Blower

ITEM1.16 BLOWERS for AERATIONTANK 022MEK001/123

Handbook for Operation and Maintenance of Compressor KA5S-GK200STC-GO (7-1-KA1KG)

SIEMENS Order no. COMPRESSOR Serial no.

62008043 8043 8044 8045

PROJECT:

Nevsehir WWTP

Energy Sector

Siemens Turbomachinery

Turbomachinery Equipment A/S

Allegade 2, DK-3000 Helsingr, DenmarkTel.: +45 4921 1400 Fax: +45 4921 5225

Siemens Turbomachinery Equipment A/SAllegade 2, DK-3000 Helsingr, DenmarkTel.: +45 4921 1400 Fax: +45 4921 5225

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 2/54

CONTENTS Chapter 1 Operation of the compressor 0. EC Declaration of Conformity Important Machinery - Safety Requirements Shipment - Storage - Installation Shipment Storage Installation Pipe Connect./Permissible Loads Tech. Doc. "Allowable Load" Tech. Doc. "Installation" Technical Specifications Technical Specifications for Compressor. Tech. Doc. "Oil Specification" Tech. Doc. "Oil Specification" Unit Design Main Construction Compressor - Main Parts Compressor Casings Impeller/Rotor Shaft Sealings Diffuser System Gearbox - Main Parts Gear Casings Shafts - Gearwheels Bearings Oil Sealing Base Cone Diffuser Blow-off Valve Check Valve Coupling - Drive Motor/Gearbox Inlet Silencer Drawing Inlet Filter Drive Motor Reference to Manufacturers instruction Acoustic Enclosure 930 940 083 930 940 077

1. 1.1 1.2 1.3 1.3.1

930 910 007 930 840 008

2.

930 870 003 930 870 005

3. 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.4 3.5 3.6 3.7 3.8 3.9 3.10 4.

933 005 7240

5.

6. 6.1 6.2 6.3

Lubricating Oil System Design and function Oil filling Oil Types Accessories Control System Local Control PI-Diagram Compressor Instability Surge Recirculation

7. 7.1 7.2 7.3 7.3.1 7.3.2

935 004 939

Created on 16-02-2009 at 16:00:35, LF 01-Operation_KA5S-GK200.doc



Page 3/54

8. 8.1 8.2 8.3 8.4 8.5 8.6 9. 9.1 9.2 9.3 9.4 9.5 9.6 10. 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8

Instrumentation Thermostat E151 Thermostat E138 Thermostat E104 Thermostat E111 Pressostat E106 Surge Controller SUC-3, Drawing Start-up Preparations Simulated Test Run of Compressor Test Run of Compressor Master Control Start General Trouble Shooting No Flow, no Pressure at Start Insufficient Flow Too Great Power Consumption Surge / Recirculation Noisy Operation / Vibration Level High Bearing Temperature too high Oil Pressure too Low Oil Temperature too high

933 0061480

Chapter 2 Maintenance of the compressor11. 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 12. 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8.1 12.8.2 12.8.3 12.8.4 12.8.5 12.8.6 Maintenance Introduction Service intervals Service Simulated Test Run Test Run of Compressor Master Control Panel Inlet Silencer Disposal of waste Orders for spare parts Dismounting and Mounting Tech. doc. Coupling Alignment Outer diffuser System Adjustment of Clearances and axial play Tech. doc. Internal Gaps Weight of single parts Special tools Tightening torque Dismounting and remounting drawings Compressor-gearbox, drawing Rotor drawing Outer diffuser System drawing Inner diffuser System drawing Lube oil pump drawing Aggregate drawing 930 920 041UK

930 920 036UK

9330502950 9330523220 9330554160 9330554180 GK200S017 9330503140




Page 4/54

Chapter 3 Dimension DrawingDimension drawing no.14541

Chapter 4 Local Control PanelOperation Manual Circuit diagram LC-1AT

Chapter 5 Master Control PanelOperation Manual Circuit diagram MCP-3T

Chapter 6 Main MotorOperating instructions for Schorch motors

Chapter 7 Acoustic EnclosureMounting instructions for Acoustic Enclosure Acoustic Enclosure, drawing

Chapter 8 AccessoriesCoupling Blow off Valve Actuator for Blow off Valve Check Valve Actuators for Diffuser Lube Oil Filter Lube Oil Cooler Air Filter Bags Thermostats Pressostat Thermometer Manometer Surge Detector Compensator Cone Diffuser Silencer for Blow of valve Noise hood Fan

Chapter 9 Performance CertificatesCompressor test certificate




Page 5/54




Page 6/54

IMPORTANT (TECH.DOC. 930940077UK) This compressor unit is a high-capacity machine. If not operated correctly it will be damaged and also expose the personnel in the immediate vicinity of the machine or the electric wiring to hazards. The Instruction Handbook shall be studied entirely prior to final installation, electric connection, and start-up. Especially, note the following sections.

Safety of Machinery: Installation: Direction of Rotation:

See the handbook, 0 (See the handbook) Note that even a minor period of operation in the wrong direction of rotation will damage the bearings in gear and compressor. (See the handbook) Check of alignment before start. (See the handbook) After about 10 operating hours the coupling bolts shall be re-tightened. (See the handbook) SIEMENS recommends having the oil analyzed after approx. 500 operating hours, and then to decide the intervals of oil change on the basis of regular oil analyses. (See the handbook) Grease lubricated bearings in electric motors must be lubricated immediately after start-up of the unit. Correct type and quantity of grease as well as frequency are stated on the motor nameplate and/or in motor supplier's instruction. In case of oil lubricated bearings in electric motor, oil quality and oil level should be checked before start-up. The customer is obliged to and responsible for compliance with the lubrication instructions.

Coupling:

Re-tightening:

Oil Check:

Electric motors

In case of defects, damage, or faulty delivery, the supplier shall be notified immediately.




Page 7/54

0.

MACHINERY SAFETY REQUIREMENTS

PUTTING INTO SERVICE

The compressor unit shall only be operated in compliance with the operating conditions agreed upon, as indicated on the nameplate and described in Technical Data.

LIFT

The weight of the compressor unit is stamped on the consignment. Lifting is carried out according to Instruction Concerning Straps.

The compressor is started from the local panel. START BY MANUAL CONTROL See operation manual for Local Control Panel.

The compressor is stopped from the local panel. STOP BY MANUAL CONTROL See operation manual for Local Control Panel.

EMERGENCY STOP

An emergency stop (EN418) is positioned on the front of the local control panel. The emergency stop is not to be activated unless hazardous situations threaten or have already occurred. The safety monitor activates the emergency stop function when a control device is activated by a malfunction. All functions will stop immediately. Under these circumstances the compressor will emit a lot of noise. The emergency stop shall not be used as an ordinary stop function, as repeated emergency stops may damage the compressor. Compressor units may be set in remote control. See operation manual for Local Control Panel and Master Control Panel in section 4 and 5 of the Operation Manual. In this mode the compressor can start and stop without forewarning. An ISO 7000-0017 symbol warns of remote control start/stop. In this mode all guards must be correctly mounted and no persons allowed in the immediate vicinity of the rotating machine parts.

AUTOMATIC START/STOP

MECHANICAL HAZARD

Fixed guards acc. to EN294 & EN953 shall protect all rotating parts. The guards are not to be removed unless the machine is safeguarded against unintentional start. Loose clothing is to be avoided and it is advisable to keep a safe distance as long as the machine is in the remote control mode. Do not mount the compressor; the surface may be greasy and slippery.

INLET SYSTEM

The inlet system shall be correctly mounted before start of the compressor. Avoid blocking the inlet and staying near connected inlet channels when the machine is ready to start.




Page 8/54

HOT SURFACES

A sign warning of hot surfaces has been placed directly on the machine. It is indicated by symbol EN1012-annex 3. Avoid touching the hottest surfaces, which are normally more than 70C.

NOISE HAZARD

Noise emission from the compressor unit is measured acc. to ISO3744, normally without silencer hood. The measurements are recorded in the noise certificate. See certificates. At the entrance to the compressor room and/or silencer hoods an ISO3864 warning sign is placed which illustrates the use of ear protection.

ELECTRICAL HAZARD

Any contact with electrical high-/low-voltage installations is to be avoided as long as the machine is connected to the power supply. See EN60204-1. Check at regular intervals that all main components of the machine are correctly grounded.

SPECIAL TOOLS

The compressor delivery includes a toolbox with special tools. The tools shall only be used as described in the paragraph on assembly and disassembly of the compressor.

MAINTENANCE & REPAIRS

Repairs and maintenance work is only to be performed when all energy sources to the machine have been properly isolated/insulated. The emergency stop shall be activated, the motor disconnected and the terminals short-circuited. The danger of back flow from the pipe system is safeguarded against by either closing and locking a valve positioned immediately after the check valve or by placing a blind flange upstream by the check valve. Sign: "Warning: Maintenance work in progress".

NOTIFY!

In case SIEMENS deliver consignments that are neither assembled nor serviceable machine units, e.g. compressor units without drive motor and/or control systems, the following will apply: "The compressor unit is comprehended by Machine Directive 89/392/EEC and appurtenant amendment directives, and shall not be put into service until the entire unit, of which it is a part, complies with the said Directive and appurtenant normative standards.




