Ingersoll Rand Industrial Technologies Air Solutions ... Compressors...
Transcript of Ingersoll Rand Industrial Technologies Air Solutions ... Compressors...
Ingersoll Rand Industrial Technologies provide products, services and solutions that enhance our customers’ energy effi ciency, productivity and operations. Our diverse and innovation products range from complete compressed air systems, tools and pumps to material and fl uid handling systems and environmentally friendly microturbines. We also enhance productivity through solutions created by Club Car®, the global leader in golf and utility vehicles for business and individuals.
www.ingersollrandproducts.com
Ingersoll Rand Industrial TechnologiesAir SolutionsStrada Provinciale Cassanese, 108I-20060 Vignate (MI), Italy
10/2010 CPN 23729361 © 2010 Ingersoll Rand plc
Ingersoll Rand compressors are not designed, intended or approved for breathing air applications. Ingersoll Rand does not approve specialized equipment for breathing air applications and assumes no responsibility or liability for compressors used for breathing air service.
Nothing contained on these pages is intended to extend any warranty or representation, expressed or implied, regarding the product described herein. Any such warranties or other terms and conditions of sale of products shall be in accordance with Ingersoll Rand’s standard terms and conditions of sale for such products, which are available upon request.
Product improvement is a continuing goal at Ingersoll Rand. Designs and specifi cations are subject to change without notice or obligation.
More Than Air, Peace of MindIngersoll Rand is now well into our second century
of providing industries throughout the world with
innovative solutions and expertise in compressed
air technology and service. With our new line of
Centac oil-free centrifugal compressors, Ingersoll
Rand continues the tradition of Simplicity by Design— fewer parts and integrated component
— and takes compressed air reliability, effi ciency and productivity to even higher levels.
Ingersoll Rand has demonstrated an ongoing
commitment to excellence in product design,
manufacture and air quality. When it comes to
centrifugal compressors, you can count on Ingersoll
Rand to deliver the peace of mind that comes only
from dealing with the world leader.
Ingersoll Rand provides the complete compressed
air solutions to following industries since years…
● Air Separation ● Petrochemical● Automotive ● Pharmaceutical● Electronics ● Plastic Bottle Blowing● Fiberglass ● Pneumatic Conveying● Flue Gas Desulphurization ● Power Generation● Food & Beverage ● Printing● Glass Blowing ● Pulp & Paper● Iron & Steel ● Textile● Material Handling ● Tyre & Rubber● Off shore Drilling ● Wastewater Treatment● Oil & Gas and many more.....
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Aircare and preventative maintenancePredictable maintenance costs higher uptime
PipingDesigned for lowestpressure drop
Air fi ltrationImproved air qualityReduced maintenance
DryersEffi cient removal ofunwanted moisture
CompressorsMost reliableoil-free design
Process Air
Instrument Air
Plant Air
Reliability Energy Savings
A complete compressed air system is much more than an air
compressor. It’s the complete system - the piping, fi lters, dryers,
drains, hoses, valves and point-of-use tools. And it all needs to work
at peak effi ciency with the quality and reliability to get the job done.
System and Reliability...
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Solutionizing –The Complete Compressed Air System
System controlsOptimized system effi ciency
Cooling systemsDesigned to matchsystem requirements
Leasing and FinancingImproved cash fl ow
AuditsMaximized effi ciency and productivity
Project Management and InstallationSingle-source responsibility
Productivity Environmental Health and Safety
Powered by ExperienceIngersoll Rand is the worldwide leader in centrifugal
technology. In 1911, Ingersoll Rand started
development of the centrifugal compressors.
The design capabilities of Ingersoll Rand led to
the creation of the Centac product line in 1968.
Currently, more than 20,000 Centac compressors
have been installed worldwide.
Ingersoll Rand manufacturing facilities are
spread across the world to meet local needs.
The Centac manufacturing plants are located
at Davidson (USA), Vignate (Italy), Naroda (India)
and Shanghai (China).
