Equipment

 When there is need in large amounts of compressed air, modern screw compressors are more efficient as they do not contain elements prone to quickly becoming disabled. They are more adjusted to long work cycles. Screw compressors are easy to maintain: their construction

allows an easy replacement of separate parts and units. The main difference is absence of valves and rubbing parts and high reliability of the main component – its screw compressed air unit. Its life cycle amounts to approximately 40,000 operating hours while the overhaul life of a plant on the piston compressor head base equals 9,000-12,500 hours.

The leading domestic producers of compressor stations widely used  in construction are well-known: the St.Petersburg “Arsenal” engineering plant, the Chita engineering plant, the Chelyabinsk compressor plant, the Bezhetsk ÀÑÎ plant. The Poltava (Ukraine) turbomechanical plant production also falls into the category of home produce in its technical and pricing parameters. Among foreign makers Atlas Copco (Sweden) production has gained the greatest popularity in the Russian market.  The German Irmer+Elze (Irmair make) and Czech Atmos Chrast compressor stations have got a wide distribution as well as separate Kaeser (Germany), Compair Holman (Great Britain), Rotair (Italy) and some other companies. 

The ZIF compressor stations produced by Arsenal engineering plant have been household names for Russian builders for several decades.  The plant is currently releasing compressor stations with a screw compressor element. The ZIF lineup includes 5.2 to 12 m³/min ñapacity plants with a diesel drive, and  4 to 6.3 m³/min plants with an electric drive.  The stations have a simple and reliable construction and can be used in various climatic zones including areas up to 1,500 m above the sea level. The Arsenal in-house oil-flooded screw compressor blocks are used in the basis of all stations. Reinforced construction elements such as bearings and seals ensure the life cycle up to 40,000 motor hours. The compressors are designed for widely spread economy domestic fuels and lubricants and filter elements and have a maintainable construction. Diesel stations are powered by the MMZ diesels. The lineup of electric compressor stations is powered with the Eldin electric drives by the Yaroslavl electromotive plant.   All stations are air-cooled with in-built fans. A simple and reliable control system and an auto emergency protection device allows the staff without special qualification to efficiently and safely operate the stations.     To meet customers’ requirements the compressors can be supplied in configurations with or without bodies.   Trailer stations are provided with a vehicle passport   or a self-propelled machine passport  registration and receiving a vehicle plate issue.     

According to the plant specialists calculations, it is the ZIF compressor (considering all above-mentioned costs) that produces the most economically efficient compressed air (0.61 rub./m³).

In 2008 Arsenal prepared for launch a range of the MZÀ70 type powerful electric compressor stations with 11, 12.5 and 16 m³/min production capacity. Unlike their predecessors they achieve higher end pressure of compressed air – up to 1 ÌPà and are equipped with a moisture trap system with an aftercooler    and a moisture and oil extracting filter.    A new control system with an on-board computer is used in these stations to facilitate an operator;s performance.  Beside, the plant updated series-produced trailer compressor stations in 2008. Now in accordance with the new legislation  all ZIF trailer compressor stations are fitted with Knott –manufactured overrunning brakes. It will raise transport safety and boost allowed towage speed to 70 km/h. In addition to this, they will be fitted with new valves of minimal pressure, safety valves and   throttle valves of an upgraded construction. This year the enterprise intends to showcase another new ZIF-PV4/0,7 fuel-saving and affordable compressor station. It will be driven by a small air-cooling diesel and fitted with the MZ20-09 direct drive screw compressor as a compressed air unit. The production capacity will be 3.5-4.5 m³/min to perform simultaneous operation with two pick hammers. A motor car can tow the compressor station easily.

The lineup of compressor stations made by the Chita engineering plant, one of the oldest in the industry, includes models with a screw compressor element in two modifications – diesel-driven with 6 to 15 m³/min production capacity and electrically-driven with with 6 and 10 m³/min production capacity. The diesel stations are powered by the home YaZ and MMZ engines. Compressing equipment is mounted on a two-axle bogie or frame skids. Diesel stations are fitted with a shield tip-up body. .

The engineering plant’s innovations are the   ÏÂ-15/7 diesel and ÍÂ-6Ý electric plants. They have both boosted and reduced production capabilities. Among the ÍÂ-6Ý construction characteristics we should note the upward position of the oil catcher to reduce oil entrainment by compressed air.

