Transcription of OPERATION & MAINTENANCE MANUAL
1 OPERATION & MAINTENANCEMANUALCENTAC ModelsIngersoll-Rand - Air Solutions Heavy Industrial SystemsStrada Statale Cassanese, 108 20060 Vignate (MI), ItalyIndex1 Data sheet..1 General ..1 Compressor performance characteristics ..2 Cooling water characteristics ..3 Lubrication characteristics ..3 Vibration limits ..4 Main driver ..4 Controls..5 Electric Components characteristics ..6 Minimum recommanded spare parts ..62 Safety precautions. Read carefully before installing the compressor ..773 Receiving/Handling/Storage .. Receiving.. Handling .. Recommended lifting method for CENTAC model .. Recommended lifting method for air filter (when supplied) .. Storage ..21214 Machine description .. General description .. Air end .. Bull-gear .. Rotor assembly .. Diffuser .. Plain (or radial) bearings.. Thrust bearings .. Shaft sealing .. Vibration probes.. Air system .. Water cooling system .. Lubrication system.
2 Driver ..3737 OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage Coupling .. Control system .. Baseplate .. Sound enclosure for enclosed version ..39395 Installation .. General .. Plant layout .. Foundation .. Leveling .. Adjusting the compressor for level .. Grouting .. Inlet air filter (if supplied loose) .. Atmospheric by-pass silencer mounted at a remote location .. Piping .. Air inlet piping (When Inlet Air filter is supplied loose).. Air discharge piping.. Air by-pass piping .. Control air and instrument air piping .. Control air piping (when supplied) .. Instrument air piping .. Water piping system .. Condensate drain piping (not applicable for nitrogen compressors) .. Electrical connections..56566 Control System .. General - CMC Panel .. Control Methodology .. Performance Control .. Unload .. Constant Pressure Control - Modulate .. Energy Saving Control - Autodual.
3 Oil System Control .. Protection and Monitoring .. Compressor operating Methodology .. User Interface .. OUI (Operator User Interface) ..6666 OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage Command Keys .. Enter Key - Display operating Mode .. Navigation Keys .. Contrast Key .. Scroll Mode .. Graphic Display .. Edit (Setpoint Changes) Mode .. Navigation Mode .. SYSTEM Folder .. INFO Folder .. SETTINGS Folder .. General Sequence of OPERATION .. Indicator, Switch and Light Layout .. Lights .. Push Buttons.. Switches .. CMC Tuning Procedures .. Setting MaxLoad (HLL).. Setting MinLoad .. Setting MinLoad Surge Index Increment .. Setting Surge Sensitivity .. Tuning Stability .. Calibrating the Control Valves .. Autodual Control Settings .. Unload Point (Bypass Valve % Open) .. Unload Delay Time (seconds) .. Reload Percent .. Setting the Start Time.
4 Setting the CT Ratio .. Inlet Unload Position .. Setting Set Point Ramp Rate .. Alarm and Trip Settings.. Communication (When provided) .. Human Machine Interface (HMI) Systems .. Direct CMC Communications with RS422/485 .. The CMC-MODBUS Interface..9797 OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage Introduction.. Serial Modes ..99997 Pre-start check list .. General .. Impeller to diffuser clearance .. 1st stage rotor preparation (only for 5 CII units) .. Coupling alignment .. Main driver preparation .. Basic control system set-up .. Lube oil system adjustment .. Check out summary ..1101108 Routine start-up/stop.. Lubrication .. Routine start-up/stop ..1161169 MAINTENANCE .. MAINTENANCE schedule ..12012010 Troubleshooting ..12912911 Parts & Service .. Parts & Service .. Goods Return .. Spare Parts..13413412 Drawings and Part Lists ..136136 Annex A Main Driver (Not applicable for this configuration).
