SIERRA. Oil Free Rotary HP (37-300kW) OIL-FREE ROTARY SCREW AIR COMPRESSOR HP ( kw) Point of Manufacture - Davidson, NC USA

Transcription

1 Point of Manufacture - Davidson, NC USA SIERRA OIL-FREE ROTARY SCREW AIR COMPRESSOR DETAILED SPECIFICATION Series 60 Hz L H HH Discharge Pressure 100 psig 125 psig 150 psig 50 Hz SL 7.0 BAR SM 8.5 BAR SH 10.3 BAR The SIERRA Oil-Free Rotary Compressor is an electric motor driven, continuous duty, two-stage rotary compressor with asymmetrical profile rotors. It is a totally self-contained air compressor package. The unit is pre-piped, wired, base-plate mounted, and is tested and shipped complete. SIERRA oil-free compressors may be applied wherever compressed air is required within the capacity and pressure ranges. It is ideally suited for those applications, such as food processing, electronics and chemical processes, etc., in which totally oil-free air is essential to insure high quality finished products. Compressed air intended for breathing purposes, as in diving equipment, is an exception to the unlimited application of the SIERRA compressor. Compression Module Inlet Air Filter Dry type 99.99% efficient 3 micron and above. High Dust Filter is standard for HP (37-150kW) SUPER DUTY non-european sourced models. Compression Module The rotors are manufactured from high quality forged steel and stainless steel. First-stage rotors are machined from E35 steel and second-stage rotors from X20CR13 stainless steel (400 series). Rotor housings are cast iron: GG20 (DIN 1691) material no Components are machined, precision ground, and assembled to ensure that tolerances are kept within the designed specifications. This is essential to producing airends and compression modules with required performance and durability. Both the rotors and the internal surfaces of the cast iron compression chambers receive a special Ultracoat treatment to eliminate corrosion. Ultracoat is a patented process that robotically applies a micro coating of organic, high temperature resins, with PTFE and Molybdenumdisulfide, to specially prepared surfaces. This process creates a mechanical bond of coating to metal. Additionally, this mechanically bonded coating increases airend efficiency by precisely limiting the clearances with the airend (rotor to rotor / rotor to housing). Since the rotors are pinion gear driven, no rotor contact can occur; consequently, this precisely applied coating should last the life of the airend.

2 Rotor timing and power transmission to the primary and secondary rotors are accomplished with high quality, helical cut gears. Bull gear specification: 30CRMOV9, DIN 17200, Pinion gear specification: 16 MNCR5, DIN 17210, The bearing system used on the Sierra Oil-Free airends has been designed to handle all expected radial and thrust loads. Four (4) roller bearings are used on each airend to absorb radial loads, while two (2) ball bearings per airend are provided to absorb thrust loads. Since these Sierra airends are designed to deliver a continuous flow of oil-free air it is essential that only the finest quality oil and air seals be used. All air seals are constructed of stainless steel and all oil seals are of a time proven labyrinth design. One set of air seals on each rotor is also vented to further eliminate any chance of oil leakage into the compression chamber (see Figure 1) (Figure 1) Main Drive Motor All 50Hz and 60HzSierra motors are high efficiency, and are constructed of copper wound stators with class F insulation: EUROPEAN SUPPLIED 50Hz Motor Size Star-Delta Service Factor Applied Power ODP TEFC (IP55) kW N/A 400V(+/-10%) kW 400V(+/-10%) 380V* V* V* kW 400V(+/-10%) 380V* V* V* kW 380V* 380V* V* 400V* V* 415V *Voltage tolerance of +/-6% U.S. SUPPLIED 60z & 50z Motor Size Star-Delta Service Factor Applied Power ODP TEFC Super Duty: HP N/A 200V, 230V, 460V, 575V

