Seleccion y Mantenimiento Preventivo Soplantes

• Seminario sobre Selección de Equipos y Mantenimiento Preventivo
History:
• 1864 Foundation
• 1868 Manufacture of the first european positive displacement
blower more than 130 years of experience!!!
• 1909 The Aerzen workshops supply blower no. 10.000
• 1930 Production start for rotary piston gas meters
• 1943 Production start for screw compressors
• 1967 Development and supply of special screw compressors
for air compression
• 1968 Serial production of oil injected screw compressors
for refrigeration industry
• 1971 Development and supply of oil injected screw
compressors for compressed air industry
Aerzener Maschinenfabrik GmbH 1 Bombas Bornemann S.R.L.

• 1978 The world‘s largest positive displacement blower

(conveying volume 84.000 m³/h) built for steel
production
• 1984 The world‘s largest screw compressors (conveying

volume 65.000 m³/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 m³/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
Range ofapplication
applicationof
ofAerzener
AerzenerPositive
PositiveDisplacement
DisplacementBlowers
Blowers
Sewage water Water Pneumat. Flue gas Chem./ food- Gas Chem./process Vacuum
technique treatment transport desulfurization stuff indus supply gas industry technique
Sewage
Aeration Grit Oxidation gas
basin chamber air
Increase
Mixed gases
Ventilat. of gas
Filter Rivers/ pressure
flushing Lakes Bulk
goods Techn. Pump stands
gas
Vacuum Pressure
operation operation

Mech. - biological sewage treatment
Mechanical stage
Grit chamber Oil and grease trap Primary settlement tank
Waste water
Screen
Sludge
Aeration by Biogas Aeration basin

Aerzen PD
blowers
Fowling tower Secondary settlement tank

Gas reservoir
Treated water
Sludge
Aerzen PD blowers Biological stage
(biogas arrangement)
for the gas supply to Oxidation air (O2) by Aerzen PD
the gas motor or blowers or screw compressors
burner

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

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

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

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

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

Waste water treatment Why is the air flow to be
application controlled ?
O2 content in the aeration basin
3,5
2,5
mg O2/l
2 Reihe1
1,5
0,5
0
0
0
:0
:0
:0
:0
:0
:0
:0
:0
:0
:0
:0
:0
02
04
06
08
10
12
14
16
18
20
22
00
daytime

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

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

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

The third dimension of
air conveyance

Conveying cycle of a two-lobe blower

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 !

• Seminario sobre Selección deAerzen blower
Equipos units
y Mantenimiento Preventivo
Lp12 = Lp1 + Lp2 (2-lobe)
Lp1: Sqeeze-impuls
Lp2: Pressure-impuls 2-lobe

Aerzen‘s 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

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

volumes per revolution of
the drive shaft
Intake Conveying cycle Outpouring

Gas enters the open By rotors`rotation closing of the The rotor opens the discharge
conveying chamber of intake opening and displacement of socket, the conveying gas
the blower via the the conveying gas volume to volume is pushed into the
intake opening discharge side is proceeded. system.

• Seminario sobre Selección deAerzen blower
Equipos units
y Mantenimiento Preventivo
Lp12 = Lp1 + Lp2 (2-lobe)
Lp13 = Lp1 + Lp3 = 0 (3-lobe)
Lp1: Sqeeze-impuls

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

Cross sectional drawing of a 3lobe blower GM 35S

An Aerzen three-lobe blower.....
Ring retainers....
• Sealed by O-rings against shafts
• Large neutral chambers to avoid
oil mist leakage into conveying
chamber
Housing consists of... Timing gears....

• Cylinder • Helical, hardened and ground
• Side plates • Fixed on shaft ends by conical-
• Gear- and housing cover press-on taper
Adjusted by conical pins and boltet ! • Removable by oil pressure

Inlet and outlet conditions, blower sizing

Intake conditions:
t1 = 40 °C
P1 = 1,0 bar abs.
m° = 1000 kg/h
Q1 = 900 m³/h
Outlet conditions:
p1 * Q1 p2 * Q2 t2 = 104 °C
P2 = 1,6 bar abs.
T1 T2
m° = 1000 kg/h
Q2 = 676 m³/h

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

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

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

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

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

Compressed-air production with positive displacement blowers
Machine selection and design: Evaluation of operating data
Stipulations: QN = 1936 Nm³/h

(based on: 1,013 bar abs. + 0 °C)
m° = 2503 kg/h
Sommer operation Winter 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 m³/min Intake volume flow Q1 = 30,93 m³/min

