Professional Documents
Culture Documents
DATE: JUNE·09·2016
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© 2016 HANW HA TECHWIN
CO.,LTO.
T ABL E O F CO NT E NT S
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© 2016 HANW HA TECHWIN
CO.,LTO.
S CO P E O F S U P P L Y
Hanwha Turbo Compressor, multistage centrifugal air compressor, SM4000 is fully packaged,
completely wired and equipped with all components, interconnecting pipe work and instrument control lines.
Plug & Play concept is implemented to maximize the readiness.
1.1 Cast iron compressor casing and gearbox module. Horizontally split gearbox module which
allows easy access to rotating parts and stationary seals in the inspection and maintenance
without disturbing air and water piping system.
1.2 High precision ground helical type bull gear (AGMA Quality 12) and pinion gear (AGMA Quality
13) which minimize maintenance and power losses.
1.3 Horizontally split tapered land thrust and journal bearings on the bull gear.
1.4 Horizontally split tilting pad journal and thrust bearings on the pinion gear which provide stable
operation under normal and abnormal conditions.
1.5 High efficiency, backswept impellers which provide wide operating range.
1.6 Low solidity vaned type diffusers which maximize aerodynamic efficiency and operating range.
1.7 Carbon rings, combined with labyrinth air and oil seals which designed to deliver oil free air and
minimum air leakage losses.
1.8 Common compressor base frame that has forklift holes for easy lifting, and allows the unit to be
placed on a flat and horizontal floor capable of taking the weight.
2.1 Electrically operated Inlet Guide Vane (IGV) with positioner and actuator
2.2 Piped and mounted inlet filter with high efficiency filter elements and silencer.
2.3 Piped and mounted inlet filter differential pressure gauge for scheduled maintenance.
2.4 Inlet expansion joint to ensure the stress-free connection between inlet filter and inlet guide
vane housing.
3.1 Plate finned cross-flow type intercooler between stages with water-in-tube I air-in-shell and
removable tube bundle. Interchangeable with aftercooler.
3.2 Plate finned, cross-flow type aftercooler at discharge of final stage with water-in-tube I air-in-
shell and removable tube bundle. Interchangeable with intercooler.
3.3 Anti-corrosion coating on all internal air passages throughout the compressor, for
corrosion protection.
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© 2016 HANW HA TECHWIN
CO.,LTO.
4.0 LUBRICATION SYSTEM
4.1 Oil reservoir tank with internal surface treatment for corrosion.
4.5 Pre-lubricated auxiliary oil pump for start and stop operation driven by an electric motor.
4.6 Oil ejector system with oil reservoir vacuum gage to eliminate oil fumes and generate
vacuum inside gearbox for preventing oil leakage.
4.7 Pressure control valve to maintain constant oil pressure to the bearings.
4.8 Oil temperature control valve (T.C.V) which automatically maintains optimum oil temperature.
4.9 Visual sight glass to determine the safe oil level in the tank.
4.10 Oil heater with automatic onIoff control by oil reservoir temperature.
4.11 Oil level switch to monitoring the minimum level of oil in oil reservoir tank.
5.4 Oischarge expansion joint to ensure the stress-free connection from the air piping network.
6.1 Cooling water manifolds for single inlet and outlet connection.
• Temperature Rise - F
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© 2016 HANW HA TECHWIN
CO.,LTO.
• Foot-mounted on the rigid oil reservoir tank
8.1 PLC-based, user friendly control system to control and monitor the status of compressor
8.2 Fully automated control system for safe and trouble-free operation.
8.3 Modulating BOV control mode as option - the most efficient method of maintaining
system pressure by modulating inlet guide vane and onloff blow-off valve depending on flow
demand.
8.4 Constant pressure control as an option - a constant discharge pressure is maintained along
with a continuous flow by modulating inlet guide vane and modulating blow-off valve for
utmost constant system pressure.
8.5 Easy access 7" LCO display to versatile functions - diagnostics and preventative maintenance,
maintenance history, alarm and shutdown history, etc.
