Right-sized rental compressor saves 70% in rental project costs

14/10/2020

Executive summary: if a rental compressor solution is presented as a replacement for a failed machine but does not fit with the electrical supply capabilities of that machine, that is a red flag. It means that it is not the right machine for the application and could cost considerably more money to operate and maintain.

Caption: Aerzen Rental found the right-sized rental compressor to match the production needs and the electrical service connection, while providing significant energy savings compared to other rental options.

Aerzen Rental recently provided a low-pressure compressor package to a plant that had experienced a catastrophic failure of its installed centrifugal compressor. The existing machine provided ~1200 cfm of air at 22 psig and was driven by a 250-horsepower motor.

Without the compressor, the plant – which operates 24/7 – would have had to halt production. The maintenance manager immediately searched for a temporary option with his local service company. The available presented electric-drive option was a 1600 cfm, 400HP, two-stage, oil-free rotary screw compressor – a machine for which the plant, unfortunately, did not have the necessary 800-amp electrical service.

The plant was then presented with a 1600 cfm diesel-drive option, but it became clear that the cost of 24/7 operation (including the cost of diesel fuel, maintenance and rental charges) would be significant.

Finally, the plant was referred to Aerzen Rental, who provided a single-stage oil-free rotary screw compressor that is designed to operate at the low-pressures required by the plant’s process. Because the machine was equipped with a 250hp motor and variable frequency drive, the plant could utilise the electrical feed for the failed compressor and run the rental unit at a fraction of the available breaker capacity, consuming only 125hp.

Compared to the diesel-drive solution presented to the plant, the Aerzen Rental solution represented over 70% savings in overall monthly project costs. An additional benefit: the environmental impact of not running a diesel-driven compressor around the clock was equivalent to 270,000 vehicle miles not driven each month.