Page 9/54

1. 1.1

SHIPPING - STORAGE - INSTALLATION SHIPPING On receipt of the compressor unit, check that the individual parts correspond with those listed on the delivery note. When unloading, check immediately for possible damage of the compressor unit that may have happened during shipment, such as damaged dents, scratches, corrosion, torn electric cables, bent pipes, or the like. In case of defects or damage, the carrier and supplier shall be informed immediately. The aggregate shall only be lifted with straps fastened to the 4 lifting hooks mounted on the base. In order to avoid squeezing of instruments, piping, etc., use a lifting yoke. Weight of compressor aggregate: See section 2. Use of straps: See fig. below.

1.2

STORAGE Prior to leaving SIEMENS, the compressor aggregate has been submitted to a test run. After the test the lubricating oil has been drained off, preservative oil applied and pumped through the lubricating oil system, and all excess preservative oil drained off. All untreated parts of the aggregate, which are likely to corrode, have been treated with a corrosionpreventing agent.




Page 10/54

This ensures that the compressor aggregate is protected against corrosion for a minimum of 6 months, provided that it is stored indoors. It is not necessary to remove the corrosionpreventing agent before starting up the aggregate, as the preventive agent does not affect the lubricating oil. If the compressor is stored for more than 6 months, it shall be treated with a long-term preventive agent. A corrosion-preventing agent used for long-term storage will have to be removed before start-up. This is done by disassembling and cleaning all the compressor parts. In this case only SIEMENS service engineers shall prepare the compressors for operation. The preparation shall be carried out in a dry and clean environment. Do not use the compressor unit or parts of it as scaffolding. For further information, require technical information 930920009UK.

1.3

INSTALLATION It is possible to mount / install the compressor prior to removing a long-term corrosion protection. The compressor can be mounted on any level floor that can carry the weight. A special vibration damping concrete foundation is only used in exceptional cases.

The compressor shall be mounted on vibration damping machine mounts, the underside of which can be glued directly to the concrete floor (see mounting instructions) or the machine mounts can be screwed or welded to its base, depending on the floor construction. In case of uneven floor construction insert shims in order that the machine mounts get in touch with the floor (see fig.).

Important! Before the compressor aggregate is fastened to the floor, check its position to make sure that flanges (and possibly other pipe connections) are placed correctly with a view to the final pipe installation. Do not uncover the flanges until the pipe system is ready for installation. This prevents foreign substance from entering the compressor. All pipe systems shall be cleaned and inspected before they are connected to the aggregate. If the drive motor shaft has been securely fastened for shipping, this fastening shall be removed and the dismounted coupling remounted.

1.3.1

PIPE CONNECTIONS/PERMISSIBLE LOADS It is essential that there is a flexible connection in the following places: - between compressor discharge and cone diffuser - between compressor inlet and air inlet duct. Permissible loads: See Technical Information 930910007.UK.




Page 11/54

ALLOWABLE LOAD ON COMPRESSOR DISCHARGE FLANGE 930910007UK

Reactions of piping systems connected to turbocompressors, if of sufficient magnitude, will result in misalignment of the compressor sufficient to cause rough operation and in worst case serious mechanical damage. The external load comes from thermal expansion, pressure loads the weight of the pipe system, and is mainly transmitted to the compressor through the expansion joint, attached on the discharge flange. If the external loads on the compressor are limited to the figures in the table below, the loads should not influence the compressor operation.

FAX FLAT M

= = =

Forces in the discharge pipe direction Forces perpendicular to FAX Moment in any direction

TYPE KA2 KA5 KA10 KA22 KA44 KA66 KA80 KA100

FAX N 1100 2700 4000 5500 7600 10000 13500 17500

FLAT N 330 800 1200 1600 2200 3000 4000 5000

M NM 65 225 350 600 900 1500 2000 3500

The pipe system must be supported thus minimizing the external loads. The allowable loads, alignment tolerances etc. of the flexible joint positioned at the discharge flange, must be carefully considered, when designing the pipe system. The external loads on the compressor are transmitted through the base to the machinery supports and must be included when sizing the supports. For further information, see the standards NEMA SM23-1985, section 9.4 and API 672, section 2.2.3 and 2.3.4.




Page 12/54

INSTALLATION 930840008UK




Page 13/54

2.

TECHNICAL SPECIFICATIONSUNIT Serial No. Year Weight, approx. Dimension Drawing : : : : 8043, 8044, 8045 2009 2360 kg 14541

COMPRESSOR - Pos. No. K100 Make Type Medium flow Inlet flow, min. Inlet flow, max. Inlet pressure Discharge pressure, max. Inlet temperature, normal Inlet temperature, max. Revolutions Power consumption, min. Power consumption, max. : : : : : : : : : : : : Siemens KA5S Air 3943 m/h 8762 m/h 0.898 bar abs. 1.590 bar abs. 10,4C 25,2C 18952 rpm 92.7 kW 184.2 kW

The power is indicated at min./max. inlet flow, inlet pressure normal and inlet temperature normal

GEAR - Pos. No. G100 Make Type Gear ratio Oil requirement : : : : Siemens GK200 172 / 27 14 litres / min

DRIVE MOTOR - Pos. No. A401 Make Type Weight Insulation class Degree of protection Power, nominal Mains frequency Voltage Revolutions : : : : : : : : : Schorch KN7 315M-AB01B-Z 860 kg F/B IP 23 200 kW 50 Hz 400 V 2975 rpm

COUPLING (Motor/Gear)- Pos. No. A301 Make Type : Rexnord Thomas : SR52-MSH-225




Page 14/54

LINEAR MOTOR - Diffuser - Pos. No. D224 Make Type Pull-/push power Max. length of stroke Velocity Degree of protection Mains frequency Voltage : : : : : : : : Framo Antriebtechnik Unipush - Mini 0 1000 N 100 mm 2.7 mm/s IP 54 50 Hz 1 x 230 V

Mechanical oil pump Pos. No. S129 Make Type : : SIEMENS Integrated in gearbox

OIL FILTER - Pos. No. S303 Make Type : : FBO FRCA 60/1

OIL COOLER (AIR-COOLED) - Pos. No. S301 Make Type FAN MOTOR Type Make Revolutions Insulation class Degree of protection Main frequency Voltage Power : : : : : : : : : : Oil Tech LAC2-011-2-D

Oil Tech 3000 F IP 54 50 3 x400 1.1

rpm

Hz V kW

AIR INLET FILTER - Insert - Pos. No. L102 Make Type EU-class DIN 24185 Filter clean/replace at max. Manometer Pos. No. E137 : : : : Camfil Pocket filter G4 + 20 mm WC




Page 15/54

LUBRICATING-OIL PRESSURE Min. Normal operating pressure, approx. : : 0,8 1,0 1,2 bar bar*

* The oil pressure depends on temperature and load MANOMETER Pos. No. E121

LUBRICATING-OIL TEMPERATURE Max. Normal operating temperature Thermometer - Pos. No. E122 : : 80C 55 - 75C

LUBRICATING OIL Normal filling, see enclosure: OIL SPECIFICATION, SIEMENS Tech. Info. 930.870.003 (2 pages) Lubricating oil types, see enclosure: OIL SPECIFICATION, SIEMENS Tech. Info. 930.870.005 (1 page) - both inserted after "TECHNICAL SPECIFICATIONS". OIL RESERVOIR IN GEAR - Pos. No. G100 Normal filling : 35 litres

FAN FOR SILENCER HOOD Make Type Flow Degree of protection Mains frequency Voltage Power Speed : : : : : : : : EMB Papst W4D500-DD03-02 9,000 m3/h IP 54 50 Hz 400 V 0.83 kW 1360 rpm

THERMOSTAT - Pos. No. E151 Make Type Sensor Function Set point Difference : : : : : : Danfoss A/S RT103 In air at compressor panel Start / Stop of Ventilator fan 30 C Minimum




Page 16/54

THERMOSTAT - Pos. No. E104 Make Type Sensor Function Set point Difference : : : : : : Danfoss RT 107 In oil reservoir Stops compressor at high oil temperature 80C Minimum

THERMOSTAT - Pos. No. E111 Make Type Sensor Function Set point Difference : : : : : : Danfoss RT 101 In oil reservoir Stops compressor at recirculation (high inlet air temperature) 65C Minimum

Pressure Switch - Pos. No. E107 Make Type Sensor Function Set point Difference : : : : : : Danfoss RT 110 In the gearbox oil lubrication system Stops compressor at low oil pressure 0.8 bar Minimum

THERMOSTAT - Pos. No. E138 Make Type Sensor Function Set point Difference : : : : : : Danfoss RT 101 In oil reservoir Start/stop of oil cooler fan 50C Minimum

SURGE DETECTOR - Pos. No. E113 Make Type Sensor Function : : : : Siemens SUC-3 In compressor's inlet Stops compressor at surging




