Kaeser Compressors` Blower System Installation Guide: Layout
Contents
1. KAESER COMPRESSORS Blower System Installation Guide Layout Considerations for a Reliable Energy Efficient and Safe Blower System By Kaeser s Blower and Engineering Experts www us kaeser com About the Authors This e book was written for you by Kaeser s blower system ex perts At Kaeser we believe the more you know about operating blower systems the more you ll get out of them That s why we re com mitted to offering you the most current information you need to wisely install operate and maintain yours Our goal is to help you install the most successful blower system possible The tips guidelines and warnings included in this e book are meant to do just that While the information included in this e book is comprehensive we recognize that each system and application is unique Ap plying the principles you read here is an excellent place to start For the best in system optimization that is tailored to your needs contact us for additional support Throughout the e book there are boxes with efficiency tips and additional resources The links included in those will take you directly to more information that our engineers and blower sys tem experts have selected specifically to further assist with your blower system Introduction Receiving a a s 2 Equipment Location Ventilation Electrical Piping Copyright 2015 Kaeser Compressors2. front Preventive Safety Advisories More Resources Check out some of our more creative system design solutions in Tip Contact us for help planning your Additional installation to ensure proper Resources clearances for service and your plant equipment this blog entry www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 11 Appendices www us kaeser com Location Environmental Considerations Be mindful of how the system temperature impacts equipment operation and make sure temperatures remain within the manu facturer s stated temperature ranges Low temperature may impede the proper flow of some types of lubricant and promote moisture condensation For lower ambi ent temperature applications Kaeser offers a sound enclosure heater option to protect the blower package High ambient temperatures on the other hand often result in reduced lubricant life They may also result in excessively high approach temperatures Kaeser s lobe blower packages are designed to operate in ambient temperatures up to 104 F and screw blowers 113 F Operating the blower packages at higher temperatures than indicated can affect performance cause com ponent damage and may also void the warranty 4 4 Kaeser s lobe blower packages are designed to oper ate in ambient temperatures up to 104 F and screw blowers 113 F Copyright 2015 Kaeser Compressors Inc All Righ
3. calculated as 1 03 times the block power consumption MOT The thermal output of the motor increases by about 1 when under partial load down to half rated power Electrical Of the motor is driven from a frequency converter the thermal output increases a further 3 6 Supply Qp Thermal output of V belt transmission ca 3 of motor shaft power Piping Q Blower block thermal output 1 2 of block power consumption Q Silencer thermal output 1 2 of block power consumption Packag Overall thermal output QcomBineD MoT Qpr Q Qsp KW Building an Efficient n Q i 1 Pipework Thermal Output not insulated Q ne 3 2 105 d I 0 6 T Tiup kW LINE Preventive Because of the high flow velocity the heat take up of the gas is insignificant and can be ignored Maintenance d pipe diameter in mm pipe length in m Safet T blower discharge temperature in C Advisori Tug ambient temperature in C Additional mesources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved www us kaeser com Appendix B Helpful Formulas and Calculations Volume flowing into the blower room VI 3600 Q BLOWER ROOM COMBINED Quine p e AT p Cooling air density 1 19 kg m at 20 C 1 bar c Thermal capacity of air 1 0 kJ kgK AT Room temperature rise 5 10 K Airflow into the room not necessary if 3 BLOWER R
4. Inter net of Things continues to expand package and communication integration will become even more important to a plant s energy and asset management strategy Location Ventilation For more information see the Master Controllers section Electrical IU VDDIY Piping Package ntegqration Building an Efficient EL When looking for a master controller consider its overall ability to integrate with your existing network communications Preventive J J Maintenance Safety More Resources Click here to read our blog entry Additional on the benefits of adaptive control Resources systems www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Appendices Building an Efficient System Package vs System Efficiency Introduction Building an Efficient System Receiving QUININCH Ee Le CA ea System engineers do their best to combat wasted energy by se lecting energy efficient equipment This has led to an increased focus on energy and has helped spur innovations in blower technology Blower manufacturers are taking advantage of the Location increasing interest in wire to air efficiency to promote these new technologies which can produce more efficient blowers for certain performance points Ventilation Wire to air efficiency is simply the total energy used to provide the specified flow and pressure and is expresse
