NEWS STORIES

2AN35D_Kateeva A Case Study in Nitrogen: Kateeva OLED Displays

Customer: Kateeva
Model: 2AN35D-H3321-BLMVA10-20/10T
Gas: Ultra high purity nitrogen
Suction Pressure: .8 psig
Discharge Pressure: 95 psig
Flow: 17.75 SCFM

Situation: California based Kateeva is creating a new class of production equipment for advanced flat panel display products like OLED (organic light-emitting diode) TVs. Through this process they questioned, what is the most efficient and effective way to compress nitrogen? They desired a compressor manufacturer that would assist in building equipment for their development.

Their major concern was finding a compressor that would not allow outside oxygen to contaminate the manufacturing process and product. It needed to keep nitrogen pure while stopping ingress of oxygen higher than 5 ppb (parts per billion). They struggled to find anyone that would even come close to solving their situation.

Solution: Mr. Mauck could not find a compressor to meet these requirements until he spoke with representatives from Hycomp. The Hycomp team worked together to understand the problem and find the correct solution for Kateeva to meet their difficult requirements.

Justin Mauck, Senior Mechanical Engineer for Kateeva, approached Hycomp with this situation. Hycomp accepted the challenge. They worked together to understand the problem and find the correct solution for Kateeva to meet their difficult requirements.

“Talking to the Hycomp engineers gave me a strong sense that they could really solve our difficult problem,” Mauck commented, “We had a hard time finding anyone that could even come close to meeting our need. When we found Hycomp, I thought ‘this is it’ and I was excited to work with them.”

H Series The solution was a Hycomp ‘H’ Series: Extreme Control packing arrangement. The ‘H’ Series is designed to compress difficult to contain industrial gases. Suction gas is plumbed through the upper plenum chamber, equalizing pressure on, and providing cooling to, the upper packings. Three pairs of packings per rod provide the first isolation of the process gas. A second plenum chamber was added, through which purge gas may be run. Five pairs of segmented packings per rod, with a purge chamber between the top three and the bottom two packings are located in the bottom of the lower plenum chamber.

“Once I understood the technical aspects of the solution, I was confident that the approach was sound and that it would work. This helped me to be really confident when I went to present the solution to my manager and others that had to approve the purchase,” concluded Mauck.

Results: Hycomp tested the compressor at the desired conditions. It was observed that less than 5 ppb oxygen entered the nitrogen gas stream upon compression. The packing arrangement performed as expected. Kateeva received the compressor and installed the unit in to their process. They are still pleased with the performance and have experienced ultra high purity nitrogen results over the last 30 months.

This solution can be customized to not only help Kateeva but also solve your similar concerns. Additional quantities of packings may be added for tighter control. Applications where the suction pressure is lower than the pressure in the upper vent/purge chamber (vacuum or high pressure padding) can also be handled in standard configuration.

nitrogen A Study in Nitrogen

Nitrogen (N2) is a colorless, odorless and tasteless gas that constitutes 78.08% by volume of the air we breathe. Nitrogen is an inert gas.

Nitrogen occurs in all living organisms. It is a constituent element of amino acids and thus of proteins and nucleic acids (DNA and RNA). It resides in the chemical structure of almost all neurotransmitters, or in other words, nitrogen is an important chemical in the thinking process. As you read this article you are utilizing nitrogen to connect cognitive thought patterns via synapses in your brain.

The bulk of nitrogen produced in the United States is done via cryogenic separation of air; air is supercooled to a liquid state, and the different gases stratify, just as water and oil do in a glass. Nitrogen is then pulled out as a liquid. Air separation plants can be large facilities serving multiple customers covering several states, or site specific for large users of nitrogen. Cryogenic nitrogen purity can vary depending upon need, but can hold in the ppb (parts per billion) of contaminant gases.

A method of Nitrogen production gaining rapid favor for its ease of installation and relatively low cost are nitrogen generators that separate the nitrogen from air in the gaseous phase, either through the use of a membrane, or via pressure swing adsorption (similar to regenerative air dryers). These units are fairly small in size and production volumes (roughly 100-10,000 scfh per system), but can be 1/10th to 1/100th the cost of a cryogenic separation plant. However, gaseous nitrogen generators don’t produce pure nitrogen – they actually remove oxygen. So while the oxygen content can reach less than 10ppm, there will still be other gases present in the nitrogen that are also present in air – gases like argon, helium, carbon dioxide, etc. In many applications, this is acceptable, as the nitrogen is being used because oxygen cannot be present in the process.

Nitrogen has many commercial and technical applications. As a gas, it is used in heat treating of primary metals; blanketing of oxygen-sensitive liquids and of volatile liquid chemicals; the production of semiconductor electronic components, as a blanketing atmosphere; the blowing of foam-type plastics; deaeration of oxygen-sensitive liquids; the degassing of nonferrous metals; food processing and packing; inhibition of aerobic bacteria growth; magnesium reduction of aluminum scrap; and the propulsion of liquids through pipelines.

13 Natural Gas Compressor for Ceprot Systems

Ceprot Systems have been a packager of natural gas compressors for well head applications in Estonia and the Baltic region since 2005. They offer engine and motor driven reciprocating and rotary screw compressors.

In mid 2012, Hycomp received a request from Ceprot Systems for a vapor recovery compressor to operate in a remote region of Ukraine. The application required a compressor to recover the natural gas vapors and compress them to a pressure that could be re-introduced into the production system. Due to the remote installation location and lack of cooling water, Ceprot required an air cooled system with very high reliability.

Hycomp was able to build exactly what Ceprot Systems required with an oil-free, air-cooled “F” block compressor and “G” series packing arrangement. This package included a skid-mounted compressor with motor, and air cooled intercooler and after cooler. It was supplied to the Sakhalin gas treatment plant near Kharkov, Ukraine. UKROilDrilling Company, LLC is the company now using the Hycomp compressor via rental agreement with Ceprot Systems.

“The unit is working in a very heavy application and remote location and we have had no service calls in the last six months”, stated Alex Shvets, General Director of Ceprot Systems.

G Series The “G” series packing configuration is designed for service with flammable or hazardous industrial gases. Suction gas is plumbed through the plenum chamber, equalizing pressure on, and providing cooling to the packings. This design incorporates a purge/vent line to prevent leakage of the process gas.

Let Hycomp help determine the best possible solution for your application. Please contact Ben Brough or Ken Shiefer at 435-563-3695.

BrianFinal-cropped again Hycomp Welcomes Brian Llewellyn

Hycomp is proud to introduce Brian Llewellyn as our new Engineering Manager. As Hycomp continues to grow, Brian is now part of this exciting expansion. Brian is able to use both his engineering degree and MBA to manage a highly efficient and effective team. This team is committed towards continuous quality improvements at every step from designing to shipping of Hycomp products.

Brian understands that the customer comes first. He is able to make changes quickly and efficiently with Hycomp’s highly skilled workforce, while maintaining their quality standards. Hycomp excels at providing a quality product to customers and often in about half the time that competitors can accomplish.

“It is great to be part of the Hycomp team! I have been so impressed with each individual at all levels and their commitment to our quality products.” commented Brian.

Brian started his career at a Fortune 500 company where he learned the sustainable practices required for supporting a growing business. Using these practices, he will be able to apply that same knowledge into Hycomp. He understands the stages of growth and that each must be treated differently at every stage. It is vital for him to provide the quality products that Hycomp’s customers deserve and expect.

Brian stated, “I have never worked with such a devoted group of people. They will do whatever it takes to not just meet, but exceed our customer’s expectations. This type of commitment can be seen in the quantity of repeat business in both domestic and international markets.”

INSTEP-1 Hycomp Donates to INSTEP for Expansion

Hycomp is proud to donate a portion of four compressor packages that were sent to Institut Teknologi Petroleum Petronas (INSTEP) in Kuala Terengganu, Malaysia. INSTEP is being expanded as part of a technical training partnership between Petrofac and Petronas. The donation is a gesture of goodwill and support for the industry, and INSTEP in particular.

Established in 1981, INSTEP was primarily set up to train skilled technicians and operators in meeting the rapid growth of the country’s petroleum industry. To date, INSTEP has trained almost 10,000 technical staff in the various facets of the oil and gas industry.

INSTEP The units will be part of a new expansion of the facility to include an Upstream and Downstream Theme Park (UDTP), including two upstream plants, and one downstream plant, designed and built to replicate real units that will look and feel like the ‘real thing’. For safety purposes, the facility will not involve any hazardous substances. The upstream plant will be fed with non-volatile synthetic oil to simulate crude oil, and nitrogen will simulate the associated natural gas. The downstream plant will utilize an ethylene glycol/water mix to mimic crude oil, and nitrogen to mimic the hydrogen requirement. The four Hycomp compressors will simulate offgas and recycle compressors in the plants. Hycomp is pleased to be a part of this educational facility.
Hycomp Made the List, Inc. 500|5000

For the third year in a row, Hycomp is listed on Inc. Magazine’s annual Inc. 500|5000 list, an exclusive ranking of the nation’s fastest-growing private companies.

Thirty two years ago (1981) Inc. Magazine began to publish an annual report of what was originally titled: “The Inc. Private 100: One Hundred of the Fastest-Growing Privately Held Companies in the United States.” They have refined the title of this report and expanded it to a list of 5000 with a concentration on the top 500.

Hycomp has earned the rank of 2908 out of 5000 companies. In an industry top 100 list, Hycomp was ranked at 61 on the list of top manufacturing companies; in 2011 Hycomp was listed at 91.

From 2008 to 2012 Hycomp has experienced a growth of 226%. Hycomp’s Sales and Marketing Manager, Martin Malzahn attributes our constant growth to having a niche in the manufacturing market and a great ability to customize.

“We grow because we provide service to our customers.” said Martin.

We continue to push forward by researching new markets and applications where our compressors and boosters can provide quality solutions. Our niche market is increasing, and we look forward to more growth at Hycomp.

lisa-perkes Lisa Perkes: New Hycomp Marketing Specialist

Hycomp is pleased to announce the addition of Lisa Perkes, a marketing specialist. Lisa comes to Hycomp with a background in web design and public relations.

Lisa will be heading up the newsletter and website. For any comments or questions about the newsletter, contact her at lperkes@hycompusa.com.

helium-2 Helium Shortage Creates Need for Reclaim Compressors

Whether you have noticed or not, a global shortage in helium (He) has existed since May of 2012. Have you recently tried to buy a floating balloon for your kid’s birthday party? You will have a hard time finding helium to fill the balloons and if you do, it is very expensive to purchase. This shortage has now reached a level the U.S. Government describes as a crisis. While the causes are many, the net result is helium prices are skyrocketing while supply is diminishing.

While helium is abundant in the universe, it is rare on earth. This gas is created when heavy elements like uranium radioactively decay in the earth’s crust. Most helium atoms diffuse to the surface and escape the earth’s atmosphere. Only a small percent of helium atoms are trapped in the Earth’s crust, much like natural gas. Helium extraction becomes economically viable in a select few deposits. Currently, the annual global use of helium is larger than the amount produced. This situation is convincing many companies to recover the helium rather than vent the gas into the atmosphere.

This is where Hycomp helium compressors have become a popular solution. Hycomp’s oil free compression keeps the gas stream pure. Our gas packing arrangement keeps O2 and other contaminants from ingressing into the gas flow. Our unique self-adjusting tangent/tangent gas packing arrangement enables Hycomp to maintain purity. One customer reported less than 5 parts per billion of oxygen.

helium Hycomp creates an extremely efficient piston ring seal by using our unique ‘L’ style piston ring designed around a proprietary material formulated specifically for helium.

Helium generates high heat in compression. Hycomp Engineers address this challenge utilizing low compression ratios and liquid cooling.

Demand for Hycomp helium compressors has increased dramatically over the past few months and we anticipate this trend will continue. Here are a few sample applications where helium is used:

helium-3 Metal Processing
Oil and Gas Production
Offshore Industrial Diving (Heliox)
Semiconductor Manufacturing
Healthcare (MRI)
Glass/Mineral Production
Nuclear Energy Generation
Aerospace
Automotive
Cryogenics
Many Others

If you have questions concerning helium compressors, or any compressor for that matter, please contact Hycomp and ask for Ken Schiefer or Ben Brough.

Map International Hycomp

A major contributor to Hycomp’s growth these past few years has been the international market. Hycomp has expanded its worldwide presence into eight new countries, increasing the number of countries that have Hycomp compressors to thirty.

According to industry experts, air and gas compressor exports are expected to increase 8.9% annually for the next five years. Hycomp has been exceeding this trend and is prepared to meet international demand. We have experience in packaging systems to ASME, ATEX, IECex, UL/NEC, CE/PED, KGS/KOSHA, GOST, and SQL standards.

As the world’s awareness of Hycomp’s quality and dedication to providing the best possible solution to each application increases, we expect international activity to continue increasing. We look forward to continued relationships with our international customers.

oil pump housing Oil Pump Housing: Bigger – Better – Stronger

We all want to torque bolts down so that they are tight and snug. But when dealing with standard NPT threads, too much torque can lead to big problems.

The oil pump housings on a majority of Hycomp compressors have, in the past, been made from cast aluminum. The crankcases used on Hycomp compressors are supplied by an OEM and then modified to fit our customer’s needs. When the NPT bolts are over torqued, they can cause the oil pump housing to crack and fail. To fix this problem we decided to further our modifications to this crankcase and manufacture our own oil pump housings from billet aluminum rather than cast aluminum, and we have completely redesigned them for dramatically increased strength and longevity.

OLD Oil Pump Housing As you can see from the 3D rendering of both oil pump housings version (past and current), the new design is far more robust than its predecessor. The revised design is also more intuitive for installation, as there is only one correct way to install it. You simply install the oil pump housing with the word “TOP” at… well, the top.
NEW Oil Pump Housing All new compressor orders, starting in June of this year, are being built with these new oil pump housings and these housings are also available for older models. The following Hycomp compressor blocks will utilize the new design: B, C, D, E, G, H and V. The A-Block is splash lubricated due to its small size and the F-Block compressors already have been utilizing the billet aluminum oil pump housings since the early 1970’s.

The redesigned oil pump housing bolts directly to the same location as the old design and only require longer bolts, a different oil filter and a properly sized o-ring; all of which are offered as a kit for retrofitting older model compressors. Please contact Hycomp for more information and/or to order the new oil pump housing kit.

Ragnar Relay - Hycomp Team: If We Weren't All Crazy, We Would Go Insane 197.4 Miles Through the Utah Mountains
Hycomp Team Runs the 2012 Ragnar Relay
Click on image to enlarge.

If you were to drive 197.4 miles it would take you between 2 and 3 hours. Running that same distance through the mountains of Utah only took our team of relay runners 36 hours and 6 minutes. Yeah, that’s right!

“If We Weren’t All Crazy, We Would Go Insane” has been our team name for the last 3 years and like the years preceding this one, our team has been comprised of Hycomp employees and friends. A dozen people that were crazy enough to collectively run almost 200 miles as fast as their feat could carry them.

Ben Brough, Hycomp OEM Sales Manager had this to say about his first experience with the Ragnar Relay. “Running was the easy part to prepare for. I found that it is the lack of sleep and not being able to eat right that makes the Ragnar challenging. The energetic atmosphere is something that can’t be explained, it has to be experienced!”

The Ragnar race is a relay, each runner has three sections of the course to run and each team has 12 runners and 2 drivers. But when you factor in the fierce terrain of Utah’s mountains, the almost complete lack of sleep for 36 hours, and running in the heat of June 15 – 16 the runners of this relay take a serious beating. And yet, year after year, they keep coming back for more.

The average person would ask the obvious question, “Why would anyone want to do this?” But to our runners and anyone else that has run in a Ragnar Relay, the question is quite the opposite, “Why wouldn’t you want to do this?” During the relay, there is a camaraderie forged among all runners, and especially tight friendships and bonds among teams as they cheer each other on. People who have not run a Ragnar Relay may never understand why anyone would want to do something like this… and that doesn’t matter to a runner, they will just keep on running.

Click on following images to enlarge.


Team “If We Weren’t All Crazy, We Would Go Insane” Runners:

Runner Distance
Tom Knowles 21.1 miles (39 km)
Ben Brough 13.7 miles (22 km)
Barbara Tidwell 19.4 miles (31.2 km)
Stacey Moss 14.6 Miles (23.5 km)
Angela Smith 14.8 miles (23.8 km)
Andy Hansen 17.2 miles (27.7 km)
Erinn James 11.7 miles (18.8 km)
Reid Andrews 15.9 miles (25.6 km)
Pete Hyde 17.6 miles (28.3 km)
Robert James 15.3 miles (24.6 km)
Mike Wiser 19.8 miles (31.9 km)
Taryn Ricks 15.9 miles (25.6 km)

Hycomp Special Tools Special Tools & Engineered Solutions

When you are the only distributor around that has the right tools for the job, and when potential customers need help, who are they going to call? They will contact a trained service provider who has the right tools to handle the job with agility and precision.

In any industry, when a majority of products are similar, the same tools can be used on most of the products for maintenance and repairs. However, when a product is specifically engineered to match an application, special tools are often employed.

Hycomp compressors and boosters utilize over 10 special tools to administer precision maintenance. The most often used of which are the SA001, SA003 and SA004.

Hycomp Special Tools SA001: Valve Removal
The SA001 is used on all of our compressors that have unloader towers. It is used to remove and tighten the valve clamp screw. This tool will be used every time the valves are removed on a compressor that has unloaded towers. (4,000 and 8,000 hour preventative maintenance intervals).
Hycomp Special Tools SA003: Piston Rod Removal
The SA003 is used on all of our compressors. It is used to hold the piston rod in place while removing and installing the compression piston. This tool will be used on all 8,000 hour preventative maintenance intervals or whenever the compressor is disassembled ant further then the compression cylinders.
Hycomp Special Tools SA004: Oil & Gas Packing Installation
The SA004 is used on all of our compressors except F-Blocks. It is placed over the piston rods to make the installation of the oil scrapers and gas packings possible. SA005: Oil & Gas Packing Installation is used on our F-Block compressors and boosters. The SA004 and the SA005 are nearly identical; there is only one slight difference; the SA004 is a male connection to the piston rod and the SA005 (F-Blocks) is a female connection.

Special Tools & Engineered Solutions
A majority of the time, Hycomp compressors cannot be worked on without the use of the necessary special tools. Additionally, use of Hycomp special tools provides protection to the compressor and the soft goods. For example; when you are installing a pair of gas packings, each set costing about $300 (most compressors use multiple packing sets), the small cost of a $100 tool makes a lot more sense, especially when you could possibly be installing $1,500 worth of gas packings. If one or more of those expensive gas packings get damaged or chipped, it will not seal properly and then the compressor will have to be disassembled again to figure out which packing is causing the sealing issues. It makes simple sense that the purchase of a relatively inexpensive tool far outweighs the risks of wasting product due to poor or improper installation, not to mention possible extended downtime.

When providing service on a specialized machine, it makes sense to protect that investment by using the right tools for the job. When the proper tools are always used, absolute precision is always obtainable.

Click here to contact a Hycomp Service Technician for special tools support or call 435-563-3695

2012 AICD AICD 2012: Return & Report

“We talked to nearly everyone at the show” said Rob Hunt, Hycomp Area Sales Manager, “And we were happy to attend the 2012 AICD, it is always a great show to be part of.”

Four members of our sales team represented Hycomp at the 27th Annual AICD (Association of Independent Compressor Distributors) Membership meeting in Florida: Ken Schiefer – Eastern US Area Sales Manager, Marty Malzahn – Sales & Marketing Manager, Freda Lasley – Sales Coordinator and Rob Hunt – Western US Area sales Manager. Each Hycomp team member agreed that the overall feel of this year’s AICD was a little different for Hycomp, Ken explains, “There really was not much general conversation about our product, it seems people are starting to really understand what Hycomp does and the products we offer. This year’s individual discussions seemed to all be centered on business.”

Through interaction at the AICD meeting and other communications with our distribution network we are finding that there is a strong desire to learn more about the applications where Hycomp compressors and boosters apply. Our distributors want to specifically know where to look for Hycomp sales and our training videos and other materials are covering that.

Hycomp has a new booth setup, which got several accolades from folks while at the show. Included as part of that booth, we use a flat screen LCD TV to display either a photograph slideshow presentation or in this case, a recorded power point sales training presentation. Rob and Ken both utilized the short 10 minute video to explain to distributors how Hycomp can more effectively train their entire sales staff and how this short video presentation can be used internally by their team.

The seminars at AICD were fantastic. Every member of the Hycomp team had great things to say about the seminars and were especially impressed with a presentation given by Bill Scales, which was titled: The Future of Distribution. Bill expounded on the wants, needs and fears of distributors and also talked about what manufacturers should be doing for their distributors.

Loyalty from manufacturers to distributors was a big topic of discussion during the entire weekend. It is always an important topic to us here at Hycomp as well. In our industry we have recently seen a little bit of a trend in which some manufacturers are cutting distributors out by selling direct to the customer. We highly value our distributors and have even fought to protect them in numerous cases. “Trust… It’s What We Build” is not just some sort of warm fuzzy slogan or tag line we use, we really believe in it and we take it very seriously. The trust of our customers and our distributors is paramount to our business plan. We thank our distributors for their continued partnership and we look forward to working with them, side by side, in the years to come.

CLICK HERE to see where Ken, Freda and Rob went on their way home from the 2012 AICD

Hycomp Technical Bulletin Technical Bulletin: Hycomp ID Coding System UPDATED

The Hycomp documents T111 Air Compressor ID Coding System, T112 Air Booster ID Coding System and T113 Gas Compressor ID Coding System have been recently updated and may be found by clicking the previous links or by visiting the Hycomp Literature Page.

