Air Compressor And Accessories.

Faults And Remedies Of Diesel Engine Coupled With Screw Air Compressor.

noreply@blogger.com (Prasanna) — Tue, 13 Jan 2009 02:54:00 +0000

Below are the some faults which may occur in any diesel engine.The rectification are also given below suggested go through it for better performance of engine.

01) Engine Will Not Start:-

A) Fuel-have at least six inches high in the tank and insure that the air breather is open to avoid air-lock.

B) Engine too cool.Try to warm the engine or wait for improvement in weather conditions.

C) Dirty fuel oil filters.Clean the fuel filter or replace it if necessary.

D) Cranking is too slow,run down battery.Re-charge the battery,tighten loose connections,check key switch and solenoid relay.

E) Minimum speed adjusting screw on engine governor may be screwed out too far.Set it as per requirement.

02) Engine Starts But Stalls As Receiver Pressure Builds Up:-

A) Severe cold weather may make it necessary to open the service valve.

03) Engine Starts And Receiver Pressure Builds But Machine Will Not Slow Down Or Unload:-

A) Check the drain cock on the control unit is closed.

B)Throttle controller pipe leaking or clogged.Clean if clogged and replace/repair if leaking.

04) Engine Function Properly But Compressor Does Not Load Up Or Only Partially Loads Up:-

A) Butterfly Valve Not Open.Take necessary action for free movement of butterfly valve.

B) Air cleaner elements are clogged or dirty.Clean thoroughly or replace.

05) Diesel Engine Shut Down Due To Insufficient Cooling:-

A) Low water level in indicator.Improve the water level by adding water.

B) Radiator clogged.Clean it immediately.

C) Dirt in fins.Blow out air in reverse direction to flow of air.

D) Faulty engine thermostat.Remove the fault as per instructions of manufacturer.

E) Operating pressure is above maximum allowable.Discharge the pressure and keep it in limit.

F) Engine fan belt too loose.Adjust the tension of belts as per requirement.

06) Diesel Engine Shut Down Due To Low Engine Oil Pressure Or No Oil Pressure Shown On Gauge:-

A) Oil level n crankcase of engine is low.Top up as required.

B) Compressor level setting is wrong.Level the compressor.

C) If engine running but no oil pressure shown on gauge,stop engine and check oil pressure gauge on some known pressure.Check oil filter element for clogging.Replace if required.

D) Check engine oil pump and screen.Take rectification action as per requirement.

E) Incorrect engine oil,oil line or oil Pump screen can clog if incorrect oil grade is used.Use proper lubrication oil as per instruction of engine manufacturer.

07) Discharge Air Contains Excessive Lubricating Oil:-

A) Oil line from separator to air-end blocked.Clean choke in return line.

B) If separated oil is returning to intake in the proper way,it is possible that oil separator fiber glass wool discs needs replacement.Check separator shell for leak and rectify,if required.

C) Oil level in air/oil receiver is too high.Correct the oil level as required,up to middle in visual indicator.

08) Engine Speed Low During Start Up:-

A) Battery improper.check electrolyte level and specific gravity and recharge.

B) Loose wiring connection.Inspect and tighten.

09) Compressor Rotates In Reverse Direction When Shutdown With Pressure In The Receiver:-

A) Discharge valve malfunctioning.remove discharge valve.Inspect and rectify.

B) Oil check valve malfunctioning.Dismantle the oil check valve and inspect and repair.

10) Safety Valve Blows:-

A) Controller not functioning.Check control filter,strainer.Clean and adjust rotation per minute.(RPM)

B) Unloader transformer adjusted at higher pressure,adjust to proper pressure setting.

C) Butterfly valve not closing properly.Inspect and take necessary action.

D) Safety valve defective.Inspect and adjust,if necessary replace.Safety valve is to be set at 10% higher pressure than the maximum unloading pressure.

Hope this will help to rectify problems of your diesel engine.

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Governing Of Chicago Pneumatic Electric Screw Air Compressor.

noreply@blogger.com (Prasanna) — Fri, 09 Jan 2009 15:15:00 +0000

The Chicago Pneumatic Electric Screw Air Compressor can be govern by following way.

Description Of Control:-
This is an electro-pneumatic control system which does the following functions,

01) Automatically unloads the compressor after starting.
02) Load/Unload the compressor at preset pressure limits to match the exact demand of compressed air.
03) Blows down the receiver to a lower pressure at unload to save power.

