Sperre PDF

Sperre Air Compressor
Technical Documentation
CUSTOMER: CORPORACION ELECTRICA DEL

ECUADOR CELEC EP
HULL/ VESSEL: POWER PLANT SANTA ELENA II
SPERRE ORDER CONF.: 486856
A STARTING AIR COMPRESSOR 1 x HL2/160
Final
Working
Approval 20.11.13 TOP FHJ
ISSUE DATE PREP. BY CHECK
Sperre Industri AS Sperre Rotterdam BV Sperre Asia PTE LTD Sole suppliers of
Tel +47 70 16 11 00 Tel +31 180 463 299 Tel +65 763 63 00 genuine spare parts
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11
E-mail:industri@sperre.com E-mail:rotterdam@sperre.com E-mail:asia@sperre.com
LIST OF DRAWINGS
STARTING AIR COMPRESSOR 1 x HL2/160
No. Description Type /Dwg. Part No.
A1 General arrangement G03-0007

A2 Installation diagram D03-0007
A3 Air compressor data sheet HL16-114
A4 El. Motor data sheet M7336
A5 El. Wiring diagram E20202
A6 El. Part list E20202005
A7 Dimension sketch, starter panel E00009-V.3
A8 Non-return valve, KV-48 3-2828 4492
A9 Oil & water separator, V-23-1 3-3197 1941
A10 Solenoid drain/ unloading valve, H.P. 322H 4332
A11 Pressure switch, start/ stop PRS-30 7756
A12 Thermo switch TMS-80 7746
A13 Oil level switch VH 600M 4356
A14 Vibration damper, A2 4-1813 4606
A15 Flexible hose, 1 ¼” Bsp 4598
A16 Recommended lub. oil list
Electric Motor
Data Sheet
Part no. 7336
Manufacturer & Type Construction

Manufacturer ABB Size and dimentions according to IEC 60072
Model M3AA 200 MLB6 Design (IEC 60034-7) IMB3
Frame size (IEC 60072) 200M
Protection (IEC 60034-5) IP55
Supply Insulation class (IEC 60085) / Temp. rise F/B
House material Aluminium
Volts/Cycles/Phases 440V / 60Hz / 3 Bearing greasing Acc. to instr.man
Rated current, In 45,9 A Bearings DE/SPERRE part no. 63122ZC3/6322
Starting current 6.1 x In Bearings NDE/SPERRE part no. 62102ZC3/6333
Weight 218 kg
Output Installation
Rated power 27.0 kW Starting method DOL / Y-D
Power factor at FL (cosΦ) 0.84 Duty type S1
Efficiency at FL 91.7% Rotation (seen against shaft end) CW
Speed synchronous / FL 1200/1180RPM Wiring connection DELTA
Cable gland entries 2xM40/1xM16
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Comment
Program description:
The starter is designed with a MAN 0 AUT switch,
In MAN mode the compressor will run regardless of the start / stop pressure switch. It is not recommended to leave the compressor
running unattended in MAN mode although the parameters temperature, lub. Oil and motor overload is surveyed.
In 0 mode the compressor is switched off, but the starter is still powered.
In AUT mode the compressor is controlled by the start / stop pressure switch.
The starter is equipped with a common alarm signal lamp and a common alarm signal output. The alarm signal is a voltage free contact
programmed to be closed when the compressor condition is normal. This means that the alarm signal is open if the PLC is not running, or
there is a fault condition detected. When an existing alarm condition and a new alarm occurs, the remote alarm output goes from open to
close for one second before returning to open.
Following parameters will give alarm:
High temperature. It the temperature exceeds the setting of the temperature switch the compressor will stop and alarm will be given. The
alarm will remain until the reset button is pressed. The text HIGH TEMPERATURE will be displayed on the PLC and will remain in the
display until the reset button is pressed.
Lubrication oil failure. If the Lub. Oil level / pressure falls under the setting of the Lub. Oil switch the compressor will stop and alarm will be
given. The alarm will remain until the reset button is pressed. The text LUB. OIL FAILURE will be displayed on the PLC and will remain in
the display until the reset button is pressed.
El-motor overload. If the thermal overload relay releases, the compressor will stop and alarm will be given. The alarm will remain until the
thermal relay is reset. The text EL_MOTOR OVERLOAD will be displayed on the PLC and will remain in the display until the thermal
relay is reset.
Emergency stop. If the emergency stop push button is activated, the compressor will stop and alarm will be given. The alarm will remain
until the emergency stop push button is released and the reset button is pressed. The text EMERGENCY STOP ACTIVATED will be
displayed on the PLC and will remain in the display until the reset button is pressed.
The progtam is designed to autostart after blackout if the compressor is set to AUT mode, timer B2 will delay the start. If the compressor
is in MAN mode and there is a power blackout then the compressor will not restart when the power returns, but have to be switched to 0
and back to MAN (or AUT).
The starter is designed with an emergency run switch. When this switch is operated the PLC is overridden, and the alarm functions are
therefore not active.
This switch is intended for emergency run only and the compressor must not be left running unattended.
The program contains an hour counter with a time to service function. When the compressor is running the hour counter is shown in the
display. When the service timer have counted down to 0 the alarm lamp will go flashing to indicate time for service. To reset service
indication press reset button.
Creator: Torgeir Project: Customer:

