IntelliSurvey 3.

0
VERSION 3.0
INTELLISURVEY SOFTWARE

OPERATION MANUAL

CCN : 80442221
REV. : A
DATE : FEBRUARY 2006
TABLE OF CONTENTS

Introduction.......................................................................................................................................3
Basic Mode Features:
Welcome Screen .................................................................................................................3
Customer Profile..................................................................................................................3
Customer Floor....................................................................................................................5
Analysis ...............................................................................................................................6
Proposed System ................................................................................................................6
Proposed Customer Floor ...................................................................................................6
Reporting.............................................................................................................................7
Advanced Mode Features:
Advanced Analysis ..............................................................................................................8
Advanced Proposed System ...............................................................................................8
Technical Terms’ Glossary.............................................................................................................12
Analysis ..........................................................................................................................................13
Rotary Tool Box……………………………………………………………………………………………16

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INTRODUCTION
This manual is designed to walk you through
the many features of IntelliSurvey 3.0.
IntelliSurvey is not a quotation tool. It is
designed to assist in evaluating a compressed
air system using amps and pressure to
calculate the financial opportunity for energy
savings.

The Solution Details box enables the user to give a

BASIC MODE FEATURES suitable name to a solution for future reference.
Basic Mode: is the default option selected by This box also enables the user to choose the type
the program when first used. of solution they prefer. If Contact Cooled is chosen
a suggestion for a Contact Cooled machine will be
WELCOME SCREEN received, when IntelliSurvey recommends a VSD.
This selection is only provided to help IntelliSurvey
determine what type of machine to suggest when
necessary. Click OK when finished and this will take
the user to the Customer Profile screen.

CUSTOMER PROFILE

This is the initial screen the user will see when

the program is first opened. The toolbar has
three pull down menus. They are labeled
Solution, Edit, and Tools. By selecting
Solution the user can open a New solution, or
Open, Rename, and Delete an existing Go to the Customer Identity section, in this section
solution. The user also has the option to Import an existing customer can be selected from the pull
or Export a solution to another user from this down section. If the customer is not in the pull down
menu. By selecting the Edit pull down menu, add them by clicking on “Add New”. The following
the user can view and alter the personal box will appear:
information given during installation by
selecting Personal Information. The user also
has the option to change the application
preferences decided upon when installed.
This is where changes to currency, regional
location, language, unit of measurement, and
the application mode from basic to advanced.
If language, unit of measurement, and
application mode change, the effects will
not take place until IntelliSurvey is
restarted.
To begin a solution, select Solution scroll down
The user is required to put information in any of the
to New, and a new solution will start. The
text areas that have an asterisk (*) next to the title.
following box will appear:
The user will not be allowed to leave this screen,
until these areas are filled in. Among other
information inputted on this screen the user will be
allowed to upload a customer’s logo. The logo has

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to be less than 1Mb and in jpeg format. Once
the user has inputted the customer’s
information click “Add” to return to Customer
Profile. The Contact Information section
should be filled with the information the user
just entered. If the information is incorrect
select edit and change the information. Now
select an existing contact name or click Add
New to get the following box:

The user is required to fill in or select any fields that

have an asterisk (*) next to the title. Click OK when
all the fields are filled in with the correct information.
If the compressor needed is not available in the
database pick the closest machine and manually
enter in the appropriate information so the CSV will
be properly calculated.
Put in the contacts First, Middle, and Last
name (first name is the only required field) Caution:
click OK to return to the customer profile. Check the values given by the database, there may
The Design Settings section should be filled be discrepancies due to what year the compressor
with values. All the fields that are not grayed was built, always double check the values given
out can be changed to match data from the against data received from the machine.
CSV file. The Pressure, will be bar for more
than half the users, field is grayed out because Caution:
this is a calculated field that gives the proper The database has the full load amp value for a
pressure based on altitude. particular voltage. If the user changes the voltage
the Re-rated Amps are calculated by using the Full
The Existing Compressors section is where the Load Amps. If the Full Load Amps and Voltage are
user is able to input up to four of the changed an incorrect Re-rated Amps will be used
customer’s current compressors. Compressor when running the CSV. Only change the Full Load
information must be entered relative to the Amps or the Voltage, do not change both.
channel used for recording the data. Click on
the Add Compressor 1 button to receive the IntelliSurvey gives the user the option of duplicating
following: inputted compressors. If the customer has more
than one of the same compressors, highlight the
compressor already created and hit the right mouse
button and scroll down to Copy. Then select
another open compressor field hit the right mouse
button and scroll down to Paste to duplicate the
compressor. Once all of the compressors have
been inputted it is time to process the CSV file, click
on Choose Data File to receive the following
screen:

