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Maximum suction and discharge porting through the compressor achieves minimum pressure drop with valve plates that are made to exacting Vilter material and manufacturing requirements for long-term service.
The unique design of the piston and connecting rod assembly allows for movement only between the connecting rod bushing and piston pin, while providing positive lubrication throughout the entire compression cycle.
Energy-efficient roller bearings enable the compressor to be used for high suction pressure applications as well as high belt-drive horsepower requirements.
Removes 95% of contaminants as small as 3 microns in size. Allows full flow of oil at all times, resulting in reduced wear on compressor components. Combines extreme filtering capacity with the convenience of a throw-away recharge element. Filter is enclosed in a seamless drawn carbon steel shell with cast iron cover, and is equipped with a means for determining pressure drop across the filter.
The 450XL piston ring set consists of three compression rings and a single, special oil scraper ring for keeping oil consumption to an absolute minimum.
Heavy-Duty Crankshaft*
An over-sized crankshaft pin diameter provides years of rugged, dependable duty, while the larger bearing surface allows for higher pressure differential capabilities.
Vilters unique oil circuit drilling arrangement ensures proper hydrodynamic lubrication of insert bearings throughout the entire compression process. Rod bearings are specially designed to supply lubrication to the piston pin bushing at all times.
The 450XL shaft seal, designed to specific Vilter specifications, is manufactured from materials strictly used for industrial refrigeration applications. Seal unit assembly consists of two opposed seals one sealing from the atmosphere and the other from the crankcase. Mating seal surfaces are lubricated and cooled by circulated oil.
The single casting frame incorporates suction and discharge manifolds plus bearing supports. Its cast to exacting tolerances from a high grade of cast iron to withstand extreme changes in heat and pressure. The castings are notably free from porosity and internal strains, and display excellent wearing qualities.
*Patented Design
Far-Reaching Applications
Even with all these built-in features, youll still find the 450XL to be extremely cost-efficient. This compressor has a whopping 50-cfm/cylinder displacement while running at 1200 RPM. And the high isentropic efficiency of the 450XL means its bhp/ton is second to none when compared to other compression systems on the market today. The 450XL can be installed almost anywhere, even on an upper floor if necessary, since vibration is kept to a minimum. Noise level is low too, due to the use of quickacting, precise ring plate suction and discharge valves. The 450XL is so versatile it can handle almost any refrigeration system conditions. Up to 350 psig maximum discharge, and up to 150 psig maximum suction with a maximum 250 psig pressure differential. At different compression ratios, too, from 8:1 for ammonia to 12:1 for R-22. In V-belt configurations all the way up to 300 bhp, or direct drive setups up to 375 bhp. And its usable for both 50 cycle and 60 cycle applications up to 1200 RPM. The graph (Figure 2) on the next page depicts the broad range of applications suitable for the 450XL.
400
350
1 4 :1 1 2 :1 1 0 :1 8 :1
(R -4 0 4 a & R -5 0 7 ) (R -2 2 ) (R -1 3 4 a & R -2 9 0 ) (R -7 1 7 )
300
250
D IS C H AR G E PRESSURE (P S IG )
200
150
R -717
100 (7 5 )
100
R -404a / R -507
R -22
R -22 80 (6 0 )
R -717 R -134a
50
Tons (kWR)
R -290
BHP (kW)
0 -1 2 -5 0
S U C T IO N P R E S S U R E (P S IG )
C A P A C IT Y
60 (4 5 )
12
24
36
48
60
72
84
R -290
40 (3 0 )
M axim um M otor H P (V -B elt D rive) RPM 452X L-458X L 4512X L-4516X L 1,200 200 300 1,130 200 300 1,000 150 250
0 -40 (-40) -30 (-34) -20 (-29) -10 (-23) 0 (-18) 10 (-12) 20 (-7) 30 (-1) 40 (4) 50 (10) 60 F (16) C
S A T U R A T E D S U C T IO N T E M P E R A T U R E
F (C )
The following conditions were used in establishing these ratings: 1200 RPM Saturated suction. No subcooling. No belt losses. All ratings are based on 95F condensing temperature. Ratings are based on a 4-cylinder 450XL (454XL). For tonnage and approximate bhp gures of other 450XL models, use a direct proportion to the number of cylinders of the 454XL. For example, use a 3.0 factor for determining the 12-cylinder 450XL tons and approximate bhp gures. Complete detailed ratings for all 450XL high-stage models, plus ratings for 450XL booster compressors, special high suction pressure compressors, and even integral two-stage compressors,are available for all major refrigerants either from the Vilter homeofce, your Vilter District Sales Ofce, or from an Authorized Vilter Distributor.
