INSTALLATION Location in Plant Figure 1 : Typical Air System
Key
2. Air Receiver Dry Tank
Discharge piping should be at least as large as the discharge connection of the compressor. All piping and fittings should be suitably rated for the discharge pressure. Discharge piping should not exert any unresolved moments or force on the compressor.
3. Air Dryer
It is good practice to install line filters (4).
4. Compressed Air Filters
Include a vent or drain trap (6) to vent the discharge pipework downstream from the minimum pressure check valve located on the separator tank and upstream of the first system isolation valve (7).
1. Compressor
5. System Demand Points 6. Vent/Drain Trap
This compressor has an internal discharge check valve. An external check valve is not required. An isolation valve (7) is required within 1 m (36 in) of the compressor discharge.
7. Isolation Valve 8. Air Receiver (“Wet Tank”)
NOTICE • The compressor can be installed on any level floor capable of supporting it. A dry, well ventilated area where the atmosphere is as clean as possible is recommended. • The area selected for the location of the compressor should be free of dust, chemicals, metal filings, paint fumes and overspray. • Hard surfaces may reflect noise with an apparent increase in the decibel level. When sound transmission is important, a sheet of rubber or cork can be installed beneath the compressor to reduce noise. Flexible piping may be required. • See the general arrangement drawing for minimum space requirements for normal operation and maintenance. • Minimum space in front of the control panel door as required by national or local codes shall be maintained. • Ambient temperatures higher than 46 °C (115 °F) shall be avoided, as well as areas of high humidity.
Notice
There should be no plastic or PVC piping attached to this compressor or used for any lines down stream with exception of condensate removal lines.
NOTICE The discharged air contains a very small percentage of compressor coolant and care should be taken to ensure that downstream equipment is compatible. When two rotary compressors are operated in parallel, provide an isolation vaIve (7) and drain trap (6) for each compressor before the common receiver. Ensure the discharge piping is arranged to prevent water from being forced into the non-operating compressor. A wet tank (8) is recommended in cases where the air dryer is a regenerative desiccant type to prevent short cycling the compressor during the purging cycle when plant air demand is slow.
A minimum of 1 m (3.3 ft) all around the compressor is recommended. If headroom is restricted, then the exhaust should be ducted or deflected away from the compressor.
The built-in aftercooler reduces the discharge air temperature below the dew point (for most ambient conditions). Therefore, considerable water vapor is condensed. To remove this condensation, each compressor with a built-in aftercooler is furnished with a combination condensate separator/trap.
Screw type compressors should not be installed in air systems with reciprocating compressors without means of isolation such as a common receiver tank. It is recommended that both types of compressor be piped to a common receiver tank using individual air lines.
A dripleg assembly and isolation valve should be mounted near the compressor discharge. A drain line should be connected to the condensate drain in the base.
The compressor is shipped with the shipping restraints in place. Ensure that these are removed to allow free movement of the drive assembly during operation. Each restraint is painted yellow.
Discharge and Condensate Piping See Figure 1. It is essential when installing a new compressor (1) to review the total air system. This is to ensure a safe and effective total system. One item which should be considered is liquid carryover. Installation of air dryers (3) is always good practice since, when properly selected and installed, they can reduce any liquid carryover to zero. An air receiver tank (2) is recommended to ensure that the total system volume is sufficient.
80446164 Rev C
NOTICE The drain line shall slope downward from the base to work properly. For ease of inspection of the automatic drain trap operation, the drain piping should include an open funnel. The drain line must have a minimum inside diameter of 8 mm (5/16 in)
NOTICE For low volume systems that may not include an air receiver tank (2), compressor response time may need adjusting. Contact your local Ingersoll Rand service provider.
NOTICE Do not use the compressor to support the discharge pipe. EN-4
Watercooled
Draining the water system
Cooling Water Piping
Should it become necessary to completely drain the water system, use the following procedures specific to the water cooled option you have.
NOTICE Water piping to and from the compressor package shall be at least as large as the package connection size. Do not undersize the water piping. Isolation valves with side drains should be installed on both the inlet and outlet lines. To maintain cooler cleanliness and reliability, it is important to install a strainer of 2 mm mesh size on the inlet line. Strainers are available from Ingersoll Rand. For sea water applications (sea water option only) a zinc anode is not recommended as it will deteriorate the copper oxide film on the 70/30 copper-nickel alloy tubes in contact with sea water. To minimize galvanic corrosion and provide the greatest corrosion protection to the coolers, it is strongly recommended that a section of iron pipe (>00 mm length) be connected as close as possible to the air compressor package water inlet connection. The iron pipe will act as the sacrificial anode for the coppernickel tubes and therefore shall be considered a regular maintenance and replacement item. For this reason, the section of iron pipe should be installed so that it can be easily replaced (e.g. with a union joint.). The air compressor has a normally closed solenoid valve that is fitted to the water outlet side within the package. The valve is wired into the air compressor control circuit and closes when the compressor stops. Carefully inspect the water system before installing the air compressor package. Ensure that the piping is free of scale and deposits that may restrict water flow to the air compressor package. If water cleanliness is poor, filtration installed on the water inlet pipe line is recommended. Proper operation of the compressor requires that the cooling water flow be provided at a maximum supply temperature of 46 °C (115 °F). See the compressor engineering data sheets for cooling water flow rates. Water temperature and pressure gauges should be installed in the water piping for use in any fault finding of the water system. Water pressure should ideally be between and 5 bar (43 .5 and 72.5 psi) but shall not be above 10 bar (145 psi). Water cleanliness is also extremely important. Cleaning of coolers as a result of fouling is a customer responsibility. Therefore, it is highly recommended that proper water quality shall meet the requirements listed in WATER QUALITY RECOMMENDATIONS later in this section.
