6362

Page

Oil-free air 64

Installation 65

Weights 68

Piston speed 70

Lubricants 72

Useful Formulas & ClassificationRequirements 74

Conversion Factors 76

The Sperre / TMC alliance 78

Contacts 80

Core values 82

ApprovedSperre compressors are approved byall major classification societies.

64

Suction air with impurities

Compressor

Compressedair with impurities

DryerTechnicaloil-freecompressedair

Filters

Recommended installation instrument air compressorsProper filtration is the only way to obtain oil-free air

A compressor installed on-board a shipwill compress the ambient air, which normally contains impurities up to 1 mg/m3 of oil. Due to the large oil contentin suction air, proper filtration should always be installed downstream to ensurethe quality of the air.

An oil-lubricated compressor with properfiltration can easily achieve oil-freeair of the highest purity class underISO 8537.1.

An oil-free compressor without filtrationof the compressed air cannot achievethis.

To determine the total economy of an oil-free compressor versus an oil-lubricatedcompressor, consider the following:

Investment costsConsiderably lower for an oil-lubricatedcompressor.

Overhaul intervalsConsiderably longer for an oil-lubricatedcompressor.

ServiceConsiderably simpler and easier for anoil-lubricated compressor.

ReliabilityThe reliability of oil-lubricated Sperrecompressors is well-established.Reliability is particularly high for thosehigh ambient temperatures in which anoil-free compressor suffers.

65

Every compressor unit is supplied complete with drawings and specifications showingits dimensions and attachment points. The customer also receives installation instruc-tions giving recommendations for the installation of equipment and piping.To ensure trouble-free operation, it is important that the foundation is well stiffenedand free from vibrations from other installed machinery. The compressor unit bedplateshould lie level with its foundation. After the unit is installed, the alignment of com-pressor and motor should be checked.The compressor should be installed in a location where the air is not too hot. Normally,the ambient temperature for electrical equipment should not exceed 45ºC. For air-cooled compressors, a well-dimensioned fresh air duct must be provided to the locationwhere the compressor is to be installed. A water/oil separator should be fitted at somedistance from the compressor, and arranged so that the line slopes downwards fromthe compressor to the separator. This will prevent condensate water from damagingvalves and cylinders. Care should be taken to arrange the piping so that condensatecannot collect in pockets. A non-return valve of strong construction and offering littleair resistance should be installed after the compressor. Other equipment should not be installed around the compressor unit in a way thatmight hamper inspection and maintenance.

INSTRUMENT AIR

AIR DRYER

DRAIN

DRAIN

AIRRECEIVER

INSTRUMENT AIRCOMPRESSOR

PS

NON-RETURNVALVE

OIL / WATERSEPARATOR

CONTROL AIR PIPEFOR COMPR. UNLOADING SYSTEM

66

STARTING AIRRECEIVERNo. 1

NON-RETURNVALVE

STARTING AIRCOMPRESSOR

No. 1

STARTING AIRCOMPRESSOR

No. 2

DRAIN DRAIN

DRAIN

C.W. H.P. DRAIN L.P. DRAIN C.W. C.W. H.P. DRAIN L.P. DRAIN C.W.

STARTING AIR30 Barg

STARTING AIRRECEIVER

No. 2

OIL / WATERSEPARATOR

PS

Pres

sure

sw

itch

com

pres

sor n

o. 1

Pres

sure

sw

itch

com

pres

sor n

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PS

Recommended installation air cooled starting air compressorsRecommended installation water cooled starting air compressors

67

STARTING AIRRECEIVERNo. 1

OIL / WATERSEPARATOR

OIL / WATERSEPARATOR

STARTING AIR

COMPRESSORNo. 1

STARTING AIR

COMPRESSORNo. 2

DRAIN DRAIN

DRAIN DRAIN

STARTING AIR30 Barg

STARTING AIRRECEIVER

No. 2

NON-RETURNVALVE

NON-RETURNVALVE

PS

Pres

sure

sw

itch

com

pres

sor n

o. 1

Pres

sure

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PS

Weights Compressors & AccessoriesCOMPR. BASEPLATE MOTOR NON RETURN SPARE STARTER HOSES AND C.W. OIL/WATER SEAWORTHY TOTAL NET. TOTAL SHIPPING SHIPPING SHIPPING