Time-Honored Features
Vilters attention to detail shows wherever you look. Over a century of experience in refrigeration compressor design goes into each and every part that comprises the 450XL. Weve designed our component parts to work together, not just t together. Thats why Vilter guarantees that all Genuine Vilter Parts will match your Vilter compressor dimensionally, metallurgically and thermally for optimum compressor performance. With Genuine Vilter Parts, you can be assured of getting the engineering design and special construction features that only Vilter can offer. Consider some of the special manufacturing steps that Vilter parts go through: Select surfaces are shot-peened for added strength Mating faces are lapped for greater compressor efficiency Many parts are ultrasonically inspected for maximum reliability The steels used are of special alloys for durable performance Exacting tolerances are measured in light bands rather than in thousandths of inches
A shrink-fit wrist pin is used to increase bearing load capacity. Hardened steel wrist pins are ground and polished to size. Three cast iron compression rings and one oil ring provide a positive seal while wiping oil back to the crankcase.
Replaceable insert bearing improves lubrication and load carrying capacity. Forged connecting rods back the precision-made, steel-backed Babbitt insert bearing. Grooved wrist pin bushings are fed with pressurized lubricating oil.
Designed with a bigger crankpin diameter for greater load bearing and bearing surface. All crankshafts are statically and dynamically balanced for reduced vibration. Precision drilled crankshaft ensures proper lubrication through the compression cycle. The 6, 8, 12, and 16-cylinder crankshafts are shot-peened for greater strength.
Spring loaded safety heads provide protection against liquid slugging. The suction and discharge porting improve compressor efficiency.
A piston operated unloading mechanism lifts the suction valve plate to unload the cylinders for reduced capacity or unloaded starts. Simplified unloading piston allows easy removal for seal servicing.
General Specifications
The complete line of 450XL compressors is comprised of six models ranging from a nominal 25-ton 2-cylinder machine all the way to the high end of the scale a nominal 200-ton 16-cylinder model. In-between are the 4, 6, 8 and 12-cylinder mid-size units. All 450XL compressors run at a maximum of 1200 RPM, and all are provided with built-in capacity reduction steps for economical operation at reduced loads. V-belt and direct-connected motor operation are also available throughout the entire range of 450XL models. Weve tried to make every inch count in designing the 450XL to fit into even the tightest space requirements. The 450XL is a machine that provides 50 cfm/cylinder, giving you maximum capacity in a minimum amount of space. Theres sure to be a 450XL model thats a perfect match to your refrigeration application.
The compressor(s) shall be equipped with the additional following standard equipment: crankcase oil thermometer and heater; oil filter pressure gauge with manual 3-way valve; oil failure switch; high and low pressure cutout; capacity control switches and unloader solenoid valves for ______ steps of capacity reduction; water or refrigerant cooled oil cooler; suction, discharge, and oil pressure gauges complete with Stedy-Mounts and shut-off valves; ___ (water or refrigerant) cooled cylinder covers. Compressor(s) shall come complete with structural steel base, and be driven by a ___ HP, __________ RPM, _____ volt, _____ phase _____ cycle motor with direct coupling and coupling guard, or V-belt drive with flywheel, belts and motor sheave for _____ RPM. Compressor(s) shall have a capacity of not less than ____ tons when operating at _____ F (psig) suction temperature (pressure) and _____ psig (F) condensing pressure (temperature). Compressors are to be manufactured by Vilter Manufacturing Corporation, Cudahy, Wisconsin, or equal as approved.
Engineering Specifications
The compressor shall have double shaft seal; double tapered, roller main shaft bearings; Tri-Micro oil filter and oil strainer that removes 95% of contaminants as small as 3 microns in size; dynamically and statically balanced heavy duty crankshaft of ductile iron, also shot-peened on 6, 8, 12 and 16-cylinder models; spring safety heads; die-forged, steel connecting rods with replaceable bearing halves; aluminum type heat treated pistons with three compression rings and one oil ring; piston operated suction valve lifters to unload the compressor for starting and to provide capacity control. The piston and connecting rods shall be assembled with a shrink-fit wrist pin for higher load carrying capabilities and superior wearing qualities.