Single Circuit control: Continous control of volume flow
with one blower unit
controller with transmitter

setpoint
power consumtion
aeration basin
intake volume frequency

converter
Positive displacement blower GM 35S

drive motor with frequency converter
intake volume flow Q1 = 9,1...35,7 m³/min
absorbed power at coupling PK = 14...47 kW

Blower package: demands on the unit
Necessary scope of supply:

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:

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

DELTA BLOWER
Intake filter silencer:

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

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

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

DELTA BLOWER
Base frame with integrated

discharge silencer

DELTA BLOWER
Belt tensioning
Hinged motor support

DELTA BLOWER
Belt tensioning
Example: Blower GM 150S

Nominal bore DN 300
Motor 200 kW
Totally closed belt guard

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)
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

Driving motor
Aerzen motors Driving motors acc. to IEC and works STD TNO 1159
Name plate: Aerzener Maschinenfabrik
Operating manual: 4PG-702-D-XU
2 - pole: 1,5....37 kW make: WEG
45....160 kW make: WEG
4 - pole: 75....160 kW make: WEG
Motors acc. to IEC - STD. 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

2006: The new one‘s there...

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)

Noise Study DELTA Blower Generation 5,
GM 7L / 700 mbar
79
78
77
76
Machine noise Lp(A) [dB(A)]
75
74
73
72
71
70
69
68
67
66
65
2 3 4 5 6 7 8
Intake volum e flow Q1[m ³/m in]
GM 7L/DN 80 brochure GM 7L-G5/DN 80 measured

Noise study DELTA Blower Generation 5,
GM 25S / 1000 mbar
86
84
Machine noise Lp(A) [dB(A)]
82
80
78
76
74
72
70
68
66
5 10 15 20 25
Intake volum e flow Q1[m ³/m in]
GM 25S/DN 125 Prospekt GM 25S-G5/DN 125 gemessen

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
84
82 Customer benefit:
Maschinengeräusch Lp(A) [dB(A)]
80
78
76
74
Reduced sound emission
72 and -damage to the
70 environment.
68
15 20 25 30 35 40
Special acoustic hoods are
Ansaugvolum enstrom Q1[m ³/m in]
not necessary, the
GM 50L/DN 150 Prospekt GM 50L-G5/DN 150 Messw erte
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
Advantages
Simple operation and maintenance: Transport with fork lift truck/stacker lift truck,
Main-operation side
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
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.

DN 50 unit: constructive design
Accessibility
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 cost-
neutral as an ex-proof motor
has not to be used.

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.

Acoustic hoods / Units: Special space-saving design
800 800 800 800
GM 10S / DN 100 GM 10S / DN 100 GM 10S / DN 100

Delta Blower Delta Blower Delta Blower
1296 1296 1296
required width: 7088 mm
800 • Dimensions
GM 10S / DN 100 GM 10S / DN 100 GM 10S / DN 100 shall be as
Delta Blower Gen. 5 Delta Blower Gen. 5 Delta Blower Gen. 5
1250 1250 1250

small as
possible
required width: 4550 mm

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.

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.

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.

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.

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.

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.

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.

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

ground floor

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

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

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
Acoustic hood, incl. ventilation fan Accessories (Options)

indoor execution Instrumentation: (Ex i or ex-proof)
Driving motor
or outdoor execution pressure gauge intake / discharge
Motors acc. to IEC - std.
or for higher noise dampening pressure switch intake / discharge
explosion proof
special execution 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

Fb 617-0/4-08/02
Gebläse ⋅ Verdichter ⋅ Gaszähler
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 mine gas and dust
risks caused by explosive atmosphere from gas/air- or dust/air mixtures, dust or steams
Category M Category 1 Category 2 Category 3

G D G D G D
1 2 (gas) (dust) (gas) (dust) (gas) (dust)
(zone 0) (zone 20) (zone 1) (zone 21) (zone 2) (zone 22)
For machines applied in For machines in For machines ensuring safety to a high For machines ensuring a normal degree of
underground mines as degree. Applied for the constant, long- For machines ensuring safety to a high
underground mines as degree. Destined for cases where it has to safety. Destined in case it has to be
well as in plants above term or frequent operation in hazardous reckoned - only rarely and if only for a
well as in plants above be reckoned with an explosive
ground offering a high areas
ground offering a high atmosphere (10-1000 h/year rarely). Also short time - with an explosive
degree of safety. The degree of safety. In case (more than 1000 h/year, frequently). atmosphere (0-10 h/year, very rarely).
operation must also be in case of rare failures the machines do not
of explosive atmosphere Also in case of rare failures the show any effective source of ignition. Machines does not show any effective
ensured in case of rare a shutdown is possible. machines do not show any effective ignition source at normal operation.
failures. source of ignition.
Annex II / Nr.: 2.0.1 resp. 2.0.2 Annex II / no.: 2.1 Annex II / no.: 2.2 Annex II / no.: 2.3
Internal production control acc. to annex
VIII + storage of technical documents at
the manufacturer and deposit at an
EU-type inspection EU-type inspection indicated position for 10 years (min.) after Internal production control acc. to annex
by indicated position acc. to annex III by indicated position acc. to annex III manufacturing of the last product or VIII
individual inspection acc. to annex IX
- For the certification of these orders an
external position is necessary. For costs Certification can be carried out by AM.
and delivery time please contact our For standard machines construction kits are available.
technical department.
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 EU-type inspection Internal production control Conformity certification
Category Zone electrical non-electrical electrical non-electrical electrical non-electrical
1 0 x x x x
2 1 x x *) x x
3 2 x x x x
*) complete documentation, incl. risk analysis are to be stored at an indicated position.