Working Of Control:-
01) Load/Unload Pressure:-
For the purpose of explanation the unloading pressure is taken as 7.1 Kilogram per centimeter square and loading pressure as 6.8 Kilogram per centimeter square.

02) Starting Of Compressor:-
Before starting receiver pressure is zero Kilogram per centimeter square,hence starting cylinder plunger is extended by spring and servo cylinder plunger is retracted and butterfly valve is kept slightly open.

03) Working from zero to 4 Kilogram per centimeter square:-
Starting from receiver pressure zero Kilogram per centimeter square butterfly valve is slightly open,receiver pressure slowly increases to 4 Kilogram per centimeter square.The blow down valve is now closed.during the time motor is started in star and switched to delta,thus starting on no load is achieved.When receiver pressure approaches 4 Kilogram per centimeter square the starting cylinder plunger moves in and butterfly valve open fully,loading the compressor.As minimum pressure valve opens only at 4 Kilogram per centimeter square,the compressor does not deliver air below 4 Kilogram per centimeter square.

04) Working From 4 To 6.8 Kilogram per centimeter square:-
During this range of receiver pressure starting cylinder plunger is fully retracted and at the same time servo cylinder plunger is also retracted keeping butterfly valve fully open,delivering full air.In this condition blow down valve remains closed.

05) Working From 6.8 To 7.0 Kilogram per centimeter square:-
During this range of receiver pressure,the proportional controller P2P sends pressure signal to servo cylinder just closing it partially.

06) Unloading From 7.0 To 7.1 Kilogram per centimeter square:-
When the service line pressure rises above 7.0 Kilogram per centimeter square,pressure switch operates.This causes the solenoid valve to open,permitting receiver air to flow to servo cylinder which then closes the butterfly valve,thus unloading the compressor is done.As,there is no pressure in blow down pilot line it opens,lowering the receiver pressure to 4 Kilogram per centimeter square.

07) Loading The compressor:-
When service line pressure drops to 6.8 Kilogram per centimeter square,the pressure switch operates and the solenoid valve closes.This cut off supply of air directly from receiver to servo cylinder,opens the butterfly valve and puts the compressor on load.now,the blow down valve pilot line gets pressurised and closes.

08) Stopping Of Compressor:-
When the "Off" push button is operated,the motor stops,subsequently the quick exhaust valve relieves the air pressure from the air receiver.

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Preparation And Starting Of New Reciprocating Air Compressor.

noreply@blogger.com (Prasanna) — Thu, 08 Jan 2009 14:50:00 +0000

01) Be certain levelling screw in frame base have been backed off,and foundation bolts are tightened properly.

02) Clean off all accumulated dirt from exterior of compressor and electric motor.

03) Remove covers,tapes,wrapping from openings which had been blanked and sealed.

04) Open frame top cover and check all connecting rods,bolts etc. to see that they are correctly installed and tightened.Check crankshaft end float.
05) Check and clean thoroughly the inside of the frame.Use cloth for cleaning inside.Never use cotton waste on internal parts.

06) Remove silica gel bags if placed in valve ports,do not wipe any carbon and Teflon powder from valve or cylinder.(For Non Lubricated Compressor.)

07) Fill compressor frame with correct grade of oil up to required level.(Middle of the visual screw)

08) Rotate the compressor manually,in direction of rotation and check bearing lubrication as well as free running of crankshaft.

09) Fill oil in force feed lubricator,disconnect oil line near to cylinder and rotate handle.Check oil is coming at the end of lubricating pipe.Reconnect oil line and operate pump at least 20-25 turns.

10) Check each compressor piston rod to be certain it is smooth and rust free,especially for the section where rod is passing through packing and wiper rings.

11) Check the bumping clearance as per recommended.

12) Replace frame inspection cover on the compressor.

13) Check compressor air cleaner and suction lines for dirt and clean,if required.

14) Check all electrical connections for correct tightness.

15) Check the insulation resistance with megger.If any moisture or dirt in the winding indicated,remove it immediately.

16) Remove safety devices and start motor without v-belts.Check the incoming voltage and current drawn by motor.Check electric motor for abnormal noise and vibrations.

17) When satisfied with electric motor,fit v-belts,align motor and adjust belts tension as required.

