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DOC. NO. REV. NO. Date : 8-02-2017 PLL GTE 0 GTE-ID-17-01 PERIODIC INSPECTION & MAINTENANCE
DOC. NO.
REV. NO.
Date : 8-02-2017
PLL
GTE
0
GTE-ID-17-01
PERIODIC INSPECTION & MAINTENANCE AIR COMPRESSOR
0
PERIODIC INSPECTION & MAINTENANCE AIR
COMPRESSOR
AR
FP
HW
8 FEB 2017
REV. NO.
DESCRIPTION
PRED. BY
CHKD. BY
APPD BY
DATE
PROJECT
3 X 18 MW COAL FIRE POWER PLANT AT SANGATTA
EAST KALIMANTAN, INDONESIA
R
E
M
H
A
E
T
N
L
G
I
G
N
PT. GEMILANG THERMAL ENGINEERING
N
General & Marine Contractor
E
Batam, Riau Island - Indonesia
A
E
L
R
I
I
M
N
E
G
G
.
T
P
3X18MW COAL FIRED POWER PLANT INDONESIA Periodic Inspection & Maintenance Compressor Date: 8 Feb 2017

3X18MW COAL FIRED POWER PLANT INDONESIA

Periodic

Inspection &

Maintenance

Compressor

Date: 8 Feb 2017

PACKAGE COMPRESSOR

GTE-ID-17-01

TABLE OF CONTENT

ITEM

PAGE

1. Cover

 

1

2. Table of Content

2

3. Introduction

3

4. Requirements and specific task

3

a.

Materials

4

b.

Tools

4

c. Safety/PPE

 

4

d. Training Requirement

4

e. Inspection and Maintenance

5

5. Appendix

 

7

I. Check List Maintenance Tasks

II. Opeartion, Maintenance and Part Manual NE Series Oil Free Screw Air Compressors

2

3X18MW COAL FIRED POWER PLANT INDONESIA Periodic Inspection & Maintenance Compressor Date: 8 Feb 2017

3X18MW COAL FIRED POWER PLANT INDONESIA

Periodic

Inspection &

Maintenance

Compressor

Date: 8 Feb 2017

PACKAGE COMPRESSOR

GTE-ID-17-01

Introduction

This recommended practice for Compressor periodic inspection & Maintenance for CKP maintenance guideline. The application of any practice or guideline contained here in is reffering to the Manual Book of Compressor ELGI selected for 3 x 18 Fired Coal Power Plant Project Tanjung Bara, Sangatta. Any deviation between this guideline, please refer to Manual Book by manufacture.

This guideline is intended to assist CKP Personel in performing basic maintenance & inspection preocedures. The Compressor may be different, the procedures and steps described in this document will not necessarily be applied to, nor required for, every CKP maintenence and inspection procedure.

Compressor Periodic Inspection and Maintenance

1. Frequency of conduct Periodic inspection and maintenance task on the Compressor should be performed on regulary scheduled intervals. The frequency of any task contained within periodic maintenance and inspection should comply with all applicable state and local regulation. Further, in the conduct of periodic inspection and maintenance programs, frequencies for individual tasks may be established based on a number of additional factors, including but not limitid to:

OEM recomended intervals Industry experiences Operationing environment/condition Historical data Performance requirements Failure analysis

Industry experiences Operationing environment/condition Historical data Performance requirements Failure analysis
Industry experiences Operationing environment/condition Historical data Performance requirements Failure analysis
Industry experiences Operationing environment/condition Historical data Performance requirements Failure analysis
Industry experiences Operationing environment/condition Historical data Performance requirements Failure analysis
Industry experiences Operationing environment/condition Historical data Performance requirements Failure analysis

Task schedule usualy taken with specific period is mentioned in the check list routine

maintenance schedule attached.

2. Requirements and specific tasks

DO & DON T

DO

1.

Read the manual in detail and follow the instructions

2.

Clean the air compressor package regulary

3.

Keep the air filter clean

4.

Use only genuine ELGI spares

5.

Maintain correct oil level

6.

Use proper tools

7.

Attend immediately to anything unusual with the air compressor.

3

3X18MW COAL FIRED POWER PLANT INDONESIA Periodic Inspection & Maintenance Compressor Date: 8 Feb 2017

3X18MW COAL FIRED POWER PLANT INDONESIA

Periodic

Inspection &

Maintenance

Compressor

Date: 8 Feb 2017

PACKAGE COMPRESSOR

GTE-ID-17-01

DON T

1. Neglect the routine attention

2. Allow any leakage in the system

3. Keep any tools of loose item on the compressor/other modules

4. Meddle with any adjusments of settings

5. Use cleaning agents, when changing oil.

WARNING: only trained and qualified personnel should work on Compressor House. High voltage, high pressure, rotating equipment, chemical hazards and extremes of temperature are present and can cause serious personal injury. All precautions mandated by state and local regulator, including the wearing of personal protective equipment, must be followed.

WARNING: Use only those cleaning products and lubricant proved safe and autorized for use by CKP. Consult original equipement manufacturer (OEM) and Material Safety Data Sheet (MSDS) references for suitability of each application to prevent personal injury and damage to the equipment.

2.1 Materials The following materials are normaly required for inspection and maintenance of Compressor:

OEM manuals, including schematic and drawings

Cleaning solutions

Lubricants as approved by OEM

Compressed air / water, and

Filters and filterdryers as specified by OEM

2.2 Tools The following tools are typically required for inspection and maintenance of Compressor Vacum pump Mechanics toolbox Temperature measuring device Vibration meter* Note: Tools marked with an asterik required calibration as specified by CKP practices.

2.3 Safety / Personal protective equipment Appropriate personal protective equipment, meeting minimum ANSI standards and as required by local regulation, shall be worn at all times in the performance of these inspection and maintenance task.

4

3X18MW COAL FIRED POWER PLANT INDONESIA Periodic Inspection & Maintenance Compressor Date: 8 Feb 2017

3X18MW COAL FIRED POWER PLANT INDONESIA

Periodic

Inspection &

Maintenance

Compressor

Date: 8 Feb 2017

PACKAGE COMPRESSOR

GTE-ID-17-01

2.4 Training requirement CKP should develop and excute training programs that provide employees with the knowledge and the skills necessary to safely and effectively perform the task outline in this recommended practice. These programs should include but not limited to the following :

Fundamentals of compressor

System evacuation and dehydration

System pump-down and charging

Principals of compressor

Safety devices and lockout

Mechanical & Electrical Schematic

Preventive Maintenance

Troubleshooting and System Calibration

Working at Height

2.5 Inspection and Maintenance The following suggested inspection and maintenance procedure are intended for use in conjuction with the OEM s recommended inspection and maintenance procedures. In the event of a conflict between this guideline practice and the manufacturer s recomendations, the manufacturer s recommendations should prevail.

Kindly refer to the attached OEM Manual at Maintenance section.

2.6 Correction of deficiencies Any deficiences uncovered during the isnpection required in section 2.5.1 trought 2.5.2 should be corrected and documented in accordance with procedur and OEM recommedations.

5

PT. CITRA KUSUMA PERDANA 3 x 18 MW COAL FIRED POWER PLANT PROJECT PREVENTIVE MECHANICAL

PT. CITRA KUSUMA PERDANA

3 x 18 MW COAL FIRED POWER PLANT PROJECT

PREVENTIVE MECHANICAL MAINTENANCE CHECK LIST

PLANT PROJECT PREVENTIVE MECHANICAL MAINTENANCE CHECK LIST UNIT: Equipment Name: -Compressor Work Permit Date:

UNIT:

Equipment Name: -Compressor

Work Permit

Date:

 

S.NO.

POINTS TO BE CHECKED

DESIRED OBSERVTION

Frequ

 

ACTUAL OBSERVATION

REMARKS / CORRECTIVE ACTION TAKEN

ency

       

1

Running Hours

Hrs Should be Noted

           

2

Get the permit to work

All isolation should have been made

FN

         
 

Open the condensate drain tap of after cooler and

             

3

moisture separator.&Drain the condensates

Pressure in the system to be relieved

FN

4

Check the lub oil condition and level

Replace / top up accordingly

FN

         
 

Inspect air filter element,

clean with 30 psi pr.

To be clean and good, replace if torn (or after

FN

         

5

air blowing outwardly

4000 hrs. operation)

 

Check condition of coupling for worn out bushes,

No worn out bushes, broken bolts etc.

FN

         

6

broken bolts etc.

