Sullair Oil-Free Products Product Overvie Oil Free Products.pdf · Oil Free Line-Card Sample. Sullair Oil-Free Dry Screw. Confidential and Proprietary 17 DS Oil Free Screw Oil Free

Sullair Oil-Free ProductsProduct Overview

Confidential and Proprietary

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Oil Free Line-Card Sample

Sullair Oil-Free Dry Screw


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DS Oil Free Screw

Oil Free Screw


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DS Oil Free Dry Screw ISO 8573-1 Class 0

Oil Free Dry Screw

▪ DS13 75-150 kW

▪ DS18 150-260 kW

▪ Variable Speed Drive

▪ Air-cooled and water cooled


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DS Air End Design

Gear Box:

▪ The two individual stages are flanged mounted to a common speed-increasing gearbox with a common bull gear which drives each stage pinion for its optimum performance.

Rotors and Rotor Housings:▪ Rotors are high efficiency asymmetrical profile that are

coated to inhibit corrosion and prohibit contamination. The coating is approved by the U.S. Food and Drug Administration (FDA) as a food-grade (PTFE) to ensure contaminant-free conditions.

▪ 100% oil-free air▪ AGMA 12 precision drive gears are designed to extend air

end life.▪ Element speeds are much lower than the critical speed▪ Stainless steel high pressure elements


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DS Air End Design

Bearing

(4) Floating carbon ring air seals - with stainless steel lantern ensure 100% oil-free operation

▪ (4) roller bearings

▪ (2) angular contact ball bearings (Axial Radial Thrust)

▪ No thrust piston

▪ SKF high precision, anti-friction bearings with an L10 design life of over 100,000 hours

Seal

▪ (4) floating carbon ring air seals - with stainless steel lantern ensure 100% oil-free operation

▪ Reverse flow thread labyrinth oil seal

▪ Optional buffer gas seal for nitrogen compressor application

Labyrinth oil seal Carbon air seal


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DS Rotors

Rotors—High efficiency asymmetrical profile. Rotors are machined from a single piece of bar stock and ground to the finished shape. Male rotors are coated with an FDA approved food grade PTFE corrosion resistant coating. All rotors are finished ground and dynamically balanced. Rotors are of a particularly rugged design and are suitable for full voltage starting.

Rotor Housings—Cast and jacketed to assure thermal stability. Air passages are coated with food-grade PTFE.


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DS 2nd Stage

2nd Stage HP Element Features

▪ Stainless steel with PTFE FDA coating▪ Additional coating in housing chamber▪ Special 5/7 screw profile▪ (4) Carbon ring air seals


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DS Features

Intake Filter/Silencer—Heavy duty - three stage - dry type, with dust collector. The first stage is a built in centrifugal type using turning vanes. The primary and secondary stages are easily replaceable. Paper elements are rated at 99.9% efficiency per SAE J726. The filter is machine mounted with the intake inside the enclosure at the cooler end. The system has a differential pressure alarm on the control panel.

Inlet Valve—Normally closed - wafer type - angular seating butterfly valve with double acting hydraulic actuator.


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DS Intercooler & Aftercooler

Intercooler & Aftercooler▪ Stainless steel heat exchanger tubes▪ Water in tube - compatible to API Standard▪ Aluminum fins

Water Separation▪ Condensation fails from cooler fins▪ Stainless steel centrifugal separator

Drains▪ Zero loss drain▪ Manual valve drain


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DS Lubrication System

Lubrication System▪ Independent lubrication system▪ Auto or constant operation

Oil Pump▪ Electric motor drive▪ Full flow operation independent of VSD

Oil Cooler▪ Shell and tube design▪ Stainless steel tubes

Oil Filter▪ 6-micron full flow with internal bypass▪ Fiberglass filter media


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DS Main Motor & Coupling

Motor▪ ODP premium efficient motor▪ Class “F” insulation ▪ Flanged mounted ▪ Proper alignment guaranteed▪ TEFC IP55 motor option available

Coupling ▪ Flexible elastomer coupling▪ Safety guard


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DS Oil Sump Breather & Injector

