample Standard Oxygen (%) 21.02 18.5-23.5 Carbon Dioxide (ppm) 738.93 1000 Carbon Monoxide (ppm) <1 10 Water Vapor (ppm) 23.06 24 Dew Point (F) -65 -65 Oil/Par. (mg/m3) <1 5 Unknowns ND NA Odor ND None

Shop Air Schematic: 

Shop Air Schematic 2.1 scfm @ 90 psig per S3 x 12 = 25 scfm @ 90 psig Air Filter pump 80 Gal Tank Control Module 208 3 Phase 5” x 3/8” hose With 3/8” coupler Controllers HX/fans Compressor System Module

Concept Model: 

Concept Model 32” 80 gal surge tank Compressor Compartment 3-stage modules (12) Coolant and air lines Control Module Controller boards (12) Inlet filter and muffler Heat exchanger and cooling fans Coolant pump and tank 78” 24”

Shop Air Compressor: 

Shop Air Compressor To be installed in Robins AFB Radome Repair Shop end of March 2003

Slide 26: 

Room 16’ 9” X 16’ 9” Current Air Line Location of new compressor Location of New Air line 37’ 105 psi 100 psi Air Regulators Electrical Hook up Electrical Boxes Storage Room CE’s Machine Room Paint Room Office Compressor Humidifier Heat Exchanger Non-Working Compressor Non-Working Humidifier Shop Air Compressor

Phase III Compressor Utilization: 

Phase III Compressor Utilization Air Force uses significant industrial compressors for breathable and clean air Project target capability is 100 cfm at 125 psi 19 compressors of this category are in use at Robins AFB 8 would be perfect drop-in replacements 1100 military sites Air Force, Army, Marines, Navy, Coast Guard, National Guard, Reserve

New Compressor Utilization: 

New Compressor Utilization Applications Paint Shops At least 2 per base and depot Fuel Cell Hangar 1 per base and depot Gyro Shop 1 per depot Other Military Applications

Applications for Future Technology (100 SCFM at 125 PSI): 

Applications for Future Technology (100 SCFM at 125 PSI) Military Breathable (Masks) Air Pumps (Hoods) Compressed Air Clean, dry air desirable for use with tooling Navy (on board ships) Commercial Clean Rooms Paint Facilities Space Electronics

Phase III Performance Parameters: 

Phase III Performance Parameters Capacity 100 CFM @ 125 PSI T30 Ingersoll Rand with applicable filtration 101 cfm @ 125 psi 240 gallon surge tank 8 in use at Robins AFB Cost: $18,400 Compressor and after cooler $7,400 Filtration $11,000 Size Existing T30 Ingersoll Rand footprint Weight: 1800 lbs Dimensions: 71” L X 33” W X 61” H Does not include aftercooler and filtration footprints

Summary: 

Summary Significant advantages over current technology compressors at this capacity This capacity compressor has broad use applications throughout the military At least 1100 potential sites DOD wide

Other Potential Applications of the Technology: 

Other Potential Applications of the Technology Powder Coating Application Chemical Mixing Crushing Material Refrigeration Purification of Gases

Qualified Plastic Media (PMB) Vendors (TO 1-1-8): 

Qualified Plastic Media (PMB) Vendors (TO 1-1-8) Rick Miles, Ph.D. David Ellicks Air Force Corrosion Prevention & Control Office NCI Information Systems, Inc. 811 Park Drive Warner Robins, GA 31088 rmiles@nciinc.com Phone: (478) 975-0744 Fax: (478) 975-0756

Mil-P-85891A QPL (As of 26 Dec 02): 

Mil-P-85891A QPL (As of 26 Dec 02) Type II BIP Plastics, Inc. Composition Materials Co., Inc. MPC, Inc./Patent Plastics, Inc. Opti-Blast, Inc. Poly-Pacific International, Inc. Solidstrip, Inc. U.S. Technology Corporation Type III MPC, Inc./Patent Plastics, Inc. Solidstrip, Inc. Type V Composition Materials Co., Inc. MPC, Inc./Patent Plastics, Inc. Opti-Blast, Inc. Poly-Pacific International, Inc. Solidstrip, Inc. U.S. Technology Corporation Type VII Archer Daniels Midland e-Strip GP (Type VII)

QUESTIONS?: 

QUESTIONS?