 

Check operation of the suction valve, grease if

Linkage and moving parts to be free to operate

FN

         

7

required

 

Inspect oil sight glass and clean it

Oil level to be clearly visible without any leakage

FN

         

8

from the sight glass

 

Remove the oil filter cartridge and replace the

 

FN

         

9

same after 8000 hrs operation

-

10

Check Cooling water lines for leakage

No leakages

FN

         

11

Check oil lines for leakage

No leakages

FN

         
 

Check & clean the condensate line strainers Before solenoid valve

Clean throughly/No chocking

           
 

Moisture Seperator Auto drain to be check while trail

opened in correct timing

           
 

Check the Coupling bolts & bushes

-

           
 

Check all the fasteners tightness

To be in tight

           
 

Clean the equipment thoroughly

To be clean and in good condition

           
 

Remove all the tools & tackles used

             
 

Return the Work Permit

             
 

Observe the performance of the machine during the trial run

             

Observations:

 

Notes:

 

Signature of the Technician

Signature of the Engineer

 

Manager (Maintenance) Signature

Introduction ELGIEQUIPMENTSLIMITEDisaleadingIndianmanufacturerofRotaryScrew AirCompressors.

Introduction

ELGIEQUIPMENTSLIMITEDisaleadingIndianmanufacturerofRotaryScrew AirCompressors. ELGIRotaryScrewAirCompressorsarewidelyusedin Indiaandotherpartsoftheworld.Theequipmentareknownfortheirreliability, maintenance,friendlinessandsafety. EveryScrewTypeAirCompressoris designedkeepinginmindthreekeyqualityconsiderationviz.,

1.EnergyEfficiency

2.AirQuality

3.Maintenance

Weareconfident,thattheequipmentyouhavepurchasedwillgiveyou

satisfactoryserviceforitslife.

WethankyouforgivingusanopportunitytoserveyouwithourCompressor.

ThisOperationandMaintenanceManualhasbeenspeciallydesignedkeeping

youinmind,sothatyoucangetthemostoutofELGICompressor.Beforeyou

startusingyourcompressor,dogothroughthismanualthoroughly.Itcontains

vitalinformationonoperationsandusefultipsthatwillkeepyourcompressor

runningasgoodasnew,yearafteryear.

Allinformation,illustrationsandspecificationsinthismanualarebasedonthe latestproductdevelopmentavailableatthetimeofsupply. Wereservethe righttomakechangesintheproductatanytimewithoutnotice. Weassure youofthebestserviceinmaintaininguptimeofthecompressorthroughprompt serviceandsupplyofsparepartsasperyourrequirements.

Thismanualhasbeenpreparedwithutmostcaretohelptheusertounderstand

varioussystemsinvolvedinthecompressorthoroughlythroughdetailed

descriptions,workingconditionsandillustrations.Thismanualmustbemade

availabletothecompressoroperatingpersonnelatalltimes.

Pleasereadtheinstructionsverycarefully,righttotheend,astheoperatinglife

andreliabilityofthecompressordependstoalargeextentoncorrectoperation

andmaintenance.

iii

UserInformation EnsuretheOperationInstructionManualbemadeavailabletothecompressor operatingpersonnelatalltime.

UserInformation

EnsuretheOperationInstructionManualbemadeavailabletothecompressor

operatingpersonnelatalltime.

Pleasereadtheinstructionscarefullyandstrictlyadheretotheendasthe

operatinglifeandthereliabilityoftheCompressordependstoalargeextenton

correctoperationandmaintenance.

WhilecommunicatingwithELGIDealer/ServiceCenter/BranchOfficeregarding theCompressoryouhave,ensureallthedetailsonNamePlate(formatshown below)aregiven.ThenameplateisfixedontheCompressorcanopypost.For orderingspareparts,refer RecommendedSpareParts chapterinPARTS MANUALandprovidePartNumberalongwithquantityinadditiontothename platedataofCompressor.

chapterinPARTS MANUALandprovidePartNumberalongwithquantityinadditiontothename platedataofCompressor. vii

vii

GUARANTEE ELGIdoesnotacceptanyliabilityfordamagesintransitandhandlingintransport.

GUARANTEE

ELGIdoesnotacceptanyliabilityfordamagesintransitandhandlingintransport.

PleaseinspecttheCompressorimmediatelyafterdelivery.

Intheeventofanyothercomplaints,pleaseinformuswithinsixdaysafterthe

receiptofconsignment.PreservetheGuaranteeCertificatesentalongwiththe

Compressorsafely.

ELGIcannotacceptanywarrantyfordamagesresultingfromfailuretoobserve

theoperatinginstructionsgiveninthismanual.Thewarranteewillalsoexpire

ifyoualtertheCompressoryourselfandperformimproperrepairsorinsufficient

maintenance.Appropriaterepairandmaintenancealsoinvolvetheexclusive

useofELGIGenuineSparePartsandELGIoperatingmaterials.

Wereservetherightformodificationwithoutnoticeintheinterestoftechnology

progress.

viii

SafetyPrecautions GENERAL ELGIdesignsandmanufacturesitsproductsforsmoothandsafeoperation.

SafetyPrecautions

GENERAL

ELGIdesignsandmanufacturesitsproductsforsmoothandsafeoperation.

However,theresponsibilityofsafeoperationrestswiththosewhouseand

maintaintheseproducts.Followingsafetyprecautionsanddevicesareoffered

asguideandaccessoriesrespectively.Thesewhenfollowedwillminimizethe

accidentsandfailuresthroughouttheusefullifeoftheequipment.

AirCompressorshouldbeoperatedonlybythosewhohavebeentrainedand

delegatedtodoso,andwhohavereadandunderstoodthisOPERATIONAND

MAINTENANCEMANUAL.Failuretofollowtheinstructions,proceduresand

safetyprecautionsgivenintheManualmayincreasethepossibilityofaccidents

andfailures.

NeverstartAirCompressorunlessitissafetodoso.Donotattempttooperate

theaircompressorwithknownunsafecondition.Tagtheaircompressor

andrenderitinoperativebydisconnectingpowersupplysootherswhomaynot

knowofunsafeconditionwillnotattempttooperateituntiltheconditionis

corrected.

ThismodeloftheELGIDryScrewNESeriesOil-freeScrewCompressorisnot

designedtobeoperatedinanexplosivearea.

DonotmodifyCompressorexceptwithwrittenfactoryapproval.

PRESSURERELEASE

Manuallypop-upthepressurereliefvalvewhentheCompressorisoperating,at

leastweekly,tomakesurethepressurereliefvalveisnotblocked,closed,

obstructedorotherwiseinoperative.

DonotusetoolsthatareratedbelowthemaximumratingofthisCompressor. Selectthetools,airhoses,pipes,valves,filtersandotherfittingsaccordingly. Donotexceedmanufacturer sratedsafeoperatingpressurefortheseitems.

Secureallhoseconnectionsbywire,chainorothersuitablyretainingdevices

topreventhoseendsfrombeingaccidentallydisconnected.

ix

SafetyPrecautions Openoilfillercaponlywhencompressorisnotrunningandisnotpressurized.

SafetyPrecautions

Openoilfillercaponlywhencompressorisnotrunningandisnotpressurized.

Ventallinternalpressurepriortoopeninganyline,fitting,hose,valve,drain

plug,connectionorothercomponent,suchasfilters.

Keeppersonneloutoflinewithandawayfromthedischargeopeningofhoses

ortoolsorotherpointsofcompressedairdischarge.

Donotuseairatpressurehigherthan2.5kgf/cm 2 forcleaningpurpose.

Donotengageinhorseplaywithairhosesasdeathorseriousinjurymayresult.

FIREANDEXPLOSION

Clean-upspillsoflubricantorothercombustiblesubstancesimmediately,

ifsuchspillsoccur.

Shut-offtheaircompressorandallowittocool.Thenkeepsparks,

flamesandothersourcesofignitionawayanddonotpermitsmokingin

thevicinitywhencheckingoraddingoil.

Donotuseflammablesolventforcleaningpurposes.

Keepelectricalwiringandotherterminalsingoodcondition.Replaceany

wiringthathascracked,cut,abradedorotherwisewithdegradedinsulation;

keepallterminalscleanandtight.

Keepgroundedconductiveobjectssuchastoolsawayfromexposedlive

electricalpartssuchasterminalstoavoidarcing,whichmightserveasa

sourceofignition.

Keepoilyrags,trash,dryleaves,litterorothercombustiblesoutofand

awayfromtheCompressor.

DonotoperatetheCompressorwithoutproperflowofcoolingair/cooling

waterorwithinadequateflowoflubricantorwithdegradedlubricant.

DonotattempttooperatetheCompressorinanyclassificationof

hazardousenvironmentunlesstheCompressorhasbeenspecially

designedandmanufacturedforexplosiveapplication.

x

SafetyPrecautions MOVINGPARTS Keephands,armsandotherpartsofthebodyandalsoclothingaway

SafetyPrecautions

MOVINGPARTS

Keephands,armsandotherpartsofthebodyandalsoclothingaway

fromcouplings,fansandothermovingparts.

DonotattempttooperatetheCompressorwiththefan,couplingorother

guardsremoved.

