Fusheng Centrifugal PAP Plus Series Compressor 1
Fusheng Centrifugal PAP Plus Series Compressor 1
Fusheng Centrifugal PAP Plus Series Compressor 1
PLUS
ENGINEERED AIR COMPRESSORS
Meeting Critical
Needs
Air compression plays a vital role for processes across a range of
industries and is particularly critical in oil and gas, refining, and
chemical/petrochemical applications. Compressor designs must
meet exacting specifications—from API 672 standards to end users’
own complex needs.
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1. Ambient air enters the first 3. The air is conducted through 5. The compression process is 6. Air from the second
stage through the inlet interstage piping into the repeated as the air passes intercooler moves through
control device. first intercooler. through the second stage a third impeller, diffuser,
impeller, diffuser, and scroll and scroll casing.
2. The first-stage impeller 4. The cooled air then flows into casing and then into the
accelerates the air. A radial the second-stage inlet piping. second intercooler. 7. Air is discharged into the
Simply Superior
diffuser converts the air’s aftercooler and air system.
velocity into pressure before
the air enters the scroll casing.
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High Performance
PAP Plus compressors are known to be the most robustly
built and reliable compressors in the industry. At their
core: a state-of-the-art, backward-leaning impeller design
that provides a broad range of superior aerodynamic
performance characteristics.
Energy Savings
The impeller provides highly efficient air compression
that can be precisely controlled for optimum air flow.
Aerodynamic stage matching and intercooler efficiencies
also minimize power requirements.
Corrosion Resistance
Constructed from high-strength, precipitation-hardened
stainless steel, the impeller resists the corrosive and erosive
action of atmospheric contaminants and water vapor that
may pass through the inlet air filter.
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HIGH PERFORMANCE
Overall, our impeller designs provide optimum levels Impeller, diffuser, and scroll designs are uniquely sized to meet Adjustable inlet guide vanes control inlet flow to save energy. The
of performance in all facets of operation. your specific needs in order to provide peak efficiency and large guide vanes are automatically positioned in response to ambient
operating ranges. Superior impeller designs feature optimum blade air and system demand changes. They reduce the flow through
loading and shroud profiling for your required performance level, the compressor by imparting a pre-swirl to the incoming airstream.
which minimizes skin friction, incidence, recirculation, and other loss This pre-swirl controls the work of the first stage impeller, adjusting
mechanisms inherent in impeller performance. the power and throughput to match system demand. By controlling
the amount of air being compressed (and consequently the power
FS-Elliott engineers use the latest engineering design software to
consumed), the inlet guide vane efficiently adjusts to plant conditions
improve aerodynamic performance and enhance product design.
and load variations to conserve energy.
Computational Fluid Dynamics (CFD) is used to perform complex
flow analysis of aerodynamic components to increase stage
efficiencies and optimize compressor performance.
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Carbon Ring Shaft Seal
technology is the result of years
of operational experience. The
horizontally split design assures
ease of maintenance and
oil-free operation.
Exceptional
Pinion and Impeller Assemblies
are composed of a rotor supported
by two self-centering tilt or flex
pad journal bearings. A shaft seal
Reliability
located at each impeller seals
oil in the gearbox and out of the
compression chamber. The rotor’s FS-Elliott is as committed to keeping your facility up and
extremely short shaft lengths mean
running as you and your employees. Our design philosophy is
that centrifugal forces are not
amplified through a long lever arm. simple and consistent: We combine unyielding reliability with
leading-edge technology to ensure that your vital operations
will never be interrupted or compromised. Every component is
Bull Gear Bearings are
horizontally split for easy designed with your need for trouble-free operation in mind, and
inspection and maintenance.
is based on current codes and industry standards as well as
The combination flat-land
thrust bearings and sleeve state-of-the-art technology.
journal bearings are made
of steel with babbitt lining. Gearing
Helical gearing provides greater tooth strength, increased
contact ratio, smoother operation, and reduced noise. During
Helical Bull Gear is a high-precision
AGMA Quality 13/ISO 1328.2 Grade
running periods, the helical gear thrust force remains relatively
4 to minimize noise and vibration. The constant, while the pressure forces on the impeller can vary with
bull gear drives pinions with mounted
operating conditions.
impellers. The pinion shafts are designed
to operate at the optimal rotational speed
for best efficiency.
Journal and Thrust Bearings
For added reliability, each PAP Plus rotor has its own thrust bearing
Self-centering, Horizontally split
system to absorb thrust where it is created, rather than transmitting
Tilt or Flex Pad Journal Bearings
support rotors for the best stability the thrust forces through the bull gear to a single bearing. Bearings
through the entire operating range are designed to withstand aerodynamic and gearing loads for the
of loads and temperatures.
lifetime operation of the compressor.