Hycomp President and Engineering Manager, Robert James, explained the revision, “As we’ve grown internationally, we found that our standard compressor model scheme was insufficient to meet the wide range of both domestic and international code requirements for heat exchangers and vessels.”

Therefore, in an effort to streamline, simplify and universalize the Hycomp ID Coding System we have removed these items from our standard model number for our customer’s convenience.

Hycomp Tech Support Thriving in a Niche market

Every company should have a target market in which it thrives. Hycomp flourishes in a market segment that requires oil-free and high quality compression from 0-3,000 psig standard. Most of the larger companies do not even make a product offering in this corner of the market. This helps to make us unique, but that’s not what makes us successful.

Not a “one size fits all” Product Line
We are not looking to be everything to everyone. We do not restrict our customer’s choices to a standard compressor model from a catalog. That is not the Hycomp way. We custom build exactly what you need. This methodology is the backbone of Hycomp’s commitment to its market and one of several important characteristics that differentiate us from the competition: Our products are engineered solutions.

At Hycomp, what makes us truly successful is how we interact with each customer before the sale, then how well we back our product after it is in operation. We take the time to investigate each application to ensure that the chosen compression system exactly matches each requirement. When a new client discovers Hycomp, it is not unusual to hear that they have spent a lot of time and effort searching for a compression system that meets their specific needs. Their search ends when they call us. Hycomp compressors are tailor made to perfectly fit our clients’ individual needs and to provide efficiency, longevity and worry-free service. Add to that our high quality standards, personal customer service and endless technical support, and you begin to see a distinct pattern of why our customers choose us again and again.

Our customers are not the only ones that benefit from the Hycomp niche. Our unique product and services mean our distributors can comfortably carry both large, name brand compressor lines and Hycomp products without conflict in product function or loss of quality.

Hycomp Product Offerings
Air Compressors: When you need continuous oil-free air. Hycomp reciprocating air compressors are designed to provide continuous duty oil-free air up to 450 psig standard. Higher pressures are available. We apply heavy duty construction to incorporate the benefits of large industrial designs into our smaller oil-free compressors.

Air Boosters: When your plant pressure isn’t enough. Hycomp oil-free air boosters are engineered to increase existing plant air pressure. Our oil-free air boosters are a smart alternative to stand-alone compressors or air amplifiers because Hycomp air boosters are more cost effective, last longer and increase your overall energy efficiency.

Gas Compressors: When you need to compress any gas other than air. Hycomp oil-free gas compressors deliver a wide range of flows at pressures from a few psig up to 3,000 psig. We compress gases such as: nitrogen, natural gas, argon, helium, and carbon dioxide, to name just a few. These gases are accommodated with our safe, reliable and flexible oil-free gas compressors.

Niche Market
No matter what the market, it is always a good practice to specialize in something within that market that differentiates your company from the rest. If specialty and high quality were not important, the only stores you would see as you drive through your town would be those big box department locations.. Our specialization is providing solutions tailored to your exact needs. Rather than saying, “This is what we have,” we ask, “What do you need?”

Rome Strip Steel Testimonial Rome Strip Steel: Hycomp Service Testimonial

It always feels good when someone tells you that you have done a good job, and it’s even better when a happy customer becomes a friend and trusted ally.

An end-user was having problems with their compressor and they wanted to do some maintenance on the Hycomp valves, but had never done any major work on the unit. The original manufacture was no longer in business and they basically had no one to turn to, so they called Hycomp. Even though we did not manufacture or sell the compressor, the valves being used on the unit were ours. We did everything possible to get them back up and running in a short time frame. The following testimonial is from Leo Angelicola, Electrical Engineer for Rome Strip Steel in New York.

Rome Strip Steel Testimonial “In 2007, we purchased a metallurgical atmospheric recycling system (MARS) from a company called H2Gen. Unfortunately, H2Gen went out of business in 2009 leaving us with a $1 million machine that was still in the startup mode and that didn’t work well. One component of the MARS is a Knox Western TP

120 reciprocating compressor which was experiencing valve issues. In May of 2010, through the help of Kelly Leitch, a former H2Gen engineer, we contacted your company [Hycomp] for help. Your service technician, Andy Hansen, was in the area and agreed to stop by. Andy was a tremendous help, not only in getting us back on line, but in educating us about the compressor and training us in the rebuilding of the valve assemblies. Since that time, we have purchased all the tools that Andy recommended and are able to rebuild and change valves very quickly.”

Leo then concludes his letter, “I cannot express enough how grateful we are to this young man for what he was able to do for us. It is difficult to keep this system in operation without the support of the OEM, and Hycomp has removed a major obstacle for us. Thanks for your help!”

Andy Hansen recalls that he felt very welcomed when he arrived at Rome Strip Steel (RST), “Leo and the RST maintenance staff gave me a very warm reception and I could tell they were ready to get to work and be trained.”

Andy worked side by side with Leo and the RST maintenance crew as they jumped right into some true hands-on training. “I trained them on the Hycomp valves used on their machine: how to remove and inspect them, how to clean and rebuild them and how to reinstall them, all from start to finish. The maintenance crew was a tad apprehensive about working on the pump as they had never previously taken one apart or had any training on it. By the time we finished they felt a lot more comfortable and confident about handling any future valve issues, and through proper maintenance, they have been able to extend the life of their valves by over 1,000 percent!”

Summing up his trip to Rome Strip Steel, Andy reported: “They listened while I was there and later implemented all of my recommendations and advice. Since my visit they have had success maintaining their valves and Leo has become a good friend and ally when it comes to these MARS units. We have subsequently been able to work together to provide assistance to another company that has one of these machines out in the field.”

Quincy QDD Compressors Discontinued Discontinued Lines: Hycomp Has the Answers

Finding replacement parts for discontinued compressor models can feel like a wild search for buried treasure. If and when the parts are found the worry is still ever present concerning future maintenance.

Given the current economy, many of Hycomp’s main competitors are going through a product rationalization program. This reason is pretty straight forward, increase profits by reducing costs. The biggest loser in situations like this is the customer who purchased these discontinued model numbers in good faith, believing they would never have replacement parts issues. In some situations, the only way to obtain replacement parts was to buy a used machine and harvest parts from it. A simple online Google search will yield only a handful of these used discontinued compressors for sale.

In some cases, discontinued products are being replaced with wider range units that are not able to perform at the same level as the originally purchased units. One such discontinued air compressor, which was well known for its long lasting oil-free service and most commonly used for food and pharmaceutical applications, has been replaced by a lesser machine. The discontinued series has been replaced by oil-less compressors that claim to provide nearly the same service, but in fact, experience two major limitations:

1. Continuous Duty: Oil-less compressors struggle to provide higher pressures and have a shortened life span when operating continuously. The main reasons being sealed ball bearings, lesser materials and higher RPMs.

2. Higher Pressures: Due to the crankcase design and use of sealed bearings and therefore limited lubrication, these replacement oil-less compressors are unable to handle the increased load requirements necessary to provide higher pressures.

Enter the Hycomp Oil-Free Air Compressor
Not only will Hycomp air compressors handle the heavy duty industrial applications of the discontinued lines, it will provide truly continuous duty oil-free air. In many cases Hycomp air compressors are being purchased specifically to replace these failing compressors that could not be maintained due to lack of replacement parts. As other companies are discontinuing product lines to lower their operating costs, they are also sacrificing quality and longevity. Hycomp continues to maintain high quality oil-free compressors for continuous heavy duty operation as we always have since 1969.

Hycomp Air Compressor Capabilities:
Up to 450 psig Standard, Higher Pressures Available
Up to 75 HP
1, 2 and 3 Stage Units Available
Flows to 150 scfm

Building a Better Compressor: Oil-Free Vs. Oil-Less
Hycomp manufactures high quality oil-free air compressors that are designed for reliable continuous duty and longevity. There are 5 main factors in how we are able to accomplish this: 1) Materials of Construction, 2) Oil Isolation, 3) Crosshead Design, 4) Pressure Lubrication and 5) Lower Speeds.

Hycomp Materials of Construction Materials of Construction:
Our crankcases, compression cylinders and cylinder heads are made of cast iron and steel. Unlike aluminum, these materials hold their shape and don’t warp at elevated temperatures. The result is long term continuous duty.
Oil Isolation

Oil Isolation:
Our distance piece works in conjunction with our piston rod oil scrapers to isolate the oil in the oil lubricated lower end from the oil-free compression end. Oil scrapers remove oil from the piston rod while the open distance piece protects against oil vapor entering compression.

Hycomp Crosshead Design

Crosshead Design:
By transferring the rotary motion of the crankshaft to reciprocating motion through the use of a crosshead piston, our compression and guide rings never see side thrust, dramatically extending ring life.

Pressure Oil Lubricated

Pressure Lubrication:
Our crankcase is pressurized to provide generous lubrication to all moving parts and bearings. The oil in our crankcase is liberally delivered with pinpoint accuracy. In oil-less compressors the oil is sealed inside the ball bearing cases and not consistently circulated. This leads to more issues with heat and more ware and tear on the moving parts, especially at higher RPMs. The Hycomp oil lubricated bottom end decreases running temperatures, allows for higher discharge pressures and provides compressor longevity.

Lower Speeds:
Instead of running at speeds of 1100-1400 rpm as published in the oil-less compressor literature, we run between 400 and 800 rpm. These lower speeds offer cooler running temperatures, less wear per stroke, less vibration and lower valve impact forces.

The Hycomp Difference
If we sell it, we will support you and the compressor. In conjunction with our endless technical support and customer service our customers return to Hycomp again and again for our engineered solutions because purchasing quality capital equipment is always a good idea. Some people say, “They just don’t build them like they used to,” with Hycomp it could be said, “I am glad they still build things that last.”

Freda Lasley Meet Freda Lasley: Sales (& Parts) Coordinator

Have you called a company, needing either information or assistance, gone through an automated answering system that after 5 minutes of trying to talk with a person, you just get connected with someone’s voicemail?

That simply does not happen with Hycomp because actual humans answer our phones. If you have questions related to specifically parts or sales, all you have to do is say, “Is Freda there?” Hycomp Sales Coordinator, Freda Lasley, has the answers you want and even some you didn’t know you needed.

Freda comes to Hycomp with well over a decade of experience in sales and customer service. However, it is not merely her extensive experience that makes her so good at what she does, it is her professional attitude and ability to stand for what is right, even when it is not the popular choice at the time. She also thoroughly enjoys getting to know people and helping them find solutions to their problems. She explains, “In my mind, as a sales coordinator, I am working between the customer and Hycomp to build lasting relationships and work together with my customers to make sure they get everything they need. I want what benefits the customer most.”

Freda is very proud of the Hycomp Sales & Marketing team, of which she is an important part. “I have a great supportive team sitting right next to me every day. I have to trust my team 100% to offer true quality support and fulfill my customer’s needs… trust is a huge part of our company culture.”

In order to really know how Hycomp compressors work and to better assist her customers, Freda has spent many hours in Hycomp production and assembly. She has been in the shop, in dirty clothes with greasy hands, turning wrenches, assembling compressors and performing maintenance. When you call and ask what parts are needed for your compressor’s 8,000 hour maintenance, she knows because she has done it.

If you have already had a chance to talk to Freda, then you already know that she will take an aggressive approach in solving your problems and getting you the answers you need. “View me as your customer advocate… I will do all I can to support your needs and the needs of your company.”

Hycomp Tech Support When it seems like everything is going wrong, who’s got your back?

Even the best products from the highest quality companies have been known to occasionally experience a problem or two. What sets a company above the rest is how they react to the situation.

In June of 2011 Hycomp shipped a nitrogen booster, to a fabricating shop near the Chicago O’Hare International Airport. This booster was designed to mate with an Industrial Solutions Nitrogen Generator and provide high pressure nitrogen for a number of their laser cutting machines.

Hycomp Tech Support “We experienced a few problems in the first couple months that were not normal according to Hycomp’s reputation, but Hycomp stayed with us every step of the way, with technical support over the phone and facilitating a nearby distributor to assist us. They even sent us out replacement parts overnight to get us back up and running as quickly as possible,” explained the facility maintenance supervisor, “The booster has been working perfectly ever since.”

To sum up the situation, the nitrogen booster had a few faults that caused it to shut down. Tiny, seemingly insignificant issues, that just seemed to happen at just the wrong times as if Murphy’s Law had declared an all out assault on this particular compressor. First the oil pressure transducer went out, and then a valve gasket went out twice. After a few visits from a distributor, Hycomp opted to send the end-user a complete cylinder/head assembly to get them back up and running strong. They then shipped the original assembly back to Hycomp so the exact problem could be ascertained without causing any more downtime.

“I have never experienced such solid technical support from any manufacturer. Hycomp did everything they possibly could to get us back up and running.”

We realize that it is impossible that every single part we manufacture will always be 100% without fault. However, we can always be 100% perfect on how we respond to our customers when they need us. We take serious pride in our customer service and technical support. That is why Hycomp technicians are available 24 hours a day – 7 days a week. Hycomp has your back, every step of the way.

Sizing compressors Meet Ben Brough: OEM Account Manager (He speaks “engineering”)

When you contact a company in the compression industry it is very advantageous to connect with someone that truly understands what you are talking about and how to offer specific solutions.

Original Equipment Manufacturer Account Manager, Benjamin Brough, comes to Hycomp with a degree in Mechanical Engineering and over 7 years of sales experience. He understands the technical side of things and can speak that

engineering jargon that causes the general public to wear a blank expression. This talent allows Ben to talk directly to OEM engineers and ensure proper information is exchanged in a way both parties can understand.

Ben has a clear vision of what true sales and customer service ought to be, which has made him a valuable addition to the Hycomp Sales and Marketing Team. “I enjoy the technical side of sales,” Ben explains, “Each application is like a puzzle that I get to solve, and I enjoy getting to know my clients and provide them with real solutions.”

“I look forward to working with current and future OEMs and providing them with solutions to their applications, no matter how detailed.” Ben has an entire sales and marketing team to back him up and build on the tools and the talents he already has. No matter the application details or intricacies of a project, Ben can and will provide the best possible sales and engineering experience when a client calls and needs his help.

Whether it is hydrogen or nitrogen boosting off generators, dealing with deep sea diving breathing gas reclaim units or offshore oil projects, Ben is ready to get right into a project and provide the best possible solution Hycomp has to offer. Every contact is an opportunity to help solve problems and keep applications progressing.

Sizing Compressors Sizing Compressors – Complete Information

When precision is paramount – information is king. A well built compressor is like a tailored suit, exact measurements need to be recorded and closely followed or the suit will not fit properly.

Hycomp compressors and boosters are designed and manufactured with precision to be an exact fit for the intended application. The Hycomp Application Worksheet contains all the informational fields necessary to provide a well tailored compressor that mirrors application requirements.

Sizing compressors The Application Worksheet is just a two page document. However, the second page only exists to provide an area for detailed notes and sketches if needed. There are less than 30 fields to fill out concerning application details and less than 20 general fields, such as: Contact Name, Phone Number and email. Even though this form is very easy to fill out, the information collected is invaluable in providing the right solution.

Hycomp Area Sales Managers are available to assist Hycomp Distributors fill in the form. Working side-by-side with our distributors is very important to us. We also offer our highly skilled engineers as well honed instruments in the compressor sizing process. By talking directly with the end user engineer(s) and the distributor, Hycomp engineers are able to discuss the application and not only provide a solution tailored to the situation, but solve any potential problems before they occur.

We call this business approach: Engineer to Engineer or “E2E”. When the distributor and engineers from both sides of the sale communicate directly, the project moves forward faster while increasing product and purchase confidence.

There are some things on the Application Worksheet that appear more important than others, such as: gas, point of use pressure or flow. The hazardous location classification (Class/Division/Group) is an important factor when dealing with potentially hazardous gases. All fields are always important, as all information is necessary to provide the best possible solution. This information is more than necessary, it must be complete, or a compressor quote cannot be given.

Often in the sales process, a full and exact quote is not yet needed. Sometimes our distributors are only looking for a budgetary or “ballpark figure” to take to their client to see if pursuing a Hycomp compressor is a viable option. To accommodate these inquires we have included the “Quote Type” field where a distributor can either chose to receive a Full or Budgetary Quote.

Complete information is required for either quote type. But please remember, if there are ever any questions or even the slightest hint of doubt, our sales managers are always available to conveniently take this information right over the phone and answer questions. This method of explaining application requirements over the phone also allows our distributors to talk directly with sales and engineering experts. This interaction helps to ensure the right compression system is quoted, sold and manufactured.

When Hycomp sales professionals and engineers get involved, customer satisfaction increases as the compressor is tailored to provide an exact fit for the intended application

3 Situations You Need to Know About

Hycomp compressors fit into three main situations. This may seem like an over simplified view of what Hycomp offers, and that is why we like it.

Other than parts and service, these three “Hycomp Situations” are the main reasons people contact us. Every product in any industry tends to have a niche. These three situations explain the Hycomp niche in almost perfect clarity.

High Pressure Oil-Free Air Compressor 1. Oil-free Air Above 150 psig
The Hycomp niche begins at 150 psig and every booster and compressor we manufacture is oil-free. Hycomp compressors have oil lubricated crankcases. However, due to a distance piece and several other safe guards the air stream remains pure because oil never enters the compression cylinder.

Any pressures below 150 psig are often best handled but a screw compressor. Screw compressors can handle pressures below 150 psig so well, that Hycomp compressors really can’t compete in that lower pressure range, as they can provide pressures below 150 psig for far less money than Hycomp air compressors. Pressures between the range of 0 – 150 psig are a great examples of the niche where screw compressors shine. There are still of course times that we have sold air compressors that supply less than 150 psig, but those occurrences are few.

High Pressure Oil-Free Air Booster 2. When Plant Air Pressure Isn’t Enough
When plant pressure isn’t enough, an air booster is often the best solution. Standard compressed air systems in industrial facilities are typically designed for pressures of 80 to 130 psig. When higher pressures are required it is very effective to use a portion of your plant air and apply an air booster to obtain the desired higher pressure.

Other methods of acquiring higher pressure air such as stand-alone air compressors, air amplifiers and increasing the pressure of the entire plant are more costly and far less efficient. It simply takes more power to start from a standstill with a stand-alone air compressor, while an air booster gets a running start because it receives pre-compressed air. Air amplifiers are effective at obtaining higher pressures but they use approximately 60% of the inlet air flow to power the amplifier as they are pneumatically driven. Amplifiers are also best suited for intermittent duty applications while Hycomp air or gas boosters are built to handle continuous duty.

High Pressure Oil-Free Gas Compressor Gas Booster 3. Compressing Any Gas Other Than Air
Hycomp engineers have a deep understand of gas compression, from the easily compressible gases to complex gas mixtures. There are always many variables when dealing with hazardous gases, but rest assured that Hycomp engineers have the skills and experience necessary to provide a safe, flexible and reliable compression system that will thrive in the intended application.

Manufacturing safe and reliable compressors is a job we take very seriously. When compressing gas there are 3 main concerns: Containment, Control and Contamination. Hycomp handles containment with three increasing levels of gas packing and plenum chamber arrangements. Control is applied via an application of superior components and a vast understanding of environmental and packaging concerns. No measurable contamination is introduced into the gas stream by a Hycomp compressor and as long as the inlet gas supply is properly filtered, the gas will remain pristine.

The Three Hycomp Situations

1) Oil-free Air Above 150 psig
2) When Plant Air Pressure Isn’t Enough
3) Compressing Any Gas Other Than Air

It really is that simple. When an application falls under any of these three situations, give Hycomp a call.

Hycomp Gas University Hycomp Gas University: Helium

Description:
Helium is a unique molecule that is used for much more than inflating balloons at the county fair. After hydrogen, helium is the lightest element and has the smallest molecular cross-section of any gas. Helium is one of the rare gases in our earth’s atmosphere in which it is present in a concentration of only 5 ppm.

It is completely inert to chemical reaction and radiation. Its thermal conductivity surpasses that of any other inert gas and is three times greater than neon, its nearest inert competitor. Helium’s boiling point of -452.1oF (-268.9oC) gives it refrigeration capabilities beyond those of any other substance. Helium provides a high rate of permeability and ease of detection with only slight solubility in the bloodstream. It is nonflammable and is only slightly soluble in water. It is usually shipped at high pressures at or above 2400 psig at 70oF (16 550 kPa at 21.1oC) in cylinders and in bulk units. It is also shipped as a cryogenic liquid.

Helium Molecule Safety, Storage & Handling:
Gaseous helium is commonly stored in high pressure cylinders, hydril tubes, or tube trailers. Liquid helium is commonly stored at the consumer site in cryogenic liquid cylinders, portable customer stations, and specially designed insulated tanks. To minimize helium transfer losses, the shipping container for liquid helium is normally used for storage.

Users of liquid helium must also take special precautions in addition to those necessary for the safe handling of such inert liquefied gases as nitrogen and argon. The extremely low temperature of liquid helium makes these special precautions imperative; it can solidify all other gases and …more

Gas Compressor Pressure Drop Pressure Drop: Understand it, Plan for it

There is nothing worse than making it through a technical project only to be disrupted by some critical detail that was overlooked. Pressure drop is often overlooked, misunderstood and misdiagnosed.

Pressure drop is often the cause of excessive energy consumption and poor system performance. If unaddressed before the purchase of a compressor or booster, you could be buying an improperly sized unit. If unaddressed or misdiagnosed for an existing system, it can lead to costly downtime, unexpected and even unnecessary equipment expenses.

Pressure drop is a term used to characterize the reduction in air or gas pressure anywhere in a compression system. A properly operating system should be designed with the least amount of pressure drop that is practical. For example, it is not practical to have long runs of undersized piping, but properly sized check valves are necessary and the pressure drop associated must be taken into account.