Wearsnugfittingclothingandconfinelonghairwhenworkingaroundthis

Compressor,especiallywhenexposedtohotormovingparts.

Keepaccessdoors,ifany,closedexceptwhenmakingrepairsor

adjustments.

Makesureallpersonnelareoutofand/orclearoftheCompressorpriorto

attemptingtostartoroperateit.

DisconnectandlockoutallpoweratsourceandverifyattheCompressor

thatthecircuitsarede-energizedtominimizethepossibilityofaccidental

start-uporoperation,priortoattemptingrepairsoradjustments.Thisis

especiallyimportantwhenCompressorisremotelycontrolled.

Keephand,feet,floors,controlsandwalkingsurfacescleanandfreeof

fluid,waterorotherliquidstominimizethepossibilityofslipsandfalls.

HOTSURFACES

Avoidbodilycontactwithhotoil,hotcoolant,hotsurfaces.

Keepallpartsoffthebodyawayfromallpointsofairdischarge.

Wearpersonalprotectiveequipmentincludingglovesandheadcovering

whenworkingin,onoraroundtheCompressor.

Keepafirstaidkithandy.Seekmedicalassistancepromptlyincaseof injury.Don tignoresmallcutsandburnsastheymayleadtoinfection.

xi

SafetyPrecautions TOXICANDIRRITATINGSUBSTANCES DonotuseairfromthisCompressorforrespiration(breathing).

SafetyPrecautions

TOXICANDIRRITATINGSUBSTANCES

DonotuseairfromthisCompressorforrespiration(breathing).

OperatetheCompressoronlyinwellventilatedareas.

Oils,coolantsandlubricantsusedinthisCompressoraretypicalofthe

industry.Careshouldbetakentoavoidaccidentalingestionand/orskin

contact.Intheeventofingestion,seekmedicaltreatmentpromptly.Wash

withsoapandwaterintheeventofskincontact.

DANGER Deathorseriousinjurymayresultfrominhaling compressedairwithoutusingpropersafetyequipment.

DANGER

Deathorseriousinjurymayresultfrominhaling

compressedairwithoutusingpropersafetyequipment.

ELECTRICALSHOCK

Equipmentshouldbeproperlyearthed.

Keepallpartsofthebodyandanyhandheldtoolsorotherconductive

objectsawayfromexposedlivepartsoftheelectricalsystem.Maintain

dryfooting,standoninsulatingsurfacesanddonotcontactanyother

portionofthecompressorwhenmakingadjustmentsorrepairtoexposed

livepartsoftheelectricalsystem.Makeallsuchadjustmentsorrepairs

withonehandonlysoastominimizethepossibilityofcreatingacurrent

paththroughheart.

Attemptrepairsonlyinclean,dry,welllightedandventilatedarea.

DonotleavetheCompressorunattendedwithopenelectricalenclosures. Ifnecessarytodoso,thendisconnect. Lockoutandtakeallpowerat sourcessootherwillnotinadvertentlyrestorepower.

xii

SafetyPrecautions Disconnect,lockoutandtagallpoweratsourcepriortoattemptingto

SafetyPrecautions

Disconnect,lockoutandtagallpoweratsourcepriortoattemptingto

repairsoradjustmentstorotatethemachineryandpriortohandlingany

ungroundedconductors.

CAUTIONFORBREATHINGAIRAPPLICATION

Compressedairusedforbreathingairmustconformtoallofapplicable

laws,rules,regulationsandcodes,suchasOSHA29CFR1910.134(d)

(1).

Intakeairmustbeofhighestpurity. TheNEseriesdoesnotuseoilin compressionchamfer,however,acompressorcannotremovetoxicgas, vapoursoranyotherimpuritiesthatmaybecontainedintheatmospheric air.

Purchaserorusermustadditionallyprovidethespecialequipmentsuch

asfilters,airpurificationequipment,safetydevices,alarmsetc.,which

aresubjecttoOSHAregulation.

xiii

Do sandDont s Do s Readthemanualindetailandfollowtheinstructions. Cleantheaircompressorpackageregularly.

Do sandDont s

Do s

Readthemanualindetailandfollowtheinstructions.

Cleantheaircompressorpackageregularly.

Keeptheairfilterclean.

UseonlygenuineELGIspares.

Maintaincorrectoillevel.

Usepropertools

Attendimmediatelytoanythingunusualwiththeaircompressor.

Dont s

Neglecttheroutineattention.

Allowanyleakageinthesystem.

Keepanytoolsorlooseitemsonthecompressor/othermodules.

Meddlewithanyadjustmentsorsettings.

Usecleaningagents,whenchangingoil.

xiv

1.0StandardSpecification Discharge     Model pressure   Description NE90 NE110 NE135

1.0StandardSpecification

Discharge

   

Model

pressure

 

Description

NE90

NE110

NE135

NE145

NE170

NE200E

NE200

NE210

NE250

NE265

NE275

NE300

 

Motoroutput

kW

90SF1.1

110SF1.1

132SF1.1

160

160SF1.2

200

200SF1.1

250

250

275

275

315

 

m³/m

                       

7.0bar(g)

Capacity

in

16.2

19.1

24.4

24.9

30.5

35.4

38.5

41.5

43

47

48.5

52

Coolingwater

m³/h

                       
 

flow

12

14

15

18

24

23

23

28

30

34

35

38

 

Motoroutput

kW

90SF1.1

110SF1.1

132SF1.1

160

160SF1.2

NA

200SF1.1

250

250

275

275

315

Capacity

m³/m

14.3

17

22.7

23.1

28

NA

35.4

39.1

40.2

44.2

45.6

48.3

8.0bar(g)

in

Coolingwater

m³/hr

12

14

15

18

24

 

23

28

30

34

35

38

 

flow

NA

 

Motoroutput

kW

90SF1.1

110SF1.1

132SF1.1

160

160SF1.2

NA

200SF1.1

250

250

275

275

315

Capacity

m³/m

13.6

16

21.2

21.9

26.9

NA

34.8

37.5

38.7

41.2

44

46.7

8.8bar(g)

in

Coolingwater

m³/hr

12

14

15

18

24

NA

23

28

30

34

35

38

 

flow

Oiltankcapacity

Liter

 

50

 

70

 

100

Oilpumpmotoroutput

kW

 

1.5

 

Length

mm

3147

 

3200

 

4100

Dimensions

Width

mm

1460

 

1510

 

1750

Height

mm

1935

 

2035

 

2150

Notes:

1. Themotorcanproduceupto110%to120%ofmaximumcontinuousoutput.

2. Thesespecificationsaresubjecttochangewithoutnoticeinordertoeffect

improvements.

1.0

2.0ProcessofCompression ProcessofCompressionofNESeriesCompressor .

2.0ProcessofCompression

ProcessofCompressionofNESeriesCompressor.

Followingcompressionprocessoccurs4timesperrevolutionofmale

rotor,sincemalerotorhasfourlobes.

INLET
INLET
INLET DISCHARGE
INLET DISCHARGE
DISCHARGE
DISCHARGE

2.0

3.0StandardComponents Astandardcompressoriscomposedofthefollowing. Arrangement

3.0StandardComponents

Astandardcompressoriscomposedofthefollowing.

Arrangement-TheElgiCompressorsarebuiltaspackaged,readyto

installunit.Thecompressorpackageincludesacapacitycontroldevice,

alubricationsystem,anintercooler,anaftercooler,andadrivemotor.The

Airendhasahighspeedpinionontherotor.WhentheAirendisinstalled

ontheflangedsurfaceofthegearcasing,thealignmentbetweenbullgear

andpinionisautomaticallyattained.

Allthecomponentsareplacedonacommonbaseandthecompressor

packageisenclosedinasoundproofcover.

CompressorAirend(Fig.3-1) Twostage,oilfreerotaryscrewdesign, consistingof:

Rotors Malerotorhasthreelobesandfemalerotorhasfivegrooves,a uniquedesign.

Thetiminggearspreventtherotorsfromcontactingeachother.

PTFE+PFAcoatingisappliedonthesurfaceforexcellentcorrosionand

heatresistance.

Itprotectstherotorsagainsthightemperatureupto250deg.Candassures

smoothrotation.

Timinggears Precisionmadetiminggearsarefittedontheendofthe rotorstomaintainthe rotorsinthecorrectpositionavoidcontactwith eachother

Bearings Therollerbearingssupporttheradialloadsandthefourpoint contactballbearingssupporttheaxialloads.Highlyreliableantifriction bearingsareusedtoreducebearinglossandminimizetheclearance betweentherotors.

Theyrequireoverhaulonlyonceeverysixyears.

AirendCasing TheAirendcasinghasawaterjacketwhichsurrounds thecompressionchamberandabsorbstheheatofcompression.