Checked: Installation: Diagram No.:
Date: 1/23/02 9:28 AM/8/7/12 11:45 AM File: E20202.lsc Page:
High
B002
Trg
hi B018 X2
En
T B019/3 P X
B16 Rem = off Prio = 0 Par
I1 (S0 Emcy Stop) S

20:00s+ En B035 B026/1 Quit = off
B017 R RS
I Par P HOURCOUNTER
& B020/3 B023/En
I4 Rem=Off Prio = 3 Par
(B007-Tot
Quit = off TIME TO
I2 (S1 Man) B002 B026 EMERGENCY 2/B029/Trg SERVICE(B007-Ti
B001
I & STOP B005
Trg
& B012 Q2 (Y3 Drain Valve)
B022 B25 ACTIVATED M2 En
S B030 B014/4
>1 R RS T Inv Q
B003 Rem = off Par
I4
Par
B024/En
&
>1 05:00s+ Rem = off
Rem=Off
30:00m+ Q1 (K1 Compressor)
I8 (F11 Start/Stop)
B021 01:00s Q
I Trg
R B002 B023 X1 B025 B024
En En
T B004
P X P
Rem = off & B007 I4 B010 M1
I3 (S1 Aut) Prio = 6 Par Prio = 5 Par
R
01:00s- Quit = off Quit = off En & M
I Ral
STARTUP IN PRESS RESET
Par
PROGRESS AFTER BLACK- MI= 500h 0m+
I5 (B002-Cur) OUT IN MAN. B013
(F1 Overload) OT= 0h 0m B034
(B002-On-) B031 OPERATION >1 En
I En Q->0=R+En
Inv
P
Par
Prio = 1 Par
2/B036/Trg Rem = off
I7 (F13 Oil Level) Quit = off
B014 B015 00:50s-
I B011 EL-MOTOR 2/B037/Trg
Trg B09 B032 >1 00:50s
& OVERLOAD S En B020 Q3 (H3 Alarm)
Q2 T I4 R RS P
I6 (F12 Temp) Rem = off Par Prio = 4 Par >1 Q
B019 Rem = off
I 03:00s+ Quit = off B035
B002 & LUB. OIL
B06
S
FAILURE B033 B001/3
I4 (S3 Reset) B008 R RS En B027 M2
Par P
>1 2/B028/1
I & M
B009/R Rem = off Prio = 2 Par
B017/3 Quit = off 2/B038/Trg

B010/1
B022/4 HIGH
TEMPERATURE
Date: 1/23/02 9:28 AM/8/7/12 11:45 AM File: E20202.lsc Page: 1/2
1/B016 Trg B029
Rem = off
01:00s+
1/B031 Trg B036
T B039 M3 1/M2 B028 Q4 (Remote Alarm)

Rem = off
>1 M >1 Q
01:00s+
1/B009 Trg B037
Rem = off
01:00s+
1/B006 Trg B038
Rem = off
01:00s+

