Tandem Electric Powered Screw Air Compressors Built to last

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1 Tandem Electric Powered Screw Air Compressors Built to last kw

2 Elgi s experience in the design and manufacture of air compressors spans 50 years. Established in India in 1960 as a reciprocating air compressor manufacturing company, Elgi gained its reputation for design and manufacture of screw compressors through strategic partnerships and continuous research and development. Over the years, it emerged as a multi-product multi-market enterprise providing total compressed air solutions in all segments. Elgi s design capabilities translated into wide range of products ranging from oillubricated and oil-free rotary screw compressors, oil-free reciprocating compressors and centrifugal compressors. Screw compression elements are manufactured in-house using state-of-the-art machining centres for rotor grinding and machining intrinsic castings of various sizes. Elgi s own eta-v ( η- V) profile rotors ensure energy-efficient compressed air supply for all demanding applications. Elgi is one of the few companies capable of manufacturing wide range of airends and compressor packages in the world. Elgi has modern manufacturing facilities in India & abroad equipped with advanced high precision grinding machines, turning centres and CNC horizontal and vertical machining centres. Every manufactured component / product passes through stringent quality audits and are tested to ensure performance and reliability. Our Manufacturing test rooms are atmospheric controlled. All parts and finished products undergo stringent quality checks to ensure that Elgi delivers only high quality products to its customers.

3 Wide product range Electric Powered Air Compressors Encap Series kW / 8-7 cfm Global Series kw / m /min Oil Free Screw Air Compressors kw cfm Air Accessories Energy Saving Solution Variable Frequency Drive Capacity : kw Standalone ready to use package Automatic Supply Side Controller 2-12 compressors integration Multi-compressor control upto 12 compressors Clean Air Solution Air Filter Capacity : 1 90 m /min Working pressure : 7 1 bar g Filtration Range : microns Air Receiver Capacity : m Working pressure : 7-1 bar g Reciprocating Air Compressors Market leader in India with over a million installations Wide range of compressors for Industrial, Automotive, High volume/ High pressure, Railway & Defense applications Portable Air Compressors Wide range of diesel driven and electric powered portable air compressors for Industrial, Construction & Mining, Waterwell drilling and Oil/Gas/CBM exploration

4 Tandem Two-Stage Screw Air Compressors kw m /min High efficiency High energy saving High reliability Power Savi 12% ng s Elgi offers tandem screw compressors to help industries reduce their operating and energy costs. It is a two-stage compressor, having energy efficiency as the key feature.the compression is done in two-stages to improve the volumetric efficiency and thereby contributing to decrease in power consumption and increase in saving energy costs. Tandem air compressors consume 8-12% less power and offer a return on investment within 8-15 months when compared to single-stage compressors A single-stage compressor, operating at a discharge pressure of 9 bar, has a compression ratio of 1:9 (Ratio of Suction to Discharge of a Screw Airend). In a two-stage compressor operating at the same discharge pressure, the compression ratio is divided between the two stages of tandem airend and is about 1: in each stage.this makes the airend more reliable and efficient due to smaller loads on the bearings.the volumetric efficiency of two-stage is better than single - stage compression Compression ratio comparison for a 9 bar g Compressor Dual control mode 10 and in load-unload mode for loads below 60% Constant pressure due to gradual opening or closing of suction valve with respect to demand ( multi-point control) Option for selecting load-unload / modulation auto dual mode for all large screw compressor models as a standard feature Smooth operation by modulation ensures longer life of airend, valves and all mechanical components. It also ensure no sudden spikes or drop in line pressure Lowest power consumption in its class of compressor controls, even with fluctuating loads Compression ratio Auto dual control, operates on modulation mode from % loading Tandem 1st stage Stage II Load/Unload control Modulation control VSD control Tandem 2nd stage Intermediate cooling Single stage Stage I

5 Typical lifetime cost of compressed air over 10 years Single-Stage Compressor Equipment % Maintenance % Electricity 94% Tandem Saving 12% Electricity Equipment Maintenance Tandem Two-Stage Compressor Equipment 4% Maintenance % Energy savings The annual power cost for a 100kW compressor running on continuous duty is US$ while a Tandem two-stage compressor uses US$ and saves power costs annually by US$ Electricity 81% Electricity Tandem Saving Equipment Maintenance Tandem Two-stage screw air compressor range Model Rated Power Working Pressure FAD Weight Air outlet connection kw HP bar g psi g m /min Dimension LXBxH(mm): 400 x 1620 x 1972 mm EE /2" NPT EE /2" NPT EE /2" NPT cfm Kg EE /2" NPT EE /2" NPT EE /2" NPT EE /2" NPT EE /2" NPT EE /2" NPT EE /2" NPT EE /2" NPT EE /2" NPT Note: All models are available in air-cooled as standard and water-cooled variants as option Max pressure or unload pressure for all models is 1 bar above the working pressure i.e for EE model compressor, working pressure is 100 psig and max. pressure is 115 psig Due to continuous engineering improvements, the specifications are subject to change without prior notice