18) Check strainer/air filter before unloader and insure pressure sensing air line is clean and free from rust,dust etc.

19) Remove all suction and discharge valves and start motor.check oil pressure unusual noise,vibration and safety trippings.

20) Shut down compressor,check all prats for unusual heating.Install all suction and discharge valves.

21) Restart compressor and continue to run until the unit has warmed.Check various temperature and pressure gauges for proper operations.

22) If found every thing in order,put the compressor air discharge net to supply compressed air for plant utilities.

Follow all the above instructions while commissioning every new or overhauled reciprocating air compressor.

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Important Information About Suction And Discharge Valves Used In Reciprocating Air Compressor.

noreply@blogger.com (Prasanna) — Mon, 08 Dec 2008 15:38:00 +0000

The performance of air compressor is mostly depend upon the condition of suction and discharge valves.These valves are very important part in any reciprocating air compressor.That's why due care must be required.Every valve requires a periodic inspection and maintenance.

Here you will find,important information about suction and discharge valves used in Chicago Pneumatic Air Compressor.

01)Dismantling of valves:-
To avoid damage to the valve and inner dowel pins,it is suggested to use a simple fixture for dismantle and assemble valves.Never tightened the valve directly in a vice and do not hammer on spanner when loosening or tightening the nut.

02)Cleaning of valves:-
Examine all the parts thoroughly after dismantled the valve.Remove the carbon formation with the help of Trichlorethlyene or diesel and light scraping paper or brush.Don't scratch the valve plate or seat while cleaning.Completely dry out the valves before installing it on compressor.

03)Inspection and Reconditioning:-
When valve plate,damper plate,spring plate shows sign of wear,it is imperative to replace these parts,even if no breakage has occurred.A maximum wear of about 10 % of the total thickness of valve plate is allowed.For highest efficiency of the valve it is important that the seat face is flat and free from any traces of wear,thus preventing valve leakage.If any damage on the seat observed,it is recommended to replace the same.Dew to presence of dowel pins,re machining or lapping can not be carried out.It is also suggested to use a new valve plate with new valve seat.

04)Reassembly and Installation:-

A)Do the valve assembly in required sequence.(Refer diagram from instruction manual) Use fixture for proper tightening of valve nut.Check valve plate for free movement.

B)Test valves for leakage and insure it made dry after testing.

C)Suction valve equipped with unloader,the clearance between the valve plate and unloader lifter as well as the clearance between unloading piston and lifter is checked.

D)Valve cover nuts have to be tightened with specific torque by torque wrench.

E)The hollow side of the thin part in the centre of the valve plate must be placed upward facing,valve keeper.

The above information will help you to increase life of suction and discharge valve and hence the discharge pressure of the air compressor.

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Details About "M" Type Unloader.

noreply@blogger.com (Prasanna) — Fri, 05 Dec 2008 09:25:00 +0000

Pressure regulation is accomplished by the use of free air unloading.The purpose of such control to unload the air compressor.When more air is being compressed than is being consumed.Thus reducing to a minimum the power required to drive the compressor and providing maximum economy during the unloading period.This control was done by manual operated type unloaders such as "M" type or "W" type unloaders.Actually this is old technology and replaced by "Electro-Pneumatic Controls" which is also replaced by "Program Logic Control".Still many companies are using old technology and therefore,I am giving details about "M" Type Unloader.

* The operation of the unloader is simple and positive.When the pressure in the air discharge line from the compressor to the receiver reaches the pressure point at which the unloader is set to operate,as determined by the position of the adjusting screw,the plate valve is forced away from its seat on the unloader body.When this happens,air from the discharge line from the compressor to the receiver passes through the unloader and to the unloading suction valve covers,holding these valves open.Then the compressor operates against the atmosphere pressure only.

* When the air pressure in the discharge line from the compressor to the receiver is reduced to the predetermined pressure setting of the unloader as determined by the number of unloader shims,then the compression of the spring,over-comes the pressure of the air in the discharge line from the compressor acting against the plate valve,forcing the valve back against its seat on the unloader body.The air trapped in the unloader piping is then vented out to the atmosphere through the vent hole of unloader.

* The pressure at which the unit will unload is determined by the position of the adjusting screw.Turning this screw in,increase the compression pressure on the spring and the unloading pressure of compressor.Turning the screw out,lower the unloading pressure.To decrease the loading-unloading range,add the shims and to increase the range,remove the shims.