5. and fewer PM J J Supply visits Improve Operations with More Stable System Design Variable Pipin e Improve production equipment performance e Less downtime due to pressure alarms e Less scrap and product quality problems Package Kaeser s Sigma Air Manager SAM makes it easy to control and monitor up to 16 blowers There are numerous control schemes that you can easily customize to best meet your needs The con trols you implement will directly impact your facility s productivity and energy efficiency Building an Preventive vViaintenance Safety ice More Resources Contact your local authorized Kaeser representative for sample Additional control schemes and for help cus tomizing a solution for your system www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Appendices Preventive Maintenance Keeping Your System Up and Running www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved www us kaeser com Preventive Maintenance All mechanical and electrical equipment requires varying de grees of attention to ensure it operates efficiently Since most systems rely heavily on an uninterrupted supply of flow it makes sense to invest in preventive maintenance rather than suffer downtime and repairs It s highly recommended to establish a regular maintenance rou tine to ensure proper operation of all parts of your blower syste
6. 4 i a Safety Additional D CA NCSOUICES www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 43 Appendices Additional Resources More Tips and Resources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Additional Resources Receivin A wuipment e www kaesertalksshop com Our company blog features posts on a wide range of compressed air topics written by our subject matter experts and is updated regularly You can also sign up to follow the blog to receive updates whenever there is a new post e www kaeser com cagi Kaeser is a member of the Compressed Air and Gas Institute CAGI a non profit organization of competitive Location companies that manufacture air and gas compressor and related equipment e www kaeser com resources This webpage has a collection of technical articles material safety data sheets MSDS tools presenta tions and much more Ventilation e www kaeser com whitepapers Our collection of whitepapers provide in depth technical information on challenges those in the com pressed air industry are currently facing Electrical Q L Tolol u e Our online Kaeser Toolbox has a number of handy tools for making common compressed air calculations Piping Package Building an Effici n icient Preventive li a 7 BA z vainienance Safety Additional nesources w
7. Compressors Inc All Rights Reserved 4 Appendices Receiving Equipment General Tip www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Receiving Equipment Receiving your shipment is one of the first considerations in preparing your new installation Freight damage happens It s important to protect yourself Be sure to thoroughly inspect your commercial freight before you sign for it Our freight tips video has everything you need to know to successfully receive any kind of commercial shipment In summary e Don t sign until you have inspected e Check the Tip n Tell indicators e Open the packaging e Look for signs of replaced packaging 6 Be sure to thoroughly inspect your commercial freight before you sign for it www us kaeser com JJ Copyright 2015 Kaeser Compressors Inc All Rights Reserved 6 Introduction Receiving Location Ventilation Electrical OULU QODIV Piping Package Integration Building an Efficient Preventive Safety Additional D MCsOVUICEeS Appendices Location Placement Affects Performance www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Location General Tip Kaeser s Com paK blower packages are designed for side by side installation no additional clearance is needed For integrat ed and screw blower pac
8. Inc All Rights Reserved 4 4 Our goal is to help you install the most success ful blower system possible The tips guidelines and warnings included in this e book are meant to do just that Tip Look for these boxes throughout the e book for additional tips Package Building an Efficient II Preventive More Resources Additional resources are in these Additional boxes Want to hear the latest Resources Kaeser news Visit www kaeser com connect Appendices Table of Contents Introduction a a oe Section Receiving Equipment Section II Location ae Section III Ventilation lt a Section IV Electrical Safety i Pink s P Section V Piping r Section VI Package Integration Section VII Building an Efficient System Section VIII Preventive Maintenance Section IX Safety Advisories Section X Additional Resources Appendices www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Introduction Introduction Receiving Equipment Blowers are vital pieces of equipment in a variety of different applications Many plants face shut down when there is any kind of problem or issue with their blower system that s why proper planning is essential before installing a new system If you are upgrading an existing system you may be faced with physi cal restrictions requiring creative solutions Whether installi
9. OO 1_Blower m h n V lt vV i 1 Airflow into the room necessary if 3 BLOWER ROOM 1_Blower m h n V gt V i 1 Exhaust airflow from the room Blower air intake from the room Figure 1 n l V X l V INTAKE V BLOWER ROOM V 1_Blower i 1 If V 0 then V V INTAKE BLOWER ROOM LBY Blower air intake from outside the room Figure 2 y Vy INTAKE BLOWER ROOM Effective cross section areas of ventilation openings A V m EFF BLOWER ROOM 10800 Based on the recommended airflow rate of 3 m s Copyright 2015 Kaeser Compressors Inc All Rights Reserved te so a Ny ee ha a aE by a ME F ee oe F Ae a Introduction Receiving penta Ms eee ee N A o nN A al i Location Ventilation Electrical Piping Package Building an Efficient Preventive m gt 4 ss A vainienance Safety AaVISC Additional B La B d aal ai e mesources The Air Systems Specialist We earn our customers business by supplying superior quality equipment and services Our products are designed for reliable performance easy mainte nance and energy efficiency Prompt and dependable customer service qual ity assurance training and engineering support contribute to the value our customers have come to expect from Kaeser Our employees are committed to implementing and maintaining the highest standards of qualit