The user does not have to fill in all of the fields

to search for the compressor needed. Each
field filled in will eliminate the compressors that
do not match the search criteria giving a
shorter list to choose from. Scroll through the
list and find the compressor needed and click
on the Select button to receive the following
screen: Click on Browse and select the appropriate CSV file
to process. Under the Compressor Amp Correction
section select “Use compressor rated amps” to use
the amps found for the compressor in the data
base, or select “Use CSV max amps” to use the
maximum amps value found on the CSV file. Auto
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Drawdown is chosen by default to determine if
the machines monitored are in drawdown. When a flow controller or system controller is
Click “OK” once the CSV file has been selected, they will automatically connect to points
selected. On the Customer Profile screen on the diagram. To connect the compressor(s) to
select “Compute” on the bottom right hand another item place the mouse pointer over the
corner to initiate the CSV file processing. diamond on the right side of the compressor until
There should be six squares on the bottom left the pointer turns into a hand. Hold the left mouse
hand corner, showing that the file is button down and drag the hand to the item you
processing. While it is processing the user can want to connect. When two compressors are
go to the Customer Floor by clicking on attached to the same item a Manifold will appear. If
Customer Floor at the top of the screen. a third or fourth compressor needs to be connected,
connect the item by dragging the hand to the item
CUSTOMER FLOOR itself and not to the Manifold, or the user will receive
a warning. Place all dryers, receivers, and filters to
the left of the supply node (P3). The flow controller
should be the only item between the supply node
(P3), and the production node (P4). If the system
does not have a flow controller the user must
connect the supply node (P3) to the production
node (P4).

The text boxes associated with the components on

the Customer Floor can be edited with additional or
new text.

Once layout matches the customer’s layout press

“Compute” on the bottom right corner. ISO Air
Quality will be calculated and displayed based on
The Customer Floor will display the selected components in the system. Click the
compressor(s) that were previously chosen on button with “ISO8573” on the bottom left corner to
the Customer Profile. The dotted line is a get the following chart:
page break anything to the right of the line will
not be displayed on the report. The yellow
circle with the S in the middle is the supply
node (P3) and the yellow circle with the P in
the middle is the production node (P4). The
items at the top from left to right are Dryer,
Receiver, Flow Controller, System Controller,
Filter, and Drain. The user can place the
mouse pointer over the item and hold the left
mouse button and drag the item to the
diagram. As soon as the button is released this
screen will appear:
This chart is a list of the ISO qualities to help
explain what each value is when computed.

Remember that the layout seen on this screen is

the layout that will be in the report.

An error message will be displayed if one of the

components on the Customer Floor is not sized
appropriately for flow, pressure, or temperature.
Right click on the highlighted component and select
resize or ignore.

Once the Customer Floor and the CSV has finished

computing (the blocks on the bottom left corner
The user does not have to fill in all of the fields have disappeared) the Analysis tab will be in bold.
to search for the item needed. Each field filled Click on the Analysis tab to continue.
in will eliminate the compressors that do not
match the search criteria giving a shorter list to
choose from.
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ANALYSIS When done checking all of the data, place a value
in the “Desired Pressure [psig]:” text field to leave
this screen. This is P4, the pressure the user wants
to regulate the plant down too. The pressure
inputted will be the pressure used to calculate the
Flow Controller Savings. Now click on Proposed
System Floor.