Imagine a freeway in a large metropolitan area that has only one or two lanes, onramps that bottleneck and numerous sharp turns. Traffic becomes congested and motorists have to slow down when using the onramps and navigating the sharp turns. Compressed air and gas systems experiencing pressure drop issues are similar to an undersized and poorly designed freeway. In this example the freeway represents the pipe sizing and arrangement, the onramps represent ancillary equipment such as filters, dryers and gas separation equipment while the sharp turns represent components such as valves, fittings and junctions.

What Causes Pressure Drop?
Any type of obstruction, restriction or roughness in the system will cause resistance to gas flow and cause pressure drop. In a distribution system, the highest pressure drops are usually found at the points of use, including undersized or leaking hoses, tubes, disconnects, filters, and regulators. On the supply side of the system, aftercoolers, moisture separators, dryers, filters and improperly sized piping are the main items causing significant pressure drops.

Gas Compressor Pressure Drop The maximum pressure drop from the supply side to the points of use will occur where the compressed air flow rate and temperature are highest. System components should be selected based upon these conditions and the manufacturer of each component should be requested to supply pressure drop information under these conditions. During the design phase, it is critical that occasional large flow requirements (air bursts, startup/shutdown of equipment, etc)

are recognized, and the system is designed to handle the pressure drops for these occasional large flows. This is exactly why, during the quoting and compressor sizing process, Hycomp salesmen and engineers work with our customers to completely and accurately fill out the Hycomp Application Worksheet.

The distribution piping system often is diagnosed as having a high pressure drop because a point of use pressure regulator cannot sustain the required downstream pressure. If such a regulator is set at 85 psig and the regulator and/or the upstream filter has a pressure drop of 20 psi, the system upstream of the filter and regulator would have to maintain at least 105 psig. The 20 psi pressure drop may be blamed on the system piping rather than on the components at fault. The correct diagnosis requires pressure measurements at different points in the system to identify the component(s) causing the high pressure drop. In this example, the filter/regulator size would need to be increased, not the piping.

Gas Compressor Pressure Drop Minimizing Pressure Drop
Keeping pressure drop to a practical minimum requires a total systems approach in design and maintenance. Air treatment components, such as aftercoolers, moisture separators, dryers, and filters, should be selected with an acceptable pressure drop at specified maximum operating conditions. When installed, the recommended maintenance procedures should be followed and documented. Additional ways to minimize pressure drop are:

• Properly design the distribution system.
• Operate and maintain air filtering and drying equipment to reduce the effects of moisture, such as pipe corrosion.
• Select aftercoolers, separators, dryers and filters having the least possible pressure drop for the rated conditions.
• Reduce the distance the air travels through the distribution system. If long runs are required, properly size the pipe.
• Use new, smooth bore, clean piping.
• Specify pressure regulators, hoses, and connections having the best performance characteristics at the lowest pressure differential.

Hycomp Investigation & Experience
When Hycomp compressors and boosters are configured and sold, they are sized to accept a specific inlet pressure and flow. If the pressure drop of all the other installed components before the Hycomp booster is not taken into account, for example, what was thought to be 120 psig at inlet could be more like 100 psig, then the booster may not be able to achieve the desired discharge pressure. Even if the compressor works harder to provide that pressure and succeeds, flow and/or reliability may suffer.

One thing that may be blamed as pressure drop is actually pressure loss. This can occur when process demands exceed the supply capabilities. If an application requires a specific flow and then that requirement is increased, chances are that the booster may not be able to provide the increased demand. For example, an end-user runs a laser-cutting facility and purchased a Hycomp nitrogen booster that mates with their N2 generator to provide 3 laser-cutting machines with 600 psig at 45 scfm flow each. If the end-user then installs 2 more laser cutting units without upgrading their nitrogen boosting setup, they could be disappointed in the results as the single booster may not be able to handle the increased demand (pressure and flow) at the point of use.

Hycomp sales professionals and engineers have the knowledge to assist distributors and end-users in properly sizing a compression system to fit the desired application. This begins with a thorough investigation on the front end of an inquiry and continues until the compressor system arrives on location and is in operation. However, if precise conditions are not given and system pressure drops are not accounted for, a perfectly operating and brand new compressor or booster system may not be able to meet the requirements. So much is riding on the original info that is collected using a Hycomp Application Worksheet; it is paramount this information be accurate.

Much like a cross country road trip, if you fail to properly plan your route, you could find you could find yourself far from your intended destination. All the information collected for sizing a compressor must be accurate or you could find yourself in a situation where the compressor just purchased can’t keep your application in operation. Trust your Hycomp sales and engineering team to help you plan and investigate each application, so your process always runs efficiently.

Compressor Controls - Remote Mounted Remote Mounted Controllers

The advantages of remotely mounting a compressor control panel far outweigh the disadvantages, but when hazardous conditions are not a factor, user preference takes priority.

When dealing with a hazardous area where explosive gases will always be present such as a Class 1, DIV 1 environment, there are only two choices as far as control panels are concerned.

1. Mount the control panel to the compressor skid and utilize hazardous area rated panels (NEMA 7 for example) and components to handle the dangerous location.

2. Remote mount the controller away in a non-hazardous area.

Compressor Controls - Remote Mounted Cost is always a factor in large capital purchases such as compressor systems. More often than not, remotely mounting a control panel is far less expensive than designing/building a control panel for a hazardous environment. Standard panels and components are far less expensive than hazardous rated enclosures. Specific glands or sealed conduit must be employed for wiring, but once again, the cost of the wire and glands is almost always much lower than mounting the panel to the compressor skid in a Class 1, DIV 1 environment.
Compressor Controls - Remote Mounted Combine the advantage of lower costs with ease of use and remotely mounting a control panel is all but a done deal. Of course user preference always comes into play. Some end-users prefer to have a control panel mounted directly to the compressor skid, while others like to have a separate control room. In either case, Hycomp engineers have the skills necessary to assist in keeping your operators and process safe.
Hycomp Gas University Hycomp Gas University: Natural Gas

Description:
Methane is a colorless, odorless, tasteless, flammable gas. It is the first member of the paraffin (aliphatic or saturated) series of hydrocarbons. It is the major constituent of natural gas. Methane is soluble in alcohol or ether, and slightly soluble in water.

Methane is shipped as a nonliquefied compressed gas in cylinders at pressures up to 6000 psig at 70oF (41 370 kPa at 21.1oC). Liquefied methane (as natural gas-LNG) is shipped on bulk quantities as a cryogenic liquid on barges and tankers. Methane is a major constituent of coal gas and is present to an extent in air in coal mines.

Methane Molecule Methane is typically available for commercial and industrial purposes in a C.P. Grade (minimum purity of 99 mole percent), a technical grade (minimum purity of 98.0 mole percent), and a commercial grade that is actually natural gas as it is received from the pipeline. (There is no guaranteed purity, but methane content usually runs about 93 percent or better.) Tertiary-butyl mercaptan is added in trace amounts as an odorant. This grade of gas has a sulfur content of 0.002 grains/100 ft3 (0.0457mg/m3) and a typical gross heating value of 1044 Btu/ft3 (38 898 kJ/m3). (416 kPa).

Methane is produced commercially from natural gas by absorption or adsorption methods of purification; supercooling and distillation are sometimes employed to secure methane of very high purity. Some California natural gas wells produce methane of high purity. It can also be obtained by …more

Chevron Vs. Tangent-Tangent Gas Packings, Step Into The Ring: Chevron Vs. Tangent-Tangent

Piston rod gas packings perform the critical function of containing gas in the compression end of a compressor. The two most widely used gas packing design styles are Chevron and Tangent-Tangent. There are pros and cons to both designs. However, Hycomp employs the Tangent-Tangent packing style due to quality and efficiency. The following article will explain why.

Chevron Gas Packings Chevron Gas Packings (V-Packings):
Chevron gas packings are also referred to as V-Packings or Vee-Packings due to their shape when viewing them as a cross-section. The chevron packing arrangement is a combination of three main sections: the Base Seal (bottom), the “V-Rings” at the center and the Pressure Ring (Top). The V-Rings provide the main seal that while the base seal supports the center rings from getting extruded during high pressure applications and the Pressure Ring helps hold it all together while providing a method of adjustment. Pressure is applied to the V-Packings by both the Pressure Ring and the Base Seal, causing the V-Packings inside to widen or squish and provide the seal (see illustration). As the packings wear, the seals loosen and the Base Seal and Pressure Ring must then be re-tightened.

The main problem of this design is the constant adjustment necessary to keep a tight working seal as the packings wear. Depending on the intervals of use, the need for re-adjustment can occur frequently. Monitoring the performance of the compressor combined with the constant need for adjustment leads to higher costs and decreased efficiency in the long run.

Tangent-Tangent Gas Packings:
Tangent-Tangent Gas Packings (TT Packings) provide a dynamic seal that does not require constant monitoring and continuous tightening. This packing style is self-adjusting and therefore provides a tighter and more efficient seal throughout the entire life of the packing.

Tangent-Tangent Gas Packings Tangentially cut, this segmented packing design provides a dynamic seal by lining up and sandwiching each set of packings via a white pin for alignment at the proper rotational offset to ensure that the leakpath created by the cuts is minimized (see illustration). The Tangent-Tangent (TT) style packing inherently continues to seal as the packing wears due to the tangentially cut design, dynamic pressure and a small spring that helps hold the pieces together inside the packing gland.

TT Packing arrangements can be configured to provide even more stringent containment by increasing the amount of packing pairs, incorporating purge/vent lines or by utilizing an additional plenum chamber filled with a pad gas. Hycomp compressors can be designed and engineered using all three methods of containment when gases are either very dangerous or contain very small molecules, or both.

G-Series When increased gas containment is necessary another set of gas packings is added and purging gas lines are used to carry away any gas that has entered the purge chamber between the bottom two sets of gas packings (see illustration). For applications that require extreme containment, purge lines are employed along with an additional plenum chamber. The second plenum chamber is pressurized with an inert pad gas to provide opposing force and to ensure process gas purity (see illustration).
H-Series The end result of using Tangent-Tangent Gas Packings is a reliable and consistent seal. Chevron gas packings are less expensive as an initial purchase, but require continuous monitoring and constant re-adjustment, which leads to an overall higher cost and increased hassle. Tangent-Tangent packings are far more user-friendly as they are self-adjusting and do not require constant monitoring or maintenance.
Hycomp Gas University Hycomp Gas University: Carbon Dioxide

Description:
Carbon dioxide is a compound of carbon and oxygen in proportions by weight of about 27.3 percent carbon to 72.7 percent oxygen. A gas at normal atmospheric temperatures and pressures, carbon dioxide is

colorless, odorless, and about 1.5 times as heavy as air. A slightly acid gas, it is considered by some people to have a slightly pungent odor and biting taste when, for example, it is used in “carbonated” soft drinks.

Carbon Dioxide Molecule Carbon dioxide gas is relatively nonreactive and nontoxic. It will not burn, and it will not support combustion or life. When dissolved in water, carbonic acid (H2CO3) is formed. The pH of carbonic acid varies from 3.7 at 1 atmosphere to 3.2 at 23.4 atm. Carbon dioxide may exist simultaneously at its triple point as a solid, liquid, and gas at a temperature of -69.9oF (-56.6oC) and a pressure of 60.4 psig (416 kPa).

Carbon dioxide is normally present in the atmosphere at about 0.035 percent by volume. It is also a normal end-product of human and animal metabolism. The exhaled breath contains up to 5.6 percent carbon dioxide. The greatest physiological effect of carbon dioxide is to stimulate the respiratory center, thereby controlling the volume and rate of respiration. It is able to cause dilation and …more

Receiver Tank Setup Reciprocating Compressors: Pulsation Dampening Paramount

When purchasing capital equipment it is wise to protect that investment through proper packaging and installation. Inlet and discharge receiver tanks are often overlooked, but make all the difference in protecting a compression system and providing consistent pressure to any air/gas boosting application.

Reciprocating compressors create pulses in the gas stream. This pulsation is inherent to reciprocating motion. To accommodate this force, a proper system design and installation must be utilized to prevent failure and promote peak performance.

Think of driving a car with square wheels, each forward rotation of those wheels would create a jump forward followed by a thud and an abrupt halt in motion. Gas flow enters the piston only during the suction portion of the compressor stroke and leaves only during the discharge portion. The flow is effectively stopped on first the inlet and then the outlet of the reciprocating piston. In a compressor running at 600 rpm, this can happen as often as 10 times a second. Compression creates pressure waves, or pulsations, that travel through the system. These pulsations occur in both directions and combine to create very high pressure fluctuations.

Receiver Tank Setup Piping systems are seldom designed to handle pulsation created by reciprocating compressors, especially at fittings or components. If pulsation is not controlled, components and compressors can experience many different failures, such as: pipe failure due to fatigue, reduction in efficiency of the compressor, ‘hammering’ of the compressor valves, check valve and safety valve failure, instrumentation failure and even errors in pressure measurement.

Receiver tanks act as buffers to the inlet and discharge of the compressor. Pressure waves are dissipated inside the tanks which provide increased system longevity while creating a consistent and reliable process pressure. To ensure properly sized receiver tanks are packaged with your air or gas booster compressor system, contact Hycomp for more information.

Hycomp Gas University Hycomp Gas University: Nitrogen

Introduction

Over the next year or two we will be creating short gas information and application articles. These gas articles will be formatted to discuss the most

important information one should know when dealing with a specific gas. The goal of these gas articles is to educate, refresh and ease the anxiety of dealing with gases.

There are many different gases and gas mixtures that Hycomp can compress. Hycomp has been engineering, designing and manufacturing compressors since 1969. This has given us over 40 years experience and knowledge and earned us a reputation for supplying safe and dependable compressors of the highest quality.

Each gas article will be segmented into three main sections:
• Description
• Safety, Storage & Handling
• Uses

These articles will be released in our monthly newsletter and added to our website under the “Gases” section. This cache of information on compressible gases will also be a valuable place to link potential clients, to cull their concerns and increase their relationship of trust with Hycomp and our distributors.

Nitrogen Booster Electronics Nitrogen

Description:
Nitrogen (N2) is a colorless, odorless and tasteless gas that constitutes 78.08% by volume of the air we breathe. Nitrogen is an inert gas; the term inert basically means unreactive.

Nitrogen occurs in all living organisms. Nitrogen is a constituent element of amino acids and thus of proteins and nucleic acids (DNA and RNA). It resides in the chemical

structure of almost all neurotransmitters, or in other words, nitrogen is an important chemical in the thinking process, and as you read this article you are utilizing nitrogen to connect cognitive thought patterns via synapses in your brain.

The bulk of nitrogen produced in the United States is done via cryogenic separation of air. Air is supercooled to a liquid state, and the different gases stratify, just as water and oil do in a glass. Nitrogen is then pulled out as a liquid. Air separation plants can be large facilities serving multiple customers usually covering several states, or site specific for large users of nitrogen. Cryogenic nitrogen purity can vary depending upon need, but can hold in the ppb (parts per billion) of contaminant gases.

A method of Nitrogen production gaining rapid favor for its ease of installation and relatively low cost are nitrogen generators that separate the nitrogen from air in the gaseous phase, either through the use of a membrane, or via pressure swing adsorption (similar to regenerative air dryers). These units are fairly small in size and production volumes (roughly 100-10,000 scfh per system), but can be 1/10th to 1/100th the cost of a cryogenic separation plant. However, gaseous nitrogen generators don’t produce pure nitrogen – they actually remove oxygen. So while the oxygen content can reach less than 10ppm, there will still be other gases present in the nitrogen that are also present in air – gases like argon, helium, carbon dioxide, etc. In many applications, this is acceptable, as the nitrogen is being used because oxygen cannot be present in the process.

Safety, Storage & Handling:
Nitrogen is commonly stored in high pressure cylinders, tubes or tube trailers. Liquide nitrogen is commonly stored at the consumer site in cryogenic liquid cylinders and specifically designed vacuum-insulated storage tanks. All of the precautions necessary for the handling of any nonflammable gas or cryogenic liquid must be taken.

If levels of nitrogen become too high in confined spaces it can cause asphyxiation, leading to unconsciousness or death. Therefore, all nitrogen compression equipment must be located in a well ventilated area. We urge you to review local and regional safety standards to ensure safety compliancy.

To dispose of nitrogen gas, vent the N2 slowly to a well-ventilated outdoor location remote from personal work areas and building air intakes. For liquid nitrogen, allow it to evaporate in a similar location. Liquid nitrogen boils at -320oF, so any temperature above that will be sufficient.

Nitrogen Booster Laser Cutting Uses:
Nitrogen has many commercial and technical applications. As a gas, it is used in heat treating of primary metals; blanketing of oxygen-sensitive liquids and of volatile liquid chemicals; the production of semiconductor electronic components, as a blanketing atmosphere; the blowing of foam-type plastics;

the deaeration of oxygen-sensitive liquids; the degassing of nonferrousm etals; food processing and packing; inhibition of aerobic bacteria growth; magnesium reduction of aluminum scrap; and the propulsion of liquids through pipelines.

Gaseous nitrogen is also used in pressurizing aircraft tires and emergency bottles to operate landing gear; purging, in the brazing of copper tubing for air-conditioning and refrigeration systems; the purging and filling of electronic devices; the purging, filling, and testing of high-voltage compression cables; the purging and testing of pipelines and related instruments; treatment of alkyd resins in the paint industry; and high pressure nitrogen is used in precision laser cutting of metals (see image to the left).

Liquid nitrogen also has a great many uses, among them the freezing of highly perishable foods such as shrimp, hamburgers, and chicken; deflashing of rubber tires; cooling of concrete; and the cold-trapping of materials such as carbon dioxide from gas streams (commonly used in this way in systems that produce high vacuums). It is used as a coolant for electronic equipment, for pulverizing plastics, and for simulating the conditions of outer space. Other ways in which liquid nitrogen is used include: creating a very high pressure gaseous nitrogen (15,000 psig or 103,000 kPa) through liquid nitrogen pumping; in food and chemical pulverization; for the freezing of liquids in pipelines for emergency repairs; for low temperature stabilization and hardening of metals; for low temperature research; for low temperature stress relieving of aluminum alloys; for the preservation of whole blood, livestock sperm, and other biological; for refrigerating foods in local and long-distance hauling; for refrigeration shielding of liquid hydrogen, helium, and neon; for the removal of skin blemishes in dermatology; and for shrink fitting of metal parts.

Liquid nitrogen also has a number of classified applications in the missile and space programs, in which it is used in large quantities.

Hycomp at NAACD NAACD: Return & Report

Our Hycomp Sales Managers headed to Florida for the 2011 NAACD conference (North American Association of Compressor Distributors) with the President of Hycomp and a new 10x20ft booth setup. This marks the first time Hycomp has attended a NAACD conference, and it was a complete success.

Robert James, Ken Schiefer and Rob Hunt were very happy with the traffic the Hycomp booth received at this tradeshow. Ken commented, “It was non-stop at our booth, the whole time.” Robert James also commented on how impressed he was with the gas compression knowledge of those in attendance, “I felt like the people that I talked to at the show had a solid understanding of gas compressors and we were able to have some excellent discussions”

Hycomp at NAACD The new booth setup turned heads and got a lot of positive feedback. The Hycomp booth consisted of a new industrial styled backdrop accompanied by a full-size Hycomp compressor cutaway and a working example of a HDC2 (Hycomp Digital Controller, Level 2), each on top of matching tool cabinets. The cutaway and HDC2 were included in the booth to give our distributors physical examples of what they could offer their clients. The HDC2 showpiece is fully operational and NAACD attendees enjoyed navigating with the operation menus and screens while experiencing the benefits of our digital controllers.

The most popular feature of the HDC2 was the Preventative Maintenance prompt. These popup prompts appear whenever any maintenance needs to be preformed. All PM prompts include the contact information of the distributor that initially sold the compressor system. This helps create a continual link to the original distributor and therefore the end-user is automatically reminded who can provide the service and answers they need.

Our team was glad that Hycomp exhibited at this show and that Hycomp President Robert James was able to attend. Rob Hunt commented, “Having the President/Chief Engineer of Hycomp in our booth gave us a lot of added credibility… everyone enjoyed talking to Robert.”

Hycomp Distributor Training Webinars Distributors: Working The Hycomp System

In the world of compressor sales, knowledge is power. Becoming a Hycomp Distributor via our “Hycomp System” of training and partnership gives our distributors the knowledge to better understand their client’s needs and to offer solutions where they once had gaps in their line card.

We published an article in our July Newsletter that highlighted our distributor training program. This program trains each distributor on Hycomp products, and helps each individual salesperson feel confident in offering Hycomp solutions to their clients. It also illustrates how the Hycomp product line enhances rather than takes business away from our distributor’s main compressor lines. Hycomp is a niche product, and it is this niche that makes a Hycomp distributorship so valuable.

In our July newsletter, Area Sales Manager Rob Hunt reported, “When compared to the number of quotes in April – July of 2010, the Western US produced a 260% increase in quotes for those same months in 2011.” Those statistics have improved since then; the following paragraph is a sales report for May – August 2011.

The Western US Territory (West of the Mississippi, Alaska and Hawaii) has increased at an average of 390% in quotes each month. Moreover, the Western US territory has increased in monthly gross sales by 798%. That is astounding, and we would like to thank our distributors that have received training and stepped up their efforts. We have also seen an 800%, increase in contacts coming directly to Hycomp; those hot leads have then been handed directly to our trained and qualified distributors.

The “Hycomp System” has become a great tool for success! More and more distributors are building the foundations for their future success by embracing a partnership with Hycomp. Sales associates from our distributor force are finding that they are stacking the odds heavily in their favor by including our Area Sales Managers as a part of their team. We have been involved in training, business planning, marketing, and presenting Hycomp compressors via webinar. In several cases our distributors have been so excited about utilizing the Hycomp system that they have asked Our Area Sales Managers to provide mini webinar training sessions on a monthly and bi-monthly basis to consistently update and train their sales people.