Page 17/54

BLOW-OFF VALVE - Pos. No. P106 Make Type / size Function ACTUATOR FOR BLOW-OFF VALVE Make Type Degree of protection Insulation class Mains frequency Voltage Power Operating time (90) : : : : : : : : Bernard OA6 F IP 67 50 Hz 400 V 0.03 kW 6 sec : : : Wouter Witzel Euronomic / DN100 Pressure relief during

start/stop

NON RETURN CHECK VALVE Make Type Size : : : Cast Flow GNECVB DN350

SILENCER FOR BLOW-OFF VALVE Make Size : : STE DN100

COMPENSATOR- Pos. No. P102 Make Type SIZE : : : STE/Bredan Steel DN150

CONE DIFFUSER - Pos. No. P116 Make Type SIZE : : : STE Cone diffuser DN150/350 1100mm




Page 18/54

OIL SPECIFICATIONS (TECH.DOC. 930870003UK)

COMPRESSOR

YEAR OF CONSTRUCTION

OIL TYPE DIN 51502

SIEMENS REFERENCIES

VISCOSITY INDEX MIN. ISO 2909

VISCOSITY MIN. at 120C

FZG STAGE MIN. DIN 51354

KA2-GK2 KA2-GK190 KA4-GK4 KA5-GK200 KA2-GL180 KA2-GB255 KA5-GA200 KA5-GA250 KA5-GL210 KA5-GL285 KA5-GB400 KA5-GC150 KA10-GA200 KA10-GL210 KA10-GA250 KA10-GC150 KA22-GA250 KA22-GL225 KA22-GL315 KA22-GC150 KA22-GC215 KA44-GA250 KA44-GL225 KA44-GL315 KA44-GL400 KA44-GC215 KA66-GL400 KA66-GC215 KA80-GL500 KA100-GL500

1986 2003 1982 1996 1999 1996 1987 1993 1992 1998 1997 1988 1986 1992 1987 1979 1983 1993 1989 1981 1981 1983 1993 1992 1995 1982 1992 1982 1990 1984

PAO 1 PAO PAO PAO HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP68

930870005 930870005 930870005 930870005 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004

137 137 137 137 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100

4.20 4.20 4.20 4.20

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

1

PAO = Synthetic oil, polyalfaolifine




Page 19/54

OIL PUMP CAPACITY AND OIL RESERVOIROIL RESERVOIR LITER +/- 10%

COMPRESSOR

YEAR OF CONSTRUCTION

OIL PUMP CAPACITY STANDARD LITER/MIN.

KA2-GK2 KA2-GK190 KA4-GK4 KA5-GK200 KA2-GL180 KA2-GB255 KA5-GA200 KA5-GA250 KA5-GL210 KA5-GL285 KA5-GB400 KA5-GC150-EM KA5-GC150-GM KA10-GA200 KA10-GL210 KA10-GA250 KA10-GC150-EM KA10-GC150-GM KA22-GA250 KA22-GL225 KA22-GL315 KA22-GC150-EM KA22-GC150-GM KA22-GC215-EM KA22-GC215-GM KA44-GA250 KA44-GL225 KA44-GL315 KA44-GL400 KA44-GC215-EM KA44-GC215-GM KA66-GL400 KA66-GC215-EM KA66-GC215-GM KA80-GL500 KA100-GL500

1986 2003 1982 1996 1999 1996 1987 1993 1992 1998 1997 1988 1988 1986 1992 1987 1979 1979 1983 1993 1989 1981 1981 1981 1981 1983 1993 1992 1995 1982 1982 1992 1982 1982 1990 1990

--- ----- ----- --14 2 44 58 58 82 58 82 170 58 58 58 58 108 58 58 82 82 170 58 58 82 82 82 82 170 120 82 82 170 108 108 235 235

6 13 19 35 230 230 230 300 230 300 570 230 150 230 230 300 230 150 330 330 570 230 150 500 330 330 330 570 480 500 330 680 500 330 1000 1000

2

Oil pump integrated in the gear.




Page 20/54

OIL SPECIFICATION (TECH.DOC. 930870005UK)Specification of lubricating oils applicable for SIEMENS compressors with anti-friction bearings (ball/roller bearings).

Note:

Turbochargers Journal bearing gearboxes

}

Please see different specification

Supplier Company Oil type BP BP BP Total Fina Elf Total Fina Elf Total Fina Elf Esso Esso Exxon Mobil Mobil Mobil Kuwait Petroleum Kuwait Petroleum ----------------------Statoil --------------------Shell Shell Shell Square Oil A/S Tribol Tribol Klber Klber Klber Lubrication Fuchs Fuchs Fuchs

Scandinavia Europe North America

BP

BP ENERGOL RC-S 46

TOTAL

DACNIS SH 46

ESSO

ESSO COMPRESSOR OIL RS32

MOBIL

MOBIL SHC 624

Q8

Q8 SCHUMANN 32

STATOIL

COMPWAY SX 32

SHELL

MADRELA AS 46

TRIBOL

TRIBOL 1550/32

KLBER

KLBER SYNTH GEM 4-32

FUCHS

FUCHS COFRABAR P32




Page 21/54

3. 3.1

UNIT DESIGN MAIN CONSTRUCTION The SIEMENS compressor consists of the following main parts:Gearbox Compressor Coupling, motor/gearbox Drive motor Base Diffuser Drive Mech. Oil Pump G100 K100 A300 A401 F101 D200 S129 Cone diffuser Compensator Blow off Valve Check Valve Oil cooler Oil Filter Local panel P101 P102 P106 P110 S301 S303 E123

The entire unit is built according to the drawing. Individual parts placed outside the unit are not shown on the drawing.




Page 22/54

3.2

COMPRESSOR Main parts:Inlet Outer vol. casing Inner vol. casing H701 H401 H501 Inner diffuser Pinion shaft Impeller D100 R201 R414

The SIEMENS compressor is a single-stage centrifugal compressor. The passage of the medium through the compressor: The medium is led through the inlet and past the inlet guide vanes to the impeller, which speeds up the medium. From the impeller the medium is led through the diffuser (variable), where most of the speed energy is changed into pressure, to the volute casing where it is collected, and from there out into the cone diffuser where the speed is reduced before it is led into the discharge system.




Page 23/54

3.2.1

COMPRESSOR CASINGS The compressor casings, consisting of outer/inner volute casing and inlet are manufactured from cast items that have been heat-treated, cleaned, and then machined. The casings have been assembled vertically, in order to facilitate handling of the individual casings when mounting or dismounting the compressor.

3.2.2

IMPELLER/ROTOR SHAFT The rotor consists of the following main parts:Impeller Pinion shaft Dowel Stop ring Special screw Stop nut Positioning dowel R414 R201 R411 R409 R410 R412 R415 Rotor nut Central screw Rotor drive R407 R405 R401

The impeller has been milled out in one forged, solid piece, ensuring great strength and accuracy. The blades have been formed so as to ensure optimal control of the compressor as well as an optimal and stable current flow. The outer contour and diameter of the impeller have been specially adapted to the operating conditions defined in the order specification. The overhung design with the impeller positioned at the end of the pinion shaft secures an operation well above first critical speed and well below second critical speed. The impeller rotor can be removed from the unit by disassembling the impeller from the pinion shaft. Note that the impeller is positioned on the outlet shaft by means of a screw. Dismounting of the rotor: See section 12. By means of hydraulic tools the impeller, the rotor shaft rod, and the rotor drive are held together with the rotor and the central screw. The complete unit (rotor) has been balanced dynamically.Created on 16-02-2009 at 16:00:35, LF 01-Operation_KA5S-GK200.doc



Page 24/54

3.2.3

SEALINGS Consisting of: - Labyrinth sealing - Oil sealing ring H303 T220

Air and oil shaft seals, made of aluminium, are non-contact types and designed to prevent air and oil leakage, thus avoiding contaminating the air with oil. This type of sealing does not get worn due to the clearance between the pointed sealings and the shaft. However, a minor running-in wear may occur. The sealing prevents oil from entering into the compressor. The chambers of the sealing ring are fitted with drains, through which the oil is led back into the gear housing.

3.2.4

DIFFUSER SYSTEM The compressor is equipped with one regulating system, a diffuser system. It can be regulated continuously within the range of two limit switches. Even a small change of the system setting will influence the ability of the compressor to make pressure and volume flow, and consequently the power consumption of the compressor will be affected. SIEMENS has developed a procedure, implemented in a process computer, to regulate the diffuser system to an optimum, based on measurements of: - inlet temperature - differential pressure across compressor - volume flow demand




Page 25/54

Any change of the system setting will cause increased power consumption or, at worst, that the compressor starts to surge, which will release an emergency stop. If the system has been disassembled, it must be assembled and adjusted exactly as it was before the disassembling.

ADJUSTABLE DIFFUSER SYSTEM Main parts:Guide ring Diffuser blades Positioning lever Mounting plate D108 D116 D205 D208 Limit switches Scale Linear motor *) D210 D213 D224

The diffuser system consists of a number of adjustable vanes (optimized vanes) placed radially around the periphery of the impeller. An electric linear motor regulates the diffuser blades. A scale is mounted on the mounting plate for indication of the position of the blades. Two limit switches have been installed, which - when activated - will signal the respective MAX. and MIN. positions of the diffuser blades to the control panel. The linear motor is controlled by the local control panel.