PROPOSED SYSTEM FLOOR

The Analysis screen enables the user to see

the graphs for System Power, Flow, Pressure,
and Overview. The user also can see the flow
graphs from the individual compressors, along
with Load Duration and Base Load Profiles.
There is a zoom function for the graphs, select
which graph to zoom by selecting the name of
the graph under Summary. By placing the
mouse pointer on the graph and holding down The Proposed System Screen will show what
the left mouse button the user can drag a box savings are available. IntelliSurvey will make a
over a particular portion of the graph and it will default selection based on these savings, but the
magnify that portion of the graph. Zoom can be user has the option to change the selections to
done multiple times, up to a minute of data. To better suit the customer. The user can go even
go back to the original graph, click the left further in Advanced Mode and change the
mouse button. To zoom, the cursor must be compressor, system controller, flow controller, or
dragged from the top left corner to the right storage recommended. Read about the Advanced
bottom corner of the selected area. Mode prior to changing from Basic Mode. When
finished selecting items, click on Proposed
The Analysis screen has a button called Customer Floor.
“Configure Draw Down” when this button is
clicked this screen appears: PROPOSED CUSTOMER FLOOR

Another option used by IntelliSurvey to analyze

a modulating compressor is the “Manual”
drawdown mode. In this mode the user can
enter a pressure value that the compressor will
begin to modulate. In IntelliSurvey the This is the Proposed Customer Floor; it has the
compressor will be considered loaded at 100% same functionality as the Customer Floor. The
whenever pressure is below this value. The selected items from Proposed System will be on the
screen also, gives the user the option to right side of the screen, the user needs to add
change the drawdown to none or switch to these items to the customer’s current system.
max amps without having to go back in the Place the mouse pointer on the item to add, hold
program. The CSV file will have to be the left mouse button and drag to the existing
reprocessed if any changes are made. system. The flow controller and system controller
will automatically draw lines to the existing system.
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To add a compressor, dryer, filter, and by checking the section titled Observation Text, this
receiver, pipes will have to be drawn to the box will appear:
existing system. Selected components are not
automatically connected to the existing piping.
Old piping needs to be deleted and then
reconnected to the inlet and discharge of every
component. To delete pipe, place the mouse
pointer over the line and click the right mouse
button. This will highlight the pipe green; hit
the delete button on the keyboard to remove it.
Drains do not link or connect with piping to any
components on the Customer Floor.
This is a text editor designed for IntelliSurvey; there
Caution: are three options for font Bold, Italic, and Regular.
On the Proposed Customer Floor clean up This editor allows font size from 10pt to 72pt, and
equipment (dryers and filters) can be added to text can be put in Bullet form.
the existing system. The price of the clean up
equipment will not be included in the cost of IntelliSurvey now allows the option of including up
the system and will not be a part of the to eight pictures or images into the report. Take a
payback and savings. Also, remember that the digital camera to the customer’s site take pictures of
layout seen on this screen is the layout that will their set up and include them in the report to give it
be in the report. a personal touch. To add these images click on the
square to the left of Image 1-8 and this box will
When all of the proposed items have been appear:
connected to the existing system, click on the
“Compute” button in the bottom right corner.
There will be a chart with the new values for
Particulate, Dew Point, Oil Carryover,
Temperature, Max Pressure, and Capacity
Available. When finished click on Reporting.

REPORTING
Go to “Select Image” and find an image to display.
This box also, has a text field to give the image a
caption. The images and pictures have to be in
jpeg format and less than 1Mb.

When finished personalizing the report click the left

mouse button on “Create Report” and this box will
appear:

This is the report section; the report on the

right is just a sample and this screen will not
display the report the user created. There is a
lot of flexibility in the reporting section; remove
sections by unchecking the box to the left of
the section (Terms and Conditions, and Decide where to save the report, and give the
Proposed Supply Side Schematic can not be report a suitable name for future reference. Then
removed). The user has the option of click the left mouse button on “Save” a report will
changing the order of the sections by clicking generate and automatically open in Adobe Acrobat.
on a section, hold the left mouse button and
drag the section to where the section is wanted
and release the button. The user has the
option of placing personalized text in the report
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ADVANCED MODE ADVANCED PROPOSED SYSTEM
FEATURES
Advanced Mode is changed by the user on
the welcome screen under edit/preferences in
the toolbar. The program must be restarted for
the changes to take effect. Advanced mode
performs the same functions as Basic, but
introduces flexibility to the solutions by
allowing the user to edit the solution
selections.