3 37-75kW N/A 220V, 380V, 415V Super Duty: HP N/A 230V**, 460V, 575V kW N/A 380V, 415V HP 460V, 575V Optional Optional 2300V/4160V (AAL) kW 380V, 415V Optional Optional 3000/6000V (AAL) ** Available at 125HP only Close-Coupled Drive Assembly The main drive motor is flanged to the gear case for continuous alignment. Motor power is transmitted to the bull gear through a flexible coupling. Complete drive assembly is isolation mounted to prevent vibrations from transmitting into the package. Airend Bearings: Radial loads are carried by high quality, vacuum-degassed cylindrical bearings. Thrust loads are carried by high quality, vacuum-degassed ball bearings. No thrust pistons or diaphragms are used to offset thrust loading. Intercooler/After-cooler/ Oil-cooler Air-cooled Air-cooled Sierra includes an integrally mounted three-piece, aluminum, air-cooled heat exchanger rated for 115 F (46 C) maximum ambient temperature, with a F ( C) CTD after-cooler. The cooler assembly includes TEFC Cooling Fan Motor and fan blade: this assembly provides a static head allowance of 0.25 water (124.5 Pa). Water-cooled Integrally mounted water-cooled heat exchangers include tube and shell construction with 115 F (46 C) maximum cooling water temperature and F ( C) CTD after-cooler. A mounted and wired water solenoid valve is included as well as a small enclosure fan (TEFC/IP55 motor). The SIERRA water-cooled coolers are designed so that the compressor may be operated continuously and efficiently in ambient temperatures as high as 115 (46 C) and still provide a desirable 15 F (8.3 C) CTD. All heat exchangers are shell and tube design. To protect the intercooler and after-cooler from air pulsation damage, the air is channeled through the cooler tubes while water is directed into the shell. The oil cooler utilizes the opposite configuration as water is directed through the tubes and oil through the shell. The standard intercooler and after-cooler utilize copper tubes, nickel-plated carbon steel tube sheets, and brass baffles. To promote reliability, the hot side end bonnet is constructed of cast iron with a protective corrosion resistant coating. The cold side end bonnet is constructed of anodized, cast aluminum. The oil cooler utilizes admiralty brass tubes, and cast iron end bonnets.

4 Heat Exchangers Air-cooled Intercooler Oil Cooler After-cooler Heat Exchangers Water-cooled Tubes Tube sheet Bonnet - Cold Side Hot Side Baffles Screwed Pipe Assemblies (2" and smaller) Materials piping Material fittings Piping Schedule 80 Tube Assemblies Size 1/4" and 3/8" Material Flares Fittings Size 1/2" to 1-1/2" Material Flares Fittings Size 3" and 4" Material Fittings Electrical Components Approved By Aluminum Aluminum Aluminum Copper (Stainless Steel optional) Nickel Plated Carbon Steel (Stainless Steel optional) Cast Aluminum Cast Iron w/ coating Brass ASME SA106 Grade B; SA53 - Type E&F; Zinc plated American Standard - Zinc plated 300 psig (20.6 barg) maximum working pressure SAE J5276 SAE J double flare SAE J514; Section I & II SAE J5246, J5256 SAE J single flare SAE J514; Section I & II Seamless stainless steel ASTM A213/A A SAE J518 National Electric Code Underwriters Laboratory Canadian Standards Association National Electrical Manufacturers Association Pulsation Dampeners Provided after both stages to dampen pressure pulsations prior to entering the intercooler/ after-cooler.

5 Enclosure Sound attenuating sheet metal enclosure is included with multiple quick release latched panels. Acoustic treatment is applied internally to reduce sound level (see engineering sections for actual dba rating). The SIERRA cabinet is designed to safely contain components yet offer an aesthetically pleasing appearance, ergonomically planned maintenance access, and excellent sound attenuation. The compressor panels are composed of 14-gauge (1.905mm/0.075 inch) steel and are painted with electrostatically applied powder coat paint. Paint specification: Color: Beige, Munsell /2.9 Flexibility: ASTM D522 Adhesion: ASTM D3369 Method B Hardness: 2H pencil hardness test to ASTM D3363 Impact Resistance: ASTM D2794 Salt spray and humidity resistance: ASTM B117, ASTM D2247 The foam panels and horizontal sound bats reduce the sound level of the package and are highly resistant to degradation cause by chemical and particulate contact: Panel foam specification: ASTM C Flame resistance: UL94HFI Sound bats: Compression strength: ASTM D1564 Flammability: ASTM E84 Other applicable codes: ASTM D1175, ASTM D1682, ASTM E1050, NFPA 701 Free flowing inlet air louvers are provided to permit cooling air to reach all critical areas (such as the main drive motor, and cooling fan). A dedicated air plenum directs cool ambient air to the first stage airend via the inlet filter. A separate cooling air discharge plenum prevents the return circulation of this hot air to the inlet of the compressor and eliminates the possibility of gear case oil vapor from being introduced into the compression module. Lubricant Filtration Spin-on type, full flow; rated at 4 micron Lubrication System Lubricant sump is integral with the gear case. A positive displacement pump provides lubricant to all bearings and gears. A pressure relief valve is provided to prevent system over-pressure (25 psid / 1.72 barg). Lubricant Temperature Control Valve Fast warm-up and proper operating temperature. SAE O Rings All lubrication lines utilize SAE O ring fittings. This provides for positive alignment of all connections and eliminates leakage paths common on other types of threaded connections. Gear Case Breather Replaceable cartridge separates gear case oil mist during gear case ventilation and vents into plenum area of enclosure to prevent vapor from being drawn into first stage inlet.

