Seleccion de Soplantes

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo
History:
1864
1868
1909
1930
1943
1967
1968
1971
Foundation
Manufacture of the first european positive displacement
blower
more than 130 years of experience!!!
The Aerzen workshops supply blower no. 10.000
Production start for rotary piston gas meters
Production start for screw compressors
Development and supply of special screw compressors
for air compression
Serial production of oil injected screw compressors
for refrigeration industry
Development and supply of oil injected screw
compressors for compressed air industry
Aerzener Maschinenfabrik GmbH
Bombas Bornemann S.R.L.
1978
The worlds largest positive displacement blower

(conveying volume 84.000 m/h) built for steel
production
1984
The worlds largest screw compressors (conveying

volume 65.000 m/h) built for and supplied to
chemical industry
1987
Aerzen develops positive displacement blowers

with internal pulsation dampening
1989
Blower no. 250.000 ready for delivery

Aerzen Positive Displacement Blowers
Aerzen Positive Displacement Blowers of standard design

GM 3S bis GM 1080L, DN 50 up to DN 800
22 sizes, intake volume flows from approx. 30 to 65.000 m/h
p = max. 1000 mbar
Aerzen DELTA BLOWER (blower units of standard design)

3-lobe type blowers, GM 3S bis GM 240S, DN 50 up to DN 400
max. p = 1000 mbar pressure service, max. - 500 mbar vacuum
Aerzen bulk vehicle blowers

p = 1000 mbar, 1200 mbar max. dsign, up to max. - 500 mbar vacuum

Operating range of Aerzen blowers and screw compressors
DELTA SCREW series

DELTA BLOWER series

Rangeof
ofapplication
applicationof
ofAerzener
AerzenerPositive
PositiveDisplacement
DisplacementBlowers
Blowers
Range
Sewage water
technique
Aeration
basin
Water
treatment
Pneumat.
transport
Ventilat.
Rivers/
Lakes
Vacuum
operation
Chem./ foodstuff indus
Gas
supply
Chem./process
gas industry
Vacuum
technique
Sewage
gas
Oxidation
air
Grit
chamber
Filter
flushing
Flue gas
desulfurization
Increase
of gas
pressure
Bulk
goods
Techn.
gas
Mixed gases
Pump stands
Pressure
operation

Mech. - biological sewage treatment
Mechanical stage
Grit chamber
Oil and grease trap
Primary settlement tank
Waste water
Screen
Sludge
Biogas
Aeration by
Aerzen PD
blowers
Aeration basin
Fowling tower
Secondary settlement tank
Gas reservoir
Treated water
Aerzen PD blowers
(biogas arrangement)
for the gas supply to
the gas motor or
burner
Sludge
Biological stage
Oxidation air (O2) by Aerzen PD
blowers or screw compressors

Waste water treatment application
Screen
waste water
Aeration
basin
Grit chamber
Clarification
treated water
air
air (O2)
Plant`s structure of costs

1.) Costs of investment
2.) Power consumption
Appr. 60% of the energy
Consumption of the aeration
system
3.) Costs for maintenance / repairs

Aerzen Blowers for the aeration of the biological part and the grit chamber

Distribution of air in the aeration basin


Usual blow in depths:

municipal plants 4...8 mWS
industrial plants 10...20 mWS
Blow in depth
basin
10

pressure
increase
dirty
diffusor
clean
pressure loss piping
blow in depth
Demand on pressurized
air:
air flow
By pollution of the diffusor system the

pressure can increase by 20% !
11
oil free
stable performance curve
ability of flow control

Waste water treatment
application
Why is the air flow to be

controlled ?
O2 content in the aeration basin

4
3,5
3
mg O2/l
2,5
Reihe1
2
1,5
1
0,5
00
:0
0
22
:0
0
20
:0
0
18
:0
0
16
:0
0
14
:0
0
12
:0
0
10
:0
0
08
:0
0
06
:0
0
04
:0
0
02
:0
0
daytime
12

Delta Blower GM 3S for the aeration of the grit chamber

13

Delta Blower Gen. 5, GM 60S in STP Sports City Dubai, UAE

14
Subjects
1. Blower and DELTA BLOWER
- Operating ranges of Positive Displacement Blowers and Srew Compressors
- Range of application of Aerzen Positive Displacement Blowers
- 3-lobe blowers with pre-inlet channel, working principle
- History of Aerzen blower units
- Package Delta Blower: advantages, scope of supply, modifications
2. Delta Blower Generation 5
- Noise study
- Construction of units, constructive modifications
- Advantages and customer benefit
- Possibilities to deliver
- Possible modifications
3. ATEX-solutions from Aerzen
15
The third dimension of

air conveyance
16
Conveying cycle of a two-lobe blower
17
Conveying cycle of a two-lobe blower

4 partial conveying gas
volumes per revolution of
the drive shaft
The PD blower operates acc. to the displacement principle without internal

compression (only isochore ), therefore the counter system pressure only
determines the amount of compression and consequently the power consumption.
Alteration of volume flow can only be achieved by speed control.
Vibrations and pulsations !

