SEMINARIO SELECCION Y MANTENIMIENTO PREVENTIVO · PDF fileAerzener Maschinenfabrik GmbH 3...

Aerzener Maschinenfabrik GmbH 1 Bombas Bornemann S.R.L.

• Seminario sobre Selección de Equipos y Mantenimiento Preventivo

History:• 1864 Foundation

• 1868 Manufacture of the first european positive displacement

blower � more than 130 years of experience!!!

• 1909 The Aerzen workshops supply blower no. 10.000

• 1930 Production start for rotary piston gas meters

• 1943 Production start for screw compressors

• 1967 Development and supply of special screw compressors

for air compression

• 1968 Serial production of oil injected screw compressors

for refrigeration industry

• 1971 Development and supply of oil injected screw

compressors for compressed air industry



• 1978 The world‘s largest positive displacement blower

(conveying volume 84.000 m³/h) built for steel

production

• 1984 The world‘s largest screw compressors (conveying

volume 65.000 m³/h) built for and supplied to

chemical industry

• 1987 Aerzen develops positive displacement blowers

with internal pulsation dampening

• 1989 Blower no. 250.000 ready for delivery



Aerzen Positive Displacement Blowers

• Aerzen Positive Displacement Blowers of standard designGM 3S bis GM 1080L, DN 50 up to DN 800

22 sizes, intake volume flows from approx. 30 to 65.000 m³/h

∆p = max. 1000 mbar

• Aerzen DELTA BLOWER (blower units of standard design)3-lobe type blowers, GM 3S bis GM 240S, DN 50 up to DN 400

16 sizes, intake volume flows from approx. 30 to 15.000 m³/h

max. ∆p = 1000 mbar pressure service, max. - 500 mbar vacuum

• Aerzen bulk vehicle blowers4 sizes, intake volume flows from approx. 600 to 2.250 m³/h

∆p = 1000 mbar, 1200 mbar max. dsign, up to max. - 500 mbar vacuum



DELTA BLOWER series

DELTA SCREW series

Operating range of Aerzen blowers and screw compress ors



Range of application of Aerzener Positive Displacement BlowersRange of application of Aerzener Positive Displacement Blowers

Sewage watertechnique

Watertreatment

Pneumat.transport

Flue gasdesulfurization

Chem./ food-stuff indus

Gassupply

Chem./processgas industry

Vacuumtechnique

Aerationbasin

Gritchamber

Filterflushing

Ventilat.Rivers/Lakes Bulk

goods

Vacuumoperation

Pressureoperation

Oxidationair

Sewagegas

Techn.gas

Increaseof gas

pressure

Mixed gases

Pump stands



Mech. - biological sewage treatment

Oxidation air (O2) by Aerzen PD blowers or screw compressors

Aerzen PD blowers (biogas arrangement) for the gas supply to

the gas motor or burner

Aeration by Aerzen PD

blowers

Waste water

Mechanical stage

Biological stage

Screen

Grit chamber Oil and grease trap Primary settlement tank

Sludge

Aeration basin

Secondary settlement tank

Treated waterSludge

Biogas

Fowling towerGas reservoir



Clarification

Waste water treatment application

waste waterAeration

basinGrit chamberScreen treated water

air

air (O2)

Appr. 60% of the energy Consumption of the aeration

system

Plant`s structure of costs

1.) Costs of investment

2.) Power consumption

3.) Costs for maintenance / repairs



Aerzen Blowers for the aeration of the biological part and the grit chamber




Distribution of air in the aeration basin




Blow in depth

Usual blow in depths:

• municipal plants 4...8 mWS

• industrial plants 10...20 mWS

basin




pressureincrease

dirty diffusor

cleanpressure loss pipingblow in depth

air flow

Demand on pressurized air:

� oil free

� stable performance curve

� ability of flow controlBy pollution of the diffusor system the pressure can increase by 20% !




O2 content in the aeration basin

0

0,5

1

1,5

2

2,5

3

3,5

4

02:00

04:00

06:00

08:00

10:00

12:00

14:00

16:00

18:00

20:00

22:00

00:00

daytime

mg

O2/

l

Reihe1

Why is the air flow to be controlled ?