10. Rights Reserved Introduction Safety Advisories Health and Safety Considerations Receiving oOmMment Installation should be conducted in a safe manner in accordance with OSHA and appropriate local regulations Compressed air can be dangerous and should never be directed towards people Improper and unsafe contact with compressed air can cause eye damage sub cutaneous embolisms and other serious injuries including death Location When working in a lift technicians should use a proper harness and rigging Qualified technicians must perform electrical work in a safe manner using UL approved materials and properly insulated tools equipment and appropriate personal protective equipment PPE for the work All applicable local state and national regulations must be followed Ventilation The blower system must be installed so that normal operation poses no threat to work health or safety The system must be sufficiently ventilated so that it poses no health threat to persons nearby Electrical ey 74 wd Po IODIV Hearing protection must be worn in accordance with OSHA standards Where applicable prominently display signs warning of noise haz ards Blower operating sound levels are listed in Kaeser service manuals Follow OSHA recommendations for electrical lock out tag out Pipin Follow all safety recommendations in the manufacturers service manual Package Building an Efficient Preventive J M
11. d as a ratio of the power to the flow While this metric is relatively new to the blower market it is widely used for industrial compressors and compressed air systems and is often referred to as specific performance Standards developed by groups like ISO CAGI PNEUROP and ASME provide testing guidelines for specific performance comparison Electrical v o 4 4B amp Piping Package Integration Building an 6 Wire to air efficiency is simply the total energy used to provide the specified flow and pressure and is expressed as a ratio of the power to the flow Preventive IJ ea Safety Advisories More Resources Click here to download a copy of Additional our whitepaper on energy efficient Resources system design for wastewater treatment plants www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved y Appendices Introduction Building an Efficient System Receiving Fquioment Whether using the term wire to air or specific power it is impor tant to differentiate between each individual piece of equipment s efficiency and the overall system efficiency Be careful of focus ing on individual blowers instead of considering how each piece Location will work with one another Even if you select the most energy ef ficient blowers if they aren t properly applied and controlled they system Splitting won t yield the anticipated energy savings Thi
12. d wire should be equally sized to the power conductors FE ve manka Ventilation Electrical Piping Threw phase star F Three phase defa Wei ourin mon piii arihed moubral ee Integration Building an Efficient ee Thirphase diii o The p urst open a Threes phaset opin four wine oarthod dalta four wira deha hron winr Hid panl et phase garhe ma poani of earthed jinin of phase phases Preventive Maintenance Tip Consult the NEC Code and local regulations for guidance in determining the acceptable limits for ground electrode impedance www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 22 Appendices Introduction Electrical Supply Receiving QUININCH Nee Re LA Aa WARNING Insufficient and or improper grounding practices may lead to premature motor or VFD component failure Location WARNING Never use air piping or electrical conduit as a means of grounding Ventilation Electrical WARNING All wiring and electrical connections must be performed by a qualified electrician in accordance with NEC and Supply local electrical codes Supply conductors must be properly sized in accordance with all applicable national and local codes Piping WARNING The electrical service disconnect should be within sight of the blower and have an easily recognizable lock out tag Package Integration Building an WARNING Some projec
13. delta start or variable frequency drive should never be installed outdoors JJ www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 13 Introduction Receiving Equipment Location Ventilation Electrical SY Ey Piping Package Integration Building an Efficient Preventive Maintenance Safety Advisories Additional Appendices Introduction Location High dust Environments Receiving Equipment Blowers are often in dusty areas or applications Protecting blow ers from ingesting particulate and keeping dust dirt from build ing up on components will extend service life and maintenance intervals Location Kaeser blower packages come standard with inlet silencers fil ters equipped with differential pressure indicators to signal when service is needed Enclosures are also highly recommended to reduce particle load on inlet air and to prevent particulates from building up on drive components Ventilation Electrical at 4 AL Piping Package Integration Building an Efficient 4 4 Kaeser blower packages come standard with inlet silencers filters equipped with differential pressure indicators to signal when service is needed Preventive Safety Advisories More Resources Contact your local authorized Additional Kaeser representative for Resources accessories for a hig