ADVANCED ANALYSIS
In Advanced mode Analysis gives you the
option of adding customized graphs. The In Advanced mode the Proposed System gives the
customized graphs add flexibility to what data option of editing equipment selections given by
is displayed on the graph shown to the IntelliSurvey. This gives the user the ability to
customer. Right click on the Available Graphs provide a solution that is custom tailored to a
to see the following menu: customer’s needs. To edit a selection check the
box next to the item and click on “Edit Selection”.

System Controller

When you click on “Edit Selection” for System

Controller the following screen appears:

Select “Add Custom Graph” to get the

following box:

This screen shows the recommended selection and

allows the user to choose another, by clicking on
“Choose Another”. When “Choose Another” is
clicked the following screen appears:

This box enables the user to name the graph

and select any of the data sets to be displayed
vs. a time stamp. The user has the ability to
decide what the customer will see and can
select multiple data sets per graph.

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This screen allows the selection of any above has two EP100 compressors and one EP50-
Ingersoll Rand System Controller in the SE and with the default configuration from
Database. Once the System Controller is IntelliSurvey; trimming with an EP100 gives savings
found left click on the controller, then click on of $4108 by keeping the EP50-SE from coming
“Select”. The System Controller will show up online. The trim flow requirement is 198.05 cfm, the
on the previous screen as the User Selection EP50-SE produces 215 cfm suggesting the EP50-
and be checked as the System Controller the SE could effectively trim and keep one of the
program will use. EP100s offline giving higher total savings of $8372
as seen in the screen below.

The user also has the option to adjust the

savings by adjusting the Trim Flow
Requirements of the System Controller. Click
on “Custom Savings” to receive the following
screen:

Variable Speed Drive

To change the VSD compressor selected by

IntelliSurvey select the box next to Variable Speed
Drive and click on “Edit Selection” to receive the
following screen:

This screen allows the user to reorder the

Base load order of the compressors to obtain
the optimal setup for the System Controller. To
reorder, highlight a compressor by left clicking .
on the compressor and use the up and down
arrows to move that compressor in the order. This screen allows the user to resize the VSD by
IntelliSurvey always starts with the biggest changing the trim requirement. The trim
compressor on the bottom, so the stack goes requirement is changed by reordering the
from the biggest first to smallest compressor compressors. As stated earlier, IntelliSurvey
last. This is not always the best way to meet always places the largest compressor as the base
plant demands. For example the screen and orders the compressors from largest on the
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bottom to smallest on top. To reorder highlight
the compressor you want to move and use the
up and down arrows to move the compressor.
Depending on the size of the compressors you
have, will determine how much the Max VSD
Trim Requirement changes. If the Max VSD
Trim Requirement is higher than the system
recommended compressor, IntelliSurvey will
automatically change to a compressor that
meets the trim requirement. The user may
want to recommend a different compressor; by
clicking on “Choose Another” the following
screen appears: Scroll through the list and find the compressor
needed and click on the Select button to receive the
following screen:

The user will be returned to the previous

screen with the selected compressor filled into The user is required to fill in or select any fields that
the User Selection. IntelliSurvey will now use have an asterisk (*) next to the title. Click OK when
this compressor to calculate Annual Savings. all the fields are filled in with the correct information.
Since the flow output for a Nirvana compressor The user has the option to revert to the original
changes relative to the discharge pressure, customer floor by clicking on “Restore”. When
Nirvana compressors have been entered in the finished managing the compressors click on “Close”
database for several pressure settings. Make to return to the previous screen. If a compressor
sure the selected Nirvana is capable of was replaced the replacement should show up
supplying the required pressure ahead of filters under the VSD Resize column. When finished
and dryers. making changes click “OK” to proceed to the
Proposed System screen. The Annual Savings will
The user also has the option of changing a be changed based on the compressor changes
current compressor by selecting “Manage made.
Compressors”. The following screen will
appear: System Controller and Variable Speed Drive