EachAirendisassembledinablockandisflangedonthegearcasing.

3.0

ShaftSeals Carbonringsandvisco-typesealsarefittedontherotors.

ShaftSeals Carbonringsandvisco-typesealsarefittedontherotors.

Thevisco-typesealspreventtheoilfrominvadingfromthebearingtothe

compressionchamber,Thecarbonringsalsopreventthecompressedair

fromleakingalongtherotorshaft.

Thecarbonringsarenon-contact,lubricationfreeshaftsealshavingself-

lubricatingandautomaticalignmentfeatures.

Minimumclearanceisaccomplishedbetweentherotorandtheshaftseal

byaccuratemachiningandsurfacefinishtoassuretheleastpossible

leakageoveralongperiod.

MainMotor(Fig.3.2) Themainmotoristotallyenclosedfancooled type.ItsPoleflangemountedinductionmotor.

Gearcasing(Fig.3.2) Themotorspeedisincreasedbythebullgearto themalerotordrivingspeed.Asinglehelicalgearofkeylessstructure, madeofproperlyheat-treatedandpreciselygroundalloysteel,isusedas thebullgearandthepiniongeartoensurehighaccuracyandalonglife span.

Capacitycontrol(Fig.3.2) ONLINE/OFFLINECONTROLSYSTEM,

eitherat100%loadornoloadoperationwithautomaticblowing-offof

dischargepressuretoatmosphere.

CoolerwithDemister(Fig.3.2) Thetubebundleisofremovaltype havingafloatingtubesheet.Squarepitchisusedasatubepattern,which makesiteasytoremovedirt,calcium,otherdepositsandcleanthetube bundle.Cleaningcanbeeasilyconfirmedbyvisualinspection.Airflows insidethetube.Themoistseparatorinstalleddownstreamofthetube bundleseparatesmoistureorcondensatefromthecompressedair.

Checkvalve(Fig.3.2) Checkvalveislocatedbetweenthe2 nd stage Airendandtheaftercoolerandstopsbackflowfromthedischargeline. Thecheckvalveisoflifttype.Thecheckvalvehassuchalightweight valvediskthatitassuresahighreliabilityagainstrepeatingaction.

3.1

LubricationSystem Consistsofoilpump,oilpumpmotor,oilstrainer, oilfilter,oilcoolerandreservoir.

LubricationSystem Consistsofoilpump,oilpumpmotor,oilstrainer, oilfilter,oilcoolerandreservoir.

Theoilpumppressurizestheoiltolubricateandcoolthesystem.

Allgearsandbearingsarepositivelylubricated.

Theoilfiltersuppliedis10micron.

IntakeAirFilter(Fig.3.2) Replaceabledrytypefilter.

Relaypanel(Fig.3.2) Containspressureswitches,temperatureswitches

and4-waysolenoidvalve.Thepanelisinstalledonthebase.

Controlpanel(fig.3.3) Controlpanelisinstalledonadoorofsoundproof cover,andcontainspowerandcontrolelements.Electricalequipmentfor operationofcompressorareplacedunderthepanel,andoperationdisplay andstopswitchesareinstalledonthepanel.

SoundproofCover(Fig.3.3) Theunitiscompletelyenclosedbya soundproofcover,anditiscarefullysilencedtoaverylownoiselevel. Thesoundproofcoverconsistsofshapedsteelandseveraleasily removableaccessdoors,throughwhichcompressorandmotorcanbe inspected.Theintakeairfilterofcartridgeisassembledinthesuctionbox panelofthesoundproofcover.

panelofthesoundproofcover. Fig.3.1SectionalViewofAir-End 3.2

Fig.3.1SectionalViewofAir-End

3.2

Blo woffsile ncer After Cool er Discharg eSi lence r Mainmotor IIStageairend Capacity ControlValve Inte
Blo woffsile ncer After Cool er Discharg eSi lence r Mainmotor IIStageairend Capacity ControlValve Inte
Blo
woffsile
ncer
After
Cool
er
Discharg
eSi
lence
r
Mainmotor
IIStageairend
Capacity
ControlValve
Inte
rcool
er
IStageairend
A ntivib
ra
tion
mount

Fig.3.2GeneralConstruction

3.3

Fig.3.3Generalconstructionwithsoundproofcover 3.4
Fig.3.3Generalconstructionwithsoundproofcover 3.4

Fig.3.3Generalconstructionwithsoundproofcover

3.4

4.0MaterialofComponents 4.1Airend Parts Material Remarks Airendcasing FG260,IS210 Greyironcasting

4.0MaterialofComponents

4.1Airend

Parts

Material

Remarks

Airendcasing

FG260,IS210

Greyironcasting

Rotor

EN8M

Carbonsteel(Coated)

Timinggear

AISI8620H

Ni-Cr-MoSteel

CarbonSeal

Carbon+SS304

VISCO typeseal

BronzeC90500

Bronzecasting

Ballbearing

-

SKF(Specialorder)

4.2Gearcasingunit

Parts

Material

Remarks

Gearcasing

FG250,IS210

GreyironcastingorRolledsteel

Bullgear

AISI8620H

Cr-MoSteel

Piniongear

AISI8620H

Ni-CrSteel(Casehardening)

4.3Cooler

Parts

Material

Remarks

Shell

FG220,IS210

Greyironcasting

TubeSheets

Muntz

60%Cu,40%Zn

Cover

FG220,IS210

Greyironcasting

Fins

Copper

CopperSheet

Tube

CuNi90/10

Coppernickelalloy

Bolt

IS1364

Carbonsteel

Nut

IS1364

Rolledcarbonsteel

4.0

4.4Soundproofcover Parts Material Remarks Panel Shapedsteel(CRCSteel   D/DD,IS513)+

4.4Soundproofcover

Parts

Material

Remarks

Panel

Shapedsteel(CRCSteel

 

D/DD,IS513)+

Retardantfibre

Base

ST42W,IS2062+ISMC+

Rolledsteel

ERWIS1239

4.5Piping

Parts

Material

Remarks

Airpiping

ASTMA53&IS1978,

Carbonsteelpipe

ERWSch40

Waterpiping

ASTMA53&IS1978,+SAE

Carbonsteelpipe

100R1DIN20022

Oilpiping

Nylontube+DIN2391+SAE

-

100R1DIN20022

Instrument

SS304+Nylontube

 

4.1

5.0FlowSystem CompressorAirFlow Airflowsthroughthesuctionboxpanel,intakeairfilterandsuction butterflyvalvetothe1 s t

5.0FlowSystem

CompressorAirFlow

Airflowsthroughthesuctionboxpanel,intakeairfilterandsuction butterflyvalvetothe1 st stageAirend.Aftercompressedbythe1 st stage Airend,theairflowsthroughintercoolerandentersthe2 nd stageAirend. The2 nd stageAirendfurthercompressestheairuptotherequired pressure.Thentheairpassesthroughthedischargesilencer,thecheck valve,theaftercoolerandthedischargeairoutlet.

OilFlow(Fig.5.1)

Oilreservoirislocatedinthebottomofthegearcasing.

Theoilcirculatesthrough:

1. Oilstrainerhaving150meshfilterscreen,whichisinstalledinsidethegear

casingandremoveslargeparticlesfromtheoil.

2. Oilpumpofvanetypewhichpressurizestheoil.

3. Oilcoolerwhichkeepstheoiltemperaturebelow55deg.C.

4. Oilpressureregulatorwhichkeepstheoilpressurewithin2.5 4.5kgf/

cm 2 .

5. Oilfilterhaving10micronfilterelementwhichimprovesthepurityofoil.

6. Oilheaderinwhichoilbranchestoeachpart.Theoilis,thus,injectedto

thebearings,gearsandrotorsandreturnedtotheoilreservoirafterlubrication

andcooling.

5.0

VentilatingAirFlow(Fig.5-1) Duetoheatgenerationbycompressorandmotor,thetemperatureinsidethe soundproofcoverwillrise.

VentilatingAirFlow(Fig.5-1)

Duetoheatgenerationbycompressorandmotor,thetemperatureinsidethe

soundproofcoverwillrise.

Toremovetheheatandtokeepallthecomponentscool,aventilatingfanis

mountedatmainmotorshaft.

GearCasingVent(Fig.5.1&5.2)

Iftheinternalpressureofgearcasingrises,theoilwillinvadethemainmotor

andthecompressionchamberwhichconsistsofrotorsandcompressorcasing.

Topreventtheoilfrominvadingthem,agearcasingventisprovidedtorelease

theairwithoilmisttotheoutdoors.

Theventpipingshallbeinstalledfromtheflangeattachedonthesoundproof

covertotheoutdoors.TheopenendofthepipingshallbebentdownasperFig.

5.2.

