Turnkey compressor room: design, construction and servicing
We deliver complete compressor rooms for industrial plants: from measuring compressed air demand, selecting and supplying equipment, designing the room and installing compressed air pipework and electrical systems, through to commissioning, documentation and a service agreement. We build new compressor rooms as part of plant construction and upgrade existing compressor stations. We carry out projects throughout Poland.
Scope of work
Our compressor room construction services include:
- measurement of compressed air demand (logging power consumption and air delivery in the existing system) or a demand calculation based on the documentation for the air consumers
- selection of fixed-speed and variable-speed screw compressors, including multi-compressor systems with master control
- selection of compressed air receivers with documentation for registration with UDT, the Polish Office of Technical Inspection
- selection of refrigerant or adsorption dryers and filtration to meet the required air purity class under ISO 8573-1
- compressor room design: equipment layout, supply and extract ventilation, condensate drainage and separation, electrical supply and distribution board
- compressed air pipework from the compressor room to the air consumers, using aluminium or steel pipes with take-off points
- heat recovery from compressors for space or domestic hot water heating
- installation, commissioning, leak testing, pressure and control settings, and dew point measurement
- as-built documentation and operator training
- a service agreement with a maintenance schedule.
We supply Hertz Kompressoren compressors, Hertz and BEKO Technologies DRYPOINT dryers, BEKO Technologies CLEARPOINT filtration and pressure vessels with UDT documentation. We also integrate serviceable compressors from other manufacturers that the plant already owns into the new system.
Equipment selection
Selection is based on measurements, not the sum of the air consumers' power ratings. At an operating plant, we connect a data logger for several days to a week and use the results to determine actual demand, the daily demand profile and the required pressure. For a new plant, we calculate demand using machine documentation, simultaneity factors and planned shift utilisation.
For variable demand, we use a variable-speed compressor; for a constant load, a fixed-speed unit; and for higher demand, a system of two or three compressors with a master controller that distributes the load and balances operating hours. We agree the reserve capacity with the customer according to whether a production stoppage is acceptable if one machine fails.
We size the air receiver according to compressor output and demand characteristics, and select the dryer and filters to meet the required purity class: requirements differ between a paint shop, a food processing plant and applications where air supplies only cylinders and tools.
See also: compressor sales, compressed air audit.
Compressor room design
The design covers equipment layout with maintenance access, heat balance and ventilation selection, pipe routing, condensate drainage and electrical supply. Requirements we consider in every design:
- maintenance clearance from walls and between units, usually at least 1 m on the service door side
- ventilation to remove heat from the coolers; an oil-lubricated compressor releases approximately 90% of its electrical input into the room as heat, which means over 30 kW of heat for a 37 kW unit
- a room temperature of 5-40°C throughout the year, with the air intake on the shaded side, away from dust sources
- an oil-water condensate separator before discharge to the sewer
- a floor with adequate load-bearing capacity and a transport route for equipment replacement or overhaul
- an electrical supply with protective devices rated for the starting currents.
We provide the design before construction starts so that the building contractor can prepare the room, utility connections and service penetrations.
Upgrading an existing compressor room
We start an upgrade with a compressed air audit: measuring power consumption, air delivery and leaks in the system. We use the results to determine which compressors should remain, which are suitable for an airend overhaul and which need replacing. In many plants, instead of adding another machine, master control, sealing leaks and reducing operating pressure are sufficient, cutting energy consumption by around 10-20%.
We carry out the work in stages without stopping production. We provide a replacement compressor while the system is switched over. We schedule the supply switchover for a weekend or a maintenance shutdown.
Containerised compressor room
For plants with no spare floor space inside the building, we build containerised compressor rooms: an insulated container with ventilation, lighting, heating and a distribution board, equipped with a compressor, dryer, air receiver, filtration and condensate drainage. The equipment is assembled and interconnected before delivery. The customer is responsible for a hardstanding or foundation slab, the electrical connection and the connection to the system inside the building.
Commissioning and documentation
After installation, we leak-test the system, set operating pressures and controls, and check the dew point downstream of the dryer and each compressor's operating parameters under load. The customer receives as-built documentation: a system diagram, equipment documentation, test and setting reports, and operating recommendations. We train operators in daily equipment checks and reading the controllers.
Compressor room servicing
A service agreement covers maintenance based on operating hours with consumables replacement, servicing of dryers and condensate drains, annual leak measurement, priority for emergency call-outs and fixed parts and labour prices for the contract term. After each service, we provide a report with readings and recommendations. We overhaul airends ourselves, allowing compressors to remain in service for many years without replacement.
How we work together
After receiving your enquiry, we arrange a visit to the plant. We assess the room, existing equipment and system on site and, if necessary, leave a data logger for several days. Based on the measurements, we prepare a quotation with two or three options differing in power, control and operating costs, including calculated annual energy consumption for each option. Once an option is selected, we prepare the design, agree the schedule with the maintenance team and carry out the work. The lead time from the visit to commissioning is usually six to twelve weeks and depends mainly on equipment delivery times.
Questions and answers
Compressor room enquiry
Please include your type of production, the number and power ratings of existing compressors, the number of shifts and the required air purity class, if specified. We respond within one working day. Telephone: 606 282 624.
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ul. Słowackiego 201 26-600 Radom Mazovian Voivodeship, Poland