Ingersoll-Rand 125-200 HP/90-160 KW Compressed AIR System The air system is composed, Operation

5.4COMPRESSED AIR SYSTEM The air system is composed of:

1)Inlet air filter

2)Inlet valve/stepper motor

3)Rotors

4)Coolant/air separator

5)Minimum pressure/check valve

6)Aftercooler

7)Moisture separator/drain trap

Air enters the compressor, passing through the inlet air filter and butterfly inlet valve.

Compression in the screw-type air compressor is created by the meshing of two helical rotors (male and female) on parallel shafts, enclosed in a heavy-duty cast iron housing, with air inlet and outlet ports located on opposite ends. The grooves of the female rotor mesh with, and are driven by, the male rotor. Tapered roller bearings at the discharge end prevent axial movement of the rotors.

The air-coolant mixture discharges from the compressor thru a discharge check valve into the separation system. This system, self-contained in the separator tank, removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the system and the air passes to the aftercooler. The aftercooling system consists of a heat exchanger, a condensate separator, and a drain trap. By cooling the discharge air, much of the water vapor naturally contained in the air is condensed and eliminated from the downstream plant-piping and equipment.

During unloaded operation, the butterfly inlet valve closes, via stepper motor, and the blowdown solenoid valve opens, expelling any compressed air back to the compressor inlet.

5.5 COOLANT/AIR SEPARATION SYSTEM

The coolant/air separation system is composed of a separator with specially designed internals, a two-stage coalescing-type separator-element, and provision for return of the separated fluid back to the compressor.

OPERATION

The coolant and air discharging from the compressor flow into the separator through a tangential discharge outlet. This outlet directs the mixture along the inner circumference of the separator, allowing the coolant stream to collect and drop to the separator sump.

Internal baffles maintain the circumferential flow of remaining coolant droplets and air. In an almost continuous change of direction of flow, more and more droplets are removed from the air by inertial action and then returned to the sump.

The air stream, now essentially a very fine mist, is directed to the separator element.

The separator element is constructed with two concentric, cylindrical sections of closely packed fibers, each held in steel mesh. It is flange-mounted at the separator-outlet-cover.

The air stream enters the separator element radially and the mist coalesces to form droplets. The droplets collected on the outer first stage fall to the separator sump. Those collected on the inner second stage collect near the outlet of the element, and are drawn back to the compressor inlet through a filter-screen and orifice fitting installed in the separator scavenge line.

The air stream, now essentially free of coolant, flows from the separator to the aftercooler, then to the condensate separator, and on to the plant air system.

5.6 ELECTRICAL SYSTEM

The electrical system of each SSR compressor is built around the microprocessor-based Intellisys controller.

The standard electrical/electronic components, enclosed in a readily accessible enclosure include:

1)IntelIisys controller

2)Compressor motor starter, with auxiliary contacts and overload relays

3)Cooling fan motor overload relays and circuit breaker or fuses

4)Intellisys Power Supply Board

5)Control transformer and fuses

Options, such as power outage restart can be enabled by installing plug-in (option) modules in the Intellisys controller.

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