Two NEW training sessions offer a detailed focus on the products and associated applications:
• Air Booster Sales Training
• Gas compressor Sales Training

Additional training and sales programs COMING SOON:
• Pre-recorded distributor training, available 24-7. Distributors will be able to review Hycomp training modules and train sales associates.
• How to Sell and Close Hycomp Applications.
• Hycomp Power Point Presentation. Distributors can use this tool to present Hycomp quotes to clients.
• Hycomp Flip Chart Presentation. This is a valuable asset in presenting face to face client quotes.

The Hycomp Sales and Marketing Team are working hard to have these new tools ready and in our distributor’s hands as soon as possible. But we will not be stopping there, more sales tools are on the horizon. There has never been a better time than now to be a Hycomp distributor.

9/11 Memorial Plaza 9/11 Memorial Plaza: Names Chiseled in Bronze

September 11th means a lot more to Americans since the tragedy of 2001 took nearly 3,000 lives and decimated the World Trade Center buildings in New York. Now that same area, known as “ground zero,” has been opened to the public as the 9/11 Memorial Plaza.

The Associated Press reported: “The 9/11 Memorial Plaza opened its gates at 10 a.m. (Sep. 12) under tight, airport-style security. Visitors were allowed to walk among hundreds of white oak trees on the eight-acre site and gaze at the water on the exact spots where the World Trade Center’s twin towers stood.

9/11 Memorial Plaza They will also be able to run their fingers over the names of the 2,977 people killed in the terrorist attacks in New York, at the Pentagon and in Pennsylvania, as well as the six who died in the bombing of the trade center in 1993.”

Those names, “chiseled-in-bronze” and surrounding the reflecting pools, provide a place for people to honor the lives lost on that dark day. The bronze plates are held in place by a stainless steel support system manufactured by Service Metal Fabricating. The New Jersey based company, Service Metal Fabricating, serves many different industries, such as: manufacturing, pharmaceutical, construction and food packaging, to name only a few. Service Metal Fabricating utilizes two Hycomp nitrogen boosters combined with their nitrogen generators to provide high pressure/high purity nitrogen for laser cutting machines used for the 9/11 memorial project.

9/11 Memorial Plaza The new memorial plaza will stand as a reminder of the tragedies that took place a decade ago. This memorial will also forever remind us of what The United States of America can accomplish when we are truly united. Service Metal Fabricating and Hycomp are very proud to have been a small part in the construction of the 9/11 Memorial Plaza.

Click here for more information about the 9/11 Memorial Plaza

INC 500/5000 Hycomp Makes The List!

We are very pleased to announce that Hycomp is currently one of the fastest growing companies in the United States according to Inc. Magazine’s exclusive annual ranking – “Inc. 500|5000: America’s Fastest Growing Private Companies.”

Thirty years ago (1981) Inc. Magazine began to publish an annual report of what was originally titled: “The Inc. Private 100: One Hundred of the Fastest-Growing Privately Held Companies in the United States.” They have refined the title of this report and expanded it to a list of 5000 with a concentration on the top 500.

The 2011 Inc. 500|5000 is ranked according to percentage revenue growth from 2007 through 2010. To qualify, companies must have been founded and generating revenue by March 31, 2007. Additionally, they had to be based in the United States, privately held, for profit, and independent – not subsidiaries or divisions of other companies – as of December 31, 2010.

INC Magazine 500/5000

From 2007 to 2010 Hycomp has experienced a growth of 83%. Our hard work and customer service based business model has earned Hycomp a rank of 2719 out of 5000 companies and a manufacturing industry rank of 91.

We continue to push forward by researching new markets and applications where our compressors and boosters can provide quality solutions. Hycomp compressors are manufactured to handle three main high pressure situations: 1) Compressed air above 150 psig, 2) When plant air pressure isn’t enough and 3) Compressing any gas other than air. Hycomp continues to grow through solid engineering, industry-specific market research and by building strong relationships of trust with our distributors and end-users. In 2011 we have been noticed for our efforts by Inc Magazine, and to be honest, it feels really good!

Compressed Nitrogen Market and Applications Understanding The Nitrogen Market

The market for nitrogen compression continues to expand and the applications for high pressure nitrogen are nearly everywhere. However, once you find an application, many questions still need to be answered.

This article will discuss three main topics when handling nitrogen applications: 1) Examples of where to find nitrogen applications. 2) Nitrogen generation or delivery methods. 3) How Hycomp boosters fit in to the realm of nitrogen application.

Applications:

Nitrogen Charged Autoclave

Autoclave Pressurization – Autoclaves, ovens and curing facilities for materials such as metal, carbon fiber, Kevlar and other high-strength or pre-preg fibers are an ideal application for nitrogen. Maintaining a dry, oxygen-free environment prevents metal from oxidizing, regardless of the temperature. Resins cure more quickly, evenly, and without bubbles in the dry, low O2 atmosphere of a nitrogen rich atmosphere.

Pharmaceutical Blister Packs

Blow Molded Packaging – Pre-form plastics and polymers such as PET (polyethylene terephthalate) are used to blow mold various products using high pressure air or nitrogen. The applications that continue to rise to the top of the list are: food packaging and pharmaceutical packaging. Oil-free high pressure air is used for many of these applications; however, nitrogen is also employed when there are more stringent FDA regulations on a process.

Nitrogen Assisted Laser Cutting

Metal Laser Cutting – The benefits of nitrogen assisted laser cutting are well known for processing stainless steel and Aluminum but with today’s new fast motion systems with rapid acceleration and deceleration it is necessary to use nitrogen cutting assist gas even on mild steel to get the full value from these new machine tools. Some other benefits of cutting with nitrogen are reduced cost for consumed oxygen, no smut or oxidized edges that are a potential problem for paint and powder coating, and improved welds.

Nitrogen Blanketing - Steel Mill

Nitrogen Blanketing – Nitrogen blanketing is used in many different manufacturing processes to not only increase fire safety but to improve the industrial process. In steel and other metal applications, nitrogen is used to blanket the hot metal to prevent flare-ups and metal oxidation.

Fire suppression is an emerging nitrogen blanketing application, where the nitrogen is used to snuff out fires in case of emergency. Nitrogen fire suppression systems are commonly used in oil processing applications including offshore oil rigs, FPSO vessels and hot oil fired heater snuffing at processing plants.

Accelerant Blanketing is a blanketing process that provides safety when dealing with highly flammable accelerants used in auto air bag production. The airbag’s inflation system reacts sodium azide (NaN3) with potassium nitrate (KNO3) to produce nitrogen gas. Hot blasts of the nitrogen inflate the airbag. During production those flammable gases are blanketed by with nitrogen for safety.

Nitrogen Choices:

When you need nitrogen, there are basically only two ways to obtain it: buy it in bulk tanks from a distributor or create it in an on-site nitrogen generator.

PSA Nitrogen Generation
Each PSA (Pressure Swing Adsorption) nitrogen generation system has two adsorber beds, or tanks, filled with a carbon molecular sieve (CMS). Compressed air enters at the bottom of the bed. Oxygen molecules are trapped in the porosities of the sieve, allowing nitrogen molecules to pass through and be stored. When the first tank is saturated with oxygen, the harmless waste gas mixture is purged while the second adsorber starts the process over again.

The standard PSA nitrogen generation system includes a feed air compressor, generator, high pressure nitrogen booster, the necessary inlet/discharge reservoirs and proper plumbing.

Membrane Nitrogen Generation
Air separation using Membrane Technology occurs when compressed air is forced into a vessel containing a hollow tube in the middle surrounded by a polymeric hollow fiber. These hollow fibers selectively permeate oxygen, water vapor, and other impurities out of its side walls, allowing Nitrogen to flow through its center and emerge as product.

The standard membrane nitrogen generation system includes a feed air compressor, air booster, generator, the necessary inlet/discharge reservoirs and proper plumbing.

Bulk Purchase Nitrogen
Bulk nitrogen is very expensive and is usually accompanied by contractual obligation. However, there are applications where purchasing bulk tanks of liquid nitrogen may be the best choice, depending on amount of nitrogen used, how fast it is used and what pressure it is consumed at.

To fill a customer’s liquid container, a bulk liquid tanker truck is filled at the cryogenic air separation plant and weighed. The weight of the truck determines the number of gallons of liquid in the truck. The customer is charged based on this figure.

Since the DOT has strict guidelines about the pressure allowed in the truck, it starts releasing N2 into the air as soon as it’s filled. Estimates vary between 3 and 5% of the truck’s volume is released during the deliveries. If the truck stops at another customer’s location before yours, an estimate is made as to how much goes to one customer and how much goes to the next and the next, etc. In fact, the best-case scenario is that you get about 90-95% of what you are charged for into their bulk tank. Then the tank evaporation continues in the storage tanks at your plant.

Bulk Nitrogen vs. Nitrogen Generation
Nitrogen Generator systems operate automatically and in direct response to demand, where bulk nitrogen tanks sit and await use. Since Nitrogen boils at 320 degrees (F) below zero, the N2 in a bulk liquid tank is always boiling. Most standard bulk tanks have a relief valve, much like a pressure cooker, which releases evaporated (boiled off) liquid N2 when the pressure builds to a certain point. The speed which the customer uses N2 has very little effect on the amount of boil-off, as it is constantly boiling.

PSA vs. Membrane
Joe Moretti of Industrial Solutions LLC, a PSA nitrogen generation manufacturer specializing in laser cutting applications, commented on the simple difference between using a nitrogen generator as opposed to buying N2 in bulk, “Ask yourself, why would we pay someone for the elements that are free for the taking? You don’t need to, you can own the equipment and generate your own N2, and do it for less then you are currently paying for it.”

Joe makes a great point, but which style of nitrogen generation do you need? It is all a matter of purities and pressures. If your process generally calls for lower pressures and a top purity of about 95% nitrogen, a membrane generator may be the best option. Membrane nitrogen generators are perfect for applications such as, fire suppression and some food processing application. However, when your application requires higher purities, such as 95% – 99.999%, then a PSA nitrogen generator is the best option. PSA nitrogen generation is a perfect fit in the metal laser cutting industry and anywhere else elevated purities and pressures are required at either intermittent or continuous duty.

Hycomp Logo

Hycomp Nitrogen Boosters:

Hycomp nitrogen booster compressors are specifically engineered and designed to handle nitrogen by employing gas specific materials. The materials used for the rings and packings in a Hycomp nitrogen booster are selected specifically to perform well with nitrogen and provide longevity.

Nitrogen generator systems, both PSA and membrane, discharge nitrogen at a range of 90 – 130 psig, depending on the desired purity and inlet air pressure. That pressure is often too low for the intended application and must then be increased or boosted to the required level. Hycomp nitrogen boosters are some of the leading boosters in the industry, especially when oil-free compression is important

When that nitrogen needs to remain free from contamination such as oil, Hycomp manufactures boosters specifically engineered to compress nitrogen gas without introducing any contamination. These nitrogen boosters are designed to mate perfectly into any nitrogen generation system to provide the required pressures. Conversely when connected to bulk nitrogen tanks, Hycomp N2 boosters can provide a vacuum to ensure that you can utilize all the nitrogen inside rather than returning a tank that is not completely emptied of the gas that you have already paid for.

The market for nitrogen is vast, but finding the right method of obtaining that nitrogen is very important to the demands and requirements of each individual application. When higher pressure is required and contamination cannot be tolerated, Hycomp manufactures the oil-free nitrogen solutions your application requires.

LaSalle Nuclear Power Plant Nuclear Nitrogen Running Strong

The Exelon LaSalle County Generating Station is a nuclear power plant located in Illinois about 75 miles Southwest of Chicago. This dual reactor facility produces enough energy to power more than 2.3 million average American homes.

Hycomp Performance Case Study

In 2005, the plant’s original nitrogen compression system was experiencing constant failures and proving very unreliable. The nuclear power plant needed a compression system that was not only reliable, but that would not contaminate their high purity nitrogen. They chose Hycomp to meet their project requirements and replace the failing system.

Six years later, in April of 2011, the Hycomp oil-free nitrogen booster duplex system tallied just over 42,000 (over 21,000 per unit) hours of operation on only oil changes for preventative maintenance. The facility maintenance crew decided to change out the valves and invited a Hycomp service technician to assist and train their maintenance staff. The standard Hycomp schedule for changing out valves is 8,000 hours of operation; at 21,000 hours (per compressor) of operation the Hycomp system showed no significant signs of decreased performance. After the rebuild, the compressors continue to run as smoothly and reliably as they were at startup.

nitrogen boosters in a nuclear power plant

Amy Myer, Mechanical Engineer at the LaSalle County Generation Station is very pleased with the performance of their nitrogen system, “Our Hycomp compressors give us the flexibility we wanted, we can easily switch between the lead and lag compressors, change set-points on the fly, and the maintenance is straight forward.”

The nuclear power plant’s nitrogen system is used to eliminate the introduction of compressed air into the reactor’s dry well and to minimize the need for venting to the environment. The nitrogen system provides pneumatic service for instrumentation to ensure the oxygen concentration is maintained at less than 5% inside the dry well.

Compressor Redundancy Downtime Hurts, Redundancy is The Answer

Redundancy is a big word in business; it can be a great word or a bad word. If you have it, it’s a really good word. If you don’t, it’s a bad reminder of when you should’ve had it.

Hycomp Communications Downtime, caused by a cut fiber optic cable

Recently at Hycomp Inc. we lost our internet and phone services for nearly an entire day due to a cut fiber optic cable over 500 miles away. This misfortune disconnected our ability to communicate with the outside world via phone and email—vital elements in the day to day operations of our company. This communication downtime put us behind on several issues; for those that were affected, we apologize.

Not wanting to repeat this ordeal, we are installing a backup internet connection via a completely different service, that will guarantee us the ability to operate in our usual productive manner if our primary connection ever fails again. We will be able to communicate to those who matter most to our business, namely our customers. We are securing our ability to operate and remain online through the protection of redundancy.

Redundant Compressor System

Downtime can be a detriment to any company, from not being able to communicate with clients to completely disabling production. PET blow molded packaging, nitrogen-assisted metal laser cutting, air starting diesel engines or vapor recovery in the oil & gas industry—no application is exempt from the harm of downtime. That is, unless they are protected by redundant systems.

When it comes to reciprocating equipment like Hycomp compressors, even when a company follows preventative maintenance schedules to the letter, there are still unforeseen incidences that can cause a compressor to be offline for a time. With a second compressor readily available, customers can instantly switch to the secondary compressor, allowing the primary compressor to be maintained while the system is still up and running, resulting in zero downtime.

For example, an international pharmaceuticals manufacturing company is currently building a new facility in Central America. Downtime is so expensive (over $200,000 a day) for their manufacturing process that they purchased a pair of duplex Hycomp air booster systems that provide full redundancy. Although the entire system cost more on the front end of the project, when compared to the cost of downtime and its accompanying stress, a redundant system will end up costing them less in the long run, and they consider it an inexpensive insurance policy.

Just like Hycomp and our backup phone and internet system, we hope end-users will enjoy the benefit of a simple solution: redundancy. Redundancy offers the benefit of peace of mind to any company, knowing they will always avoid costly downtime while continuing to experiencing peak performance.

Compressor Tracking Record Database Tracking History, One Compressor at a Time

At Hycomp, we take manufacturing compressors seriously. When one of our compressors is placed with an end-user we do not believe our responsibility with that customer ends, not even when the warranty period is far past. In fact, we take that service a step further than most other companies.

The Compressor Tracking Record (CTR) is a database where we record all communications regarding individual compressors. It gives us a way to track all historical performance data and order history as well as all communication between the customer and Hycomp. Our CTR database also includes: customer contact information, design conditions, testing results, warranty card, photos, order history and performance history.

How it Works
Using the serial number as reference, we collect as much information as possible every time a customer calls, including: service conditions, changes in operation/application, customers concerns, etc. This information allows Hycomp service technicians to observe performance and diagnose/resolve potential issues before problems and unnecessary downtime turn costly.

Recently, an end-user utilized the Hycomp CTR by recording their own compressor conditions and parameters once a week for three months to track their compressor’s operational conditions and performance. They needed to ensure they would meet their scheduled date for preventative maintenance. This customer was so adamant about their air booster running perfectly—as it was such a critical piece of their pharmaceutical packaging process—that they simply could not afford to have any unscheduled downtime.

After compiling their data, they contacted Hycomp. Hycomp Service Technicians were able to review the performance of the compressor, via recorded data, and assured the customer that their compressor would meet the scheduled date for maintenance. Recording this customer’s conditions and parameters allowed us to keep their compressor running smoothly without a second of unscheduled downtime.

Why is this good for Hycomp Distributors?
Distributors do not need to keep a complete history on every compressor they have sold. Hycomp does it for you. We invite our distributors to use our CTR for sales and information. A distributor reminding an end-user when maintenance issues need to be handled and offering educated advice on required actions and parts purchasing can build a strong relationship of trust with their clients.

We work with our distributors to give them the exact information they need to accomplish this level of service. We are even willing to make those calls with our distributors. We want the compressor you purchase from us to run at top performance for its life, always purring and always producing.

Hycomp Digital Control: Level 2 (HDC2) Hycomp Digital Control: Smarter & Easier

Our customers spoke to us about potential improvements to the “Hycomp Digital Controllers” and specifically our HDC2 controllers, and we listened. Hycomp has completely overhauled the programming in our compressor digital control systems to streamline usability and increase functionality. We also continue to offer our standard level of control, the HDC1.

The Hycomp Digital Controller: Level 2 (HDC2) now includes several new features:
• Redesigned Process Overview and Details Screens
• Pump Up test Compressor Diagnostics
• Savable User Settings
• Restore Factory Default Settings

The Process Overview and Details Screens have been completely overhauled. Visual system improvements were made by moving from a text based interface to a graphical platform. The new design of the HDC2 interface has made navigation between screens more intuitive and user-friendly.

Pump Up Test

The Pump Up Test feature allows the user to run a diagnostic test to calculate flow to ensure the compressor is performing as designed. This gives you an estimated SCFM, and takes only a few minutes. No guess work, nearly fool-proof and a much easier way to perform a pump up test. If the flow is irregular, the collected diagnostic information can be used to accurately discover compressor performance issues.

Savable User Settings and Restoring Factory Default Settings were put in place to save our end-users and distributors time, money and to alleviate stress. Basically, if a user were to overwrite settings that they then needed again they now have two options. Instead of frantically calling their distributor and then Hycomp, a user can simply restore the compressor to their saved settings or even back to the factory settings the compressor was specifically designed to run at. No need to worry, every Hycomp HDC2 control system has got you covered.

Both the HDC1 and HDC2 continue to offer the option for energy savings using a Variable Frequency Drive (VFD). VFD’s are used to provide tighter pressure control of either the discharge, or the suction, by varying the speed of an electric motor. The VFD also allows your electric motor to consume less energy because the VFD parallels motor speed and energy usage to match the demand of the application.

No matter what level of monitoring and control your application requires, Hycomp offers the digital control options to give you exactly what you want, when you want it. However, our offer of 24 hour a day free and endless tech support still stands; if you need us at any time of the day–give us call.

Hycomp Distributor Training Distributor Training: Closing More Sales

Hycomp Distributor Training explains where we fit into your sales plan. We sell a niche product and are not looking to overtake any of your main product lines. We simply offer engineered solutions where others do not.

Receiving training offers many benefits, some benefits are obvious while others are not. Sometimes an end-user comes directly to Hycomp and requests a quote. When this happens, we try to match them with a trained distributor located within their area. This doesn’t happen every day, but it happens more often than one might think.

Distributor Training Webinar

Last year we trained a distributor in the Southeastern United States. A few months later, a nearby steel company requested a quote directly from Hycomp for a nitrogen blanketing application. Hycomp Area Sales Manager, Ken Schiefer, felt confident our newly-trained distributor in that area could assist this company. Ken knew the distributor understood our products and knew how to sell them. A nitrogen booster was sold and is currently in operation.

That particular steel company was so impressed with the Hycomp equipment that they are currently looking at installing the same unit is several sister plants across North America. All sales will be going through trained Hycomp Distributors.

Webinar Training slides

Our distributor training is specifically designed to provide you with the tools you need to make more high-dollar sales and build a deeper relationship of trust with your clients. They will know that when they have a problem, you have the solution.

“If opening up a distributor’s options to more quotes/opportunities is our goal (which it is), then the Hycomp Distributor Training can be called a huge success,” commented Rob Hunt, Hycomp Area Sales Manager, “When compared to the number of quotes generated in April, May & June of 2010, the Western US produced a 260% increase in quotes for those same three months this year! This just happens to parallel when the new distributor training was introduced and implemented with the distributor force.”

No matter what your needs are as a distributor or what markets you serve in your area, we offer the training that provides you with greater access to high-quality engineered solutions for your clients. Give them solutions – not just products. In return, they will give you loyalty – not just their business.

Major topics covered in initial training session:
• Who is Hycomp / The Hycomp Niche
• When & How to Sell Hycomp
• Industries & Applications
• Distributor Protection
• Sales Process Help

Hycomp Service Training Service Training: Success With Air Liquide

When major OEM Air Liquide contacted us and asked if they could receive some service training on site at the Hycomp factory, Hycomp said… YES!

Ten men from multiple Air Liquide Process & Construction hubs around North America joined us for a two day service training seminar on June 7 & 8. Managers, engineers & service technicians came from Air Liquide to receive hands-on and classroom service training. When training was completed they walked away with a solid understanding of how to properly service and perform maintenance on Hycomp compressors, receiving the official Hycomp certification of: Hycomp Service & Repair.