CoolingWaterFlow(Fig.5.3)

Maincoolingwaterlinehastwobranches.Thefirstbranchflowsthroughthe intercoolerandthentotheaftercooler.Thesecondbranchflowsthroughtheoil cooler,thewaterjacketof1 st stageAirendand2 nd stageAirend.

Allthebranchesagainjoinatthemainoutletline.

5.1

transmitter transmitter transmitter transmitter transmitter transmitt er transmitter 5.2
transmitter transmitter transmitter transmitter transmitter transmitt er transmitter 5.2
transmitter
transmitter
transmitter
transmitter
transmitter
transmitt
er
transmitter
5.2
WP 5.3 WP-WaterPr.Sensor
WP
WP
WP 5.3 WP-WaterPr.Sensor

5.3

WP 5.3 WP-WaterPr.Sensor
WP 5.3 WP-WaterPr.Sensor

WP-WaterPr.Sensor

6.SafetyDevices DuringOperation Inadditiontothesafetyvalve,thecompressorisequippedwiththefollowingswitches,which

6.SafetyDevices

DuringOperation

Inadditiontothesafetyvalve,thecompressorisequippedwiththefollowingswitches,which

willtriptheunitinordertoprotectitagainstabnormalrunningconditions.

*toolowanoilpressure(LOPS) *toohighablow-offpressure(HBPS)

*motoroverload(e1,e2)

*toohighadischargetemperature(HDTS)*toohigh/lowa1 st dischargepressure(HISPS) *toohighoiltemperature(HOTS) *toosmallaflowofcoolingwater(HISTS,HDTS,HOTS)

Thefollowingtableshowsthedetector,predeterminedvalue,andsymbolofwiringdiagramforeachitem.

*toohigha2 nd stagesuctiontemperature(HISTS)

.

No.

Item

Detector

Symbol

Predetermined

Switch

Comp.

value

Position

Condition

 

FeedOil

Pressure

       

1

pressure

Transmitter

LOPS

1.1bar(g)

ON

Shutdown

 

2 nd Stage

Thermal

       

2

Suction Temperature

Transmitter

HISTS

50°Cmore

ON

Shutdown

 

Compressor

         

3

Discharge

Temperature

Thermal

Transmitter

HDTS

- °.Cormore

(see*1)

ON

Shutdown

       

7.2/8.2/9.0

 

Unload

Compressor

Pressure

bar(g)

OFF

operation

4

Discharge

Pressure

Transmitter

UPS

6.7/7.7/8.5

bar(g)

ON

Load

operation

 

MainMotor/

Overcurrent

       

5

OilPump

Relay

`e1/e2

Overload

ON

Shutdown

 

Compressor

         

6

intake

Pressure

DiffPressure

Switch

-

-625mmwater

ON

Alarm

7

Compressor

Safetyvalve

 

Setpressure7.7/

   

pressureHigh

-

8.7/9.5bar(g)

-

-

 

Blow-off

Pressure

       

8

Pressure

switch

HBPS

0.4bar(g)

ON

Shutdown

 

FeedOil

Thermal

       

9

Temperature

Transmitter

HOTS

55°Cormore

ON

Shutdown

 

1 st Stage

         

10

discharge Temperature

TempSwitch

HDTS1

225°.Cormore

ON

Shutdown

 

1 st Stage

Pressure

       

11

compressor discharge pressure

Transmitter

(High)

HISPS

-bar(g)

(see*2)

ON

Shutdown

   

Pressure

       

12

Water

Transmitter

LWPS

1.1bar(g)

-

-

pressure

(Low)

13

IIndstageinlet

Pr.Transmitter

LISPS

bar(g)(see*2)

ON

Shutdown

pressure

(Low)

6.0

*1 Discharge NE90 NE110 NE135 NE145 NE170 NE200E NE200 NE210 NE250 NE265 NE275 NE300
*1 Discharge NE90 NE110 NE135 NE145 NE170 NE200E NE200 NE210 NE250 NE265 NE275 NE300

*1

Discharge

NE90

NE110

NE135

NE145

NE170

NE200E

NE200

NE210

NE250

NE265

NE275

NE300

pressure

7.0bar(g)

200

200

200

200

200

200

200

200

200

200

200

200

8.0bar(g)

225

225

225

225

225

225

225

225

225

225

225

225

8.8bar(g)

225

225

225

225

225

225

225

225

225

225

225

225

*2

Model

NE90

NE110

NE135

NE145

NE170

NE200E

NE200

NE210

NE250

NE265

NE275

NE300

1 st Stage Compressor Discharge pressurehigh

2.5

 

2.5 2.8

2.5

2.5 2.8

   

2.5 2.5

 

2.5

2.5 2.5

 

2.5

2 nd Stage Compressor suction pressurelow

1.6

 

1.6 1.6

1.6

 

1.6 1.6

 

1.6 1.6

 

1.6

1.6 1.6

 

1.6

Atstarting

Theprotectionsystemconfirmsthattheunitmeetstheconditionsforstart-up.

Theinterlockforstart-upincludesthefollowing.

No.

Item

Detector

Symbol

Interlock

Switch

Condition

position

1

Feedoilpressure

PressureTransmitter

OPS

1.1bar(g)

ON

2

OilPump

Electromagneticswitch

SV

Running

ON

6.1

7.0CapacityControl ElgiCapacitycontrolsystemprovidesONLine/OFFlinecontrolwith

7.0CapacityControl

ElgiCapacitycontrolsystemprovidesONLine/OFFlinecontrolwith

blowing-offdischargepressuretoatmosphereatpartloadornoload

condition.Itisnotamodulationcontrol.Whentheairrequirementby

theplantreducesorstops,theairlinepressureincreasesandwhenit

reachestheuppersetpointoftheunloadpressureswitch,thesystem

unloadstheunit.Whentheairlinepressuredropstothelowersetpoint

oftheunloaderpressureswitch,thesystemreloadstheunit.

Theunloadpressureswitchisconnectedtothedischargepipe

downstreamoftheaftercooler.

Standardfactorysettingforcapacitycontrolandstartingunloadisas

follows.

 

7bar(g)Models

8bar(g)Models

8.8bar(g)Models

UpperSetPoint

7.2bar(g)

8.2bar(g)

9.0bar(g)

LowerSetPoint

6.7bar(g)

7.7bar(g)

8.5bar(g)

7.0

ATSTARTING Thestartingautomaticallyworksasfollows.Thesuctionbutterflyvalveisclosed
ATSTARTING Thestartingautomaticallyworksasfollows.Thesuctionbutterflyvalveisclosed

ATSTARTING

ATSTARTING Thestartingautomaticallyworksasfollows.Thesuctionbutterflyvalveisclosed

Thestartingautomaticallyworksasfollows.Thesuctionbutterflyvalveisclosed

whiletheunitstops.The4-waysolenoidvalveisde-energizedforawhileafter

theSTARTbuttonispushed.Theoperatingoilflowsinthefollowingdirection. P A B R
theSTARTbuttonispushed.Theoperatingoilflowsinthefollowingdirection.
P
A
B
R
Theoperatingoilissuppliedfromtheoilhole1anddeliveredtooilhole2

Thenthesuctionbutterflyvalveiskeptclosedtoreducethestartingload.

7.1

UNLOADING Whentheairvolumerequiredbytheplantreducesandthedischargeairline

UNLOADING

Whentheairvolumerequiredbytheplantreducesandthedischargeairline pressurereachestheuppersetpointofunloadpressureswitch,de-energizes

the4-waysolenoidvalveandtheoperatingoilflowsinthefollowingdirection. P A B R
the4-waysolenoidvalveandtheoperatingoilflowsinthefollowingdirection.
P A
B
R
Theoperatingoilissuppliedfromtheoilhole1anddeliveredtooilhole 2
Thenthesuctionbutterflyvalveisclosedtothrottletheinletairflowtothe
Airend.Atthesametimethecompressedairinthedischargeairlineisreleased
toatmospherethroughtheblow-offsilencer,sotheidlingpowerisreduced.
LOADING
Whenthedischargeairlinepressuredropstothelowersetpointofunloader
pressureswitch,theunloadpressureswitchenergizesthe4-waysolenoidvalve
andtheoperatingoilflowsinthefollowingdirection.
P B
A
R
Theoperatingoilissuppliedfromtheoilhole 2 anddeliveredtooilhole 1.

Thenthesuctionbutterflyvalveisopenedcompletelyandtheunitcomesto

loadcondition.

ATSTOPPING

Whentheunitisstopped,therouteofoperatingoilflowsischangedtothe

sameastheoneofunloading.Sotheunitstopsintheunloadcondition.

RECEIVERCAPACITY

Thiscontrolsystemshouldnotbeintheunloadconditionfrequently.

Beparticularlycarefulwhenthecompressorhasonlyasmallvolumedischarge

line.