Delta Blower GM 3S for the aeration of the grit chamber




Delta Blower Gen. 5, GM 60S in STP Sports City Duba i, UAE




Subjects

1. Blower and DELTA BLOWER- Operating ranges of Positive Displacement Blowers andSrew Compressors- Range of application of Aerzen Positive Displacement Blowers- 3-lobe blowers with pre-inlet channel, working principle- History of Aerzen blower units- Package Delta Blower: advantages, scope of supply, modifications

2. Delta Blower Generation 5- Noise study- Construction of units, constructive modifications- Advantages and customer benefit- Possibilities to deliver- Possible modifications

3. ATEX-solutions from Aerzen



The third dimension of

air conveyance



Conveying cycle of a two-lobe blower



Conveying cycle of a two-lobe blower

The PD blower operates acc. to the displacement pri nciple without internal compression (only isochore ), therefore the counter system pressure only determines the amount of compression and consequent ly the power consumption. Alteration of volume flow can only be achieved by s peed control.

Vibrations and pulsations !

4 partial conveying gas volumes per revolution of

the drive shaft



Lp1: Sqeeze-impulsLp2: Pressure-impuls 2-lobe

Lp12 = Lp1 + Lp2 (2-lobe)

Aerzen blower units



The application of the Interference process tothe construction of rotary lobe blowers hasbeen patented by the AerzenerMaschinenfabrik under the registrationnumber DE 3527292 C2

Aerzen‘s Patent



Conveying cycle of a three-lobe blower

IntakeGas enters the open conveying chamber of the blower via the intake opening

Conveying cycleBy rotors`rotation closing of the intake opening and displacement of the conveying gas volume to discharge side is proceeded.

OutpouringThe rotor opens the discharge socket, the conveying gas volume is pushed into the system.

6 partial conveying gas volumes per revolution of

the drive shaft



Lp1: Sqeeze-impulsLp2: Pressure-impuls 2-lobeLp3: Pressure-impuls 3-lobe

Lp12 = Lp1 + Lp2 (2-lobe)

Lp13 = Lp1 + Lp3 = 0 (3-lobe)

Aerzen blower units



Advantages of the 3-lobe-blowerwith pre-inlet channels

• Pulsations are cancelled directly in the blower stage

• The vibration loading of the bearings, timing gears and casing is much more lower than regarding a two-lobe-blower

• The noise energy in the discharge piping is about 25 dB lower

• Lower investment outlays for buildings and system components



Cross sectional drawing of a 3lobe blower GM 35S



An Aerzen three-lobe blower.....

Ring retainers....• Sealed by O-rings against shafts

• Large neutral chambers to avoid

oil mist leakage into conveying chamber

Timing gears....

• Helical, hardened and ground• Fixed on shaft ends by conical-

press-on taper

• Removable by oil pressure

Housing consists of...

• Cylinder

• Side plates• Gear- and housing cover

Adjusted by conical pins and boltet !



Inlet and outlet conditions, blower sizing

Intake conditions:t1 = 40 °CP1 = 1,0 bar abs.m° = 1000 kg/h� Q1 = 900 m³/h

Outlet conditions:t2 = 104 °CP2 = 1,6 bar abs.m° = 1000 kg/h� Q2 = 676 m³/h

p1 * Q1 p2 * Q2T1 T2



Q1 intake volume flow at

intake pressure p1 = 1,0 bar abs.intake temperature t1 = 20 °C

∆∆∆∆p pressure difference∆∆∆∆ t temperature differencen blower speedP power consumption

Pressure service

Performance curve of blower GM 35S, pressure servic e

Mechanical limits

• max. speed• min. speed• max. pressure• max. outlet temperature• max. temperature difference


• Seminario sobre Selección de Equipos y Mantenimiento PreventivoBlower sizingBlower sizing

Losses included in PK :

� Pressure loss filter silencer

� Power loss of bare shaft blower

� Pressure loss of base frame

� Pressure loss of non return flap

PK = Pth + PV bare shaft+ PV access

Pth = (nG * q0 * dp) / 600.000


• Seminario sobre Selección de Equipos y Mantenimiento PreventivoBlower sizingBlower sizing

Lossesnot included in Pk:

� Belt drive

� Ventilation fan

Pth = (nG * q0 * dp) / 600.000

PK = Pth + PV bare shaft+ PV access



Compressed-air production with positive displacemen t blowers

Machine selection and design:Evaluation of operating data

Stipulations: QN = 1936 Nm³/h (based on: 1,013 bar abs. + 0 °C)

m° = 2503 kg/h

Sommer operation

Intake temperature t1 = 35° C

Intake pressure p1 = 1,0 bar abs.