Date: 1/23/02 9:28 AM/8/7/12 11:45 AM File: E20202.lsc Page: 2/2
Block Number (Type) Parameter
B002(On-Delay) : Rem = off

20:00s+

05:00s+
B006(Latching Relay) : Rem = off
B007(Hours Counter) : MI= 500h 0m+

OT= 0h 0m
Q->0=R+En

03:00s+
B012(Asynchronous Pulse Generator) : Rem = off

30:00m+
01:00s
B018(Message texts) : Prio = 0

Quit = off
HOURCOUNTER
(B007-Tota)
TIME TO
SERVICE(B007-Time)
B021(Off-Delay) : Rem = off

01:00s-

Quit = off
STARTUP IN
PROGRESS
(B002-Curr)
(B002-On-D)

Quit = off
PRESS RESET
AFTER BLACK-
OUT IN MAN.
OPERATION
B029(Wiping relay (pulse output)) : Rem = off

01:00s+

Date: 1/23/02 9:28 AM/8/7/12 11:45 AM File: E20202.lsc Page: 3
Block Number (Type) Parameter

Quit = off
EL-MOTOR
OVERLOAD

Quit = off
LUB. OIL
FAILURE

Quit = off
HIGH
TEMPERATURE
B034(Asynchronous Pulse Generator) : Rem = off

00:50s-
00:50s

Quit = off
EMERGENCY
STOP
ACTIVATED

01:00s+

01:00s+

01:00s+

Connection Label
I1 S0 Emcy Stop
I2 S1 Man
I3 S1 Aut
I4 S3 Reset
I5 F1 Overload
I6 F12 Temp
I7 F13 Oil Level
I8 F11 Start/Stop
I9
I10
I11
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
S1
S2
S3
S4
S5
S6
S7
S8
AI1

Connection Label
AI2
AI3
AI4
AI5
AI6
AI7
AI8
Q1 K1 Compressor
Q2 Y3 Drain Valve
Q3 H3 Alarm
Q4 Remote Alarm
Q5
Q6
Q7
Q8
Q9
Q10
Q11
Q12
Q13
Q14
Q15
Q16
AQ1
AQ2
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X11
X12

Partlist
Main voltage 440 V
Control voltage 220 V
Motor rated power 27 kW
Motor rated Current 45,9 A
Max rating of associated fuses 100 A
Ref Description Partnr

M1 MOTOR 7336
Q1 MAIN SWITCH 55A 14 747 11
K1 MAIN CONTACTOR 50A 66245
F1 BIMETAL 37-50A 66323
A1 LOGIC MODULE, PROGRAM: E20202 45 103 75
P2 HOUR COUNTER 43 082 09
S0 STOP PUSH BUTTON 43 032 88
S1 SWITCH 3 WAY 43 033 23
S3 PUSH BUTTON BLACK 43 032 64
S7 SWITCH 2 WAY 43 033 -2
H2 SIGNAL LAMP GREEN 43 030 07
H3 SIGNAL LAMP RED 43 030 08
T2 TRANSFORMER 440/220V 150VA 66 800 -2
F4 F5 FUSES 2A 450V 68212
F6 FUSES 0,5A 450V 68205
SWITCH BOARD h:500 b:400 d:250 24 902 12
F11 PRESSURE SWITCH 7756
F12 THERMO SWITCH 7746
F13 LEVEL SWITCH 4356
Y3 DRAIN VALVE 4332
MPS: E20202005
Solenoid drain valve
Part no. 4332
2/2 shut of valve for unloading
and drain of compressors. Technical data
Function ............... : Open when de-energized
Valve design......... : Pilot operated diaphragm valve
Poppet type pilot.
Nominal diameter. : 14.5 mm
Port sizes .............. : ½” BSP
Mounting.............. : Direct pipe mounting
Unrestricted position
Working pressure . : Max 40 bar
Pressure drops ...... : ∆ p min. 0.3 bar for opening
∆ p min 0 bar for closing
∆ p max 40 bar
Flow factor ........... : Kv = 60
Weight.................. : 880 g (incl. coil)
Material specification Electrical data - Coil

