SINGLE STAGE TURBOCOMPRESSORS

Transcription

1 W E T U R N A I R I N T O A T O O L Head Office France Germany United Arab Emirates CONTINENTAL INDUSTRIE S.A.S CONTINENTAL INDUSTRIE GmbH CONTINENTAL INDUSTRIE MIDDLE EAST Route de Baneins Emdener Strasse 10 P.O. BOX St Trivier sur Moignans D-10 Dormagen Jebel Ali Free Zone, Dubaï Tel.: Tel.: +9 (0) Tel.: export@continental-industrie.com info@continental-industrie.de cime@emirates.net.ae Italy Spain USA CONTINENTAL INDUSTRIE S.R.L CONTINENTAL INDUSTRIE S.L. CONTINENTAL BLOWER L.L.C. Via Frua 1 P.I. Errota Nave E Corporate Circle, 0 1 Milano 0.70 Anoeta East syracuse - NY 107 Tel.: + 9 (0) Tel.: Tel.: info@continental.it contindus@contindus.com sales@continentalblower.com Latin America Russia and CIS countries: China CONTINENTAL INDUSTRIE ARMORIC INC. KEYWAYS INDUSTRIES CONTINENTAL BLOWER Collins Ave, C Rambla de Catalunya 8 pral 1ª ENGINEERING (TAICANG) CO., Ltd. Miami Beach, FL Barcelona Building, Area 1 Taisheng Industry USA SPAIN Zone,No.11 Xingye South Road, Economy Tel.: Tel. : Development Area, Taicang, Jiangsu (100) Tel: +8 (0) 1 71 a.deredec@continental-industrie.com tatjana@keyways-int.com info@cblower.com.cn Keyways Industries Turbo Global International Department Sales Department info@keyways-int.com turbo@continental-industrie.com Tel. : Tel. : SINGLE STAGE TURBOCOMPRESSORS

2 Continental Industrie Factory Construction & Advantages We turn air into a tool Continental Industrie centrifugal blowers and turbocompressors are a benchmark in reliability and efficiency in air and gas applications. With more than years of experience in research, development and manufacturing of centrifugal blowers and exhausters and more than thirty thousand machines installed, Continental Industrie is a symbol of reliability and confidence for continuous duty and extremely rugged service, hours a day, 7 days a week. Our factory, located in the Ain department, fifty kilometers from Lyon, benefits from its exceptional location in centre of Europe. Over the years, Continental Industrie has set up an experienced and dynamic team and created a structure that brings together engineers, technicians and sales engineers. Its sole objective: to provide industry with the best equipment for air and gas handling. Research and development An efficient production facility New blower designs for various applications, featuring higher compression ratios and capacities, are being engineered at the Mechanical Equipment Factory R & D Department, using modern design methods. Products are tested at the factory laboratory to ensure good performance, projects are followed by the Mechanical Equipment Factory. As a result of our constant interest in improving our performance and of investing a large part of our resources in research, we have adapted and modernized our plant to meet a wider variety of demands. Our machining area is now operated by computerised digital control. Easy operation microprocessor-based control system together with sensors control the blower operation and quickly respond to any anomalies and requirements. The control program can be made according to the customer requirements. The whole process may be sent to the display system or to the central monitoring room. The minimised number of rotating parts and high standards of workmanship guarantee a high performance reliability. We offer assistance for pipe lines design, flow and pressure control according to individual needs. Greater flexibility Thanks to this modernization, we have better control over production, and can now ensure our customers even greater flexibility and even shorter delivery times. In addition, spare parts and accessories can be dispatched within hours. 1