18
blower
units
Seminario sobre Seleccin deAerzen
Equipos
y Mantenimiento
Preventivo
Lp12 = Lp1 + Lp2 (2-lobe)
Lp1: Sqeeze-impuls
Lp2: Pressure-impuls 2-lobe
19
Aerzens Patent
The application of the Interference process to

the construction of rotary lobe blowers has
been patented by the Aerzener
Maschinenfabrik under the registration
number DE 3527292 C2
20

Conveying cycle of a three-lobe blower
6 partial conveying gas

volumes per revolution of
the drive shaft
Intake
Gas enters the open
conveying chamber of
the blower via the
intake opening
Conveying cycle
By rotors`rotation closing of the
intake opening and displacement of
the conveying gas volume to
discharge side is proceeded.
21
Outpouring
The rotor opens the discharge
socket, the conveying gas
volume is pushed into the
system.
blower
units
Seminario sobre Seleccin deAerzen
Equipos
y Mantenimiento
Preventivo
Lp12 = Lp1 + Lp2 (2-lobe)

Lp13 = Lp1 + Lp3 = 0 (3-lobe)
Lp1: Sqeeze-impuls
22

Advantages of the 3-lobe-blower
with pre-inlet channels
Pulsations are cancelled directly in the blower stage

The vibration loading of the bearings, timing gears and casing is
much more lower than regarding a two-lobe-blower
The noise energy in the discharge piping is about 25 dB lower
Lower investment outlays for buildings and system components
23

Cross sectional drawing of a 3lobe blower GM 35S
24

An Aerzen three-lobe blower.....
Ring retainers....
Sealed by O-rings against shafts
Large neutral chambers to avoid
oil mist leakage into conveying
chamber
Timing gears....
Helical, hardened and ground
Fixed on shaft ends by conicalpress-on taper
Removable by oil pressure
Housing consists of...

Cylinder
Side plates
Gear- and housing cover
Adjusted by conical pins and boltet !
25

Inlet and outlet conditions, blower sizing
Intake conditions:
t1 = 40 C
P1 = 1,0 bar abs.
m = 1000 kg/h
Q1 = 900 m/h
p1 * Q1
T1
Outlet conditions:
t2 = 104 C
P2 = 1,6 bar abs.
m = 1000 kg/h
Q2 = 676 m/h
p2 * Q2
T2
26

Performance curve of blower GM 35S, pressure service
Q1
Pressure service
intake volume flow at

intake pressure
p1 = 1,0 bar abs.
intake temperature t1 = 20 C
p
t
n
P
pressure difference
temperature difference
blower speed
power consumption
Mechanical limits
max. speed
min. speed
max. pressure
max. outlet temperature
max. temperature difference
27

Blower sizing
Pth = (nG * q0 * dp) / 600.000
Losses included in PK :
Pressure loss filter silencer
Power loss of bare shaft blower
Pressure loss of base frame
Pressure loss of non return flap
PK = Pth + PV bare shaft + PV access
28

Blower sizing
Pth = (nG * q0 * dp) / 600.000
Losses not included in Pk:

Belt drive
Ventilation fan
PK = Pth + PV bare shaft + PV access
29

Compressed-air production with positive displacement blowers
Machine selection and design: Evaluation of operating data
Stipulations: QN = 1936 Nm/h

(based on: 1,013 bar abs. + 0 C)
m = 2503 kg/h
Winter operation
Sommer operation
Intake temperature
t1 = 35 C
Intake temperature
t1 = -15 C
Intake pressure
p1 = 1,0 bar abs.
Intake pressure
p1 = 1,0 bar abs.
Relative humidity
RF = 70%
Relative humidity
RF = 70%
Intake volume flow
Q1 = 35,70 m/min
Intake volume flow
Q1 = 30,93 m/min
30

Single Circuit control: Continous control of volume flow
with one blower unit
transmitter
power consumtion
controller with
setpoint
aeration basin
frequency
converter
intake volume
Positive displacement blower GM 35S

drive motor with frequency converter
intake volume flow Q1 = 9,1...35,7 m/min
absorbed power at coupling PK = 14...47 kW
31