6 Motor Starter Depending on the selected voltage, the compressor includes an integral, open-transition, star-delta starter. All medium voltage models can be ordered with an optional, remote, full-voltage (AAL) starter The control circuit transformer is included as is the cooling fan motor circuit breaker. A NEMA 4 enclosure is standard for hp U.S. built SUPER DUTY models. Microprocessor Controller (SE) HP / 37-75kW Adjustable Operating Parameters Intellisys SE control featuring energy saving, load/unload control. Heavy On-line pressure duty hydraulic cylinder controls the Off-line pressure inlet throttle valve and blow-off Display time valve. Load delay time Star-delta transition time Electrical Controls Auto start/stop shutdown time Auto start/stop on or off Intellisys - microprocessor based Remote start/stop on or off system Sequencer control (optional) Power outage restart (optional) INTELLISYS READOUTS LCD contrast 2 unit lead-lag settings Standard Display Readouts Warnings and Shutdowns Package discharge pressure Package discharge temperature Sensor failure First stage discharge temperature High line air pressure Second stage inlet temperature Low bearing oil pressure Second stage discharge temperature High bearing oil temperature Bearing oil temperature Starter fault Total hours Loaded hours Display Gauges for: Inlet vacuum First stage discharge pressure (optional) Bearing oil pressure (optional) Main motor overload Fan motor overload Emergency stop

7 Microprocessor Controller (SG) hp / kW Intellisys control featuring energy saving load/unload control. Heavy-duty hydraulic cylinder controls the inlet throttle valve and blow-off valve. Electrical Controls Intellisys - microprocessor based system INTELLISYS READOUTS Standard Display Readouts Package discharge pressure Package discharge temperature First stage discharge temperature Second stage inlet temperature Second stage inlet pressure Second stage discharge temperature Bearing oil pressure Bearing oil temperature Total hours Loaded hours Inlet filter condition Oil filter pressure drop Second stage discharge pressure Inlet vacuum Date Real-time clock Adjustable Operating Parameters On-line pressure Off-line pressure Load delay time Star-delta transition time Auto start/stop shutdown time Condensate drain interval time Auto start/stop on or off Maximum first stage temperature Maximum second stage temperature 2 unit lead-lag settings Power outage restart (optional) Remote start/stop on/off Lag offset Condensate discharge time Sequencer on/off Warnings and Shutdowns Change inlet air filter Maintenance required Second stage over ratio Change oil filter Sensor failure Inlet restriction High inter-stage pressure High second stage pressure High line air pressure Low bearing oil pressure High first stage temperature High intercooler temperature High second stage temperature High bearing oil temperature Starter fault Main motor overload Fan motor overload Emergency stop