Relative humidity RF = 70%

Intake volume flow Q1 = 35,70 m³/min

Winter operation

Intake temperature t1 = -15° C

Intake pressure p1 = 1,0 bar abs.

Relative humidity RF = 70%

Intake volume flow Q1 = 30,93 m³/min



intake volume

po

we

r co

nsu

mtio

n

controller withsetpoint

transmitter

aeration basin

frequency converter

Single Circuit control: Continous control of volume flowwith one blower unit

Positive displacement blower GM 35Sdrive motor with frequency converterintake volume flow Q1 = 9,1...35,7 m³/minabsorbed power at coupling PK = 14...47 kW



Blower package: demands on the unit

Necessary scope of supply:

� Positive displacement blower

� Filter silencer

� Discharge silencer

� Non-return flap

� Belt drive

� Pressure valve

� Flexible machinery mountings

� Flexible piping connection

� Start-up unloading device

� Drive motor

� Acoustic hood



DELTA BLOWER

Intake filter silencer:1. Silencing

2. Filtering

To avoid pollution of the system by absorption material



DELTA BLOWER

Intake filter silencer:1. Silencing

2. Filtering

To avoid pollution of the system by absorption material

Filter class G4 (EU 4) acc. EN779

Average Filtration efficiency: 92 %

Synthetic material: polyester microfibres

Food-genuinly and regenerable



DELTA BLOWER

Base frame with integrated discharge silencer

Reactive type without any absorption material

To avoid pollution of the system by absorbtion material

Discharge silencer acc. to pressure vessel equipment directive 97/23/EG



DELTA BLOWER

Base frame with integrated discharge silencer



DELTA BLOWER

Belt tensioning

Hinged motor support



DELTA BLOWER

Belt tensioning

Example: Blower GM 150S

Nominal bore DN 300

Motor 200 kW

Totally closed belt guard



DELTA BLOWER

Start-up unloading valve

....only neccessary, if the motor must be started in Star-Deltaand the blower starts against full back pressure (aeration basin)



DELTA BLOWER

Acoustic hood:• Indoor execution or

• Outdoor execution or

• Execution for higher noise dampening:

25 dB(A).

Oil level check can be done without opening of the acoustic hood

Compact IV design !



Aerzen motors Driving motors acc. to IEC and works S TD TNO 1159Name plate: Aerzener MaschinenfabrikOperating manual: 4PG-702-D-XU2 - pole: 1,5....37 kW make: WEG

45....160 kW make: WEG

4 - pole: 75....160 kW make: WEG

Motors acc. to IEC - STD. Motors should fulfill the stipulations of works STD.TNO 1159

Driving motor

Extracts from works standard TN0 1159:

•Insulation class F

•Type of protection IP 55

•Junction box on top, cable entry from fan side

•Motors must be suitable for frequency converter operation, speed range 1 :3

•Admissible radial vibration velocity of rotor: 11 mm/sec

•Bearing of the rotors in single row ball bearings

•Admissible lateral load: 1,1 x motor weight

•Defined regreasing intervals (2000h for 2-pole, 4000 h for 4-pole motors

•Nominal bearing lifetime: 25000 h



2006: The new one‘s there...



• DN 50 < 65 dB(A)

• DN 80 65….70 dB(A)

• DN 100 70….73 dB(A)

• DN 125 70….73 dB(A)

• DN 150 max. 75 dB(A)

• DN 200 max. 78 dB(A)

Sound level

Stipulated sound pressure levels: dp = 700 mbar



Noise Study DELTA Blower Generation 5 , GM 7L / 700 mbar

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

2 3 4 5 6 7 8

Intake volume flow Q1[m³/min]

Mac

hine

noi

se L

p(A

) [d

B(A

)]

GM 7L/DN 80 brochure GM 7L-G5/DN 80 measured



Noise study DELTA Blower Generation 5 , GM 25S / 1000 mbar

66

68

70

72

74

76

78

80

82

84

86

5 10 15 20 25

Intake volume flow Q1[m³/min]

Mac

hine

noi

se L

p(A

) [d

B(A

)]

GM 25S/DN 125 Prospekt GM 25S-G5/DN 125 gemessen



Advantages

� Sound pressure level of the machine noise by 6...9 dB(A) lower than the previously documented level

Schallstudie DELTA Blower Generation 5 , GM 50L / 700 mbar

68

70

72

74

76

78

80

82

84

15 20 25 30 35 40

Ansaugvolumenstrom Q1[m³/min]

Mas

chin

enge

räus

ch L

p(A

) [d

B(A

)]

GM 50L/DN 150 Prospekt GM 50L-G5/DN 150 Messw erte

� Reduced sound emissionand -damage to theenvironment. Special acoustic hoods are not necessary, the investment charges are considerably reduced!

