Kaeser Omega Blowers and Blower Packages

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Kaeser Omega Blowers and Blower Packages
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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

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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

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Kaeser Manufacturing Sites
Fredericksburg, VA Coburg, Germany Gera,
Germany Sonnefeld, Germany
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Kaeser Standards of Excellence
ISO 9001 Certified - Continuous process
improvement ISO 14001 Certified - Commitment to
environmental protection
CE Certified - Declarations of Incorporation are
available
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What is a Blower?

• High volume
• Low pressure (typically 21)
• Positive-displacement
• Oil-free
• Internally gas cooled

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What is a Blower?
Blower operating principle
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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

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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
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Tri-Lobe Versus Two-Lobe
1 Revolution
Tri-lobe design and equalization channel
efficiently reduce pulsations and noise
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Applications

• Pneumatic conveying

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Applications

• Municipal and Industrial water and wastewater
  treatment

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Applications

• Blow-off, product drying

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Applications

• Environmental remediation

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Applications

• Landfill gas extraction

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Applications

• Agricultural spraying

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Applications

• Power generation using waste steam

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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
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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

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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)

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Blower Design and Construction
Large shafts to reduce deflection
One-piece ductile iron rotor assemblies
Solid or closed-end rotors standard
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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

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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)

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Blower Design and Construction
Splash lubrication (both ends)
Easy to read oil sight glasses (factory filled
with lubricant)
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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

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Blower Design and Construction
SKF Explorertm, caged, full compliment
cylindrical roller bearings for long L10 life
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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
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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
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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

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Blower Design and Construction
Heavy-duty cast iron housing with integral
headplate
Piston ring labyrinth air and oil seals with
vented cavity
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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
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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

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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

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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

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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

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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

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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

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Omega Com-paK Plus
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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
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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
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Omega Com-paK Plus
Ducted belt guard for better seal cooling
Retained belt guard fasteners
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Omega Com-paK Plus
Motor lubrication point
Inlet silencer with replaceable absorptive media
Discharge silencer with domed head
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Automatic V-Belt Tensioner

• Visual indication of tension
• Easy maintenance
• Maintains tension
• Maintains efficiency
• Infrequent adjustments
• Prevents over-tensioning
• Prolongs component life

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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
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Omega Com-paK Plus
Com-paK Plus with integrated AFR and vent
silencer
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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

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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

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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

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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

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Omega Com-paK Plus
Special inlet louver smoothes cooling air flow to
motor
Oil chamber ventilating louvers (8K reduction)
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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

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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

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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

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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

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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

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Omega Com-paK Plus
All maintenance is performed from the front of
the package
2
4
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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
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Omega Com-paK Plus

• Package installation
• One next to the other
• Reduced floor space
• Easy to install
• Saves on construction costs
• Full maintenance access

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Omega Com-paK Plus
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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.
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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

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Omega Com-paK Plus

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

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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

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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

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Kaeser Containerized Solutions

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

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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

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Accessories - Control Panels
Kaeser Start Control - STC
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Accessories - Control Panels
On / off switch
Kaeser Start Control - STC
Kaeser control
Emergency stop button
Hour meter
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Accessories - Control Panels
Kaeser Start Control - STC
Motor
Fan
Liquid level
Temperature
Pressure
General warning
Dirty filter
Refer to manual
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Accessories - Control Panels
Omega Frequency Control OFC 3 kW 250 kW
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Accessories - Control Panels
Omega Frequency Control OFC 3 kW 250 kW
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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

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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

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Accessories - Control Panels
Sigma Air Manager
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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
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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

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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

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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

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3
6
7
5
1
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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
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Accessories Unloaded Start Valves
Air from blower package
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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

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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

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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

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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
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Performance Benefits

• Low noise levels!

Noise levels are, 3 dB(A) in accordance with
ISO 2151 in free-field conditions
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Performance Benefits

• Lower noise levels
• Lower operating costs
• Lower maintenance costs
• Longer life
• Lowest cost of ownership
• Lowest life-cycle cost

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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.

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Commercial Advantages

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

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Commercial Advantages

• System solutions
• Competitive prices
• Unsurpassed customer service and satisfaction

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Compressors and Vacuum Products

• Rotary screw compressors

• Vacuum screws

• Booster compressors

• Mobilair portable compressors

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Air Treatment Equipment and Accessories

• Breathing air systems

• Filters

• Dryers

• Sequencers

• Drain traps

• Flow controllers

• Condensate management

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