Installation kit Energy Recovery BP C67

Note Modified Date Intr./Appd

from
00 Issued. CID 27040, DN 180625 59 17/01/2019

Name: Installation Energy Recovery Date 16/01/2019

Detail Print date

Secr. Class 1102 K/ 2-Controlled distribution only (default)

Project title BP C67 (2019) Project nr E167

Written by Owner CAI

Edition 00 Compare
Designation

Status Approved Replaces 9828 0836 89

Sheet 1(16)

9828083689 – rev_00 page 1 / 16

Energy recovery for oil-injected screw compressors
BP C67 power 15-18,5-22-26 kW (20-25-30-35 hp)
Contents
Index ................................................................................................................................................................ 1
1 Description ........................................................................................................................................ 3
1.1 Low temperature rise / high flow water system ................................................................................ 3
1.2 High temperature rise / Low flow water system ............................................................................... 3
1.3 Recovery water flow.......................................................................................................................... 3
1.4 Water requirements for closed water circuit. .................................................................................... 3
1.5 Water requirements for open water circuit. ....................................................................................... 3
2 Components ....................................................................................................................................... 4
2.1 Energy recovery (E.R.) heat exchanger (HE) .................................................................................... 4
2.2 Additional Energy Recovery thermostatic valve ............................................................................... 4
3 Schema for Pack & Full Feature ...................................................................................................... 5
3.1 Assembling schema pack or dryer external (FF) ............................................................................... 5
3.2 Assembling schema FF (dryer integrated) ........................................................................................ 6
3.3 Main components .............................................................................................................................. 7
3.3.1 Main thermostatic valve connections .................................................................................... 7
3.3.2 Air/oil cooler with E.R. (additional) thermostatic valve assembled ...................................... 7
3.3.3 Right Panel Pack or dryer external (FF) ................................................................................ 8
3.3.4 Right Panel FF (integrated dryer) .......................................................................................... 8
4 ASSEMBLING.................................................................................................................................. 9
4.1 Additional thermostat assembling for energy recovery..................................................................... 9
4.2 Heat exchanger assembling ............................................................................................................. 10
4.3 Decals .............................................................................................................................................. 10
5 Operations........................................................................................................................................ 11
5.1 Start up: ........................................................................................................................................... 11
6 Techincal information ..................................................................................................................... 11
6.1 Reference conditions ....................................................................................................................... 11
6.2 Maximum allowed pressure of the heat exchanger: ........................................................................ 11
6.3 Recoverable energy ......................................................................................................................... 11
6.4 Installation proposal – Functional schema. ..................................................................................... 12
6.5 Energy recovery system in use (see drawing) ................................................................................. 12
6.6 Maximum energy recovery.............................................................................................................. 12
6.7 Operation principle at different loads: ............................................................................................. 13
6.8 Recovery water flow too high/temperature too low ........................................................................ 13
6.9 Energy recovery system not in use .................................................................................................. 13
6.10 Stopping the unit for a long period .................................................................................................. 13
7 Maintenance .................................................................................................................................... 13
7.1 Oil change:....................................................................................................................................... 13
7.2 Thermostatic bypass valves ............................................................................................................. 13
7.3 Heat exchanger (HE) ....................................................................................................................... 13
7.4 Cooling water requirements. ........................................................................................................... 14

9828083689 – rev_00 page 2 / 16

1 Description

The energy required in any compression process is mainly transformed into heat. In an oil-injected screw
compressors, the major part of this compression heat is dissipated through the oil system. This energy
recovery system is designed to recover most of the above-mentioned heat by transforming it into
warm/hot water. The water can be used for different applications.

This system can be applied to water systems with low temperature rise (high water flow) or with high
temperature rise (low water flow).

1.1 Low temperature rise / high flow water system

This system requires a high-water flow to obtain the maximum energy recovery.
Example: Heated water is used to keep another medium at moderately high temperature, like for central
heating.

1.2 High temperature rise / Low flow water system

This system grants a high-water temperature rise, and as consequence, the water flow is low.
Example: Open circuit to heat up cold water from mains supply, like heating feed water in a boiler.

1.3 Recovery water flow

Energy recovery water inters the unit at inlet connection, in heat exchanger (HE) the heat from
compression is transferred from the warm oil to the water, which leaves the compressor at outlet port.

1.4 Water requirements for closed water circuit.

The use of a closed water circuit minimizes make-up water requirements. Therefore, the use of soft or
even demineralized water is economically feasible and avoids any problem of scale deposits.
Although the heat exchanger is made of stainless steel, the water circuit connected to the compressor may
require corrosion inhibitors.
In case of storage at temperature below zero degrees, an anti-freeze product can be used, Example, add
ethylene-glycol to the water in proportion to the expected temperature to avoid freezing.
See section 7.4 Cooling water requirements.