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CENTAC - Centrifugal Air Compressor
Centac diesel or gas engine-drive compressors designed to address the electric power limitations
Six 202 m³/m Centac working in an aluminium plant
Centac machine in a POY Plant
Centac machine with in-built cartridge coolers,clocked 75000 hours in year 2007
A Centac with Heat Recovery Coolers
Concept to Reality...
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Ingersoll Rand is fi rst to be Class 0 certifi ed for centrifugal compressor technologyISO 8573-1:2001 Class 0 specifi es air quality standards for critical manufacturing
processes within most industries. It is the most stringent class covering oil
contamination in aerosol, vapour, and liquid forms.
If you need guaranteed pure air for your critical application, then you need Ingersoll
Rand. Our centrifugal compressors were rigorously tested by TÜV Rheinland® -
a global leader in independent testing and assessment services - and earned
ISO 8573-1 (2001) Class 0 certifi cation.
Simplicity by DesignThe diagram below demonstrates how a Centac
compressor operates, the same principle applies
to external coolers confi guration as well. The
sequence shown is repeated in all stages.
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The air proceeds through thediff user section which converts thevelocity energy to pressure energy.
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The built-in intercooler removesthe heat of compression, whichimproves effi ciency.
4
Air passes through a stainless steel moisture separator in a low velocity zone to remove condensate.
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Moisture carryover iseliminated when the airis forced to changedirection 180° to enterthe next stage.
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Diff user
Seal Cartridge
Carbon Ring Seals
Plain Bearing
Built-In Coolers
Thrust Bearing
Vibration Probe
Reverse Thrust Bearing
Air enters the compressor through themachine mounted inlet control valve andfl ows to the fi rst stage where the impellerimparts velocity energy to the air.
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Custom Built Package● Package that meets the actual needs
● State-of-the-art control system
● Superior lube oil system
● Effi cient heat exchangers
● Reliable bearings
Control Valves● Mounted inlet butterfl y valve
● Optional inlet guide vanes
● Mounted bypass valve
● Mounted check valve
● Single point instrument/control air connection
Superior Lube Oil System● Low pressure system (25 psig)
● Minimum 3 minutes retention time
which ensures lower frequency of
refi lling, improves life of bearings
● Shaft driven main oil pump
● Lube oil sump heater
● Optional Dual oil fi lter
Controls● Constant Pressure Modulation & Auto Dual
Control are standard
● Most advanced in the compressor industry
● Latest Micro Controller with LCD display
Condensate System● Drain - All type condensate traps
● Piped and mounted on compressor
● Two traps per stage
Cooler Options
1) Built-In Cartridge Air Coolers● Air in tubes and water in shell design
● No external piping - Easy installation
● Eliminate need for expansion joints
● No exposed hot air piping
● Compact, effi cient design
● Reduced package size
2) External Shell & Tube type Air Coolers● Designed basis TEMA & API Guide lines
● Air in shell and water in tubes design
● Designed for low pressure drop
● Tube sizes are 5/8" and 20 BWG, which
provides longer life, lower maintenance
and tubes cleaning option by "rodding",
which is not possible in case of smaller
size tube diameter
● Designed for a higher water side fouling
factor of 0.0004 Hr.m².Deg. °C / Kcal for
extended life of tubes
3) Heat Recovery Coolers● As much as 80-93% of electrical energy
used by an industrial air compressor is
converted into heat
● Heat recovery unit coolers can recover
anywhere from 50-90% of this available
thermal energy
● Typical uses for recovered heat include
supplement space heating, water heating,
make up air heating, and boiler make up
water preheating. Unique Ingersoll Rand
heat recovery design custom built coolers
to suit your requirements
Saves from Day One
Main Drive Electric Motor● High Effi ciency
● Design Temperature - Minimum 45 Deg. °C
● Degree of Protection - Minimum IP 55
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A Unique Flexible Package
C950 package with external coolers
Ingersoll Rand centrifugal features the most modern
electronic control system in the industry. The Centac
Micro Controller system utilizes an advanced, self-
regulating process computer to completely integrate
the compressor, motor and auxiliary equipment. The
CMC™ microcontroller provides increased fl exibility
and improved control ability while performing
unparalleled compressor system monitoring.