4512XL Direct Drive Recip Pak with Superseparator and VILTech Micro-Controller
General Dimensions
ITEM
Number of Cylinders Maximum RPM Bore & Stroke - In. (mm) CFM @ Maximum RPM (m3/hr) Tons(Kcal/hr x 103) Refrigeration @ 95F Condensing R-717 (10F) R-22 (20F) R-290 (0F)
452XL
2 1200 4x4 (114x114) 99.4(169) 24(73) 29(88) 16(48) 2(64) 2(51) 1900(862) 5(19) 0 50 100 300(149) 110-130 (43-54)
454XL
4 1200 4x4 (114x114) 199(338 49(148) 59(178) 31(94) 3(76) 2(64) 2700(1225) 7(27) 50 25/50/75 50/100 300(149) 110-130 (43-54)
456XL
6 1200 4x4 (114x114) 298(507) 73(221) 88(26) 47(142) 4(102) 3(76) 3100(1406) 7(27) 33/66 33/66/100 300(149) 110-130 (43-54)
458XL
8 1200 4x4 (114x114) 398(676) 97(293) 117(354) 62(187) 4(102) 3(76) 3400(1542) 7(27) 24/50 25/50/75 25/50/75/100 300(149) 110-130 (43-54)
4512XL
12 1200 4x4 (114x114) 597(1014) 146(442) 176(532) 94(284) 5(127) Two 3(76) 5300(2404) 14(53) 33/66 33/66/100 300(149) 110-130 (43-54)
4516XL
16 1200 4x4 (114x114) 796(1352) 195(590) 235(711) 125(378) 6(152) Two 3(76) 5800(2630) 14(53) 25/50 25/50/75 25/50/75/100 300(149) 110-130 (43-54)
Suction Connection - Inches (mm) Discharge Connection - Inches (mm) Unit Weight Less Motor - Lbs. (Kg.) Oil Charge - Gallons (Liters) Standard Steps of Unloading (%) Option 1 Steps of Unloading (%) Option 2 Steps of Unloading (%) Maximum Discharge Temp. - F (C) Crankcase Oil Temp. Range - F (C)
Vilter reserves the right to make changes in design and specications without notice.
C 58-1/2(1486) 62-1/4(1581)
C 40-38(1026) 39(991)
D 20(508) 20(508)
E 34-18(867) 34-34(883)
C 58-1/2(1486) 62-1/4(1581)
Cyls. A B C D E 2 78-3/4(2000) 41(1041) 49-9/16(1259) 20(508) 29-1/8(740) 4 86-3/4(2203) 41-12(1054) 51-9/16(1310) 20(508) 31-9/16(802)
E 34-1/8(867) 34-3/4(883)
Cyls. A B C D E 12 128-1/4(3258) 50-3/8(1280) 60(1524) 21-1/2(546) 59-5/8(1514) 16 128-1/4(3258) 50-3/8(1280) 63-5/8(1616) 21-1/2(546) 59-5/8(1514)
Cyls. A B C D E 2 69(1753) 48-7/8:(1241) 49-7/16(1256) 20(508) 29-1/8(740) 4 74(1880) 50-1/32(1271) 51-7/16(1310) 20(508) 31-9/16(802)
B 56-1/2(1435) 57(1448)
C 40-3/8*(1026) 39(991)
B 80-1/4(2038) 80-1/4(2038)
C 57(1448) 60-1/8(1527)
Cyls. A B C D E 2 78-3/4(2000) 41(1041) 49-7/16(1256) 20(508) 29-1/8(740) 4 86-3/4(2203) 41-12(1054) 51-7/16(1310) 20(508) 31-9/16(802)
E 34-1/8(867) 34-3/4(883)
Cyls. A B C D E 12 128-3/4(3270) 50-3/8(1280) 58-1/2(1486) 21-1/2(546) 59-5/8(1514) 16 128-3/4(3270) 50-3/8(1280) 61-5/8(1565) 21-1/2(546) 59-5/8(1514)
General Dimensions The dimensions shown above are approximate, and should not be used for construction. Vilter issues certified prints for construction purposes. These dimensions are provided in inches, and are followed in parenthesis by millimeters in. (mm) Space needed to remove flywheel 7 (178mm). Space needed to remove crankshaft, from wall to centerline of compressor 42 (1067mm) for 2-8 cylinder models, and 84 (2134mm) for 12-16 cylinder models.
EmersonClimate.com
Vilter Manufacturing LLC 5555 South Packard Ave. Cudahy, Wisconsin 53110-8904 www.vilter.com Telephone: (414) 744-0111 Fax: (414) 744-3483 Email: info.vilter@emerson.com District Sales Offices & Distributors Worldwide
2010VM-42 (4/10) (Previously Vilter Bulletin No. 1004 DLC/3.5m/01-09) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. 2009 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA. Vilter Manufacturing LLC reserves the right to make changes in design and specifications without notice.
Gaterotor
The VSM Single Screw Compressor has one main rotor and two gaterotors. All bearings are pressure fed with oil.