Air Ejector▪ Coalescing filter▪ Venturi effect


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DS Silencer & Check Valve

Silencer▪ Installed on the high pressure 2nd stage▪ Helps reduce overall sound emitted by

compressor

Check Valve

Prevents reverse air flow when compressor is unloaded or stopped

Constructed with a stainless steel spring


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DS Control Panel

Sullair Supervisor II Microprocessor▪ Accurately monitors and controls the

compressor▪ Built-in sequencing capabilities for

automatic load sharing▪ Constantly displays essential functions

and applicable alarms


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DS Variable Speed Drive

VSD Drive▪ 70% turn down from full load to improve

operating efficiency▪ Fan cooled▪ Integrated converter with EMC filter ensures

operation unstable electrical conditions

Sullair Oil-Free Centrifugal


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Centrifugal Compressor Theory

Positive Displacement Compression

One way that air can be compressed is through positive displacement. This process compresses the air by decreasing the volume in which it is contained. Positive displacement compressors must have very tight clearances between the moving surfaces in order to produce the required air pressures and flows. As a result, the moving parts must be lubricated, or coated with special materials to increase their limited lifespan.

Reciprocating compressors use a piston and cylinder design to compress air. As the piston strokes to one end of the cylinder, the air pressure is increased, opening the discharge valve and discharging the air at increased pressure and temperature.

Screw compressors are a more popular positive displacement design, where two parallel rotating ‘screws’ squeeze the air along their meshing points, causing an increase in air pressure along the screw length.


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Dynamic Compression

An alternative method of compressing air (or a gas) is through the principle of dynamic compression.

In this method, high speed rotating impellers greatly increase the velocity of the air, through the principle of centrifugal force. Then, as the air leaves the impeller, it is forced through a small space, slowing down the air and causing its pressure and temperature to increase.

The air enters the center, or eye, of the impeller, and the high rotational speed of the impeller causes the air to be discharged from the edges due to centrifugal force. As this high velocity air leaves the impeller, it enters the small space of the diffuser. The non-rotating diffuser surrounds the impeller, reducing the velocity of the air, causing the air’s pressure and temperature to increase.

A “snail-shaped” scroll or volute casing surrounds the diffuser, providing a smooth exit path with minimal pressure loss. If higher pressure is required, the air goes through an intercooler, and then on to additional compression stage(s).


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Airflow

The air enters the compressor through the inlet connection, which is proportioned to minimize shock or turbulence as the air enters the impeller. The impeller imparts the velocity to the air and delivers it to the diffuser where the flow is decelerated and the velocity energy is gradually converted to pressure energy. The diffuser portion of the compression stage can have vanes or can be “vaneless.”

The diffuser creates a narrow passage channeling the air as it leaves the impeller into the volute section of the scroll where the air is collected. A shaft seal must be provided where the shaft passes through the scroll to prevent the air from escaping out of the scroll. When the pressure ratio exceeds the limit of a single stage compressor, a multistage must be used. This construction requires a return passage for the air leaving each scroll and to deliver it to the inlet of each succeeding stage. Keep in mind that the impeller is the only means of adding energy to the air and all the work is done in this element. The flow passages, as opposed to a reciprocating unit, are open throughout. There are no mechanical means of preventing back flow in the design of the unit, and it can occur when the compressor is shut down unless a check valve is used externally downstream of the compressor discharge.

Condensate drains are included as a part of each intercooler and aftercooler to remove condensate that has resulted from cooling the compressed air.


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AIR FLOW: 3-Stage Unit with Built-in Aftercooler

(1) Inlet filter (required)(2) Compressor inlet valve (3) 1st stage of compression(4) 1st stage intercooler(5) 2nd stage of compression(6) 2nd stage intercooler(7) 3rd stage of compression(8) Aftercooler (optional on most)

(9) Intercooler condensate drains(10) Temperature sensors(11) Compressor discharge valve (bypass or blow off*)(12) Blow off silencer (only required with BOV)(13) Discharge pressure sensor(14) Discharge check valve (15) System pressure sensor(16) Isolating block valve (required)

• The type of compressor discharge valve (11) selected is dependent on the customer’s system pressure requirements.• The discharge check valve (14) must be included in the discharge line to prevent reverse flow of the compressed air in the plant air

system.• The system pressure sensor location shown (15) is for the current Maestro control systems (close to the customer’s point of use).• The block valve (16) is used to isolate the compressor from the plant air system during compressor shutdown. • NOTE: An automatic block valve is strongly recommended as added protection in the event of discharge check valve leakage or failure.


