Innovation at Ingersoll Rand

Ingersoll Rand (IR) has launched a new generation of rotary screw and centrifugal air compressors. The announcement was made at an “Innovation Showcase” event in Charlotte, NC. An entire hotel was reserved for almost a week so that 600 to 700 Ingersoll Rand salespeople from across the Americas could be trained on the new technologies. A handful of us “media types” were also invited to come and learn about Ingersoll Rand’s latest innovations in compressed air systems.

The New Ingersoll Rand

Ingersoll Rand has gone through a period where the structure of the company has changed significantly. Jim Bolch, president of IR’s Industrial Technology Sector, said, “Over the past two years, IR has taken significant steps towards becoming a diversified industrial concern through the divestiture of Bobcat and other construction businesses and with the acquisition of Trane.”

Ingersoll Rand now operates market-leading brands in the following businesses:

• Hussmann: display cases and refrigeration systems for food retailers
• Thermo King: refrigerated transport
• Trane: HVAC
• Club Car: golf cars and utility vehicles
• Ingersoll Rand: legacy brands including compressed air system products
• Schlage: security products

Ingersoll Rand recently reported 2009 full-year revenues of $13.2 billion for the whole company. IR also recently reported fourth quarter 2009 revenues for ITS of $591 million.  Due to the timing of the meeting, Mr. Bloch had to use 2008 numbers and statistics stating that IR ITS had 2008 revenues of $3 billion. Of that total, 66% came from “complete machines” and 34% from “aftermarket products”. He further explained that “Geographic sales, in 2008, were 53% from North America and 34% from the European-Served-Area (ESA).”

Mr. Bolch made the interesting comment that the integration of this new company, over the past two years, had resulted in the application of many “smart technologies to industrial technology”.

Outcome Driven Innovation

During this period of transformation, “IR spent nine months surveying 2,500 customers from 13 industries located in the United States, U.K., Germany and China”, explained Manlio Valdes, the vice president for Global Product Management at IR.  “Investments in new product development were increased significantly in 2009 and now again in 2010. Our process is called ‘Outcome Driven Innovation’ (ODI), and it focuses on listening to the needs of our customers and responding to them.” Mr. Valdes further explained that after all the market research was completed with Voice-of-the-Customer and Voice-of-the-Channel surveys, the overall drivers for new product design were identified (in no particular order) as reliability, efficiency and productivity.

Launched at this event were two main “Benchmark Platforms” for the new R-Series rotary screw and C-Series centrifugal air compressors. Mr. Valdes commented, “These new air compressor benchmark platforms integrate the drivers of reliability, efficiency and productivity.”

The New R-Series Contact-Cooled Rotary Screw Compressor

When you’ve been around a lot of product launches, you start to adopt the Missouri attitude/slogan of “Show Me” before you get excited. I confess I felt this way at the start of the showcase. When we began to review the new R-Series contact-cooled, rotary screw compressor, however, Ron Ratell (Global Category Manager) and Robert Horneman (Global Portfolio Manager) quickly got my attention. “We are now launching the first phase of the R-Series with 125–200 horsepower (90–160 kW) models,” said Mr. Ratell. “This is part of a multi-phase introduction, which will cover models ranging from 5–200 horsepower.”

The Sequential Cooling System got my attention. This new cooling system lowers standard discharge temperatures (also known as approach temperatures) to 4 ºF (2.2 ºC).  This is a significant improvement over the “industry-norm” of 15 ºF approach temperatures. The Efficiency Benefit for end users is that this will significantly reduce the energy required (and the related cost) of downstream compressed air treatment equipment. “The CTD (Control Temperature Discharge) that we use to rate compressors is a real-world 115 ºF at 40% RH (relative humidity),” said Robert Horneman. “This is quite different from the unrealistic CTDs used by other firms of 68 ºF and 0% RH.”  The independently mounted, free-floating air and coolant heat exchangers can also enable the compressor to operate in ambient temperatures up to 131 ºF (55 ºC).

An integrated cyclonic moisture separator connected to a standard electronic no-air-loss drain removes condensate from the air stream. Integrated refrigerated dryers are standard options on compressors up to 100 hp in size. Outlet air quality is further enhanced by a standard, 316 stainless steel, outlet piping system. This air quality Reliability Benefit reduces the chance of pipe scaling and the introduction of solid particulates into the outlet air.