*)

See enclosed description




Page 26/54

The position of the limit switches shall not be altered, as this may cause overload of the compressor/drive motor. A signal value for the exact position of the vanes can be obtained by way of the built-in potentiometer in the linear motor.

3.3

GEARBOX Main parts:Gear casing part A Gear casing part B Drive shaft Pinion shaft Sealing ring H101 H102 R100 R200 T101 Deep groove ball bearing Deep groove ball bearing Angular contact ball bearing Angular contact ball bearing Oil pump, mech. T103 T106 T208 T210 S129




Page 27/54

The SIEMENS GK200 gearbox is a single-stage, helical gear, where the pinion shaft is placed above the drive shaft. The pinion shaft is supported by bearings on both sides of the gearwheel. The gear ratio has been adapted to the operating conditions as specified in the order. The gearbox is vertically split for easy access to the shafts, bearings, and sealings.

3.3.1

GEAR CASING The gear casing, consisting of part A and B, is manufactured from cast elements which have been heat-treated, cleaned, and then machined.

3.3.2

SHAFTS - GEARWHEELS Shafts and gearwheels have been carburized and ground with great accuracy, to allow for the high speed and resulting stress on the teeth. A moderate backlash allows for oil film, deformations, etc. The gearwheel on the drive shaft has been shrunk on. The gearwheel on the pinion shaft has been machined in one piece with the shaft.

3.3.3

BEARINGS The pinion shaft is supported by angular contact ball bearings. Double bearings are used in the compressor end, while single bearings are used in the motor end. The bearings are pressure lubricated and cooled by an oil flow on the exterior bearing housing. The inlet shaft is supported by deep groove ball bearings.

3.3.4

OIL SEALING The sealing is a non-contact, labyrinth type sealing, which does not get worn due to the clearance between the pointed sealings and the shaft. However, a minor running-in wear may occur. This sealing ensures that oil is not leaking from the gear. Drains in the sealing chambers lead oil back into the gear casing.

3.4

BASE The base is a welded box-like construction manufactured with frame of steel profiles and steel plate. It serves additionally as base for all safety equipment and the local panel.

3.5

CONE DIFFUSER The cone diffuser is manufactured from steel plate milled into shape and welded together. The two flanges are likewise welded on. The cone diffuser is mounted on the discharge side, thereby transforming the last part of the air velocity into pressure, thus reducing the air velocity.




Page 28/54

3.6

BLOW-OFF VALVE The blow-off valve is a butterfly valve with electric or pneumatic actuator and end stops. The blow-off valve is mounted between two flanges. The blow-off valve functions as a pressure relief valve during start/stop to avoid surging. (For tech. data, see 2).

3.7

CHECK VALVE The check valve is a spring-loaded butterfly valve (dual plate) built in between two flanges. The check valve prevents the compressed air from passing backwards, thereby keeping the compressor from running backwards when not in operation. (For technical data, see 2).

3.8

COUPLING/DRIVE MOTOR/GEARBOX The coupling between drive motor and gear is a flexible disc type coupling which is flexible in both radial and axial direction and at the same time able to withstand excessive torsional stress. To ensure optimal operating conditions the coupling shall be aligned as described in 12.




Page 29/54

3.9

INLET SYSTEM See enclosed drawing no. 9330057240.0, Inlet Silencer. The inlet system consists of inlet silencer, filter, front grid or extension piece fastened together into a unit. The inlet silencer is fitted with height adjustable feet, approx. 20mm from nominal centre height. Mounting The height of the inlet silencer stud is adjusted in relation to the compressor stud, and the inlet silencer is positioned so that the air conduit between the studs is 3 - 7 mm. If the air conduit between the studs is 10 mm or more, the compressor may be damaged. The holes in the base plate are then marked out on the floor, the silencer is removed, and the holes are bored, after which the nylon dowels supplied are placed in the holes, and the silencer put back and fastened with the supplied screws. The air conduit between the studs of the inlet silencer and the compressor is checked and taped with the special tape supplied, after which it is covered with lead rubber and tightened together with the flexible connection supplied. The U-pipe manometer, which registers pressure drops, is filled up with liquid from the flask supplied. Maintenance Pressure drops must not exceed 100 mmWC, because a too high negative pressure may cause the intake silencer plates to collapse. The filters are replaced when the pressure drop during start is observed to have increased by 20 mmWC.

Suction from the compressor room: Dismount the front grid and the filter locks and take out the filters. Vacuum clean the inside with a soft brush mouthpiece. Insert new filters. Suction from the air duct: Dismount the side covers of the filter box and the filter locks and remove the filters through the side. Vacuum clean the inside with a soft brush mouthpiece. Insert new filters.

3.10

INLET FILTER See Manufacturer's material.




Page 30/54




Page 31/54

4.

DRIVE MOTOR See enclosed technical document Electric Motors Compressors KA2 - KA100 General Requirements. For motor specifications etc. see manufacturers instructions.

General remarks to monitoring and maintenance of electric motors.Immediately after the first start-up of the compressor, it is necessary to make the first lubrication of the electric motor on site. The type of grease must always be identical to the type which was used from the factory. It must be avoided to mix two different types of grease that might contain different additives not being able to be integrated. This might result in poor lubrication quality and damage to the bearings. After the first lubrication on site, it is necessary to lubricate according to intervals' indicated on the manufacturers plate at the motor. Greasing is done only with the motor running. Keep record of all the greasings in the list of lubrication. After the startup, it is necessary to control the motor once per week. To check that the sound and the temperature are correct and that there are not false vibrations. This might be done by using a large screwdriver to listen at the bearings by putting the end against the bearing cover and the wrist against the ear. If the compressor unit is not in operation for a rather long period, the compressor should remain oil-filled. Start the oil pump for some minutes and turn the compressor and the electric motor a few turns manually once per week. Engine IP23 passes the cooling air between the stator and the rotor. That is why the room in which the compressor / electric motor are placed will have to be completely clean. In general all the motors and compressors will have to be held in a state of cleanliness. If the interior of a motor is more or less filled with dirt, a short-circuit will be able to occur. The cooling air must be dry. It is always necessary to monitor the temperature as well as the absorptive current. After a long period of stop it is necessary to make sure, by the means of a measuring instrument that the electric insulation is intact, and no false currents can escape through the bearings, in order not to start a wet motor. If the motor has remained inactive for a long time, without to be turned regularly, it could be necessary to change the bearings. That is detected by touching the motor while listening to the bearings. Permanent monitoring is necessary. Any repair or any disassembling of the engine requires control of the alignment of the coupling and, if necessary, a corrective alignment.




Page 32/54

930910056UKRevision: 15

ELECTRIC MOTORS COMPRESSORS KA2 KA100 GENERAL REQUIREMENTSMC FP Date: Date: 91.12.09 07.02.07

Prepared by: Latest revision:

1.

The motors shall be manufactured according to standard IEC 60034-14, vibration grade A. This also applies to fully loaded motors. Unless otherwise specified, the motors shall be balanced according to the "HALF KEY CONVENTION" ISO 8821, and the shaft end shall be marked with an "H" according to section 4.2. of this standard.

2.

Starting: The compressor torque-speed curve follows a square law. The max. torque during start is 67% of the motor nominal torque. Note that there could be specific demands on the acceleration at certain rpm intervals. Such demands will be noted on the compressor speed-torque curve. Low-voltage motors: The motor should be capable of star/delta start within 12 seconds. High-voltage motors: The motor should be capable of starting the compressor at 80% of the normal voltage.

3.

The motors shall be equipped with a "low noise" design fan. Maximum free field sound pressure, according to ISO 3744, is 87 dB(A) at 1 m distance. Direction of rotation, when viewing the motor from the drive shaft end, see figure 1.: Gearbox GK2, GL180, GK190 Gearbox GK200 Gearbox GA Gearbox GB255 Gearbox GB400 Gearbox GC Gearboxes GL210, GL225, GL285, GL315 and GL400 Gearbox GL500 (single stage) (single stage) (single stage) (two stage) (two stage) (two stages) (single stage) (single stage) : CCW : CW : CW : CW : CCW : CCW : CW : CCW Figure 1. Gearbox type according to order specification. A terminal box with terminals shall be mounted on the motor. Unless otherwise specified, the position of the terminal box, when viewed from the motor drive end, shall be on top of the motor with terminal entry to the right or on the right side of the motor with terminal entry downwards. Cable entry location shall permit proper cable bending radius when the motor is installed on the base plate.

4.

5.

The motor windings shall be protected by 1*PTC thermistor or 1*PT100 sensor in each end winding. Thermistors are preferred. All sensors shall be galvanically separated. The motors shall be shipped to Siemens Turbomachinery Equipment A/S (STE) works in Helsingr, Denmark, according to the signed "Statement of Availability" document 930940025UK.

6.




Page 33/54

7.