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Typical Centrifugal Performance Curve at Design Conditions

DESIGN POINTEach centrifugal compressor is designed for a specified set of operating conditions that allow the compressor to deliver its design pressure and flow, at its design power.

The compressor’s design point is based on several specific jobsite conditions:▪ Inlet temperature to 1st stage of compression ▪ Inlet pressure▪ Inlet flow▪ Relative humidity▪ Coolant properties (temperature, flow,

composition)▪ Power supplied to compressor drive motor▪ Input speed to compressor gearbox

Understand that any changes to any of the specific design conditions will result in a corresponding change in the compressor output (pressure, flow, power). A second important factor is the specific pressure and flow requirements (demand) of the process. Low demand conditions result in increased system pressure, which can create compressor surging. Excessively high demand (above design) results in system pressure that is correspondingly below the design pressure.


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Centrifugal Compressor TheorySURGE

Surge is a momentary reversal of flow in the compressor. As the compressor discharge pressure increases, the discharge flow decreases. Increasing discharge pressure eventually leads to a point where the pressure developed by the compressor cannot overcome the system resistance. When this occurs, the compressor discharge pressure and flow abruptly reverses and goes backward through the compression stages. As a result, the discharge pressure drops rapidly due to the lack of air delivered into the discharge piping, and forward flow is resumed. If the conditions causing surge persist, the reverse-then-forward flow cycle continues. This is characterized by repeated slamming of the discharge check valve and an audible "whumping" noise. Continuous operation in surge will cause high interstage air temperatures (and high pinion vibration on some models), resulting in compressor shutdown. Therefore, all centrifugal compressors must have a control system to prevent continuous surging.

CHOKE

If the compressed air system demands exceed the compressor’s design, system pressure decreases, and the compressor delivers an increased volume of air. If the system pressure continues to decrease, the volume of air delivered from the compressor will eventually increase to its maximum possible flow. At this point, the flow is said to be choked because further reduction in system pressure does not result in additional air volume delivered from the compressor. Choke is the maximum flow that can be passed through the compressor.

TURNDOWN

Turndown is the ability of the centrifugal compressor to maintain its discharge pressure set point over a range of reduced discharge flows. With the control system set to maintain a fixed discharge pressure value, the compressor’s inlet valve opening will be adjusted by the control system in response to varying system air demands. As the inlet valve moves in the closed direction, the flow through the compressor decreases. As the flow decreases, the compressor moves closer to a minimum flow surge condition. When surge occurs, the turndown range at that pressure set point is established.

Sullair’s control systems routinely have an anti-surge control set point 5% above the minimum flow surge point. This allows stable compressor operation during periods of large demand swings.


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▪ Each centrifugal application requires a custom sizing curve

▪ Sizing require the ambient conditions, cooling water temp, and pressure and flow requirements

▪ The curve will show the flow and power expected at the specified pressure set point

▪ Flow will change as pressure or ambient conditions change.

▪ Lowest turndown is measured where the surge line meets the pressure set point

▪ Our curves are ±0% for flow and ±4% for power


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Centrifugal Compressor Control

Auto-dual Control <Standard>

Inlet Guide Vane

Blow off Valve

Air Tank

To Plant

PIC

(1) Unload operating (or at start)Inlet Guide Vane: Full CloseBlow off Valve: Full Open

(2) LoadingInlet Guide Vane: Full OpenBlow off Valve: Full Close

(3) Constant pressure operatingInlet Guide Vane: PIC Control

(4) UnloadingInlet Guide Vane: Full CloseBlow off Valve: Full Open


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Centrifugal Compressor Control


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Centrifugal Compressor MechanicsA Complete, Compact Package

▪ Compact compressor frame is easily mounted on a common skid with motor

▪ Integral intercoolers and aftercooler offer compact footprint and efficient air passages

▪ Front mounted cooler caps offer easy water connections and maintenance

▪ Front mounted air intake and top mounted outlet offer easy and efficient installation

▪ Shaft mounted main oil pump offers reliable lubrication even during power outages