8 Davidson, NC Sierra Two-Stage Oil-free Air Compressor H150A ENGINEERING DATA Ref: H150A Page 1 Date: 11/25/03 Cancels: All Previous Capacity FAD (at stated pressure) (1) 150 psig N/A CFM N/A m3/min 140 psig N/A CFM N/A m3/min 125 psig 690 CFM 19.6 m3/min 115 psig 691 CFM 19.6 m3/min 100 psig 691 CFM 19.6 m3/min 85 psig 691 CFM 19.6 m3/min Compressor Shaft Power (at stated pressure) 150 psig N/A BHP N/A kw 140 psig N/A BHP N/A kw 125 psig 171 BHP 128 kw 115 psig 166 BHP 124 kw 100 psig 157 BHP 117 kw 85 psig 148 BHP 110 kw Specific Power (at stated pressure) 150 psig N/A BHP/100 CFM N/A kw/m3/min 140 psig N/A BHP/100 CFM N/A kw/m3/min 125 psig 24.8 BHP/100 CFM 6.5 kw/m3/min 115 psig 24.1 BHP/100 CFM 6.3 kw/m3/min 100 psig 22.7 BHP/100 CFM 6.0 kw/m3/min 85 psig 21.4 BHP/100 CFM 5.6 kw/m3/min Unloaded Compressor Shaft Power Unloaded 26.8 BHP 20 kw Full Load Operating Pressure 125 psig 8.6 barg Maximum Off Line Pressure 128 psig 8.8 barg Minimum Operating Pressure 72 psig 5.0 barg Compression Module Number of compressor stages 2 1 st Stage Rotor Diameter 145 mm Male Rotor Speed 9427 RPM Tip Speed 72 m/s 2 nd Stage Rotor Diameter 87 mm Male Rotor Speed RPM Tip Speed 72 m/s Lubrication Data Oil Pressure -Normal Operation 45 psig 3.1 barg Oil Temperature -Normal Operation 135 o F 57 o C Oil Pump Type positive displacement, gear type Sump Capacity 11 US Gal 42 Liter Total System Capacity 13 US Gal 49 Liter Cooling Data (115 o F/46 o C maximum ambient temperature) Heat Removal at 68 o F(20 o C) (2) Intercooler BTU/hr kj/hr Aftercooler BTU/hr kj/hr Oilcooler BTU/hr kj/hr Total BTU/hr kj/hr Aftercooler Inlet Temperature (@ full load) 447 o F 231 o C Aftercooler CTD (3) 20 o F 11.1 o C Cooling Air Fan Power 7.5 HP 5.6 kw Cooling Air Flow CFM 425 m3/min Maximum Added Static Pressure 0.25 Inches H 2 O 62 Pa Cooling Air T Approx. 32 o F 18 o C Sound Level (4) Sound Pressure 79 db(a)

9 Davidson, NC Sierra Two-Stage Oil-free Air Compressor H150A ENGINEERING DATA Ref: H150A Page 2 Date: 11/25/03 Electrical Data Main Drive Motor (5) (7) Nominal Shaft Power 150 HP 112 kw Number of Poles 2 Motor Speed 3575 rpm Motor Frame Size ODP 405T TEFC 445T Efficiency at Full Load ODP 95 % TEFC 95.6 % Power Factor at Full Load ODP TEFC Compressor Full Load Current at 200 V N/A AMPS 230 V N/A AMPS 460 V 194 AMPS 575 V 155 AMPS Locked Rotor Current at 200 V N/A AMPS 230 V N/A AMPS 460 V 1200 AMPS 575 V 960 AMPS IEC Starter Size (8) 200 V N/A 230 V N/A 460 V B V B110 Fan Motor Nominal Shaft Power 10 HP 7.5 kw Number of Poles 4 Fan Motor Speed 1765 rpm Fan Motor Frame Size TEFC 215T Efficiency at Full Load TEFC 91 % Power Factor at Full Load TEFC 0.81 Full Load Current at 200 V N/A AMPS 230 V N/A AMPS 460 V 13 AMPS 575 V 10 AMPS Total Package (5) Total Installed Package Shaft Power 181 BHP 135 kw Full Load Package Current at 200 V N/A AMPS 230 V N/A AMPS 460 V 207 AMPS 575 V 166 AMPS Construction - General Data (6) Package Dimension - Length Inches 2691 mm Package Dimension - Width 62.5 Inches 1586 mm Package Dimension - Height 93.4 Inches 2370 mm Shipping Weight - Total Package, Std. Scope 6452 lb 2927 kg Compression Module Only 1168 lb 530 kg Drive Motor Only - ODP 1125 lb 510 kg Air Discharge Pipe Connection 2.0 Inch NPT Intercooler Condensate Drain 0.5 Inch NPT Aftercooler Condensate Drain 0.5 Inch NPT Electrical Power Inlet Cable Diameter 3.0 Inches 77 mm Notes (1) FAD (Free Air Delivery) is actual flow rate at the compressor inlet measured at the discharge terminal point of the package in accordance with ISO1217 Annex C. (2) Heat removal including latent heat (3) CTD (Cold Temperature Difference) based on 100 o F/38 o C inlet air at 40% relative humidity. (4) Sound levels are "free field conditions" per CAGI/Pneurop, ±3 db(a) (5) Electrical data based on Reliance ODP motors (unless otherwise stated) (6) For details on dimensions and piping conditions see General Arrangement Drawing. (7) Motor rating is maintained up to an altitude of 3,000 ft. above sea level. (8) Starter data is for the 1M/2M drive motor contactor in a Star Delta starter.