14. e fre l quency drive blower is selected that is the same size or smaller Location than the fixed speed blowers in the system This graph shows a system designed to avoid a control gap It can provide a steady airflow to meet a system design variable C N Ventilation e g DO pressure through the flow range of the system since 4 4 it is properly sized and controlled by a system master controller Control gaps are flaws in the system design that oc like Kaeser s Sigma Air Manager SAM cur when the control range of the variable frequency blower is not considered Electrical JJ go Piping Max 2 000 cfm Package Base load 73 cfm Integration 1 5 Base load 2 573 cfm VSD Range C AA Speed load 994 i _ M The VSD is able to Preventive A p p slow down and speed up to match all the compressors output 497 capacity to the existing demand capacities A p p without control gaps Speed load Building an CFM FAD AIR CONSUMPTION More Resources Control gaps can happen in any type of installation with a VFD and Additional multiple fixed speed units Resources Click here to read our Mind the Gap blog entry www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Appendices Introduction Building an Efficient Sytem Master Controllers Receiving Ea T io m el nt If you have more than one blower feedin
15. ed speed mode or pressure regulation VFD where the unit maintains a desired discharge pressure which is set locally However larger multiple unit installations will want to take full advantage of the benefits more in depth controls provide Especially if they are incorporat ing variable frequency drive units master controllers or if they will be integrating the system into larger plant management systems Adaptive control schemes often offer the best efficiency and performance and require more extensive unit controls Ventilation Electrical UD Piping Package Building an Efficient 4 4 The choice of control depends greatly on the applica tion and overall sophistication level of the installation Preventive II Safety Advisories Additional Resources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 29 Appendices Introduction Package Integration System Controls Receiving 0 i JITICTit System controls vary in scope as well When looking for a master controller consider its overall ability to integrate with your exist ing network communications Does it have communications interfaces that will easily connect with your SCADA system If your blower system is in an isolated location consider looking for a master controller with advanced remote monitoring and also maintenance tracking and notification capabilities As the
16. g the same system you should consider system master controls Master controllers con trol multiple blowers more efficiently while maintaining pressure stability and rotating like sized units to equalize service hours Location A master controllers computing capacity enables it to rapidly rec ognize changes in demand and always select the most efficient combination of blowers to meet it Ventilation Electrical Piping Package Integration 1 Building an Preventive j viaintenance Tip Advanced master controllers can monitor a specific system variable such as dissolved oxygen and trigger an alarm it the variable falls below a specific threshold value www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 36 Appendices Introduction Building an Efficient System Master Controllers Receiving EN qQuionment Benefits of Master Controllers Save Energy e Run blowers less Location e Match air production to demand e Reduce kW cfm production e Maintain blower package rotation schedule e Minimize system pressure if pressure regulating Ventilation Reduced Maintenance Costs e Less cycling and switching longer valve life e Fewer motor starts longer motor life 4 4 The controls you implement will directly impact your facility s productivity and energy efficiency Electrical e Balanced blower package operating hours
17. h dust environment www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Appendices Ventilation Ensuring Proper Cooling and Equipment Longevity www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved www us kaeser com Ventilation Proper ventilation is key to ensuring optimal equipment perfor mance and longevity Failure to properly plan and ventilate the blower room can cause equipment downtime increased mainte nance intervals and reduced performance The room s ventilation openings should be fitted with louvers or some other silencing device to limit noise in the surrounding en vironment An exhaust ventilation fan can be installed in the room to provide forced ventilation Arrange room ventilation openings so the current of cooling air flowing through the room passes over the blower inlet and exhaust ports If possible eliminate stagnant air in the room Avoid thermal short circuit discharged cooling air must not find its way to the cooling air inlet Also do not position the blower so close to a wall that the cooling air flow inlet is obstructed 191 Failure to properly plan and ventilate the blower room can cause equipment downtime increased mainte nance intervals and reduced performance Eiig Copyright 2015 Kaeser Compressors Inc All Rights Reserved Tip Check Blower Installation Data Sheets for ventilation recommendation
18. ical costs Electrical w A M a Y Using larger diameter piping and eliminating elbows and T s whenever possible will help keep pressure drop as low as pos sible Piping Above image shows an ample sized header with insulation to limit heat transfer to the package cooling air Package Integration Building an Efficient 4 4 Reducing pressure losses leads to lower operating temperatures and lower electrical costs Preventive Maintenance JJ Safety Advisories Additional Resources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 25 Appendices Introduction Piping Materials oOmMment Piping materials can also impact pressure drop as some materi als are more prone to contaminant build up Kaeser strongly cautions against using PVC piping While it is a Location cheap readily available material it s important to understand its eau ea_ aeaeeeleeeee eee limitations PVC piping is not recommended for operating temper atures above 140 F this includes Schedule 40 and 80 piping bb PVC piping is not recommended for operating tem In fact any time the temperature is above 20 C 68 F a thermal peratures above 140 F this includes Schedule 40 Ventilation derating factor must be applied to determine the maximum al and 80 piping lowable working pressure Additionally pipe diameter affects the J J derati