System Controller and Variable Speed Drive,

computes what the customer would save if both
items where purchased. The Annual Savings are
not just the sum of System Controller savings and
Variable Speed Drive savings. The System
Controller savings are calculated by showing the
savings of pressure band reduction and base load
with online/offline trim. The Variable Speed Drive
savings are calculated by showing the savings of
In order to add flexibility for the proposed base load with VSD trim. When you combine a
system, the software allows the user to see the System Controller with Variable Speed Drive, the
savings available when base loading with savings are pressure band reduction and base load
alternative compressors. To replace an with VSD trim.
existing customer compressor, change a
compressor left click on a compressor and
click on “Replace”. The following screen will
appear:

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There are two “Edit Selection” buttons, the top
button allows the user to edit the System
Controller, and the bottom button edits the
Variable Speed Drive. The edit function is the
same as found in the individual sections of Check that the selected flow controller will meet the
System Controller and Variable Speed Drive, customer’s needs and click “OK”, to return to the
please see previous sections for instruction on Proposed System screen.
use.
Storage
Flow Controller
IntelliSurvey calculates storage based on a fifteen
The flow controller savings rely on the desired second permissive time, and a five psig (0.345barg)
plant pressure (P4) that was inputted on the pressure drop below the load point. The Advanced
Analysis screen. The flow controller takes the version allows the user to change these initial
cost to run at the current pressure and settings by clicking the “Edit Selection” button in the
subtracts the cost to run at the new desired Storage section, and this screen appears:
plant pressure (P4). This equation calculates
the Annual Savings. The flow controller can be
changed by clicking on “Edit Selection” in the
flow controller section, and this screen will
appear:

The user can also change the recommended

receiver by clicking on “Choose Another”. The
following screen will appear:

This screen gives the Load Duration Profile of

the system to aid in making the correct Check that the selected receiver will meet the
decision when choosing the flow controller customer’s needs and click “OK”. This returns the
size. IntelliSurvey automatically chooses the user to the Proposed System Screen.
smallest flow controller with the largest Time
Coverage (%). If the flow controller the user
wants is not shown IntelliSurvey gives the
option to make another choice by clicking on
“Choose Another”. This database search
screen appears:

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 represents the percentage of total system demand
TECHNICAL TERMS that is influenced by a change of P4 pressure
GLOSSARY
Artificial Demand: Consists of the leak % and
CSV file: a Comma Separated Values file poorly regulated % and can not exceed more than
created by an IntelliSurvey data logger. 100% when added together. Example: Leak % is
30% and Poorly Regulated % is 50% the total
Drawdown: the point where the compressed artificial demand on the system is 80%. Note:
air system can not produce enough air to keep IntelliSurvey uses artificial demand to calculate
up with demand. On a graph with pressure savings.
and power the two values will decrease at the
same time, but not necessarily at the same Caution: Artificial Demand should not exceed
rate. 100%.

Max Measured Amps: the maximum amp load

Example: measured on the CSV file.

1 2 3 P1: Ambient Pressure

P2: Running Pressure (compressor discharge)

P3: Measured Pressure (supply side) after filters

and dryers.
Pressure
P4: Desired Pressure (demand side)
Power

Control Modes

From 1 to 2 the machine is in modulation (the

pressure is still increasing and the power is
decreasing)

From 2 to 3 the machine is dropping pressure

and the power is increasing to keep up with
demand.

After 3 the pressure and power are decreasing

because the demand is greater than the
supply. This is the point of drawdown where
the compressor is fully loaded (100%
capacity).

Auto Drawdown: a setting which allows the

program to find when each compressor is in
drawdown based on a comparison between
amps and pressure.