7.2

Thereforethereceivercapacity(requiredvolumeonthedischargeline),which

Thereforethereceivercapacity(requiredvolumeonthedischargeline),which

determinestheswitchingbetweenloadandunloadoperations,mustbecarefully

calculatedasfollows:

V = 16xQs where V=requiredcapacityforcompressorcontrol(m³)

Qs=flowratehandledbythecompressor(m³/sec)

ExampleQs=20m³/min(=0.33m³/sec)thanV=16x0.33=5.23m³

Thusthereceivercapacity(includingdischargepipingcapacity)isapproximately

5m³.

1ft3 = 0.02832m³ 1cfm= 0.000472m³/sec.
1ft3 =
0.02832m³
1cfm= 0.000472m³/sec.

7.3

8.Operation 8.1PreparationForFirstStart-up Beforestartingtheunitforthefirsttime,anoperatorshouldbecomefamiliar

8.Operation

8.1PreparationForFirstStart-up

Beforestartingtheunitforthefirsttime,anoperatorshouldbecomefamiliar

withallpartsandassemblies.

8.1.1 Oilfilling

Oilinthegearcasinghasbeendrainedoutbeforedelivery.Removetheoil fillingcap,andfilltherecommendedoiltotheupperlineoftheoillevelgauge (Fig.8.1) DONOTMIXOILBRANDS.

8.1.2OilFlushing

Oilflashingshallbeperformediftheinductionofoilpressuregaugeshows1.5

kgf/cm 2 orless.

Especiallypayattentiontotheoilpressuregaugebeforethefirststart-upand

anystart-upsduringcommercialoperationwhentheunithasbeenputinthe

followingconditions.

a) Thepreservedtermbetweentheshipmentandthefirst

start-upexceed3months.

b) Everyoverhaul.

Therecommendedoilshallbeusedasaflushingoil.Itisnotnecessarytochange theoilafterfinishingtheoilflushing.Aftertheflushingoilissuppliedtotheoil reservoirtothespecifiedlevel,theflushingworkisperformedbytheoilpumpsolo operation.Ifthereisalotofdirtorrustinthesystem,theytendtoclogtheoilfilter andcauseadropofoilpressure.Theflushingshallbecontinueduntiltheoil pressureexceeds1.5kgf/cm 2 ,whiletheoilfilteriscleanedatintervals.(Fig.8.2)

8.1.3 PriortoStart-up

Beforestartingthecompressor,performthefollowingitems,

Makesurethattheunitisprovidedwithadequateelectricalgrounding.

Closethedrainvalvesinthecoolingwaterline(inletandoutlet)completely

(Fig.8.3)

Closethewaterreleasevalves(Fig.8.1&8.2)

8.0

Opentheinletandoutletvalvesinthecoolingwaterline(suppliedbythe (customer)andchecktheflowrateandthewatertemperature.

Opentheinletandoutletvalvesinthecoolingwaterline(suppliedbythe

(customer)andchecktheflowrateandthewatertemperature.

Opentheballvalvebetweentheaftercoolerandthereceiverorotherprocess

devicescompletely.

Makesurethattheoillevelisbetweenredlinesoftheoillevelgauge.

(Fig.8.1)

Releasetheairtrappedinthecoolingwaterlinebyopeningthewater

releasevalves(Fig.8.1&8.2)

Closethewaterreleasevalves.

releasevalves(Fig.8.1&8.2) Closethewaterreleasevalves. 8.2 InitialStart-up 8.2.1Rotationcheck
releasevalves(Fig.8.1&8.2) Closethewaterreleasevalves. 8.2 InitialStart-up 8.2.1Rotationcheck

8.2 InitialStart-up

8.2.1Rotationcheck

8.2 InitialStart-up 8.2.1Rotationcheck

Besuretocheckthesmoothrotationofrotorsbyrotatingthemotorshaft

byhandfromthemotorinspectioncover.(Fig.8.2)

TurnonthemainpowerandmakesurethattheOILPUMPSTOPlight

andCOMPSTOPlightstayslit.

Makesurethattheballvalveinthedischargeairlinehasbeencompletely

opened.

8.1

PushtheSTARTbutton.Checkthedirectionofrotationfromtheinspection

PushtheSTARTbutton.Checkthedirectionofrotationfromtheinspection

openingofmainmotorwhileINCHINGtheunit(approx.1sec.)(Fig.8-2)

Starttheunitagainandrecheckthedirectionofrotation.Atfirst,theoil

pumpisoperatedandtheoilispressurized.

. Makesurethattheinletoilpressureis1.1kgf/cm 2 ormore.

Aftertheoilpressurereaches1.1kgf/cm 2 ,20secondsafterSTARTbutton ispushed,theunitstartsrunningintheunloadcondition.Unloadingis

carriedoutbythrottlingthesuctionof1ststageandsimultaneouslyblowing

offthecompressedairdischargedfrom2 nd stagetoatmosphere.

! WARNING
!
WARNING

Mainpowertotheunitshallbedisconnectedwhendoing

anyelectricalwork

Torestartthecompressorafteraprotectivesystemshutdown, pushthe Reset button.Afterthecauseforshutdownis corrected,thesystemshallberesetandthecompressorshall bestarted. Reset button.Afterthecauseforshutdownis corrected,thesystemshallberesetandthecompressorshall bestarted.

! CAUTION
!
CAUTION

Donotrestartthecompressorimmediatelyaftershutdown.

Restartthecompressoratleast20minutesaftershutdownto

preventoverheatofthemainmotor

8.2

Fig.8.3Piping 8.2.2.RaisingDischargepressure ! CAUTION Atthefirststart-upofthisunit,besuretoraisethedischarge
Fig.8.3Piping 8.2.2.RaisingDischargepressure ! CAUTION Atthefirststart-upofthisunit,besuretoraisethedischarge

Fig.8.3Piping

8.2.2.RaisingDischargepressure

! CAUTION
!
CAUTION

Atthefirststart-upofthisunit,besuretoraisethedischarge

pressurestepbystep.Thisisoneofthemostimportant

proceduresforfirststart-upofthisunit.

Afterunloadoperationof30seconds,thecapacitycontroldeviceopens

thebutterflyvalveofthesuctionpipeandclosestheblowoffline.

Runtheunitfor30minuteswiththedischargeballvalvecompletelyopened

sothattheunitrunsatthelowestpressure.

Whenthecompressordischargepressureislowerthantheratedpressure,

closethestopvalveasslowlyaspossibleuntilthecompressordischarge

pressurereachestheratedpressure.

Checkandconfirmthattheoiltemperaturegaugeindicates55deg.Cor

lowerandthedischargetemperaturegaugeindicatesthetemperaturebelow

thesetvalue.

8.3

8.2.3.Stopping PushtheSTOPbutton(Fig.8.4) Thecontactorformainmotorwillopen,andthesolenoidvalveofcapacity

8.2.3.Stopping

PushtheSTOPbutton(Fig.8.4)

Thecontactorformainmotorwillopen,andthesolenoidvalveofcapacity

controldevicewillbede-energized.Thenthebutterflyvalvewillbeclosedand

theblow-offlinewillbeopenandtheunitwillstopintheunloadcondition.

Theoilpumpwillstop3minutesafterthepowerofmainmotoristurned

off.

Closethestopvalvebetweentheaftercoolerandthereceiverorother

processdevices.

Closetheinletvalveinthecoolingwaterline(Fig.8.3)

Iffreezingweatherispredicated,openthedrainvalveanddrainoffthe

waterinthesystem.Payattentiontotheintercooler,theaftercoolerand

theoilcooler.

! CAUTION
!
CAUTION

Withthecompressorstopped,drainoffwater,sludge,dirt

orotherforeignmatterbyopeningalldrainvalves.

Afterdrainingoff,shutalldrainvalvescompletely.

8.4

8.2.5.Post InstallationStorage Thefollowingprocedureisnecessarytoprotectthecompressoragainstrustif

8.2.5.Post InstallationStorage

Thefollowingprocedureisnecessarytoprotectthecompressoragainstrustif

itisgoingtobestoredforalongperiod.Inanycase,whenpost-installation

storageisrequired,contactthenearestELGIoffice.

Runthecompressorfor5minutesonceinaweek.

Afterrunning,drainoffanddryoutcompletelythewaterpassageofcoolers

andshutoffthedrainvalves.(Fig.8-3)

Marktheunitwithacautionsigntodeclarethestoragecondition.The

signwarnsanoperatoragainstpotentialhazardsorunsafepractices.

Inaddition,thereisadrynitrogenpurgemethodoradryagentmethodfor

longtermstorage.

ELGIwillchoosewhichofthemissuitableforthelocalcondition.

8.3 DailyOperation

8.3.1BeforeOperation

MakesurethattheOILPUMPSTOPlightandtheCOMPSTOPlight

stayslit(FIG.8.4)

Checkifthedrainvalveshavebeenclosedcompletely.(FIG.8.3)

Makesurethatcoolingwaterflows.