Discharge Manifold Labyrinth Seal Journal Bearing Shaft Seal
Slide System
The VSM Vilter Single Screw compressor is a rotary, positive displacement compressor which incorporates a main screw and two gaterotors. Compression of the gas is accomplished by the engagement of the gaterotors with the helical grooves in the main screw. An electric motor imparts the rotary motion through a driveshaft to the compressors main rotor, which in turn rotates the two intermeshed gaterotors. The compressor is comprised of three fundamental components which rotate and complete the work of the compression process. This typically includes a cylindrical main screw with six helical grooves and gaterotors with 11 teeth. The rotational axes of the gaterotors are parallel to each other and mutually perpendicular to the axis of the main screw.
Pressurized Seal Chamber for Increased Reliability
TM
Discharge Port
This side view cross-sectional drawing of a Vilter oil flooded Single Screw illustrates the suction and the discharge ports as well as the various seals and drive shaft.
Star Gaterotor
Vilter Manufacturing LLC P.O. Box 8904 Cudahy, Wisconsin 53110-8904 www.vilter.com
Vilter reserves the right to make changes in design and specifications without notice. Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. 2010 Emerson Electric Co. All rights reserved. Printed in U.S.A
CAPACITY CONTROL
Rotation
The discharge port Rotation opens early in the cycle allowing only a small reduction in volume and a small Maximum increase in presCapacity and sure. Minimum Volume
Ratio
The capacity slide is set to compress the maximum (100%) of the swept volume while the volume slide is set to allow a minimal increase in discharge pressure.
Rotation
Its the key to part load efficiencies far superior to twin screw compressors. Capacity and volume slides (with an expanded volume ratio of 1.2 to 7.0) move independently of each other based on load, eliminating over or under compression and saving motor horsepower.
Rotation
A shaft seal system prevents any of the process gas from leaking around the drive shaft of the main screw to the environment. The oil flooded Single Screw compressor has two seal types; the standard single mechanical face seal or a triple mechanical face seal with purge capabilities depending on the process requirements. The stationary carbon face of the seal rides on a hydrodynamic film of oil on the rotating mating ring which is fixed on the shaft. The optional triple seal allows various options including a purge and vent to be connected to the housing thus adding a secondary safety buffer during operation. The incorporation of this seal is shown in the cross-section of the oil flooded gas end. Each rotating assembly within the gas end has two sets of bearings. A typical oil flooded Single Screw compressor consists of two rotating gaterotor assemblies and a main screw assembly, each having one pair of angular contact bearings to maintain axial position of the assembly and a cylindrical roller bearing to support the opposite end. All of the bearings are pressure fed with oil. The oil, upon draining from the bearings, is drawn into the suction of the main screw and is discharged with the process gas and injected oil. Since the main screw has no loads except for gravity, the bearings are considered over designed since they are determined by the required shaft diameter for the applied horsepower. The Single Screw design does not restrict the bearing sizes for the gaterotor supports. As a result, the bearings are optimized for maximum reliability.
Design
The dual slide design on the Vilter Single Screw compressor offers the highest level of flexibility and performance optimization for screw compressors. This design actually has two slides per compression side of the gas end. The two slides are commonly referred to as the capacity slide and the volume slide. The capacity slide moves from positions of 20% to 100% of flow to allow the compressor to match the system flow requirements. Although lower flow rates are possible, they are not recommended since this reduces the amount of oil flowing through the gas end and may result in overheating. The volume slide allows the discharge port to be positioned in the optimum location depending on the capacity slide location, the properties of the gas and the injectant. A unique feature of the dual slide design is that it allows the compressor to start completely unloaded. This is unlike any other screw compressor. When both slides are in the open position an unrestricted flow path through the compressor is created. If for any reason the gas end is completely full of oil, the position of the slides on startup will allow the oil to be swept out of the gas end thus preventing the possibility of hydraulic lock. The slides also allow the operation at extremely low ratios down to 1.2. However, the recommended operating points for optimum design efficiency occurs at pressure ratios of 2.0 and greater. Due to their design, Single Screw compressors are able to operate more efficiently and reliably with higher suction pressures and lower ratios than other types of screw compressors. Since the capacity and volume slides operate in paral-
Slide Design
Approximately 20% of the volume of the groove is trapped and allowed to be compressed.
Rotation
The slide and resulting discharge port location are in the maximum position resulting in the maximum reduction in volume and a maximum increase in discharge pressure.
lel (not in series like other types of screw compressors), an important feature of the Single Screw compressor is the ability to operate with optimum efficiency even at part load conditions. Other types of screw compressors have dual slides which operate in series. This results in one of the slides blocking off some of the porting behind the other slide creating a restriction and performance penalty at part load conditions.