Customer benefit:



� Simple operation and maintenance: Transport with fork lift truck/stacker lift truck,the maintenance work „oil“ and „filter“ are effected from the front. The oil level check can be carried out with running blower.

Main-operation side

Advantages



� Simple operation and maintenance: Transport with fork lift truck/stacker lift truck,the maintenance work „oil“ and „filter“ are effected from the front. The oil levelcheck can be carried out with running blower.

Main-operation side

Advantages



� Simple operation and maintenance: Transport mit fork lift truck/stacker lift truck,the maintenance work „oil“ und „filter“ are effected from the front. The oil level check can be carried out with running blower.

Main-operation side

Advantages



� Easy handling ofassembly/commissioning.The time- and expenditure for operation andmaintenance work is considerably minimized.

Customer benefit:

� Simple operation and maintenance: Transport mit fork lift truck/stacker lift truck,the maintenance work „oil“ and „filter“ are effected from the front. The oil level check can be carried out from the outside with running (DN 80....DN 200)

Advantages



DN 50 unit: constructive design

Accessibility



� Considerable reduction of the investment charges as anauxiliary drive has not to be installed electrically.

� In case of ATEX-applications the Aerzener solution is cost-neutral as an ex-proof motorhas not to be used.

Customer benefit:

� Hood ventilation by mechanical fan

Advantages



� Smallest possible bases reduce the space requirementand consequently the machine room size. The variant „Sideby Side“ is designed for special tricky space proportions.

Customer benefit:

� Acoustic hoods / Units: Special space-saving design

Advantages



• Dimensions shall be as small as possible

800 800 800 800

required width: 7088 mm

Delta Blower Delta Blower Delta Blower

1296 1296

GM 10S / DN 100 GM 10S / DN 100 GM 10S / DN 100

1296

800

GM 10S / DN 100 Delta Blower Gen. 5

1250

required width: 4550 mm

1250



1250

� Acoustic hoods / Units: Special space-saving design



Customer benefit:

� Operational reliability ! Optimal ventilation of the unitalso with critical environmental conditions.

� Acoustic hood inlet air (Process and ventilation): at the „cold“ side of the unit,exhaust air of the hood at the „warm“ side.

Advantages



Customer benefit:

� Operational reliability ! Optimal ventilation of the unitalso with critical environmental conditions.

� Acoustic hood inlet air (process and ventilation): at the „cold“ side of the unit,exhaust air of the hood at the „warm“ side.

Advantages



Customer benefit:

� After initial installation the belt tensioning has not to be controlled any longer.Saving with installation- andmaintenance costs.

� The belt re-tensioning is effected really automatically, i.e. without spring construction

Advantages



Customer benefit:

� Motors with the highest possible efficiency reduce the energy costs considerably. Re-lubricating devices increase the lifetime of the motor bearing.

� Driving motor in efficiency class EFF 1, with re-lubricating nipples

Advantages



Customer benefit:

� No uncertainties during unit planning and –realization. Aerzener units fulfill the stipulated regulation.

� Discharge silencer and pressure valve correspond to the pressure device guidelinePED

Advantages



Customer benefit:

Positive displacement blowers show as potential ignition spark producer a risk area inmany cases of application. Atsite, costly spark traps are notnecessary any longer.

� Discharge silencers certified as spark trap: ATEX-applications

Advantages



Customer benefit:

� Outdoor installation is possible on a favourable line on costs. Reduction of the investment charges.

� Acoustic hood applicable for indoor- and outdoor installation (modified)

Advantages


• Seminario sobre Selección de Equipos y Mantenimiento PreventivoValue analysis

Measures.....