* The most important care that the unloader should receive is to be kept clean.If the operation of it becomes sluggish,the operator should first make sure that all unloader piping is free from leakages since leakage from these places will affect the operation of the unloader.Also the vent hole in the unloader valve seat is open.The gauze of the air cleaner in the unloader line should be removed and cleaned.If problem is not solved,remove the unloader valve seat and clean.If the cleaning and adjusting fail to make the unloader operate satisfactorily,the valve may require grinding.

* Use fine grinding compound for valve seat grinding.The valve is provided with two small holes on the top surface for the insertion of the tool to turn it in grinding.Avoid excess grinding since this may change the point of contact sufficiently to affect operation adversely.Clean out all the compound thoroughly after grinding.

* A single "M" Type unloader will work either at 0% or 100% load-unload condition.To achieve 0%,50% and 100% load-unload condition of air compressor two numbers of unloaders are required to be used.This requires in Double Stage Air Compressor.

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5 Important Points About Cooling Water Used In Reciprocating Air Compressor.

noreply@blogger.com (Prasanna) — Wed, 03 Dec 2008 00:51:00 +0000

In water cooled air compressor the quality and quantity of cooling water plays the vital role in performance of machine.A due care must be taken by below points to increase the life and performance of air compressor.

01)a good clean water should be provided for cooling.If the Cooling water has a high percentage of lime sulphur,slit,mud or other water impurities,these will be deposited in the cylinder jackets,head,inter-cooler,after-cooler's tube and shell.The scale deposited unless are removed,will obstruct the flow of water,lower the rate of heat transfer and may result in damage to the air compressor.The cleaning holes are provided in the side of cylinder for cleaning of jackets and cylinder head s.Periodically the cylinder jackets,cylinder heads,inter-cool,after-cooler tubes and inside of the shell should be inspected and cleaned.

02)The cooling water piping connections for the compressor cylinder,inter-cooler and after-cooler should be arranged as shown on the general arrangement drawing and water piping diagram.A main stop valve should be situated in the water pipe,inlet header and flow regulating valve in the supply line to each cylinder,inter-cooler and after-cooler(means parallel water circuit.)

03)It is preferable that the outlet water from each cylinder,inter-cooler and after-cooler should empty into the funnels to facilitate the operator to observe whether the water is flowing or not and also to control the flow of water.The outlet water can be then taken to a underground pit tank and pumped to cooling tower.In case the closed water system is made then a Visible Flow Indicator must be installed n each water outlet pipe.

04)A generous amount of cooling water should be provided to each cylinder,inter-cooler and after-cooler.The flow to each of them should be capable of individual adjustment.The inlet water pressure is recommended to be maintained between minimum 2.5 kilogram/centimeter square and maximum 4 kilogram/centimeter square.The inlet water temperature must not exceed 40 degree centigrade and this should be very strictly taken care off.The water temperature differential between inlet and outlet should not exceed 7 to 8 degree centigrade and should preferably be lower.

05)A leaky tube."O" ring and gasket of inter-cooler or after-cooler or cylinder head can be detected by observing the water flowing into the outlet funnel.A small pin hole will cause air bubble in the water and a larger hole will cause the outlet water spurt.Whenever such a leaky tube is found it should be repaired or replaced without delay.

I hope,now you can take right decision about cooling water,which is circulated in water cooled reciprocating air compressor.

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Which Air Compressor You Can Use In Gas Turbine Power Plant?

noreply@blogger.com (Prasanna) — Mon, 28 Jul 2008 13:14:00 +0000

Gas Turbine is used in Power Plant for driving the Generator,by which we can produce Electricity with other arrangements.Compressed Air plays the vital role in every Gas Turbine Plant.This Compressed Air is obtained from Air Compressor.

Usually Rotary Air Compressor are used with a Gas Turbine.Mostly Centrifugal Compressors or Axial Compressors are used.

Now we will see the details of each Air Compressor.

01)Centrifugal Air Compressor:-

The Impeller which consist of large number of Blades,is mounted on the Compressor Shaft,inside the Stationary Casing.As the Impeller rotates,the Pressure in suction region falls and hence the Air enters through the Eye and flows Radially outwards through Impeller Blades.As a result Velocity and Pressure of Air increases.