Conclusion
The Vilter single screw compressor with the 5/15-year warranty and ParallexTM slide system makes it the most efficient and reliable compressor in the world. Its superior to any other single screw and most certainly every twin screw. Thousands of single screws are in operation worldwide for gas compression, air conditioning, refrigeration, and petrochemical industries.
Approximately 50% of the volume of the groove is trapped and allowed to be compressed.
Rotation
The discharge port opens later in the cycle allowing a significant reduction in volume and a significant increase in pressure.
Rotation
The capacity slide is set to compress the maximum (100%) of the swept volume while the volume slide is set to allow a maximum increase in discharge pressure.
BALANCED LOADING
COMPRESSION PROCESS
Rotation
DISCHARGE PROCESS
Rotation
START OF COMPRESSION
START OF DISCHARGE
The gas in the groove is at discharge pressure. The main screw aligns with the discharge port in the housing and pushes the gas through the port into the discharge chamber.
TM
Rotation
Rotation
Rotation
As the groove increases to maximum, the gas flows into the open grooves.
Rotation
SUCTION
Gas Intake
END OF COMPRESSION
The gas continues to be compressed until it reaches the minimum volume and maximum pressure for the application.
The compression cycle begins after suction gas fills the top and bottom grooves of the main screw at the suction end of the casing. Since the screw compressor has a gaterotor(s), the compression process occurs simultaneously on opposite sides of the screw; the top and bottom. As the main screw rotates, it in turn drives the gaterotor(s). The engagement of the gaterotor with a screw groove traps the suction gas and begins the compression process. As the screw rotates, the engagement of the gaterotor continues, thus reducing the initial volume of the groove and increasing the pressure in the groove. Once again this occurs simultaneously on opposite sides of the screw. Finally, as the main screw rotates toward the completion of the compression cycle, the groove aligns with a port in the housing at the discharge end of the casing. The gas and any liquid in the groove are radially discharged through the port into the discharge plenum. Since there are six grooves in the main screw, the compression process simultaneously occurs six times in two locations per revolution of the screw. Operation at 3600 RPM results in 21,600 simultaneous compression strokes at the top and bottom grooves per minute and a relatively smooth flow of discharge gas. One advantage of the Single Screw compressor is the fact that there are no net radial or axial forces exerted on the main screw or drive shaft components due to the work
Theory
Balanced Loading
of compression. Since the compression process occurs symmetrically and simultaneously on opposite sides of the screw, the forces due to compression are canceled out. The only vertical loads exerted on the main screw bearings are due to gravity. Since the discharge end of the screw is vented to suction, the suction gas pressure is exerted on both ends of the screw resulting in balanced axial loads. The Single Screw has an inherent design advantage of reduced loading during the compression process. This is due to the fact that the gaterotor tooth area decreases as the gas pressure in the groove approaches discharge pressure. When the gaterotor first engages with the main screw the compression process begins. As rotation continues, the gaterotor tooth area exposed to the gas pressure increases. The resultant force creates the axial loads on the gaterotor assembly. Approximately half way through the stroke, or when the radial axis of the gaterotor is perpendicular to the rotational axis of the main screw, the maximum area of the gaterotor is exposed to the gas pressure. As the compression cycle continues, the pressure within the groove increases but the area of the gaterotor exposed to the discharge pressure continues to decrease. The lower loads transmitted to the components and bearings result in higher reliability. At the end of the stroke, the area of the gaterotor has been reduced to zero as it disengages from the main screw. Another design feature of the Single Screw compressor that enhances reliability is the loads on the gaterotor assemblies are well defined and isolated from the main screw. Since the gaterotor assemblies are independent
and do not interfere with the rest of the main screw body, bearings can be sized for maximum reliability.
Sealing is accomplished by the combination of precision running clearances and an injected liquid (coolant/lubricant) which is allowed to leak through and thus seal the clearances during the compression process. In the Single Screw compressor, this liquid must also have adequate viscosity to lubricate the bearings. The liquid is swept into the groove during the suction process and also injected into the compression groove during the compression process to maximize sealing of the running clearances. Due to the rotation of the screw, centrifugal force impels the injected liquid to the circumferential clearance volume between the screw and the housing. This minimizes the leakage described as cascading. Cascading is defined as the leakage from the high pressure groove past the land separating the grooves into the trailing low pressure groove. Another inherent attribute of the Single Screw design is that there is more surface area on the lands near the discharge end of the groove than near the middle of the groove. This attribute also minimizes leakage from the highest pressure region of the groove. Another area where the leakage is minimized is between the high pressure end of the groove to the volume behind the screw which is at suction pressure. This potential leak path is sealed by means of a non-contacting hydrodynamic seal known as a viscoseal, windback seal, or labyrinth seal.