Rotordynamics
PAP Plus rotordynamic characteristics have been meticulously
analyzed using the latest analytical tools to assure smooth, reliable,
and lasting compressor operation. Superior rotor assembly
configurations and precision component and assembly balance
procedures ensure the lowest level of vibration, the main cause of
equipment wear and tear.
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EXCEPTIONAL RELIABILITY
Filter
Thermal Valve
Cooler
Thrust Bearing
Check PAP Plus Double Acting
Valve Fundamentals
Air End
Thrust absorbed at
each rotor
Control Panel Oil Mist Check
Eliminator Valve
Oil Temp. Bearings absorb thrust in
Shaft Driven Transmitter both axial directions
Oil Pump
Lightly loaded
Oil Pressure
Transmitter
Auxiliary Babbitt to metal construction
Oil Pump
Relief Valve
Check Can operate safely under
Valve all conditions
Oil Reservoir
maintenance, the system is self-contained within the Stability and Low Vibration Good Modest Good
compressor package. All of the oil connections are
Self-centering Yes No Yes
positioned in the lower half of the gearcase for quick
Our exclusive Corona™ lubricants are offered with every Low Oil Supply Pressure Yes Yes No
and simple access to the bearings, gears, and pinions.
new FS-Elliott compressor for superior protection, optimum
The system includes a full-flow auxiliary oil pump that Accommodates Shaft Radial Yes Moderately Low
performance, and maximum service life. These premium Movement/Eccentricity
operates automatically during start-up, shutdown, and
lubricants offer: Friction Losses Low Low Low
emergency situations to provide additional protection to
• Extended lubricant life
the overall package. Sensitivity to Damage Low Moderately High
• Less build-up of lacquer, varnish, and resins by Foreign Matter
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Ease of Ownership
No matter how well a compressor performs, if it’s difficult
to install, commission, and maintain, why own it? Each
PAP Plus compressor is custom-built to be easy to own and
operate over years of demanding use.
Installation Ease
The PAP Plus compact, unitized package design minimizes
the number of external connections as well as foundation
and floor space requirements.
Operation Ease
A variety of touch-screen displays and an array of
standard features and options accommodate any site and
compressor system application. Tailoring the control system
to your specifications allows for precise system control that
maximizes energy savings while providing outstanding
operational benefits.
Maintenance Ease
Centrifugal compressors are inherently reliable over long
periods with minimal maintenance. What
sets PAP Plus compressors apart
is the package design that allows
easy access to critical components
for fast, efficient inspection and
maintenance during off hours and
at scheduled intervals. This feature virtually
eliminates unexpected shutdowns and production
interruptions. All scheduled maintenance can be performed
by your plant personnel, or FS-Elliott can provide a
maintenance plan to fit your specific needs.
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EASE OF OWNERSHIP
Bolts are easily accessible to remove the Seal and Bearing Inspection Time Comparison
gearcase cover. The cover lifts off easily,
Overall, PAP Plus owners spend significantly less time and effort on maintenance.
exposing gears, bearings and seals without
removing any other components. The top half Horizontally Split Centrifugal Compressor
Vertically Split Screw
of the bearing comes off by removing two Inspection Procedure PAP Plus Brand “X” Centrifugal Compressor Compressor
screws. The bottom half can be rolled out Remove Inlet Piping, Valve & Filter Not Required ¾ hour 1 hour
Remove Interstage Piping Not Required ½ hour Not Required
and removed from the casing for inspection.
Remove Oil Piping to Bearings Not Required ¼ hour Not Required
The two-piece seal assembly can be removed Remove Main Oil Pump Not Required ¼ hour Not Required
by sliding it into the bearing cavity area, Disconnect Main Drive Coupling Not Required ¼ hour Not Required
allowing the bearing to be removed following Open Intercooler Casing Not Required Not Required 3 hours
Remove Intercooler Bundles Not Required Not Required 4 hours
the above procedure.
Remove Impellers Not Required Not Possible 4 hours Not
Remove Gearcase Cover ½ hour ½ hour Not Required Permitted
Voids
Pull Bullgear Not Required ½ hour Not Required Warranty
Remove Bearing Assemblies ½ hour Not Possible 2 hours
Remove Shaft Seal Assemblies ½ hour Not Possible 1 hour
Remove Casing & Diffusers Not Required 1½ hours Not Required
Remove Complete Rotor Assemblies 1 hour, Return Rotor Assemblies with Bearings
Not Required Not Required
with Bearing Attached Attached to OEM to Maintain Warranty
Reverse Above Operations 1½ hours 5½ hours 15 hours
11 hours + Weeks for OEM to Return Rotor
Total 3 hours 30 hours
Assemblies and New Bearings
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CUSTOMIZATION EXPERTISE
rugged, reliable packages for API 672 applications. These inlet air flow is 2,585 cfm
packages can be customized to accommodate rigid customer (4,390 m3/hr). The end
product for this refinery
specifications and special operating parameters. Here are
upgrade project is
a few examples of the custom work we’re known for around
unleaded gasoline.
the world.