As a minimum the documentation must include: a. A certified dimension sketch, including shape and dimensions of the motor fan cover, location of the coolant inlet, shape and exact position of the feet, weight and centre of gravity. The drawing must be available both in paper version and as scaleable AutoCad data in dwg format (Version: AutoCad Mechanical 2004 or previous versions). Alternatively, the data can be supplied in dxf data format (Version: AutoCad 2000/AutoCad Light 2000 or previous versions). In case of doubt, please contact STE. Technical data including full-load torque, full-load speed, full-load current, speed-torque curve, speed-current curve, load-power-factor curve, load efficiency curve (shaft power/ terminal power ratio), inertia of rotor and drive shaft torsional stiffness to be specified and/or filled in acc. to "Standard Specification for 3-Phase Squirrel Cages" 930920063UK and "Efficiency of Electric Motors" 930920064UK. Terminal markings/wiring specifications for motor winding protection. Noise emission at full load specified as sound power emission Lw, A-weighted value and/or octave bands (dB, reference 2*10-12 W).

b.

c. d.

8.

When equipped with sleeve bearings, the rotor shall be locked in place during transport. If the rotor is to be axially positioned by means of external thrust bearings, the maximum axial load of the motor and the predicted thermal expansion shall be specified. Lubricating oil system requirements, including oil/grease type, shall be specified. Grease nipples shall be according to DIN 71412. Minimum grease lubrication interval: 1500 hours.

9.

In cases where the compressor applications include an acoustic enclosure covering the whole compressor unit, the motor fan shall provide the necessary amount of cooling air when working against an external pressure of 60-80 Pa. The fan capacity, at maximum pressure drop, shall be specified. The fan cover dimension (shape) shall be specified.

10.

The motors shall be protected for normal shipment and storage indoors, not heated, up to 6 months. Special requirements during shipment and storage shall be specified or the STE instruction "Conservation, Transportation, Storage, Start-up" 930920009UK approved of. If used under tropical conditions the motors shall be equipped with electrical heaters and drains. Manuals including instructions for installation and operation shall be provided in English, German, French or Spanish, whatever is specified. Electric motors to be mounted on compressor units for the EU and EFTA markets shall comply with European Directives and Harmonized Standards in force at the specified time of delivery. The documentation shall include a Declaration of Conformity (EN45014). The information specified herein must be at our disposal not later than 3 weeks from receipt of order.

11. 12.

13.

14.




Page 34/54

5.

ACOUSTIC ENCLOSURE On request SIEMENS supplies an enclosure, which through careful choice of design, assembly methods and sealing strips, will provide optimal noise reduction. The enclosure is equipped with sound muffling material adapted to the prevailing conditions. The SIEMENS acoustic enclosure is built up as a modular system on a chassis frame in which panels and doors can be inserted. This simple construction means fast mounting and dismounting of the complete enclosure or parts of it. The enclosure is delivered as a construction kit, which requires only a minimum of space during storage and transport. "Do it yourself" mounting instruction - technical info 930940099 - is included in the delivery. However, SIEMENS will be pleased to mount the enclosure on request.

CONSTRUCTION Frame construction made of OMEGA profiles (channel section with webs) mounted on bottom rails bolted to the floor. Sound absorbing elements are placed in the frames. Dimensions: Modular system for individual adaptation. NOISE REDUCTION The sound absorbing elements are made of alu-zinc coated steel plate on the outside, and of alu-zinc coated perforated steel plate on the inside. The interspace is filled up with mineral wool. The ceiling elements are placed in webs in the cross braces. The wall elements are placed in top and bottom rails. The enclosure is fitted with detachable wall panels for inspection and service. VENTILATION The silencer hood is ventilated by means of a fan mounted inside the hood in one of the ceiling elements. Intake and discharge of ventilating air is done via noise reducing ducts. The outlet can be connected to a pipe channel leading the hot air out of the compressor room.

TYPICAL NOISE REDUCTIONOctave band (Hz) Noise reduction (dB) 31,5 2 63 6 125 6 250 10 500 14 1000 19 2000 21 4000 40 8000 18

Note: From compressor, valves etc., sound is emitted into the pipe system. Therefore, the nearest parts of the pipe system outside the enclosure shall be insulated in order to obtain optimal noise reduction.




Page 35/54

6. LUBRICATING OIL SYSTEM 6 1 Design and Function The lubricating oil system provides oil for all bearings in the gear and for the gear meshing. The lubricating oil system has been designed as shown on the P & I diagram and the aggregate drawing. In the technical specification, the P & I diagram and the aggregate drawing (section 2, 7.2, and 12 respectively), control of the oil/cooling system is shown as well as the function and location of sensors, thermometers, manometers, thermostats, and pressostats. The lubricating oil system is equipped with one oil pump which can deliver the quantity of oil required. The oil reservoir may be equipped with electric oil heaters to heat the oil after a period of stand-still, i.e. when the temperature has fallen below the 10C necessary during startup The oil is pumped via oil cooler and oil filter to the lubricating points. The oil cooler may be either air-cooled or water-cooled. When cooling by air the cooler shall not be placed in such a way that the warm air blows towards the LC-panel or other electric installations. When cooling by water the regulating valve shall be mounted on the inlet pipe to ensure that the water pressure is always kept lower than the oil pressure; thereby preventing water from penetrating to the oil. The inlet pipe shall be connected to the lowest pipe connection to keep air out of the system. The aggregate is equipped with 1 pressure switch (pressostat:). The pressostat E107 gives signal to stop the compressor. If - due to power failure or damage (oil leakages) to the lubricating system - the pressure falls below approx. 1 bar excess pressure, the compressor will be stopped via the pressostat and the electric control system, and also if the oil pressure has not been established within 30 seconds from start-up. The aggregate is equipped with thermostats for oil temperature: The thermostat E104 gives signal to stop the compressor if the oil temperature gets too high. The thermostat E138 gives signal to start and stop the oil cooler fan. For lubricating oil pressure and temperature, see 2. The lubricating oil system has been cleaned in advance by SIEMENS. Therefore, be extra careful when dismounting, etc., in order to avoid contamination of the oil system. 6.2 Oil filling Fill oil pipe S215, on top of oil cooler, and oil filter S303 with oil before first start-up and at each oil change. Check the oil level in the level glass E130, see the unit (aggregate) drawing. 6.3 Oil types The compressor must only operate with synthetic oil types, which are approved by SIEMENS (see 2 Technical Specifications). Different types of oil must not be mixed, i.e. if the oil type is changed all oil must be changed. Oil from tanks, which have been opened for some time, must not be used, as particles from the atmosphere will be absorbed in the oil. Accessories: The lube oil pump is integrated in the gear, see 12. Lube oil filter and cooler: See section Accessories Lube oil heater : not included.Created on 16-02-2009 at 16:00:35, LF 01-Operation_KA5S-GK200.doc



Page 36/54

7.

CONTROL AND MONITORING SYSTEMS

7.1

DESIGN AND FUNCTION The control and monitoring systems shall ensure correct operating conditions at start and stop of the compressor as well as during operation. The control system runs the start and stop functions, the compressor operation, the lubricating oil system, and the activation of the blow-off valve, the diffuser and/or the prerotation. The monitoring system consists of minimum 5 current circuits connected to pressostats, thermostats, and sensors. The current circuits are part of a safety chain which stops the compressor immediately on indication of error. Important: The design of the local control panel and all its electric functions are described in the separate Operation Manual for the Local Control Panel.

7.1.1

START AND STOP FUNCTIONS START AND OPERATION The start function ensures that the compressor only starts if it has been correctly prepared. The conditions for a correct start are as follows: no alarms or emergency stops activated blow-off valve open diffuser and/or prerotation in MIN position.

The start sequence may now be activated as follows: Compressors with gear: - GK2, GK4 and GK200:

Start of compressor at once while feed back signal is awaited from motor starter.

If the unit is equipped with SIEMENS electric control system LC-, Local Control panel, the panel controls the daily operation and monitoring. The following conditions of start and operation will be observed by the logic system of the local control panel: 1. When the START button is activated the automatics will open the blow-off valve and set the diffuser in MIN position. At the same time the instruments of the safety chain are checked, and if they are in order the drive motor of the compressor will start. When the compressor has been started the blow-off valve will close. During operation the diffuser will be adjusted continuously corresponding to the operational conditions. In case of errors, as too high oil temperature, too low oil level, too high counter pressure in the outlet pipe etc., the compressor is stopped. When the error has been located and corrected the monitoring system has to be reset.

2. 3.

4.

5.




Page 37/54

STOP The stop function ensures that the compressor stops under controlled conditions: NORMAL STOP 1. Diffuser moves to MIN position. 2. As soon as the diffuser is in MIN position, the blow-off valve opens quickly. 3. When the blow-off valve is open, the compressor motor stops (however, max. 100 seconds after "Normal Stop" has been activated). ALARM STOP (NOT OIL PRESSURE) 1. Blow-off valve opens quickly (max. 8 seconds after "Alarm Stop" has been activated). 2. Compressor stops. 3. Diffuser and prerotation move to MIN position. EMERGENCY STOP (ONLY EMERGENCY AND OIL PRESSURE) The compressor stops at once, while the blow-off valve, the diffuser and/or the prerotation open simultaneously and move to MIN position. For KA2-GK2, KA4-GK4 and KA5-GK200 please note: After each stop the compressor cannot be restarted for 1 minute.