User-Friendly● Simple twelve-button keypad● More on-screen data increases your ability to
determine the compressor operating status● Operating parameters, alarm settings and trip
settings appear on the graphic display panel● Set points can be changed at the touch of a button● Multi-language and units from the display
Self-Diagnostic● First-out indication and event log details the
last 224 events that occurred● Event log screen simplifies troubleshooting
and analysis of your compressor● Includes logic to determine a microcontroller
malfunction● Surge Absorber™ reduces the impact, both
duration and magnitude, to system pressure
changes from a surge condition for more
reliable operation
Control Flexibility● Standard energy optimization in auto dual
control mode● Standard constant pressure in modulate
control mode
Dependable Operation● Fail-safe feature stores operating parameters
at the time of shutdown due to power loss● System automatically adjusts to a start condition
when power is restored after a power failure
System Management● Older centrifugal compressors (even non-IR)
can be easily upgraded and automated into
a single system
State-of-the-art Electronics andCommunications● The Optional Universal Communications Module
(UCM) allows for integration into a plant-wide
control system● The UCM supports MODBUS and Allen-Bradley
DF-1 protocols● The UCM also communicates through and accepts
modem commands● Energy management software is available to
provide signifi cant energy savings
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Flexible, Effi cient Control SystemVibration Monitoring ProtectAgainst Bearing FailureTo provide re l iable predict ive
maintenance and to guard
against failure of the bearings
support ing the rotat ing
assemblies, vibration monitoring
is standard on all stages (vibration
monitoring at each impeller).
Seals Minimize Air Leakage and Oil Migration, Ensuring Oil-Free AirFull-floating non-contact carbon
ring seals minimize air leakage and
prevent oil from migrating
up the rotor shaft under all
operating conditions.
Techtrol Gold - SyntheticLubricant● Extended operating life of 16000 hours or 2 years● Stable viscosity over a wide temperature range● Bearings run cooler● Improved heat transfer characteristics● Superior fi lm strength protects against metal-to-
metal contact● Environment friendly
Vertically Split Casing Reduces Maintenance DowntimeIngersoll Rand’s exclusive vertical split casing provides
easier access to the machine. It makes it possible to
have a single-piece bearing and seal design which
helps quick and easy fi eld replacement of internal
components. In addition, it also provides the fl exibility
of the external setting of required running clearances
without opening the casing at all.
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Proven. Reliable. Versatile.A Flexible Package At the heart of every unit are the
essential components, designed,
manufactured or specif ied by
Ingersoll Rand that set the Ingersoll
Rand centrifugal apart from all other
compressors.
A Balanced, Stable Rotor AssemblyIncreases Effi ciency, Extends Gear LifeThe impeller, designed and manufactured by
Ingersoll Rand from high-grade stainless
steel (15-5 PH), features vane geometry
developed by Ingersoll Rand for maximum
pressure control over the widest operating range.
A thrust collar allows aerodynamic thrust loads to
dissipate to the bearings without being transmitted
to the main gear train, eff ectively extending gear life.
Superior Bearing System Design Provides Longer Maintenance Intervals The stability of the rotor assembly permits
Ingersoll Rand to use simple bearings with no
moving parts. The rotor spins on a stable fi lm of
oil, providing long intervals between scheduled
maintenance checks.
Vibration Monitoring Protects Against Bearing FailureTo provide reliable predictive maintenance and to
guard against failure of the bearings supporting the
rotating assemblies, vibration monitoring is standard
on all stages (vibration monitoring at each impeller).
Audit SolutionsIngersoll Rand’s Complete Consultancy Services
Your air system problems require total solutions.
Ingersoll Rand Audit Solutions will help you defi ne
system problems, whether they are in demand,
distribution or supply, and develop cost-effi cient
solutions that meet your return on investment
goals.
Ingersoll Rand Air Solutions is helping customers
optimize their systems and even more ...