▪ Ease of access to all sides of the compressor simplify reliability monitoring and maintenance


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Centrifugal Compressor Mechanics

▪ Oversized oil cooler is easily accessible and serviced

▪ Duplex oil filter can be serviced during operation

▪ Venturi of electric air ejectors draw a vacuum in the gearbox to eliminate oil leaks

▪ Auxiliary electric oil pump provides lubrication during startup and shutdown

▪ Drive coupling has easy access for inspection and maintenance

▪ Allen Bradley or Siemens PLC controls ensure reliable control and compatibility with customer plant controls

A Complete, Compact Package


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Centrifugal Compressor Mechanics

Inside the Gearbox▪ Horizontal Split Line allows

easy access to inspect and replace parts within the gearbox

▪ A heavy-duty bull-gear ensures high efficiency and tolerance to upset thrust loads

▪ Pinion thrust collars transfers axial loads to the larger bull-gear thrust bearings for long bearing life

▪ High speed 5 pad tilt bearings provide long life and low vibration

▪ Aluminum labyrinth air and oil seals provide long life and do not require sealing air

▪ Atmospheric space between air and oil seals ensures no oil contamination can ever enter the product stream


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Centrifugal Compressor TheoryINLET TEMPERATUREInlet temperature changes produce large changes in performance. In cold weather, a centrifugal can deliver much more weight flow of air than in warm weather if the drive is sized to provide the additional power required.

• Lower temperature:• Increases the surge pressure• Increases the maximum capacity (weight flow) at a given discharge pressure• Increases power consumption (horsepower)

• Higher temperature:• Decreases the surge pressure• Decreases the maximum capacity (weight flow) at a given discharge pressure• Decreases power consumption (horsepower)

INLET PRESSUREChanges can be caused by fouled inlet filters or changing barometric pressure.

• Lower inlet pressure:• Decreases the discharge pressure along the entire curve• Decreases the maximum capacity (weight flow)• Decreases power consumption or horsepower (due to reduced weight flow)

RELATIVE HUMIDITYHumidity has a slight affect on discharge pressure and a greater affect on weight flow.

• Higher relative humidity:• Decreases the discharge pressure at surge• Decreases the maximum capacity (weight flow)• Decreases the flow at which surge occurs• Decreases power consumption (horsepower)

The higher condensate losses on a high humidity day results in a reduction of the flow delivered to the plant air system.


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Centrifugal Compressor TheoryOTHER CAUSES THAT AFFECT COMPRESSOR PERFORMANCE:

Dirty Inlet Air Filter Element(s) – Will cause a reduction in inlet pressure and / or flow, reducing the compressor output accordingly. This will also result in an increase in motor amperage as the control system will try to increase the inlet valve opening to compensate for the restricted air flow into the compressor.

Dirty Impellers – Will have a similar affect as dirty inlet air filters. Impellers can get quite dirty in ‘rough’ environments or in cases where incorrect inlet filter elements are used.

Intercooler Condensate Problems – If uncorrected, can cause damage to intercoolers, inlets, impellers and diffuser plates, reducing the compressor’s output accordingly.

Fouled Intercoolers – This can occur in the tubes (coolant side), or in the aluminum fins (air or condensate side). When intercoolers become fouled, their design heat transfer performance is reduced, causing an increase in air temperature to succeeding compression stages. The compressor performance reduction is proportional to the increase in interstage air temperatures.

Jobsite Voltage Problems – In some cases, the site voltage to the main drive motor can drop, resulting in an increase in motor amps. The compressor control system will limit the opening of the inlet valve accordingly, reducing the output until the voltage returns to the correct value.

Inlet, Diffuser, or Impeller Erosion – Damage to these critical parts can cause a significant reduction in performance. The most common causes are failure to remove intercooler condensate or inadequate inlet air filtration.


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SUMMARY

Centrifugal compressors use the principle of ‘dynamic compression’, resulting in much fewer wearing parts, as compared to positive displacement compressors.

As is the case with all compressors, centrifugals are designed to operate at specific jobsite conditions. In addition, a centrifugal is designed to operate at a very specific input speed.

Centrifugals have an operating, or turndown range that allows them to adapt to varying customer air demands.