7.1.2

CONTROLLING THE LUBRICATING OIL SYSTEM COMPRESSORS WITH MECHANICAL OIL PUMP Compressors with gear GK200 only have a mechanical oil pump. The pump starts directly and the control records the oil pressure during operation. If the oil pressure is insufficient, the control stops the compressor.

7.1.3

ACTUATION OF BLOW-OFF VALVE, DIFFUSER AND/OR PREROTATION The monitoring system ensures that the blow-off valve, the diffuser and/or the prerotation are controlled within the range of the respective end stop switches.

7.1.4

SAFETY CHAIN (CLOSED-CIRCUIT PROOF) The Safety Chain consists of minimum 5 current circuits: oil level and/or oil pressure oil temperature surging recirculation motor temperature (motor windings)

If an error occurs in one of the current circuits, the Safety Chain ensures that the compressor is stopped at once.Created on 16-02-2009 at 16:00:35, LF 01-Operation_KA5S-GK200.doc



Page 38/54

IMPORTANT! Operation without monitoring (Safety Chain) must not take place!

7.1.5

SUPPLY OF AUTO-CONTROL If the control automation is supplied by SIEMENS, please see the electrical documentation LC/MCP for further information. If the control automation is not Siemenss make, the minimum design criteria shall be in accordance with Siemenss technical specifications: Control automation for SIEMENS compressors Type KA2-GK2, KA4-GK4 and KA5-GK200 Minimum Design Criteria No. 930920011UK Control automation for SIEMENS compressors Type KA5-KA100 Minimum Design Criteria No. 930920010UK

7.2

P/I DIAGRAM See enclosed P/I diagram.




Page 39/54




Page 40/54

7.3

COMPRESSOR INSTABILITY (SURGE) Surge (Stalling) and recirculation are both situations which arise in connection with operational errors or errors in the automatic control system or the controlled functions. In both cases the compressor will run an unstable operating range and must be stopped at once.

7.3.1

SURGE Pressure air expands jerkily through the operating compressor. Usually stalling is caused by operating at too high differential pressure. Stalling may also arise if the inlet temperature is much higher than the maximum design temperature. At increasing inlet temperature the max. achievable discharge pressure of the compressor will drop. Stalling reveals itself through audible pressure blows the frequency and strength of which are determined by among others the resonant conditions of the connected piping system on the pressure side. Strong pressure blows mean heavy load on the mechanical parts of the compressor, and therefore the compressor must be stopped. (see the manual for the local control panel). Operating under these conditions will expose the mechanical parts of the compressor to heavy loads and should, therefore, be avoided. If the compressor is operating within the unstable range, the SUC-switch (SU = Surge, C = Control) will activate the alarm and stop the compressor immediately. The following malfunction may cause surge: 1. Too high header pressure 2. Too high inlet temperature 3. Decrease in compressor RPM as well as mechanical errors, etc.

7.3.2

RECIRCULATION The medium recirculates through the compressor, whereby a large amount of energy is added to a small amount of medium (the medium heats up). The following malfunctions may cause recirculation when: 1. The diffusor/prerotation is closed completely (MIN.-setting of the limit switches has been moved) 2. The discharge from the blow-off valve is led back to the inlet duct, causing the medium to recirculate for a long time Operating with recirculation must be avoided, as it may cause damage through overheating, and - at worst - fire in the compressor. If the compressor is operating for a long time with recirculation, a thermostat with sensor in the compressor inlet will activate the alarm signal and stop the compressor immediately.




Page 41/54

8.

INSTRUMENTATION THERMOSTAT RT103 Acoustic Enclosure Temperature above 30C Pos. no. E 151

8.1

Data : See 2, Tech. Specifications : -40 - +70C : 100C : Start and stop of ventilator fan at temperature above/below 30C in acoustic enclosure. : Dismount the front cover of the thermostat and set the differential adjusting nut 19 on MIN. Set scale 9 on 30C using knob 5.

MAX ambient temperature MAX sensor temperature Function

Setting




Page 42/54

8.2

THERMOSTAT RT101 Oil Temperature above 55C Pos. No. E138 By Air Cooling of the Oil System Data : (See also 2, Tech. Specifications)


: :

-50 - +70C 300C

: Start and stop the ventilation motor of the oil cooler at rising oil temperature, exceeding 60C. : Dismount the front cover of the thermostat and set the differential adjusting nut 19 on MIN. Set scale 9 on 60C using knob 5.

Setting

Testing :

If the ventilator is running, the thermostat is set on a value higher than the indication of the oil thermometer: The ventilator must stop. If the ventilator is not running, a value lower than the indication of the oil thermometer is chosen: The ventilator must start.

The thermostat is closed but not sealed, as adjustments will have to be made occasionally, according to changes in the surrounding temperature.




Page 43/54

8.3

THERMOSTAT RT107 Oil Temperature too high Pos. No. E104

Data : See also Accessories


: :

-50 - +70C 300C

: To stop the driving motor of the compressor at rising oil temperature, exceeding 80C. : Dismount the front cover of the thermostat and set the differential roll 9 on MIN.

Setting

Testing :

Using knob 5 the thermostat is set at dropping temperature until the switch opens. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. Adjust scale 9 until indicator setting of the thermostat corresponds with the oil thermometer of the gear. Adjust thermostat with knob 5 to 80C on scale 9. Remount the front cover.

The thermostat is part of the electric safeguard, and it is sealed with lead after adjustment. Important: During the period of guarantee set for the compressor, sealed thermostats and pressure controllers must only be adjusted by SIEMENS personnel. The guarantee no longer applies if the seal is broken.




Page 44/54

8.4

THERMOSTAT RT101 Air Temperature too high Pos. No. E111 Data : See also Accessories


: :

-50 - +70C 300C

: To stop the drive motor of the compressor at rising air inlet temperature, exceeding 65C. Securing against overheating caused by recirculation.

Setting

: Dismount the front cover of the thermostat and set the differential roll 9 on MIN. Set scale 9 on 65C, using knob 5.

Testing :

Set the scale on 65C. the sensor is taken out of the inlet and heated in water to above 65C. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. Remount the front cover.

The thermostat is part of the electric safeguard, and it is sealed with lead after adjustment. Important: During the period of guarantee set for the compressor, sealed thermostats and pressure controllers must only be adjusted by SIEMENS personnel. The guarantee no longer applies if the seal is broken.




Page 45/54

8.5

Pressure Controller RT110 Oil Pressure too low - Pos. No. E106

Data : (See also section 2, Tech. Specifications) MAX ambient temperature MAX medium temperature MAX testing pressure Function : 70C : 100C : 25 bar : To start the electric oil pump if the oil pressure drops below 0,8 bar o. : Dismount the front cover of the pressure controller and set the differential roll to MIN. Set scale 9 to 0,8 bar o using knob 5.

Setting

Testing : Set the pressure controller to scale value below the oil pressure shown on the lubricating oil manometer. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. After testing, the scale is reset to 0,8 bar o. Remount the front cover. The pressure controller is part of the electric safeguard, and it is sealed with lead after adjustment. Important: During the period of guarantee set for the compressor, sealed thermostats and pressure controllers must only be adjusted by STE personnel. The guarantee no longer applies if the seal is broken.




Page 46/54

8.6

Pressure Controller RT200 Oil Pressure too low - Pos. No. E107

Data : (See also section 2, Tech. Specifications) MAX ambient temperature MAX medium temperature MAX testing pressure Function : 70C : 100C : 25 bar : To stop the drive motor of the compressor if the oil pressure drops below 1 bar o. : Dismount the front cover of the pressure controller and set the differential roll to MIN. Set scale 9 to 1 bar o using knob 5.

Setting

Testing : Set the pressure controller to scale value below the oil pressure shown on the lubricating oil manometer. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. After testing, the scale is reset to 1 bar o. Remount the front cover. The pressure controller is part of the electric safeguard, and it is sealed with lead after adjustment. Important: During the period of guarantee set for the compressor, sealed thermostats and pressure controllers must only be adjusted by SIEMENS personnel. The guarantee no longer applies if the seal is broken.




Page 47/54

8.7

PRESSURE SWITCH SUC-3 - Pos. No. E113

Function

: Surge indicator, gives alarm (stop of the drive motor) in case of surging. : Inductive sensor. : In the compressor inlet housing.

Sensor Mounting

A: Pressure direction at normal operation. B: Pressure direction at surging.

The surge indicator is mounted vertically on the compressor inlet. At normal operation a small steel disc is forced down (away from the inductive sensor) by the vacuum in the inlet housing. At surging the direction of the pressure is reversed, this causes the steel disc to approach the inductive sensor, which then gives alarm.

BLUE (MINUS)

WHITE (SIGNAL)

BROWN (PLUS)




Page 48/54

9. 9.1

START-UP PREPARATIONS The list below is applicable to the first start-up. The automatic control system shall fulfil the minimum requirements as described in 7. When the automatic control system is delivered by SIEMENS the customer is referred to the LC/MCP documentation, which includes operating instructions for the local control panel.1. Check oil pan for impurities and/or water. Drain-off possible condensate.