Blower package: demands on the unit
Necessary scope of supply:
32
Positive displacement blower
Filter silencer
Discharge silencer
Non-return flap
Belt drive
Pressure valve
Flexible machinery mountings
Flexible piping connection
Start-up unloading device
Drive motor
Acoustic hood

DELTA BLOWER
Intake filter silencer:

Silencing
2.
Filtering
To avoid pollution of the system
by absorption material
1.
33

DELTA BLOWER
Intake filter silencer:

Silencing
2.
Filtering
To avoid pollution of the system
by absorption material
1.
Filter class G4 (EU 4) acc. EN779

Average Filtration efficiency: 92 %
Synthetic material: polyester microfibres
Food-genuinly and regenerable
34

DELTA BLOWER
Base frame with integrated

discharge silencer
Reactive type without any absorption
material
To avoid pollution of the system by
absorbtion material
Discharge silencer acc. to pressure
vessel equipment directive 97/23/EG
35

DELTA BLOWER
Base frame with integrated

discharge silencer
36

DELTA BLOWER
Belt tensioning
Hinged motor support

37

DELTA BLOWER
Belt tensioning
Example: Blower GM 150S
Nominal bore DN 300
Motor 200 kW
Totally closed belt guard
38

DELTA BLOWER
Start-up unloading valve
....only neccessary, if the motor must be started in Star-Delta

and the blower starts against full back pressure (aeration basin)
39

DELTA BLOWER
Compact IV design !
Acoustic hood:
Indoor execution or
Outdoor execution or
Execution for higher noise dampening:
25 dB(A).
Oil level check can be done without

opening of the acoustic hood
40

Driving motor
Aerzen motors
Motors acc. to IEC - STD.
Driving motors acc. to IEC and works STD TNO 1159

Name plate:
Aerzener Maschinenfabrik
Operating manual:
4PG-702-D-XU
make: WEG
2 - pole:
1,5....37 kW
make: WEG
45....160 kW
make: WEG
4 - pole:
75....160 kW
Motors should fulfill the stipulations of works STD.
TNO 1159
Extracts from works standard TN0 1159:

Insulation class F
Type of protection IP 55
Junction box on top, cable entry from fan side
Motors must be suitable for frequency converter operation, speed range 1 :3
Admissible radial vibration velocity of rotor: 11 mm/sec
Bearing of the rotors in single row ball bearings
Admissible lateral load: 1,1 x motor weight
Defined regreasing intervals (2000h for 2-pole, 4000 h for 4-pole motors
Nominal bearing lifetime: 25000 h
41
2006: The new ones there...

42

Sound level
Stipulated sound pressure levels: dp = 700 mbar
DN 50
< 65 dB(A)
DN 80
65.70 dB(A)
DN 100
70.73 dB(A)
DN 125
70.73 dB(A)
DN 150
max. 75 dB(A)
DN 200
max. 78 dB(A)
43

Noise Study DELTA Blower Generation 5,
GM 7L / 700 mbar
79
78
77
Machine noise Lp(A) [dB(A)]
76
75
74
73
72
71
70
69
68
67
66
65
2
Intake volum e flow Q1[m /m in]

GM 7L/DN 80 brochure
44
GM 7L-G5/DN 80 measured

Noise study DELTA Blower Generation 5,
GM 25S / 1000 mbar
86
Machine noise Lp(A) [dB(A)]
84
82
80
78
76
74
72
70
68
66
5
10
15
20
25
Intake volum e flow Q1[m /m in]
GM 25S/DN 125 Prospekt
GM 25S-G5/DN 125 gemessen
45

Advantages
Sound pressure level of the machine noise by 6...9 dB(A) lower than the previously
documented level
Schallstudie DELTA Blow er Generation 5,
GM 50L / 700 m bar
Maschinengerusch Lp(A) [dB(A)]
84
Customer benefit:
82
80
78
76
74
72
70
68
15
20
25
30
35
40
Ansaugvolum enstrom Q1[m /m in]

GM 50L/DN 150 Prospekt
GM 50L-G5/DN 150 Messw erte
46
Reduced sound emission

and -damage to the
environment.
Special acoustic hoods are
not necessary, the
investment charges are
considerably reduced!