Hands-On Hycomp Factory Service Training

Quality Manager Todd McGregor and Service Technician Andy Hansen headed up the training instruction in the classroom and hands-on demonstrations. Mike Durbin of Air Liquide commented, “Todd & Andy kept the class interesting… they included a good mix of ‘real world’ examples and experiences.”

When the training ended, Hycomp employees took the Air Liquide crew to nearby Logan Canyon, a local hot-spot for hiking, to walk The Crimson Trail and enjoy a Dutch oven dinner. Though the crew got caught in the rain towards the end of the four-mile hike, they certainly didn’t let that dampen their spirits. Dan Davey of Air Liquide commented, “Best corporate event ever!”

We would like to thank Air Liquide for the opportunity and privilege of providing them with service training at our manufacturing facility in Hyde Park, Utah. It was an honor to have them with us and we look forward to our next training session with them. We would also like to train any Hycomp Distributor that would like to be able to offer certified Hycomp Service & Repair.

Ragnar Relay - Hycomp Team: If We Weren't All Crazy, We Would Go Insane 191.5 Miles, But Who’s Counting
Hycomp Team Hits the 2011 Ragnar Relay
Click on image to enlarge.

A day, a night, and half a day of continuous running? Sign us up, please! Meet team “If We Weren’t All Crazy, We Would Go Insane” —a crew of Hycomp employees and friends.

June 17 – 18, the team competed in the renowned challenge of the Ragnar Relay Wasatch Back. The relay, an annual tradition for the company, covers approximately 192 miles of arduous terrain through the mountains from Logan to Park City, Utah.

Teams of twelve individuals ran three legs each, all varying in difficulty and distance (between 3 and 10 miles each). As one team member ran, the rest followed along in vans or trucks offering support, eventually meeting up at an exchange point where the next runner took on the task.

Despite steep climbs, knee injuries and sleep deprivation, team Hycomp, “Had a BLAST!” finishing with an unofficial time of 35 hours and 59 minutes.

From drenching each other with water shot from a weed sprayer to cheering for Spencer Hansen (office traffic assistant) while he ran with a Hawaiian grass skirt and coconut bra, the 2011 Ragnar certainly created memories for the Hycomp history books.

Click on following images to enlarge.


Team “If We Weren’t All Crazy, We Would Go Insane” Runners:

Runner Distance
Spencer Hansen 16.0 Miles (25.7 km)
Stacey Moss 13.3 Miles (21.4 km)
Freda Lasley 18.4 Miles (29.6 km)
Andrew Hansen 14.6 Miles (23.5 km)
Reid Andrews 13.1 Miles (21.1 km)
Robert James 22.1 Miles (35.6 km)
Kyle Ricks 12.0 Miles (19.3 km)
Taryn Ricks 16.3 Miles (26.2 km)
Pete Hyde 15.7 Miles (25.3 km)
Barbara Tidwell 15.5 Miles (25.0 km)
Erin Buttars 16.0 Miles (25.0 km)
Tom Knowles 18.5 Miles (29.8 km)

Hycomp Gas Compression: Safe & Reliable Hycomp Gas Compression: Safe & Reliable

Hycomp engineers truly understand gas compression, and more importantly, we know how to engineer gas compressors and boosters that are both safe and reliable.

In 1979 we were chosen to manufacture four units for the Susquehanna Nuclear Power Station. Because of the nuclear incident at Three Mile Island, this was an extremely sensitive decision. Pennsylvania Power and Light was very selective and discriminating in their search for a company to provide reliable nitrogen containment compressors. Characteristically, those compressors we provided 34 years ago are still in operation today.

Manufacturing safe and reliable compressors is a job we take very seriously. When compressing gas there are 3 main concerns: Containment, Control and Contamination.

Containment
No matter what gas is being compressed, from inert gases to hazardous gases, containment is paramount. Gas containment is usually an issue of keeping gas from escaping the compressor to atmosphere and possibly hazardous surroundings, but is can also be an issue of external gases (i.e., air) contaminating the gas being compressed.

Design
Every gas compressor Hycomp builds is designed, engineered and manufactured to provide containment you can trust. We utilize 3 levels of containment with our gas packing configurations. In all 3 containment options the suction gas is plumbed through the plenum chamber, equalizing pressure on, and providing cooling to the pistons and piston rings while rendering balanced piston rod loads.

• The B-Series compressor is designed to compress air or nonhazardous gases.
• The G-Series compressor is designed to compress standard industrial gases.
• The H-Series compressor is designed to compress difficult to contain industrial gases.

Control
Hycomp engineers know how to control of the factors involved in gas compression. These main factors are: Components (primarily: Rings & Gas Packings), Environment and packaging.

Within each of the three gas packing configurations we offer there are also gas specific containment features. Hycomp matches the gas to the piston ring and gas packing materials to ensure that the gas or gas mixture is fully contained and/or protected from external contamination.

Components
Hycomp quality means attention to detail. By holding our materials and production methods to a higher standard, we provide you with industrial duty compressors that outlast and outperform the competition. We match the controls and packaging to our compressor quality, and tailor the whole system for your application. Hycomp simply means quality & longevity. For example, our pressure lubricated crankcase allows for 24 a day operation for nearly 5 years before the main bearings will need to be changed out.

Piston Rings
The proper selection of a piston ring material and design will add years of reliable service to your gas compressor. We stock seven different polymer based piston ring materials to meet today’s varying gas demands. From PTFE to PEEK and PPS, we can provide the right ring material for your application.

Our angle cut design allows for flexing of the ring end to seal the gap better than butt cut designs, yet retains its strength vs. step cut designs. In situations where gap leakage becomes significant, such as low molecular weight gases and small cylinder bores, we use a 2-piece ‘L’ style design that removes the end gap by using an inner and outer ring for sealing.

Tangent Gas Packings VS. Chevron Packings

Gas Packings
Piston rod gas packings perform the critical function of containing the gas in the compressor, while providing pressure on the underside of the pistons to balance the rod loads. Our tangentially cut segmented packings are free floating and self adjusting for long wear life. The design inherently continues to seal as the packing wears. Gas packings are pinned together in pairs at the proper rotational offset to ensure that the leakpath created by the cuts are sealed.

Just like our piston rings, we stock seven different packing materials to meet your needs. And unlike chevron type packings, our segmented packings do not need constant adjustment to ensure a tight seal.

Environment
The surrounding environment is a very important factor when considering compressor packaging. For example, if nitrogen, or any nonflammable gas, is being compressed in an environment where an explosive media is always present, then the compressor and packaging must be packaged to the proper explosion proof ratings. Conversely, any time an explosive or flammable gas is being compressed, that compressor system must be “explosion proof.”

Packaging
Safety is, once again, of the highest importance or items such as control panels, motors and VFDs. Whether UL, IEC, ATEX / CE or other rating systems, Hycomp works with the distributor and end-user to understand what is needed.

Hycomp offers NEMA 7 control panel enclosures to ensure that the electric components inside the control panel are isolated from any dangerous gases. Manufacturing a safe compressor system goes further than just the control panel. All electric and mechanical equipment must also be packaged or enclosed correctly to protect against accidental explosions.

Hycomp has the experience and engineering expertise to handle the packaging and enclosures that your application requires. Our engineers get involved from the outset to provide the proper system packaging for the rating system of your region.

Contamination
Everything Hycomp manufactures is oil-free. Our design incorporates the strengths of the oil-less and oil flooded reciprocating compressors and none of their weaknesses. To accomplish this, our compressors are both oil lubricated and oil-free. However, the oil used to lubricate the crankcase never enters compression. CLICK HERE. for more information on how Hycomp gas compressors provide all the strengths of oil-less and oil flooded compressors without any of their weaknesses.

Hycomp safety does not only protect against gas leakage, we also protect your system and end product. Every Hycomp compressor is oil free. Therefore, your system remains oil free and your product is kept safe from oil contamination.

Gas compression may appear dangerous and truth be told it truly can be, however, you can trust Hycomp to manufacture a safe compression system that is built to the specifications you application requires. We are compression experts and we have come to understand that gas compression is not something to be feared, it is to be respected. That is why we make sure to investigate the intended application and gas mixture during the quotation phase of the sales process. We want your personnel and property to be kept safe.

If you have never worked with Hycomp concerning gas compressors, call us when you are compressing any gas other than air and we will show you The Hycomp Difference. We will demonstrate that you can trust Hycomp and that you can trust our experience and engineering. Trust… it’s what we build.

Rob Hunt Rob Hunt: NEW Hycomp Area Sales Manager

The beginning of this year has been very busy for Hycomp as we have experienced a myriad of jobs come roaring through our main offices. During these first fast paced few months, one bit of news we are pleased to announce is the addition of Robert J. Hunt to our Sales & Marketing team.

Rob comes to Hycomp with over 15 years of experience in manufacturing, production, R&D and sales. Rob explains, “I have been down on the production floor turning wrenches, I understand what it is like to be on the front lines. I also have a solid background in sales and marketing, with a focus in sales training. I want to help the distributors in my area, to not only understand who Hycomp is and what we do… I also want to assist our distributors to find and close more sales.”

Rob is very excited for the opportunity to use all of his past experience in his new position as Area Sales Manager of the Western United States. This means that Rob manages all sales west of the Mississippi, including Hawaii and Alaska. While acting as manager for these areas, Rob will work to improve customer relationships, provide training, and assist Hycomp distributors to increase their sales.

As a very self motivated business man, Rob concludes with this simple statement, “I’m here to assist you and your sales staff to increase your sales. I am here to help you create reliable and duplicatible results with Hycomp.”

Factory Service - Intuitive Edge Solid Factory Service With An Intuitive Edge

In the multi-billion dollar empire of medical product manufacturing, contaminations such as oil and debris cannot be allowed to enter the process.

If a compressed air or gas system were to experience contamination of any kind, the Food and Drug Administration (FDA) could possibly stop production until proper recertification, causing costly downtime.

A leading developer, manufacturer and global supplier of scientific laboratory products installed a Hycomp air booster for their PET plastic blow molding process. A Hycomp oil-free air booster was chosen because this process takes place in a cleanroom environment where contamination is absolutely unacceptable and reliability was very important.

In the spring of 2010, Hycomp was contacted by this company requesting onsite service support to handle their regularly scheduled preventative maintenance. A Hycomp Service Technician had been to their plant once before for repairs and the quality of the work, level of service and expertise, built a relationship of trust that caused them to invite us back.

When Hycomp Service Technician, Andy Hansen, concluded the required service, he decided to examine the pistons and cylinders as he reassembled the compressor. Andy discovered a moderate amount of scarring in the cylinders and on the piston rings, which he concluded was caused by debris from the intake air. Even though air compressors always use filters for suction from ambient air, once that air leaves the initial compressor and travels to the booster, it can pick up debris along the way.

Ball Valve Debris

Harmful debris, such as: welding slag, mill scale, rust, Teflon tape and pipe dope could become dislodged from inside the piping or tanks and damage whatever is downstream. In this case the air booster did not have any additional filtration at its intake and was therefore absorbing 100% of the debris collected between the air compressor and booster. A 1/8th inch piece of welding slag was found lodged in one of the valves and signs of additional debris were easily detected.

The debris was not causing any significant problems yet, but would have absolutely lead to substantial problems had it not been caught as early as it was. Andy made recommendations on correct booster arrangement and how to properly filter their plant air before running it though the Hycomp air booster. Future issues stemming from this problem were averted and the air booster continues to provide pure and reliable air for their pharmaceutical PET blow molding application.

2011 AICD Las Vegas AICD 2011: Las Vegas, May 14 – 17

The 2011 Association of Independent Compressor Distributors (AICD) meeting is just around the corner on May 14 – 17. This year The AICD meeting is heading to The Red Rock Resort in beautiful Las Vegas, Nevada.

This year, Hycomp will be represented by three members of our Hycomp Sales Team: Ken Schiefer – Eastern US & International Area Manager, Rob Hunt – Western US Area Manager and Freda Lasley – Customer Service Representative. Our team is very excited to meet and speak with everyone at the show.

Hycomp is launching a new and in depth training schedule for 2011. Hycomp has been an engineered solutions provider since 1969, and as such each compressor we make is unique and built for a specific application. In order to gain all the information needed to manufacture a customized compressor or booster we use a Hycomp Application Worksheet. In the new training being offered, the Application Worksheet is explained and our distributors will learn why every piece of information on it is important.

This training will also discuss how we protect our distributors and how Hycomp understands the old saying, “don’t bite the hand that feeds” …meaning that we need our distributors and that we do not try to push a distributor out of a sale and simply deal with the customer directly. We enjoy the relationships of trust that we have built with our distributors and dealers throughout the years and we do all we can to protect that trust.

We’ll see you in Las Vegas… don’t forget your sunscreen!

2011 ICDA Florida ICDA 2011: Florida – Return & Report

Rob Hunt and Ken Schiefer had the honor of attending the 32nd Annual Industrial Compressor Distributor Association (ICDA) meeting April 17 – 19, 2011. The ICDA meeting is unique in that it is attended by owners and senior management of Gardner Denver distributors throughout the United States and Canada.

The objectives of ICDA include:

1. Provide a vehicle for the solution of common industry problems in an effective and efficient manner.
2. To increase market volume and profits for its members.
3. To provide an effective communication vehicle between manufacturers, distributors and retailers.
4. To promote the anticipation and awareness of change in the economic, social and technological environment and positive reaction of these forces.

These goals are facilitated by holding an annual meeting where distributor owners and senior management get together to solve their challenges.

We were an invited participant to assist executives in solving their sales and market share challenges. Hycomp has experienced continual and significant growth. Rob and Ken shared with these executives a graph demonstrating this growth. We discussed in detail how Hycomp can interface with these distributors so they too can participate in this success. With this foundation, Rob and Ken are working with each of these distributors to provide sales training and support.

Our objective is to multiply our efforts through distributors within the United States allowing all to experience continued healthy sales and market penetration.

Hycomp’s participation was a tremendous success. We want to thank all involved in supporting at the 2011 ICDA meeting and in our sales effort.

Japan Earthquake and Pacific Tsunami Hycomp & Japan

Like many Americans, we watched the Japanese tragedy unfold online and on television. We saw families mourning those they lost and we saw the fear on their faces.

Hycomp employees banded together to raise money via our own donations, with some help from a few of our vendors. Hycomp then matched the total amount collected dollar for dollar. We only hope that, in the hands of The American Red Cross, this donation will help the people of Japan.

Hycomp Purchasing Agent, Brian Ogden, commented, “My family has been very blessed, and we know that something like Japan’s natural disaster could happen here… not everyone’s prepared. We just wanted to help as much as we could.”

We would like to thank all of the Hycomp employees that donated to the “Japan Earthquake and Pacific Tsunami” relief effort.

The American Red Cross still needs your help, CLICK HERE to donate.

Air Booster setup P&ID Proper Filtration First Priority

You wouldn’t run your car without an air filter, so you certainly wouldn’t want to operate a compressor without proper filtration. Sounds simple enough, but some important precautions concerning filtration often go overlooked.

Click here for a PDF of the above booster compressor P&ID setup

Valve - welding slag debris Click on images to enlarge

The number one problem with new installations of air and gas boosters is debris from the piping system damaging the new compressor. Hycomp service technicians have found weld slag, mill scale, Teflon tape, pipe dope, filter element fibers, rust and even carbon dust contaminating newly installed air boosters and gas compressors.

Rings - damage from debris This debris can become embedded in the polymer piston rings, causing scoring of the cylinder wall, or get lodged in the valves, causing valve damage and valve leakage. Perhaps the worst case was an air booster attached to 1,000 ft. of old, underground iron pipe. The owner started the air booster for the first time, went to lunch, and upon return found the connecting rod had punched out the side of the crosshead cylinder because the compressor had literally filled with rust particles and other debris, seizing the entire compression end.
1 (one) micron filter When installing a Hycomp air or gas booster into your system, setup is not complicated. But if the proper installation method is not followed, it can lead to a variety of problems. Simply put, the inlet air/gas absolutely must be filtered. However, due to the pulsations caused by a reciprocating compressor, it is not acceptable to simply put a filter directly in front of the Hycomp booster. The pulsing air/gas can tear the filter element apart, causing it to be sucked into the booster, leading to the same damage the filter was designed to prevent.

The solution is to place a receiver directly upstream of the booster compressor, with a properly sized filter at the inlet of the receiver. In addition to providing a local capacitance for the booster, the receiver acts as a pulsation dampener to prevent damage to the inlet filter. It then becomes a question of sizing the filter properly, and ensuring the receiver and piping from the receiver to the booster, are clean of debris.

The inlet filter should be rated at one (1) micron to remove any contaminant introduced by the original plant piping. To properly size the inlet filter, remember that the booster doesn’t flow smoothly, but takes in gasps at 600 RPM, an air booster takes gasps of air 10 times per second. Since filter elements are rated for smooth continuous flow, and the inlet stream to the compressor is pulsing, consideration must be made to accommodate the difference. Hycomp recommends sizing the inlet filter for twice the nominal flow of the booster, to ensure pressure drop is minimized and damage to the filter element does not occur. Install the filter directly at the inlet to the receiver.

Next, the inlet receiver must be clean of any foreign contaminant. During manufacturing, air and gas receivers are welded, hydro-tested, and then shipped to the customer, leaving mill scale, slag, rust, water and oil inside the ‘new’ receiver. This must be removed, or the debris from the ‘new’ inlet receiver will cause problems. Hycomp recommends getting the receiver epoxy lined (when compatible with the gas stream), to ensure the interior is clean and free of debris. The receiver should not restrict the gas flow, so for larger systems, it is often necessary to use a larger receiver. Contact Hycomp for assistance in sizing a standard receiver.

Teflon tape - Wrong & Right Finally, the piping from the inlet receiver to the booster compressor must be cleaned. Hycomp service technicians have found newly installed piping filled with weld slag, mill scale, Teflon tape and pipe dope. Hycomp strongly recommends against the use of pipe dope, as it is often applied too liberally, causing excessive dope to be pushed inside the pipe during the assembly process.

Teflon tape with a proper sealant such as a few drops of Loctite 545, is an excellent method of sealing pipe threads. Just remember that the tape should be placed at least one full thread back, to ensure no tape can make its way into the pipe during assembly – and at no time should the Teflon tape overhang the end of the thread. If the pipe is welded or soldered, cleaning before welding/soldering, and especially after, will prevent oxidized particulates from breaking free during operation and entering the booster.

Remember these key points during installation:
• Install the inlet filter directly at the inlet to the receiver, sized for twice the nominal flow, and rated at one (1) micron.
• Use a clean or epoxy lined receiver.
• Keep the piping between the receiver and the booster as short as possible to prevent unwanted pressure drop. Plus, short piping means less chance of debris.
• Use a flexible metal hose at the booster inlet to isolate vibration.

Hycomp can supply a packaged air/gas booster compressor with inlet filtration and a receiver pre-assembled and either installed on the skid, or shipped loose for local installation. As this is not complicated, we certainly don’t require that a pre-assembled inlet setup is purchased from us. We do, however, require that no debris enter the booster compressor, and this method of installation has proven to be very successful at allowing smooth, worry free startup and operation.

Cylinder Damage Filtration Quality VS. Price

No one wants the blame for low quality unreliable equipment. Lower priced compressors may save money on the front end, but more often than not, are costly in the long run.

Comparing Hycomp compressors against lower priced alternatives is actually a lot easier than you may think. The differences can be organized into four main categories: Endless Technical Support, Oil-Free, True Continuous Duty and Quality Construction/Packaging.

Endless Technical Support
Hycomp factory support is second to none. We offer full factory phone-in support 24 hours a day 7 days a week as a standard service at no additional charge. Think of our technicians as valued assets on your team.

Our factory technicians have been involved in all aspects of our manufacturing process, because they start out on the production floor they are literally trained from the ground up. They know firsthand how our compressors are built and exactly what makes them “tick”.

A detailed tracking record for each compressor assists our service technicians in quickly resolving concerns. Every time a distributor or end-user contacts Hycomp about a specific compressor, the service technician taking the call records notes from those communications. Information such as current operating conditions, problems & solutions and recurring symptoms that will help identify potential future problems are recorded for our entire service department to review. Tracking this history allows us to provide better support and build on our relationship of trust with our distributors and end-users. It also provides a valuable knowledge base for similar concerns.

Oil-Free
Every compressor and booster Hycomp manufactures is oil-free. Oil-less and oil-flooded compressors have their strengths and their weaknesses. Oil-less compressors can provide a clean air stream, however they are not continuous duty. Most oil-less compressors only provide moderate pressures and while they are often labeled as ‘continuous duty’, we all know that when pushed to their limits for extended periods of time, they fail.

Unlike oil-less compressors, oil-flooded units have no problem providing moderately high pressures continuously, due to their oil lubrication. The obvious downside to oil-flooded compressors is that by design, they push a substantial amount of oil into the air or gas stream which is very costly to clean out, and even costlier when the filtration system fails.

Crankcase Oil Path Cutaway Hycomp compressors and boosters accomplish the best of both worlds by combining their strengths without any of their weaknesses while providing constant high pressure and volume. Hycomp compressors are both oil-lubricated and oil-free. Each Hycomp crankcase is oil-lubricated and fully self-contained via oil scrapers and a distance piece. Oil never enters the heat of compression and therefore never enters the air/gas stream. The compression end, conversely, is entirely oil-free, utilizing polymer based piston rings, and workhorse compressor valves specifically designed for oil-free, industrial type duty.

TRUE Continuous Duty
Continuous duty means something different to those of us at Hycomp. Each Hycomp compressor is engineered to run continuously for 24 hours a day and 365 days a year, nonstop. Oil-less compressors can produce low to moderate pressures at continuous duty, but they tend to fail when providing those moderate pressures continuously for extended periods of time. That is why we say TRUE continuous Duty, because our compressors are literally designed, engineered and manufactured to be run all day every day.