3 Overview Performance A new generation Turbocompressor range The extremely simple design of our machines guarantees maximum reliability, which is absolutely necessary in all fields of industry in which production depends on the distribution of clean and dry air at a constant pressure. The Continental Industrie TC type radial turbo compressors are modern flow machines for compression of large quantities of air or gas from 1,00 to 0,000 m³/h with pressure up to. barg. TCH Turbo Thanks to the minimisation of the parts in contact and continuous control of working paremeters, our compressors have high reliability during operation. The application of new techniques coming from spatial technology machining of the impeller blades ensures high compression efficiency (over 8%) and high general efficiency. The turbocompressor is a monolithic unit consisting of the centrifugal turbo compressor, transmission unit, main drive electric motor, frame, oil installation and control cabinet. TCH Turbo Hydrodynamic journal bearings Flow range from,000 to 0,000 m³/h Pressure up to. barg Differential Pressure (barg) TCH1 TCH TCH TCH TCH (Nm³/h) Fields of application (Ncfm) (kg/s) Inlet Flow (1.01 bar, 0ºC, % RH) WATER & WASTE WATER TREATMENT FILTER BACKWASH BIOGAS LANDFILL DEGASIFICATION DESALINATION CARBON BLACK COMBUSTION SULPHUR RECOVERY FLUIDIZATION FLOTATION SULPHURIC ACID PLANTS VACUUM CLEANING PNEUMATIC CONVEYING TCB Turbo Ceramic angular ball bearing technology Flow range from 1,00 to 1,000 m³/h Pressure up to 1 barg Advantages Reliable Energy saving Low vibrations Low noise emission Simple and precise design Stable performance Discharge Pressure TCB Turbo (PSGI) (kpa g) (Nm³/h) (SCFM) Air Flow

4 TCH Specifications TCH Turbo TCH Turbo Elements 1. Volute. Gearbox. Actuator VDV. Inlet guide vanes (IGV). Impeller in overhung design. Variable difusser vanes (VDV) Main Parts 1. Inlet Filter/Silencer. Turbocompressor. Stainless steel compensator. Cone Diffuser/Silencer. Base Frame. Local Control Panel 7. Air Cooling (Water cooling optional) 8. Compressor Drive Material specification Volute Casing Casing Impeller Vanes Gear / Wheels Fast Shaft Drive Shaft Bearings Base Frame Coupling Cast iron EN GJL-0 Cast iron EN GJL-0 Aluminium alloy (18A) or stainless steel Aluminium alloy, Stainless steel, Bronze High tensile 18CrNiMo7 High tensile 18CrNiMo7 High tensile CrNiMo Alloy Steel with white metal film Structural Steel Flexible disc coupling with spacer Performance data Flow Range Flow Regulation Pressure Range Power Range Discharge Velocity Vibration Level Noise Level See Performance chart 100% - % of rated flow with Combined control 0. to. bar (g) 00 1,700 kw Below 0m/s after Cone Max..mm/s per ISO db(a) Without enclosure 7-78 db(a) With enclosure Panels Auxiliaries Inlet Filter/Silencer IGV/VDV Actuation Expansion Joint Cone Diffuser Blow-off-valve Check valve Oil for Gearbox Lube oil cooling Cooling Fan 9% filtration as per Filter Class EU G & baffle type silencer Electric linear actuator DN0/0 steel flanges with Stainless Steel or EPDM Bellows Inlet DN0 Oulet DN00/00 DN 1/10, Electric actuated DN00/00, dual flap wafer type Approx 0 liters (ISO VG8/) Air or external liquid to oil IP 0/0Hz Compressor Drive Drive Motor Voltage Input frequency Motor speed Protection class Standard Quality Test Procedure Mechanical Test Quality Optional Electrical motor, -Pole Low-medium - high voltage 0/0 Hz 000 rpm or 00 rpm IP ISO 89 & ASME PTC10 Internal Standard ISO 9001:01 API 17/7 Human Interface PLC Instrumentation Optional: Siemens KTP700 Basic 7 Allen Bradley Panel View Plus Siemens ET00 SP CPU Allen Bradley Compac Logixs Air Pressure transmitter -0 ma Air Temperature transmitter -0 ma Oil Temperature Switch and oil tank Bearing Temperature RTD Oil Pressure Switch Low Oil Level Switch Vibration Transmitter -0 ma Surge Switch X,Y,Z Vibration Detector

