Atlas Copco Oil-free centrifugal compressors

Transcription

1 Atlas Copco Oil-free centrifugal compressors ZH kw/ hp

2 Extending the limits in energy efficiency, safety and reliability The shortest route to maximum profitability is to minimize operational cost. The design of the Atlas Copco ZH centrifugal compressors is focused on substantially saving energy, ensuring product safety only oil-free machines can exclude any contamination risk for 100% and guaranteeing the utmost reliability around the clock for many years. Minimal maintenance, few service interventions and long overhaul intervals sustain true peace-of-mind. The thorough needs assessment Real savings rely on facts. Atlas Copco consultants assess the air demand profile of your application and suggest the best compressor selection for the job. Choice Atlas Copco masters each compression principle and offers the most energy efficient technology and solution for the application. The innovative accessories For each ZH there's a matching XD dryer offering high capacity quality dry air. Negligible use of energy and the lowest pressure drop lead to further energy savings. Safe Process, products and environment free from contamination Simple 100 % oil-free air = no filters needed Efficient No filter pressure drop = less energy 100% oil-free air guara nteed The experienced partner Atlas Copco is the world leader in compressed air technology, with over 100 years of experience in air compression systems. For over 50 years, Atlas Copco has been building turbo compressors for air separation, chemical, process and plant air applications. The ZH is the ultimate development from this widely accepted technology. A complete package Internal piping, integrated coolers, motor, lubrication, inlet guide vanes, control system, 100 % matched components,... an integrated design to ensure total reliability. Trouble-free installation & commissioning An oil-free ZH compressor is truly plug-andrun. Put it on a flat floor, connect the power line, the cooling water circuit and the compressed air outlet and push the start button.

3 ZH the complete solution for the industry Optimal use Central control of a multi-compressor installation can reduce the pressure band and achieve the lowest overall energy cost. Energy Safety The professional follow-up Service Contracts will ensure you of the right preventative maintenance, immediate response and genuine spare parts all over the globe. Reliability

4 Turbo power - more value for the customer The ZH range is the most advanced centrifugal compressor series on the market. It s a unique package, meeting customer expectations for low installation, operating and maintenance costs, with high reliability and ease-of-use. No other turbo equals its efficiency and economy and is supplied so complete. ZH oil-free turbo power from Atlas Copco is your guarantee for a continuous, cost-efficient and highly reliable air supply. Excellence by design Two and three-stage models Clear capital costs, no surprises A complete, plug-and-run compressed air system Easy and low cost installation no foundations Low energy consumption at full and partial load High reliability and peace-of-mind Low maintenance cost and service friendly Caring for the environment Completely oil-free air no risk of oil contamination No seal air consumption No instrument air required for actuators Silenced versions (optional) Energy saving Elektronikon control system

5 Horizontally-split hydrodynamic bearing Low speed hydrodynamic bearing Oil seal Air seal Horizontally-split gearbox Main oil pump Impeller Two-stage centrifugal compressors ZH stage ZH air/oil/coolant flow Air out Air filter Air in Low pressure element Aftercooler Intercooler High pressure element Oil cooler Air Oil Water

6 Low speed hydrodynamic bearing Horizontally-split hydrodynamic bearing Horizontally-split gearbox Oil seal Air seal Main oil pump Impeller Three-stage centrifugal compressors ZH stage ZH air/oil/coolant flow Air filter Air in Air out Aftercooler Low pressure element High pressure element Intercooler Oil cooler Air Oil Water

7 A complete scope meeting all needs ZH Pressure/capacity range Many features are included as standard. Some applications may also need or benefit from additional options. bar(e) psig ZH 3-stages ZH 2-stages Standard Air intake filter and silencer Inlet guide vanes Aftercooler Check valve and flexible discharge compressor See data page for range details cfm x 1000 m 3 /h x 1000 Cooling water manifold Drain traps on all coolers Compensators on air and water in and outlet Main motor Complete lubrication system Control and safety system Integrated modulating blow-off valve silencer Complete centrifugal compressor range Options barg 41- psig -600 PLC based control system Silencing canopy ZH 4000/7000 HM7 HL7 ZH 6000/10000 HM8 HL8 ZH 9000/15000 ZH 16000/26000 HM9 HL9 HR9 HM10 HL10 HR10 Duplex oil filter Hot air version Electronic drains ANSI flanges for air and water terminals MODBUS interface PROFIBUS interface HA7 HA8 HA9 HA10 DH+ (PLC control only) IP55 / TEFC enclosure for medium voltage motors cfm x 1000 m 3/ h x 1000 PT100 motor winding protection PT100 motor bearing protection Anti-condensation heater for motor Water reverse valve Water shut-off valve