1.5 Water requirements for open water circuit.

For open, non-recirculation water circuits, the main problems are related to deposit, corrosion and
microbiological growth control.
To minimize these problems, the water should meet a few requirements. See section 8.4 Cooling water
requirements.

9828083689 – rev_00 page 3 / 16

2 Components

The energy recovery system is completely integrated, and its main components are:
• Oil/water heat exchanger, made of stainless steel (1180).
• Additional Thermostatic valve for the oil/water heat exchanger (1120).
• Additional fittings and pipes to connect the above devices to the oil circuit and to customer water
circuit.

2.1 Energy recovery (E.R.) heat exchanger (HE)

OIL OUTLET

WATER INLET

OIL INLET

WATER OUTLET

2.2 Additional Energy Recovery thermostatic valve

R1: to tee coupling

oil cooler outlet
(use fittings 1100 and 1110)

E: to heat exchanger oil

outlet U: to oil cooler inlet
(use fittings 1100 and 1110) (use fittings 1100 and 1110)

9828083689 – rev_00 page 4 / 16

3 Schema for Pack & Full Feature

3.1 Assembling schema pack and FF (dryer external)

Pos Qty Partnumber Name Pos Qty Partnumber Name

1010 1 2204 2129 01 STIRRUP 1170 4 0661 1000 44 SEAL WASHER
1020 1 2204 1191 00 SUPPORT H.E. FRAME 1180 1 1613 7805 00 HEAT EXCHANGER
1030 4 0147 1325 03 SCREW 1190 1 2202 8681 07 FLEX.HOSE 3/4" WATER IN
1040 2 0300 8019 00 PLAIN WASHER 1200 1 2202 8681 08 FLEX.HOSE 3/4" WATER OUT
1050 1 0147 1344 03 SCREW 1205 2 0606 0000 28 SWIVEL ELBOW
1060 2 0301 2335 00 PLAIN WASHER 1210 2 0571 0035 52 NIPPLE HEX.
1070 5 0291 1110 00 LOCK NUT 1220 1 2204 1187 00 FLANGE WATER CONN.
1080 1 2200 7503 28 TEE ADAPTER 1230 6 0129 3270 46 BLIND RIVET
1090 1 2202 8884 01 STR.COUPLING SWIVEL 1240 1 2202 9162 00 LABEL ARROW IN
1100 3 0603 4200 24 NIPPLE HEX. 1250 1 2202 9163 00 LABEL ARROW OUT
1110 3 0661 1000 45 SEAL WASHER 1260 2 0348 0101 13 CABLE STRIP
1120 1 2203 0352 02 VALVE THERMOSTATIC 1290 2 0661 1000 39 SEAL WASHER
1130 1 2202 9863 05 FLEX.HOSE 3/4" 1300 2 0603 5522 03 NIPPLE HEX.
1140 3 0606 0000 28 SWIVEL ELBOW 1310 1 2202 8681 10 FLEX.HOSE 3/4"
1150 1 2202 8681 18 FLEX.HOSE 3/4" 1320 1 2202 9325 17 FLEX.HOSE 3/4"
1160 4 0603 4200 14 NIPPLE HEX.

Due to updates the provided components can deviate from above items

9828083689 – rev_00 page 5 / 16

3.2 Assembling schema FF (dryer integrated)

Pos Qty Partnumber Name Pos Qty Partnumber Name

1010 1 2204 2129 02 STIRRUP 1170 4 0661 1000 44 SEAL WASHER
1020 1 2204 1191 00 SUPPORT H.E. FRAME 1180 1 1613 7805 00 HEAT EXCHANGER
1030 4 0147 1325 03 SCREW 1190 1 2202 8681 07 FLEX.HOSE 3/4" WATER IN
1040 2 0300 8019 00 PLAIN WASHER 1200 1 2202 8681 08 FLEX.HOSE 3/4" WATER OUT
1050 1 0147 1344 03 SCREW 1205 2 1088 0803 08 GROMMET
1060 2 0301 2335 00 PLAIN WASHER 1210 2 0571 0035 52 NIPPLE HEX.
1070 5 0291 1110 00 LOCK NUT 1220 1 2204 1187 00 FLANGE WATER CONN.
1080 1 2200 7503 28 TEE ADAPTER 1230 6 0129 3270 46 BLIND RIVET
1090 1 2202 8884 01 STR.COUPLING SWIVEL 1240 1 2202 9162 00 LABEL ARROW IN
1100 3 0603 4200 24 NIPPLE HEX. 1250 1 2202 9163 00 LABEL ARROW OUT
1110 3 0661 1000 45 SEAL WASHER 1260 2 0348 0101 13 CABLE TIE STRIP
1120 1 2203 0352 02 VALVE THERMOSTATIC 1290 2 0661 1000 39 SEAL WASHER
1130 1 2202 9863 05 FLEX.HOSE 3/4" 1300 2 0603 5522 03 NIPPLE HEX.
1140 3 0606 0000 28 SWIVEL ELBOW 1310 1 2202 8681 10 FLEX.HOSE 3/4"
1150 1 2202 8681 18 FLEX.HOSE 3/4" 1320 1 2202 9325 17 FLEX.HOSE 3/4"
1160 4 0603 4200 14 NIPPLE HEX.