EL./DIESEL VALVE PARTS PANEL RESILIENT MOUNT. PUMP SEPARATOR PACKING WEIGHT WEIGHT DIMENSIONS VOLUMEKG KG KG KG KG KG KG KG KG KG KG KG (LxWxH) CM M3

HLH/119* 30 45 N/A N/A 0.5 N/A N/A N/A N/A 45 75 120 106x46x91 0.40HLF2/77 73 23 24 2 2.3 14 5 N/A 20 45 160 205 90x65x70 0.41HL2/77 138 58 50 2 2.3 14 12 N/A 20 90 300 390 130x75x85 0.83HL2/90 138 58 59 2 2.3 14 12 N/A 20 90 305 395 130x75x85 0.83HL2/105 138 58 87 2 2.3 14 12 N/A 20 90 335 425 130x75x85 0.83HL2/120 317 126 130 10 4.8 21 16 N/A 20 150 645 795 175x110x125 2.41HL2/140 319 126 145 10 4.1 21 16 N/A 20 150 660 810 175x110x125 2.41HL2/160 319 126 205 10 4.1 21 16 N/A 20 150 720 870 175x110x125 2.41HV1/85 133 68 49 2 0.7 11 22 N/A 20 70 310 380 120x55x105 0.70HV1/120 159 84 79 2 1.0 11 22 N/A 20 80 380 460 135x55x105 0.78HV1/140A 394 135 93 10 4.2 14 32 12.4 37 120 730 850 155x75x140 1.63HV1/156A 386 135 145 10 4.3 21 32 12.4 37 120 780 900 155x75x140 1.63HV2/200 543 150 225 13 5.2 21 32 12.4 37 170 1040 1210 205x75x140 2.77HV2/210 543 150 225 13 5.2 21 32 12.4 37 170 1040 1210 205x75x140 2.77HV2/219 542 150 225 13 5.3 21 32 12.4 37 170 1040 1210 205x75x140 2.77HV2/220 992 280 255 20 7.9 21 64 12.4 37 220 1690 1910 225x110x155 3.84HV2/240 990 280 320 20 8.3 21 64 12.4 37 220 1750 1970 225x110x155 3.84HV2/270A 1353 344 500 20 14.5 21 84 12.4 37 260 2390 2650 240x115x165 4.55HV2/285A 1348 344 500 20 14.6 32 84 12.4 37 260 2395 2655 240x115x165 4.55HV2/300A 1347 344 575 20 14.9 32 84 12.4 37 260 2460 2720 240x115x165 4.55HLF2/77-D** 73 32 81 2 2.3 N/A 13 N/A 20 45 225 270 110x70x80 0.62HL2/77-D** 138 60 185 2 2.3 N/A 14 N/A 20 90 420 510 160x90x110 1.58HL2/90-D** 138 60 185 2 2.3 N/A 14 N/A 20 90 420 510 160x90x110 1.58HL2/105-D** 138 60 185 2 2.3 N/A 14 N/A 20 90 420 510 160x90x110 1.58HL2/120-D** 317 155 277 10 4.8 N/A 16 N/A 20 150 800 950 200x100x190 3.80HL2/140-D** 319 155 277 10 4.1 N/A 16 N/A 20 150 800 950 200x100x190 3.80HL2/160-D** 319 155 322 10 4.1 N/A 16 N/A 20 150 845 995 200x100x190 3.80LL2/77 142 58 50 2 3.6 14 12 N/A 20 90 300 390 130x75x85 0.83LL2/90 142 58 59 2 3.6 14 12 N/A 20 90 310 400 130x75x85 0.83LL2/105 142 58 87 2 3.7 14 12 N/A 20 90 340 430 130x75x85 0.83LL2/120 331 126 145 10 8.1 21 16 N/A 20 150 680 830 175x110x125 2.41LL2/140 335 126 165 10 8.5 21 16 N/A 20 150 700 850 175x110x125 2.41LL2/160 332 126 225 10 8.6 21 16 N/A 20 150 760 910 175x110x125 2.41

68

* Baseplate for HLH/119 is a 30L Air Receiver. ** Diesel engine driven units.

