Oil-free Air Division презентация

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ZH-Series The unique packaging concept Convenience of the Integrated Packaged Unit Performances of a State-of-the-art Process compressor

Слайд 2


ZH-Series
The unique packaging concept
Convenience of the
Integrated
Packaged Unit
Performances of a


State-of-the-art
Process compressor

Слайд 3ZH-Series
Unique Package Concept

Слайд 4COOPER

Слайд 5ZH and TA product range

Слайд 6TA2000
2 and 3 stages

2.5 – 10.5 bar
130 – 300 kW

45 –

150 Psig
150- 350 Hp

TAC2000:
Air-cooled unit
Ambient temp. up to 40°C (105 F)

Слайд 7TA3000
2 – 3 stages

2.5 – 10.5 bar
1500 – 2500 kW

45 –

150 Psig
400-800 Hp

Слайд 8TA6000
2 and 3 stages

2.5 – 10.5 bar
685 – 1290 kW

45 –

150 Psig
800-1500 Hp

Слайд 9TA11000


2 – 3 and 4 stages

2.5 – 16 bar
900 – 1900

kW

35 – 232 Psig
1250 – 2500 Hp

Слайд 10Convenience of a packaged unit
Complete packaged unit








Clear capital cost

No costly additions

Easy

installation

Conventional packaged design








Uncomplete machine

Loose delivered items

Costly installation

ZH

Competition

Слайд 11Lowest Noise level in industry
Optional noise hood
68 ... 74 dBA
No silencing

hood available
Typically 82+ dBA

ZH

Competition

Слайд 12Convenience of packaged unit
Complete packaged unit









Levelled floor
No anchoring system
Conventional packaged unit









Heavy

fundations
Anchoring systems

ZH

Competition

Слайд 13Clear capital cost
The complete package includes
Air intake filter and silencer
Inlet guide

vanes
Aftercooler
Check valve
Cooling water manifold
Drain traps on all coolers
Compensators on air and
water inlet and outlets
IP23 motor
Control and safety system
integrated modulating blow-off valve
and blow-off silencer

Слайд 14Conventional package
$50’000
adders

Слайд 15Convenience of packaged unit
Complete packaged unit

AIR INLET SYSTEM
MOUNTED IN PACKAGE
Conventional

packaged unit

LOOSE DELIVERED
MOUNTED BY CUSTOMER ON-SITE
Inlet filter system
Air intake piping
Air intake screen
Air in/out compensators

ZH

Competition






Слайд 16Convenience of packaged unit
INTEGRATED & MOUNTED








Low noise Integrated Blow-off silencer
Piping
No need

for external air
Modulating blow-off valve
Integrated after cooler

LOOSE DELIVERED COMPONENTS











Relying on external instrument air

ZH

COMPETITION




Слайд 17Auto-Dual & Constant Pressure Control Configurations of TA’s

Слайд 18Convenience of packaged unit
INTEGRATED & MOUNTED
Cooling water manifold
Water in/outlet compensator
Condensate drain

system

LOOSE DELIVERED
MOUNTED ON-SITE

ZH

Competition



Слайд 19Lasting compressor performance
Clearances between impeller and inducer not affected over time

due to coating




Cooler performance not affected due to corrosion-resistant coating

Deterioration of performance with larger clearances due to corrosion




Lower heat removal capacity of coolers due to obstructed cooler tubes

ZH

Competition

Слайд 20Reliability first with Stainless Steel
STAINLESS STEEL
Superior corrosion resistance
Welded construction

Water-in-tubes, straight
Rodding with

bundles in-place

COPPER + ALUMINIUM
Carbon steel end plates
Cu + Al > galvanic corrosion
Prone to water leaks
Price adder for SS: $34’000 !
U-bend >> no rodding
Clogging of small tube diameters

ZH

Competition

Слайд 21Reliability first with quality gears
COMPLETE GEAR/PINIONS
AGMA Q13
Aircraft quality gearing

Increase of reliability
Lower

mechanical forces
Lower noise levels
Reduced gearbox losses



AGMA Q12
Replacement of bull gear and pinions in case one fails
>> very high cost if it happens
>> complicated maintenance

ZH

Competition

Слайд 22Designed for easy maintenance
MICRO SPLIN
Disassembly of impeller on-site
Micro-splin attachment avoids fretting

corrosion


SHRINK FIT (HEAT)
No inspection of bearings on-site
Complete rotor assembly to be returned to factory

ZH

TA2000-3000-6000

Слайд 23No compromises on reliability
ZH
Horizontally-split bearings
Flexible path radial









Thrust bearings
Cooper TA, I-R Centac
Fixed

geometry bearings
Fixed geometry radial








Thrust collar (rider rings)


Highest stability and reliability
Inspection & replacement on-site

Слайд 24No comprises on reliability
TILTING PAD
HORIZONTALLY-SPLIT
Maintenance and inspection







Thrust bearings for axial forces

FIXED

GEOMETRY BEARING
(Hydro-squeeze)






Thrust collar (rider rings)

ZH

TA2000-3000-6000

Highest stability and reliability
Inspection & replacement on-site

Слайд 25No comprises on reliability ??



