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Kaeser Omega Blowers and Blower Packages

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Title: Kaeser Omega Blowers and Blower Packages


1
Kaeser Omega Blowers and Blower Packages
2
Presentation Objectives
  • Introduction to Kaeser
  • How blowers work and where they are used
  • Blower features, benefits, and special purpose
    designs
  • Blower package features and benefits
  • System design, containerized systems and Kaeser
    Air Utility
  • Accessories
  • Quality control, performance benefits, and
    commercial features

3
About Kaeser
  • We have more than 92 years of manufacturing
    experience
  • We are 4,000 employees and growing
  • We are a global company with representation in 89
    countries
  • Air systems are all we do
  • We offer a complete line of air products
  • Our products are manufactured in the U.S.,
    Germany, and France

4
Kaeser Manufacturing Sites
Fredericksburg, VA Coburg, Germany Gera,
Germany Sonnefeld, Germany
5
Kaeser Standards of Excellence
ISO 9001 Certified - Continuous process
improvement ISO 14001 Certified - Commitment to
environmental protection
CE Certified - Declarations of Incorporation are
available
6
What is a Blower?
  • High volume
  • Low pressure (typically 21)
  • Positive-displacement
  • Oil-free
  • Internally gas cooled

7
What is a Blower?
Blower operating principle
8
Tri-Lobe Versus Two-Lobe
  • 120 design
  • Greatly reduced pulsation levels
  • Quieter operation
  • Reduced rotor deflection
  • Bi-directional rotation
  • In smaller displacement models, 180 design is
    more resistant to contamination

9
Tri-Lobe Versus Two-Lobe
Six pockets of air per revolution
Relief channel allows internal and discharge
pressure to equalize
95 pulsation cancellation inside the blower
Tri-lobe relief channel
10
Tri-Lobe Versus Two-Lobe
1 Revolution
Tri-lobe design and equalization channel
efficiently reduce pulsations and noise
11
Applications
  • Pneumatic conveying

12
Applications
  • Municipal and Industrial water and wastewater
    treatment

13
Applications
  • Blow-off, product drying

14
Applications
  • Environmental remediation

15
Applications
  • Landfill gas extraction

16
Applications
  • Agricultural spraying

17
Applications
  • Power generation using waste steam

18
Applications
Thousands of process applications
  • Vacuum hold-down
  • Fish farming
  • Industrial vacuum cleaning
  • Mixing or metering gases
  • Wash and rinse tank agitation
  • Product heating
  • Evaporation, vapor compression
  • Product cooling
  • Processes which require air at high velocity

And many more
19
Blower Design and Construction
  • 24 models for air service
  • 2.5 through 8 gear diameters
  • Tri-lobe and two-lobe designs
  • Pressures to 15 psig and vacuums to 15 Hg
  • Flows to 5,500 icfm
  • Package sizes to 335 hp
  • Port sizes from 2 to 12 inches

20
Blower Design and Construction
  • Horizontal or vertical blower arrangement
  • Drilled and tapped holes on all sides for
    versatile mounting
  • Inlet and outlet connections are DIN flange
  • Adapters are available for the inlet and outlet
    ports
  • NPT (4 and below)
  • ANSI flange (6 and above)

21
Blower Design and Construction
Large shafts to reduce deflection
One-piece ductile iron rotor assemblies
Solid or closed-end rotors standard
22
Blower Design and Construction
  • Advantages of the Kaeser rotor design
  • Tri-lobe design with large shaft diameters
    prevent rotor deflection due to high differential
    pressures
  • The first critical speed is 4 times the
    recommended maximum speed
  • The maximum bearing speed is twice the
    recommended maximum speed

23
Blower Design and Construction
Advantages of the Kaeser rotor design
  • Rotors are balanced to ISO 1940/1 G 2.5 (grade
    for turbines and turbo compressors)

24
Blower Design and Construction
Splash lubrication (both ends)
Easy to read oil sight glasses (factory filled
with lubricant)
25
Blower Design and Construction
  • Advantages of oil over grease lubricated
    bearings
  • Reduces friction
  • Provides for cooling of the bearings
  • Flushes contaminants out of bearing races
  • When oil is changed, contaminants are flushed
    from blower sump
  • Easily checked for proper oil level
  • Allows for visual inspection of lubricant
    condition