69

Weights Heat ExchangersTYPE NET SEAWORTHY TOTAL SHIPPING VOLUMEDIA/LENGTH WEIGHT PACKING WEIGHT DIMENSIONSMM KG KG KG (LxWxH) CM M3

102/332 13 5 18 50x20x20 0.02102/512 18 7 25 70x20x20 0.03102/700 23 8 31 90x20x20 0.04139/512 30 8 38 80x25x25 0.05139/700 40 10 50 100x25x25 0.07152/700 70 15 85 104x35x40 0.15152/1000 80 20 100 134x35x40 0.19152/1200 85 25 110 154x35x40 0.22152/1500 95 30 125 184x35x40 0.26152/1800 105 35 140 214x35x40 0.30152/2200 115 40 155 254x35x40 0.36152/2500 125 45 170 284x35x40 0.40219/700 145 20 165 105x42x49 0.21219/1000 165 30 195 135x42x49 0.27219/1200 175 35 210 155x42x49 0.31219/1500 195 40 235 185x42x49 0.37219/1800 215 45 260 215x42x49 0.43219/2200 245 50 295 255x42x49 0.51219/2500 265 60 325 285x42x49 0.57219/2800 285 65 350 315x42x49 0.63298/700 245 35 280 113x51x60 0.34298/1000 280 45 325 143x51x60 0.43298/1200 305 50 355 163x51x60 0.49298/1500 345 60 405 193x51x60 0.58298/1800 380 70 450 223x51x60 0.67298/2200 430 85 515 276x51x60 0.83298/2500 465 90 555 293x51x60 0.88298/2800 500 100 600 323x51x60 0.97406/1000 520 75 595 156x62x74 0.72406/1200 550 85 635 176x62x74 0.81406/1500 625 100 725 206x62x74 0.95406/1800 700 115 815 240x62x74 1.10406/2200 775 130 905 276x62x74 1.27406/2500 850 145 995 306x62x74 1.41406/2800 900 160 1060 336x62x74 1.55558/1200 1100 140 1240 192x82x88 1.38558/1500 1250 160 1410 222x82x88 1.60558/1800 1400 180 1580 252x82x88 1.81558/2200 1550 200 1750 292x82x88 2.10558/2500 1700 220 1920 322x82x88 2.32558/2800 1850 240 2090 352x82x88 2.53711/1500 1900 230 2130 230x97x105 2.34711/1800 2100 260 2360 260x97x105 2.65711/2200 2350 290 2640 300x97x105 3.06711/2500 2550 320 2870 330x97x105 3.36711/2800 2750 350 3100 360x97x105 3.66711/3000 2900 370 3270 380x97x105 3.87

70 71

Piston speedFrequency 50 Hz 60 HzNo. of poles 4 6 8 10 12 4 6 8 10 12Synchronous 1500 1000 750 600 500 1800 1200 900 720 600speed [rpm]

Nominal 1450 975 725 580 480 1750 1150 875 700 580Compressor speed [rpm]model Stroke [mm] PISTON SPEED (mean) [m/s] PISTON SPEED (mean) [m/s]HLF2/77 40 1.9 1.3 1.0 0.8 0.6 2.3 1.5 1.2 0.9 0.8HL2/77-90-105 80 3.9 2.6 1.9 1.5 1.3 4.7 3.1 2.3 1.9 1.5HL2/120-140-160 100 4.8 3.3 2.4 1.9 1.6 3.8 2.9 2.3 1.9LL2/77-90-105 80 3.9 2.6 1.9 1.5 1.3 4.7 3.1 2.3 1.9 1.5LL2/120-140-160 100 4.8 3.3 2.4 1.9 1.6 5.8 3.8 2.9 2.3 1.9HV1/85-120 85 2.8 2.1 1.6 1.4 3.3 2.5 2.0 1.6HV1/140A-156A 100 3.3 2.4 1.9 1.6 3.8 2.9 2.3 1.9HV2/200-210-219 110 3.6 2.7 2.1 1.8 4.2 3.2 2.6 2.1HV2/220-240 140 4.6 3.4 2.7 2.2 4.1 3.3 2.7HV2/270A-285A-300A 140 4.6 3.4 2.7 2.2 4.1 3.3 2.7

