SIERRA®
50 – 400 HP (37 – 300kw)
Typical Specification
Sierra Typical Spec
Date: 6 July 2005
Cancels: 12 Jan 2005
Davidson, NC 28036
TYPICAL SPECIFICATIONS SIERRA® 50 - 400 HP (37 - 300 kW)
TYPICAL SPECIFICATIONS
SIERRA® 50 - 400 HP (37 - 300 kW)
AIR-COOLED / WATER-COOLED
COMPRESSOR:
The compressor shall be an air-cooled, positive displacement, two-stage, oil-free rotary screw
type, delivering __________ CFM / m³min. of free air at __________ psig / barg full flow. The
compressor shall be capable of continuous full flow operation 24 hours/day at rated capacities
and pressures. All components are to be mounted on a rigid steel base with forklift access holes
for easy mobility.
AIRENDS:
Both compressor airends shall be designed for peak efficiency range at rated design. Rotors shall
be forged steel/stainless steel and be of asymmetrical profile. The rotors and compression
chamber surfaces are to be micro-coated with a mechanically bonded surface of Ultracoat® to
prevent corrosion this must remain on the coated surfaces for the life of the airend. Rotor to rotor
contact shall be prevented through the use of pinion gears fitted to each rotor.
BEARINGS:
Radial loads are to be carried by high quality vacuum degassed cylindrical roller bearings. Thrust
loads are to be carried by high quality vacuum degassed ball bearings. Thrust balance pistons
shall not be used to offset thrust loads.
SEALS:
Stainless steel air seals shall be used in both the first and second stage airends to minimize air
leakage.
Labyrinth style oil seals shall be used in both airends to prevent oil leakage into compression
chambers. One set of oil seals on each rotor shall be vented to atmosphere to prevent bearing oil
from seeping into the air seal area.
GEARCASE:
The main drive bull gear and speed optimizing gears shall be installed in a rugged cast iron gear
case. All gears shall be rated to general classes of DIN 17200, 17210. A leak-free lip seal shall be
used to prevent oil leakage along the bull gear input shaft. A labyrinth style seal shall not be used.
The gear case shall have an integral oil sump with oil level sight glass provided in the gear case
housing.
COMPRESSOR COOLING SYSTEM:
The compressor shall be cooled with a three (3) part heat exchanger integral to the compressor
package.
The heat exchangers shall include the intercooler, after-cooler and oil cooler. The air-cooled
coolers shall be constructed of aluminum. The heat exchanger shall be capable of cooling the
compressor under continuous full load conditions 24 hours/day at a maximum ambient
temperature of 115°F (46°C). The after-cooler CTD shall not exceed 18-25°F (8.3 – 14°C) at
rated capacities and pressures.
SIERRA®
50 – 400 HP (37 – 300kw)
Typical Specification
Sierra Typical Spec
Date: 6 July 2005
Cancels: 12 Jan 2005
Davidson, NC 28036
TYPICAL SPECIFICATIONS SIERRA® 50 - 400 HP (37 - 300 kW)
Cooling air for the compressor package shall be provided by a rugged, adjustable pitch fan and
driven by a TEFC motor. Full flow louvers are to be provided on the compressor package to allow
for adequate cooling airflow to the compressor drive motor, fan motor, airend and three part
cooler.
A dedicated inlet air plenum, integral to the compressor package, shall be provided to supply
clean, cool air to the compressor inlet filter. A separate plenum shall be provided at the top of the
compressor package to prevent the package cooling air from circulating back to the package inlet
air louvers.
WATERCOOLED:
The coolers designed for the SIERRA® allow it to be operated continuously and efficiently in ambient air temperatures as high as 115°F (46°C) with water temperatures as high as 115°F (46°C)
and still provide a desirable <15°F (8°.3C) after-cooler CTD.
The heat exchangers are shell and tube design. To protect the intercooler and after-cooler from
damage due to air pulsations, the air is channeled through the cooler tubes while the water is
directed into the shell. The oil cooler utilizes and opposite configuration as it has water in the tube
side and oil in the shell side. All standard coolers utilize copper tubes (oil cooler has admiralty
brass tubes). Tube sheets are nickel-plated carbon steel and baffles are constructed of brass.
To protect the cooler end bonnets, the “hot side”, cast iron bonnet should be protected by a
corrosion resistant coating and the “cold side”, cast aluminum bonnet should be anodized.
Package cooling has been optimized to allow high ambient cooling (115°F/46°C). Free flowing
inlet air louvers are provided to permit cooling air to reach all critical areas, (such as main drive
motor, airends and the standard enclosure fan motor). A dedicated inlet air plenum to the intake
filter is provided to insure that only clean, cool air enters the first stage airend. A separate cooling
air outlet plenum is built into the package. This prevents return circulation of hot air into the
package and eliminates possibilities of gear case oil vapor from being introduced into the
compression area.
THE BEST COOLING SYSTEM FOR EVERY CUSTOMER
The combination of the air-cooled and water-cooled SIERRA® allows Ingersoll-Rand the unique
ability to provide the optimum cooling system for an application based on system requirements.
MOTOR:
The motor is to be specifically designed for the torque, speed, and horsepower characteristics of
the compressor. The motor is to be operated by a __________ volt, three phase, ______ Hz
power source.
The motor shall be applied such that full load brake horsepower requirements will permit operation in the motor's peak efficiency range.