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BASIC PACKAGES
PAP Plus compressors combine more than 50 years of Electric Motors or Steam Turbines Coupling Guard encloses the Full-capacity Oil Filter eliminates Single or Twin Heat Exchangers Custom Instrumentation, including
are selected to meet operating coupling and shafts to protect contaminants 10 microns or provide oil cooling for all control panels, transmitter racks,
operational and design experience in an extremely
conditions and specified personnel from contacting larger. Twin filters in parallel conditions. Twin air coolers are junction boxes, and more, is
rugged and reliable package. These quality- area classifications. rotating parts during operation. arrangement with an integral piped in parallel arrangement configurable to meet specific
three-port positive shutoff, zero with zero leakage tandem requirements. RTDs, vibration
built packages are routinely required to operate
leakage transfer valve are also transfer valves. These valves monitoring, and customized
uninterrupted for up to three years while maximizing Spacer Type Coupling (forged available for maximum protection enable switching from one controls provide maximum
steel, non-lubricated, flexible- and for maintenance switchover cooler to the other for routine machinery protection.
efficiencies and minimizing unplanned downtime.
element), in accordance with during operation. maintenance while the
API 672 requirements, is included compressor continues operating.
with every PAP Plus compressor.
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CONTROL SYSTEMS
At the heart of every PAP Plus compressor is the Regulus® Energy Savings Operating Simplicity
Control System. A touch of the screen lets you control • Multiple compressor unit energy management capabilities • All control set points are accessible from one interface
and manage the performance of one or multiple • Precise air system pressure control maximizes turndown • Numerous language display capabilities
compressors, at the unit or remotely, to meet air demands capability and energy savings • Multiple choices of communication protocols with
while maximizing energy savings. An extensive array of • Advanced adaptive controller saves energy by permitting interfacing systems
Sirius™ Integrator is an advanced software
optional features is available to accommodate any site. protected operation closer to actual surge • Supervisory capabilities include monitoring the entire
package that lets you monitor and control the
• Innovative adjustable inlet guide vane design maximizes air system from one location
entire compressed air system—even different
efficiency at off-design operations • One-touch, instantaneous data storage and historical types and brands of compressors—from a single
• Suction Throttle and Auto-Dual control modes add trend viewing enables detailed operating analysis and location. By increasing overall system efficiency
operational flexibility and efficiency the ability to identify and avert potential problems and energy savings, the Sirius Integrator has a
• Compressor can run virtually unattended at optimum very short payback period, typically within one
efficiency through various plant air demand conditions year of installation.
REGULUS R200 CONTROL SYSTEM REGULUS R300 CONTROL SYSTEM REGULUS R400 CONTROL SYSTEM
The R200 model includes an enhanced PLC and The R300 model is packaged with many The R400 model is the control system of choice
is packaged with control and monitoring features standard features and available options that for those applications requiring the highest level
that are considered optional on comparable make it easily adaptable to a wide variety of of customization. Tailor the enclosure, hardware,
systems. Its larger memory provides for advanced applications. It is ideal for situations that call control mode, communication package, and more
trending and diagnostics while still maintaining for increased analog and digital input and than a dozen indication, alarm, and trip functions
the cost benefits of a standardized design. output requirements. to fit your needs.
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WEIGHTS AND DIMENSIONS
3 /hr
0m
/ 374
0 0 ICFM kW
22 335
HP /
450
3 /hr
0m
F M / 153 85 kW
I C
900 50 HP / 1
2
m / 3 hr
M / 5780
PAP Plus Overall Dimensions Approximate 3400 ICF k W
520
700 HP /
Compressor A* B* C* Weight*
1500 ICFM
/ 2550 m
3 /hr
A1
Frame 0 H P / 2 60 kW
35
in. mm in. mm in. mm lb. kg
S1 124 3150 61 1549 81 2057 9500 4309
A1 124 3150 61 1549 81 2057 14000 6350
3500 ICFM / 5950 m3/hr 5700 ICFM / 9700 m3/hr
BH 174 4420 75 1905 96 2438 27000 12245 800 HP / 597 kW 1250 HP / 932 kW
CH 195 4953 152 3861 120 3048 38000 17235
D 252 6401 134 3404 153 3886 70000 31750
11000 IC
BH
FM /
2000 HP / 18700 m 3/hr
1492 kW
Discharge Pressure:
45 to 150 psig/3.1 to 10.3 bar g 1000
0 ICF
M/
2000 17000 m 3
Performance may vary based on HP / /
1492 hr
kW
actual site conditions. Consult your
B
authorized FS-Elliott distributor for
more information.