Quality Construction & Packaging
• Made in The USA & Fully Stocked.
• Large Design – Small Compressor: (heavy duty construction) Allows the compressor to run at speeds much lower than others, Instead of 1100-1400 rpm we run between 400 and 800 rpm. These lower speeds mean, lower temp, less wear, less vibration and lower valve impact.
• Pressure lubricated crankcase: Every moving part inside the isolated crankcase gets oil.
• Engineer to Engineer communication: Our engineers get involved from enquiry through installation, ensuring an exact fit.
• Microprocessor based controllers providing real time answers and options, allowing for more efficient operation of the compressor system.
• Crankcases, compression cylinders and cylinder heads are made of cast iron and steel. Unlike aluminum, these materials hold their shape and don’t warp at elevated temperatures. Plus they have the added benefit of providing additional vibration dampening.
• Factory Tested: Every compressor, for at least four hours, under application specific conditions.
What does all of this mean?

Our compressors and boosters can operate for years without major component replacement. For example: Our pressure lubricated crankcase allows 24 hour a day operation for nearly 5 years before the main bearing will need to be changed.

Hycomp manufactures high quality compressors that truly separate us from our competitors by focusing on our intuitive engineering, design and materials of construction. Hycomp engineers have designed our compressors to be completely modular. We offer multiple block and cylinder sizes, cooling methods, and packing arrangements. This means we have nearly endless component and material configurations which equates to custom built compressors and boosters without the custom price.

Hycomp compressors cost less in the long-term and provide more peace of mind than the alternatives. Why? Because high quality always beats lower price, when you factor in the hassle of future maintenance parts and labor, costly downtime and having to buy multiple oil-less or oil flooded machines to provide the same longevity and pure gas as one Hycomp compressor.

Pharmaceutical Compressed Air Pharmaceuticals: Clean & Reliable Compressed Air
Engineering Support Case Study

In the pharmaceutical manufacturing industry, clean and reliable compressed gas is paramount. Pharmaceutical plants must meet the Food and Drug Administration’s regulations (FDA). If the process and product is not free of contaminates, plants can experience unplanned downtime and possibly be shutdown until recertified by the FDA.

In 2006 Abbott Labs was working very closely with Dave Beacham and Matt Verdu of Atlas Copco to provide the right air booster system and installation arrangement their process needed. Dave recalls interacting with the engineering firm they were working with on this project, “Abbott had the need for high pressure air… the engineering firm came to me and asked me, ‘how do we solve this?’ I said, ‘I know who to call, Hycomp!’”

At Hycomp, our engineers get involved from the outset of each project. Hycomp engineers work closely with the distributor’s and end-user’s engineers to ensure that the right equipment is being matched to the application’s requirements. When all three parties are involved, (the distributor, the end-user and Hycomp) the right solution is identified and everyone is on the same page and understands exactly what is required. We do this for two reasons, to provide the best customer service in the industry and to build solid trust with our distributors and end-users.

Hycomp sales and engineering teams work side by side with our distributors to make sure the customer gets everything their application needs and everything they expect. This often means producing documents and drawings tailored to a specific compressor or booster project. “I asked Ken Schiefer to provide me with a flow diagram of how the whole installation setup would fit together so I could explain things better to my client and solve their problems before they had the chance to occur,” Dave continues, “I received the diagram quickly and it absolutely helped me clearly illustrate the booster arrangement for my customer.”

Hycomp engineering and technical support is always offered for the life of every compressor we manufacture as a standard service and at no extra charge. Whether in the planning and design stages, installation or twenty years down the road, we are here to back up our product 100%. Dave understands the value in this and he has worked with us to provide the best possible solution for his clients, “I have spent enough time working with Hycomp to learn the right method of installation. Once I learned that, all the problems went away. It all comes down to doing it right, and it’s the quality of the install… if you get off that path, nothing works right.”

There is no substitution for a properly integrated system design. With over 40 years in the business, we offer solid engineering and technical support you can rely on. Lean on our engineering knowledge of how to integrate our compressors, to give you exactly what your application needs. Trust… it’s what we build.

Hycomp 2010 In Review 2010: A Letter From the President of Hycomp

It’s 9am and I’m on the first leg of a twenty six hour flight to Singapore. I received an email from Delta just three days ago, telling me that because of my Medallion status, I’ve been upgraded to first class. You can imagine the feelings of gratitude that immediately flooded through me – and left just as quickly when I opened the email to find it was only for the first 1:46 segment from Salt Lake City to Portland. The remaining 24 hours I am still in coach.

But as I write this article, I am for now in the first class cabin, and I think to myself that I’m lucky to have been upgraded, because at least there’s more leg room, coffee and breakfast coming.

As we all know, luck is a fickle thing. Hycomp has been blessed with an abundance of it. We are lucky to have a product that has a solid niche. We are lucky to have landed multiple major accounts. We are lucky to have a dedicated core group of managers that lead an equally dedicated family of employees. Perhaps most of all, we are lucky to have experienced a 35% growth this year in a poor economy.

Yet is it really luck? I have flown around the world this year, and am going halfway around now. I’ve earned enough Skymiles to qualify for the free upgrade to first class – even if it is for just under two out of twenty six hours.

Our product line has been developed and defined over 40 years, and we have reacted quickly to market changes that forced us to redefine our product twice in the last 15 years. Major accounts have found us by talking to existing happy customers, via our marketing campaigns, and through our dealers. And those managers I am so proud of? Two of them came to us as mid grade employees and have worked their way up through dedication and perseverance. So it made me wonder – how much is luck, and how much can be attributed to hard work, foresight and good decision making?

Looking back over 2010, I know our growth was not truly luck. Hard work, foresight and good decision making? Absolutely. But there is another very significant reason: sticking with our core value of building trust with our customers. One particular sale early in my career impressed upon me the amount of trust a user places in their compressors. An air conditioner manufacturer purchased an oil-free air booster system to run the coil testing for the entire production line at one plant. If they failed, production would continue to run for no more than a day before nearly a million square feet of manufacturing would come to a halt. In the end, we built more than a duplex air booster system. A decade later, the two original units are still operating that plant. We built trust.

Similar successes over the years stick with me. An aircraft engine manufacturer that has Hycomp compressors in four different facilities because of the reliability of the first installation. A laser cutting specialist that places our compressors with every nitrogen generation system they sell because of personal experience with our product. A company with whom we developed a compressor line that allowed them to build the first reclaim breathing gas system for divers nearly 1,000 feet beneath the surface of the ocean.

Each of these successes came because we stuck to that core value of building trust. Trust that our compressors would perform. Trust that our compressors would last. Trust that we would stand behind our product. Trust that we would do what we said.

This year I am sorry to say that we drifted some from this core value. We focused on dealing with expansive growth while limiting our cash-flow to ensure a strong position in a weak economy. Some customers were affected by this in a negative way: we missed delivery deadlines; we placed compressors that did not fully meet expectations; we failed to do what we said we would. In short, we became like other compressor manufacturers. We failed to build trust.

Luckily for me, Bill Scales pulled me aside at a trade show and told me point blank that we were not living up to what we said we would do. Luckily, I listened. Actually, when Bill pulls you aside, it’s just a good decision to listen. It’s hard work and dedication that gets you back on track. And it’s foresight that keeps you there. We had a trying summer as we re-examined where we were and struggled to right ourselves, but I’m proud to say we have been successful.

I take full responsibility for any failure to build trust. But I cannot take full responsibility for returning us to our core values. I credit the willingness to change, the hard work and the dedication of our employees and their families, and the faith of our dealers.

In the end, I urge you to stick with your core values. If you don’t know exactly what those are, figure them out. Business and personal, they should be the same. Here at Hycomp, we will continue producing a reliable product, we will stand behind that product, we will encourage open and honest communication, and we will fulfill our promises to you. If at any time you feel we are not following through on this, please take an example from Bill and pull me aside and tell me so.

Thank you for a wonderful year, a good learning experience, and most especially for allowing us to do what we do best. Trust… it’s what we build.

Robert James
President, Hycomp Inc.

Hycomp Distributor Protection Hycomp Distributor Protection

Have you ever heard a distributor say, “I did all the work and somebody else got the sale”? At Hycomp we understand how tough sales can be and that’s why we do all we can to protect our distributors.

It is not just a matter of protection; it’s really about loyalty and trust. Ken Schiefer, Hycomp Area Sales Manager of North America, sums up Hycomp Distributor loyalty, “We reward those who find the sale and make the effort… we reward the hunters.”

Tim West an Outside Salesman for Comp-Air in Orlando, Florida, recently experienced Hycomp Distributor protection. “When I figured out my client’s purchasing agent was going to shop the product out, I called Hycomp… they agreed that I did all the work to get the sale. I asked Hycomp to protect me on this sale, and with no questions asked, Ken Schiefer said he would.” Ken protected Tim on pricing because Tim was the first to work on this sale and he put in all the ground work.

Tim had never sold a Hycomp product. He commented on why he decided to go with Hycomp, “Response time for this nitrogen booster was critical, I had several good sources to choose from and I thought that Hycomp’s price was a bit high, but I believe Hycomp makes a better product and they have an excellent reputation,” Tim concludes, “Hycomp’s response time is excellent. I received the drawings, engineering documents and quality performance information I needed very quickly.”

Hycomp sales people, like Ken Schiefer, are usually able to spot when two or more distributors/dealers are trying to sell the same compressor. From first contact, Hycomp sales people get personally involved in what is basically a group discussion between Hycomp, the distributor and their customer (the end-user). When all three parties talk together about the application, everyone is on the same page, the customers get exactly what they need and the Hycomp sales person gains an in-depth knowledge about the application. The more we know, the easier it is to provide the best possible solution and protect our distributor.

On the flipside of collecting all of this information, a distributor might think that Hycomp is trying to gain this knowledge to push him or her out of the deal entirely and deal with end-user directly. This would simply be a poor business decision for Hycomp because we need our distributors. As the old saying goes, “Never bite the hand that feeds.” Tim West gave Hycomp a wonderful compliment when he summed up his experience, “They worked with me and they protected me when it came down to it.”

It really is a simple equation: if you do the work and are first in the door you reap the rewards of your hard work. We know that in sales, a relationship of trust and loyalty is what matters most. At Hycomp, we realize that we could not do as much business with nearly as many clients if it were not for our distributors. We not only respect that bond, we do all we can to protect it. Trust… it’s what we build.

Hycomp Oil-Fre Gas Booster Big Problems & Big Solutions

Big issues require big solutions, and we have the knowledge and skills necessary to handle the jobs that come our way.

From the humid climate of Cadereyta, Mexico, to the extreme dry heat of the Algerian Sahara Desert, Hycomp is providing large solutions specifically engineered for their application and environment. Both of these locations are associated with projects that required extensive design, engineering, documentation and packaging arrangements.

At Hycomp, we welcome the opportunity to provide the right solution as we continue to build relationships of trust with every distributor and end user with whom we do business. We recently had the opportunity to tackle a couple of large projects head on and provide the exact compressor system required for each application.

Location: Algerian Sahara Desert
Client(s): Petrofac, El Merk, Anadarko, Sonatrach

In the North East region of the Algerian Sahara Desert, the $3 billion El Merk oil Central Processing Facility (CPF) is being built and will be operated by Sonatrach and Anadarko on behalf of the El Merk partners: Sonatrach, Anadarko, Maersk Oil, Eni, ConocoPhillips and Talisman (Algeria) BV.

Hycomp Oil-Free Gas Compressor

Petrofac is one of the largest design, build and investment companies for oil & gas production projects in the Middle East with annual revenues of $3.3 Billion (USD) and a backlog approaching $8 Billion (USD). Hycomp will be supplying Petrofac, the primary contractor for the El Merk Central Processing Facility (CPF), with a nitrogen gas compressor system that will be used for fire suppression.

This nitrogen system will be boosting 80 psig of nitrogen up to 565 psig then delivering it into a nitrogen storage vessel. The high pressure nitrogen will then be discharged to the Hot Oil Fired Heater snuffing application in the event of a fire. Hycomp has provided Petrofac with extensive documentation and engineering services prior to installation and will provide onsite technical support as well as startup services during and after installation.

Rendering of a Hycomp Oil-free Gas Compressor

The complexities of engineering this application were many and at the top of the list were certification requirements and environmental conditions. This project was designed and built to meet the stringent certification requirements of the Autorité de Régulation des Hydrocarbures (French: Hydrocarbon Regulatory Authority; Algeria). An extensive control panel was designed and built to comply with all ATEX certification requirements. The gas compressor also had to be specifically designed to handle desert sand storm conditions and extreme temperatures of 23˚ to 140˚ F (-5˚ to 60˚ C).

We are very confident in our products and this Petrofac project is no exception. There has been a lot of documentation on the front end of this project and a great deal of specialized fabrication to ensure exact specifications are provided. All regional regulations were met and Petrofac is very satisfied. Hycomp is making a strong push in the oil & gas industry and we are proving very successful where safety and reliability are paramount.

PEMEX Gas Compressor

Location: Cadereyta, Mexico
Client: PEMEX

PEMEX, a Mexican petroleum company, needed to load & unload of isobutane from rail tanker car in the city of Cadereyta, Mexico, which is approximately 175 miles South of Laredo, Texas. PEMEX is a Mexican state-owned company with a total asset worth of $415.75 billion and it is the second largest company in the world by market value (as estimated by the Financial Times in 2006).

Hycomp’s design conditions for the two compressors ordered had to be flexible as isobutane pressures are altered by changing ambient conditions. The compressors were designed to handle an inlet pressure ranging between 21 – 85 psig and a discharge pressure that could also vary from 78 – 142 psig. The flow would depend on both of these factors and the twin compressor systems were designed to produce between 108 – 377 scfm.

Each turn-key system included a NEMA 7 control panel to meet the necessary regional explosion proof safety requirements. These NEMA 7 control panels weighed approximately 1,000 pounds and were sized to contain the complex electrical components to make each system fully automated.

When isobutane is shipped in tanker rail cars, it is primarily in a liquid state. However, during loading and unloading it is predominantly a gas with a liberal amount of moisture. For this reason, Hycomp utilized liquid separators before and after compression. Pulsation dampeners were also employed to provide a steady flow at both the inlet and discharge of the compressor by absorbing the shock waves created by the compressor.

Hycomp Project Engineer, Jeff Brown commented on how proud he was to be in charge of the PEMEX compressor build, “I remember walking out to the production room floor and literally seeing [our people] we have working on the PEMEX compressor system, like bees in a hive, working as one for a common goal. When this project was complete and finally loaded on the truck, as I watched it leave, it was like losing my baby. I am so proud of what we had accomplished.”

The Hycomp Solution
Our clients and distributors come to us for three reasons: 1) Engineered Solution: the client’s application requires a specifically engineered oil free solution that few offer. 2) Quality: our customers want a quality compression system that will last. 3) Trust. We stand behind our product, our distributors and our end users by offering customer service and technical support that is unmatched in our industry.

When our clients bring us applications that require a great deal of engineering, design, and manufacturing we are ready for the challenge and, when necessary, we will design a completely new system configuration we have never built before, because that is what we do; we provide solutions.

Heavy Duty Industrial COmpresors Heavy Duty Industrial Compressors
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Hycomp compressors are designed, engineered and manufactured with two main goals in mind. 1) To provide performance that exceeds expectations and 2) To produce safe oil-free compressors and compressor systems that outlast the competition.

We exceed our customer’s expectations by offering high quality specifically engineered compressors. Each compressor is manufactured for its intended application. Our modular style of engineering and manufacturing creates nearly endless compression possibilities.

Hycomp compressors and boosters are uniquely flexible, allowing us to meet your needs rather than you changing to meet our specifications. By combining the modularity of our compressors with high quality materials, dependable components and innovative engineering, Hycomp compressors outrun and outlast the competition.

In the fall of 2005 Jeff Jeanguenat, System Engineer for PPL Susquehanna explained how impressed he was with the operation of the four Hycomp compressors they purchased in 1979. “All four Hycomp compressors have operated reliably for their entire lifetime. The maintenance is straightforward and inexpensive. The factory support is outstanding. I have not experienced any compressor failures in their operating history,” Jeff continues, “I would highly recommend the Hycomp reciprocating compressors to anyone who desires reliability and endurance in their compressed gas systems.”

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Hycomp Materials of Construction

Cast Iron & Steel Construction
Our crankcases, compression cylinders and cylinder heads are made of cast iron and billet steel. Unlike aluminum, these materials hold their shape and don’t warp at elevated temperatures. The result is long term continuous duty and dependable performance, plain and simple.

Plenum Intake

Plenum Intake
Our unique “Plenum Intake” design receives intake air/gas below the compression cylinder through the plenum chamber. This innovative style of intake and compression provides three major benefits: cooling effect on rings and packings, balanced piston rod loads & a small internal air/gas reservoir.

Oil Isolation

Oil Isolation
Our distance piece works in conjunction with our piston rod oil scrapers to isolate the oil in the lubricated lower end from the oil-free compression (top) end. Scrapers remove oil from the piston rods while the open distance piece protects against oil vapor entering compression. Plainly put, our compressors are both oil lubricated and oil-free, and as such we utilize the best attributes of both worlds: oil-less and oil-flooded.

Oil-less compressors provide a clean air/gas stream, however they cannot provide higher pressures at continuous duty. Oil flooded compressors can handle higher pressures at continuous duty but contaminate the air/gas stream, forcing the operator to use high pressure filtration, which is very costly and requires a high level of maintenance.

Inside Hycomp compressors the oil never experiences the heat of compression and is therefore never introduced into the gas stream. Hycomp compressors simply utilize all of the strengths of oil-less and oil flooded compressors, but none of their weaknesses.

Lower Speeds
Instead of running at speeds of 1100-1400 rpm we run between 400 and 800 rpm. These lower speeds offer cooler running temperatures, less wear per stroke, less vibration and lower valve impact forces.

Hycomp Crosshead Design

Crosshead Design
Hycomp transfers the rotary motion of the crankshaft to reciprocating motion through the use of a crosshead piston. Our compression and guide rings never experience the side thrust of rotary motion. This means the rings wear evenly and the overall life of your compressor is dramatically extended.

Pressure Oil Lubricated

Pressure Oil Lubricated
Our crankcase is pressurized to provide generous lubrication to all moving parts and bearings. Unlike splash lubrication that spreads oil sporadically, the oil in a Hycomp crankcase is liberally delivered with pinpoint accuracy via an oil pump and riffle drilled channels through the crankshafts and connecting rods. This pressurized lubrication system decreases running temperatures, allows for higher discharge pressures and provides compressor longevity.

We take compressor manufacturing very seriously; we also take great pride in our finished product. Hycomp means quality and every compressor that leaves our factory is tested to ensure it meets our high standards of quality. When you purchase a Hycomp compressor you are not just buying a machine, you’re buying quality compression equipment that is built to last and has the lifetime factory support to back it. Buy quality, trust Hycomp.

Hycomp Hy-Syn Compressor Oil Hycomp Goes Synthetic

Click here for the Hycomp Synthetic Oil “Hy-Syn” Product Sheet

Cut the amount of oil changes your compressor needs by 75% by switching to Hycomp’s new synthetic crankcase oil. Hycomp now offers “Hy-Syn” as premium performance crankcase lubrication.

Using Hy-Syn instead of traditional oil equates to 75% longer life, less downtime and lower maintenance costs. The standard oil change interval for traditional oil is 2,000 hours. Hycomp Hy-Syn Synthetic Compressor Oil offers oil change intervals of at least 8,000 hours.

The cost of a single conservatively priced oil change, using conventional oil and if done by an outside service technician, could be about $250 (the bulk of which is labor). An oil change with Hycomp Hy-Syn using the same conservative scale would be around $350. You could pay about $1,000 on four oil changes in 8,000 hours of runtime using conventional oil or about $350 for one oil change in 8,000 hours of runtime by using Hy-Syn. The difference is clear and the choice is yours.

Product Description
Hy-Syn incorporates the highest quality, thermally-stable PAO synthetics fortified with premium non-detergent and ashless additives for maximum protection. Hy-Syn compressor oils contain anti-foam and anti-wear additives. Good foam control reduces heat, oxidation and wear. Water from condensation builds up in compressors and can cause unwanted oil/water emulsions, environmental discharge hazards and rust. Hy-Syn is also hydrolytically stable, resists acid formation and readily separates from water.

How to Use Hy-Syn
Hycomp Service Technician, Andy Hansen explains the ease of switching out your traditional crankcase oil for the more efficient synthetic Hy-Syn, “Switching to Hy-Syn is like an oil change upgrade. Simply change the oil and oil filter as usual and replace the oil with Hycomp Hy-Syn. That’s really all there is to it, just take a little extra care to drain out as much of the traditional oil as possible before using Hy-Syn and remember to never top off or mix Hy-Syn with traditional oil.”

The Hy-Syn Specs
Hycomp offers Hy-Syn in three different ISO/SAE rating viscosities: Hy-Syn 20 (46/20), Hy-Syn 30 (68/30) and Hy-Syn 40 (100/40). Hy-Syn is engineered to handle extreme temperatures, with pour points as low as -54oF and an ambient temp range of 36oF to over 95oF.

The Bottom Line
The upfront cost for Hy-Syn is more than double that that of traditional oil. By comparison, you will only need one oil change using Hy-Syn for every four oil changes using traditional oil. When you calculate the cost of parts and labor for four oil changes, using Hy-Syn dramatically reduces your maintenance expenses while providing increased longevity for crankcase components.

If you want top performance, efficiency and longevity, Hycomp Hy-Syn Synthetic Compressor Oil is the best choice for your crankcase lubrication. For high quality and peace of mind, trust Hycomp.