Leak %: This volume is used for the artificial

demand calculations and represents the
percentage of total system demand that is
associated with leaks that are influenced by a
change of P4 pressure

Poorly Regulated %: This volume is used for

the artificial demand calculations and

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ANALYSIS
The Analysis (graphing) section of the IntelliSurvey program is helpful when results don’t make sense. Look for
these patterns for common problems:

Description Samples

Power and pressure move opposite one

another when the compressor is actively
reacting to system pressure.

For example, as pressure increases, the

machine will slow down and make less flow in
order to compensate. This causes power to
decrease. If pressure is dropping, the machine
will try to make more air, therefore using more
power.

Control modes where this opposition will occur:

1. Modulation or ACS
2. Geometry Control Figure 1. Week in modulation control
3. VFD or VSD (Nirvana/ Unigy)

If there is an online/ offline compressor with

pressure and power curves moving in
opposition, the wrong control mode was
chosen.

Figure 2. One day in modulation control

Power and pressure move together when a
compressor is not adjusting its flow based on
pressure.

For example, in Online/ Offline control, as long

as the system pressure is within the load/
unload band, the compressor will run at 100%
speed as pressure fluctuates. As pressure
decreases, the power to compress the air
decreases. As pressure increases, the
compressor has to work harder to compress
the same amount of air. The curves therefore
move together.

Power and pressure also move together Figure 3. Week in online/ offline control
when a machine is in drawdown. This is
because the machine is running fully loaded,
trying to reach the desired system pressure,
and as pressure fluctuates, so does the power
required.

If a graph shows some areas where the

pressure and power move together and some

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where they move in opposition, there are areas
of drawdown, or that the control mode is being
changed during the week.

Figure 4. Day in online/ offline control

In the IntelliSurvey graphing tool, each point
graphed is the average over four minutes. This
means that frequent cycling is not captured
point-by-point. However, it is still easy to see
cycling.

Cycling occurs in the following control modes:

1. Online/ Offline
2. Auto Start Stop
3. 2 Step

In these control modes, at any point in time, the

compressor is only making 100% flow or 0 flow
(neglecting start-up and shut down ramps).
Figure 5. Week look at frequent cycling of online/ offline
If there are points on a flow graph between 0 machines
and 100%, this means that the machine cycled,
and the average flow is somewhere in-
between.

Flow plateaus at 100% show the machine

running constantly without cycling. Plateaus at
0 show either the machine running unloaded or
off. Anything in-between shows cycling in less
than four minutes.

Figure 6. Day look at frequent cycling

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Individual compressor power and flow
graphs can be a great way to verify that the
correct input amps were chosen.

For example, if a compressor has a “full load

power” of 200hp (150kW) and is running in
online/ offline mode, the graph should show
power hovering around 166kW (Running power
= full load rated power / motor efficiency) when
loaded and between 33 and 66kW when
unloaded.

If the graph is showing loaded power hovering

lower than this, it is a sign that the wrong amp Figure 7. Power hovering around 140 kW when machine is
value was chosen, or that a bad running fully loaded.
pressure is making the amp re-rating invalid.
Check your CSV file for full load amps, and
verify your machine’s running pressure.

Also notice here that as power fluctuates, the

compressor flow is steady when fully loaded.
This indicates that the user has chosen “online/
offline” as the control mode.

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15
Rotary Tool Box
The tools that are available in this program are
designed to ease the selection and application of
Ingersoll Rand rotary screw air compressors. They
provide an easy timesaving way to calculate various
performance figures, power usage, operating costs,
and competitive comparisons. The program also
allows the user to ask what-if questions to make
product selection more of a science than an art. This screen enables the user to select a basic color
by clicking on any of the colored squares. If a
custom color is desired click on “Define Custom
Colors” Select the hue desired and click on “Add to
Custom Colors”. When the color desired by the
user is chosen click “OK”. This will take the user
back to the User default screen click on “Save” to
save the settings.

Once the settings are to the user’s specification,

input the ambient settings of the compressor(s).
The ambient pressure will be calculated based on
the altitude inputted by the user. To add
compressor(s) go to Compressor Details.