Advantages
Simple operation and maintenance: Transport with fork lift truck/stacker lift truck,
the maintenance work oil and filter are effected from the front. The oil level
check can be carried out with running blower.
Main-operation side
47

Advantages
Simple operation and maintenance: Transport with fork lift truck/stacker lift truck,
Main-operation side
48

Advantages
Simple operation and maintenance: Transport mit fork lift truck/stacker lift truck,
the maintenance work oil und filter are effected from the front. The oil level
Main-operation side
49

Advantages
Simple operation and maintenance: Transport mit fork lift truck/stacker lift truck,
check can be carried out from the outside with running (DN 80....DN 200)
Customer benefit:
Easy handling of
assembly/commissioning.
The time- and expenditure
for operation and
maintenance work is
considerably minimized.
50

DN 50 unit: constructive design
Accessibility
51

Advantages
Hood ventilation by mechanical fan
Customer benefit:
Considerable reduction of the

investment charges as an
auxiliary drive has not to be
installed electrically.
In case of ATEX-applications
the Aerzener solution is costneutral as an ex-proof motor
has not to be used.
52

Advantages
Acoustic hoods / Units: Special space-saving design
Customer benefit:
Smallest possible bases

reduce the space requirement
and consequently the machine
room size. The variant Side
by Side is designed for
special tricky space
proportions.
53

Acoustic hoods / Units: Special space-saving design
800
800
800
800
GM 10S / DN 100
Delta Blower
GM 10S / DN 100
Delta Blower
GM 10S / DN 100
Delta Blower
1296
1296
1296
required width: 7088 mm
800
GM 10S / DN 100
Delta Blower Gen. 5
GM 10S / DN 100
Delta Blower Gen. 5
GM 10S / DN 100
Delta Blower Gen. 5
1250
1250
1250
Dimensions
shall be as
small as
possible
required width: 4550 mm

54

Advantages
Acoustic hood inlet air (Process and ventilation): at the cold side of the unit,
exhaust air of the hood at the warm side.
Customer benefit:
Operational reliability !
Optimal ventilation of the unit
also with critical
environmental conditions.
55

Advantages
Acoustic hood inlet air (process and ventilation): at the cold side of the unit,
exhaust air of the hood at the warm side.
Customer benefit:
Operational reliability !
Optimal ventilation of the unit
also with critical
environmental conditions.
56

Advantages
The belt re-tensioning is effected really automatically, i.e. without spring construction
Customer benefit:
After initial installation the

belt tensioning has not to be
controlled any longer.
Saving with installation- and
maintenance costs.
57

Advantages
Driving motor in efficiency class EFF 1, with re-lubricating nipples
Customer benefit:
Motors with the highest

possible efficiency reduce the
energy costs considerably.
Re-lubricating devices
increase the lifetime of the
motor bearing.
58

Advantages
Discharge silencer and pressure valve correspond to the pressure device guideline
PED
Customer benefit:
No uncertainties during unit

planning and realization.
Aerzener units fulfill the
stipulated regulation.
59

Advantages
Discharge silencers certified as spark trap: ATEX-applications
Customer benefit:
Positive displacement blowers

show as potential ignition
spark producer a risk area in
many cases of application. At
site, costly spark traps are not
necessary any longer.
60

Advantages
Acoustic hood applicable for indoor- and outdoor installation (modified)
Customer benefit:
Outdoor installation is
possible on a favourable line
on costs. Reduction of the
investment charges.
61

Value analysis
New: different fasteners
Measures.....
New: Front panels reach

ground floor
62

Value analysis
New base frame and
connecting housing,
pressure service DN 100
63

DELTA BLOWER : biogas / landfill gas, pressure service
Only available as compact IV, not Generation 5
Options blower:
Options accessories:
Combined rotor chamber sealing
Intake silencer, base frame and pipings made from
Internal parts protected with ChemCoat-Coating
Stainless steel
64

DELTA BLOWER
biogas / landfill gas, pressure service
DELTA BLOWER Package
consisting of:
blower GM 3S.....GM 240S,modified and w. options
intake silencer
base frame with integrated discharge silencer
hinged motor support
elast. Machinery mountings
connecting housing
non-return flap
saety valve or bypass controller incl. Bypass
flange compensator for intake / discharge side
flange compensator for bypass pipe
V-belt drive
belt guard if blower is equipped w/o acoustic hood
Accessories (Options)
Acoustic hood, incl. ventilation fan

indoor execution
or outdoor execution
or for higher noise dampening
special execution
Driving motor
Motors acc. to IEC - std.
explosion proof
65
Instrumentation: (Ex i or ex-proof)

pressure gauge intake / discharge
pressure switch intake / discharge
temperature switch
Subjects
1. DELTA BLOWER
- Operating ranges of Positive Displacement Blowers and Srew Compressors
- Range of application of Aerzen Positive Displacement Blowers
- 3-lobe blowers with pre-inlet channel, working principle
- History of Aerzen blower units
- Package Delta Blower: advantages, scope of supply, modifications
2. Delta Blower Generation 5
- Noise study
- Construction of units, constructive modifications
- Advantages and customer benefit
- Possibilities to deliver
- Possible modifications
3. ATEX-solutions
66
Fb 617-0/4-08/02
Seminario sobre Seleccin de Equipos y Mantenimiento