The key elements to the long term success of a centrifugal compressor are to keep the inlet filters and intercoolers clean, and to properly maintain the supporting systems (lubrication system, drive motor, controls, etc.).


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T-Series Centrifugal ISO 8573-1 Class 0

Oil Free Centrifugal

T2 – 2 Stage: 110kW to 260kW / 4BARS to 9.3BARSTRA – 3 Stage: 298kW to 559kW / 2BARS to 9.9BARSTRE – 3 & 4 Stage: 372kW to 932kW / 2BARS to 12BARST3 – 3 Stage: 745kW to 1319kW / 2BARS to 12BARSTRX – 3 Stage: 894kW to 1789kW / 2BARS to 12BARS


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T-Series Design

Standard Features Benefits

Titanium Impeller with high strength and efficiency

High strength and are free of corrosion and wear

100% oil-free “Class 0” Certification to ensure 100% oil free air

Energy saving inlet guide vanes increasing the turndown capacity of

the compressor

Reduces energy consumption –lowest power cost

Constant pressure, load/unload control

Modulation provides a constant discharge pressure with variable

capacity from design to zeroHorizontal split designed gearbox,

maintenance friendlySimply removing the gear cover to

inspect all moving parts


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Gearbox

▪ Quick and simple inspection of all moving parts performed by removing gear cover

▪ This includes the bull gear, pinion gear, shaft seal, bearings, etc.

▪ Horizontal split and single piece bearings and seals eliminate risk of contamination

▪ Simplicity in design increases reliability and speed of inspection/maintenance


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Rotors

▪ Single rotating assembly for each stage

▪ Optimal speed

▪ High efficiency

▪ Impeller design

▪ Backward leaning

▪ Peak performance

▪ Stable operating range

▪ Titanium construction

▪ High strength

▪ Free of corrosion and wear


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Impellers

▪ 150 years of rotating machinery E\experience

▪ Designed with Computational Fluid Dynamics (CFD) tools

▪ Data collected from 9,000+ machines


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Oil Pump

▪ Self-contained lubrication for gears and bearings

▪ Dual Pump System – electric motor and shaft driven

▪ Constant oil flow, even during shutdown or main power failure

▪ Superior long-life lubricant

▪ Standard features: integrated 10 micron oil filter, thermostatic valve, and pressure regulator

▪ Options available: dual oil filter with transfer valve


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Pinion Bearings

▪ Tilting 5 pad journal bearings – excellent lifespan

▪ Flexible pads tilt for optimal shaft centering

▪ Pad inclination adjusts automatically in response to bearing load changes

▪ Response to load changes is smooth and rapid


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Air & Oil Seals

▪ Labyrinth air and oil seals -maintenance free, long-lasting, no need for seal gas

▪ The seals are matched and fit to the rotor shaft with a close clearance.

▪ Atmospheric air space between the air/oil labyrinth seals eliminates oil contamination

▪ Split design for ease of inspection and maintenance


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Thrust Collars

▪ Thrust load is transmitted to bull gear via thrust collars

▪ Bull gear is supported by tapered bearings

▪ Provides increased stability and mechanical efficiency


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Coolers

▪ Intercooler and Aftercooler - removable, water in the tube, bundles

▪ Cools the inter-stage air to maximize the compressor’s overall efficiency.

▪ The intercoolers and aftercooler are plate-fin extended surface type

▪ High-quality tubes with no internal obstructions for easy inspection and cleaning

▪ Both cooler bundles are interchangeable and designed for easy inspection

▪ Standard cooler materials: copper tubes, carbon steel tube sheets, and aluminum fins


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Inlet Guide Vanes

▪ Variable inlet guide vanes:

▪ Maximize performance

▪ Provide precise compressor inlet stream control

▪ Provide energy savings when operating at turndown conditions.