Due to updates the provided components can deviate from above items

9828083689 – rev_00 page 6 / 16

3.3 MAIN COMPONENTS

3.3.1 Main thermostatic valve connections

- Main thermostatic valve - Air/oil cooler with pipes to disassemble

to Tee coupling of oil cooler

outlet (1310)

to oil inlet port of heat

exchanger (1320) cooler oil
INLET

cooler
oil OUTLET

main thermostat hose to re-used (1310)

hose to re-used (1320)

3.3.2 Air/oil cooler with E.R. (additional) thermostatic valve assembled

- Energy recovery thermostatic valve assembly

Cold oil return

to return port oil vessel inlet

main thermostatic valve
(1310)

to oil outlet port heat exchanger

(1150)

Hot oil delivery

to oil inlet port heat exchanger

(1320)

9828083689 – rev_00 page 7 / 16

3.3.3 Right Panel Pack or dryer external (FF)

Pre-punched holes
(push out to assemble the water connection flange)

Compressor frame (right panel) Right panel detail

3.3.4 Right Panel FF (integrated dryer)

Open pre-punched holes

and insert grommet to
protect water flexible pipes

Compressor frame (integrated dryer) Internal panel next to integrated dryer

9828083689 – rev_00 page 8 / 16

4 ASSEMBLING

Safety warning: Follow the “Lock-out Tag-out” procedure (INSTRUCTION MANUAL)

- Make sure that the unit is disconnected from power supply and the compressed air line is securely closed
- Close the ball valve at the outlet of the unit and depressurise.

4.1 Additional thermostat assembling for energy recovery

PARTS:
- 1080 Tee coupling swivel
- 1090 Straight coupling double swivel
- 1100 Nipple reduction hexagonal
- 1110 Seal washer
- 1120 Thermostat Energy Recovery (ER)
- 1140 Elbow coupling swivel

TEE (1080):
- Connect central male port of tee coupling to R1 port of ER thermostat
- Connect the swivel top port to cooler nipple oil outlet.
- Connect bottom male side of tee coupling trough re-used flexible hose (1310) to oil return port of main
thermostatic valve (on oil vessel).

THERMOSTAT ENERGY RECOVERY (1120):

- Connect U port to cooler oil inlet using flexible hose (1130)
- Connect E port to heat exchanger (1180) oil-outlet port using flexible hose (1150).

9828083689 – rev_00 page 9 / 16

4.2 Heat exchanger assembling

- Connect nipples (1160), washers (1170) to heat

exchanger (1180) oil (top) and water (bottom)
ports.

- Assemble heat exchanger (1180) on its support

frame (1020) to the stirrup (1010) using bolt
(1050), washers (1060) and nut (1070).

- Hang the assembly between the cooler and the

right panel, or the internal panel if integrated
dryer machine. Lock it through the screws (1030),
washers (1040) and nuts (1070).

- Assemble water connection flange (1220) to

external right panel using the rivets (1230).

- Connect the oil and water hoses.

- For variant with integrated dryer, use the

grommets (1205 on page 8) when the pipes pass
through the inner panel next to the dryer.

NOTE: Loxeal 58-10 or Loctite 243 can be used

on nipples

4.3 Decals
- Add decals (1240 and 1250) to indicate cold water inlet (top) and heated water outlet (bottom) connections.

9828083689 – rev_00 page 10 / 16

5 Operations

5.1 Start up:

- Switch on power supply.
- Pressurise the compressor and check for leaks.
- Stop the compressor and check the oil level in the vessel.
- Check the type of oil installed on the machine (service label on left panel)
- Top oil level (refer to instruction manual). Approx. two extra liters are required.