8 Innovative design in every detail In every detail Atlas Copco ZH compressors are designed and manufactured to the highest standards of quality and reliability. There are no hidden extras or complicated installation requirements: every unit is delivered as a complete and integrated package, ready to run. Highly efficient operation Maximum efficiency and excellent response to plant load variations exclusive backward lean impeller design highest efficiency at full load large turndown capability Advanced Elektronikon control and monitoring system High efficiency motor Inlet guide vanes Air intake silencer % discharge pressure surge line % flow < by-pass > < turn-down range > 80 Blow-off regulation & silencer Integrated inter & aftercoolers Efficient air intake filtration Precision balanced impeller assembly Smooth running, low noise and low vibration operation LABYRINTH WATER SEPA balancing of individual rotating components Check valve balancing of assembled rotor Cooling water manifold & flexible connections stainless steel impellers with precision micro-spline mounting

9 Integrated inter and aftercoolers coolers with tubes and end plates of special corrosion resistant stainless steel enhanced water separation drain traps standard on every cooler Integrated discharge check valve high quality, corrosion resistant check valve internals discharge compensator for stress-free connection to the compressed air net Advanced Elektronikon control and monitoring system overall system performance status with pro-active service indications, alarms for malfunctions and safety shutdowns multi-language selectable display all monitoring and control functions via one interface wide communication possibilities integration in many process control systems (field bus system) maximized turndown range bar(e) alt. blow-off < unload surge line load > operating curve % flow m 3 /h pressure % bar(e) power % kw inlet throttle 90 valve at 100 % pressure plant demand inlet guide vanes at 100 % pressure energy savings capacity % RATOR Regulating blow-off for constant pressure applications Auto-dual control for cost-effective response to variable air demands Energy saving inlet guide vanes Inlet guide vanes save up to 9% in energy at reduced air demand. They increase the turndown capacity of the compressor due to accurate regulation of pressure and flow close to surge.

10 Maintenance friendly Easily accessible gearbox Rugged and precise, yet easy to maintain horizontally split gearbox easy access to gears and low/high speed bearings minimal downtime for inspection / maintenance maintenance-free flexible disk coupling High precision gears for increased lifetime both pinions and bull gear according to AGMA Q13/DIN Class 5/6 high stability under varying load low transmission losses, low noise, low vibration easy maintenance Superior seals and durable bearings Minimal air leakage and uncontaminated air, combined with easy maintenance carbon ring air seals, combined with labyrinth oil seal or stainless steel labyrinth sleeves rotating on the impeller, ensure 100% oil-free air compression without buffer air horizontally split low speed shaft sleeve bearings horizontally split high speed flexible pad pinion bearings

11 Optimize your installation Tailored to the application, Atlas Copco has developed complementary equipment for the optimal quality air solution and the lowest cost compressed air. Energy-free XD adsorption dryers If your process needs dry air, add the unique and environment friendly XD adsorption dryer, combining the best technologies heat of compression regeneration and twin tower design. dewpoints down to -70 C / -100 F very low energy use as an option, ZERO PURGE models available for even further energy savings very low pressure drops ES Energy Saving control and monitoring systems The Energy Saver compressor room controller communicates with the individual Elektronikon controllers and optimizes the energy efficiency of the complete system, reducing the overall pressure band. Each compressor operates in its optimum working zone and the net pressure is kept within tight boundaries. The benefits are multiple: substantial energy savings, improved reliability and increased lifetime of the machines. integrated heater for stable dewpoint Elektronikon controlled For each ZH hot air variant, there is a matching XD to obtain the most stable dewpoint. General range: l/s ( cfm). The XD-S model uses the heat of compression for regeneration, resulting in a negligible energy consumption; the dewpoint is -10 to -20 C, depending on the ambient conditions. The XD-G model combines heat of compression and internal The ES allows for remote monitoring and condition based maintenance: Atlas Copco s AIRConnect TM and AIROptimizer TM contracts provide for the ultimate peace-of-mind and the lowest energy cost throughout the life cycle of your compressed air system. Contact Atlas Copco for an energy audit... and see what ES can do for you! heaters to offer a constant dewpoint of -40 C, regardless of the ambient conditions.