19. ing variable frequency drives VFD s to optimize process low pressure air systems offers many advantages When properly ap plied VFDs are an excellent choice in variable flow applications Blowers with VFDs can be used as stand alone units and also Location have an important role to play in larger more complex control schemes However in either case sufficient attention must be paid to factors such as proper connection methods grounding managing electromagnetic interference EMI with communica Ventilation tions and proper parameterizing Additionally care must be taken in sizing the system to avoid control gap which causes system fluctuations and leads to un necessary energy inefficiencies bs TTL WVU Mgnt Electrical U IWI Yy Piping Package Integration Building an 4 4 Blowers with VFDs can be used as stand alone units and also have an important role to play in larger more complex control schemes Preventive 3 URAA te narice Safety Additional Re source www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 34 Appendices Introduction Building an Efficient System Avoiding Control Gap Receiving A SEQuipmMen Control gaps are flaws in the system design that occur when the control range of the variable frequency blower is not considered The majority of the time this happens because a variabl
20. kages with variable frequency drive we recommend clearance of 30 36 inches on the drive cabinet side only for access and ventilation 4 4 Com paK blower packages are designed for side by side installation www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Tip Consult your local NEC code for rules and regulations on drive cabinet clearances for packages with variable frequency drive 8 Introduction Receiving Equipment Location Ventilation Electrical Supply Piping Package Integration Building an Efficient Preventive Maintenance Safety Advisories Additional Resources Appendices Introduction Location Floor Receiving Equipment No special foundation or base is needed for Kaeser s blower packages The blowers should be placed on a level surface able to withstand the combined load of the blower and the equipment used to move it into place Location Ventilation Electrical Piping Package Building an Efficient Preventive Safety AQ O MM VIoVvVIIC CY Additional Resources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 9 ee Introduction Location Anchoring Receiving Z SMCA ph he a Though Kaeser blowers have minimal vibration many customers choose to anchor all thei
21. lues must be mul tipled together Motor Shaft Power Ambient Temperature Motor Shaft Power Derate Chart 100 95 90 Ambient Temperature C Ambient Temperature Motor Shaft Power Derate Chart 100 Motor Shaft Power O O O UI 00 Nn SPo00 1750 2500 3250 4000 Elevation m Motor Shaft Power www us kaeser com Ambient Temperature Motor Shaft Power Derate Chart 100 95 90 85 80 05 110 115 120 125 130 135 140 Ambient Temperature F Copyright 2015 Kaeser Compressors Inc All Rights Reserved Ambient Temperature Motor Shaft Power Derate Chart 100 Motor Shaft Power O O O Sz oe UI 3 o0 5200 7200 9200 11200 13200 Elevation ft Introduction Receiving HSAmmimant EFaquioment Location Ventilation Electrical UDOIV ww VA Piping Package Building an Efficient Preventive J i 4 i a ACQ Vis Safety Additional B 2 f af MesOQurces ppendices Introduction Appendix B Helpful Formulas and Calculations Receiving r eee IOR 7 Wal gt EqQuiome ant Thermal Outout of Rotary Blowers Q Thermal output of the drive motor Motor power 3 7 5 kW ca 14 Location 11 185 kW ca 10 22 55 kW ca 7 75 200kW ca 5 The percentage values relate to the corresponding shaft power of the motors Because of the V belt transmission loss these can be Ventilation
22. m and maintain a service log for each component Regular preven tive maintenance will ensure optimal performance and longer equipment life Your blower service manual has specific service recommenda tions Follow all recommended maintenance procedures Taking the few minutes to perform these checks will maintain the quality of your flow and equipment reducing the costs associated with repairs and lost production Kaeser s integrated and screw blower packages come equipped with computerized controllers which monitor equipment health and operation in real time as well as provide maintenance inter val reminders They offer the capability to send these messages to plant control systems or provide messaging to plant personnel responsible for the equipment Copyright 2015 Kaeser Compressors Inc All Rights Reserved bb Regular preventive maintenance will ensure optimal performance and longer equipment life JJ More Resources Click here to take flight and explore our screw blower packages Tip Need a service manual Contact your local authorized Kaeser representative Introduction Receiving Equipment Location Ventilation Electrical N a oly Piping Package Integration Building an Efficient Preventive vViaintenanc Safety Advisories Additional Appendices Introduction Preventive Maintenance General Guidelines Recei