Body ..................... : Forged brass Material......................: Encapsulated in synthetic material.
Internal parts......... : Stainless steel, Plug connection..........: 3 pin DIN 43650A, incl. Plug with
brass and nickel PG11 for cable conn.
Sealing.................. : Synthetic rubber (FKM) Voltage ......................: DC 24 V AC 110 V (50 and 60 Hz)
Valve sealing ........ : Pressure/spring loaded AC 220 V (50 and 60 Hz) Other
seat disc (O-Ring) voltages on request.
against a carefully Voltage tolerance .......: -10% to +15% of nominal
machined nozzle provides Class of insulation......: F
bubble tight sealing. Solenoid duty .............: Continuos
Life expectancy .... : Hundreds of thousands Power rating...............: 8 W
of cycles. Protection class ..........: IP 65
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Data Sheet
Pressure switch PRS-30 Part no. 7756
Adjustable pressure switch
for control of compressor's START and STOP.
Range: 3,5 - 35 bar
Construction: Adjustment:
Pressure switch type ........ : Diaphragm Range of switching point ... : 3,5 - 35 bar
Fluids controlled.............. : Hydraulic oils, fresh water, (50,75 - 507,5 psi)
sea water, air Min. diff. at low setting ...... : 1,7 bar (24,65 psi)
Weight ............................. : 0.75 kg Min. diff. at high setting ..... : 2,55 bar (36,97 psi)
Max. diff. at high setting .... : 20 bar (290 psi)
Design: Installation:
Max temperature.............. : 70°C Fluid connection.................. : ¼" BSP
Max. permissible pressure : El. connector type ............... : DIN 43650A, 4-pin male,
Per cycle 45 bar (652,5 psi) plug PG11
Occasional surge 80 bar (1160 psi) Enclosure............................. : IP65
Destruction pressure ........ : 160 bar (2320 psi)
6 Ship approvals:
Mechanical life.................: 5 x 10 operating cycles
DNV, LRS, GL, BV, RINA
CE marked acc. to 89/336/EC, 92/31EEC, 93/68/EEC
PRESSURE SWITCH
Range
Plage
350 50,8 3,5

1
2000 290 20
PH
3500 508 35
N6
3
PRS-30 Electrical wiring:

Part no. 7756
Differential
Ecart
2000 290 20
2
1
900 130,5 9
PB
13
11
170 24,7 1,7

3
3
IEC/EN60 947-5-1
Ui : 250V IP65IP65 1
PH- High setting point SPERRE
14
12
AC15
www.sperre.com Ue : 240V
0 PB- Low setting point Ie : 1,5A

Ie : 1,5A FranceFrance
Tel +47 70 16 11 00 Tel +31 180 463 299 Tel +65 67 63 63 00 genuine spare parts
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 67 63 18 11
E-mail: industri@sperre.com E-mail: rotterdam@sperre.com E-mail: asia@sperre.com
Data Sheet
Temperature switch TMS-80 Part no. 7746
Adjustable temperature switch
for alarm indication and shut down of compressor
Alarm: S.P. 75°C, Shut down: S.P. 80°C
Construction: Performance:
Temperature switch type ............. : Rigid sensor Setting range ..................................: 50-100°C
Weight ......................................... : 0.35 kg Differential .....................................: 3°C
Permissible operating temp. ...........: 200°C
Environmental conditions:
Operation temperature ................. : -40 to +70°C Installation:
Enclosure ..................................... : IP65, IEC 529 Process connection.......................: ½" BSP
Vibration stability El. connector type ........................: DIN 43650A, PG11
Sinusoidal 20g, 25 Hz - 2 Hz ... : IEC 68-2-6
Shock resistance Material:
Shock 50 g/6 ms, 500 g/1 ms .. : IEC 68-2-27 Wetted Parts: Sensor pocket ...: Brass
Free fall ................................... : IEC 68-2-32 Enclosure Parts: Housing ...........: AlMGSi1
Plug fixture ......: Glass filled polyamid
Electrical specifications:
Switch.......................................... : SPDT Ship approvals:
Contact load: AC15 .................. : 0.5 A, 250 V DNV, ABS, LRS, GL, BV, RINA, MRS, KRS
DC13 .................. : 12 W, 125 V CE marked acc. to EN 60 947-5-1
Adjustment: When the top cover is removed, the