5 TCB Specifications TCB Turbo TCB Turbo Elements 1. Volute. Gearbox. Actuator VDV. Inlet guide vanes (IGV). Impeller in overhung design. Variable difusser vanes (VDV) Main Parts 1. Inlet Filter/Silencer. Turbocompressor. Compensator. Cone Diffuser/Silencer. Base Frame. LCP Panel 7. Air Cooled (Watercooled in option) 8. Compressor Drive 9. Noise Enclosure Material specification Volute Casing Casing Impeller Vanes Gear / Wheels Fast Shaft Drive Shaft Bearings Base Frame Coupling Cast iron EN GJL-0 Cast iron EN GJL-0 Aluminium alloy (18A) or stainless steel Aluminium alloy, Stainless steel, Bronze High tensile 18CrNiMo7 High tensile 18CrNiMo7 High tensile CrNiMo High precision ceramic angular ball bearings Structural Steel Flexible compat type Performance data Flow Range Flow Regulation Pressure Range Power Range Discharge Velocity Vibration Level Noise Level See Performance chart 100% - % of rated flow with Combined control 0. to 1 bar (g) 00 0 kw Below 0m/s after Cone Max..mm/s per ISO db(a) Without enclosure 7-78 db(a) With enclosure Panels Auxiliaries Inlet Filter/Silencer IGV/VDV Actuation Expansion Joint Cone Diffuser Blow-off-valve Check valve Oil for Gearbox Lube oil cooling Cooling Fan 9% filtration as per Filter Class EU G & baffle type silencer Electric linear actuator DN00/0 steel flanges with Stainless Steel or EPDM Bellows Inlet DN0 Oulet DN00/00 DN 1/10, Electric actuated DN00/00, dual flap wafer type Approx 80 liters (ISO VG8/) Air or external liquid to oil IP 0/0Hz Compressor Drive Drive Motor Voltage Input frequency Motor speed Protection class Standard Quality Test Procedure Mechanical Test Quality Optional Electrical motor, -Pole Low-medium - high voltage 0/0 Hz 000 rpm or 00 rpm IP ISO 89 & ASME PTC10 Internal Standard ISO 9001:01 API 17/7 Human Interface PLC Instrumentation Optional: Siemens KTP700 Basic 7 Allen Bradley Panel View Plus Siemens ET00 SP CPU Allen Bradley Compac Logixs Air Pressure transmitter -0 ma Air Temperature transmitter -0 ma Oil Temperature Switch and oil tank Bearing Temperature RTD Oil Pressure Switch Low Oil Level Switch Vibration Transmitter -0 ma Surge Switch X,Y,Z Vibration Detector 7 8

6 Construction Construction High operating efficiency Body of the Compressor A wide operating range is ensured by a special impeller design optimised to the operating requirements, a high-efficiency transmission and a control system. Stepless capacity control between % and 100% at a constant rotational speed of the impeller. During operation, the capacity is controlled automatically by suitable turning of inlet guide vanes on the inlet and/or the vaned diffuser on the outlet. The body of the compressor is made of cast iron. The collector shape has been designed on the basis of many years of experience in co-operation with the Mechanical Fluidisation Deparment of the Technological University from Lyon. This design allows us to attain high compression efficiency and a low sound level. At the request of the client, we can adapt the outlet direction to individual requirements. Impeller TCH Hydrodynamic journal bearing TCH gearbox uses the highest quality hydrodynamic lubricated journal bearings for longer life and minimum vibration. The impeller is made of aluminium alloy. It is radial type impeller with deflected blades. The deflection angle on inlet β=0º to 0º results in high polytropic efficiency of approximately 87 %. It is machined on a -axis milling machine for three dimensional space machining of the blades. Thanks to the complex shape, it is possible to attain high compression efficiency (over 8%). All rotating parts (impeller, impeller shaft, seal, thrust bearing disk) are dynamically balanced. The driving shaft is balanced in the same way (shaft, driving wheel, coupling). Labyrinth Seal TCB Ceramic angular ball bearing TCB gearbox uses the highest quality ceramic angular ball bearings, this construction results in exceptionally long life with minimum vibration. Labyrinth seal on the impeller's shaft effectively separates air space (impeller side) from oiled space (gears). In applications that require the compression of hazardous gases, we design an air-tight solution with buffer gas. We can adapt the seal to the individual requirements. 9 10