CH
1800
0I
4000 CFM / 3
HP / 060
2980 0 m 3/hr
A C kW
D
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PROJECT ENGINEERING
Within FS-Elliott, our customer-focused Project Engineering The basic package includes an air compressor, Intercoolers & Aftercooler Oil Coolers
team plans and executes all new equipment orders, driver, heat exchangers, controls, and lubrication
serving as the single contact point for all internal system. In addition, we have the expertise and
and external contributing groups and suppliers. The hands-on experience to extend this basic
organization is responsible for assuring the end product scope to include many optional interfacing
meets or exceeds your requirements and is delivered on systems. Typical examples include air dryers,
time and in accordance with the project specifications. aftercoolers, separators, closed-loop cooling-water
In addition to the project’s hardware scope of supply, the systems, pulse jet air filtration systems, and off-skid
project engineer is responsible for providing you with the lubrication systems.
complete documentation package.
Quality Systems Testing Technical Manual • Normal maintenance parts listings and spare parts
We take nothing for granted at our manufacturing facility and To ensure our compressors stand up to your requirements, we make Every FS-Elliott technical manual meticulously describes the interchangeability records
headquarters located in Export, PA. Every PAP Plus compressor sure they stand up to ours. Every FS-Elliott compressor is rigorously installation, operation, and maintenance of our air compressor • Instructions for ordering replacement parts and obtaining service
is carefully crafted under our stringent quality program and tested in our ultra-modern test facility equipped with the most system. The information is the culmination of years of design and assistance and training for operators and maintenance personnel
accompanying standards. By the time your compressor arrives progressive test equipment, instrumentation, and control systems operational experience. Following the recommended procedures
at your site for installation, it has undergone a rigorous available. This 16,000 ft2/1,490 m2 facility allows us to test three and guidelines will result in years of reliable operation. The
execution process encompassing marketing, sales, engineering, complete compressor units at once, using variable speed drives that manual includes:
manufacturing, inspection, and testing. The entire process is provide 50 and 60 hertz capabilities up to 4,000 HP/2,980 kW • Technical drawings specific to each equipment package
governed by our ISO 9001:2008 Certified Quality Management and 6,600 volts. Wide-ranging resources allow us to accommodate • Drawings and literature of the major accessories
System. This quality process also assures that our suppliers are project-specific testing requirements as well as mechanical testing
qualified and continuously monitored to the same high standards we in compliance with API 672 standards and performance testing in
demand of ourselves. accordance with the ASME Power Test Code.
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LOCAL SERVICE AROUND THE WORLD
Installation and Start-up provide these parts to exacting dimensions, material specifications, and reduce life cycle cost. Given today’s rising energy costs,
Our services range from qualified direction and assistance for your and quality standards. We maintain a large inventory of quality- rerates can generate very fast returns.
own installing and commissioning team to providing a total turnkey made parts to assure quick delivery. Many high-usage components,
As the Original Equipment Manufacturer (OEM), FS-Elliott has
installation, including project management, supervision, and all of such as bearings, seals, gaskets, and o-rings, can be shipped
direct access to the authentic manufacturing drawings, material
the craft labor and tools to complete the job. within 24 hours.
specifications, and assembly clearances. Our customers can have
total confidence and peace of mind that by using genuine OEM
Maintenance Repairs
parts for rerates and upgrades, their equipment will perform as
Maintenance programs can be customized to your specific needs. ISO-certified authorized shops are fully capable of performing
intended—the first time and every time.
You can design them to coincide with and support your scheduled repairs. The experienced FS-Elliott service team is dedicated to
ensuring that emergency situations are handled with urgency
outages, or to provide comprehensive, long-term maintenance for Training
your air compressor, including scheduled visits by local, qualified 24/7/365.
We offer a wide range of operator and maintenance training
service personnel. programs, including standard, self-contained packages and
Rerates
customized sessions to fit your needs. Programs feature an
Parts Rerating an existing compressor to a new set of operating conditions effective mix of cut-away models, hardware components, and
Having the correct replacements parts available and easily is often the most economical way to meet a system’s changed textbooks to develop and train individuals in a wide range of
accessible is a critical issue for compressed air users. FS-Elliott can compressed air demands. We can also provide new design oil- free compressor system subjects. Training can be delivered
modifications and upgrades that enhance an air system’s reliability at your facility or one of ours.
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