Later this Air enters and flows through the Convergent Passages formed by the Diffuser Blades.At this stage the Velocity of Air is decreases but the Pressure increases still further.We may say that,during this stage the Velocity Energy is converted into Pressure Energy.

Finally this High Pressure Air escapes from the Compressor Delivery Portion.This is Single Stage Compression and is suitable for small pressure ratios.You can obtain High Pressure Ratios by arranging the number of Air Compressor in series.

02)Axial Air Compressor:-

This type of Compressors are more commonly used now a days.In Axial Compressor,the Air flows in an Axial Direction right from Intake to the Delivery.

The Working Principle is as illustrated below.

The Stator,which have Stator Blades encloses the Rotor,which are provided with Rotor Blades.As the Air enters from Suction Region,it flows through the alternately arranged Stator and Rotor Blade Rings.

In flowing through each pair of Blade Rings formed up of one Rotor Blade Ring and one Stator Blade Ring,the Air gets Compressed successively.The Air is finally Delivered from Delivery Region,which is smaller in size compare to Suction side.

I have tried to disclose as much as knowledge,I have.You can still search from Internet for more details.

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What is the use of Log Book in Electric Screw Air Compressor?

noreply@blogger.com (Prasanna) — Tue, 15 Jul 2008 02:54:00 +0000

Whenever you carried out any servicing in Screw Air Compressor,it must be note down in Log Book.This will help to all people who are concern with the Machine.

This will work as Record of the Compressor.
Prepare an Operational Diary and keep the Record of Periodical Inspection of Various Parts.This will help to find the Abnormality of the Air Compressor Functioning prior to any Trouble.

In the Log Book,record the Discharge Pressure,Oil Pressure,Discharge Air Temperature,Incoming Voltage,Load and Unload Amperage etc..,as well as Operating Hours along with type of Servicing done and amount of Oil Replenished,which will become a precious record.

For your Reference,typical form of the Log Book is as below.

01)By keeping daily operation records,check the variation of Discharge Temperature.In case the temperature differential between Atmospheric and Discharge Air Temperature is gradually becoming greater,the cause may be,the soiled Oil Cooler or sticked sludge.Clean the Oil Cooler in this case.

02)The reason for the Oil Filter Bowl to become tight is that much Sludge and Rust mixed in the Oil are sticking to the Oil Filter.In this case,Replace the oil and clean the oil filter and Oil Cooler.

03)Take Sample of Lubricating Oil and Check for any abnormal smell.The Compressor Oil has basically no smell.Abnormal odour is due to deterioration of the Oil with Oxidized Substance.Replace the Oil.If the Condition is extremely bad,an Overhaul of Air End may be required.

04)When the Sample of Oil is unclear and whitish in colour,water is mixed in.Replace the Oil and try to keep the lubrication oil constantly in good condition.

05)Check if the Oil is green in colour,if so,replace the oil.

06)As a rule,Oil should be replaced every 1500 working hours.However,replace totally when it is extremely dirty or it contains much of impurities even before 1500 working hours.

07)Take Oil Sample periodically.First sampling should be made at 250 working hours of start of the air Compressor and thereafter,every 500 working hours.During summer or in tropical area,sampling should be made once a month or every 250 working hours of Operation.

You will find all this data,if you record it in Log Book.I hope,this information will help you to increase performance and life of Screw Air Compressor.

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Various Important Valves and its Functions in Electric Screw Air Compressor.

noreply@blogger.com (Prasanna) — Mon, 14 Jul 2008 05:22:00 +0000

For the perfect operation of Screw Air Compressor some valves are fitted inside the Compressor Unit.This Valves has to perform different function as per requirement of the Screw compressor.details about various Valves are as below.

01)Minimum Pressure Valve (MPV):-

The function of Minimum Pressure Valve is to maintain Air Pressure of 4 kilogram per centimeter square in the Air-Oil Receiver.It is of extreme importance that Air Pressure is developed in the Air Receiver as soon as the Compressor is started,since this Air Pressure Circulates the Lubricating Oil to the Compressor unit through the oil cooler,filters,strainers etc.

02)Safety Valve:-

The Safety Valve is adjusted to 10% Higher Pressure than the Maximum Unloading Pressure.This can adjusted by tightening the Pressure Transformer,keeping Delivery Valve open.Start closing the Delivery Valve till Safety Valve Blowing.Note the Air pressure at which Safety valve Blows.