12 True performance Global presence Local service When specifying the true performance of an air compressor, at least three parameters must be considered: Capacity The standard to which the capacity is measured Working pressure The point where the delivery pressure is measured Power consumption The compressor package power required at an effective working pressure (including all internal losses from inlet to outlet). The main drive motor efficiency. Intake volume Inlet flow referred to compressor element inlet conditions. Seal leakages and inlet losses should not deprive you the air you paid for. Atlas Copco ZH compressors are measured according to ASME PTC 10, stipulating the FAD measurement at the outlet of the package, net of all losses. Atlas Copco specifications correspond to the capacity and pressure which the customer receives, not to what the compressor sucks in. Differences are substantial. Delivered volume FAD according to ASME PTC 10. A ZH compressor truly gives what is promised. Site conditions Intake volume - l/s - m 3 /min - cfm External leakages FAD - l/s - m 3 /min - cfm Atlas Copco offers a complete portfolio of Aftermarket products, unrivalled in today s compressed air industry. High quality service is delivered locally: Atlas Copco is present in 150 countries around the world. A sophisticated logistics concept brings genuine parts to your doorstep in record times, across the globe. Service Plans perfectly meet the needs of your business and ensure a constant productivity at peak level. Three levels are available: Total Responsibility Plan, Preventative Maintenance Plan and Inspection Plan. Consultancy services and on-site measurements help optimizing the complete air net, minimizing leak losses and maximizing energy savings. Following packages can be included individually or combined: in-depth system audits based on actual measurements remote monitoring via the Internet energy savings via system control and management. External leakages Net usable air

13 Technical data ZH (50 Hz) & ZH (60 Hz) 50 Hz Free air delivery (1) Installed motor (2) Weight (3) Dimensions in mm (4) m 3 /h kw kg A B C Three-stage, watercooled ZH to to ZH to to ZH to to ZH to to Two-stage, watercooled ZH to to ZH to to ZH to to ZH to to Hz Free air delivery (1) Installed motor (2) Weight (3) Dimensions in in (4) cfm hp lbs A B C Three-stage, watercooled ZH to to ZH to to ZH to to ZH to to Two-stage, watercooled ZH to to ZH to to ZH to to ZH to to (1) Reference conditions: - barometric pressure: 1 bar(a) / 14.5 psia - air intake temperature: 35 C / 95 F - relative humidity: 60 % - cooling water inlet temperature: 26.7 C / 80 F (2) Depending on pressure variant (3) With silencing canopy and standard M.V. motor (4) With silencing canopy Sound pressure level: Acc. to ISO 2151:2004 and using ISO Depending on model: - 80 to 85 db(a) without silencing canopy - 70 to 74 db(a) with silencing canopy A B C

14 ISO 9001 A consistent quality earned us the industry s leadership and the customer s trust. ISO Atlas Copco s Environmental Management System forms an integral part of each business process. Never use compressed air as breathing air without prior purification in accordance with local legislation and standards. What sets Atlas Copco apart as a company is our conviction that we can only excel in what we do, if we provide the best possible know-how and technology to really help our customers produce, grow and succeed. There is a unique way of achieving that - we simply call it the Atlas Copco way. It builds on interaction, on long-term relationships and involvement in the customers' process, needs and objectives. It means having the flexibility to adapt to the diverse demands of the people we cater for. It's the commitment to our customers' business that drives our effort towards increasing their productivity through better solutions. It starts with fully supporting existing products and continuously doing things better, but it goes much further, creating advances in technology through innovation. Not for the sake of technology, but for the sake of our customer's bottom line and peace-of-mind. That is how Atlas Copco will strive to remain the first choice, to succeed in attracting new business and to maintain our position as the industry leader Printed in Belgium - Subject to alterations without prior notice