Control Detection
No Description
Display Alarm Shutdown
1 IGV Position ● - -
2 BOV Position ● - -
3 Set Point ● - -
4 System Air Pressure ● - -
5 Lube Oil Supply Pressure ● ● ●
6 Operation of Auxiliary Oil Pump ● ● -
7 Operation of Oil Heater ●
8 Oil Reservoir Oil Temp. Control ● ● -
9 Lube Oil Level ● ●
10 Oil Supply Temperature ● ● ●
11 Final Stage Outlet Air Pressure ● - -
12 Final Stage Inlet Air Temperature ● ● ●
13 Main Motor Current ● - -
14 Vibration X axis - All Stage ● ● ●
15 Surge Recognition ● ● ●
16 Surge (24data) and Shutdown (20data) History ● - -
17 IlO Board Failure and Program Error ● ● ●
18 Transmitter and RTO Sensor Failure ● ● -
19 Multiple Alarm & Oanger Message Oisplay ● - -
20 Bar Graph Oisplay ● - -
21 Manual IGV & BOV Control ● - -
22 Power-on, Running and Loading Time ● - -
23 Calendar & Clock ● - -
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© 2016 HANW HA TECHWIN
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8.7 Hanwha standard gauge and indicator :
Control Oetection
No Oescription
Oisplay Alarm Shutdown
1 Inlet Air Filter Oifferential Pressure ● - -
2 Oil Filter Oifferential Pressure ● - -
3 Oil Reservoir Oil Level ● - -
4 Oil reservoir vacuum gage ●
• P & IO drawings
• Two (2) hour run test of complete package at factory prior to shipment to check
mechanical status and all function.
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© 2016 HANW HA TECHWIN
CO.,LTO.
K E Y D E S I G N F E AT UR E S
Hanwha's SM4000 is the world best centrifugal compressor developed by the technologies and reputation
Hanwha has accumulated through the outstanding performance of its aircraft engines in the global market.
Experience the real value of the SM4000 in any applications requiring an efficient and reliable
compressor. The SM4000 with the outstanding performance will meet and exceed your expectations.
A high performance system has been designed by advanced aerodynamic design and analysis.
• Rotor design optimized by dynamic analysis from the aerospace industry analyzes low
vibration.
• Static and dynamic properties of the components are improved by the finite element analysis
method.
• The high speed rotating Impeller is precisely balanced, and designed for optimum stability and
efficiency.
• While impeller rotates from the mechanical rotational kinetic energy from motor, it sucks
intake air from the direction of axis and exhausts air to the radial direction of air compression.
It is connected to the high speed pinion shaft and is made of corrosion-resistant materials.
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© 2016 HANW HA TECHWIN
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• There are 3 basic types of impeller geometry; BACKWARO TYPE, RAOIAL TYPE
and
FORWARO TYPE. Turbo Master uses BACKWARO TYPE for wide operation range.
• Impellers are made of corrosion resistant stainless steel for unlimited life cycle with
low vibration and low noise.
• Impellers passed 115% over speed spin test to guarantee greater reliability.
• The #2 and #3 stage scroll cases compress air along with rotor on each stage. These cases
diffuse the air flow accelerated at the impeller to convert the speed energy into the pressure
energy. In addition, this leads the air accelerated at the impeller to intercooler.
IGV
Figure 1.2.3 Scroll Case Figure 1.2.4 IGV with Scroll Case
• When the bull gear is driven by motor, pinion gears on both sides are increased in speed for
driving and impeller assembled to the pinion shaft is accelerated and rotated.
• Hardening of the gears and thrust collars results in an indefinite product life cycle.
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© 2016 HANW HA TECHWIN
CO.,LTO.
• Bull gear and pinions are designed and manufactured to AGMA 12 and AGMA 13
specifications respectively.
Helical Gear
Helix Angle: 16.90
.
Figure 1.3.2 Pinion Ass'y Figure 1.3.3 Pinion & Bullgear
• The IGV (Inlet Guide Vane), which is located at the front of compressor #1 stage, reduces
the energy used for driving the compressor by adjusting intake flow, and reduces the
resistance resulted from air flow at the inlet of impeller by maintaining the optimum condition
of intake air direction coincident with the rotation of the impeller.