range can be set with the setting-screw.
The differential is non-adjustable
Electrical wiring:
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Data Sheet
Oil level switch Part no. 4356
Technical data:
Nominal pressure ..................... : PN25
Weight ..................................... : 0.35 kg
Max. medium temp. ................. : 110°C
Max. ambient temp. ................. : 80°C
Switching hysteresis ................ : ca. 1-4 mm
Switching-on point reffered to
center position : ........................ : -4 to 0 mm
Electrical specifications:
Max. switching current .......: 1A
Max. switching voltage .......: 230 VAC/ 48 VDC
Max. rating .........................: 26 VA / 20 W
Protection class ...................: IP 65
Material:
Body ............................. : Brass (Cu Zn 39Pb)
Float ball ....................... : PVDF
Installation:
Process connection ....... : ¾" BSP
El. connector type .......... : Plug connector DIN 43650 type
A ISO 4400 including cable box, suitable for cables of
outside dia. 4.5 - 7 mm.
Adjustment of the switching unit

The contacts are normally set for "normally open" operation, The switching point is adjustable within the WHITE or
i.e. the contacts are closed when the lubricating oil level is the RED arrow. The direction of the arrow shows that
high enough. the switching unit switches at a lower level. After
For adjustment, the locking screw has to be released and the adjustment the locking screw has to be fastened again.
switching unit has to be moved, so that the RED arrow
(normally open operation) or the WHITE arrow (normally
closed operation) is located at the input of the cross drilling.
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Data Sheet
Flexible hoses
1. 2. 3.
Opening Minimum Sperre part no. Sperre part no.

Sperre w/ one end flange w/ both end flange
A B C D E F of the bending part no.
(inch) (mm) (mm) (mm) (mm) (mm) spanner radius (2) (3)
(mm) (mm) (1)
PN40 PN40
½” 600 500 ø31 ø25 ø22 27 180 4595 4666 (DN15) 7495 (DN15)
¾” 600 470 ø38 ø33 ø29 33 240 4596 4667 (DN20) 7492 (DN20)
1” 800 670 ø43 ø38 ø38 38 300 4597 4668 (DN25) 7493 (DN25)
1 ¼” 800 600 ø57 ø50 ø50 50 420 4598 4669 (DN32) 7494 (DN32)
1 ½” 800 600 ø70 ø57 ø54 60 500 4599 4687 (DN40) 7496 (DN40)
2” 800 580 ø80 ø70 ø66 70 635 4601
Hose construction :
Tube : Oil resistant synthetic rubber
Reinforcement : Two high tensile steel wire braids
Cover : Abrasion and weather resistant synthetic rubber
Temperatur range : - 40°C to + 100°C
Flexible hoses acc. to SAE 100 R2
Sperre Industri AS Sperre Rotterdam BV Sperre Asia PTE LTD Sperre China
Tel +47 70 16 11 00 Tel +31 180 463 299 Tel +65 763 63 00 Tel +86 21 65070436
Fax +47 70 16 11 10 Fax +31 180 463 264 Fax +65 763 18 11 Fax +86 21 65070402
E-mail:industri@sperre.com E-mail:rotterdam@sperre.com E-mail:asia@sperre.com E-mail:china@sperre.com
Sole suppliers of genuine spare parts - www.sperre.com
List of recommended lub. oil
Issue date: 16.11.2007
Replace list of: 23.12.2004
Synthetic oil Mineral oil