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)!
Aerzen -
one step ahead!

Seleccion y Mantenimiento Preventivo Soplantes

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• Seminario sobre Selección de Equipos y Mantenimiento Preventivo

Aerzener Maschinenfabrik GmbH 1 Bombas Bornemann S.R.L.

• 1978 The world‘s largest positive displacement blower

• 1984 The world‘s largest screw compressors (conveying

• 1987 Aerzen develops positive displacement blowers

• 1989 Blower no. 250.000 ready for delivery

Aerzener Maschinenfabrik GmbH 2 Bombas Bornemann S.R.L.

Aerzen Positive Displacement Blowers

• Aerzen Positive Displacement Blowers of standard design

• Aerzen DELTA BLOWER (blower units of standard design)

• Aerzen bulk vehicle blowers

Aerzener Maschinenfabrik GmbH 3 Bombas Bornemann S.R.L.

DELTA SCREW series

DELTA BLOWER series

Aerzener Maschinenfabrik GmbH 4 Bombas Bornemann S.R.L.

Aerzener Maschinenfabrik GmbH 5 Bombas Bornemann S.R.L.

Aeration by Biogas Aeration basin

Fowling tower Secondary settlement tank

Aerzener Maschinenfabrik GmbH 6 Bombas Bornemann S.R.L.

Waste water treatment application

Plant`s structure of costs

1.) Costs of investment

Aerzener Maschinenfabrik GmbH 7 Bombas Bornemann S.R.L.

Distribution of air in the aeration basin

Usual blow in depths:

Aerzener Maschinenfabrik GmbH 10 Bombas Bornemann S.R.L.

air flow oil free

By pollution of the diffusor system the

Aerzener Maschinenfabrik GmbH 11 Bombas Bornemann S.R.L.

O2 content in the aeration basin

Aerzener Maschinenfabrik GmbH 12 Bombas Bornemann S.R.L.

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

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

2. Delta Blower Generation 5

3. ATEX-solutions from Aerzen

Aerzener Maschinenfabrik GmbH 15 Bombas Bornemann S.R.L.

The third dimension of

Aerzener Maschinenfabrik GmbH 16 Bombas Bornemann S.R.L.

Conveying cycle of a two-lobe blower

Aerzener Maschinenfabrik GmbH 17 Bombas Bornemann S.R.L.

Conveying cycle of a two-lobe blower

The PD blower operates acc. to the displacement principle without internal

Vibrations and pulsations !

Lp12 = Lp1 + Lp2 (2-lobe)

Aerzener Maschinenfabrik GmbH 19 Bombas Bornemann S.R.L.

The application of the Interference process to

Aerzener Maschinenfabrik GmbH 20 Bombas Bornemann S.R.L.

6 partial conveying gas

Intake Conveying cycle Outpouring

Aerzener Maschinenfabrik GmbH 21 Bombas Bornemann S.R.L.

Lp12 = Lp1 + Lp2 (2-lobe)

Lp13 = Lp1 + Lp3 = 0 (3-lobe)

Aerzener Maschinenfabrik GmbH 22 Bombas Bornemann S.R.L.

Advantages of the 3-lobe-blower

• Pulsations are cancelled directly in the blower stage

• The vibration loading of the bearings, timing gears and casing is

• The noise energy in the discharge piping is about 25 dB lower

• Lower investment outlays for buildings and system components

Aerzener Maschinenfabrik GmbH 23 Bombas Bornemann S.R.L.

Aerzener Maschinenfabrik GmbH 24 Bombas Bornemann S.R.L.

Housing consists of... Timing gears....

Aerzener Maschinenfabrik GmbH 25 Bombas Bornemann S.R.L.

Inlet and outlet conditions, blower sizing

Aerzener Maschinenfabrik GmbH 26 Bombas Bornemann S.R.L.