ZH
TA 11000 & MSG

Why not on the

smaller frames if they know that the tilting pad bearings give the best result?


Слайд 26High speed and Low speed bearings
AXIAL FORCES
in TWO DIRECTIONS







Reliability and

safe design
Sleeve bearings on low speed shaft >> extended lifetime

THRUST COLLARS
ROLLER BEARINGS







Sensitive to varying load/unload cycles
Risk of metal fretting
Large clearance between shroud and impeller
>> higher SER

ZH

TA

Слайд 27Lasting compressor performance
CARBON RING AIR SEAL
LABYRINTH OIL SEAL







Patented combination
No external air


Minimal losses

LABYRINTH SEAL







Aluminium labyrinth teeth
Vibrations will damage seal

ZH

TA2000/3000/6000

High leakage rate
Prone to wear

Слайд 28Designed for easy maintenance
MOTOR DRIVEN DEMISTER








No external air
No fumes leaking to

atmosphere

EJECTOR TYPE VACUUM








visible oil spill to atmosphere
25 m³/h (15 cfm) instrument air permanent consumption

ZH

TA2000-3000-6000

Слайд 29INGERSOLL-RAND

Слайд 30Ingersoll Rand - Centac Models

Слайд 31Product range
ZH RANGE

Слайд 32Product range

Слайд 33CENTAC Product naming
50 Cycles

3ACII Frame size
C Centac
255 255 im³/min
M Motor driven
X 50 Hz
3 3 stages

60 cycles

3ACII Frame size
C Centac
90 90x

100 icfm
M Motor driven

3 3 stages

Слайд 34Convenience of a packaged unit
Complete packaged unit








Clear capital cost

No costly additions

Easy

installation

Conventional packaged design








Uncomplete machine

Loose delivered items

Costly installation

ZH

I-R CENTAC

Слайд 35Lowest Noise level in industry
ZH
Optional noise hood
68 ... 74 dBA
Competition
No silencing

hood available
Typically 82+ dBA

Слайд 36Convenience of packaged unit
Complete packaged unit









Levelled floor
No anchoring system
Conventional packaged unit









Heavy

fundations
Anchoring systems

ZH

Competition

Слайд 37Clear capital cost
The complete package includes
Air intake filter and silencer
Inlet guide

vanes
Aftercooler
Check valve
Cooling water manifold
Drain traps on all coolers
Compensators on air and
water inlet and outlets
IP23 motor
Control and safety system
integrated modulating blow-off valve
and blow-off silencer

Слайд 38Standard Scope of Supply Includes:
Built in lubrication and cooling systems

Flanged mounted motor
Control system
Single point flanged connections for air and water
Single point power connection for low voltage motors
Inlet air filter & by-Pass silencer shipped loose, to be mounted separately

Options:
Silencing canopy 75 dB(A), adder $9,000
Inlet guide vanes, adder $8,000
Cu-Ni cooler bundle tubes, adder $4,000

Centac CV2

Слайд 39Standard Scope of Supply Includes:
Built in lubrication and cooling systems,

including aftercooler
Foot mounted motor
Control system
Inlet air filter & by-Pass silencer shipped loose, to be mounted separately

Options:
Silencing canopy, adder $12,000
Inlet guide vanes, adder $10,000
Cooling water manifold, adder $6,000
Copper-nickel cooler bundle tubes, adder $5,000

Centac C950

Слайд 40Standard Scope of Supply Includes:
Built in lubrication and cooling systems,

including aftercooler
Foot mounted motor
Control system
Inlet air filter & by-Pass silencer shipped loose, to be mounted separately

Options:

Silencing canopy, adder $15,000
Inlet guide vanes, adder $16,000
Cooling water manifold, adder $8,000
Copper-nickel cooler bundle tubes, adder $7,000

Centac 3CII

Слайд 41Convenience of packaged unit
Complete packaged unit

AIR INLET SYSTEM
MOUNTED IN PACKAGE
Conventional

packaged unit

LOOSE DELIVERED
MOUNTED BY CUSTOMER ON-SITE
Inlet filter system
Air intake piping
Air intake screen
Air in/out compensators

ZH

Competition






Слайд 42Convenience of packaged unit
INTEGRATED & MOUNTED








Low noise Integrated Blow-off silencer
Piping
No need

for external air
Modulating blow-off valve
Integrated after cooler

LOOSE DELIVERED COMPONENTS











Relying on external instrument air

ZH

Competition




Слайд 43Convenience of packaged unit
INTEGRATED & MOUNTED
Cooling water manifold
Water in/outlet compensator
Condensate drain

system

LOOSE DELIVERED
MOUNTED ON-SITE

ZH

Competition



Слайд 44Gearbox configuration
HORIZONTALLY-split gearbox









PROCESS REQUIREMENT
Reliable
Easy inspection & maintenance
Integration of gearbox and donut

