Compressor Specification

Single-Stage
Oil-Injected Rotary Screw

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1.0 SCOPE
1.1 This specification covers the general requirements for operational conditions, design, and materials of
construction and performance of a packaged single-stage, oil-injected, pulsation-free, rotary screw air
compressor, models GA355-GA500.
1.2 The Vendor shall state in his quotation any and all exceptions to this specification.
2.0 GENERAL
2.1 A positive displacement rotary screw compressor shall be delivered as a fully packaged system including air
compressor, prime mover, after-cooler, lubrication system, regulation, and control system mounted on a
common base frame and fully enclosed in a steel sound-dampening canopy.
2.2 The compressor shall consist of a single twin-element compression stage flanged to an integral speed
increaser to insure optimum speed and highest possible efficiency. Silencers, lubricating system, cooling
system, control system, after-cooler, and driver shall be mounted as a part of the package. A common base
frame for the compressor system and driver shall be furnished. The Vendor shall also provide a sound
enclosure over compressor and driver.
2.3 The capacity and specific power quoted shall be guaranteed per modified CAGI-Pneurop PN2CPTC2 with
tolerances of +/-4% for capacity and +/-5% for specific power.
3.0 COMPRESSOR UNIT
3.1 Casing - The compressor air end shall be a cast iron, one-piece casing housing a dual set of precisionmade screw-type rotors for optimal efficiency and long lifetime. The air end shall be designed with a large
inlet port to provide fast filling time and low air velocities. The twin set of rotors shall be bolted to a common
bull gear.
3.2 Rotors - Rotors and shaft shall be of one-piece heat-treated carbon steel construction. The rotors shall
have an asymmetric profile that keeps leakage losses at a minimum to ensure high efficiency. The male
rotor shall have four equally spaced helical lobes, and the female rotor shall have six equally space flutes.
A five lobe design will not be acceptable. Rotors are required to be balanced dynamically to provide
vibration-free operation.
3.3 Bearings - Bearings shall be of the high precision anti-friction type with high stability under varying process
conditions and able to adapt well to changing loads. The discharge side of the air end shall have a paired
set of 4-point contact ball bearings for axial loads and cylindrical roller bearings for radial loads. The inlet
side of the air end shall have roller bearings for radial loads.
3.4 Speed Increaser - The speed increaser shall be an integral part of the compressor unit and include the
main drive shaft and bull gear. The main drive shaft shall be supported by anti-friction bearings. Male rotor
speed shall not exceed 3000rpm, insuring maximum lifetime of the air end.
3.4.1 Shock Pulse Monitoring (SPM) studs shall be available to facilitate the installation of a
continuous SPM monitoring option.
3.5 Coolers - The compressor package shall be equipped with an oil cooler and an after cooler factory
mounted on the compressor skid with no addition in footprint size. A remote cooler configuration will not be
considered.
3.5.1 An air-cooled compressor shall have a finned aluminum block-type design for the oil- and aftercooler, mounted on rubber buffers to avoid vibration and thermal stress. The fan guards,
housings, and fan motor shall be installed on a hinged assembly for easy maintenance. The
fan motor shall be TEFC.
3.5.2 A water-cooled compressor shall have both the oil- and after-cooler combined into one brazed
plate stainless steel heat exchanger. There shall be no gaskets to avoid possibility of leaks.

Compressor Specification
Single-Stage
Oil-Injected Rotary Screw
3.5.3
3.5.4

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All coolers shall include a separator and automatic water condensate drain for optimal
efficiency and ease of maintenance.
The cooler design shall maintain approach temperatures under 11F for water cooled units and
under 17F for air cooled units to provide maximum efficiency and condensate removal.