23. mance values e g CAGI data sheets Since energy management is an important consideration for any plant proper controls should always be addressed in any blower system When addressing the issue of controls there are individ ual unit controls to consider as well as broader system controls that manage and coordinate the overall low pressure air system 4 4 A complete package design reduces time spent engi neering and purchasing individual components Introduction Receiving Equipment Location Ventilation Electrical JUDD Piping Copyright 2015 Kaeser Compressors Inc All Rights Reserved Package ILC UratiO 4n Building an Efficient Preventive Safety Advisories More Resources Visit CAGI s website for more Additional information on their testing standards Appendices Introduction Package Integration Blower Controls Receiving Individual unit controls can range from very basic packages with essential pressure and vacuum gauges to more comprehensive packages that also include temperature oil level and filter moni toring sensors as well as remote monitoring capabilities Location The choice depends greatly on the application and overall sophistication level of the installation Smaller individual unit ap plications may require only basic controls These local or indi vidual unit control options are often either a fix
24. ng a brand new system or upgrading an existing one the information contained in this e book will assist you in identifying the best configuration and in getting the best possible performance from your blower system Location Ventilation For the purposes of this e book it s assumed you have already Se _ identified pressure flow and blower sizing requirements If you mee IIM EZENN ie are unsure how to determine these for yourself we strongly nTa a E E cai ici moet ma eS ai ah recommend you contact a blower system specialist to accurately measure these parameters for you Electrical SY Ey ee be Piping This e book should be used as a Supplement to the service man uals with your Kaeser blower equipment These contain installa tion information pertaining to the specific model s purchased Package Integration Diagrams in this e book are presented only as examples They are not necessarily the best way of installing your particular sys tem If you need assistance consult your local authorized Kaeser representative for expertise installing blower systems nnn nnn nnn Ruilding an Efficient 4 4 The information contained in this e book will assist you in identifying the best configuration and in get ting the best possible performance from your blower system J J Preventive Maintenance Safety Advisories Additional www us kaeser com Copyright 2015 Kaeser
25. ng factors as larger diameters are de rated faster Electrical If you have PVC piping or are considering using it make sure to understand how your particular installation s operating conditions will affect it From a pressure drop as well as a safety standpoint its probably best to use a different material BLUDDIV wd UA Piping Package Integration Building an Efficient Preventive J M 4 i a Burst PVC piping from a compressed air installation AQVIS es Safety More Resources For more information on the Additional dangers of using PVC piping read MesOQurces our blog entry www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Appendices Package Integration Blower and System Controls www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved www us kaeser com Package Integration The most significant recent advances in blower technology have been in package integration A complete package design reduces time spent engineering and purchasing individual components Additionally each component is selected for optimal efficiency and to work together to achieve the best package performance Integrated machines are often equipped with a suite of sensors and onboard controller which monitor package performance and health As factory built machines they come with full documen tation testing and stated perfor
26. r Compressors Inc All Rights Reserved 40 Appendices Introduction Preventive Maintenance General Guidelines Receiving Equipment In addition to regular checks by your plant personnel an effective preventive maintenance program should include regular professional servicing Standard services are usually performed at manufacturer recommended intervals but may be recommended more often de pending on the usage and operating environment Location Kaeser has a factory trained national distribution network that is always ready to assist you with your maintenance needs Contact your local authorized Kaeser representative to schedule a service appointment Ventilation WARNING Lack of proper maintenance may invalidate any warranty claims if failures are directly related to a failure to perform routine preventive maintenance A preventive maintenance contract with your local Kaeser represen tative is a means of having this work carried out properly Electrical JUDD CAUTION Before performing any work be sure to follow OSHA recommendations for electrical lock out tag out ae Package Integration Building an Efficient Preventive Safety Advisories Additional www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 41 Appendices Safety Advisories Health and Safety Considerations www us kaeser com Copyright 2015 Kaeser Compressors Inc All