▪ When operating in turndown, inlet guide vane allows up to 9% efficiency


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Control Systems

▪ High reliability CPU (Siemens or Allen Bradley PLC)

▪ Abundant digital and analog I/O

▪ Smart and sophisticated panel

▪ Power failure function

▪ Various and perfect control method

▪ Clear color LCD display

▪ Touch panel, easy operation

▪ Operating status and alarms displayed

▪ Trend graph of each operating data

▪ PROFIBUS (Standard)

▪ MODBUS RTU (Option)

▪ Ethernet (Option)

▪ Constant pressure + load/unload

▪ Full constant pressure

F-Series Centrifugal


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• Main air and nitrogen compressors

• Recycle nitrogen and booster air compressors

• Oxygen compressors

MAC and N2 – F25-44 Series


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• Model: f 25/30/36/44

• Packaged 1-4 stages

• Flow Rate: 33.9～566 m3/min

• Suction Pressure: -2.0～20 kPaG

• Discharge Pressure: 1～15.9BARS (f 25/30)

1～24.9BARS (f 36/44)

• (2600) Operation

F25-44 Range


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• Model: f 53/64/78/95/115

• Non-Packaged 3-4 stages

• Flow Rate: 566～3341m3/min

• Suction Pressure: -2.0～20 kPaG

• Discharge Pressure: 1～24.9BARS (f 53/64)

1～15.9BARS (f 78/95/115)

• (31) Operation


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Recycle and BAC – F25-F53 Series


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• Model: f 25H/30H/36H/44H/53H

• 3-4 stages

• Flow Rate: 38.2～339.8 m3/min

• Suction Pressure: 3.9～9.9BARS

• Discharge Pressure: 15.9～49.9BARS

• RNC: (39) Operation

• BAC: (24) Operation


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F25-44 System Layout


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• Packaged f 25/30/36/44

IGV Compressor

Local Panel

Gas Cooler

Oil Lub. System

Exhaust Fan

Motor

Compressor Bed with Oil Tank



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• Semi-Packaged f 53/64

Compressor

IGV

Gas Cooler Compressor Bed (Concrete or Steel)

Oil Lub. System

Oil Mist Separator

Motor



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• Non-Packaged f 78/95/115

Compressor

IGV

Gas Cooler Compressor Bed (Concrete or Steel)

Oil Lub. System

Oil Mist Separator

Motor

O2 Systems


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• Model: f 25/49/64, 1-6 stages

• Flow Rate: 481～849.5 m3/min

• Suction Pressure: 5～50 kPaG

• Discharge Pressure: 2.7～ 30BARS

• (22) Operation

• (86) Single Stage Operation

O2 Product Range


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Sullair Oil-Free ProductsApplications

Why Oil-Free?


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Oil Free should be the RULE, not the EXCEPTION

“A customer does not need to ask for oil free for it to be offered to them.”

▪ Oil free air is not just for processes that require clean, dry air

▪ Every customer would prefer oil free air, if offered

▪ All customers will benefit from not maintaining oil removal equipment

▪ Long term operation of centrifugal and dry screw products save money when lubricants and maintenance are considered

▪ Initial higher investment will be offset by lower maintenance and operating costs in the long term

Why Oil-Free?


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▪ 100% Class ZERO oil free air: ISO 8573-1

▪ Low maintenance costs

▪ Low energy consumption at full load and part load

▪ Dry Screw VSD to match customers demand

▪ Centrifugal base load and up to 50% turndown

▪ Small footprint

▪ Large HP range within frame

▪ Wide operating pressure within frame range

▪ Less pressure drop across the system

▪ Heat of compression dryer option – energy efficient

Typical Oil-Free Customers


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▪ Large air consumers▪ Pharmaceuticals▪ Food/beverage▪ Power gen▪ Metallurgical▪ Petrochemical▪ Industrial gases▪ General manufacturing▪ Electronics▪ Snowmaking▪ Mining▪ Textiles▪ Chemicals▪ Glass

Sullair Oil-Free ProductsCompetition Analysis


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Becoming the

best place to work

Becoming our customers’ most valued partner

Providing the

highest returns

in the industry

Leading Accudyne to Becoming a Great Company

High Ethical Standards

Employee

Well-Being

Flawless

Execution

Corporate Citizenship

CustomerIntimacy


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For more information, please contact:

Name: Marek Cieslak

Title: Area Sales Manager

Email: [email protected]

Phone: +48 508 23 99 73

Documents

Sullair Oil-Free Products Product Overvie Oil Free Products.pdf · Oil Free Line-Card Sample. Sullair Oil-Free Dry Screw. Confidential and Proprietary 17 DS Oil Free Screw Oil Free