26
Blower Design and Construction
SKF Explorertm, caged, full compliment
cylindrical roller bearings for long L10 life
27
Blower Design and Construction
Bearing life example Gear-side bearings on 6
gear blowers with similar displacement operating
at 14.5 psid/1.0 bar - the same radial load of
1,258.93 lbf/5.6 kN
L10 (C / P)10/3 (B / n) a
28
Blower Design and Construction
VitonTM lip seal with hardened shaft sleeve,
polished and coated with tungsten carbide
Precision, spur type, hardened timing gears
Proprietary equalization channel on tri-lobe
blowers
29
Blower Design and Construction
  • Optional Input shaft seal
  • Kaeser design sliding ring type seal
  • Stator carbon, rotor DIN material code 1.7139,
    16MnCrS5, AISI 5117), Elastomers Viton
  • Positive seal to contain gases and prevent air
    ingress
  • Can handle higher temperatures
  • Allows for field repair

30
Blower Design and Construction
Heavy-duty cast iron housing with integral
headplate
Piston ring labyrinth air and oil seals with
vented cavity
31
Blower Design and Construction
Labyrinth seals
Gas side seals
  • Four hardened-steel piston rings
  • Provides reliable, long-life sealing
  • Seals both the gas and oil chambers

Oil side seals
Rotor seal vents
32
Optional Gas Tight Sealing
  • Optional rotor seal vent piping
  • Rotor seal vents are recirculated to suction
  • Gas is contained
  • No possibility of air ingress even in the case of
    a labyrinth seal failure
  • Filter with transparent bowl indicates seal
    condition

33
Blower Design and Construction
  • Optional teflon cap ring seal
  • Teflon packing (between the working chamber and
    drain). Teflon lip seal (between the drain and
    oil chamber)
  • Stator carbon, rotor DIN material code 1.7139,
    16MnCrS5, AISI 5117, Elastomers Viton
  • Improved corrosion resistance
  • Can handle high differential pressures

34
Blower Design and Construction
Optional casing and rotor materials
  • Stainless steel rotors DIN 1.4008, G-X8 CrNi 13,
    AISI 414
  • Stainless iron cylinders Ni-Resist 3, DIN
    0.6676, GGL-NiCr 30 3, AISI A436
  • Optional materials offer improved corrosion
    resistance

35
Omega Special Blower Designs
PV series pre-inlet cooled blower
  • Dry-type exhauster design
  • Vacuum to 27 Hg with a single-stage
  • Available in the Omega 6 and 8 series

36
Omega Special Blower Designs
PV series pre-inlet cooled blower
  • For use on
  • Sweeper trucks
  • Vacuum trucks
  • Central vacuum systems
  • Systems too dirty for lubricated machines
  • Requires no water for sealing or cooling

37
Omega Special Blower Designs
WVC vacuum boosting blowers
  • For use as the pre-pump in a high vacuum system
  • Improves system pump-down time
  • Improves end vacuum

38
Omega Com-paK Plus
39
Omega Com-paK Plus
  • All inclusive, factory-manufactured packages
  • Pre-assembled for easy installation
  • Low friction loss for high wire-to-air efficiency
  • Very price competitive

DB 236 C
DB 236 C integrated package
40
Omega Com-paK Plus
Inverter-rated, EISA compliant motor with PTC
thermistors
Absorptive inlet silencer with integral filter
Easily removable belt guard
Omega plus tri-lobe blower
Combination discharge silencer/base
Integral base with fork lift/ pallet jack access
41
Omega Com-paK Plus
Ducted belt guard for better seal cooling
Retained belt guard fasteners
42
Omega Com-paK Plus
Motor lubrication point
Inlet silencer with replaceable absorptive media
Discharge silencer with domed head
43
Automatic V-Belt Tensioner
  • Visual indication of tension
  • Easy maintenance
  • Maintains tension
  • Maintains efficiency
  • Infrequent adjustments
  • Prevents over-tensioning
  • Prolongs component life

44
Omega Com-paK Plus
Inlet silencer adaptable for pressure or piped
inlet
Pressure relief valve protects blower Piped
exhaust prevents recirculation of hot air and
protects operator
Flexible connector
45
Omega Com-paK Plus
Com-paK Plus with integrated AFR and vent
silencer
46
Omega Com-paK Plus
Low-cost polyester inlet filter is easily
replaced
3D oil sight glasses
  • Oil drain valves with caps
  • Oil chambers are separate

47
Omega Com-paK Plus
  • Sound enclosure
  • Factory assembled
  • Sheet steel
  • Powder-coated finish
  • 20 dB(A) noise reduction
  • Optional stainless-steel cover for outdoor
    installation