6 Energy efficient Unique eta-v ( η-v) profile rotors for maximum air flow and minimum power consumption Microcontroller edge AUTO Efficient coupling Airend and motor shafts are coupled through a permanently aligned cushion type claw coupling. Elgi s efficient coupling ensures efficient power transmission and constant FAD throughout the life Efficient air oil separation with OSBIC Elgi has perfected the OSBIC ( Oil Separation by Impact and Centrifugal Action) process which enables efficient separation of air and oil with minimum pressure drop. The process results in low oil carry-over ( < 2 ppm) level at the output of the compressor Elgi s Neuron II is a high end RISC microcontroller for control of medium to large screw air compressors.the system allows you to monitor and control overall system performance with service indications, malfunction alarms and safety shutdowns. It also includes a service and operational history feature to provide real-time feedback and increases system productivity Reports Cumulative Report(Run Hours, Load Hours, Unload Hours, Stop Hours, Fault Hours and remaining AFCT,OFCT,OSCT,OCT and RGT) Detailed Report - Previous 15 Days (Load Hours, Unload Hours, Stop Hours, Fault Hours, and Number of times machine stopped due to standby) Fault Report - (Previous 99 Faults in chronological Order with Real Time stamping and type of fault) DCS ver 1.0 Remote monitoring DCS ( MODBUS RTU/RS 485): Controller is enabled to synchronize with Distributed Control System control of compressor from control panel of customer SCADA : Compressor control through PC with remote monitoring by Supervisory Control and Data Acquisition Process Alerts on GSM: Connection to phone (GSM)/ RS485 networking

7 Energy saving - The CONSERVE way 28% Advantages Mechanical Minimum maintenance Smooth start Smooth control Electrical Low starting current High efficiency Improved power factor Reduced maximum demand Model ELVD 75 ELVD 90 ELVD 110 ELVD12 ELVD 160 ELVD 200 ELVD 250 Compatible Compressor Model E75 & EE75 E90 & EE90 E110 & EE110 E12 & EE12 E160 & EE160 E200 E250 Input Power % Controls VFD SAVINGS Load % Example: For a demand of 70 % of full load, the savings from ELGI Conserve compared to a fixed speed compressor will be about 28% of full load power Load-Unload Modulation VFD

8 !! CAP Automated Supply Side Controller (ASSC) In multiple compress installation, it is difficult to choose the correct combination of compressors manually. This results in wastage of 20-60% of power.to cut such operating costs, ELGI has introduced the Automated Supply Side Controller The Big Picture at a Glance Be Energy Efficient While Increasing Reliability ELGI s ASSC, Master controller can manage up to 12 positive displacement compressors including compressors of different capacities, different types (fixed speed, variable speed and variable capacity), and in any combination or configuration.through advanced control functionality and universal connectivity the ASSC will work with your existing compressors, from ELGI or any manufacturer, to improve operating efficiency and reduce energy costs. Here s how the ASSC controller delivers a unique combination of efficiency and reliability: Operate compressors only as needed, bringing standby compressors on-line incrementally during periods of increased demand Dynamically match the most energy efficient compressor or combination of compressors with compressed air demand Manage the compressed air system at your minimum required pressure without compromising the reliability of your compressed air supply Running a compressor in standby mode (unloaded), to ensure maximum capacity when needed, uses approximately 0% or more of the energy required to run that same compressor fully loaded. Systems with multiple compressors of varying sizes, types and configurations further complicate the task of manually coordinating and maintaining the correct compressor settings.the larger the system, the more 0% of unproductive energy will cost! The ASSC eliminates the complexity of compressor control coordination and increases energy efficiency. Only the specific compressors operate at a given time. Other compressors used for normal operations with manual control will be kept offline and shall be available during emergency requirements or during primary equipment breakdown.this ability to tap existing resources to maintain system operation even in emergency situations makes the system more reliable. In addition to optimising the energy usage, efficient compressor utilization reduces costs due to less downtime Energy Consumption - Pressure Conventional Cascade Additional cost of +6.25% input power above +5.00% assumed optimum % % +1.25% 4 System Pressure bar Pressure Optimisation Additional cost of input power above assumed optimum +0.5% +0.5% +0.5% +0.5% +0.5% Air Demand 100% 100% 6.5 Optimised System Pressure Air Demand 100% Manage Your Battery of Air Compressors Efficiently The primary functions of Energy Control Mode in ELGI ASSC System Automation are: Match compressed air supply to compressed air demand, dynamically Utilize the most energy-efficient combination of air compressors to satisfy demand Manage multiple compressors at minimum required pressure band

