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Geared Turbocompressor The core compressor unit comprises of the volute casing, impeller, speed increasing precision turbo gearbox one lubricating oil system and ball bearings with coupling and all safety controls required for the monitoring system. The oil lubrication system consists of oil cooler and single oil filter. All mounted on a common console and prepared for electric motor, incl. mounting of same.
to learn more about the important choice to select the right control systematic, click here
Electrical Drive Motor The electrical motor is connected to the compressor units via a flexible coupling within a fixture console. It is the main drive for the compressor working machine. The motor size is determined by the compression work required at the design point under design conditions, derated by the ambient temperature and elevation above sea level.
The motor is a three-phase AC electric motor for continuous operation (S1) made of cast iron. Temperature probes in the windings can be ordered as upgrade. The configuration is a B5-type (hanging on flanges). the rated motor voltage is for xxx, xxx or xxx. Selection for 50 or 60 Hz frequencies possible. Rated motor speed: around 3.000 rpm.
Protection class is IP55; Insulation class F utilized to B; Efficiency class IE2. The motor complies with the standards IEC, DIN, ISO, VDE, EN and is designed for ambient temperatures from -20 to +40 C degrees.
A routine test of the motor(s) is included in the price. Please note: Motor brand is selected by manufacturer based on availability and from a list of qualified vendors.
B3 (feet) Configuration Electrical Drive Motor The electrical motor is connected to the compressor units via a flexible coupling within a fixture console. It is the main drive for the compressor working machine. The motor size is determined by the compression work required at the design point under design conditions, derated by the ambient temperature and elevation above sea level.
The motor is a three-phase AC electric motor for continuous operation (S1) made of cast iron. Temperature probes in the windings can be ordered as upgrade. The configuration is a B5-type (hanging on flanges). the rated motor voltage is for xxx, xxx or xxx. Selection for 50 or 60 Hz frequencies possible. Rated motor speed: around 3.000 rpm.
Protection class is IP55; Insulation class F utilized to B; Efficiency class IE2. The motor complies with the standards IEC, DIN, ISO, VDE, EN and is designed for ambient temperatures from -20 to +40 C degrees.
A routine test of the motor(s) is included in the price. Please note: Motor brand is selected by manufacturer based on availability and from a list of qualified vendors.
Variable Frequency Drive (VFD) For start and regulation, 3x400V 50 Hz, incl. EMC filter, Input choke, Contactor and Automatic switch, with dual point regulation for maximum efficiency according to pressure and ambient temperature. No further soft-starter or direct starter is required.
Within the Compact enclosure, the VFD and all relevant filters have their own compartment and are fully integrated, cabled and pre-tested.
Direct Starter (DOL) Direct starter DOL, 3x400V 50 Hz or 60 Hz, including automatic switch. Please note: When a VFD is already selected, a Direct Starter is not required.
Softstarter (MCC)
Soft starter, 3x400V 50 Hz or 60 Hz, including contactor and automatic switch. Please note: When a VFD is already selected, a Soft Starter is not required.
Inlet filter/ Silencer Inlet filter:
Compact pocket filter elements, easy to exchange from outside. Suction filter with 95% filtration as per G4 EN779 (upgrade possibilities available). Including visual Umeter for fouled filter indication. Please note that the H2S content in the atmospheric air should not exceeed 10 ppm and the salt water content be limited to 50 mg per m3/hr.
For suction directly from compressor room. An adapter can be purchased to connect to suction channel from outside the blower room.
Inlet silencer
Compact labyrinth type integrated in the Compact enclosure.
Flexible Compensator Flexible outlet compensator, mounted between compressor outlet and discharge diffuser is reducing the vibration and other forces from and to the main discharge pipe.
The compensator is with stainless steel AISI 321 flexible element and turnable aluminium flanges.
Discharge Diffuser The discharge diffuser is a key component of any centrifugal turbocompressor, as he converts the kinetic energy (high velocity) of the gas into pressure by gradually slowing (diffusing) the gas velocity. The diffuser can be selected either un-silenced or silenced, whereas latter reduces the sound emission in combination with an isolated main discharge pipe. Within a Compact enclosure the discharge diffuser is always isolated to reduce heat dissipation into the enclosure.