COMPRESSION
END OF DISCHARGE
Gas Discharge
All of the gas that was trapped in the groove is pushed out. The volume of the groove is reduced to zero.
Vilters VSM single screw compressors deliver longer life, higher reliability and better energy and have fewer moving parts than reciprocating compressors. The key to the single screw design. The balance design results in ultra-low anced design advantages allows Vilter to offer bearing loads with significantly decreased the exclusive 5/15 compressor compressors reliability is in its balanced vibration and sound levels. The inherent balWarranty, including efficiency than the twin screw compressors
5-years on the 15-years on the bearings. The key to the single screw compressors high and
compressor to run at optimum efficiency through its full range of capacity. Providing the ciency... The Worlds Best Compressors are available only from Vilter! highest reliability and surpassed energy effi-
efficiency is Vilters
VSM-152* VSM-182*
CFM 152 177 202 305 353 405 502 609 691
VSM-152E* VSM-182E* VSM-202* VSM-301 VSM-361 VSM-401 VSM-501 VSM-601 VSM-701 VSM-202E* VSM-301E VSM-361E VSM-401E VSM-501E VSM-601E VSM-701E
52 68 72 79 61
Base Ratings (a) Ammonia R-22 Tons BHP Tons BHP 76 84 79 50 60 70 67 81 101 119 118 139 135 160 173 199 211 245 239 276 58 78 85 96 98 87
VSM Specifications
Length 8'-2" 8'-2" 8'-2" 8'-2" 8'-2" 8'-2" 8'-2" 9'-9" 9'-9"
Unit Dimensions and Weights (b) Width, Single Width, Dual Height Oil Filter Oil Filters 3'-7" 3'-11" 5'-9" 3'-7" 3'-7" 3'-7" 3'-7" 3'-9" 3'-9" 3'-11" 3'-11" 3'-11" 3'-11" 3'-11" 3'-11" 3'-11" 4'-0" 4'-5" 4'-5" 5'-9" 5'-9" 5'-9" 5'-9" 5'-9" 6'-11" 7'-3" 7'-9"
Shipping Weight (lbs) 3800 3800 3950 4100 4100 5000 6150 6700 6900
57
88 93 98
107 136 146 185 229 260 111 139 161 203 252 285
107 136 147 155 168 175 190 207 220 237 255 264 283
(a) Tons and BHP based on + 20F and 95F; 10F liquid subcooling, saturated suction. Ratings for other refrigerants are available, consult Vilter for more informationon. (b) Dimensions and weights are approximate, and are based on use with thermosiphon plate oil cooling, standard size oil separator and standard motor. * Models operate at 1775 RPM; all others operate at 3550 RPM
VSM Single Screw Compressor From Nominal 150 CFM thru 700 CFM
VILTER
VSS Single Screw Compressor From Nominal 750 CFM thru 3000 CFM
The Worlds Best Compressors For Industrial Refrigeration Single Screw Ammonia Heat Pumps
TM
Conventional Food and Beverage Processing Plants Utilize Two Opposing Paths of Energy
Refrigeration Heat Energy OUT Refrigeration systems absorb heat but then reject it back into the atmosphere. Fossil Fuel Heat Energy IN
Simultaneously, plant demands for hot water, such as process room clean-up activities, use fossil fuel energy to heat water.
Vilter Single Screw Ammonia Heat Pumps Harness the Heat from Refrigeration and Bridge the Gap for the Beneficial Use of Rejected Heat
High pressure Vilter Heat Pump Compressors allow plants to conserve energy by transferring refrigeration waste heat into useful hot water heating, while reducing or eliminating hot water boilers and the fossil fuels they consume.
Single Screw Ammonia Heat Pump
Condensing
Subcooling Condensing
A scavenging heat pump system is designed to pull heat out of an existing refrigeration system by diverting ammonia discharge gas away from refrigeration system condensers to the suction inlet of the heat pump system. Vilter single screw compressors are designed to handle the high suction pressures required of this duty, and deliver the very high discharge temperature vapors for water heating in order to make use of the refrigeration systems waste heat. In heating water to moderate temperatures, up to 160 F (71 C), single stage single screw heat pump systems provide optimal performance (COPs) due to the dutys relatively low differential pressures, up to 350 psid.