6 Techincal information

6.1 Reference conditions

Cooling water inlet temperature 20 ˚C (68 ˚F)
Maximum cooling water outlet temperature 50 ˚C (122˚F)

6.2 Maximum allowed pressure of the heat exchanger:

Oil side 15 bar (217 psi)
Water side 10 bar (145 psi)

6.3 Recoverable energy

The recoverable energy can be calculated from:

RECOVERED ENERGY (kW) = 4.2 x water flow (l/s) x water temperature rise (˚C)

6.3.1 Data for low temperature-rise/high water-flow systems

Unit kW 15 18,5 22 26
HIGH FLOW
(HP) 20 25 30 35
Recoverable kW 13,2 16,3 19,4 22,9
energy kcal/h 11350 14020 16680 19690
l/min 18,9 23,4 27,8 32,8
Water flow
cfm 0,67 0,83 0,98 1,16
Inlet water °C 50 50 50 50
temperature °F 122 122 122 122
Outlet water °C 60 60 60 60
temperature °F 140 140 140 140

6.3.2 Data for high temperature-rise/high water-flow systems

Unit kW 15 18,5 22 26
LOW FLOW
(HP) 20 25 30 35
Recoverable kW 13,2 16,3 19,4 22,9
energy kcal/h 11350 14020 16680 19690
l/min 4,7 5,8 7 8,2
Water flow
cfm 0,17 0,2 0,25 0,29
Inlet water °C 20 20 20 20
temperature °F 68 68 68 68
Outlet water °C 60 60 60 60
temperature °F 140 140 140 140

9828083689 – rev_00 page 11 / 16

6.4 Installation proposal – Functional schema.
- Below an example where the Energy Recovery is used to heat up the water in a boiler.
- The boiler can be replaced by an other heat exchanger, radiator, etc.)

Pump

6.5 Energy recovery system in use (see drawing)

When the compressor is started up from cold, the oil temperature will be low. Bypass valve (BV1) shuts off
the oil supply to the cooling system to prevent the compressor oil from being cooled. Oil flows from the oil
separator vessel through the oil filter back to compressor element.
All energy input is used to rapidly warm up the compressor oil. No energy is recovered.

6.6 Maximum energy recovery

As the oil temperature reaches the set point (opening temperature) of main thermostatic valve, the valve
starts closing off the bypass over the oil cooling system, allowing gradually the oil to flow through the heat
exchanger (oil/water).
As oil temperature rises to approx. 75 ˚C (167 ˚F) , all the oil passes through the cooling system. The
exchange of heat between the compressor oil and the heat recovery water is maximum.
The oil from the heat exchanger outlet flows via oil filter, back to compressor element.
The auxiliary thermostatic valve bypasses the main oil cooler as long as the oil temperature remains below
its set point.
9828083689 – rev_00 page 12 / 16
6.7 Operation principle at different loads:
Low consumption of recovered energy: The temperature of the oil leaving heat exchanger rises. When the
temperature rises above its set point, the aux. thermostatic valve will gradually allow the oil to be cooled in
the main air/oil cooler.

6.8 Recovery water flow too high/temperature too low

In this case, the main thermostatic valve will open the bypass line allowing oil from heat exchanger to be
mixed with oil from separator. Energy is transferred from the compressor oil to the water, but at a relatively
low temperature level

6.9 Energy recovery system not in use

Auxiliary thermostatic valve opens bypass to air/oil heat exchanger. The oil circuit is the same as without
installation of the energy recovery system. No energy is recovered.
This situation should be considered as exceptional, e.g. in case of maintenance of the energy recovery
system or when no energy is required for a long period.

6.10 Stopping the unit for a long period

In case of an open water system and/or if freezing temperatures can be expected, isolate the compressor
water system and blow it through with compressed air.

7 Maintenance

7.1 Oil change:

Resume oil change as described in section Oil and Filter Change in the instruction manual.

7.2 Thermostatic bypass valves

Change the thermostat of the E.R. system at the same interval as the main thermostat of the unit.

7.3 Heat exchanger (HE)

If the temperature rise over the energy recovery system declines over a period with the same basic working
conditions, the heat exchanger should be inspected.

To clean the oil side, soak the heat exchanger in a degreasing solution.
To remove scale formation in the water compartment, a proper descaling process should be applied.
Consult your dealer.

9828083689 – rev_00 page 13 / 16

7.4 Cooling water requirements.
Cooling water needs to fulfill certain requirements in order to avoid problems of scaling, fouling, corrosion
or bacterial growth.

No general recommendation can encompass the effects of all combinations of the various compounds, solids
and gases typically found in cooling water in interaction with different materials. Therefore the
recommendations formulated in our Cooling Water Specifications are a general guide line for acceptable
coolant quality. However, where strict limits apply, a statement is made in the specification.