Checktheoillevel(FIG.8.1)

DrainoffthecondensateintheY-typestrainersforintercoolerandaftercooler

withthedraindetectionvalve(FIG.8.3)

Releasetheairtrappedinthecoolingwaterlinebyopeningthewater

releasevalve(FIG.8.1,8.2)

Closethewaterreleasevalves.

8.5

8.3.2Starting PushtheSTARTbutton. Checkiftheoilpressuregaugeindicated1.1kgf/cm 2 orhigher20seconds

8.3.2Starting

PushtheSTARTbutton.

Checkiftheoilpressuregaugeindicated1.1kgf/cm 2 orhigher20seconds afterthestart.Normaloilpressureis1.5to2.2kgf/cm 2 (FIG.8.4)

8.3.3Duringoperation

Checktheoiltemperature.Normaloiltemperatureis55Deg.Corless.

(FIG.8.4)

Checkthedischargeairtemperature.

Checkifthedustindicatorshowsyellow.

Measurethecycletimeofload-unloadoperation.Checkifthecycletime

is30secondormore.

OpenthedraindetectionvalveinstalledontheY-typestrainerandcheck ifthecondensateflowsthroughtheorificeplateandtheY-typestrainer

(FIG.8.3)

Confirmthatnotrappedairexistinthecoolingwaterlinebyopeningthe

waterreleasevalves.

8.3.4Stopping

PresstheSTOPbutton(FIG.8.4)

Makesurethatthepressure(dischargeandinterstage)indicatezeroafter

thestop(FIG.8.4)

Aftertheoilpumpstops,shutoffthecoolingwaterline.

Openthedrainvalvestodrainoffthewaterintheunit.Thisactionis especiallyimportanttoavoidfreezingofthesystemincoldseason.

(FIG.8.3)

8.6

8.3.5LongTermStorage A.Ifthecompressorisgoingtobestoredformorethan8Hours, Closethewaterinletandoutletvalves

8.3.5LongTermStorage

A.Ifthecompressorisgoingtobestoredformorethan8Hours,

Closethewaterinletandoutletvalves

Drainthewaterfromthecompressorsystem

Closethemainairoutletvalve

B.Ifthecompressorisidleformorethanaweek

Rotatethecompressorshaftoncein7daysandensurethefreerotation

Supplydryairatintercoolerdryairinletfor30min

8.7

9.0 Piping DischargeAirPiping(FIG.9.1) Thesizeofdischargeairlineshallbeatleastaslargeasthedischarge

9.0 Piping

DischargeAirPiping(FIG.9.1)

Thesizeofdischargeairlineshallbeatleastaslargeasthedischarge

pipingsizeinstalledontheunit.Adrainageopeningandastopvalve

shallbeinstalledinthedischargeairline.

Preparetheflangeconnectionattheappropriateportionofthedischarge

airlinetotakeoffthedischargepipinginstalledinsidethesoundproof

covereasily.

Watercondensationhasabadinfluenceupontheoperationofpneumatic

devicesortools.Theinstallationofairdryerscaneliminatethistrouble.

ParallelOperation(FIG.9.2,9.3)

ParallelOperation(FIG.9.2,9.3)

Iftheunitisoperatedinparallel,besuretoprovideastopvalveandadrainage

openingineachdischargeairline.

Iftheunitisoperatedinparallelwithreciprocatingcompressor,thedischarge

airlineoftherotaryscrewunitshallbeconnecteddownstreamoftheairreceiver.

9.0

ElevatedPiping(FIG.9.4) Ifthedischargeairlineiselevatedneartheunit,besuretoprovidedrainvalve

ElevatedPiping(FIG.9.4)

Ifthedischargeairlineiselevatedneartheunit,besuretoprovidedrainvalve

ordriplegtocollectthecondensate.

Manifoldpiping(FIG.9-5)

Connectthedischargeairlinetothetopofthemanifoldpiping.Otherwisethe

condensateattheplantpipingwillreturntotheunitwhiletheunitisatstandstill.

ExternalAirReceiver

Itisrecommendedtoinstallapropersizeexternalairreceiverfortheunit,

sincethecapacitycontrolis2step(0%or100%)control.

Choosetheappropriatesizeforthereceiverinaccordancewiththeselection

guideofreceiverdescribedinSECTION.8CAPACITYCONTROL.

! CAUTION
!
CAUTION

Donotinstallacheckvalvebetweentheunitandthe

airreceiver

CoolingWaterPiping

Thetake-overpointsofcoolingwaterlineareatthebaseofunit,whichconsists

ofoneinletlineandoneoutletline.Installastopvalveateachline.Amotor

drivenvalveshallbeselectedtoavoidwaterhammerifautomatictypeisrequired.

CoolingWaterQuality

Qualitystandardofcoolingwater

Ifacoolingtowersuppliesthecoolingwatertotheunit,corrosion,scaleor

slimemaybeaproblemcausedby:

a)Waterhavingahighmineralcontent.

b)Foreignmatterlikeinsects.

c)Alageorbacterium.

9.1

2.ControlofcoolingwaterQuality Thelifetimeofthecoolingwatersystemdependsonthewaterquality.Ifthe

2.ControlofcoolingwaterQuality

Thelifetimeofthecoolingwatersystemdependsonthewaterquality.Ifthe

coolingwaterQualityisnotgood,thecoolerpipescanbecorroded,orscale

canbegenerated.Inordertopreventsuchaproblem,samplethecoolingwater

periodicallyandtestittocheckifitmeetsthequalitystandard,correctif

necessary.

CoolerDrainPiping

Condensateisseparatedfromthecompressedairwiththemistseparator

installedatthedownstreamofthetubebundle.Thecondensateisdischarged

withasmallamountofthecompressedairthroughanorificeplateandtheY-

typestrainereasily.

Whenthecoolerdrainpipingofintercoolerisconnectedtothecondensate

pipingofaftercooler,thecondensatedischargedfromaftercoolerflowstothe

intercoolerbecauseofpressuredifference.Soitisimportanttoopeneach

coolerdrainpipingtoatmosphere.

GearCasingVentPiping(FIG.9.6)

Toreleaseinternalpressure,thegearcasinghasaventpipe.Theventpipe

shallbeextendedtotheoutdoorsasshownbelowsothatoilfumesfromthe

gearcasingdonotenterintothecompressorinlet.

Thepipesizeshallbe3 ormoreandthepressuredropshallbe5mmHgorless

at800l/min.

Thepipingshallhaveagradientof1/100to1/20toreturntheoil,whichcondenses

onthewaytotheoutlet,tothegearcasing.

Usecleanpipefortheventpiping,otherwisedirtorrustinthepipecanflow

backtothegearcasing,whichmaycausecloggingofthefilter.

Theoutdooropeningshallbebentdownwardtoavoidenteringofrainordirt.

Theoutletofventpipingshallnotbelocatedneartheinletofanyairduct.

9.2

! CAUTION Allservicepipingmustbeinstalledsoastoexertzeroforceof momentontheunit 9.3
! CAUTION
!
CAUTION

Allservicepipingmustbeinstalledsoastoexertzeroforceof

momentontheunit

! CAUTION Allservicepipingmustbeinstalledsoastoexertzeroforceof momentontheunit 9.3
! CAUTION Allservicepipingmustbeinstalledsoastoexertzeroforceof momentontheunit 9.3

9.3

10.0Foundation Whilethefoundationforscrewcompressorsneednotbeasmassiveasthatfor

10.0Foundation

Whilethefoundationforscrewcompressorsneednotbeasmassiveasthatfor

reciprocatingmachinery,itshallhaveastrengthsufficienttoprovideasupport

fortheunit.Sincetherearenounbalanceforcessuchasreciprocatingorshock

loads,allloadsimposedonthefoundationmaybeconsideredasstaticloads.

Iftheunitistobelocatedinthearea,whereothermachinery,avibration

dampeningmaterialshallbeplacedbetweenthefoundationandthebedrock.

10.1LevelingandGrouting(RefertoSEC.16InstallationPlan)

Ingeneral,thefoundationofscrewcompressorsismadeofgroutpad

liner.

Settingofpadlinershallbefinished3daysbeforeinstallingtheunitto

shortentheworkingtime.

Thedifferenceofelevationamongthelinersshallbe1mmorless.The

levelofpadlinershallbe2mmorlessineverydirection.

Aftersettingofpadlinersvariousamongthem,itisnecessarytoadjust

theheightoflinerwithshimliners.

Thepurposeofgroutingistosolidlyfillthespacebetweenthebaseand

thefoundationandtogiveauniformload-bearingsurfacefortheunit.

Theuseofwedges,shims,orlevelingscrewsforpermanentinstallationis

notrecommended,theyaretobeusedasamethodoflevelingandaligning

theunitpriorgrouting.