ANDEROL 555 BP ENERGOL RC 68
BP ENERSYN RX 100 CASTROL AIRCOL PD 100
CASTROL AIRCOL SN 100 CALTEX RPM COMPR. OIL 68
COSMO RECIPRO SX 100 COSMO RECIPRO 100
DAPHNE MARINE COMPR. 100 ESSO / EXXON EXXCOLUB 77
ESSO / EXXON ZERICE S 100 FAMM COMPRESSOR OIL EP VDL 100
ESSO / EXXON SYNNESTIC 68 GENERAL COMPOL A 100
FAMM CETUS DE 100 MITSUBISHI COMPR. OIL 100
MOBIL RARUS 827 MOBIL RARUS 427
NIPPON OIL CO. FAIRCOL SA 100 PHILLIPS COMPR. OIL 68
STATOIL FRIDGEWAY S 100 SHELL CORENA P 68
SHELL CORENA AP 68 STATOIL COMPWAY 68
TOTAL LUBMARINE BARELF AL 100 TOTAL DACNIS P
STATOIL COMPWAY SX68
Quantities, application points and intervals for lubrication oil and grease.
Air Lub. Oil for Air compressor Grease for El.motor
Compressor Quantity Application Change Quantity Grease Grease
type [Liters] point interval [Grams] Application interval
HLF2/77 1,8
HL2/77 4,0 Bearings lubricated for life time
and then after every 1000 hours of operation
HL2/90 4,0
HL2/105 4,0
After first 200 hours of operation,
HL2/120 10,0 20
HL2/140 10,0 20
HL2/160 10,0 20
HV1/85 1,5 20
Electric motor bearings
Crank case
Once every 12 months
HV1/120 2,0 20
HV1/140 * 4,0 20
HV1/156 * 4,0 20
HV2/200 8,0 30
HV2/210 8,0 30
HV2/219 8,0 30
HV2/220 20,0 30
HV2/240 20,0 30
HV2/270 24,0 30
HV2/285 24,0 30
HV2/300 24,0 30
* Cylinder lubrication from separate oil tank. (HV1/140A and HV1/156A does not have a separate cylinder
lubrication system, and these compressor models should be run on synthetic lub. oil only).
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Sperre Air Compressor

CUSTOMER: CORPORACION ELECTRICA DEL

A STARTING AIR COMPRESSOR 1 x HL2/160

STARTING AIR COMPRESSOR 1 x HL2/160

No. Description Type /Dwg. Part No.

A1 General arrangement G03-0007

Manufacturer & Type Construction

Creator: Torgeir Project: Customer:

I1 (S0 Emcy Stop) S

B017/3 Quit = off 2/B038/Trg

T B039 M3 1/M2 B028 Q4 (Remote Alarm)

Creator: Torgeir Project: Customer:

B002(On-Delay) : Rem = off

B005(On-Delay) : Rem = off

B006(Latching Relay) : Rem = off

B007(Hours Counter) : MI= 500h 0m+

B009(Latching Relay) : Rem = off

B011(On-Delay) : Rem = off

B012(Asynchronous Pulse Generator) : Rem = off

B016(Latching Relay) : Rem = off

B018(Message texts) : Prio = 0

B021(Off-Delay) : Rem = off

B023(Message texts) : Prio = 6

B024(Message texts) : Prio = 5

B025(Latching Relay) : Rem = off

B029(Wiping relay (pulse output)) : Rem = off

Creator: Torgeir Project: Customer:

B031(Message texts) : Prio = 1

B032(Message texts) : Prio = 4

B033(Message texts) : Prio = 2

B034(Asynchronous Pulse Generator) : Rem = off

B035(Message texts) : Prio = 3

B036(Wiping relay (pulse output)) : Rem = off

B037(Wiping relay (pulse output)) : Rem = off

B038(Wiping relay (pulse output)) : Rem = off

Creator: Torgeir Project: Customer:

I7 F13 Oil Level

Creator: Torgeir Project: Customer:

Creator: Torgeir Project: Customer:

Ref Description Partnr

Material specification Electrical data - Coil

350 50,8 3,5

PRS-30 Electrical wiring:

170 24,7 1,7

0 PB- Low setting point Ie : 1,5A

Adjustment: When the top cover is removed, the

Adjustment of the switching unit

Opening Minimum Sperre part no. Sperre part no.

Synthetic oil Mineral oil

Once every 12 months

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