5 137137 Annex B Air Filter (Not applicable for this configuration) ..138138 Annex C Oil Filter (Not applicable for this configuration) ..139139 Annex D Condensate Traps (Not applicable for this configuration) ..140140 Annex E Pre/Post Lubrication Pump (Not applicable for this configuration) ..141141 Annex F Oil Cooler (Not applicable for this configuration) ..142142 Annex G Oil Vapor Separator (Not applicable for this configuration) ..143143 OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage VAnnex H Power Kit Seal Air (Not applicable for this configuration) ..144144 Annex I Coupling (Not applicable for this configuration) ..145145 Annex L External Air Coolers (Not applicable for this configuration) ..146146 OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage VI1 Data sheetGeneral FRAME .. MODEL .. GAS TYPE (note 1) ..( Air = "A", Nitrogen = "N")A AREA (Safe, Classified) ..(Safe= "S", Classified = "H")S AREA CLASSIFICATION ..(for Classified Area only) SERIAL NUMBER.
6 ORDER NUMBER .. CUSTOMER .. DESTINATION COUNTRY.. PED UNIT ..(Yes = Y , No = N )Y QUANTITY SUPPLIED .. MANUFACTURING YEAR.. OVERALL DIMENSIONS-LENGTH ..-WIDTH ..-HEIGHT .. "PACKAGE" TOTAL WEIGHT .. WEIGHT W/O MAIN DRIVER" .. MAIN DRIVER WEIGHT" .. NOISE LEVEL (SOUND PRESSURE), db(A) .. SILENCED UNIT (WITH SOUND ENCLOSURE) ..(Yes = Y , No = N )YOPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage 1 ALLOWED FORCES AND (Inches)AXIALVERTICALHORIZONTALF orceKgMomentKg x mForceKgMomentKg x mForceKgMomentKg x mInputBy-PassDeliveryCompressorperforman cecharacteristics BAROMETRIC PRESSURE .. INPUT PRESSURE .. INPUT TEMPERATURE .. RELATIVE HUMIDITY .. OPERATIONAL PRESSURE .. MAXIMUM PERMISSIBLE PRESSURE ..(only for PED Unit) MINIMUM AND MAXIMUM PERMISSIBLE TEMPERATURE ..(only for PED Unit) INPUT FLOW RATE .. DELIVERY FLOW RATE.. COOLING WATER TEMPERATURE .. ABSORBED POWER.. MAIN DRIVER NAMEPLATE POWER .. RATED SPEED .. COLD TEMPERATURE DIFFERENCE (CTD), C(Difference between output air temperature and input water temperature)-CTD 1st stage.
7 -CTD 2nd stage ..-CTD 3rd stage ..-CTD 4rd stage ..-CTD 5rd stage .. EXCHANGED HEAT, Kcal/h-1st stage.. OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage 2-2nd stage ..-3rd stage ..-4rd stage ..-5rd stage ..-Oil coolant .. GUARANTEED TOLERANCES-ON FLOW RATE, % ..-ON SPECIFIC CONSUMPTION, % ..Coolingwatercharacteristics MAXIMUM INPUT TEMPERATURE .. MINIMUM PRESSURE .. MAXIMUM PRESSURE .. RATED FLOW RATE (oil coolant included), Liters/min .. MAXIMUM PRESSURE DROP BETWEEN INPUT AND OUTPUT .. T BETWEEN INPUT AND OUTPUT ..Lubricationcharacteristics TANK CAPACITY, liters .. OIL INPUT PRESSURE .. OIL INPUT TEMPERATURE .. OIL MINIMUM PRESSURE UPON STARTING .. OIL MINIMUM TEMPERATURE UPON STARTING.. OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage 3 VibrationlimitsRadial XRadial YAxial Z 1ST STAGE- Alarm- Block 2ND STAGE- Alarm- Block 3RD STAGE- Alarm- Block 4TH STAGE- Alarm- Block 5TH STAGE- Alarm- BlockMaindriverIn case of electric motor driven compressor MANUFACTURER.