Click here for the Hycomp Synthetic Oil “Hy-Syn” Product Sheet

Hycomp Performance Cse Study Compressor Maintenance: “No Worries”

With over 40,000 hours of operation and only oil changes for maintenance, a Hycomp nitrogen compressor in Eugene, Oregon is proving its worth.

When installed correctly, given proper inlet filtration and adequate receiver/discharge tanks, Hycomp compressors and boosters provide years of worry-free service.

We do not recommend running one of our compressors for approximately 16 hours a day, 365 days a year, for 7 years without regular preventative maintenance other than oil changes. However, this example stands as a testament to Hycomp compressor quality and longevity.

Pacific Metal Fab specializes in laser metal cutting. In June of 2003 they purchased a Hycomp 2AN17B nitrogen booster/compressor to increase the pressure of nitrogen coming from a generator to supply three Bystronic laser cutting machines with steady streams of high purity nitrogen. Pacific Metal Fab has a high demand for nitrogen and their nitrogen generation system runs, on average 16 hours a day to keep up with their heavy workload.

Wayne Dawson, Machine Maintenance for Pacific Metal Fab in Eugene, Oregon has been with the company for over 12 years and enjoys the continuous and worry-free nature of their Hycomp nitrogen booster. He refers to the Hycomp compressor as, “…very simple and user friendly.” Over the last 7 years Wayne has experienced only minor maintenance issues which consist of changing out a pressure relief valve and the drive belt.

“The Hycomp compressor performs very well for us. We have no complaints,” Wayne continues, “I don’t have to do much with it, I just walk by and see that it is working… it just keeps running.” This is basically the best compliment a compressor manufacturer can get, that our compressors are working so well that our customers don’t have to worry about them.

If an issue were to arise with any compressor we have made, we have an excellent service and support staff that will work for you and with you to resolve any concerns or technical questions you may have.

With over 40,000 hours of service with only oil changes for maintenance, Wayne has mentioned that the compressor’s performance has started to mildly decline. We are currently working with him to provide the advice and parts to return their Hycomp compressor to peak performance. As we continue to manufacture compressors and compressor systems we will always back those compressors. More importantly, we stand behind our customers and we hope to hear from Wayne again in 2018.

Hycomp Factor Packaging Fully Packaged to Your Application

Hycomp compressor packaging is high quality, safe, flexible, and reliable. Our engineers are the compressor experts so you don’t have to be. We will work with you to engineer a compressor system tailored to your exact application requirements.

When your compressor system needs specialized packaging, Hycomp provides the options to get your process running safely while maintaining worry-free service. Our packaging options are organized into four main categories: specialized design, control panels, skid construction and motors.

Specialized Design
When compressing air and other gases at higher pressures the components used must stand up to the rigorous demands placed upon them. And when our clients bring us specialized requirements we design what their application needs. Hycomp engineers have often designed components for specific requirements and conditions, such as: “shell and tube” water cooled aftercoolers to handle 3000 psig, brazed plate (flat plate) interstage coolers to regulate interstage pressures at 1000 psig, and balanced piston rings to deal with the severity of high pressures.

Safety is absolutely paramount when designing and manufacturing gas compressors. When a potentially explosive substance is present under normal operating conditions, the right explosion proof packaging must be utilized to meet regulations and keep personnel safe. Each compressor is packaged, using high quality components and materials, to meet regional safety standards.

Hycomp quality means attention to detail. We match the controls and packaging to our compressor quality, and tailor the entire system for your application. Our clients often have specific requirements that demand innovative engineering and design specific to their application. To manufacture high quality compressors, Hycomp utilizes high quality components that are both high performance and long lasting.

Hycomp is currently working on two different projects that will experience very harsh ambient conditions. One project is being designed to handle ambient temperatures as low as -50o F and needs to be mounted inside a mobile trailer, while another project is engineered to withstand temperatures as high as 160o F on desert tundra. Our modular style of engineering and manufacturing creates nearly endless compression and packaging possibilities to handle nearly any conditions.

Control Panels
Even the best compressor in the world would be a headache if it were difficult to operate. To create a more simple and precise user interface, Hycomp provides the Hycomp Digital Controller or HDC. Hycomp provides two levels of control to meet your applications needs, the HDC1 and HDC2.

The HDC1 is Hycomp’s factory standard level of control. The HDC1 offers precise control of your compressor system. Settings are all easily adjustable and current system values are displayed on the main screen at all times. “Click here for more information about the HDC1

The HDC2 provides all the benefits of the HDC1, plus additional monitoring and individual troubleshooting screens. This additional information is invaluable for complete control and a full understanding of everything your compressor is doing in real time. When required, the HDC2 can also be remote mounted for ease of use and safety. To learn more about the HDC2, please read the HDCs & VFDs article by clicking here.

Hycomp also offers an energy savings option by combining an HDC2 with a Variable Frequency Drive (VFD). Your HDC2 microprocessor can be configured to automatically adjust compressor speeds to match your demand requirements, while saving energy and wear on the compressor.

Hycomp control panel packages are built to meet the safety rating system requirements for your region and application, such as: NEMA, IP and ATEX rated control panels. To learn more about XP packaging and when it applies, please see our Question and Answer article: “How does Hycomp handle XP packaging?”

Skid Construction
Some applications require modified compressor skid mounting. Whether you need to mount the compressor on top of a tank, the footprint needs to fit into a particular area, or if you need a complete “plug and play” system, we will work with you to provide a solution. We design and manufacture compressor systems to your needs and requirements rather than you having to change your requirements to match our compressors.

Motors
Our motors and motor enclosures are also tailored to meet various safety rating systems, such as: NEMA, IP, ATEX… etc. Hycomp electric motors are sized and specified to your operating requirements and to comply with recent US federally mandated energy standards, Hycomp utilizes premium efficiency motors.

The bottom line is that our compressor packaging is designed for one purpose: to give you exactly what your application needs. Hycomp has been manufacturing engineered solutions since 1969. We have the engineering experience and expertise you can trust. We manufacture high quality packaging and controls to ensure your Hycomp system performs to its full potential for a very long time, giving the system operator the performance and reliability they need.

Full Control & Energy Savings Full Control & Energy Savings

The inclusion of the Hycomp Digital Controller (HDC) increases your compressor’s efficiency, precision and ease of use. It basically comes down to this question: When you need to adjust the discharge pressure or temperature switch, do you want approximate or precise adjustments?

A Hycomp Digital Controller will provide exact setting control. For example: when you enter 411 psig discharge pressure, you get precisely 411 psig. By comparison, when using an analog control panel, you only get close approximate settings.

The HDC1
The HDC1 is Hycomp’s standard level of control which gives you the ability to monitor and control your compressor system with precision. Current system values are displayed at all times on the main menu screen for quick and easy reference, while an hour meter serves as a Preventative Maintenance (PM) reminder.

The Hycomp Digital Controller 1 Screen

For your operational convenience, the HDC1 monitors the following: oil pressure, suction pressure, discharge pressure, discharge temperature and motor overload. The HDC1 also provides the following capabilities and information to keep your compressor system running smoothly: PM hour meter indication, trouble alarms, shutdowns, digital readout of system values and digital entry of set points.

The HDC2
The HDC2 gives you all the benefits of the HDC1, plus additional monitoring of interstage pressures and temperatures, password protection, event history, troubleshooting walkthroughs, and Ethernet communications. The individual troubleshooting screens are invaluable when diagnosing potential problems with your compressor, while the event history provides a clear indication of current and past operation. With the inclusion of TCP/IP communications ability, you can remotely monitor and control your entire system. A larger full color touchscreen is also included to facilitate ease of use.

Energy Savings: The VFD Solution
Variable Frequency Drives (VFD’s) are used to vary the speed of an electric motor. They do this by altering the input/output frequency of the electric motor. The VFD will allow your electric motor to consume less energy because the VFD fluctuates the motor speed and energy usage to match the demand of your application.

The HDC2 Main Menu Screen

Think of how a VFD works as the difference between a standard on/off light switch in your home and a modern dimmer light switch. But, this dimmer switch responds automatically to the need for light in the room per your control settings. You use less energy because the VFD provides exactly what your process needs when it needs it. The control logic is based on standard PID functions, which are field adjustable to match your local conditions. Hycomp proudly offers this energy saving option with our HDC2 packages.

No matter what level of control, monitoring and precision your application requires, Hycomp offers the packaging options to give you exactly what you want, when you want it. For packaging that provides precision, safety and energy savings, trust Hycomp.

Hycomp Service Technician and end-user standing next to a Hycomp compressor on an oper cliff in Texas. Full Hycomp Factory Support
Click on image to enlarge.

Click here to contact a Hycomp Service Technician

Hycomp offers full factory support. When you need us we will be there for you 24 hours a day and 7 days a week as a standard service.

We stand behind our product 100%, which also means we stand behind our distributors and end-users. No matter what happens we will do everything in our power to make sure that at the end of the day our customers can say they trust Hycomp to get the job done right. We offer our support in three main categories: Free Unlimited Technical Support, Factory Startup and Factory Service.

Free Unlimited Technical Support
Our factory support commitment begins from the moment you purchase a Hycomp compressor. Hycomp provides free unlimited technical support for every compressor we make. This 24 hour a day and 7 days a week service is offered at no additional charge.

We understand that downtime can be expensive. If there is a possibility that troubleshooting and repair can be managed over the phone, we always want to make that happen. Our Service Technicians will work with you to answer all your questions and concerns.

As part of our goal to provide the best service in the industry, we also keep a complete history on every compressor we manufacture. Every time a distributor or end-user contacts us about a specific compressor we create notes from those communications and record them in our Compressor Tracking Database. This information is confidential and retained for the life of the compressor.

A compressor tracking database is a rare service in the compressor industry. Tracking the history of each compressor allows us to provide better service and technical advice when you need us the most and before a significant problem presents itself. For example: if a compressor has been experiencing small problems periodically, it may be a symptom of a larger issue that the customer may not realize. We simply want to show our customers our appreciation for choosing Hycomp by offering a higher level of support and service.

Hycomp Factory Startup
Two main questions often come up during a capital equipment purchase. “How many other unforeseen expenses are there going to be?” and “How long will it take to be up and running?”

Hycomp Factory Startup eliminates these concerns and provides peace of mind with an additional six months manufacturer’s warranty, efficient worry-free startup, and assurance that proper installation guidelines were followed.

Every time a Hycomp Factory Service Technician arrives on site they will always check the compressor installation to ensure our Installation and Operations Manual guidelines were followed.  These compressors are a good example of how to properly install Hycomp Compressors for maximum efficiency and performance.

When Hycomp Factory Startup is purchased, you have our commitment that an experienced Hycomp Technician will: 1) Guide you through a correct installation process before arriving onsite. 2) Perform a thorough installation inspection onsite. 3) Perform a detailed Factory Startup procedure including dynamic control checks, application tuning, and factory training for onsite staff.

Larry Smith, Plant Electrical Engineer at Gerdau Ameristeel commented on the help he received from a Hycomp Service Technician, during a recent Hycomp Factory Startup. “He explained all the ins and outs of our Hycomp compressor to me and our technicians: from why the oil pressure starts out low, to how to drain the water out of the system to extend compressor life. His advice went beyond what we would regularly expect and this has made our system even more reliable.”

Hycomp Factory Startup not only provides peace of mind, it is simply the best and most efficient way to get your Hycomp compressor up and running. Each compressor is fine tuned to application specific conditions and requirements. Trust Hycomp to get your process moving efficiently and safely.

Factory Service
Whether you need regularly scheduled maintenance and service or a complete compressor overhaul, Hycomp Factory Service is here to help.

Hycomp Factory Service is a straightforward process. If the concern cannot be handled over the phone or if the distributor would simply prefer a Hycomp Factory Service Technician to handle the service in person, we can make that happen for you.

Scarring found inside the cylinders at a service call helped the Hycomp Service Technician diagnose intake filtration issues that would have caused major failure in the near future.

Hycomp strives to excel in our service reporting. As service is performed, it is documented via photographs (when possible and where permitted) and through detailed notes. Our technicians go into great detail explaining what was done and also offering advice and action items to improve system performance and longevity.

We make an extra effort to explain how to prevent similar problems in the future through proper maintenance, operation and system improvements. You will also be provided with a list

of action items that need to be completed by either the end-user, Hycomp or both. The service report will also contain suggestions for the compressor that will increase efficiency and dependability.

We take our factory support seriously as we work with our customers closely to ensure satisfaction. We have found that it is important that all parties involved understand exactly what to expect before, during and after any service has been rendered. Customer satisfaction is very important to us and that is how we have been doing business since 1969.

Ragnar Relay - Hycomp Team: If We Weren't All Crazy, We'd All Go Insane It’s a 189 Mile Party
Hycomp Team Finishes 2010 Ragnar Relay – Utah
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If running 189 miles through the mountains of Utah sounds crazy, you are probably a normal and sane individual. If running 189 miles on a team of 12 sounds like a lot of fun, you are a Ragnar runner.

The Wasatch Back Ragnar Relay Race follows a rigorous mountain course from Logan to Park City, Utah. The Hycomp team, “If We Weren’t All Crazy, We’d All Go Insane” finished the full 189 miles while dealing with less than two hours of sleep, blisters, dehydration and leg cramps.

The Ragnar Relay Race is attempted by teams of twelve brave runners whom each run 3 legs that vary between 3 and 10 miles, while the other runners drive to the next exchange point in a van and wait. This is the fifth year of the race, and the second year that Hycomp has participated as a team.

Averaging a 6 mph pace, the team finished in an unofficial time of 31:46:17.8. This time placed our Hycomp team, “If We Weren’t All Crazy, We’d All Go Insane” at a respectable 358th out of 658 coed teams and 47th out of the 84 corporate teams. The team was exhausted, but still smiling, after being part of about 14,000 runners to run the grueling 189.7 mile trail (305.3 km). Everyone had a good time, and certainly developed stronger bonds of respect and friendship.

In 2009 Hycomp ran this relay race as a team and a couple runners couldn’t finish the race so fellow team members ran for them. This year every runner finished all three of their legs. To celebrate their hard earned victory, Team Captain Robert James took everyone out to dinner at the Red Rock Brewery in Park City, Utah.

Click on following images to enlarge.


Team “If We Weren’t All Crazy, We’d All Go Insane” Runners:

Runner Distance
Natalie Young 21 Miles (33.8 km)
Angela Smith 13 Miles (20.9 km)
Barbara Tidwell 18.4 Miles (29.6 km)
Kelli Jensen 13.1 Miles (21.1 km)
Jessica Sanders 14.6 Miles (23.5 km)
Tom Knowles 18.1 Miles (29.1 km)
Stacey Moss 12 Miles (19.3 km)
Pete Hyde 16.5 (26.5 km)
Andy Hansen 16.7 Miles (26.9 km)
Spencer Hansen 15.3 Miles (24.6 km)
Robert James 16.1 Miles (25.9 km)
Brian Lyman 14.9 Miles (24 km)

Hycomp Gas Leakage Control Gas Booster Niche & Higher Profits

In the gas compression market Hycomp offers an engineered product that provides the end user with what they need while distributors experience higher profit margins.

Our gas compressor niche basically exists because most large manufacturers do not address the problems that Hycomp compressors solve.

Many of the companies that have been serving this market are also pulling out of the gas compression market, even as it is growing. This increasing demand for gas compressors offers Hycomp distributors very exciting opportunities.

When a customer has a specific application that requires detailed engineering involvement, Hycomp is often the perfect fit. Whether you are dealing with nitrogen assisted laser cutting, the corrosive nature of wet carbon dioxide or compressing methane off a landfill; Hycomp has the answers and the experience to get the job done.

Trust Hycomp to be the experts and lean on our experience of over 40 years, to provide the right solution that each application demands. Our engineers address any and all concerns from the onset by talking directly with the distributor and end user engineers. This way everyone involved is on the same page and moving forward together.

Hycomp oil free gas compressors are capable of delivering a wide range of flows at pressures from a few psig to over 1,500 psig. Multiple gas packing options and our broad variety of existing modular compressor components allows us to offer an extremely versatile line of gas compressors.

We have found that the three most important factors when dealing with gas are: safety, flexibility and reliability.

Safety:
The most common leaking points in a compressor are along the piston rod and rings. That is exactly why Hycomp utilizes ring and gas packing materials that are specifically matched to the gas or gas mixture being compressed.

Hycomp G-Series & Compressor Cutaway

Hycomp provides three increasingly secure methods of gas leakage control, including our B-Series gas compressors for inert gases, our G-Series for standard industrial gases and our H-Series for extreme gas control.

Hycomp safety does not only protect against gas leakage, we also protect your system and end product. Every Hycomp compressor is oil free. Therefore, your system remains oil free and your product is kept safe from oil contamination.

Flexibility:
Our engineered solutions are flexible to your requirements. Bring us your conditions and we will engineer a compressor to match your needs. We gauge compatibility and select materials accordingly. Hycomp does not build a single “one size fits all” compressor. Every compressor and system packaging we manufacture is built for its intended use.

Our modular style of design allows us to utilize a wide range of high quality materials and methods. We offer 2 cooling methods, 9 block sizes, 12+ gas packing arrangements, and over 100 different cylinder sizes to provide nearly endless possibilities to match the compatibility requirements of most industrial gases and applications.

Reliability:
Hycomp gas compressors are designed and built with quality for continuous duty. Our compressors are engineered for slower running speeds to handle a full 60 minutes per hour, 24 hours a day and 365 days a year of actual continuous operation.

The bottom line is your Hycomp gas compressor will provide safe, reliable and continuous compression while keeping your product free from oil contaminates.

Hycomp AICD Presentation AICD Presentation – Understanding The Booster Market

It was a pleasure to meet with so many of Hycomp’s good friends and colleagues during the recent AICD Meetings at the beautiful Sawgrass Marriott Resort in Florida.

This meeting was a great opportunity for Hycomp to learn more about how the AICD member companies are doing and share some of our experience about where we are finding success. Hycomp truly appreciates all of the AICD member companies and how they have welcomed our participation in this event.

Hycomp had the opportunity this year to present information about the Air Booster and Gas Compressor niche market. Ken Schiefer led an energetic discussion about how AICD members can find opportunities and applications for these products. Ken shared some tips and tricks to understanding gas compressors and how to break into this niche market utilizing the Hycomp strategy of heavy engineering involvement and working directly with the distributor and end user.

One of the big reasons Hycomp attends the AICD meetings is that we learn so much from our distributor partners by discussing business during the vendor exhibit sessions. Hycomp was able to meet and discuss business with virtually every AICD member company. We really appreciate all of the good questions; look for them in our Q&A section of this newsletter and on our website.

There was a lot of positive energy at the meeting and many companies reported that their business is bouncing back after a relatively flat 2009. If you missed the session and would like to know more about the booster market email to sales@hycompusa.com. We would be happy to share our presentation and discuss booster opportunities with you.

Hycomp came away from the 2010 AICD Meetings with a number of very useful ideas and strategies for controlling costs, enhancing revenues, and keeping customers really satisfied. Thank you to all who contributed to making it such a great meeting. We look forward to seeing our AICD friends again next year at Red Rock in Las Vegas!

Nitrogen Applications On The Rise Nitrogen Applications On The Rise

The demand for pure, high pressure reliable nitrogen is increasing, and Hycomp has the answers that your clients want.

In the last six months 42% of the inquires we received were for nitrogen compressors and boosters. These inquires represent a wide assortment of applications, such as: pharmaceuticals, steel mills, laser cutting, nitrogen blanketing, autoclaves etc. Moreover, in the last six months, nitrogen pumps represented 35% of the total compressors we manufactured for our distributors.

At the same time that interest is increasing, some of the larger manufacturers are discontinuing production of their gas compressor lines. Opportunities abound for nitrogen applications that our distributors are identifying and capitalizing on. Hycomp continues to manufacture quality nitrogen pumps that are oil free, continuous duty and offer higher pressures.

Many nitrogen applications need higher pressures, whether the N2 supply is coming from bulk nitrogen tanks, dewars or a nitrogen generator. The point of use pressure is often higher than is provided by these means. Hycomp boosters are meeting the needs of various nitrogen applications and our customers keep coming back.

“Hycomp gas compressors have outperformed any other competitor. The units keep up with demand and are cost efficient. Our evaluations show the compressors gave us a payback within an eight month period,” said Eddie Cunningham of Pratt & Whitney, “We tried one Hycomp compressor running our TRUMPF laser cutting machines. We now have four Hycomp gas compressors.”

Hycomp distributors are able to sell our nitrogen compressors based mostly on three main points: Oil Free (nitrogen purity), True Continuous Duty (no unplanned downtime) and low maintenance (quality and longevity). We provide engineered solutions tailored to the operating conditions of individual customers.

Oil Free – Everything Hycomp makes is oil free. Oil will not contaminate your client’s nitrogen supply, leaving their nitrogen pure and their process clean and efficient. When blow molding blister packs for the pharmaceutical industry, laser cutting metal or chemical curing in an autoclave, oil simply cannot be present or the product will be damaged.

True Continuous Duty – Continuous duty means something different to us. Every Hycomp compressor is engineered to run continuously for 60 minutes an hour, 24 hours a day, 365 days a year. When downtime is not an option, trust Hycomp.

Low Maintenance – Hycomp quality means attention to detail. By holding our materials and production methods to a higher standard, we provide you with industrial duty compressors that outlast and outperform the competition. Hycomp utilizes heavy duty construction that incorporates the benefits of larger designs into our smaller compressors and boosters. We manufacture compressors that provide longevity and continuous oil free service by taking advantage of cast iron cylinders/heads, pressure oil lubricated crankcases, thick PTFE based piston rings and radial tangent gas packings. We match the controls and packaging to our compressor quality, and tailor the whole system for your application.