The Bezhetsk plant has been releasing compressor plants for over 70 years. But earlier it specialized in garage compressor equipment and now it has considerably expanded its production range and offers mobile compressor stations for construction site applications. Smaller productivity plants    (less than 2 m³/min) are released with a piston pump while more powerful plants have a screw pump. Piston pumps are electrically driven but there are models with petroleum (gasoline) and diesel engines as well as power shaft drives. They are fitted with various capacity receivers. Piston compressors have a special sensor switching the engine off till the receiver pressure is preserved above the established minimal level.   

Thanks to Rotorcomp and GHH-rand modern screw blocks, the screw compressors of this producer are fuel-saving. It is worth mentioning the fact that the plant has considerably increased the screw compressor lineup recently. Besides its previous models with low productivity, it releases the most popular with builders 5 m³/min model: the ÂÊ-70 plant is powered by  Deutz diesel engine, and the ÂÊ-69 – electic engine.   The running gear of mobile compressor stations   is certified with Russian State standard (ÑÑ ¹ ÐÎÑÑ RU.ÌÒ22.Â02746). Mobile plants have height adjustable draw tongues and the ÂÊ-59 and ÂÊ 70 are also fitted with a  parking brake.

The Chelyabinsk plant produce has been known and popular with builders for a decade. It is a relatively young plant which implemented launching compressor plants in 1999.   Its ÊÂ series compressor plants  are driven by a diesel engine and fitted with a screw compressor.   There are mobile versions on chassis (single- and two-axle) or on skids.  The ÊÂ-25/10 (25 m³/min capacity at    1 ÌPà pressure) and ÊÂ-20/16 ( 20 m³/min capacity at      1.6 ÌPà pressure) are unparalleled in Russia and the CIS. The standard modification is for applications at  +1 ^ÎÑ to +35 ^ÎÑ. The category temperature range at a starting preheater set-up is -35 ^ÎÑ to +35 ^ÎÑ. Diesel engines with water and air cooling systems of home (YaMZ-236, YaMZ -238, D-120, D-245) or foreign (Deutz) manufacturers are used here. They are fitted with a stepless control system  and guarantee safe and reliable performance.  At air consumption growth the oil catcher pressure falls and vice versa.  This pressure change is taken up by an inlet valve ensuring automated control of the compressor plant’s productivity. The diesel rotation rise increasing productivity at the same time. The compressor plants are automatically controlled and supplied with safety systems with automatic switch off at deviations from normal working parameters. They are also fitted with an air filter loading indicator. Optionally they can be fitted with compressed air filters for cleaning from oil and dust.

The Chelyabinsk plant developed mobile screw compressor plants whichare based on chassis and electrically driven: ÄÝÍ-18Ø, ÄÝÍ-22Ø, ÄÝÍ-30Ø, ÄÝÍ-37Ø, ÄÝÍ-55Ø, ÄÝÍ-75Ø, ÄÝÍ-132Ø. Mobile screw compressor plants used to be powered by a diesel engine. In the nearest future the enterprise is planning to release an electric compressor plant   ÄÝÍ-200ØÌ on chassis. The Yanmar engines are being currently implemented to drive diesel plants. 

The compressor plants of the Poltava turbomechanical works, Ukrrosmetal concern, are    the most widespread at construction sites in Russia.   The secret is in their affordable price and high maintainability as its equipment is based on home components. The plant still produces piston compressor plants of the ÏÊÑÄ series with a diesel engine and the ÏÊÑ series with an electric engine.  It has also launched the production of the ÂÂÏ series screw compressor plants.   The lineup of piston plants comprises models with 75 to 5.25 m³/min, screw models with 4.5 to 15 m³/min. All models are produced on single-axle chassis in three configurations: without a braking system and light signalling; with light signalling; with a braking system and light signalling (in this case it is considered a transport facility).

Despite various foreign makers’ presence in the Russian market of compressor stations  Atlas Copco products have no competitors. It has been producing compressors for 135 years, its annual supplies outstrip the supplies of its rivals  several times. Hardly any other producer can boast its lineup scale of over 50 models. The main asset of Atlas Copco compressor stations is their exclusive operational cost-saving figures (according to Atlas Copco, the data are based on the results of the comparative tests). Even though Atlas Copco compressors are more expensive, you will profit from their purchase more than from opting for an initially  cheaper but more ruinous in operation plant.   Only a small share – 13-15% – accounts for original cost while 85-87% – account for operational and fuel costs.