72

Lubrication Oil ChartMineral oilsBP ENERGOL RC 68CASTROL AIRCOL PD 100CALTEX RPM COMPR. OIL 68FINA EOLAN ACGENERAL COMPOL A 100MITSUBISHI COMPR. OIL 100SHELL CORENA P 68MOBIL RARUS 427NYNÄAS COMPR. OIL 68PHILLIPS COMPR. OIL 68ESSO / EXXON EXXCOLUB 77

Synthetic oilsBP ENERSYN RX 100CASTROL AIRCOL SN 100CHEVRON HD COMPR. OIL 100DAPHNE MARINE COMPR. 100BARELF AL 100ESSO / EXXON ZERICE S 100ESSO / EXXON SYNNESTIC 68MOBIL RARUS 827NIPPON OIL CO. FAIRCOL SA 100STATOIL COMPWAY S 100TEXACO CETUS DE 100SHELL CORENA AP 68

Normal Oil ConsumptionValues stated are average after running-in period(500 hours) and based on lubricating oil type MOBILRarus 427 (mineral oil, 84 cSt/40ºC). The oil con-sumption may vary from one brand to another, and isalso dependent on lubricating oil temperature.

Compressor Capacity Oilmodel F.A.D. consumption

[g/h]HV1/85 22 m3/h @ 1150 rpm 4HV1/120 45 m3/h @ 1150 rpm 5HV1/140A 71 m3/h @ 1150 rpm 17HV1/156A 94 m3/h @ 1150 rpm 17HV2/200 177 m3/h @ 1150 rpm 20HV2/210 195 m3/h @ 1150 rpm 20HV2/219 182 m3/h @ 975 rpm 20HV2/220 234 m3/h @ 975 rpm 17HV2/240 279 m3/h @ 975 rpm 17HV2/270A 358 m3/h @ 975 rpm 20HV2/285A 398 m3/h @ 975 rpm 22HV2/300A 441 m3/h @ 975 rpm 26HLF2/77 13 m3/h @ 1750 rpm 6HL2/77 28 m3/h @ 1750 rpm 7HL2/90 38 m3/h @ 1750 rpm 10HL2/105 47 m3/h @ 1750 rpm 12HL2/120 88 m3/h @ 1750 rpm 14HL2/140 123 m3/h @ 1750 rpm 15HL2/160 160 m3/h @ 1750 rpm 17LL2/77 50 m3/h @ 1750 rpm 8LL2/90 68 m3/h @ 1750 rpm 10LL2/105 94 m3/h @ 1750 rpm 14LL2/120 114 m3/h @ 1150 rpm 17LL2/140 155 m3/h @ 1150 rpm 17LL2/160 203 m3/h @ 1150 rpm 20

73

Tips for safe and reliable operationJust a little attention to maintaining your compressor will keep it runningsmoothly and efficiently. To avoid problems and save money, schedule preventivemaintenance with the right lubrication and cleaning, and replace wear partsat the right time.

Choose the right lube oil The choice of lubrication oil is very important. We have approved all the oilsin our Lubrication Oil Chart after testing them on our compressors. Duringthe warranty period, approved oils must be used. When the warranty periodis over, it is still a good idea to use an oil that Sperre has tested and recommended. In our experience, this improves performance and reducesrunning costs. Some oils are far more suitable for compressors than others.The pictures below illustrate this. The picture on the left shows a compressorvalve after only 300 operating hours with a compressor oil that has not beenapproved by Sperre. The picture on the right shows a similar valve after thesame number of operating hours with an approved compressor oil.