New: Front panels reach ground floor

New: different fasteners


• Seminario sobre Selección de Equipos y Mantenimiento PreventivoValue analysis

New base frame and connecting housing, pressure service DN 100



DELTA BLOWER : biogas / landfill gas, pressure service

Options blower:

Combined rotor chamber sealing

Internal parts protected with ChemCoat-Coating

Options accessories:

Intake silencer, base frame and pipings made from

Stainless steel

Only available as compact IV, not Generation 5



DELTA BLOWER biogas / landfill gas, pressure service

Acoustic hood, incl. ventilation fanindoor executionor outdoor executionor for higher noise dampeningspecial execution

Driving motorMotors acc. to IEC - std.explosion proof

Accessories (Options)Instrumentation: (Ex i or ex-proof)pressure gauge intake / dischargepressure switch intake / dischargetemperature switch

DELTA BLOWER Package

blower GM 3S.....GM 240S, modified and w. optionsintake silencerbase frame with integrated discharge silencerhinged motor supportelast. Machinery mountingsconnecting housing non-return flapsaety valve or bypass controller incl. Bypassflange compensator for intake / discharge sideflange compensator for bypass pipeV-belt drivebelt guard if blower is equipped w/o acoustic hood

consisting of:



Subjects

1. DELTA BLOWER- Operating ranges of Positive Displacement Blowers andSrew Compressors- Range of application of Aerzen Positive Displacement Blowers- 3-lobe blowers with pre-inlet channel, working principle- History of Aerzen blower units- Package Delta Blower: advantages, scope of supply, modifications

2. Delta Blower Generation 5- Noise study- Construction of units, constructive modifications- Advantages and customer benefit- Possibilities to deliver- Possible modifications

3. ATEX-solutions


• Seminario sobre Selección de Equipos y Mantenimiento PreventivoFb 617-0/4-08/02 Gebläse ⋅⋅⋅⋅ Verdichter ⋅⋅⋅⋅ Gaszähler

Machine groups, categories and zones acc. to 94/9/E G Procedures with conformity evaluation for non-electrical machines

Group I

mining below ground, risks caused by mine gas and dust

Group II risks caused by explosive atmosphere from gas/air- or dust/air mixtures, dust or steams

Category M Category 1 Category 2 Category 3

1 2 G

(gas) (zone 0)

D (dust)

(zone 20)

G (gas)

(zone 1)

D (dust)

(zone 21)

G (gas)

(zone 2)

D (dust)

(zone 22)

For machines applied in underground mines as well as in plants above ground offering a high degree of safety. The

operation must also be ensured in case of rare

failures.

For machines in

underground mines as well as in plants above ground offering a high

degree of safety. In case of explosive atmosphere a shutdown is possible.

For machines ensuring safety to a high degree. Applied for the constant, long-

term or frequent operation in hazardous areas

(more than 1000 h/year, frequently) . Also in case of rare failures the machines do not show any effective source of ignition.

For machines ensuring safety to a high degree. Destined for cases where it has to

be reckoned with an explosive atmosphere (10-1000 h/year rarely). Also in case of rare failures the machines do not

show any effective source of ignition.

For machines ensuring a normal degree of

safety. Destined in case it has to be reckoned - only rarely and if only for a

short time - with an explosive atmosphere (0-10 h/year, very rarely) . Machines does not show any effective

ignition source at normal operation.

Annex II / Nr.: 2.0.1 resp. 2.0.2 Annex II / no.: 2.1 Annex II / no.: 2.2 Annex II / no.: 2.3

EU-type inspection by indicated position acc. to annex III

EU-type inspection by indicated position acc. to annex III

Internal production control acc. to annex VIII + storage of technical documents at

the manufacturer and deposit at an indicated position for 10 years (min.) after

manufacturing of the last product or individual inspection acc. to annex IX

Internal production control acc. to annex VIII

- For the certification of these orders an external position is necessary. For costs

and delivery time please contact our technical department.

Certification can be carried out by AM.

For standard machines construction kits are available.

Special machines are certified separately via an individual analysis.

Necessary scope of documentation for non-electrical and electrical machines and operation means depending on zone and category

Machine group II EU-type inspection Internal production control Conformity certification Category Zone electrical non-electrical electrical non-electrical electrical non-electrical

1 0 x x x x 2 1 x x *) x x 3 2 x x x x

*) complete documentation, incl. risk analysis are to be stored at an indicated position.



Air inlet

Air deflection

Air outlet

The Aerzener base support - also discharge silencer - exclusively functions by means of deflections! Absorption material will notbe used(combustible and not suitable for the food industry)!

New ATEX-solutions from Aerzen

Certified base support:



Aerzen -

one step ahead!

SEMINARIO SELECCION Y MANTENIMIENTO PREVENTIVO · PDF fileAerzener Maschinenfabrik GmbH 3...

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Transcript of SEMINARIO SELECCION Y MANTENIMIENTO PREVENTIVO · PDF fileAerzener Maschinenfabrik GmbH 3...