Instead of a fan, the Sequential Cooling System uses a centrifugal blower to evacuate the heat. The Efficiency Benefit is that the motors are significantly smaller (vs. the fan motor) and that it is a lower-noise solution. Overall sound attenuation ratings are 74 dba (air-cooled) and 71 dba (water-cooled).

Productivity Benefits of the R-Series focus on the new Progressive Adaptive Control^™ (PAC) system. This is an intelligent system, monitoring key operating parameters and adapting to prevent unexpected downtime. This involves the use of sensors to prevent components from causing the air compressor to shut down due to high-temperature or differential pressure conditions. I thought this was a great example of what Mr. Bolch referred to as “bringing smart technology to industrial technology.” The idea is that the air compressor will receive signals to automatically run slower, rather than shut down and affect production in the facility. True differential pressure sensors are installed on the intake filter, lubricant filter and separator. The PAC control system monitors their readings, and can adjust the operation of the air compressor to not only optimize efficiency but to ensure up time.

Efficiency Benefits are further offered with the cleverly simple way so many airend and drive options are available on the same R-Series base design. Customers can specify four energy-efficient packages combining these two critical components.

1. Nirvana VSD Premium Efficiency: variable speed drive with a two-stage airend, which provides 15% more air than single-stage units.
2. Nirvana VSD Efficiency: variable speed drive with a single-stage airend.
3. Premium Efficiency: Fixed speed with a two-stage airend
4. Fixed speed with a single-stage airend

The New Centac C-Series C1000 Centrifugal Air Compressor

Did you know that Ingersoll Rand has an installed base of 22,000 Centac oil-free centrifugal air compressors!?  So says Chad Larrabee, Global Category Manager, Configured Air Products, at Ingersoll Rand. “IR introduced the first oil-free centrifugal compressors in 1912, and launched the Centac centrifugal package in 1968,” said Larrabee. “Brand studies show that customers perceive the Centac as a compressor which will last forever!” he explained. “We are continuing with features like the AGMA-rated gearing designed for a 25-year life, high-quality and efficient impellers, and a leak-free oil system design guarantee. These are just some of the Reliability Features which have long established the IR Centac as the market leader.”

The new C1000 represents a new benchmark platform for the Centac C-Series centrifugal compressor. A significant change to the design is the new transverse-mounted, water-in-tube coolers. Unlike the prior coolers with longitudinal mounting, the new transverse-mounted coolers allow for in-place cleaning from either side.  The fact that the coolers don’t have to be shipped out for cleaning is a significant Productivity Feature for a facility. The coolers are oversized for greater fouling resistance and provide low compressor discharge temperatures and pressure drop. Another Productivity Feature is the fact that the impellers can be inspected and removed in only two steps thanks to a new “vertically-split” package design.

The New C1000 Centrifugal Compressor

The new XE Series Controller has an intuitive display, which reminds me of what you see in newer cars today. Randy Finck, IR’s Global Category Manager for Air Treatment and Controls, said, “Each controller is web-enabled to allow users to monitor and control the compressor from remote locations. One no longer needs to have a smudged-up, clip-board hanging next to the air compressor — the C1000 will email you up-to-date maintenance logs!”  No special software is required for the new controller to communicate and the connectivity is easy to Plant DCS, automation or the internet.  Finally, the XE Series Controller has Efficiency Features like optimized turndown, simplified ambient control and advanced surge control.

A History of Innovation

I came away from the meeting with a real sense that Ingersoll Rand is just now starting an important new chapter both as a company and in compressed air systems.  The marketing materials do a nice job of showing the innovation timelines, beginning in 1872 (reciprocating compressors), to 1912 (oil-free centrifugal compressors) and through 1952 (oil-free rotary screw compressors).

The company has reorganized itself internally and is now in the launch phase of new “benchmark” designs of IR’s main air compressor product lines. The managers I met are excited about the “smart technology” and the “service-friendly” features of the new air compressors.  Innovation is an exciting thing when you know you are providing your customers with more value.  Leaving surprisingly snowy Charlotte to ever-snowy Pittsburgh, I had the feeling that Ingersoll Rand had accomplished their product design goals of delivering Reliability, Efficiency and Productivity Benefits to their customers.

For more information, please contact Rod Smith at email: rod@airbestpractices.com, www.airbestpractices.com.