The water requirements refer to untreated water. When water is treated, some parameters will change.
Water treatments should be carried out by a specialized water treatment company, taking the responsibility
for the performance of the treated cooling water and the compatibility with the materials in the cooling
circuit. This includes not only the selection of the appropriate additives, but also the correct application,
monitoring of concentrations and properties, prevention of sludge formation and maintenance of the system.
This applies also to treatment with antifreeze products. They must be provided with suitable stabilizers and
inhibitors. Specifications are also depending on the type of cooling circuit (open, once through / recirculating
with tower / closed) and on the application (Standard – max 65 °C cooling water temperature at the outlet) or
Energy Recovery (water temperature up to 95 °C).

In case water is not in line with recommended values or if any doubt, consult the manufacturer.

7.4.1 pH
Open circuit: PH shoud be between 6.8 and 9.3
Closed loop: PH shoud be between 7.5 and 9.3

7.4.2 Total dissolved solids (TDS) and conductivity

The conductivity is expressed in μS/cm, the TDS in ppm.
Both parameters are related with each other. The conductivity is convenient for quick monitoring of general
water quality, but the TDS is required for calculating the RSI. If only one of both parameters is measured, an
estimation can be obtained by using a theoretical conversion factor (0.67):
TDS = conductivity x 0.67

7.4.3 Hardness
Different types of hardness are in relation with each other and together with the pH and the alkalinityof the
water they determine the equilibrium situation of the water, determined and specified by the RSI.
In addition, the calcium hardness must be limited to:
Open circuit: <2
Closed loop: <50

9828083689 – rev_00 page 14 / 16

7.4.4 The Ryznar Stability Index (RSI)
The Ryznar Stability Index is a parameter for predicting whether water will tend to dissolve or precipitate
calcium carbonate. The adhesion of scaling depositions and their effect are different on different materials,
but the equilibrium of the water (scaling or corrosive) is only determined by its actual pH value and by the
saturation pH value (pHs). The saturation pH value is determined by the relationship between the calcium
hardness, the total alkalinity, the total solids concentration and the temperature.
The Ryznar Stability Index is calculated as follows:
RSI = 2*pHs - pH,
in which
• pH = measured pH (at room temp) of the water sample
• pHs= pH at saturation
pHs is calculated from:
pHs = (9.3 + A + B) - (C + D),
in which
• A : depends on the total solids concentration
• B : depends on the water temperature at the outlet of the heat exchanger
• C : depends on the calcium hardness (CaCO3)
• D : depends on the HCO3
- concentration or M-alkalinity
The values of A, B, C and D can be found in below table:

Interpretation of the values obtained:

• RSI < 6: boiler scale formation
• 6 < RSI < 7: neutral water
• RSI > 7: corrosive water

As a general rule, the RSI index should be between 5.6 and 7.5. If that is not the case, contact a specialist.
9828083689 – rev_00 page 15 / 16
7.4.5 Free chlorine (Cl2)
Disinfecting with chlorine is not done in closed systems, neither in energy recovery systems.
A continuous level of 0.5 ppm should not be exceeded. For shock treatments, a maximum limit of 2
ppm for maximum 30 minutes/day applies.

7.4.6 Chlorides (Cl-)

Chloride ions will create pitting corrosion on stainless steel. Their concentration should be limited,
depending from the RSI value.

For energy recovery systems: <100 ppm.

7.4.7 Sulphates (SO42-)

For Energy recovery systems: <200 ppm

7.4.8 Iron and Manganese

For Energy recovery systems: <0,05 ppm

7.4.9 Copper
For Energy recovery systems: <0,2 ppm

7.4.10 Ammonium
The limit is <0.5 ppm
The limitation only applies for copper containing systems.

7.4.11 Suspended solids

Large particles (size > 10 μm) should not be present as they can be filtered out.
Small particles (< 0.5 μm) are not taken into account.
For particles between 0.5 μm and 10 μm, the limit is <1 ppm:

7.4.12 Oil or grease

< 1 ppm (rejection value)

7.4.13 Biology
If biology is present, it must be aerobic. Anaerobic biology (in closed systems) must be avoided.
For Energy recovery systems: <103 – 105 (CFU/ml) – (Rejection Limit is in bold)

7.4.14 Additives
If additives are used in the cooling water, take into account that the cooling capacity will change.

Δm = ((Cpw - Cpa) * X) / (Cpw *(1-X) + X*Cpa) * 100 %

With:
Δm: change of mass flow of the coolant
Cpw: specific heat capacity of water
Cpa: specific heat capacity of the additives
X: the percentage of additives

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