8 POWER .. SPEED, rpm .. SERVICE FACTOR .. VOLTAGE, VOLTS .. FREQUENCY, Hz .. PROTECTION DEGREE .. INSULATION CLASS.. TEMPERATURE CLASS .. SUPPLIED BY INGERSOLL-RAND ..(Yes = "Y", No = "N") OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage 4In case of turbine driven compressor MANUFACTURER .. POWER .. SPEED, rpm .. MAXIMUM SPEED, rpm .. STEAM FLOW ..(Design; Maximum; Minimum) INPUT STEAM FLOW TEMPERATURE ..(Design; Maximum; Minimum) OUTPUT STEAM FLOW TEMPERATURE ..(Design; Maximum; Minimum) INPUT STEAM PRESSURE ..(Design; Maximum; Minimum) OUTPUT STEAM PRESSURE ..(Design; Maximum; Minimum) SUPPLIED BY INGERSOLL-RAND ..(Yes = "Y", No = "N")Controls PANEL TYPE .. VOLTAGE, Volts .. PROTECTION DEGREE .. MANUFACTURER .. SUPPLIED BY INGERSOLL-RAND ..(Yes = "Y", No = "N") OPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage PRE/POST LUBRICATION PUMP MOTOR HEATER/S OIL OIL VAPOR EXTRACTION FAN MOTOR(where PROVIDED) SAND EXTRACTION MOTOR FOR INRTIAL FILTER(where PROVIDED) FAN MOTOR FOR SOUND ABSORBING HOUSING(for models where contemplated)Minimumrecommandedsparepart sDescriptionQuantityPartNumber Absolute air filter Air prefilter Oil filter cartridge Oil fume separator cartridge Lubrificant barrel (5 gallons) Lubrificant barrel (55 gallons)Note 1: For Nitrogen compressors, all references to the term air mustbe read as Nitrogen.
9 NOTEOPERATION & MAINTENANCE MANUAL - CENTAC ModelsPage 62 Safety precautions. Read carefully before installing the compressorIn any work concerning the OPERATION , conversion or adjustment of the machine and its safety devicesor any work related to MAINTENANCE , inspection and repair, always observe the start-up and shut-downprocedures set out in the operating instructions and the information on MAINTENANCE YOU OPERATE, MAINTAIN OR IN ANY OTHER WAY OPERATETHIS UNIT: READ and STUDY this MANUAL . KNOW how to safely use theunit's controls and what you must do for safe machine has been built in accordance with state-of-the-art standards and the recognized wear or use the proper safety items required for your personal protection. For reasons ofsecurity, long hair must be tied back or otherwise secured, garments must be close, fitting and nojewellery - such as rings- may be worn. Injury may result from being caught up in the machinery orfrom rings catching on moving you have ANY QUESTIONS about safety or MAINTENANCE procedures not included in this MANUAL ,ASK YOUR SUPERVISOR OR CONTACT ANY INGERSOLL-RAND OFFICE OR QUALIFIEDINGERSOLL-RAND DISTRIBUTOR.
10 NEVER GUESS, ALWAYS make any modifications, additions or conversions which might affect safety without thesupplier's approval. This also applies to the installation and adjustment of safety devices and valves aswell as to welding work on load-bearing FOR THESE SYMBOLS WHICH POINT OUT ITEMS OF EXTREME IMPORTANCE TOYOU AND YOUR CO-WORKERS' SAFETY, READ AND UNDERSTAND THOROUGHLY,READ THE DANGERS, WARNINGS, CAUTIONS AND NOTES AND FOLLOW is used to indicate the presence of an immediate hazard whichWILL result in SEVERE personal injury or & MAINTENANCE MANUAL - CENTAC ModelsPage 7 WARNING is used to indicate the presence of a hazard or unsafepractice which could result in SEVERE personal injury or is used to indicate the presence of a hazard or unsafepractice which could result in MINOR personal injury or product orproperty is used to indicate an important installation, OPERATION , ormaintenance MANUAL contains instructions for installation.