Priortogrouting,roughenthefoundationsurfacebyremovingapproximately

13mmdeepofthesurfacebychippingorothermeanstoprovideagood

bondingsurface.

10.0

Buildaframearoundtheperimeterofthebase. Whenbuildingtheframe,preparethespaceforremovalofwedges,shims

Buildaframearoundtheperimeterofthebase.

Whenbuildingtheframe,preparethespaceforremovalofwedges,shims

orotherlevelingafterthegrouthasset.

Toobtainagoodbondbetweenthefoundationandthegrout,thefoundation

shallbecompletelycleanandfreeofanyoil,waterorotherforeignmatters

priortopouringgrout.

Prepareaminimumof25mmofgroutbetweenthebaseandthefoundation.

Allairpocketsandvoidsshallberemovedfromthegrout.Aftergrouthas

set,removethelevelingdevices.Andthentightentheanchorboltsandfill

thevoidleftbythelevelingdeviceswiththesamegroutingmaterial.

10.2Wiring

Wiringwithintheunithasbeencompletedbeforedelivery.

Wiringrequiredatthesiteistheconnectionofpowersupplyandgrounding.

Agroundingterminalisprovidedinthestarter.

Notethatanisolatorisnotprovidedontheunit.Theisolatorperthelocal

requirementsshallbeprovidedbytheinstaller.

! WARNING
!
WARNING

TwoveryImportantprecautionstobeobservedwhen

connectingtheunittothepowersupplyare;

Whenmakinganyconnectionorchangesinthewiring

oftheunit,DISCONNECTTHEMAINPOWER.

Besuretheunitisadequatelygrounded.

10.1

12.0TroubleShooting Asaguide,themostlikelyproblemswithpossiblecausesarelistedinthe followingchart.

12.0TroubleShooting

Asaguide,themostlikelyproblemswithpossiblecausesarelistedinthe

followingchart.

Beforedoinganyworkonthisunit,besuretheelectricalsupplyhasbeencut

offandtheentirecompressorsystemhasbeenventedoffallpressure.

* Markeditemsofsuggestedremedyhavetobeperformedbynearestbranch.

NOTE

Inthecaseofshutdownofsafetydevices,thedisplayshows

faultdetails.Findthecaseofshutdown,correctitandpressthe

RESETbutton.

Donotstartthecompressoragainifthecauseofshut-downis

unknown.Neverperformatrialrunningtofindthecause.Whenever

thecauseisunknown,contactthenearestbranch.Beforestarting

thecompressoragain,besuretocheckforsmoothrotationof

rotorsbyrotatingthemotorshaftbyhandfromthemotorinspection

cover.Besuremainelectricalpowerisoff.Ifmotorturnsfree,

reconnectpower.

ThenpushtheRESETbuttonandtheRUNbutton.

12.0

12.1TroubleShooting CONDITION POSSIBLECAUSE SUGGESTEDREMEDY 1.Failuretostartor a. Powerfailure a.

12.1TroubleShooting

CONDITION POSSIBLECAUSE SUGGESTEDREMEDY 1.Failuretostartor a. Powerfailure a. Inspectpowersource. restart
CONDITION
POSSIBLECAUSE
SUGGESTEDREMEDY
1.Failuretostartor
a.
Powerfailure
a. Inspectpowersource.
restart
2.Highdischarge
a.
Highaltitude
a. Resetratedpressurelower.
temperature

12.1

CONDITION POSSIBLECAUSE SUGGESTEDREMEDY 3.Highoiltemperature a. Lowcoolingwaterflow a. SeeCONDITION14.
CONDITION POSSIBLECAUSE SUGGESTEDREMEDY 3.Highoiltemperature a. Lowcoolingwaterflow a. SeeCONDITION14.
CONDITION
POSSIBLECAUSE
SUGGESTEDREMEDY
3.Highoiltemperature
a.
Lowcoolingwaterflow
a.
SeeCONDITION14.
4.Lowoilpressure
a.
Oilstrainerand/oroilfilter
a.
Clean
5.Mainmotoroverload
a.
Highdischargepressure
a.
Adjustpredeterminedvalueof
6.Lowdischarge
a.
Airleakfromthedischargeline
a.
Locateandrepair
pressure
7. Highinterstage
a.
Damaged2 nd stageairend
a.
Contactthenearestbranch*.
pressure
8.Lowsuctionpressure
a.
Intakeairfilterclogged
a.
Cleanorreplace
of2ndstageairend

12.2

CONDITION   POSSIBLECAUSE   SUGGESTEDREMEDY 9.Highinterstage a. Lowcoolingwaterflowrate a.

CONDITION

 

POSSIBLECAUSE

 

SUGGESTEDREMEDY

9.Highinterstage

a.

Lowcoolingwaterflowrate

a.

SeeCONDITION14.

temperature

temperature
temperature

10.Nochangingfrom

a.

Damagedunloaderpressure

a.

Replace

unloadtoload

unloadtoload
unloadtoload

11.Blowingofsafety

a.

Closeddischargestopvalve

a.

Open

valve

valve
valve

12.Huntingof

a.

Smallreceiversize

a.

Installtheappropriatesize.

capacity

 
capacity  

controldevice

controldevice
Installtheappropriatesize. capacity   controldevice 13.Highsource a. Dirtyintercoolerand/orafter a.

13.Highsource

a.

Dirtyintercoolerand/orafter

a.

Clean*.

current

current
current

14.Lowcoolingwater

a.

Failureofwatersupply

a.

Checkandrepair

flowrate

flowrate
flowrate

15.Dischargeair

a.

Gearcasingventlineclogged

a.

Checkandclean.

containingoil

containingoil
containingoil

16.Highoil

a.

Loosejointsintheoilsystem

a.

Retighten

consumption

consumption
consumption

12.3

CONDITION POSSIBLECAUSE SUGGESTEDREMEDY 17.Oillevelincreased a. Waterenteringtheoil a. Checkandrepair*.

CONDITION

POSSIBLECAUSE

SUGGESTEDREMEDY

17.Oillevelincreased

a. Waterenteringtheoil

a. Checkandrepair*.

a. Waterenteringtheoil a. Checkandrepair*. 18.Noise a. Airleakfromloosejoints a. Retighten

18.Noise

a. Airleakfromloosejoints

a. Retighten

a. Waterenteringtheoil a. Checkandrepair*. 18.Noise a. Airleakfromloosejoints a. Retighten
a. Waterenteringtheoil a. Checkandrepair*. 18.Noise a. Airleakfromloosejoints a. Retighten
a. Waterenteringtheoil a. Checkandrepair*. 18.Noise a. Airleakfromloosejoints a. Retighten
a. Waterenteringtheoil a. Checkandrepair*. 18.Noise a. Airleakfromloosejoints a. Retighten

12.4

11.0 Maintenance PreventiveMaintenanceWork ThemaintenancescheduleisinTable11.1

11.0 Maintenance

PreventiveMaintenanceWork

ThemaintenancescheduleisinTable11.1

Theintervalsshownthereareaguidebasedonnormaloperatingconditions.If

operatedinaharshenvironment,performtheservicemorefrequently.Carry

outthemaintenancework,basedoneitherrunninghoursorcalendartime

whichevercomesfirst.

Itemsmarkedwith o shouldbeperformedbyauserwhiletheothermarked with * shouldbemaintainedbythenearestbranch.

Theactionsmentionedintheschedulearerepetitiveunlessotherwisespecified,

theactionsat3,000hoursinterval,asaninstance,shallbecarriedoutagain

after6,000hoursofoperation.

Keepingarecordisaverygoodpracticeforgoodpreventivemaintenance.

TherecordalsoenablesELGItofindapotentialcauseoftroubleandthereby

performasuitablerepair.Usetheattachedrecordform.

StandardMaintenanceSchedule

ThemaintenanceinstructionsaresummarizedinTable11.1.Beforetakingany

maintenanceactions,readtheconcernedsection.TimementionedintheTable

11.1.arenotaperformanceguaranteeperiod.

11.0

TABLE11-1STANDARDCHECKANDMAINTENANCESCHEDULE   MAINTENANCEINSTRUCTIONS            

TABLE11-1STANDARDCHECKANDMAINTENANCESCHEDULE

 

MAINTENANCEINSTRUCTIONS

 
  MAINTENANCEINSTRUCTIONS  
           

Everyyear/

 

Slno

Activity

Description

Daily

Monthly

2000hrs

8000hrs

Everytwoyear

1

Check

OilLevel

         

2

Check

IntercoolerDrain

         

3

Check

AftercoolerDrain

         

4

Check

Waterleakage

         

5

Check

Oilleakage

         

6

Check

WorkingParameteres

         

7

Check

AirfilterindicatorforAirfiltercondition

         

8

Clean