• Inlet guide vanes feature a unique airfoil profile for improved efficiency.
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© 2016 HANW HA TECHWIN
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1.5 HIGH PERFORMANCE LONG LIFE BEARINGS
• Compressor has Tilting Pad Journal and taper-land thrust bearings on the pinion shafts. Four
lobe & tapered land thrust bearings are used on bull gear axis to transfer stable force in the
direction of axis.
• Oversized four lobe bearings and thrust bearings absorb loads while minimizing friction losses.
• The control monitors all critical parameters including temperatures, pressures and vibration
levels along with motor data.
• Critical functions are monitored for shutdown to prevent any damages on the components.
• The compressed gas from the compressor is hot after compression, often 70 - 200℃. An
Intercooler andlor aftercooler is used to lower the temperature, which also reduces the coolant
content and is included as standard equipment in a compressor installation (aftercooler
depends on the client condition or requirement). Intercooler should be placed directly between
each stage and aftercooler placed after the compressor. It is the heat exchanger that cools the
hot gas, to then precipitate the main part of the condensation coolant as quickly as possible
that would otherwise follow out into the system.
• The coolers are conducted through water cooled heat exchangers (shell and tube type). The
water cooled installation makes little demand on the ventilation of the compressor, as
the larger part of the heat produced is led off by the cooling water. The cooling water from a
water cooled compressor contains, in the form of heat, approximately 90% of the energy taken
up by the electric motor.
• Shell and tube type heat exchangers are built of plate finned tubes and are mounted in shell.
Compressed gas of each stage with high temperature passes through shell and coolant with
normal temperature flows inside tube (water in tube).
• It is easy to maintenance and provides relatively large ratios of heat transfer area to volume.
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© 2016 HANW HA TECHWIN
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Air Inlet
Oil Drain
Air Outlet
• Lube oil system supplies oil to each lubricating area of motor and inside gear box to
prevent friction and abrasion and cool down the friction area. When the compressor operates,
each lubricating area generates friction heat. The accumulated heat may cause bearing to be
stuck. Therefore, lube oil system makes oil film on lubricating area to reduce friction
resistance by converting solid friction to hydraulic friction. It also prevents the friction area
temperature from rising. Lube oil system consists of oil strainer, oil pump(main pump,
auxiliary pump), oil cooler, oil heater, oil demister, each valve (check valve, relief valve, etc),
etc.
1.8.1 Reservoir
• Oil tank holds oil to be supplied to equipments and provides base frame for the main motor.
• Two oil level sensors are used to measure the level of oil tank. This sensor is designed with
a float ball installed on the sensor axis to move along with the level.
• It increases oil temperatures to setting values before startup to ensure smooth operation
of gears and bearings.
1.8.3 Pumps
• When the main motor is powered up, bull gear is rotated by the main motor. Operating MOP
connected to bull gear by coupling to supply oil to lubricating area.
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© 2016 HANW HA TECHWIN
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• AOP is used to supply lubricating oil to gears until there is sufficient oil flow to operate the
main pump at the beginning of operation or in case of lack of lubricating oil due to failure
of main pump.
1.8.4 Filters
• Oil filter is installed in front-end of lubrication areas and provides better filterability, reliability
and strength than oil strainer. Mesh filter in oil filter shows pressure loss of 0.25-0.5 ㎏I㎠ for
lubricating oil at a temperature of 40℃ and can withstand a differential pressure of up to 16
㎏I㎠. (Oifferential pressure between front-end and back-end of filter)
• Oual filter is designed so that it has no effect on operation of equipment when replacement
of one filter is required or it becomes inoperative.
• Oil cooler allows water cooling of hot oil supplied to the gear box. Oil is routed through
shell side and cooling water is routed through tube side.
Hanwha Techwin's state-of-the-art mechanical design and rigorous attention to quality control along with
anticipating customer requirement result in the most reliable compressor available.
• Sealing system consists of carbon ring seal (A, B) to prevent air leakage, carbon ring seal
(C) to prevent oil leakage, vent line and oil drain line between labyrinth type oil seal and
carbon ring seal.