03)Air Discharge Valve:-

This Valve opens when the Air at Discharge Port of Air End is more than Receiver Pressure.This Valve Remains closed during Unloading Condition when Receiver Pressure is more than Pressure at Discharge Port.scavenging air is absorbed through Intake Valve during Unloading Condition to make up for Air Venting out through Unloader Body.Mixture of Oil and Scavenging Air is passed through this Valve during Unloading Condition.

04)Oil Check Valve:-

The function of this Valve is to stop the supply of Oil immediately after stopping the Air Compressor.Hence Oil is not accumulated in Air End during next starting.This Valve remains opens when compressor is running both in Load and unload condition.During Unloading Condition,this Valve opens slightly to supply sufficient Oil to Air End.

05)By Pass Valve:-

This Valve is fitted in Oil Line between Receiver and Oil Cooler.A Thermostat is fitted in By-Pass Valve.When oil temperature is less than 80 Degree Centigrade,Oil Cooler is By-Passed and Oil flows directly from Receiver to Oil Filter.

One Ball Valve is also fitted in Oil Line near By-Pass Valve.If this Valve is closed,Oil will always pass through Oil Cooler.If Thermostat fails to function, the problem can be temporarily solved by closing the Ball Valve.

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How Oil Flows in Electric Screw Air Compressor?

noreply@blogger.com (Prasanna) — Sun, 13 Jul 2008 02:35:00 +0000

In my previous post,you come to know about Air Flow of Screw Air Compressor.The flow of Oil is much more important in any Screw Air Compressor.

The Oil in Screw Air Compressor works as Coolant,Sealant and Lubricant.Therefore it is very important to take due care about oil.

In Screw Air Compressor the Flow of Air and Oil has made combined effect on performance of the Compressor.It will be better to know the circulation of Oil for clear knowledge of screw air compressor.

From below description,you will come to know,How Oil flows and what is the importance of Oil in Screw Air Compressor.

Oil is circulated by the Receiver Air Pressure to various parts of the Compressor where it serves as Lubricant,Coolant and Sealant.Cool Oil is injected directly on to the Rotors limiting the Temperature rise of the Air during Compression and Sealing the Clearance between the Rotor Lobes,Casing and End plates.

In addition Oil is directed to the Bearings and Gears.The Air which is being Compressed mixes with the Oil which is introduced into the compression chambers and forms Mist.This Air-Oil mixture then enters the Receiver.

The Oil flows from the Air-Oil Receiver to Oil Cooler through a By-Pass Thermostat which By-Passes Oil Cooler up to 80 Degree Centigrade.The Oil flows through Strainer,oil check valve, and then to Oil Filter.

Should the Filter become so Clogged with Dirt so as to seriously restrict the flow of Oil,a Relief Valve inside the Filter opens to allow the Oil to By-Pass the Filter Element.The Cooled Oil from the Filter is then piped to Oil Inlet Manifold.

At the Manifold three outlet connections are taken to
A)"Y" type Strainer and Choke to Step-Up Gears.
B)Male and Female Rotors.
C)Bearings.

The Air and Oil Mist passes through Air Discharge Valve to Air-Oil Receiver.The Cycle is thus repeated.

For Detail Working of Electric Screw Air Compressor,you have to read my previous posts.

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How Air Flows in Electric Screw Air Compressor?

noreply@blogger.com (Prasanna) — Sat, 12 Jul 2008 02:42:00 +0000

In my previous post,you come to know about the working of Electric Screw Air Compressor in general.This post will increase your knowledge about the Air Flow in Compressor.

The Air is drawn in by the compressor through a two stage dry type Air Cleaner where the dirt particles are separated from the Air by Filter Elements.

The Air then flows into the Rotor Casing from where it enters the Inter lobe space of the Rotors Axially.The Rotor rotate so that the Inter lobe space opens progressively from Inlet to Outlet.

This phase corresponds with the suction stroke of a Reciprocating Air Compressor.When the Inter lobe space is filled,it is isolated from the Suction Chamber by continued rotation.

The volume of the Inter lobe space is reduced as meshing progresses from Inlet to Outlet.The Air cannot yet escape as long as the Compression continues and also until the tips and the flanks of the lobes have passed the stationary edges arranged at the Discharge End of the Rotor Casing.
During the Compression process,Oil is injected through the lower gusset of the Compressor Casing.