9 A significant value addition Typical Compressed Air Supply system Demand Side Controller Particulate filter Vapour filter Dryer Oil Filter Receiver Air compressor Drain taps Oil/Water Separator Downstream filter Capacity : cfm Working pressure : 7-60 bar Filtration range: microns Air receiver Capacity : ltrs. Working pressure : 7-60 bar Code of construction: ASME sec. VIII Div.I or IS 2825 Airmate Filters Designation - Economy Series Filters PF E 0400 Filter type Economy Filter size PF- PreFilter FF - Fine Filter CF - Carbon Filter w Economy Series Filters Filter Type Pipe size Engineering Data Flow bar g (100 psi g) Dimensions (mm) cfm m /h H W C D (Filter Type)E 0400 G Weight (kg) (Filter Type)E 0620 G (Filter Type)E 0840 G 2 1/ (Filter Type)E 1120 G (Filter Type)E 1600 G (Filter Type)E 2540 G (Filter Type)E 00 G Due to continuous engineering improvements, technical specifications are subject to change without prior notice. CLEARANCE TO CHANGE ELEMENT H D C

10 Technical Data Maximum operating pressure 16 bar g (0019 to 2119) with Autodrain (22 psi g) Maximum operating pressure 20 bar g (0018 to 2119) with manual drain (290 psi g) Maximum recommended operating temperature (Grade PF/FF) 66 d C 0 (150 F) Max. recommended operating temperature (Grade CF) C (86 F) 0 0 Min. recommended 1.5 C (5 F) For Flow Rates at other pressures, apply the factor shown The CF Filter will not remove CO/CO2or other toxic gases or fumes. Ordering example: To order a 0.01 micron filter flowing 125 cfm at 7 bar specify type FF Replacement element is FFE0127. Initial dry Initial wet differential pressure differential pressure Grade PF - 70m bar (1.0 psi) Grade PF - 140m bar (2.0 psi) Grade FF - 100m bar (1.5 psi) Grade FF - 200m bar (.0 psi) Grade CF - 70m bar (1.0 psi) Grade CF- N/A Maximum recommended pressure differential for element change: (PF, FF filters only) 40m bar. Line bar g Pressure psi g Correction Factor Airmate Air Receiver The Elgi Air Receiver is engineered to handle the stress of fluctuating air demands, reduce wear and tear and increase the life of the end use equipment. Model Capacity ltr. m Max Working Pressure Dimensions (mm) bar g Height Dia. VA VA VA VA VA VA VA VA VA VA VA VA VA VA VA VA VA VA VA Dimensions are approximate Air receivers of higher capacities are available on request. All air receivers are made as per ASME section VIII Div 1/IS2825 Level sensing auto drains are also available. Due to continuous engineering improvements, technical specifications are subject to change without prior notice. Drain valves Timer controlled and zero loss Capacity : upto 100 cfm Working pressure : 7-1 bar

11 Total Compressed Air Solution Power Generation Cement Textile Ship building Automobile Engineering and more... Elgi s full range of After sales products and services For enhancing performance and productivity Benefits that you get Increase compressor life No production interruptions Reduces operational costs Coolants and Lubricants For reliability and long service life Benefits that you get Maximize lubricant service life Reduces wear of compressor components Low oil consumption Provides excellent resistance to oxidation Compressor Health Check System and Service Agreements For ensuring complete peace of mind Benefits that you get Combined advantage of warranty and annual maintenance In the unlikely event of breakdown, your compressor shall be restored within 24 hours Optimal extended warranty scheme Reduces compressor breakdowns Path to reducing compressed air cost Benefits that you get Optimization of compressed air system Reduction in overall system pressure Transparent audit methodology to identify, analyse, and solve the wastage and misuse of compressed air Reduce maintenance costs realized through better use of compressed air Selection of compressed air piping and distribution Air leak reduction

12 Elgi serves the world marketplace. Over two million compressors are powering business in 6 countries worldwide.the company offers a strong sales and service network of 14 domestic and 6 overseas offices, besides a well-knit distribution network of 114 dealers in India and 165 distributors worldwide. In addition to manufacturing facilities in India, Elgi has manufacturing facilities in China and France. Elgi has also set up warehouse facilities in Brazil and Middle East. Customers Personnel Wholly owned Subsidiaries Production Centres and Offices Overseas Offices Elgi Equipments Ltd. Singanallur, Coimbatore , India, Tel: Fax: International Division: Fax: enquiry@elgi.com Visit us at Production centre and offices: India, China, France Wholly-owned subsidiaries and offices : France, Sharjah, Brazil, China Overseas offices: Indonesia, Bangladesh, Thailand, Srilanka, Australia Marketed by: