Installation guidelines

GA 90 – 160 A/W
Introduction:
Good product performance is dependent on a good installation. Poor installation can
affect machine performance. It can also create costly service problems.

Typical example for good compressor installation:

Storage instructions:
(Valid for 3 months)

Don’t store the machine out in the air. Store the compressor, preferably indoors, in a
clean dry place.
Cover up the unit with tight fitting plastic or canvas, so as to avoid ingression of dust and
moisture.
Place the unit on a clean and level floor. The floor should be well ventilated. The floor
should be free from vibration or pulsation emanating from nearby machinery.
Make sure all coolant is drained and all connections closed off in water cooled units.
Avoid extreme ambient conditions (Temperature and moisture)
Min/Max ambient temperature during storage is 0 and 45 deg cel.
Once every two weeks, turn the motor/compressor coupling 10 turns by hand in order to
redistribute the oil (or grease) film on all moving parts.

Checking receipt of the compressor:

Check the crate for the sign of transport damages.

Check that no moisture penetrated the packaging. Check that contents not moved inside
the box.
Check that loose components (if any) are still properly wrapped and secured to the
bottom of the motor compartment.
If any transport damages observed, please report ACIL immediately.
Erection:

4 slotted hole (small) provided in compressor frame which can be used for horizontally
pulling compressor out of container.
Compressor can be moved by lift truck using the slots (big) in the frame and ensure that
the folks protrude from the other side of the frame.
Compressor can also be lifted after inserting beams in the slots and ensure that beams
cannot slide and that they protrude from frame equally.
The chains must be held parallel to the bodywork by chain spreaders in order not to
damage the compressor.
The lifting equipment must be placed in such a way that the compressor will be lifted
perpendicularly.

Weight of the compressor:

GA 90/110 (A) without dryer : Approx 2515 kg

GA 90/110 (A) with dryer : Approx 2825 kg
GA 90/110 (W) without dryer : Approx 2415 kg
GA 90/110 (W) with dryer : Approx 2685 kg
GA 132/160 (A) without dryer : Approx 3025 kg
GA 132/160 (A) with dryer : Approx 3355 kg
GA 132/160 (W) without dryer : Approx 2895 kg
GA 132/160 (W) with dryer : Approx 3175 kg

Foundation:

Foundation bed should be flat surface and should have sufficient bearing capacity.
For ventilation proposal, minimum distance between the top of the body work and the
ceiling is 1200 mm.
If more compressor (Air cooled) in one room, it is advisable to provide ducting even
distance between top of the compressor body work and ceiling is around 1200 mm.
Distance between two compressors should be minimum of 1600 mm and distance
between compressor & wall should be minimum of 1600 mm.

Ventilation:
Air cooled machines must be installed in such a way that an adequate flow of cooling air
is available and that the exhausted air doesn’t recirculate to the compressor air inlet or
cooling air inlet.

Inlet grid (s) and ventilation fan should be installed in such a way that any recirculation
of cooling air to the compressor is avoided.
The air velocity to the grid (s) has to be limited to 5 m/s
For alt. 2, 3, 4 the maximum allowable pressure drop over cooling air duct is 30 Pa
For alt. 1, 3, required ventilation to limit the compressor room temperature can be
calculated from

Qv = 0.1 N/Delta T
Qv is the required ventilation capacity (m3/sec)
N is the shaft pf the compressor (kw)
Delta T is the compressor room temperature over the outdoor temperature

Ducting procedure:
Ducting should be individual and it should not be connected together between
compressors.
Compressor suction should not have any obstruction and if any suction duct provided,
Hot air exhaust ducting should not reduce from compressor grating. Poorly designed
ducting can lead to overheating of compressor.

Compressor room location:

Compressor room should be a dust free location.
If compressor located very near to generator or carbon/other dusty location, preventive
measure to be taken for healthy running of compressor.

Piping:
In system with a large distribution network it is preferable to have the compressor located
centrally in order to minimize piping between the compressor and the farthest work
station in the plant.

The compressor system should be arranged to minimize the number of valves, fittings
and flow obstruction in order to reduce pressure drops.

Isolation valve should be installed (Not in ACIL scope) in compressor discharge air
outlet line. It should be closed whenever compressor not in operation.
For water cooled compressor, shut off valves should be provided in water line (in and
out) pipes (Not in ACIL scope) and water drain valve should be provided in water in &
out pipe.
Delivery pipe:
Maximum length of pipe can be calculated from,
L = (Delta P * d5 * p) / 450 * (Qc power of 1.85)
Where,
L : length of pipe in meter
Delta P : max allowable pressure drop in bar (recommended is 0.1 bar)
d : inner dia of pipe in mm
p : absolute pressure at the compressor outlet in bar
Qc : Compressed FAD in l/s

Pressure drop over the air outlet pipe can be calculated as follows

Dp : Pressure drop (recommended maximum 0.1 bar)

L : Length of outlet pipe in m
D : inner diameter of outlet pipe in mm
P : absolute pressure at the compressor outlet in bar (a)
Qc : free air delivery of the compressor in l/s

It is recommended that the connection of the compressor air outlet pipe is made on top of
the main air net pipe to minimize carry over of possible remainder of condensate

When air receiver is placed after the compressor air outlet, the air receiver will act as
safety buffer which will prevent condensate from flowing back into the compressor.
Piping has to be aligned properly in the compressor. There should not be any stress on the
piping.

Discharge air pipe:

GA 90/110 : 2 ½” or 2 ½ - 8 NPT
GA 132/160 : G 3” or G 3 – 8 NPT

Water pipe size:

GA 90/110 :G1½
GA 132/160 : G 1 ½

Condensate drain pipings:

Condensate drain piping (manual and auto drain) should be separate pipe line and it
should not be connected together. Condensate drain (manual & auto) must hang free over
a receptacle which helps to have visual inspection at all times to ensure that condensate
drain systems are functional. Condensate drain should not be immersed in receptacle.
Provide a condensate drain valve in the lowest part of the pipe between the compressor
outlet valve and the air net.

Cooling water requirements:

Cooling water quality equipment must meet certain minimum requirements. The
following recommendation is general guidelines for acceptable coolant quality.
Detailed cooling water quality calculation can be obtained from compressor instruction
book.

Ph – Greater than 6.8

TDS:
TDS is sum of all ions in the water.
For closed cooling system lesser than 3000 mg/l
For open cooling system lesser than 450 mg/l
Chlorides (CL-):
Chloride ion will create pitting corrosion on stainless steel. Their concentration should be
limited.
For closed cooling system lesser than 500 PPM
For open cooling system lesser than 150 PPM
If there is risk of boiler scale formation, then lower limit should be used.
Free chlorine (CL2):
Maximum allowable level – 0.5 PPM on continuous basis.
For shock treatments, a maximum limit of 2 PPM for maximum 30 minutes/day applies.
Sulphates (SO4):
For closed cooling system lesser than 400 ppm
For open cooling system lesser than 150 ppm
Carbonate hardness:
For closed cooling system 50 to 1000 ppm CaCO3
For open cooling system 50 to 500 ppm CaCO3
Ammonia:
Maximum allowable concentration is lesser than 0.5 ppm
Copper:
Maximum allowable concentration is lesser than 1 ppm
Iron and manganese:
Maximum allowable concentration lesser than 1 ppm
Electrical:
Electric cables have to provide with proper cable lugs and it has to be properly crimped
with cable.
If 2 run of cable provide in the compressor, both run of cable should be the equal
conductor sizes

Compressor Voltage/ Cable – Cable – Drive motor

model (GA Frequency CU 3 core AL 3 core OLR (A)
air/water cooled)
GA 90 415V/50Hz 95 150 110
GA 110 415V/50Hz 120 185 134
GA 132 415V/50Hz 185 240 161
GA 160 415V/50Hz 240 150-2 runs 191

Compressor model Max fuse rating Max fuse rating

Class gl/Gg Class gl/Gg
Type - 2 Type - 1
GA 90 2 * (3*224) 355
GA 110 2 * (3*160) 315
GA 132 2 * (3*250) 400
GA 160 2 * (3*400) 500

Technical data’s:
Compressor Pressure ranges Oil capacity Cooling water flow (l/s) –
model (bar) (liter) (temp rise 10 deg cel)
GA 90 A 7.5 /8.5 /10 /13 69
GA 110 A 7.5 /8.5 /10 /13 75
GA 132 A 7.5 /8.5 /10 /13 93
GA 160 A 7.5 /8.5 /10 /13 100
GA 90 W 7.5 /8.5 /10 /13 63 2
GA 110 W 7.5 /8.5 /10 /13 63 2.5
GA 132 W 7.5 /8.5 /10 /13 85 3
GA 160 W 7.5 /8.5 /10 /13 85 3.6

Commissioning procedures:
Gearbox, Motor is fixed with two metal spacers for transit purpose. Remove the metal
spacers before commissioning the compressor. Don’t start the compressor without
removing metal spacers.
Ensure installation as mentioned above
For water cooled compressors, flush the water line pipes before connecting. Check that
the cooling water drain valves (customer installation) in the inlet and outlet lines are
closed and that the water shut off valves (customer installation) are open and check for
water flow
On full feature compressor check that the dryer by-pass valve is closed and that the dryer
inlet and outlet valves are open.
Ensure the oil level is proper in oil tank
Check whether proper lugs are provided in electric cable and confirm the tightness of
electrical cables. Check that earthing connection provided properly and megger the
motor.
Check incoming voltage and Transformer T1 & T2
Check wirings and ensure that there are no loose connections
Ensure the main fuses are as mentioned above
Check the motor rotation direction by bumping the motor. On air cooled compressor,
check rotation direction of the cooling fan motor.
Ensure the discharge pressure settings as required
Set the drive motor OLR, cooling fan motor OLR and ensure the correctness of the same
Ensure the compressor discharge valve in open condition
Start the compressor and run at unload for few minutes. Stop the compressor and top up
the oil if required.
Run the compressor at unload and check that it operates normally.
Load the compressor and observe running parameters and ensure that it operates
normally.
Check the current of main drive motor and compare with the limit ranges
Check correctness of sensors, electrical interlocking
Observe compressor running parameters for at least 2 to 3 hours
Ensure there are no air/oil leakages
Check and confirm loading/unloading cycle
Check whether manual/auto drains are working properly
Customer should be informed to monitor whether condensate is draining automatically

SPM values:

dBi settings: GA 90 – 110 : 20 (Motor: 10)

GA 132 – 160 : 25 (Motor: 10)

Reference level during load:

Measurement point GA 90 – 160
(1) dBm 25
(3) dBm -
(7) dBm 25
Mot A dBm 20
Mot B dBm 20

Alert level: reference level during limit for new unit +20 dB
SPM Measurement points:

Service schedule:

Period Running hours Operation

Daily - Check reading on display
Check that condensate is discharged during
loading
3 monthly - Operate safety valve
- Remove, dismantle and clean float valve of
- condensate traps
- Clean compressor
- Check for possible leaks
 500 Check coolers, clean if required
500 Remove air filter and inspect
2000 Change oil – refer oil change intervals mentioned
below
Have all flexible inspected
Have safety valve tested
4000 Change below parts:
1.Check valve seal washer
2. Check valve o ring
3. Check valve o ring
4. Check valve spring
5. Air filter
6. Oil filer
7. Oil stop valve kit
8. Minimum pressure valve kit
9.Water separator drain valve kit
10. Seal washer oil filler plug
11. Seal washer gear casing
8000 Change below parts :
1. Parts mentioned in 4000 hrs check
2. O ring – oil filter housing
3. Thermostatic valve (7.5/8.5/10 bar)
4. Oil separator
5. Unloading valve kit
6. Flex master joint kit
7. Drain valve kit

Oil change intervals:

Roto inject fluid:

Ambient Element outlet Exchange interval* Max time interval

temperature temperature
Up to 25 deg cel Up to 90 deg cel 4000 hrs 1 year
25 to 35 deg cel 90 to 100 deg cel 3000 hrs 1 year
Above 35 deg cel Above 100 deg cel 2000 hrs 1 year

* Whichever comes first

Service activities
Pre commissioning report
Commissioning report