27. r blowers Anchoring the blower package should be according to the drawing found in the service manual Location Ventilation Electrical Piping Package Integration Building an Efficient Preventive Maintenance Safety Advisories Additional www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 10 Appendices Introduction Location Access Receiving Equipment The entrance to the blower room must be large enough to ac commodate both the blower package and the equipment used to move it into place such as a forklift crane or pallet truck The space designed for the blower system must provide enough Location clearance to ae me 5 e Maneuver the unit into place j F mi de a zi e Open maintenance doors and access panels e Te e Remove and replace components ies n ii 411M Ventilation e Provide adequate ventilation E OF gin at E apes Kaeser has designed its blower packages so that the internal components can be easily accessed from the front Do not defeat this feature by blocking the maintenance doors Your service manual includes dimensional drawings for your specific model Electrical awh oly Piping Package Integration Building an Efficient 4 4 Kaeser has designed its blower packages so that the internal components can be easily accessed from the
28. r that is short circuiting or preheated cooling air at the blower inlets Location Ventilation Electrical Piping Package Building an Efficient Preventive Safety AQ 10 FAUVIVDVIICD Additional mesources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 18 Introduction Ventilation Receiving Equipment This example shows a properly ventilated blower room The airflow is properly pulled across the blower packages and preheating of the air is prevented Although not shown here it is also important to insulate any exposed discharged piping Location Ventilation Electrical Piping Package Integration Building an Efficient Preventive Maintenance Safety Additional www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 19 Appendices Electrical Supply Important Warnings to Follow www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Introduction Electrical Supply Receiving Equipment Before installing the blower package check to ensure that your electrical service voltage matches the voltage on the blower nameplate located inside the electrical cabinet or the tag on the outside of the machine Whether your blower is a dual or a tri voltage model ensure it is internally wi
29. red for the proper voltage Location Ventilation Kaeser recommends that each blower have its own dedicated electrical circuit and disconnect panel This makes it possible to lock out and tag out an individual piece of equipment without having to shut down other equipment that may be on the same panel Disconnects should eliminate power from the entire machine including all accessory equipment and instruments Electrical planning should include wiring for a master controller multi unit control device if it is to be installed Piping The blower should be properly grounded Install an appropriately sized fuse or circuit breaker between the blower and main electric ser vice Consult the NEC and local electrical codes regulations for sizing guidelines Building an Efficient Preventive Maintenance Safety Additional Resources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 21 Appendices Introduction Electrical Supply ane Eau ip nent For variable frequency drive units make sure that the power supply transformer has a symmetrical three phase supply In a symmetrical three phase supply the phase angles and voltages are all the same Location Kaeser s VFD units require a symmetrical power supply trans former with a wye configuration output The circled configurations indicate the two acceptable options for Kaeser s VFD packages Groun
30. s 16 Introduction Receiving Equipment Location Ventilation Electrical al l M dh m Piping Package Integration Building an Efficient Preventive Maintenance Safety Advisories Additional Appendices Ventilation If the blower is located in the middle of a large room its exhaust air can be extracted by a duct above the exhaust port While this air is not likely to be warm enough for process use it could be recovered and used to warm other areas of the plant and reduce heating costs If no duct is required extract the exhaust air from the upper third of the room as this is where the heat collects The installation diagrams on the following pages show examples of proper blower room ventilation For formulas for calculating the volume flowing into the room ventilation fan capacity and effec tive cross section of ventilation openings see Appendix B www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Introduction Receiving Equipment Location Ventilation Electrical ws St Ji 3 Piping Package Integration Building an Efficient Preventive Maintenance Safety Advisories Additional Resources 17 Appendices Introduction Ventilation Receiving Equipment This example shows a poorly ventilated blower room The orange arrows indicate ai
31. s is why system specific power is crucial in system design Ventilation System specific power takes into account the combined efficien cy of all package component and in the case of variable fre quency drive units drive losses With this machine information the combined performance of these machines can be allocated to selected operating points of system demand to determine the Electrical SUDODIV overall blower system performance From here these results can e M i be compared from solution to solution and across blower tech Average savings compared to traditional system design Pibin nologies is ai a Don t be fooled by the efficiency curves of an oversized blower If the blower will not be operating in its optimum performance curve for your application it will not deliver the energy efficient savings you are expecting Building an 4 4 Even if you select the most energy efficient blowers if they aren t properly applied and controlled they won t yield the anticipated energy savings Preventive IJ via int Cnance More Resources Our System Splitting video explains Additional how to design an energy efficient Resources blower system Click here to view it www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Appendices Introduction Building an Efficient System Avoiding Control Gap Receiving Us