Fill up the compressor with lubricating oil, check the oil level. Fill on only NEW and absolutely CLEAN oil. Check oil level in sight glass. If lubricating oil has already been filled on, check quality of oil as well as oil level. For type of oil, see technical specifications, 2. 2. Check lubricating oil piping for damage that may have occurred during mounting. In case the oil system has been disassembled or modified, the system shall be flushed with oil that has been bypassed gear and compressor, using the procedure described below: Dismount pipe connections leading to gear and compressor. Lead oil back to the oil reservoir via clean pipes. The external oil system is then flushed out for one hour with oil at temperature above 10C Pipe connections for gear are remounted and new oil is filled. Check that the passage through connections to gear and compressor is Important! free. The oil system is then flushed out for at least hour with the oil temperature above 10C and the oil pressure at 1,5 3,0 bar. Turn the compressor manually, very carefully, one entire revolution in reverse. (This is easily done by means of the coupling between drive motor and gear). Then flush further for at least hour. Check oil filter insert. Replace if necessary.3. Check the compressor suction system, silencer(s), compensators and air filters (internal/external) for correct mounting and cleanliness.

Important!

Check especially the area in front of the impeller, the inlet, and the inlet pipe. Check the flexible connection between the inlet pipe and inlet filter/inlet duct for correct mounting.

4. Check diffuser cone, blow-off valve and non-return check valve on pressure side of compressor for correct mounting. The check valve must be mounted with vertical shaft. An arrow indicates the sense of direction of the air. 5. Check the non-return check valve for correct function and control. Check the limit switch function. 6. Check that function and adjustment of the regulation system of the diffuser are correct. Check the limit switch function. Created on 16-02-2009 at 16:00:35, LF 01-Operation_KA5S-GK200.doc



Page 49/54

7. Check oil cooler for correct function and control. 8. Check the acoustic enclosure fan for correct function and check the sense of rotation. (If installed)

9.2

SIMULATED TEST RUN OF COMPRESSOR In order to check start/stop sequence and cable connections a simulated test run is performed. It may be performed with dismounted coupling lamellas on the motor-end. When simulating operation the safety monitoring equipment (pressostats and thermostats) shall be tested with satisfactory result. (For pressure and temperature see 2).

Turn compressor manually to check that rotation is smooth. This is most easily done at the coupling between drive motor and gear. Start up compressor (motor) briefly, max. 2-3 seconds, to check direction of rotation. If direction of rotation is wrong, repole motor. IMPORTANT! Wrong direction of rotation of the gear for more than a few seconds may cause permanent damage to gear bearings and journals.

Note: Do not restart more than 4 times per hour. Repeated starts within 15 minutes will block the drive motor for restart for one hour (to protect motor coils). Check that mounting of the coupling and tightening of the screws is correct (see 12). Check the coupling alignment before start-up (see 12).

9.3

TEST RUN OF COMPRESSOR During test run the following shall be checked and/or adjusted:

Opening and closing of blow-off valve. Normally the blow-off valve will indicate "closed" max. 180 sec. after start-up (depending on valve type and site conditions). Function of recirculation-valve. Build-up of air pressure in pressure pipe. Lubricating oil pressure and temperature shall be stable. Lubricating oil pressure and temperature during operation (see 2). Function of mechanical oil pump Lubricating oil cooler adjusted. When air-cooled, the thermostat is adjusted for start and stop of fan motor. Lubricating oil temperature during operation. Test diffuser adjustment manually. Test safety monitoring, oil level switch and emergency stop during operation. Test normal start and stop sequence. Motor overload protection (diffuser limitation). Check for oil leaks at operating temperature. Check of cable connections from compressor control panel to master control panel.




Page 50/54

9.4

MASTER CONTROL (if installed) Check at start-up of Master Control (MCP): Start/stop function, priority sequence and adjustment procedure for all compressors.

Check and adjustment of step controller (adjustment of diffuser via mA-signal). Check of output signal from pressure and oxygen transmitter.

9.5

START 5 seconds approx. after start-up the valve between the compressor and the manifold is opened. The blow-off valve is closed. At plants equipped with non-return valve between compressor and manifold: Close the blowoff valve approx. 5 seconds after start. The compressor can now be set for max airflow, during which the counter pressure and the power consumption of the motor are surveyed. At low counter pressure the airflow may increase considerably and the motor will be overloaded (see performance certificate). The compressor electric control system (Local Control Panel) will monitor all necessary functions before and after start, when the start order is given by pressing the respective button. In case of errors or if the starting conditions are not fulfilled the local control panel will indicate ERROR (see Manual for Electric Control System).

DURING OPERATION Pos. Nos. refer to aggregate drawing/instrument panel drawing. Operating temperature (see 2). During operation the following is checked: Oil level: Pos. No E130 E120 Pos. No. E122 E104 Pos. No. E121 Pos. No. E107 Pos. No. 113 Pos. No. 111 Sight glass Level switch Thermometer Min. 10C at start-up Thermostat Pressure gauge, Min 1,0 bar. Pressure switch SUC-3, pressure switch Thermostat To be measured at the SIEMENS test point; 10-1000 Hz: ISO. Ammeter on control panel. Test by means of a tongs ammeter. Pressure gauge, Pos. E137.

Oil temperature:

Oil pressure:

Compressor surging Compressor recirculation Vibrations:

Power consumption:

Differential Pressure at inlet filter:




Page 51/54

9.6

GENERAL When the compressor has been put into operation, the starting priority of the machines shall be changed periodically by the machine operator in order that all compressors of an installation are frequently in operation and over a period will have an equal number of operation hours. On plants where the diffuser system is not frequently run from fully open to fully closed, due to special operating conditions, the local panel shall be set on "Manual" at least once a week, and the diffuser run from fully closed to fully open at least twice. This also applies to compressors which are not in operation. If the compressors have not been in operation for a month, the following procedure shall be followed, to avoid that the ball bearings are damaged by standstill in the same position: Rotate the compressor for about a minute in the normal direction of operation. This can most easily be done by turning the coupling between drive motor and gear by hand.

NOTE AFTER START-UP 1. The screws of the coupling shall be checked after approx. 10 hours of operation. 2. Operation with electric motor: Grease lubricated bearings must be lubricated according to the prescriptions in the supplier's manual or acc. to indications on the name plate of the motor. The first lubrication is to take place immediately after start-up (always with a warm compressor). The lubrications are to be continued at stated intervals. A scheme of lubrication intervals should be established. 3. Lube oil quality must be checked according to prescriptions (See section 11) 4. Check for possible oil leaks. Retighten pipe joints if needed.




Page 52/54

10.

TROUBLE SHOOTING

When trouble shooting, compare all operational data with the specifications in 2. Flow, no pressure at start-up Insufficient flow Excessive power consumption Surge (pressure pulsation)/ Recirculation (overheating) Noisy operation/too high vibration level Bearing temperature too high Lubricating oil pressure too high Lubricating oil temperature too high Drive motor Oil cooler 10.1 10.2 10.3

10.4 10.5 10.6 10.7 10.8 See separate instruction: Section 5 See separate instruction, section 6

10.1

NO FLOW, NO PRESSURE AT START Possible causes: - Drive motor error, current failure. - Wrong direction of rotation. NOTE: Drive motor and compressor are rotating in opposite directions. - A coupling or shaft has broken. - A shaft has been blocked.

10.2

INSUFFICIENT FLOW Possible causes: Blow-off valve completely or partly open. Pipe system leaking or a valve is open. Inlet diffuser blades/- guide vanes completely closed. Inlet system partly blocked.


HANDBOOK FOR OPERATION AND MAINTENANCE 10.3


Page 53/54

TOO GREAT POWER CONSUMPTION Possible causes: - Low flow pressure compared to design pressure with stuck diffuser. - Maladjusted diffuser. - Mechanical defect in gear or compressor (defective bearings, gearwheels or shaft). NOTE: If the electric motor has been wrongly poled (connected to the external power supply), the power consumption may rise excessively.

10.4

SURGE (PRESSURE PULSATION)/ RECIRCULATION (OVER-HEATING) Possible causes: - Too low RPM. - Header pressure too high compared to design pressure (see rating plate). - Inlet duct/- silencer defective/ fouled up. - Inlet air filters blocked due to fouling (inlet pressureloss too high). - Inlet temperature too high. - Inlet guide vanes/diffuser blades maladjusted or too closed. - Clearance between impeller and contour ring too large. - Impeller damaged. - Blow-off valve defective; causes surging at start/stop only. - Defective counter valve and blow-off valve.

10.5

NOISY OPERATION /VIBRATION LEVEL TOO HIGH Possible causes: Gear: - Defective gearwheel or bearings. - Defective coupling or bad alignment. Compressor: Defective bearings. Rotor/impeller out of balance. Defective sealings. Defective coupling or bad alignment.

10.6

Bearing TEMPERATURE TOO HIGH Possible causes: Wrong type of oil. Defective bearings, gearwheels, etc. Insufficient cooling of lubricating oil Insufficient oil feed. Lubricating oil pressure too low. Defective oil pump.