For SIERRA® 50-200HP (37-150kW), the motor shall have a service factor of 1.25; however, the
applied load point shall be limited to a service factor of 1.15 or less. For SIERRA 250-400HP
(200-300kW), the motor is to have a service factor of 1.15, with maximum load point of 1.05 or
less.
SIERRA®
50 – 400 HP (37 – 300kw)
Typical Specification
Sierra Typical Spec
Date: 6 July 2005
Cancels: 12 Jan 2005
Davidson, NC 28036
TYPICAL SPECIFICATIONS SIERRA® 50 - 400 HP (37 - 300 kW)
Models designated as 60Hz, “SUPER DUTY” shall have TEFC as standard. TEFC (IP55) motors
are standard on 37-150kW / 50Hz, European models and optional on 200-300kW
The motor bearings should be type M vacuum degassed for uniform hardness of bearing surfaces. Single row ball bearings shall carry radial and thrust loads and should be designed with a
B10 bearing life, at least double those required by National Electric Manufacturers Association.
Insulation for the motor shall be Class F; Class B is not acceptable. The motor shall be applied
such that the motor windings will not experience a temperature rise greater than 95°C, above
ambient at full load BHP/kW. The construction of the motor frame and bracket should be such
that the material provides for maximum strength and rigidity for bearing support.
Motor leads are to be protected by high temperature glass braided insulation, and are to be
extended out of the motor to the starter connection terminals, without the use of an intermediate
terminal box. Motors are to be flange faced to accommodate alignment with the compressor and
motor coupling.
STARTER:
The compressor package shall include an integrally mounted, Star-Delta, main motor starter.
This starter should be contained in separate enclosure and include the fan motor starter and all
necessary components for safely operating the compressor. The starter shall be mounted, wired
and tested as part of the complete compressor package prior to shipment.
Models designated as 60Hz, “SUPER DUTY” shall have NEMA 4 electrical protection as
standard.
European 50Hz models should have IP56 electrical protection as standard.
CONTROLS:
The compressor shall include a microprocessor-based control system to provide starting logic,
capacity control, operating control, and safety control of the compressor.
The compressor shall use an inlet control valve in coordination with a blow-off valve to regulate
the loading and unloading of the unit. The inlet valve and blow-off valve are to be mechanically
interlocked and will be actuated by a heavy-duty hydraulic cylinder which is energized by the
compressor’s lubrication pump (integral) and related solenoid valves.
A flexible-style unloading diaphragm shall not be used to control compressor unloading or blowoff.
Automatic starting and stopping of compressor, based on system needs, shall be provided.
All control functions shall be managed and displayed from a central control panel. This
microprocessor panel should be capable of providing information and adjustments to an operator
or technician so that they may safely and intelligently initialize, adjust, and review the operating
parameters of the compressor.
SIERRA®
50 – 400 HP (37 – 300kw)
Typical Specification
Sierra Typical Spec
Date: 6 July 2005
Cancels: 12 Jan 2005
Davidson, NC 28036
TYPICAL SPECIFICATIONS SIERRA® 50 - 400 HP (37 - 300 kW)
50-100HP (37-75kW) INTELLISYS SE Controller: includes eight Standard Display
Readouts, twelve Adjustable Operating Parameters (including two-unit lead/lag setting), and eight
Warnings and Shutdowns
125-400HP (90-150kW) INTELLISYS SG Controller: includes sixteen Standard Display
Readouts, fifteen Adjustable Operating Parameters (including multiple unit sequencing), and
eighteen Warnings and Shutdowns.
250-400HP (200-300kW) CMC Controller: includes twenty-four Information and System
Displays, eleven Operator Set Points (with an additional nine option settings), and twenty-seven
Alarms and Trips.
ENCLOSURE:
The compressor shall have a complete sheet metal enclosure with latched panels that can be
easily removed for servicing the compressor. The enclosure shall have a dedicated inlet air
plenum for the compressor intake filter and a dedicated exhaust air plenum to prevent the return
of heated, exhaust air to the intake of the compressor. The sound level will be 79 dBA (or less,
depending on the model) per CAGI/PNEUROP S5.1.
INTAKE FILTER:
The airend (first stage) intake filter shall be a replaceable element type that is 99.99% efficient at
3 microns or larger.
Models designated as “SUPER DUTY” shall have a premium, High Dust Filter as standard.
LUBRICATION SYSTEM:
Lubrication throughout the compressor shall be maintained by a positive displacement lubricant
pump and should be directly driven off the main bull gear shaft. An electric motor driven lubricant
pump is not acceptable.
The lubrication system shall include strainers, filters, relief valves, and other safety components
as necessary to ensure trouble free operation.
The entire cooling system shall be filtered by a 4 micron, full flow oil filter. A
thermal control valve is required to maintain the proper operating temperature of
the oil.
PIPING:
The compressor shall utilize steel piping, flexible connectors and nylon tubing as necessary to
minimize package vibration. Fittings on all connections larger than 0.25" (6.35mm) diameter shall
be SAE “O”- ring type. Pipes and fittings are anodized and plated for corrosion free operation.
TESTING:
SIERRA®
50 – 400 HP (37 – 300kw)
Typical Specification
Sierra Typical Spec
Date: 6 July 2005
Cancels: 12 Jan 2005
Davidson, NC 28036
TYPICAL SPECIFICATIONS SIERRA® 50 - 400 HP (37 - 300 kW)
The complete compressor package must be fully tested following assembly. Testing shall include
a mechanical run and performance test with compressor capacity and power consumption
verified against unit standards. This performance testing shall be certifiable as required.