Venting the water system Air should be vented from the water side of the system to avoid poor performance and water hammer. Since the air compressor uses different type heat exchangers depending on your selection of “fresh water cooled” or “harsh water cooled” system, the venting procedure is different. Be sure to use the correct procedure below: Fresh water coolers (brazed plate heat exchangers): 1. Disconnect the water stop valve in the water outlet line of the compressor. 2. Open the inlet water valve(s) to allow the water to flow to the compressor. 3. Allow all the air to escape from the system and observe water at the water outlet port. 4. Connect the water stop valve. Harsh water coolers (shell and tube heat exchangers): 1. Locate the water system vent cocks on top of the aftercooler and oil cooler. 2. Open the water valve(s) allowing water to flow to the package.
Fresh water coolers (brazed plate heat exchangers): 1. Disconnect the inlet water line from the connection located at the rear of the compressor. 2. Disconnect the water stop valve in the water outlet line of the compressor. 3. Allow the system to completely drain. Harsh water coolers (shell & tube heat exchangers): 1. Disconnect the inlet and discharge water lines from the connections located at the rear of the compressor. 2. Locate the aftercooler and oil cooler. Remove the drain plugs located at the bottom of the coolers. 3. Open the vent ports in the top of the aftercooler and oil cooler. 4. Allow the system to completely drain. Adjusting the aftercooler trim valve See the piping and instrumentation diagram provided separately from this manual. The coolers are piped in a “parallel” water flow arrangement with a manual trim valve controlling the flow through the aftercooler. The aftercooler trim valve is factory set and should not need adjusting but if disturbed use following procedure. 1. Close valve fully clockwise and then open two full turns. 2. With the compressor running loaded observe the package discharge temperature on the controller display. It should be approximately 8 °C (15 °F) above the water inlet temperature. 3. If the temperature is too high, open the valve ¼ turn and wait one minute. If the temperature is too low, close the valve ¼ turn and wait one minute. Repeat the incremental movements until the desired temperature is reached. 4. Put a “Warning − Do Not Adjust” label on the valve or fit a lock.
Water quality recommendations Water quality is often overlooked when the cooling system of a watercooled air compressor is examined. Water quality determines how effective the heat transfer rate, as well as the flow rate, will remain during the life of the compressor. It should be noted that the quality of water used in any cooling system does not remain constant during the operation of the system. Evaporation, corrosion, chemical and temperature changes, aeration, scale and biological formations affect the water makeup. Most problems in a cooling system first appear as a reduction in the heat transfer rate, then in a reduced flow rate or increased pressure drop, and finally with damage to the system. Scale: Scale formation inhibits effective heat transfer, yet it does help prevent corrosion. Therefore, a thin uniform coating of calcium carbonate is acceptable on the inner surface. Perhaps the largest contributor to scale formation is the precipitation of calcium carbonate out of the water. This is dependent on temperature and pH level. The higher the pH value, the greater the chance of scale formation. Scale can be controlled with water treatment. Corrosion: In contrast to scale formation is the problem of corrosion. Chlorides cause problems because of their size and conductivity. Low pH levels promote corrosion, as well as high levels of dissolved oxygen. Fouling: Biological and organic substances (slime) can also cause problems, but in elevated temperature environments such as cooling processes they are not a major concern. If they create problems with clogging, commercial shock treatments are available.
3. Open the vent cocks and allow all air to escape from the system. When water is observed at the vent cocks, close them.
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80446164 Rev C
To ensure good operation life and performance of the compressor cooling system, the recommended acceptable ranges for different water constituents are included below: Table 3 : Acceptable Limits for Cooling Water Constituents
Substance
Test Interval
ACCEPTABLE MAXIMUM LIMITS Fresh Water Dirty Water / Sea Water (Brazed Plate Heat Exchanger) (Shell & Tube Heat Exchanger) 0 to 1 -0.5 to 2.5
Langelier Index (LI)
Monthly
Ammonia [NH3 ], ppm
Monthly
<1
<2
Ammonium [NH4-1], ppm Chlorides [Cl-], ppm Copper [Cu], ppm Dissolved Oxygen (DO) [O2], ppm Iron + Manganese [Fe + Mn], ppm Nitrate [NO3 -], ppm Oil & Grease, ppm
Monthly Monthly Weekly Monthly Monthly Monthly Monthly
<2 <80 <0.01 <0.1 <0.3 <100 <5
<5 <1000 <0.5 <3 <2 <125 <5
Silicon Dioxide (silica) [SiO2], ppm Sulfates [SO4-2], ppm
Monthly Monthly
<30 <70
<100 <250
Integrated Dryer
Environmental Limits
Do not connect condensate drains common to other pressurized drain lines in a closed circuit. Make sure the outflow from the condensate drains is unimpeded. Connect the condensate piping in such a way to ensure that sound levels are kept to a minimum during drainage.
The standard compressor package is designed for the following conditions:
Ensure that all condensate is disposed of in a responsible manner, in compliance with all applicable standards and regulations (local, state, country, federal, etc.).
- Ambient temperature range 2 to 46 °C (5-115 °F)
The ambient air around the dryer and compressor shall not contain solid or gaseous contaminants. All compressed and condensed gases can generate acids or chemical products which may damage the compressor or components inside the dryer. Take particular care with sulphur, ammonia, chlorine and installations in marine environments.
- Indoors only • Area not considered to be a high dust area.
Ingersoll Rand offers the following options for fixed speed compressors that extend the environmental limits: • Outdoor modification • Low ambient option (-23 to 46 °C / -15 to 115 °F) at sea level • High ambient option (2 to 55 °C / 5 to 13 1 °F) at sea level • High dust air filter • High dust package filter
80446164 Rev C
En-6
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