Page 54/54

10.7

OIL PRESSURE TOO LOW Possible causes: Defective oil pump Oil filter blocked Oil temperature too high Safety valve defective Leaks on pressure pipe (under tank cover). Too low oil level

10.8

OIL TEMPERATURE TOO HIGH Possible causes: - Too high ambient temperature. - Wrong type of oil. - Defective bearings, gearwheels, etc.




Page 1/50

11.

MAINTENANCE INTRODUCTION The SIEMENS compressor is designed to operate for many thousand hours with a minimum of maintenance. Control and cleaning is most important. Some vital parts of the compressor and gear require dismounting. Instructions of such dismounting and remounting are given below. Follow these instructions carefully, and if any doubt please contact SIEMENS for assistance. The SIEMENS compressor is built with very fine tolerances and operates at very high speeds. Therefore, be very careful during maintenance works. Use the correct tools only and avoid any kind of bumps and blows on the compressor parts. Observe proper cleanliness. Do not use cotton waste for cleaning or drying as it may contain unobserved particles of dirt or metal.

11.1

SERVICE INTERVALS GEARBOX / COMPRESSOR Below is a table of the service intervals recommended by SIEMENS, with references to the various s giving a more detailed description of what is to be done. Local conditions may cause deviations from the norm. Therefore, read each carefully with a view to local conditions before the service intervals are laid down. This applies especially to the parts in touch with the medium. The frequency with which these parts shall be cleaned may vary to some extent, and the service instructions shall be progressively evaluated. SIEMENS's standard instructions are as follows: Job to be done Oil change Oil Filter Change Bearing change gearbox, pinion shaft incl. O-rings, Bearing change gearbox, inlet shaft Service Inlet filter Inlet silencer Drive motor Oil cooler Acc. 11.6 See 6 Acc. 3.3.3 3.3.3 11.2 Intervals First oil change after 8,000 hours of operation. Subsequent changes every 8,000 hours., however, at least once a year When changing the oil or at max. differential pressure, acc. To tech. spec., 2. Every 40000 hrs, change oil too. See drawings next page Every 80000 hrs, change oil too. Every 18,000 hours of operation / every 3 years, whichever comes first. At max. pressure drop according to technical specifications. Shall be cleaned during service. See manufacturers instructions or contact the local SIEMENS representative. See manufacturers instructions

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc



Page 2/50

Oil Change Under normal operating conditions, the compressor can operate 8000 hours before an oil change is required. A pump and a suction pipe is used to drain off the oil. The oil is sucked up through the filler stud (See aggregate / unit drawing) The pump and suction pipe is not standard equipment. Prior to filling on new oil, the oil filter shall always be cleaned / changed according to filter type, see filter description. Important! Do not use other types of oil than the one specified in the technical specifications, as bearings gearwheels etc. have all been dimensioned for this specific type of oil. Damage caused by using wrong type of oil is not covered by the guarantee. Oil level(when unit is not operating)between min and max on the sight glass / dipstick. Oil type and amount: see technical specifications in 2.

Change of Bearings Operational hours between changing of bearings for GK gear mounted with hybrid bearings onto the rotor shaft. Rotor shaft 24,000 40,000 40,000 Pinion shaft 48,000 80,000 80,000

KA2-GK190 KA5-KG200* KA10-GK200

See instructions and illustrations for disassembling and assembling of the compressor and gearbox later in this chapter

BEARING HOUSING GEARBOX

1 Bearing housing 2 O-ring

1 Bearing housing 2 Race 3 Spring

4 O-ring 5 Washer 6 Screw




Page 3/50

11.2

SERVICE Service 1 includes: Inspection of inlet filter and silencer Dismantling of compressor Cleaning and check of compressor impeller Inspection and cleaning of diffuser system Check of diffuser geometry Inspection and cleaning of inlet guide vanes Check of inlet guide vanes geometry Changing of flexible seals (o-rings etc.) Check of lubricating oil Changing of oil filter Visual check of gearwheels (only GL gears) Assembly of compressor and accessories Check / test of control and safety functions (thermostats, pressure switches, transmitters etc.) Test run of compressor with accessories and electric equipment Preparation of service and state report for customer

Estimated time consumption for Service 1 (depending of e.g. plant conditions silencer hood crane facilities etc.): Preconditions: KA5 - 10: Participation of 1 STE service engineer + 1 local assistant. Complete special tools should be available. KA5 / KA10 SV-GK200 11 hours

Detailed description of the service activities. Service requires cleaning and checking of all parts exposed to the medium; as well as checking/replacing of all flexible gaskets; test and, if necessary, adjustment of control panel; test run. If the diffuser ceases to operate smoothly (due to impurities in the compressor) before the 18.000 hrs have lapsed, the first service check shall be moved forward and the services following it timed accordingly, as a dirty compressor is less effective than a clean one. CHECK LIST FOR SERVICE Test run of compressor to check oil-tightness. Vibration level in test point (RMS-value) measured before disassembling of compressor. Dismounting of air inlet duct. - Dismounting of silencer and air-inlet filter. - Dismounting of silencer. - Check and cleaning/replacement of air-inlet filter. - Check of silencer. - Repair of silencer. Dismounting of outer diffuser drive system. Dismounting of inlet housing, spiral casing, contour ring, impeller/rotor and diffuser plate. - Check and cleaning of all air-exposed surfaces, especially of impeller/rotor. - Disassembling of inner diffuser drive system.Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc



Page 4/50

- Check, lubrication, and cleaning of all parts in the diffuser drive system. - Assembling and measuring of diffuser drive system. Check of throat area. Disassembling of gear. - Visual check of gearwheel and sealings. - Replacement of sealings (optional). - Replacement of ball bearings and O-rings. - Cleaning of all parts. - Assembling of gear. - Check and measuring of axial play in gear. Assembling of compressor. Visual check of all parts, including check of clearance of axial bearing in rotor. - Check of clearance between impeller and covering. - Replacement of O-rings. Mounting, check, and adjustment of outer diffuser drive system. Check of mechanical limit switch to stop at scale value "0". Check of limit switch. Mounting of silencer. Mounting of silencer and air-inlet filter. Mounting of air-inlet duct. Replacement or cleaning of oil filter Check of coupling (alignment). Check of drive motor (cleaning of fan and lubrication). Check of blow-off valve and non-return valve (functional test). Check of lube oil pump. Replacement of bearing and seals in lube oil pump.




Page 5/50

11.3

SIMULATED TEST RUN OF COMPRESSOR In order to check the start/stop sequence as well as the cable connections a simulated test run shall be undertaken. When simulating operation the entire safety monitoring equipment shall be tested with satisfactory result. For pressure and temperatures, see technical specifications 2. Turn compressor manually to check that rotation is smooth. This is most easily done at the coupling between drive motor and gear.

11.4

TEST RUN OF COMPRESSOR During the test run the following shall be checked/adjusted: Opening and closing time of blow-off valve. The blow-off valve shall normally signal "closed" at max 180 seconds after start (depending on type of valve and plant conditions). Function of non-return valve. Build-up and stability of air pressure in pressure pipe. Lubricating oil pressure and temperature shall be stabilized. Test diffuser adjustment manually. Test normal start and stop sequence. Adjust motor overload protection (diffuser limit). Check for oil leaks at operating temperature.*)

Test safety monitoring system and emergency stop during operation.

OBSERVATIONS AND MEASUREMENTS DURING MAINTENANCE

Vibration level before service Diffuser throat area after maintenance Clearance rotor/covering Limit switch diffuser Coupling alignment round/flat impact Vibration level after maintenance Hour counter

RMS (mm/S): (mm): (mm): MIN/MAX: (mm): RMS mm/S: (hours):

*)

Lubricating oil pressure and temperature see technical specifications 2.




Page 6/50

11.5

MASTER CONTROL PANEL (if supplied) Check and start-up of Master Control Panel (MCP), during which the start/stop sequence, the priority sequence and control sequence are tested on all compressors. Check of cable connections from Local Control Panels to Master Control Panel. Check and adjustment of step controller (adjustment of diffuser via mA signal). Check of output signal from pressure/oxygen transmitter.

11.6

INLET SILENCER The inlet silencer is designed for atmospheric air and lined with sound-absorbing material. Cleaning of the sound-absorbing baffles can be done by a vacuum cleaner during service. Avoid bending the baffles. The sound absorbing material shall never be exposed to steam or washed with water. IMPORTANT: Organic solvents will damage the material and its adhesion to the supporting frames.

11.7

DISPOSAL OF WASTE Disposal of waste according to the instructions of the local authorities. A compressor in operation shall have air filter elements and lubricating oil changed at regular intervals. Used air filter elements or used filter cloth can be disposed of as combustible waste. Used lubricating oil to be treated as chemical waste and disposal according to the instructions of the local authorities. Oil moistened cloths used for oil absorption and used oil filters can be disposed of as combustible waste. Iron and metal from the replacement of compressor parts can be removed as scrap.

11.8

ORDER FOR SPARE PARTS Orders for spare parts shall state in writing serial number, type of compressor and gear, and position number of each part.


HANDBOOK FOR OPERATIO

Blower

Documents

Transcript of Blower