48
Omega Com-paK Plus
  • Kaeser enclosures attenuate all blower noise
    sources
  • Blower discharge pulsations
  • In-rush air noises
  • Blower mechanical noises
  • Gears
  • Bearings
  • Motor mechanical noises
  • Cooling fan
  • Bearings
  • Enclosure cooling fans
  • Relief valve

49
Omega Com-paK Plus
  • Sound enclosure vent fan
  • Factory installed enclosure vent fan sized to
    provide optimal flow at all drive speeds
  • Provides constant flow during variable speed
    operation
  • Operates independent of drive motor
  • Can operate after blower is shut down to remove
    latent heat from motor windings

50
Omega Com-paK Plus
Special inlet louver smoothes cooling air flow to
motor
Oil chamber ventilating louvers (8K reduction)
51
Omega Com-paK Plus
Omega Com-paK Plus
  • Standard instrumentation and protection
  • Inlet filter differential gauge (45 mbar/0.65
    psid)
  • Discharge pressure gauge
  • Discharge temperature gauge
  • Discharge temperature switch
  • Instrument cover to protect gauges
  • Motor PTC thermistors
  • Mechanical relief valve

52
Omega Com-paK Plus
Omega Com-paK Plus
Optional instrument package
  • Inlet filter differential pressure switch
  • Discharge pressure switch
  • Enclosure safety switch
  • Oil temperature sensors
  • Oil level sensors
  • Terminal strip in electrical enclosure
  • All instruments are mounted and wired to
    electrical enclosure

53
Omega Com-paK Plus
Optional integrated design with Omega Control
Basic
  • Highest level of protection for the blower and
    the operator
  • Includes superior blower protection
  • Remote start / stop
  • Remote monitoring via dry contacts
  • Optional blower speed monitoring
  • Control panel is CE, UL, and EMV compliant

54
Omega Com-paK Plus
Optional integrated design with Omega Control
Basic
  • Omega Control Basic calculates differential
    temperature and pressure
  • Available with
  • OFC variable frequency drive
  • STC wye-delta reduced current starting
  • Available for both pressure and vacuum packages
  • Protects unit from system casualties and poor
    maintenance

55
Omega Com-paK Plus
Optional integrated design with Omega Control
Basic
  • High safety, compliant with international
    electrical standards
  • Ready to operate
  • requires only connection to the piping and power
    supply
  • Self-protecting suitable for remote
    installations
  • One vendor for sourcing
  • One vendor for integration
  • One vendor for after sales service

56
Omega Com-paK Plus
All maintenance is performed from the front of
the package
2
4
57
Omega Com-paK Plus
All utility connections are in the rear of the
package
Utility connections
Process air inlet and outlet
Relief valve exhaust
Control cubical cooling vents
Enclosure cooling vents
58
Omega Com-paK Plus
  • Package installation
  • One next to the other
  • Reduced floor space
  • Easy to install
  • Saves on construction costs
  • Full maintenance access

59
Omega Com-paK Plus
60
Omega Com-paK Plus
Lowest noise levels in the industry
  • All components engineered to work together
  • Tri-lobe technology
  • Custom design silencers
  • Advanced enclosure with effective
    sound-proofing
  • Optional silencer for vacuum pump exhaust shown

Free field conditions at 1 meter from
equipment, installed values may differ.
61
Omega Com-paK Plus
  • Quick-Ship series
  • Kaeser stocks a full range of packaged blowers
    from 5 to 150 hp
  • Most orders can be shipped within one working day
  • Speed changes can be completed quickly

62
Omega Com-paK Plus
  • Com-paK Plus series is currently available from
    2 to 250 hp
  • Packages are available from 75 to 335 hp

63
Omega Packages for High Flow
  • High flows up to 5,500 icfm
  • NEMA or IEC frame motors
  • Low and medium voltage motors
  • Optional enclosure with separate process air and
    cooling air circuits
  • Polyester inlet / in-line filter
  • Spool piece with check valve
  • Flanged expansion joint, shipped loose

64
Kaeser System Design Services
Kaeser designs complete systems with air system
controllers, variable frequency drive and dual
control
  • Air Manager
  • Room Exhaust Fan
  • Common Header
  • Intake Louvers

Kaeser systems feature adaptive control for best
efficiency
  • Line Regulator

65
Kaeser Containerized Solutions
  • Systems are custom-built to meet customer
    specifications
  • Reduces the project construction and installation
    time
  • Reduces project cost

66
Kaeser Air Utility
We can supply a system and then invoice the user
for the volume used
  • We own and maintain the equipment
  • We guarantee up time