Preventivo
Geblse Verdichter Gaszhler
Machine groups, categories and zones acc. to 94/9/EG
Procedures with conformity evaluation for non-electrical machines
Group I
Group II
mining below ground,
risks caused by explosive atmosphere from gas/air- or dust/air mixtures, dust or steams
risks caused by mine gas and dust
Category M
Category 1
G
(gas)
(zone 0)
For machines applied in

underground mines as
well as in plants above
ground offering a high
degree of safety. The
operation must also be
ensured in case of rare
failures.
For machines in
underground mines as
well as in plants above
ground offering a high
degree of safety. In case
of explosive atmosphere
a shutdown is possible.
Category 2
D
(dust)
(zone 20)
G
(gas)
(zone 1)
For machines ensuring safety to a high

degree. Applied for the constant, longterm or frequent operation in hazardous
areas
(more than 1000 h/year, frequently).

Also in case of rare failures the
machines do not show any effective
source of ignition.
Annex II / Nr.: 2.0.1 resp. 2.0.2
Annex II / no.: 2.1
EU-type inspection
by indicated position acc. to annex III
EU-type inspection
by indicated position acc. to annex III
For the certification of these orders an

external position is necessary. For costs
and delivery time please contact our
technical department.
Category 3
D
(dust)
(zone 21)
G
(gas)
(zone 2)
D
(dust)
(zone 22)
For machines ensuring safety to a high

degree. Destined for cases where it has to
be reckoned with an explosive
atmosphere (10-1000 h/year rarely). Also
in case of rare failures the machines do not
show any effective source of ignition.
For machines ensuring a normal degree of

safety. Destined in case it has to be
reckoned - only rarely and if only for a
short time - with an explosive
atmosphere (0-10 h/year, very rarely).
Machines does not show any effective
ignition source at normal operation.
Annex II / no.: 2.2

Internal production control acc. to annex
VIII + storage of technical documents at
the manufacturer and deposit at an
indicated position for 10 years (min.) after
manufacturing of the last product or
individual inspection acc. to annex IX
Annex II / no.: 2.3
Internal production control acc. to annex

VIII
Certification can be carried out by AM.

For standard machines construction kits are available.
Special machines are certified separately via an individual analysis.
Necessary scope of documentation for non-electrical and electrical machines and operation means depending on zone and category
Machine group II
Category
Zone
1
2
3
0
1
2
EU-type inspection
electrical
non-electrical
x
x
Internal production control

electrical
non-electrical
x
x
x
x
*)
x
x
x
Conformity certification
electrical
non-electrical
x
x
x
*) complete documentation, incl. risk analysis are to be stored at an indicated position.
67

New ATEX-solutions from Aerzen
Certified base support:
Air inlet
Air deflection
Air outlet
The Aerzener base support - also discharge silencer - exclusively

functions by means of deflections! Absorption material will not
be used (combustible and not suitable for the food industry)!
68
Aerzen one step ahead!

69

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Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Aerzener Maschinenfabrik GmbH

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

The worlds largest positive displacement blower

The worlds largest screw compressors (conveying

Aerzen develops positive displacement blowers

Blower no. 250.000 ready for delivery

Aerzener Maschinenfabrik GmbH

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Aerzen Positive Displacement Blowers of standard design

Aerzen DELTA BLOWER (blower units of standard design)

Aerzen bulk vehicle blowers

Aerzener Maschinenfabrik GmbH

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

DELTA SCREW series

Aerzener Maschinenfabrik GmbH

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Aerzener Maschinenfabrik GmbH

Chem./ foodstuff indus

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Oil and grease trap

Primary settlement tank

Secondary settlement tank

Aerzener Maschinenfabrik GmbH

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Plant`s structure of costs

Aerzener Maschinenfabrik GmbH

3.) Costs for maintenance / repairs

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Distribution of air in the aeration basin

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Usual blow in depths:

Aerzener Maschinenfabrik GmbH

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

By pollution of the diffusor system the

Aerzener Maschinenfabrik GmbH

stable performance curve

ability of flow control

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Why is the air flow to be

O2 content in the aeration basin

Aerzener Maschinenfabrik GmbH

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo

Delta Blower GM 3S for the aeration of the grit chamber

Bombas Bornemann S.R.L.

Seminario sobre Seleccin de Equipos y Mantenimiento Preventivo