3.6 Driver - The driver shall be high efficiency TEFC flange-mounted to the gear casing via a standard NEMA D
flange. The motor shall be direct-coupled to the compressor via a flexible coupling only, so that no
compression forces are transmitted to the motor. The coupling will require no lubrication or frequent
maintenance. The motor speed shall be 1500 rpm. The motor shall have class F insulation and a class B
temperature rise. The severe duty painting system shall exceed specifications of IEEE841. The motor shall
be of an extreme duty design and nameplated for a hazard classification of Class I Division II Groups B, C,
and D.
3.7 Drive Motor Starting The compressor package shall be provided with a Wye-Delta starting configuration
to provide machine starting with minimal power usage. Starter components and wiring shall be an integral
part of compressors. The starter enclosure shall have a NEMA 3R (IP54) or equivalent rating.
3.8 Lubricating System The lubrication oil for the compressor shall be contained in an integral sump. The
drive gear and bearings are to be spray lubricated. The lubrication shall be a synthetic composite with a
minimum service lifetime of 8000 hours.
3.9 Oil Separator The compressor package shall include an oil separator. The element shall include a zincelectroplated steel grating. The maximum pressure drop across the oil separator shall not exceed 3psig.
3.10 Regulating System The regulating system shall be full load/no load for maximum efficiency. Geometrybased regulation will not be acceptable.
3.11 Electronic Monitoring and Control System - An electronic control and monitoring system shall be
integral to the compressor package and shall consist of a microprocessor based regulator designed to
provide manual and automatic running. This system shall provide the following functions: control of the
compressor, protection of the compressor, monitoring of components subject to service, and auto restart
after voltage failure. The system shall also provide for automatic shut-off of the compressor during periods
of low demand and excessive idling to conserve energy, and for two pressure bands to be programmed for
automatically switching based on a weekly timer. A step-down transformer will be provided for control
voltage.
3.12 Monitoring and Control Capabilities The compressor package shall have the appropriate displays,
controls, and indicators to monitor operation as specified below:
LED Indicators:
- Automatic operation
- Voltage on

- General alarm / shutdown

Push Button/Tactile Switch:

- Start / stop
- Emergency stop
- Function Keys (F1-F3)

- Scroll keys
- Tabulator keys (more data)

Available Data:
- Element outlet temperature
- Delivery air pressure
- Air filter delta P
- Oil separator delta P
- Element oil inlet pressure

- Cooling medium temperature

- Running hours
- Loaded hours
- Elektronikon regulator hours
- Dryer dewpoint temperature (FF only)

Shutdown/Warning Indications
- High element outlet temperature

- Fan motor overload

Compressor Specification
Single-Stage
Oil-Injected Rotary Screw
- Drive motor overload

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- Emergency stop

Service Indicators:
- Air filter
- Oil filter
- Oil separator

- Oil lifetime
- Regreasing of motor
- Sensor error

Alphanumeric Displays:
- Line 1 - Data description
- Line 3 Status

- Line 2 - Reading
- Line 4 - F Key function

Configuration Parameters:
- Time
- Date
- Format of date
- Language of display

- Units for pressure

- Units for temperature
- Auto restart after power failure (factory disabled)
- Motor start mode

Digital Input Commands (voltage free contacts)

- Start
- Programmed stop

- Load / unload
- Emergency stop

Digital Output Compressor Status (relay outputs)

- Unit running
- General warning
- Load / unload
- General shutdown
- Automatic operation
3.12 Networking The compressors must have the ability to interface to a plant control system or the internet.
To achieve this, the compressors shall be networked via a Controller Area Network (CAN) using
electromagnetically shielded cable to ensure an undisrupted signal between compressors.
3.12.1 Plant Interface The compressor network shall have the optional capability to communicate to
a plant DCS via a RS485a interface for monitoring the parameters listed in 3.12 and to allow
light control including start / programmed stop, load / unload, emergency stop, and modification
of pressure band level.
3.12.2 Internet Interface The compressor network shall have the optional capability to communicate
operation parameters over the internet. This internet interface shall be configurable to provide
an alert message via phone or e-mail to designated service personnel when a compressor
using the service has a warning, shutdown, or alternate service requirement.
3.12.3 Sequencing The compressor microprocessor shall have the optional capability to function as
a multi-compressor controller, allowing it to control several other networked compressors,
significantly reducing the pressure band while equalizing the running hours of the networked
compressors.
3.13 Intake Air Filter System The air intake filters are to be enclosed in the compressor package. The filter
shall be paper cartridge type with an inner and outer zinc plated frame. The rating shall be a minimum of
SAE fine for a particle size of 3m at 99.9% efficiency and 1m at 98% efficiency. The filter shall have fire
resistance class F1 according to DIN 53438.
3.14 Compressor Enclosure The compressor unit including motor shall be enclosed in a sectionalized steel
sound insulating canopy with doors to provide ready access for normal maintenance. The doors shall be
removable. Sound insulating material shall be nominal two-inch thick flame retardant polyurethane
foam.
3.15 Noise Levels - The compressor package shall not exceed 76 dB(A) when measured in free field
conditions at one meter in accordance with the CAGI-Pneurop Test Code.
3.16 General Installation Requirements - The compressor shall be of design to facilitate simple installation.
The compressor shall have a structural steel skid so that no special foundation is required other than a

Compressor Specification
Single-Stage
Oil-Injected Rotary Screw

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Revision:

level, weight-supporting floor. Compressors shall not require bolting to the floor. Unit is to be delivered
with all internal piping and wiring completed at time of delivery. Compressor shall have individual
connections for inlet air, discharge air, inlet and outlet water when applicable, and provisions for incoming
power cables.