John Cantu, Operations Manager for US Precision Manufacturing has been using a pair of nitrogen boosters for several years, “The [Hycomp] nitrogen boosters worked great… we liked our first one so much we bought a second unit without even shopping around, we wanted more of what we had.”

Hycomp At The AICD Hycomp Presentation At AICD

Hycomp has been chosen as a presenter to explain the air and gas booster market on Monday, May 17th during the 2010 AICD meeting in Florida.

Hycomp is very excited and honored to provide this presentation. Hycomp is already a recognized leader in the air and gas booster market and we are rapidly gaining additional traction in the market

with many new applications and additional customers. Hycomp is particularly qualified in booster applications where purity of product, true continuous duty, and long-term reliability are paramount.

The air and gas booster market is one that is often misunderstood; therefore some distributors tend to approach the market with hesitancy. Distributors that have experience and are comfortable handling air and gas boosters have learned when and where to effectively apply these machines and are seeing some solid success.

The presentation will help distributors better understand the market and how to find more opportunities and success. The basics of air and gas boosting will be addressed. We will also delve into some key technical engineering points to help those in attendance fully understand when, where, and why air and gas boosters are excellent solutions.

Distributor and dealer managers continue to ask us for more information about when, where and how air and gas boosters can be sold. We will address a lot of applications that have proven very fruitful for Hycomp. An understanding of these applications, along with an explanation of how to identify and respond to these opportunities will provide a good starting point for those wishing to get a better hold on the air and gas boosting market.

Our goal is to inform you about this niche booster market in an interesting and interactive presentation. We’ll be available to answer any further questions in Booth 204 at the vendor exhibits throughout the conference. We hope to see you there!

Beaver Bash 2010: Hycomp Team Riders Engineering A Better Cardboard Sled
The 2010 Beaver Mountain Bash: Cardboard Boxcar Derby & Pond Skim
Click on image to enlarge.

Zooming down a snow covered hill in a cardboard box may seem like a bad idea to some people, but to those who piloted the “cardboard box derby cars,” it was a hilarious adrenaline rush.

Matt Logan, Hycomp Marketing and cardboard box derby car team captain was very pleased with their run, “We were screaming down that hill, the crowd was cheering… there was no stopping us. We crossed the finish line, went up and over an embankment [that was supposed to stop us], crashed through a few photographers and kept sliding down the hill.”

On March 27, 2010, a three-man Hycomp employee team entered and raced in the “First Annual Beaver Mountain Bash Cardboard Box Derby.” Beaver Mountain is a local ski resort that is only about 45 minutes away from Hycomp’s front doors. The “Beaver Bash” is held at the end of the ski season and all are welcomed to have fun as either competitors or spectators.

A cardboard box derby is an event in which 1 to 4 person teams construct “sleds” made out of only three things: cardboard, tape and string. The teams then line up at the top of a football field length (100 yards) hill and attempt to cross the finish line at the bottom with the fastest time. Teams are sent down one at a time, and hilarity ensues as teams crash or their cardboard sleds disintegrate before they can reach the end.

“My favorite part of the day was when we crashed though those photographers at the end of the run. We couldn’t stop and they weren’t moving,” commented Matt Baldwin, Hycomp Machinist and team rider, “We were all laughing so hard, and I’m glad that no one got hurt.”

Matt Logan also participated in the “Pond Skim,” which is basically snowboarding or skiing down a short run, trying to get up enough speed, and then skimming across a 50-60 foot body of water without stopping or falling in. He made it twice, and then inevitably, couldn’t make it all the way across the third time and sprayed the crowd with an icy sheet of water as he went down.

Team Hycomp came in second place in the cardboard box derby, which is not bad for a first attempt. However, Hycomp will be back next year with an improved design to claim the title of fastest cardboard box derby car on the hill!

Click on following images to enlarge.

“Hycomp Inc.” Cardboard Boxcar Derby Team:

Team Member Position
Robert James “The Boss” & Team Sponsor
Larry Howard “Pit Boss” & Duct Tape Expert
Logan Howard “Pit Crew” & Duct Tape Apprentice
Matt Logan “Team Captain” & Front Boxcar Pilot
Andy Hansen “Design Specialist” & Center Boxcar Pilot
Matt Baldwin “Momentum Engineer” & Rear Boxcar Pilot
Sizing A Compressor: Application Worksheet How To Size A Compressor: Application Worksheet Success

When we say Hycomp offers engineered solutions, we mean just that. Hycomp oil free compressors are not “off the shelf” or “one size fits all.” We engineer each compressor for specific applications.

A well built compressor is like a tailored suit, exact measurements need to be recorded and followed or the suit will not fit properly. Hycomp compressors are engineered to be an exact fit for their intended use and the Application Worksheet helps provide all the necessary measurements.

“There are so many variables when sizing a compressor,” said Terry Terwelp an outside salesman for Sullair of Houston, “The Hycomp engineering support is very helpful.”

At first glance, the Application Worksheet may be slightly intimidating; there is a lot of information required to provide the right solution. However, Hycomp engineers are ready to help our distributors and end users. By talking directly with the end user engineer and distributor, Hycomp engineers are able to discuss the application and not only provide a solution tailored to the situation, but solve any potential problems before they can occur.

We call this business approach: Engineer to Engineer or “E2E”. When the distributor and engineers from both sides of the sale communicate directly, the project moves forward faster while both product and purchase confidence increase. Mike Tiedt, Vice President of Sales for A-1 Air Compressor Corporation was very impressed with the Hycomp sales process, “Hycomp’s engineering involvement was very useful… They [Hycomp] really worked hard to help us get the order.”

There are some things on the Application Worksheet that appear more important than others, such as: gas, point of use pressure or flow. The hazardous location classification (Class/Division/Group) is an important factor when dealing with potentially hazardous gases. However, everything is important, as all information is necessary to provide the best possible solution. When Hycomp engineers get involved, customer satisfaction increases as the compressor is tailored to provide an exact fit for your application.

Click here for an Application Worksheet (PDF)

Ken Schiefer - Hycomp at ICDA 31st Annual ICDA Meeting
Industrial Compressor Distributor Association
Palm Springs, California
April 25 – 28, 2010

Ken Schiefer, Area Manager – North America, will be representing Hycomp Inc. at the 31st Annual ICDA meeting located in Palm Springs, California on April 25 – 27. “I am very excited to talk to Gardner Denver distributors about gas compressors. Hycomp has an amazing oil free gas compressor line, and due to recent events with Gardner Denver, people are coming to us more and more.” said Schiefer.

“Hycomp is moving forward in the natural gas market and making a hard push in the oil industry. Our gas compressors and boosters are 24/7 continuous duty, which is very important in these industries or anywhere unplanned downtime is not an option,” said Schiefer.

Hycomp specializes in oil free compression engineered solutions. Hycomp engineers design oil free air compressors, air boosters and gas compressors to fit the specific demands of each application. At the ICDA meeting, Ken will demonstrate for dealers how Hycomp gas compressors can provide the solutions their clients need.

To explain how Hycomp goes to market, an online distributor training webinar is offered at no charge and with flexible scheduling. Ken enjoys sharing training with Hycomp distributors, “We have experienced only success with our training webinars. Our distributors understand where Hycomp fits into their line cards and they are excited to offer their customers solutions where they previously had limited or no options.”

The Hycomp product line blends well with compressor distributor main product lines because Hycomp sells niche products. This is great news for Hycomp dealers, because Hycomp products do not compete with the products they already sell, dealers are simply provided with more solutions to offer their customers.

Hycomp provides excellent solutions for the following situations:

• When you need compressed air above 150 psig – Hycomp Oil Free Air Compressors
• When plant air pressure is not enough – Hycomp Oil Free Air Boosters
• When you need to compress any gas other than air – Hycomp Oil Free Gas Compressors

To sell Hycomp, a dealer simply needs to find one of these three “Hycomp Situations” and then call Hycomp. The Hycomp sales and engineering staff will work closely with distributors to ensure customer satisfaction. Hycomp also stands by its dealers with free continual technical support and advice.

We hope to see you at the 2010 ICDA meeting in sunny Southern California!

Hycomp Factory Startup Worry-Free Factory Startup

Two key questions often come up during a capital equipment purchase. “How many other unforeseen expenses are there going to be?” and “How long will it take to be up and running?”

Hycomp Factory Startup eliminates these concerns and includes: an additional six months manufacturer warranty, efficient and worry-free startup, assurance that proper installation guidelines were followed and system training for end user technicians.

When Hycomp Factory Startup is purchased, you have our commitment that an experienced Hycomp technician will: a) Guide you through a correct installation process. b) Be on-site to perform a pre-start inspection and factory startup procedure, which includes: dynamic control checks, application tuning, and scope of supply validation.

Larry Smith, Plant Electrical Engineer at Gerdau Ameristeel commented recently on the help he received from Todd McGregor, Hycomp Service Manager, during a Hycomp Factory Startup. “Todd explained all the ins and outs of our Hycomp compressor to me and our technicians: from why the oil pressure starts out low, to how to drain the water out of the system to extend compressor life. His advice went beyond what we would regularly expect and this has made our system even more reliable.”

McGregor explained the three most common installation mistakes that he has seen when he goes out to provide Hycomp Factory Startup:

1. Foundation Construction. Reading and following the Hycomp Installation & Operation Manual, may seem like a simple task, but sometimes it’s the details of simple things that are overlooked. Reciprocating compressors can produce mild to moderate vibration. If improperly mounted to a foundation or if an improper foundation is used, problems can occur during operation. Hycomp technicians work closely with all of our factory startup clients to be sure that they have the best advice and we make ourselves available to answer any questions or problems they may have.

2. Lack of Inlet Cleanliness and Filtration. “It is very common to have debris issues if you have a lot of welded or even threaded piping in front of your compressor without proper filtration,” said McGregor.

3. Maintenance Access. When maintenance is needed, access to the compressor is essential. For example: hoists are necessary to remove the cylinder heads of our larger sized compressors and if adequate access has not been provided then future maintenance is more difficult. Hycomp works with all of our factory startup clients to ensure that the Installation & Operation instructions are understood and utilized.

Once your compressor is up and running as designed, Hycomp continues to provide tech support at no additional charge. We want you to feel like you can call Hycomp directly with any questions you may have. Anytime.

Commenting on technical support calls, McGregor said, “Our customers can call 24 hours a day, 7 days a week and 365 days a year. We will do our best to get them the answers they need so their Hycomp equipment is operating in a correct manner.”

Larry Smith, of Gerdau Ameristeel, commented further on the support he received from Hycomp after startup. “Most people are willing to help a customer until they get paid, then their interest to help tapers off. I have been in contact with Todd McGregor since the factory startup via email and over the phone and he has been very willing to provide additional technical support and advice.”

At Hycomp, our ability to respond to customer questions and concerns is very important to us. We want our customers to be satisfied with our product and our organization. We also have great distributors to help trouble-shoot and provide constant local support and we use all of these resources to effectively serve our distributors and customers.

Hycomp Factory Testing Factory Testing

At our Hycomp factory in Northern Utah, we test every compressor we manufacture to ensure that it performs as designed.

Each compressor is tested for a minimum of four hours under application simulated conditions to ensure that the compressor startup is safe and reliable.

After successful completion of testing a Hycomp Performance Certificate is prepared by our Quality Department and shipped with the compressor. This documents that the compressor has met our stringent performance and quality standards, while listing out several of the key test parameters and requirements such as: gas being compressed, inlet and discharge pressures/temperatures, and flow.

Our testing involves actual run time. During the first two hours of testing, known as “the break-in period,” the compressor is run at a reduced load. This allows the piston rings to seat themselves against the cylinder walls and the rod gas packings to wear to an exact fit with the rod. The compressor is then brought up to the maximum design condition for two or more hours of run time.

To verify performance with end user requirements, each compressor is monitored by a data logger for the entire testing process. The data logger records measurements such as: inlet/interstage/discharge temp & pressure, flow rate, coolant temp, motor amp draw and oil pressure. System control functions of the compressor are also tested to ensure proper function and system response.

Petrofac ElMerk Algeria Hycomp Awarded Petrofac Contract

Hycomp, Inc. has been awarded a compressor design, build, installation and service contract by Petrofac International LTD. Petrofac is one of the largest design, build and investment companies for oil & gas production projects in the Middle East with annual revenues of $3.3

Billion (USD) and a backlog approaching $8 Billion (USD). Hycomp will be supplying Petrofac, the primary contractor for the El Merk Central Processing Facility (CPF), with a nitrogen gas compressor system that will be used for fire suppression.

This Hycomp nitrogen gas compressor system will be boosting 80 psig of nitrogen up to 565 psig then delivering it into a nitrogen storage vessel. The high pressure nitrogen will then be discharged to the Hot Oil Fired Heater snuffing application in the event of a fire. Hycomp is also providing Petrofac with engineering services prior to installation and onsite technical support/services after installation.

Due to the severe weather conditions of the Algerian Sahara Desert, Hycomp is providing a 3-stage air cooled gas compressor specifically engineered to handle the sandy desert conditions and extreme temperatures of -5˚ to 60˚ Celsius (23˚ to 140˚ F). Coupled with these tough environmental conditions, the Hycomp Compressor must also meet ATEX certification and have explosion proof system packaging.

The El Merk CPF will be operated by Sonatrach and Anadarko on behalf of the El Merk partners: Sonatrach, Anadarko, Maersk Oil, Eni, ConocoPhillips and Talisman (Algeria) BV. The El Merk CPF is located in the 208 block of the Berkine Basin of Algeria (see image above), approximately 550 miles South East of Algiers, Algeria. Oil and gas from this development will be primarily exported to European markets.

Petrofac’s decision to utilize Hycomp for this large scale oil and gas project continues to solidify Hycomp as a leader in engineered solutions for oil free compressors. Hycomp is making a strong push in the oil & gas industry and proving very successful where safety and reliability are paramount.

Commenting on the award, Robert James, President and CEO of Hycomp Inc. said, “Petrofac is extremely careful with whom they do business. To be considered for this project we submitted to an extensive 3rd party audit of our quality management system. The fact that we were awarded the Petrofac project is a testament not only to the quality of our actual product, but to the quality and engineering processes that we have in place.”

hycompusa.com What’s New On The Hycomp Website

At Hycomp, we are pressing forward in the areas of distributor communication and engineering involvement, while keeping up our commitment to quality, reliability and safety.

At Hycomp, we are pressing forward in the areas of distributor communication and engineering involvement, while keeping up our commitment to quality, reliability and safety. As such, our website has grown, meaning: we have some new pages and more new content than ever before.

So, visit hycompusa.com often as new content is continuously being added. We have added three new pages: Engineer To Engineer, Newsletter and Question & Answer. These new additions to our website offer interesting information about our approach to compressor manufacturing.

Engineer To Engineer
The Engineer to Engineer or “E2E” page explains the selling approach that has been proven to work best for our engineered solutions. The E2E Concept is: Hycomp engineers working directly with distributors and the end user’s engineers to provide the exact solution each application requires.

Newsletter
2010 marked the launch of our monthly Hycomp Newsletter Performance Under Pressure. As stated in the first issue (January 2010) these newsletters have been designed with our distributors and their clients in mind. We plan to utilize this monthly publication to inform and inspire.

Question & Answer
This new page is meant to give our distributors, OEMs and clients the information they want and need. If you would like to know more on a specific topic or product, need engineering advice or anything related to our company, please send us an email at: support@hycompusa.com and we will cover that subject on our website in the Question & Answer section and possibly in a future issue of the Hycomp Newsletter Performance under Pressure.

Literature
Near the end of 2009 we published a complete new series of Hycomp literature. We have created three new product brochures: Oil Free Air Compressors, Oil Free Air Boosters and Oil Free Gas Compressors. We have spent a great deal of time on these brochures to ensure that they are extremely useful and informative.

We have also added two new application specific cut sheets to the literature page: Water System Oil Free Air Compressors and PET Bottle Blowing Oil Free Air Boosters. We will be adding more cut sheets in the future and we would like to know if you have any ideas for an application specific cut sheet that you would find useful as a distributor or end user.

The Hycomp technical literature has also been completely updated. Hycomp is an engineering solutions provider and as such our technical literature is intended to provide detailed technical information to guide discussions and decisions about applications, options, and performance.

One very important addition to our literature page is the Hycomp Application Worksheet. This tool will prove very helpful to Hycomp distributors, as it pin points the exact information we need to know to quote a job. This electronic form can be filled out on your computer or printed out and completed manually.

Thank you for visiting hycompusa.com. Come back often to see what’s new. We invite you to experience the Hycomp difference.

Letter From The President: 2009 In Review

Now that 2009 is in the rear-view-mirror, I thought I would share a few 2009 Hycomp achievements with our valued Distributors, Dealers, and other industry friends.

First off, we are very proud to announce that in the midst of a hard-hitting recession and a very difficult climate for capital equipment expenditures, our revenues grew for a fifth straight year. We give a lot of credit to our valued Distributors, Dealers, end users and employees for their great efforts.

During the course of the year, we had our share of difficulties as some of our key customers saw their businesses struggle. This gave us the opportunity to re-calibrate our Distributor/Dealer Network and to further diversify our business across more industries and applications. We developed completely new Distributor Literature Kits and Distributor Training Programs, which are already proving to be very valuable tools in capturing the situations that require our unique and individualized solutions.

Internally we focused on production efficiency and quality. Through stricter control on our manufacturing floor, we reduced our internal cost of goods, allowing us to keep our prices level during the wildly fluctuating raw materials markets of the past few years. I am also very proud that we improved our delivery performance by 4%, reducing lead-times to your customers.

As our quality department continues to grow, our overall warranty levels continue drop. Our total warranty claims were a record low 0.17% of total sales, meaning for every thousand dollars sold, we had less than two dollars in warranty costs. I can think of no better testimony to the craftsmanship of our employees than this.

We enter 2010 poised to have another record year. Organizationally, we are now better structured to support our Distributors and Dealers. We are already well ahead of pace to have a record month in January and we consider our outlook for this year to be very positive, despite the tough economic conditions that still prevail.

Thank you again for your diligent efforts and continued support of Hycomp. We look forward to working with you in 2010, and I personally wish you success in the coming year.

Robert James
President and CEO
Hycomp, Inc.

Ragnar Relay - Hycomp Team: Performance Under Pressure Hycomp Runs For Glory?
The 188 Mile 2009 Ragnar Wasatch Back Relay

Click on image to enlarge.

So what do you get when you load two large vehicles with 2 drivers, 12 runners, and collectively run 188 miles (302.6 km) on next to no sleep? Two vans full of stinky, zombie-like crazy relay runners who are having an amazing time!

The Wasatch Back Relay Race follows a rigorous mountain course from Logan to Park City, Utah. The Hycomp “Performance Under Pressure” team managed to finish it all while dealing with less than two hours of sleep, rashes, blisters, dehydration, cramps and even a bum knee. This is the fifth year of the race, but only the first year that Hycomp has participated as a team. Twelve runners each run 3 legs that vary between 3 and 10 miles, passing a wrist baton to the next, while the other runners drive to the next exchange point in a van and wait.

Averaging just under a 6mph pace, the team finished in an unofficial time of 31:13:45. While not winning any awards, this places them at a respectable 305th out of 438 coed teams. While a total of 650 teams started the race, making it a race of 7,800 runners, only about 600 teams actually finished the grueling 187.9 mile run.

Everyone had a good time, and each group of 6 certainly developed stronger bonds of respect and friendship. Several runners were unable to complete their legs, but supportive teammates substituted for them before or after running their own legs. Many who participated have already agreed to run again next year – even some that initially said ‘no way’, but for whom the draw was too great and have since expressed a desire to do it again!

Click on following images to enlarge.


Team “Performance Under Pressure” Runners:

Runner Distance
Kyle Ricks 18.4 Miles (29.6 km)
Taryn Ricks 13 Miles (21 km)
Maureen Koeven 18.4 Miles (29.6 km)
Debbie McGregor 13.1 Miles (21.1 km)
Tom Knowles 14.1 Miles (22.7 km)
Barbara Tidwell 18.1 Miles (29.1 km)
Shanna Futral 12.4 Miles (20 km)
Kathy Willis 13 Miles (21 km)
Meagan Lachmar 16.7 Miles (26.9 km)
Haley Kohfeld 15.2 Miles (24.5 km)
Pete Hyde 18.4 Miles (29.6 km)
Robert James 13.4 Miles (21.6 km)

ROMER INFINITE 2.0 CMM Hycomp’s Newest Piece Of Equipment:
The ROMER INFINITE 2.0 Portable CMM

Click on image to enlarge.

The ROMER INFINITE 2.0 Portable Coordinate Measuring Machine (CMM) is Hycomp’s newest equipment addition. The Romer CMM has six joints of fully articulated movement to track and record measurements. This translates to an even higher level of Hycomp quality for our customers.

The flexibility and unlimited movement of the Romer combined with the integrated software and its portability makes this CMM accurate and efficient for quality inspection. Hycomp’s new Romer came equipped with multiple probe selections. An extended probe allows us to reach parts that may have been impossible to measure through previous conventional means.

“The Romer allows us to measure complex parts in a greatly simplified manner. Measurements that were often time consuming and difficult, are now fast and easy,” said Greg Steele, Quality Inspector. Steele, a new addition to Hycomp, has been working with CMM equipment for over three years and was excited to start using the new machine.

Quality inspection efficiency has dramatically increased with the ROMER INFINITE 2.0 CMM. For example: a cylinder head casting would usually take about 30 minutes for a single inspection using traditional equipment such as: calipers, a bore gauge and a height gauge. However, after just 20 minutes of programming, every subsequent cylinder head casting will only take 5 minutes. From a 30 minute process to only 5 minutes, there is really no comparison.

Click here for the journal article Hycomp Takes Quality Personal and Mobile