coolers







More high-speed rotation components

ZH

I-R CENTAC

1

3

2

WEAK POINT

Слайд 45High speed and Low speed bearings
AXIAL FORCES
in TWO DIRECTIONS







Reliability and

safe design
Sleeve bearings on low speed shaft >> extended lifetime

THRUST COLLAR
in ONE direction









Sensitive to varying load/unload cycles >> only CPC
Risk of metal fretting

ZH

I-R CENTAC

Слайд 46
Designed for easy maintenance
HORIZONTALLY-split
Gearbox and bearings









Inspection of internal parts:
2 ½

hours
PROCESS REQUIREMENT

VERTICALLY-split gearbox










Inspection bearings: 30 hours !
High maintenance cost
Only AGMA Q11/Q12

ZH

I-R CENTAC

Extremely high service cost



Слайд 47Reliability first with quality gears
COMPLETE GEAR/PINIONS
AGMA Q13
Highest quality in industry

Increase of

reliability
Lower mechanical forces
Lower noise levels
Reduced gearbox losses



AGMA Q12
Replacement item

ZH

Competition

Слайд 48Designed for easy maintenance
MICRO SPLIN
Disassembly of impeller on-site
Micro-splin attachment avoids fretting

corrosion


POLYGONE SHRINK FIT + BOLT





Difficult to (dis)assemble
High risk of fretting


ZH

I-R CENTAC

Слайд 49Designed for easy maintenance
FIXED GEOMETRY
Less stable
Low frictional losses
Low manufacturing cost
Sensitive to

oil quality
Very small tolerances
to maintain stability during start-up
Complete compressor disassembly required for inspection or replacement

ZH

I-R CENTAC


TILTING PAD
HORIZONTALLY-SPLIT
Maintenance and inspection






Thrust bearings for axial forces

Highest stability and reliability
Inspection & replacement on-site

Слайд 50No dependence on external air

ZH
I-R CENTAC
Carbon rings
for oil and air

seal

Seal air required
to ensure oil-free air

CARBON RING AIR SEAL
LABYRINTH OIL SEAL







Patented combination
Double protection
No external air
Minimal losses


Слайд 51Reliability first with Stainless Steel
STAINLESS STEEL
Superior corrosion resistance
Welded construction

Water-in-tubes, straight
Rodding with

bundles in-place

COPPER
Both for tubes & fins
Fins: copper with solder coating
Cu + Al > galvanic corrosion
Prone to water leaks
Air-in-tubes
Chemical cleaning, no rodding

ZH

I-R CENTAC

Слайд 52Designed for easy maintenance
COPPER
Coolers are consumable parts

Chemical cleaning
Corrosed internals




Stainless steel extremely

expensive option
Copper Nickel optionally

ZH

I-R CENTAC

Cooler performance not affected due to corrosion-resistant coating





Clearances between impeller and inducer not affected over time due to coating

WEAK POINT

Слайд 53Designed for easy maintenance
HORIZONTALLY-split gearbox
Only 250 l
Operating life time over 2

years with sampling after the second year

Increased uptime, reduced downtime

OIL TANK OIL QUANTITIES
Oil containging frame
400 l oil
Expensive oil
Operating life time 2 years


ZH

I-R CENTAC


Designed for service revenues

Слайд 54Designed for easy maintenance
MOTOR DRIVEN DEMISTER








No external air
No fumes leaking to

atmosphere

CARTRIDGE








visible oil spill to atmosphere


ZH

I-R CENTAC


Слайд 55Efficient operation with IGV
INLET GUIDE VANES (IGV)
save 9% of energy
Redirecting

the flow path by pre whirling
Increased turndown
Efficient control in case closely positioned to the first impeller

THROTTLE VALVE
Higher energy consumption and smaller turndown
throttling the flow increase pressure drops
>> money down the drain






IGVs on Centac not effective due to location

ZH

I-R CENTAC

Слайд 56Capacity control

Inlet throttle valve
Standard Inlet throttle valve
pneumatic actuator requires externally-provided instrument

air at 60-90 psig (4- 6 bar)
Waste of energy at part load up to 9% compared to inlet guide vanes

Слайд 57Capacity control
Optional inlet Guide Vanes are not effective as the distance

to the first stage is too large
$6,000 to 12,000 depending on machine size


Optional
Inlet Guide Vanes (IGV)

Слайд 58No dependence on external air
ELECTRICAL ACTUATORS

No dependence on external air supply
On

IGV and Blow-off valve


PNEUMATIC ACTUATORS

Machine trips due to failure in supply of instrument air


ZH

I-R CENTAC

Слайд 59Aftercooler
Cooling Water Manifold
Check Valve
Blow-off Valve
Blow-off Silencer
Control Valve
Inlet Filter/Silencer
Anchor Bolts Special Foundation
Inlet Compensator
Outlet

Compensator

Additional Piping



External Buffer Air









UNIQUE
COMPLETE
SOLUTION

CREATING CUSTOMER’S ADDED VALUE


Competitor’s Puzzle













ZH SERIES

Слайд 60Thank You

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