32. ts Reserved Introduction Receiving Equipment Location Ventilation Electrical Supply Piping Package Integration Building an Efficient Qa Preventive Maintenance Safety Advisories Additional Resources Appendices Location Outdoor Installations While it s best to install any type of blower indoors if it must be installed outdoors it should have protection from rain and snow Note that the integrated and screw blower packages with wye delta start or variable frequency drive should never be installed outdoors Weather hoods If there is no shelter provided for the blowers or if wind driven rain or snow can reach the packages weather hoods must be added to the air inlet and exhaust of the cabinet exterior These are available from Kaeser factory installed or as a retrofit kit Sound enclosure heaters If the ambient temperature drops be low 28 F but is still above 5 F a sound enclosure heater must be installed Sound enclosure heaters are designed to to raise the machine temperature to about 50 F This ensures proper oil viscosity during start up and inhibits moisture collecting in the sound enclosure It is thermostatically controlled to shut off when 41 F is reached within the sound enclosure is reached They are available from Kaeser factory installed or as a retrofit kit 4 4 Integrated and screw blower packages with wye
33. ts installations will have limits on Total Harmonic Distortion THD THD limits must be clearly Efficient defined by the methods outlined in IEEE 519 To achieve a desired THD value additional external ancillary devices may be System required These devices may either be a passive harmonic filter or an active harmonic filter All Kaeser packages include passive harmonic filters but may not meet stringent project requirements Preventive Maintenance Safety Advisories Additional Resources www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 23 Appendices Piping Impact of Pressure Drop and Piping Materials www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Introduction P p n g Receivin Equipmen Pressure drop directly affects blower temperature and conse quently blower efficiency Positive displacement blowers use external compression This means the more resistance there is to airflow the more energy they will consume Additionally while Location a blower may be designed for 15 psig it will only operate at 15 psig if there is enough resistance to the airflow that would require 15 psig pressure from the blower Ventilation Limiting pressure losses between the blower and the point of use reduces the load on the blower as well as the kW consumption of the machine leading to lower operating temperatures and lower electr
34. ving Below is a general list of maintenance items to monitor Check your service manual for more recommendations Keep in mind that based on your application and operating environment you may need to adjust the frequency Contact your local authorized Location Kaeser representative with any additional questions e Check oil level via sight glasses at least monthly e Check belt tension visual indicator at least monthly Ventilation e Tighten electrical connections after first 50 hours and an nually thereafter e Change oil after first 500 hours and at least annually there after e Check diff pressure indicator on silencer and enclosure at least monthly e Replace air inlet filter silencer at least annually e Check safety valve and other safety device operation an Electrical UD Piping nually e Lubricate replace motor bearings at least every three years permanent five years regreasable e Replace belt set at least every three years Package e Install check plate kit every three years Integration e Install start valve kit every three years if applicable e Check compensator hose lines every eight years Building an Efficient 4 Keep in mind that based on your application and operating environment you may need to adjust the frequency of the service intervals J J Preventive Safety Advisories Additional Resources www us kaeser com Copyright 2015 Kaese
35. ww us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 45 Appendices Appendices Charts and References www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved Introduction Appendix A Elevation Derate Chart for Motors Receiving TA Equipment ft S SF over 16 500 Consult Manufacturer Altitude 1 0 1 15 Ventilation Electrica Led ET NABII Piping Package Building an Efficient Preventive f H E vaintenance Safety Additional COOUTICES www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved 47 Appendix A Elevation Derate Chart for Motors Motor derating Three phase asynschronous motors Class F windings are designed by Kaeser so that they are loaded to Class B at air cooling tempera tures up to only 40 C elecations up to 1000m above sea level and their mentioned rated power If these limitations are exceeded the motor must be de rated so that the motor windings used are Class F and not Class B Mains voltage fluctuations particularly under voltage can then lead to motor overheating as there is no longer a reserve These diagrams should help in determining the motor shaft power depending on ambient temperature and elevation If derating is necessary because of simultaneously higher ambient temperature and elevation the motor shaft power va
36. y to merit customer satisfaction We aim for excellence in everything we do KAESER COMPRESSORS Built for a lifetime www us kaeser com Copyright 2015 Kaeser Compressors Inc All Rights Reserved USBSIGEB 09 15 Kaeser Compressors Inc 511 Sigma Drive Fredericksburg Virginia 22408 USA Phone 540 898 5500 Toll Free 800 777 7873 Email info usa kaeser com ENERGY STAR PARTNER
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