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© 2016 HANW HA TECHWIN
CO.,LTO.
• Eductor or vacuum pump exhausts air in gear box to the outside, and maintain the pressure in
gear box lower than atmospheric pressure. The negative pressure in gear box prevents the
supplied oil from leaking in casing or air flow passage after passing carbon seal. In addition, it
prevents high pressure air at the rear of impeller from leaking in the gear box through vent
line, and collects the leaked oil through oil drain line in the gearbox.
Nut Cap
Shaft
• New surge control logic improves surge margin by 3 to 5% resulting in more stable operation.
• Optional power interruption control minimizes unscheduled stops due to power "glitches".
• Hanwha has added its own quality assurance program based upon the aviation industry's
quality control practices resulting in the highest quality compressor available.
• Hanwha Customer Support Network provides the most reliable after-sale service 24 hours
a day, 365 days a year.
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© 2016 HANW HA TECHWIN
CO.,LTO.
3.0 NO REVISION NECESSARY
Fully packaged Hanwha compressor series result in lower cost in operation from installation to maintenance,
and the SM's high efficiency helps minimize electrical costs
• High efficiency impeller with wide operational turndown range results in lower overall
operating expense and less loading and unloading.
• Inlet guide vanes help match compressor output to demand while providing proportional
turndown in power consumption.
• Loading and unloading cycles are minimized by the wide turndown, saving power and
increasing reliability.
• Horizontally split bearings, gearbox and seals allow quick service with minimal downtime.
• Plate-finned tube design enhances cooler performance with minimal pressure drop.
• Entire bundle treated with corrosion resistant material ensures longer life.
State-of-the-art design provides user-friendly interface capable of easy monitoring and sophisticated control
• User friendly interface provides the real-time operation status of the functions and the
values can be read at a glance.
• When compressed air usage is less than full capacity, the control system fine-tunes inlet guide
vanes to reduce output and power demand to the maximum turndown level, at which point the
blow off valve automatically opens unloading the machine to minimum power.
• An industry leading 35% turndown allows smooth and efficient operation over a wide range.
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© 2016 HANW HA TECHWIN
CO.,LTO.
4.3 SUPERIOR SCALABILITY ANO ACCESSIBILITY
• The blending of SM3000 Controls with Hanwha's world class electronics and technology offers
an easy interface with existing control systems.
• WEB-based Controls (optional) allows operators to access to the control system any time and
everywhere.
The compressor's design is the result of the latest technologies in aerodynamic and electronic engineering
and offers the world's most advanced centrifugal compressor
• Unitized frame construction based on the modularized design of the assemblies eliminates the
need for an expensive foundation and saves on installation costs.
• Power wiring from starter to main motor and simple control interconnections from SM control
to starter simplifies electrical installation.
• Simple connections for water-inlout and compressed air discharge are the only work required
for initial installation and operation.
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© 2016 HANW HA TECHWIN
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6.0 INSTRUMENTAION
6.1 Pressure
• This sensor is used to be sense the air pressure changes and measure the pressure of the
compressor. Pressure sensor has its own sensing range, so if replacement required, it shall
be installed complying with the operating pressure of the compressor.
• Pressure sensor, as an electronic unit, may be subject to high temperature and shock. It is
located inside the panel and connected with SUS tube at the measuring location.
• System pressure, discharge pressure and oil supply pressure are input to the pressure sensor.
6.2 RTO
• RTO is used to be sense the temperature changes and are attached to the place required to
measure the compressor temperature. There are several temperature sensors, but generally
Resistance Temperature Oetector (RTO) is used. RTO in the sensor maintains 100(0) under
0℃ and its resistance increases depending on temperature rise.
• Temperature sensor is generally installed on the place with the highest temperature among
the measuring locations. Temperature sensor cable is directly connected to the controller of
the control panel.
• There are oil supply temperature, 2-stage inlet temperature, oil tank temperature, motor
temperature, bearing temperature, etc.
6.3 Vibration
• It is to sense any minute movement of the object and installed in compressor gear box
and pinion to detect the compressor vibration. The sensing scope of the vibration sensor
depends on sensor type, cable length and transmitter. Care must be taken for
replacement. The vibration sensor operates at the distance of 1mm. Vibration sensor is
installed in the rotating area and used depending on the installation direction.