178 (12.1) 94 (34.5) 474 (32.2) 159 (70.5) 178 (12.1) 94 (34.5) 468 (31.9) 178 (12.1) 94 (34.5) 469 (31.9) 158 (70) 158 (70)
OIL COOLER
OIL COOLER
OUTLET WATER
CONDENSER
Two-stage scavenging heat pump systems are utilized where the desired water temperatures are higher than those provided by single stage systems. Higher differential water temperatures correlate to higher differential pressures in heat pump compressors. By splitting the heat pump design from a single stage to a two-stage system, superior COPs are realized in achieving very high water temperatures, up to 195 F (90 C). Vilter single screw compressors employed to satisfy the high pressures and temperatures of two-stage ammonia heat pumps operate reliably and efficiently at such intensive duties due to their naturally balanced axial and radial design.
178 (12.1) 94 (34.5) 371 (25.2) 141 (60.5) 366 (24.9) 140 (60) 721 (49.0) 193 (89.5) 178 (12.1) 94 (34.5) 370 (25.2) 141 (60.5) 365(24.8) 140 (60) 720 (49.0) 193 (89.5) 178 (12.1) 94 (34.5) 371 (25.2) 141 (60.5) 366 (24.9) 140 (60) 721 (49.0) 193 (89.5) 178 (12.1) 94 (34.5) 370 (25.2) 141 (60.5) 365 (24.8) 140 (60) 720 (49.0) 193 (89.5)
158 (35.9)
10680 (3130)
942 (703)
4.45
234 (53.2)
15819 (4636)
1534 (1144)
4.06
271 (61.6)
18339 (5375)
1694 (1264)
4.25
BEFORE
Courtesy of Star Refrigeration
Emerson.com/StarRefrigeration
Vilter reserves the right to make changes in design and specifications without notice. Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. 2010 Emerson Electric Co. All rights reserved. Printed in the USA v11 3/2010
Allen-Bradley Programmable Controller ParallexTM Slide System - Its the key to part load
efficiencies far superior to twin screw compressors. Capacity and volume slides move independently of each other based on load, eliminating over or under compression and saving motor horsepower. The CompactLogix programmable controller with an A-B PanelView 1000 graphic display provides high performance in a small footprint for stand alone operation or for integrated system control.
Applications
Gas Liquification Vapor Recovery Flare Gas Recovery Coal Bed Methane Recovery Field and Fuel Gas Boosting Wellhead Recovery Enhanced Oil Recovery Landfill Gas Recovery LNG Boil Off Gas Gathering BIO - Gas Digester CO2 Nitrogen Hydrogen Refrigerant
Vilters VSG single screw gas compressors deliver longer life, higher reliability and better energy efficiency than twin screw compressors and have fewer moving parts than reciprocating compressors. The key to the single screw compressors reliability is in its balanced design. At the core of the positive displacement rotary compressor is a single main rotor intermeshed with two opposing gaterotors. The balanced design results in ultra-low bearing loads with significantly decreased vibration and sound levels. The key to the single screw
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Single Screw with Parallex Slides Typical Twin Screw with Variable VI
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Percent Capacity
compressors high energy efficiency is Vilters exclusive Parallex slide system allowing the compressor to run at optimum efficiency through its full range of capacity.
Providing the highest reliability and unsurpassed energy efficiencyThe Worlds Best Compressors are available only from Vilter!
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Compression Ratio
Unit Features
Standard Construction:
Main bearings Roller and ball type angular contact thrust. Gaterotor bearings Roller and ball type angular contact thrust. Hand wheels or optical slide valve motor for capacity and volume control. Suitable for Class 1, Group C+D, Div. II. Variable Vi - Independent volume control and capacity control for improving efficiencies. Separate prelube oil pump with TEFC drive motor. Lube oil piping is carbon steel, using socket weld or butt weld connections. Threaded connections are kept to a minimum. ASME designed oil separator with coalesing oil filter. CompactLogix programmable controller with an A-B PanelView 1000 graphic display Separate stop and check valves for both suction and discharge lines.
Available Options:
Stainless steel lube oil circuit. Suction bypass connection for fuel gas booster application. Dual oil pumps. Dual oil filters. Water cooled or air cooled oil coolers. High & Low ambient temperature options.
Note Because the oil system on the VSG compressor utilizes discharge gas pressure as the means to move the injection oil through the system, it must be remembered that all components of the oil system are exposed to full discharge pressure and must be pressure rated accordingly.
Low Oil Injection Temperature High Oil Injection Temperature Low Suction Pressure High Discharge Pressure Prelube Oil Pressure Low Oil Pressure High Starting Oil Filter Differential Pressure High Running Oil Filter Differential Pressure High Motor Amperage Limit
Safety Setpoints: Low Gas Suction Temperature High Gas Discharge Temperature Low Oil Separator Start Temperature Low Oil Separator Run Temperature
In most cases, the safety setpoints described will have settings which are dictated by process requirements, and not necessarily mechanical constraints of the compressor. Process pressures and temperatures may vary considerably depending on the application of the compressor. The VSG compressor is designed to operate in a broad range of applications. Minimum and maximum values for each safety setpoint are provided, while precise settings for the safety setpoints must be derived for each installation.