The discharge diffuser diameter is selected keeping the airspeed at the outlet as per our standard under 25 meter/ sec to reduce pressure losses in the main pipe and limit sound emission. A different value can be set in Step 2 of the configurator under 'Settings'.
Made of galvanized steel with 1/2'' BSP stud for possible connecting of a measuring equipment. The outlet direction can be changed in 90 degree angles, please refer to upgrade options.
Blow-off Valve/ -silencer The blow off valve (BOV) is used for unloading during the start-up and rundown sequence of the compressor. It can also be used for antisurge
purposes. The blow off valve is equipped with a silencer. It is made as a butterfly valve for mounting between flange, and equipped with electric
actuator and limit switches.
Within a Compact solution the BOV is fully integrated and cabled in the enclosure. The air is blown off into the enclosure, which further reduces the sound emission. The logics is carried out by the local control panel (LCP).
Not Return Check Valve A check valve, non-return or one-way valve allows the compressed air to flow through it in only one direction, protecting the impeller/ compressor from reverse rotation and damage.
The check valve is with dual spring-loaded flaps. Wafer type to be mounted between flanges. The body is of cast iron and plates of nodular cast iron. Shafts and spring-loaded flaps of stainless steel and with EPDM or Viton seals, suitable for the rated outlet temperature. This valve is supplied loose for mounting by others on horizontal pipe, before the common discharge header
Isolation Valve Electrical actuated compressor discharge isolation valve, butterfly type. The valve is equipped with limit switches and it is powered and controlled by the LCP. The valve material is cast iron , stainless steel flap and spindle.
This valve is installed after the check valve on compressor discharge pipe.
Silent blocks & Machine mounts Silent blocks for 95% vibration reduction. The silent blocks are mounted between the compressor base and the hood frame. This solution enables to place the complete compressor/hood directly on the ground floor without the need for additional isolated foundations or special grouting. No significant, or none, vibrations are transmitted to the ground floor.
Local Control Panel The Local Control panel (LCP) is either integrated in the Compact enclosure and mounted on a separate, removable steel plate or separately placed outside of the Modular enclosure. It features the basic functions for start and stop of the compressor, as well as the security scheme. Other features:
Diffuser capacity control (flow control)
Basic functions (compressor control & monitoring of key compressor parameters)
HMI is a 7'' touch panel of color type
PLC type as defined; our standard is Siemens ET200SP PLC based control system
Connection to Master Control system (MCS) via communication protocol defined (standard is Ethernet)
Power supply 3x400 VAC + N + PE Master Control System The MCS (Master Control System) is equipped with the same PLC platform as the LCP and Siemens HMI. The MCS is controlling all compressors airflow thru the high efficiency cascade mode to perfectly match process air requirement and with priorities in order to equalize compressor duty hours. The MCS communicates with the DCS via the defined network communication protocol (standard is: Ethernet network).
The MCS panel is a stand-alone panel, typical size is H=600, L= 600, W=300mm
Compact enclosure Silencing hood integrated with all above described accessories, factory mounted and tested. All the side and top panels are either hinged as a door, or quickly and easy removable for comfortable access to the internal components. Each side is equipped with inspection window. The hood is equipped with Internal light and heat extraction fan, all operated from the control panel. Construction material: The frame is made of welded steel profiles, powder painted and soud absorbing panels are made of sandwich bended Aluzinc steel sheets. Residual noise: Depending on working parameters, typically: <75 dB(A) ISO 3744/46, with well isolated outlet piping.
The power part is integrated inside the hood in a segregated compartment. Only one external connection for power supply is necessary. Available from top or from bottom.
MODULAR enclosure The enclosure is build with alu-zinc coated steel covers, with layers of mineral wool, a perforated, galvanized sheet, strengthening sheets
and sealing strips of rubber. The hood is equipped with a door for easy access to the inside room, one sight window and a thermostatic controlled ventilation fan. Each panel of the acoustic enclosure is provided with handles, which makes assembly or reassembly of the enclosure easy.
Please note, that assembly and installation on-site is required, as the enclosure is delivered in loose parts. Most compressor components mentioned here are supplied loose and have also be installed and cabled on-site. A commissioning and start-up by a authorized technician might also be required.
Compressor Bearing Temperature monitoring A set of two temperature sensors for the fast and low speed shaft constantly monitor the gearbox bearing temperatures. The sensors are wired to the LCP (into the noise enclosure). Actual bearing temperature is shown on the HMI with alarm and trip level.