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© 2016 HANW HA TECHWIN
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Figure 4-1 Pressure Transmitter Figure 4-2 RTD
7.0 VALVES
• If the supplied pressure increases higher than the set value, blow-off valve vents the
compressed air and controls the supplied pressure.
• Oischarge Check Valve prevents high pressure air outside compressor from flowing
backward inside compressor.
• Similarly with check valve, it prevents high pressure air outside compressor from
flowing backward inside compressor.
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© 2016 HANW HA TECHWIN
CO.,LTO.
8.0 ACCESSORIES
• Free filter and cylindrical element in inlet filter assembly prevent foreign materials from
being mixed inside compressor.
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© 2016 HANW HA TECHWIN
CO.,LTO.
Project Name PT. Gajah Tunggal Project No Date 2016-5-24
a. Customer requirements
Gas Air
Relative Humidity 90 %
Motor Frequency 50 Hz
b. Performance
Flow 99.75
15.000 barG
Turn-Down Ratio 28 %
42.00 oC
c. Utility
The shaft power of the entire compressor package is a sum of the gas power and the mechanical losses. The gas power will be evaluated
based on the measured gas flow, gas temperatures and gas pressures at each stage. The mechanical losses will be evaluated based on
the oil flow, oil supply and return temperature. Capacity and specific power will be evaluated using the specific conditions defined in this
performance sheet. All data other than the guaranteed capacity and the specific power are provided as a reference.
aSEP Ver1.212
Project Name PT. Gajah Tunggal Project No Date 2016-5-24
17 5
IGV 100%
. IGV 70%
15 0
IGV 30%
IGV 95%
Discharge Pressure,
.
12 5 DESIGN POINT
.
10 0
barG
.
75
.
50
50 60 70 80 90 100 110 120 130
Flow Rate,
1100
Im3/min{Dis)
1000
IGV 70%
800 IGV 30%
IGV 95%
kW
700
DESIGN POINT
600
500
400
The shaft power of the entire compressor package is a sum of the gas power and the mechanical losses. The gas power will be evaluated
based on the measured gas flow, gas temperatures and gas pressures at each stage. The mechanical losses will be evaluated based on
the oil flow, oil supply and return temperature. Capacity and specific power will be evaluated using the specific conditions defined in this
performance sheet. All data other than the guaranteed capacity and the specific power are provided as a reference.
aSEP Ver1.212
PRICING SUMMARY
UNIT TOTAL
PRICE PRICE
PRICING SUMMARY Qty.
(USD) (USD)
Not
HMI System Not Included NA
Included
PRICE TERMS FOB Jakarta Port, Custom Duty and Import Tax not included.
PACKING hTW export standard packing.
WARRANTY TWELVE (12) months after start-up test at site customer's site or eighteen (18)
months after shipment whichever comes first.
PAYMENT TERMS 30% Downpayment Upon Receiving PO, Balance 70%, 60 days LC at Sight.
PENALTY 0.1% per day of total amount if the order not reached as per agreed delivery term
INSPECTION The products covered by this quotation are inspected according to the
manufacturer's standards, at the manufacturing workshops, before being shipped.
PRICE VARIATION The stated price is firm and fixed, and not subjected to escalation for the duration of
the contract.
Yours faithfully,
APEX AIR ENGINEERING (M) SDN. BHD.
KS 0 3711 SCM440
Bearing & Bearing Pad Chromium Molybdenum Steels (JIS G 4105 SCM440)
(ASTM A29 Grade4140)
Carbon rings held in holder l
Air & Oil Seals ASTM B116 C36000 l C0A360
Brass
KS 0 5301 C1220T
Interlafter-cooler tubes Copper Alloy (JIS H 3300 C1220T)
(ASTM B88 C12200)
KS 0 6701 A1100P
Interlafter-cooler fins Aluminum Alloy (JIS H 4000 A1100P)
(ASTM B209 Alloy1100)
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© 2016 HANW HA TECHWIN CO.,LT0.