This is the opening screen for Rotary Tool Box. The

File menu contains the option to start a new
opening screen by selecting Compressor. The File
menu also contains the option to change the default
user settings. Select Settings for the following
screen:

Click on “Add” to get the following screen:

“Units” enables the user to change from English to

Metric units. The “Language” has a drop box,
select the language that corresponds to the region
the user is from. The “Currency” has a drop box of
predefined items with the option of adding other
currencies by clicking on “Add” and filling in the
fields. The “Standards” gives the option of ISO,
ANR, and Custom. The standards change the
standard pressure, temperature, and humidity used
for standard flow calculations. The non-editable cell
color can be changed by the users, select “Back” to
change non-editable background color and choose On the bottom left hand side of the Search
“Text” to change the non-editable text color. The Compressor box is a list, select from Compressor1
following screen appears when you click on “Back” to Compressor4. Then fill in information under
or “Text”. Search Criteria to find a compressor in the
database. Highlight the compressor from the
database, and click on “Add”. If more than one

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compressor is needed select another compressor Energy Cost Configuration
from the list and search the database until all
compressors are inputted. There is a maximum of
four compressors. Click on close to go back to the
previous screen. The Compressor Details screen
should have the information selected from the
database.

Caution:
Check the values given by the database, there may
be discrepancies due to what year the compressor
was built, always double check the values given
against data received from the compressor. The user must calculate the Standard Flow
Correction before Energy Cost Configuration can be
Once the compressor(s) have been chosen go to calculated. The user then provides the number of
the Compressor Calculators: hours each shift works along with the percent each
machine is loaded in the appropriate fields. Then
change the Days/Year to the actual amount of Days
per Year and click “Compute” to calculate the cost
of energy, also known as the Annual Power Cost.

ROI & LCC: Comparison Tools

ROI Calculator

There are seven calculators to choose from. The

Standard Flow Correction and Energy Cost
Configuration tools must be completed in order to
use the others. Select a calculator by left clicking on
one of the calculators. The field under the selected
compressor(s) will change according to the ROI Calculator requires the calculation done by the
calculator selected. Fill in all areas that are white Energy Cost calculator before the ROI can be
the other fields are non editable fields. calculated. The ROI calculator takes the
compressor price, installation, and VFD bolt on
Standard Flow Configuration price and subtracts any rebates given by power
companies. The calculator then determines the
number of months needed to see a payback, known
as Return on Investment (ROI).

To compare the return of a new compressor

compared to a compressor the customer currently
owns, pick “Existing Compressor.” To compare the
return of one new compressor against another new
Input the Running Pressure for each of the compressor pick “New Compressor.”
compressor(s). Click on “Compute” to get the
Standard flow delivered and the power required.

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Life Cycle Cost Calculator System Controller Calculator

The System Controller Calculator requires the user

to calculate the Energy Cost Configuration first. It
determines if a System Controller were added to
this system, and if the plant were to run at the
The Life Cycle Cost Calculator requires the user to proposed pressure. Then the user may input the
calculate the Energy Cost Configuration first. Then existing plant pressure and the proposed plant
the user must enter the Life Cycle Term or years pressure. Click on “Compute” to get the savings a
the equipment is expected to be used. Fill in all the system controller will give you by reducing the plant
costs associated with owning the piece of pressure.
equipment Maintenance Cost, Installation Cost, and
Compressor Price. Click “Compute” to get the Flow Controller Calculator
comparison of first year and lifetime savings
compared to the selected compressor. There is
also a chart that can be viewed by the user by
clicking on “LCC Chart”.