67
Accessories - Control Panels
Kaeser Start Control - STC
68
Accessories - Control Panels
On / off switch
Kaeser Start Control - STC
Kaeser control
Emergency stop button
Hour meter
69
Accessories - Control Panels
Kaeser Start Control - STC
Motor
Fan
Liquid level
Temperature
Pressure
General warning
Dirty filter
Refer to manual
70
Accessories - Control Panels
Omega Frequency Control OFC 3 kW 250 kW
71
Accessories - Control Panels
Omega Frequency Control OFC 3 kW 250 kW
72
Accessories - Control Panels
Omega Frequency Control OFC 3 kW 250 kW
  • 380V-480V, 3ph, 50-60Hz
  • EMV filter class B (37 kW and up)
  • IP 54 protection
  • RS 485 interface with USS protocol
  • Emergency stop switch
  • Off button with galvanic separation

73
Accessories - Control Panels
Omega Frequency Control OFC 3 kW 250 kW
  • Programming unit
  • Control enclosure fan
  • PID controller for external 4 20 mA
    signal
  • Remote on / off
  • Alarm messaging
  • Optional Profibus interface

74
Accessories - Control Panels
Sigma Air Manager
75
Accessories - Control Panels
  • Reasons to use a master controller
  • Adaptive control of multiple blower packages
  • Reduce energy costs
  • Provide a reliable system
  • Match blower output to system demand
  • Control system pressure
  • Balance blower package operating hours

Sigma Air Manager Basic
76
Sigma Air Manager
Complete Air System Management
  • Omega Control Basic packages
  • Non-Omega controlled blowers
  • Overall air system control and monitoring
  • Can receive input from process system controller

77
Accessories Unloaded Start Valves
  • When to use unloaded start valves
  • Blower packages in parallel
  • Reduced current starting
  • Sparging systems
  • Purposes
  • Accelerate drive motor to full-speedbefore
    loading
  • Reduce in-rush current
  • Prevent motor overloading
  • Reduce pneumatic shock to system at startup

78
Accessories Unloaded Start Valves
2
  1. Main pipe
  2. Adjusting screw
  3. Orifice
  4. Diaphragm chamber
  5. Valve seat
  6. Valve disc
  7. Exhaust port

4
3
6
7
5
1
79
Accessories Unloaded Start Valves
  • The normally open valve is mounted on a piping
    tee
  • When the blower is started, the pressure acts on
    the diaphragm and modulates the valve closed

Air from blower package
80
Accessories Unloaded Start Valves
Air from blower package
81
Accessories Unloaded Start Valves
  • Available models
  • AFE - standard unloaded start valve
  • AFEM - unloaded start valve with solenoid valve
    to unload the system on demand
  • AFR - unloaded start valve with pressure
    regulating function to maintain steady system
    pressure
  • AFVM - unloaded start valve with vacuum
    regulating function to maintain steady system
    vacuum

82
Quality Control
  • Kaeser manufactures all major components
  • All critical components (rotors and housings) are
    dimensionally checked prior to assembly
  • Set-up clearances are checked and documented

83
Quality Control
  • Bare blowers are run-tested for 30 minutes at
    full pressure and full speed
  • All blowers are tested and conform to ISO 1217
    Part 1, Annex C
  • The mechanical run-test, slip-test, and clearance
    data are retained electronically
  • All packages are mechanically tested prior to
    shipment

84
Performance Benefits
  • Energy efficient design means less bhp per cfm
    and lower power costs!

Kaeser Omega
Competitors
Up to 20 more efficient!
Life Cycle Cost
Time
85
Performance Benefits
  • Low noise levels!

Noise levels are, 3 dB(A) in accordance with
ISO 2151 in free-field conditions
86
Performance Benefits
  • Lower noise levels
  • Lower operating costs
  • Lower maintenance costs
  • Longer life
  • Lowest cost of ownership
  • Lowest life-cycle cost

87
Commercial Advantages
  • 24-month blower warranty
  • 5-year warranty on blowers purchased as part of a
    Com-paK Plus package!
  • Emergency replacement blower guaranteed available
    in one working day for 5 years.

88
Commercial Advantages
  • Global network of stocking subsidiaries and
    distributors to provide after sales service
  • Dense network of qualified service technicians

89
Commercial Advantages
  • System solutions
  • Competitive prices
  • Unsurpassed customer service and satisfaction

90
Compressors and Vacuum Products
  • Rotary screw compressors
  • Vacuum screws
  • Booster compressors
  • Mobilair portable compressors

91
Air Treatment Equipment and Accessories
  • Breathing air systems
  • Filters
  • Dryers
  • Sequencers
  • Drain traps
  • Flow controllers
  • Condensate management

92
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