Choose genuine Sperre parts Sometimes non-genuine parts cause no problems. Sometime they just takemore time to fit. But sometimes they start vicious circles of trouble for thecompressor: oil coke deposits, overheating, excessive oil consumption,unnecessary strain on your system, leaks, scuffing and cracks. With essentialequipment like a starting-air compressor on a ship at sea, it is not worthgambling with imitation parts.

Because of the enormous pressure at work in the compressor, safetyand reliable operation must come first.

7574

n · qV=

2 (Pmax – Pmin)

Required volume of starting air receiversAccording to classification society requirements, main engines started bycompressed air must have at least two (2) starting air receivers of about equalcapacity, and which may be used independently. The air receivers must havecapacity for the number of starts specified below without reloading the receivers.Required receiver capacity, V, based on two receivers of equal capacity:

[m3]

where:Pmax = Max. receiver pressure*) [bar]Pmin = Min. required start pressure **) [bar]q = Air consumption per start **) [Nm3]n = Number of starts required as follows:

Duty of engine(s) Number of starts requiredPropulsion engine, reversible 12 startsPropulsion engine, non-reversible 6 startsEngines for driving electric generators 3 starts eachand emergency generators, and engines for other purposes

Notes: *) Normally 30 bar. **) Normally informed by diesel eng. manufact.

Required capacity of starting air compressorsAccording to classification society requirements, two (2) or more compressorsof approximately equal capacity must be installed. At least one of thecompressors must be independently driven (for emergency use).The total capacity of the compressors should be sufficient for charging thestarting air receivers from atmospheric to full pressure in one (1) hour.Required compressor capacity, based on two (2) equal starting air receiversand two (2) equal starting air compressors:

[m3/h]

where: Pmax = Max. receiver pressure (normally 30 bar) [bar]V = Starting air receiver volume [m3]

Charging time of air receiversCapacity for starting air compressors is normally quoted as “Pumping UpCapacity”, i.e. the capacity is measured by filling an air receiver with an exactknown volume. The charging time is normally calculated as follows:

[min.]

V= Receiver volume [m3] P0 = Absolute press. in receiver at start [bar a]Q= Compressor capacity [m3/h] P1 = Absolute press. in receiver at end [bar a]

If the temperature increase in the air receiver during the test should be takeninto account, the capacity has to be calculated by formula as follows (accord-ing to ISO1217, Annex F):

[m3/h]where:Vr = Receiver volume [m3]P1 = Absolute pressure at standard inlet point [bar a] T1 = Absolute temperature at standard inlet point [ºK]P40= Absolute pressure in receiver at beginning of charging period [bar a]T40 = Absolute temperature in receiver at beginning of charging period [ºK]P4Z= Absolute pressure in receiver at end of charging period [bar a]T4Z = Absolute temperature in receiver at end of charging period [ºK]z = Charging time (z) [sec.]

Classification requirements electrical componentsClass. Temp. Oil press. or Separate Remote Main Type HeatingSociety switch air level switch alarms control switch approved element

SP 80°C SP 0.8 bar el. motorLR � � � �GL � � �*) � �BV � � �RINA � �NK � �KR �DNVCCS �CR �**)RMRS � � � �Notes: *) Notation AUT-Z only. **) El.motors 40 kW and up.

Q = V · Pmax

T = 60 · V (P1 – P0)

Q

qZ = Vr · T1 P4Z – P403600

z · P1 ( T4Z T40)

7776

Masskg lb (pound) slug oz (ounce) tons (long) (UK) tons (short)(US)1 2.20462 68.5218x10-3 35.274 0.984207x10-3 1.10231x10-3

0.45359237 1 31.0810x10-3 16 0.446429x10-3 0.5x10-3

14.5939 32.174 1 514.785 14.3634x10-3 16.0869x10-3

28.3495x10-3 62.5x10-3 1.94256x10-3 1 27.9018x10-6 31.25x10-6

1016.05 2240 69.6213 35840 1 1.12907.185 2000 62.1619 32000 0.892857 1

Volumem3 in3 ft3 yd3 gallon (UK) gallon (US)1 61023.7 35.3147 1.30795 219.969 264.17216.3871x10-6 1 0.578704x10-3 21.4335x10-6 3.60465x10-3 4.32900x10-3