VSD, SC, & FCC: System Tools

VSD Calculator

The Flow Controller Calculator requires the user to

calculate the Energy Cost Configuration first. Then
the user may input the unregulated demand (%).
This is the percentage of the total volume that is not
being regulated. The Leaks % is the percentage of
demand associated with the unregulated leaks
found in the air system. It determines the savings if
a flow controller were added to this system, and if
the plant were to run at the proposed pressure. The
The VSD Calculator requires the user to calculate flow controller also, needs the Existing Plant
the Energy Cost Configuration first. It determines Pressure, and the Proposed Plant Pressure. Click
the savings if a VSD were added to this system, “Compute” for the calculator to take the four inputs
and shows the flow required by that machine. There and calculate Annual Power Cost, Demand
are no fields that have to be entered for the VFD Controller Saved, and Total System Flow.
Calculator, just click on “Compute”. The calculator
will give a break down of the annual power cost,
trim flow required, and total System Flow. The
Tools
calculator takes these values and finds the New
Rotary Tool Box has an assortment of additional
Annual Power Cost, with the Annual Power
tools that can be found in the file menu under Tools.
Savings.
These tools are designed to help compare
competitive products to what Ingersoll Rand has to
offer.

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Coolant Carryover Calculator
Cycle Time Calculator

The Cycle Time Calculator is a tool that can show

The Coolant Carryover Calculator determines how the effect of various Receiver sizes, Operating
much coolant (oil) will pass into the air system from Pressure Ranges, and System loads on the Cycle
the compressor. The calculator determines the Time of any compressor operating in On-Line/Off-
amount of carryover by: Line Control Mode.
Gallons Carryover = (Compressor Flow The cycle time calculator equation is:
(cfm) X Air Density X Annual Hours (hrs) X TotalCycleTime = Online Time + Offline Time
PPM) / (Specific Gravity X 138833.3).
Pipe Volume Calculator
Condensate Calculator

The pipe volume calculator determines the volume

of storage a plant has. The calculator takes into
This tool is designed to help with sizing condensate account how much piping along with the amount of
separators, also enables the user to check the storage receivers available. Then it takes the
validity of competitor claims. largest compressor flow, with a permissive time,
The condensate calculator takes site conditions and pressure drop set by the user to calculate the
(altitude, ambient temperature, relative humidity, amount of additional storage needed.
annual hours, flow from compressor, discharge
pressure, and discharge temperature after cooler)
and computes the condensate rate and annual
condensate.

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Plant Volume Estimator Receiver Pump up Calculator

The plant air volume estimator determines how

much flow and pressure requirements a plant
actually needs to meet a customer’s requirements.
Input the site conditions and click “Compute” to
determine the flow and pressure required for the
plant.

Cost of Pressure Drop Calculator

The Receiver Pump Up Calculator is useful in many

instances when testing compressor capacity, sizing
receivers, and determining the cycle time or useful
storage in a system.

The following is taken from the Compressed Air and

Data Book:

Pump Up Formula

To estimate the time required to pump-up a given

receiver or air system, the following formula may be
used. The result disregards temperature
differences and changes throughout the system.
The Cost of Pressure Drop Calculator allows you to
The formula gives, therefore, a somewhat longer
assign a cost in dollars to the pressure drop in a
time than should actually be required.
compressed air system.
T= V(P2 - P1)
The Theory used is simple, the following
Po (free air delivery)
assumptions are made:
where T is time required
• The pressure requirement at the point of
V is tank (or system) volume
use is fixed.
Po is initial tank pressure
• The compressor discharge pressure is P1 is initial tank pressure
equal to the point of use pressure plus the (usually atmospheric)
pressure drop in the air clean-up and P2 is final tank pressure,
delivery system.
• A system with a higher pressure drop will Reverse Pricing Calculator
require the compressor to operate with a
higher discharge pressure.
• Running a single stage flooded rotary
screw compressor at a higher pressure
requires 0.5% more Horsepower (or kW) for
every 1 psi increase in the discharge
pressure.

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The Reverse Pricing Tool will calculate the
recommended selling price of an energy savings
solution based on the payback period (price
difference) entered by the user. Just input the
energy savings per year and the number of months
required for project payback. Click “Compute” to
receive the new compressor price.

Standard Flow Calculator

This calculator takes the actual conditions and

calculates the standard flow at these conditions.
The free air delivery section takes a standard flow
value and converts it to free air delivery at ambient
conditions. The Standard/Normal Air flow section
takes free air delivery and converts it to standard
flow at ambient conditions.

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