● Reduce operating costs● Improve productivity and reliability● Improve quality● Reduce capital spending● Stabilize system pressure
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We off er compressors on rent and also carryout Air System Management and Air Over Fence Projects.
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Advanced ControlAnticipating your control systems needs whether
it’s local compressor controls or systemwide
confi gurations, Ingersoll Rand has solutions.
Peer to Peer Control● Proven Anti-Blowoff / Loadsharing control● Automatic compressor control with sequenced
start / load / unload / stop functionality
ASC - Air System Controller &ASM - Air System ManagerThe ASC and ASM are total system integration
software, which provides....
● Energy management through load sharing● Total system management including all
compressor technologies, dryers and coolers● Remote communications - monitor from
anywhere at any time● Multiple pressure set point control
The Ingersoll Rand TeamIngersoll Rand’s team of professionals from product
design and development to sales consulting,
application engineering, installation, startup
and aftersale service, knows how to keep your
compressed air system operating costs down
while maintaining peak performance for the life
of your system. Ingersoll Rand’s 24/7 parts and
service network is ready to serve you 365 days a
year with whatever it takes to keep your system
up and running.
AirCare - A Committed RelationshipNo long-term maintenance program is more
comprehensive than AirCare. The highlights of the
program include:
● Certifi ed, professional technicians to perform
routine inspections and diagnostic service
● Enhanced performance through exclusive use
of genuine IR parts and lubricants
● All-inclusive fluid analysis program will
comprehensively monitor the lubricant in
the compressor to detect problems at the
earliest possible opportunity
● Vibration analysis diagnostics pinpoint the
need for component replacement through
monitoring and trend analysis that predicts
the service life of critical components
Services
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No matter what the industry orlocation, Ingersoll Rand is committedto serving you 24 hours a day, sevendays a week. Our worldwide networkof distributors, engineers andcertifi ed, factory–trained techniciansare a phone call away – ready tosupport you with innovative andcost–eff ective service solutionsthat will keep you running atpeak performance.
Global Reach, Local Service
The easiest way toprotect your air system andbudgets is UltraCare
UltraCare – much more than Extended Warranty,is a Long-Term Comprehensive Service Contract coveringvisits of expertly trained service engineers, consumablesand all parts including wear tear and breakdowns, if any. Moreover, it’s at fixed and predictable cost.
Product Range
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Progress is greener with Ingersoll Rand
Ingersoll Rand offers industry leading products and solutions that enablebusinesses around the world to reduce energy consumption and costs anddecrease harmful environmental emissions. From air compressors thatreduce energy consumption to electric-powered golf cars with near-zeroemissions, Ingersoll Rand provides the knowledge, experience andsolutions to help our clients achieve their sustainability goals.
Integrated Project Management
Single Source ResponsibilityIngersoll Rand’s 135 plus years of leadership in the compressed air industry enables us to provide turnkey solutions for your Integrated Project Management needs. From design to commissioning.
Dedicated team for Integrated Project Management ensures timely completion and world-classexecution with:
● Design Services: Design system requirements, equipment selection and layouts● Equipment Supplies: Compressors, Dryers, Cooling Water Systems, Electrical Systems ● Infrastructure: Civil Works - Compressor House, Piping & Distribution Systems, Installation & Commissioning ● Life Cycle Management: Parts, Services, Operations & Maintenance
Frame Flow* Power Pressure Range* cfm m³/min hp kW psi bar (g) CC700 1800-4250 51-120 400- 930 298-694 50-150 3.5-10.5
C950 4150-6250 118-177 500-1500 373-1119 50-150 3.5-10.5
C1000 4500-7500 127-212 700-1500 521-1119 50-150 3.5-10.5
3CII 6000-9300 170-263 1000-2100 746-1567 40-150 2.8-10.5
C3000 9000-15000 255-425 1750-3500 1306-2611 65-150 4.6-10.5
5CII 12500-30000 354-849 1750-6000 1306-4476 30-150 2.1-10.5* The above mentioned range (both in terms of fl ow and pressure) is indicative only and are most widely used. Please contact Ingersoll Rand’s representative for your specifi c needs and requirement not specifi ed above.