Instrumentation
Pressure
There are four pressure transducers to read system pressures as listed below (Figure 1). PT1 Suction pressure transducer (-15.0 - 400 PSIG) measures the gas suction pressure into the compressor housing. PT2 Discharge pressure transducer (-15.0 - 400 PSIG) measures the discharge pressure of the process gas in the separator. PT3 Oil Filter Inlet pressure transducer (-15.0 - 400 PSIG) measures the oil pressure as it enters the oil filter canisters. PT4 Oil Manifold pressure transducer (-15.0 - 400 PSIG) measures the oil pressure downstream of the oil filter as the oil is injected into the compressor.
Additional pressure transducers may be required and installed by the customer for pressure readings at customer specified points such as process gas discharge pressure from the package boundary, cooling water pressure to and/or from the oil cooler, etc.
Temperature
There are four temperature readings for processor control, as listed below (Figure 1). RTD1 Suction temperature RTD measures the temperature of the incoming suction gas. RTD2 Discharge temperature RTD measures the temperature of the gas/oil mixture as it is discharged from the compressor housing. RTD3 Oil Separator temperature RTD measures the temperature of the oil in the separator sump. RTD4 Oil Injection temperature RTD measures the temperature of the oil as it is injected into the compressor.
Additional Instrumentation
Motor current transformer Optical actuators for capacity and volume slide indication
Other Options:
Remote start/stop input Remote alarm/trip output
Additional RTDs may be required and installed by the customer for temperature readings at customer specified points such as discharge gas temperature from the package boundary, cooling water temperature to and/or from the oil cooler, gas aftercooler temperature, etc.
Application Guidelines
To ensure the successful operation of the VSG compressor, the guidelines described below should be followed. Proper lubrication is critical to the operation of the VSG compressor. The compressor relies on the injected oil to absorb and remove the heat of compression, to seal the compression chambers formed in the flutes of the screw, and to lubricate all moving parts. For this reason, it is imperative that the oil chosen be of correct viscosity, and that sufficient oil flow be provided at all times, using an auxiliary oil pump when necessary. The oil chosen must be compatible with the process gas, to prevent absorption of the gas into the oil, which would dilute the oil and reduce the viscosity. Also oil filtration to 25 micron nominal particle size is required to ensure that only clean oil is injected into the compressor. For assistance in choosing the correct oil for the application and in sizing an auxiliary oil pump, consult a Vilter representative. Injection oil temperature must be closely controlled for optimum performance. Oil temperature must be maintained a minimum of 15 - 20F above the gas mixture dewpoint at anytime to prevent condensation or liquid knockout from occurring within the compressor. Gas composition plays a role in the performance of the VSG compressor as well. While the VSG is capable of handling a wide variety of gases, if H2S is present in the process gas in any concentration, special oil additives are required to protect the compressor from corrosion. Levels below 100 PPM of H2S allow the standard warranty to apply. Typical gases handled: Natural Gas, Landfill Gas, Carbon Dioxide, Propane, Helium, Propylene and Ammonia. Other gases will need to be reviewed for compatibility and operational performance by Vilter.
Direct Drive, Electric Motor, Gas Engine From 1.2 to 7.0 (Continuously Variable Automatic, or Manual Control) From 10% to 100% (Continuously Variable Automatic, or Manual Control Available) 400 515 325 -50F 180F 210 (Contact Vilter for increased temperature limits) 190 (Contact Vilter for increased temperature limits) 485 350 450
* *Higher limits are available. Consult Vilter Manuafacturing LLC. **Higher discharge pressures are achievable. Consult Vilter Manuafacturing LLC. for approval. ***Higher differential pressures can be achieved. Consult Vilter Manuafacturing LLC. for approval. Note: MAWP (Maximum Allowable Working Pressure). The relief valve setting must be below the MAWP. The relief valve is usually set 10% lower than the MAWP.
C C
B B A D A
Models VSG 301-701, above, are shown with a standard C-Flange motor mount, single oil filter and standard water-cooled oil cooler which is noted by the D dimension on the drawing. Models VSG 751-2101 drawings illustrate the optional dual oil filter and the optional remote mounted oil cooler which can be air cooled. It is important to note that all VSG models can be fitted with single or dual oil filters, water-cooled oil cooler or remote mounted oil cooler.
* Dimensions shown are approximate and should not be used for construction.