Most small capacity models are powered by   Deutz diesel engines that meet Com 3 and Tier 3 ecological standards and are distinguished by their high fuel economy. The term between routine maintenance equals 500 hours. The smallest compressors of the  XAS37 and XAS47 series are powered by Kubota engines. There is a function of production adjustment that allows fuel consumption reduction when a compressor is not fully loaded.    The FuelXpert system of fuel consumption optimization installed in medium and high productivity compressors controls the engine rotation and air delivery  to provide minimum fuel consumption for each operation mode.  The Oil Tronix system regulates the oil injection temperature, the condensate temperature and separation process and boostes the compressor component durability.  

All Atlas Copco compressors supplied to Russia are fitted with a supplementary fuel filter to solve the low quality diesel problem. A winter package if offered for harsh Russian climate conditions. It includes engine glow plugs, synthetic oils , a thermostatic valve on a    compressor oil main, efficient accumulators, a receiver (certified at  -29 ^ÎÑ),  the starting system of a compressor without load.   The starting preheater of the engine coolant is optional for high capacity compressors. One more option  – Nordic – available in high capacity compressor stations gives additional thermo-insulation and heating of regulating devices.

The equipment can be fitted with the Cosmos remote monitoring system to effectively operate a compression fleet and transmit information about the compressor operational parameters and its location.

Atlas Copco compressors in a single-axle road chassis configuration have the Approval of the transport vehicle type and a transport vehicle passport. The compressor is registered at the State Inspection of Road Safety (ÃÈÁÄÄ) and can be towed by a car as a trailer on   public roads at under 90 km/h. High capacity compressors (up to 3 MPa pressure and 38m³/min) can also be fitted with skids.

 To meet the requirements of its customers Atlas Copco Airpower plant has changed the construction of medium-powered stations (from 14 tî 20 m³/min) – the XAMS287, XAHS237, XAMS407, XATS377, XAVS307, XAHS347, – making them more compact, lighter and boosting their maneuverability. The stations are mounted on single-axle (!) chassis which allows their registration at the State Inspection of Road Safety and towing by a motor car. Besides, a new compressor element is applied in these models that has boosted their performance compared to their predecessors.   

High-powered models have been innovated as well. Atlas Copco has always strived for its compressors higher efficiency leading to a new series DrillAir model with 2.5 MPa working pressure in the XRVS 617 and XRVS647, and 3 ÌPà – XRXS567 and XRXS 607. Their main difference from previous models is a new compression element.   It has a reduced inner leak incidence, boosted cooling and a reduced axial load on bearing assemblies leading to 4% lower specific fuel consumption.   

Next year another promising development will be launched – the XAS87 compact compressor. Its productivity equals 4,8 m³/min, which is sufficient to feed four light pick hammers. It is driven by the Kubota engine. The compressor weight is about 750 kg.

Russians know the products of a German company   Irmer+Elze founded in 1903. In 1996 ãîäó Irmer+Elze entered   Atlas Copco Group. Irmer+Elze compressors have been supplied to Russia under the Irmair brand since 2005. All of them are fitted with  Atlas Copco screw compressor element. The compressors with over 3 m³/min capacity are powered by Deutz engines. This fusion of a screw element and engine boosts efficiency output   and reduces fuel consumption.   The equipment is released in an all-season galvanized noise-insulated housing in two configurations – on chassis and without any.    These compressors are supplied with the Approval of the transport vehicle type. All vehicles supplied to Russia in a standard configuration have an option “Cold Start-up” that ensures the compression start-up at ambient temperature up to -20 ^ÎÑ.

A new lineup of Irmair compressors was showcased at the Bauma China’2008 exhibition. The range is expanded due to the Cummins engine. Now compressors can be produced   with working pressure up to 1.4 ÌPà and   up to 20.8 m³/min capacity. A Cummins powered model mounted on the chassis (1 MPa, 10 m³/min) will enter the Russian market in 2009. this combination of working pressure and output will enhance the expansion of sand-sprinkler machines.

 The compressors made by Atmos Chrast, a Czech company specializing in the industry for over 50 years, enjoy stable demand in the Russian market. The PD and PDP mobile compressor series with 17 to 225 kilowatt  diesel engines is designated for high-loaded working conditions at various construction objects. Screw units provide undisturbed operation throughout operation life. Helical rotor profiles of the latest generation provide excellent efficiency and noise level characteristics. The in-built safety system controls the compressor systems and its operation parameters. The certified chassis comply with European standards. The chassis can be fitted with an overrunning brake with automated reverse and a height adjustable towing handle depending on the compressor weight. This equipment is supplied on customers’ request for compressor under 800 kg. The housing corrosion protection is given great attention. The new anti-corrosion system is based on aluminium coat. An integral final after-cooler of compressed air, compressed air preparation system, integral lubricator, integral generator, configuration on a frame, etc. are optional.