7 Efficiency design Control of capacity Aerodynamic features Easy operation IGV Control The Inlet Guide Vane (IGV) control optimizes the efficiency of our machines against changing operating conditions such as inlet temperature, relative humidity, outlet pressure. The control system helps to reduce the probability of accidental operator errors to the minimum and uses a series of sensors to detect and quickly respond to anomalies. The flexible control system can be programmed according to customer requirements. The microprocessor-based programmable logic controller features an integrated process variable monitoring. VDV Control Pressure ratio (%) % % % Flow (%) The Variable Diffuser Vane (VDV) control offers a wide operating flow range with excellent efficiency while maintaining a constant motor speed. TO 100 % Control of capacity FROM % Improving efficiency The most significant technical change undertaken in the last decade in Turbocompressors was to combine the two regulation systems existing in the market. One was the flow regulation philosophy by means of diffuser blades on the pressure side of the compressor and the other was the pressure regulation by means of inlet guide vaness on the inlet. The use of this combination improves the efficiency when the design point of the compressor has changed because of the flow, inlet temperature and pressure. Combined Control IGV & VDV control maintains 9% of design efficiency in almost the entire range of operation. Pressure ratio (%) % % % Flow (%) Aerodynamic design Aerodynamic technology is based on additional aerodynamic vanes on the inlet of the compressor, which main task is to keep the air within a laminar flow towards the eye of the impeller. Pressure ratio (%) % 9% 90% Aerodynamic vanes That is the reason why Continental Industrie has fitted its compressor with this combination of guide vanes and diffuser vanes to guarantee the maximun efficiency Flow (%) 11 1

8 Lubrication system Control & monitoring system Pressure lubrication system Control panel The pressure lubrication system provides a safe and reliable oil lubrication for the gear set and bearings as well as cooling for the bearings and gears. The control and monitoring system shall ensure correct operating conditions at start and stop of the compressor as well as during operation. This complete system is designed to comply with the API 1-th and factory assembled and tested. The control system runs the start and stop functions, the compressor operation, the lubricating oil system, and the activation of the blow-off valve, the IGV and VDV. The oil lubrication system consists of the following components: The local control panel can be mounted on the base frame. Main oil pump The main oil pump is mechanically driven from the low speed shaft. - Gear type - Pump body in carbon steel Auxiliary oil pump The auxiliary oil pump is a pump with electrical motor, installed vertically and submerged into the oil reservoir. It has the same capacity as the main pump and is used to prime the system before start-up and acts as a standby unit in emergency and during shutdown. - Gear type - Pump body in carbon steel Oil reservoir The oil reservoir is integrated in the base frame and includes fill connection, inspection opening, gauge glass and ventilation. - Carbon steel - Painted with an oil resistant paint - min retention time Oil Filter Duplex element oil filters connected with a manual switch valve µm filtration - Electrical & visual clogging indicator - Casing in Aluminum Oil cooling heat exchanger - Air-cooled or Water-cooled Oil heater (Optional) The heating element will ensure that the oil maintains a minimum temperature in case of stand-still or site conditions Panel Carbon steel, epoxy-polyester powder painted, protection class IP Operating items at the front side Key switch to select operation mode Unavailable / Remote / Local Push buttons (and lamps) to start / stop the compressor Push button emergency stop Push button failure acknowledgement Lamps to monitor compressor status ( Running / Warning / Failure) Programmable logic controller (PLC) Siemens ET00SP CPU, with two Profinet sockets, I/O modules and software for fully automatic start / stop sequence and monitoring the process values or Allen Bradley Compact Logix 70, I/O modules and software for fully automatic start / stop sequence and monitoring the process values Control Pressure or Flow regulation with IGV & VDV control Efficiency optimization through temperature and pressure reading Surge monitoring through turbo parameters monitoring Gearbox monitoring (vibration, bearing temperature, shaft displacement) Oil circuit monitoring including : - Cooling/heating control - Pressure and temperature safety & monitoring - Level indicators - Mechanical & electrical pump management - Oil filter monitoring - Motor monitoring (overload, winding and bearing temperature) - Sound enclosure fan control Human machine interface (HMI) Installed at the front side of the panel: Siemens KTP700 Basic PN, 7, IP or Allen Bradley PanelView Plus 00,, IP Communication (DSC, MCC) Modbus TCP (the control panel is a Modbus server). 1 1