23.3168x10-3 1728 1 37.0370x10-3 6.22884 7.480520.764555 46656 27 1 168.178 201.9744.54609x10-3 277.42 0.160544 5.94606x10-3 1 1.200953.78541x10-3 231 0.133681 4.95113x10-3 0.832675 1

Aream2 in2 ft2 yd2 acre square mile1 1550.00 10.7639 1.19599 0.247105x10-3 0.386102x10-6

0.64516x10-3 1 6.94444x10-3 0.771605x10-3 0.159421x10-6 0.249098x10-9

92.9030x10-3 144 1 0.111111 22.9569x10-6 35.8701x10-9

0.836127 1296 9 1 0.206612x10-3 0.322831x10-6

4046.86 6272640 43560 4840 1 1.5625x10-3

2589990 4.01449x109 27878400 3097600 640 1

Lengthm in (inch) ft (feet) yd (yard) mile nautical mile1 39.3701 3.28084 1.09361 0.621371x10-3 0.539957x10-3

25.4x10-3 1 83.3333x10-3 27.7778x10-3 15.7828x10-6 13.7149x10-6

0.3048 12 1 0.333333 0.189394x10-3 0.164579x10-3

0.9144 36 3 1 0.568182x10-3 0.493737x10-3

1609.344 63360 5.28x10-3 1760 1 0.8689761852 72913.4 6076.12 2025.37 1.15078 1

Units in [] deviate from basic units in the system

SI and Technical System of UnitsForce Mass Pressure Energy, Heat Power

SI system N kg [g] N/m2 Pa [bar] J Nm Ws [kWh] W [kW]1 N =1 kg·m/s2 1 kg =1000 g 1 Pa =1 N/m2 1J =1 N/m =1 Ws 1 W =1 N·m/s

=10-5 bar = 2.778·10-7 kWh =1 J/s

Technical kp kp·s2/m kp/m2 [kp/cm2] [at] kp·m [kcal] kp·m/s [hk]system (old) 1 at =1 kp/cm2 1 kp·m 1 hk =75 kp·m/s

= 2.342·10-3 kcal

PowerW kcal/s kcal/h hk (metric hp (UK. US) Btu/hNm/s. J/s horse power) (horse power)1 0.238846x10-3 0.859845 1.35962x10-3 1.34102x10-3 3.412144186.8 1 3600 5.69246 5.61459 14286.01.163 0.277778x10-3 1 1.58124x10-3 1.55961x10-3 3.96832735.499 0.175671 632.415 1 0.98632 2509.63745.7 0.178107 641.186 1.01387 1 2544.430.293071 69.9988x10-6 0.251996 0.398467x10-3 0.393015x10-3 1

Energy / Heat / WorkJ kWh kpm kcal ftxlbf (foot Btu (BritishNm. Ws pound-force) thermal unit)

1 0.277778x10-6 0.101972 0.238846x10-3 0.737562 0.947817x10-3

3600000 1 367098 859.845 2655220 3412.149.80665 2.72407x10-6 1 2.34228x10-3 7.23301 9.29491x10-3

4186.8 1.163x10-3 426.935 1 3088.03 3.968321.35582 0.376616x10-6 0.138255 0.323832x10-3 1 1.28507x10-3

1055.06 0.293071x10-3 107.586 0.251996 778.169 1

Pressure / TensionN/m2 bar kp/cm2 kp/mm2 atm (normal psiPa atmosphere) lbf/in2

1 10x10-6 10.1972x10-6 0.101972x10-6 9.86923x10-6 0.145038x10-3

100000 1 1.01972 10.1972x10-3 0.986923 14.503898066.5 0.980665 1 10x10-3 0.967841 14.22339806650 98.0665 100 1 96.7841 1422.33101325 1.01325 1.03323 10.3323x10-3 1 14.69596894.76 68.9476x10-3 70.3070x10-3 0.703070x10-3 68.0460x10-3 1