Vibration monitoring system Consisting of an accelerometer mounted on top of the gearbox which constantly monitors compressor vibrations. The transmitter is wired to the LCP (into accoustic enclosure) Actual vibration is shown on the HMI with alarm and trip level
Motor Winding Temperature monitoring In order to monitor temperature in the motor windings and to protect the motor from overheating, the motor can be equipped with two sets of PT-100 temperature probes. The probes will be connected to the Local Control panel (LCP) and required alarms and trips initiated.
Motor Bearing Temperature monitoring Consisting of one sensor type PT100 sensors installed into main motor bearing DE & NDE. The sensors are wired to the LCP (into accoustic enclosure) Actual temperature is shown on the HMI with alarm and trip level.
Motor Space Heater The space heaters which are commonly used to prevent condensation in motor applications are basically resistant wire heating devices. They are used to maintain the internal motor air temperature above the dew point. (The dew point is the temperature at which water will condense from air which is being cooled at a given pressure and water vapor content).The heater is mounted directly on and wrapped around the coil head at the opposite end from the connections
The space heater is powered from the LCP and will be ON during stand-by period.
Oil Level Switch Instrumentation The oil level switch is an extra instrument, which triggers an alarm at the Local Control panel (LCP) when the oil level in the oil tank is passing below a defined threshold. This instrument increases the safety of the machine.
Reverse Monitoring System The reverse rotating monitoring is indicating a reverse rotation of the impeller shaft, which could potentially damaging the compressor machine.
Remote Monitoring System Remote monitoring system of 'compressor actual operation' is allows our factory to be on-line from remote with the MCS and each LCP (compressor). By the remote system, we have the possibility to see real-life operation and advise operators in case of failure. All operational information are available for monitoring.
Commissioning on Site A local certified technician to provide onsite commissioning and plant personnel training. After successful unit start-up a certificate is released. Typical expected time is 1 to 2 days per unit, flight/transport and accommodation included.
Recommended Spare parts for 2 or 4 years of operation including the following items (consumables are not included here and have to be provided by plant operator):
Training of Staff A certified local technician will advice the operational personnel in all unit functions, HMI navigation,simulate and alarm with PLC I/O tests and O/M manuals with basic oil, oil filter and air filter replacements.
One set of recommended other spare parts for the whole installation, including all units of same model. This spare parts kit can be considered a safty stocking. Included:
set of o-rings and gaskets
set of instrumentation
one limit switch
Standard full load performance test During our standard full load performance test a qualified test engineer will establish the performance of the machine in a certified test field. Typically only one machine from the order will be tested. The test is optional and is priced.
The machine will be run at design His (corresponding to design pressure raise at design inlet temperature, humidity and barometric pressure) and the maximum and minimum flow point will be read. The performance will be measured with the heat balance method according to ISO5389.
A certificate will be issued (please refer to ITP plan for more details)
Performance Verification Test During the performance verification test, a qualified test engineer will run the machine against the performance table provided at the contract negotiation. Customer will choose up to 4 verification points from the performance table which will be verified during the test; these points have to decide before contract closing). The verification can be un-witnessed or witnessed (expenses on side of supplier are not included).
The verification will be done according to ISO5389. A test certificate will be issued.
Overspeed test of impeller The impeller will be run at no less than 115% of the rated speed and is based on API617 (2002 edition). The rated speed corresponds with the speed at the design point. During the test, vibration levels will be measured to identify any potential deformation and material weakenings. A certificate will be issued.
Dye Penetrant test of impeller The purpose of a dye-penetrant test is to find cracks, overlaps, pores and similar defects in the surface of a non-porous material. After the part is cleaned a liquor is added to the surface to penetrate the surface. After cleaning, the defects can be identified by applying a developer. The test is a Bycotest red/white penetrant-dye test.
Acceptance criteria is that a) no crack line b) no clustered pores of significant size may appear. A certificate is issues on the results.
Hydrodynamic test of volute The volute casing will be temporarily assembled with flanges to form a closed vessel for pressurizing with water. The test pressure will be no less than 1.5 barg. The test pressure will be maintained for a minimum of 30 minutes during which no leaks should occur. A certificate will be issued.
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