The Oil not only absorbs the Heat produced during the compression but also Seals the gap between the Rotors.

After the passing the stationary edges,the Discharge commences.the Inter lobe space is reduced more and more until its Volume is almost zero at the Delivery End,and subsequently escapes through the Discharge Port.

This process is repeated in each following Inter lobe space of the two Rotors,and practically continuous and even the Air flow is produced by the rapid succession of the various Discharge Phases.

The Air-Oil mixture leaving the Compression Chamber through Air Discharge Valve is directed to an Air-Oil Receiver where most of the oil is separated from the Air.

The Air still containing Oil passes from the Air-Oil Receiver through an Oil Separator in which the Oil Mist is removed and then it passes to Outlet Service valve through Minimum Pressure Valve.

The Oil flow in electric Screw Air Compressor is also important as above Air flow.

How Oil will Flow in Screw Air Compressor? Wait for next post.

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How Electric Screw Air Compressor Works?

noreply@blogger.com (Prasanna) — Fri, 11 Jul 2008 03:15:00 +0000

Every Manufacturing Plant requires Compressed Air to perform various operations.This Compressed Air can be obtained by Air Compressor.

Air Compressor are classified by various types.The most useful and important Air Compressor,are those,who gives you Trouble Free operation during working conditions.

To avoid various faults occurs during working of Air Compressor,you must know the working principle of the Machine.Reciprocating Air Compressor are easy to understand than screw air compressor.

In this post I will cover the working of Electric Screw Air Compressor.

As the name indicates,this type of Screw Air Compressor are driven by Electric Motor.These are modified stage of Rotary Air Compressor.

The Rotary Screw Air Compressor is a Single Stage,Oil Flooded,Rotary Screw Compressor driven by Electric Motor through a Coupling.
The Compressor Casing accommodates a pair of Male and Female Helical Rotors,machined with highest precision and mounted on Rolling Element Bearings.

The Male Rotor has four Helical Lobes which mesh with six Flutes of the Female Rotor.The speed of Male Rotor is 1.5 times higher than Female Rotor.

The Male Rotor is driven by Coupling through Step-Up Gears.The Male Rotor Lobes rotate into the Female Rotor Flutes,the air is trapped in the Interlobe Spaces and smoothly Compressed until the Lobe-Flutes reach the outlet port.

Pulsation free air is delivered by Screw Air Compressor,due to continuous Compression takes place in all the Lobe-Flute spaces.

The oil injected through the lower gusset of the Air Compressor Casing mixes with the indrawn Air and ensures an efficient Sealing between the Rotors and the Casing and at the same time,giving an intensive Cooling during the compression process.

Huge quantity of Lubrication Oil cools the Compressed Air,therefore Inter coolers are not necessary in Screw Air Compressor.The Oil,which Lubricates the Compressor,Seals the clearance spaces.

In Air Cooled Models,the Oil is cooled in Oil Cooler by separate Fan motor whereas it is cooled by water,in Water Cooled Models.

You will find,how air and oil flow in Electric Screw Air compressor in coming posts.

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15 Useful Tips to obtain best result from Electric Screw Air Compressor.
How Oil Flows in Electric Screw Air Compressor?
How Air Flows in Electric Screw Air Compressor?

15 Useful Tips to obtain best result from Electric Screw Air Compressor.

noreply@blogger.com (Prasanna) — Thu, 10 Jul 2008 15:13:00 +0000

Air Compressor is the most important Plant Utility Machine.Compressed Air is used to perform various operations in any Manufacturing Plant.

As Air Compressor is an important Machine to run the Plant smoothly,we have to take due care for Trouble Free running of compressor.

Mostly Reciprocating Air Compressor and Screw Air Compressor are used to obtained Compressed Air.With compare to Reciprocating Air Compressor,Screw Air Compressor requires more daily attention towards problem free operations.

If you follow all the below Guidelines,I am confident,your Electric Screw Air Compressor will give you best result year after years.

01)Read the Instruction Manual provided by Air Compressor Manufacturer carefully and follow the Instructions given.

02)Ensure that the Screw Air Compressor unit is mounted on a firm and level surface.

03)Use only Compressor Manufacturer recommended lubrication oil in Screw Compressor.Best way,request Manufacturer to supply the recommended grade of oil.

04)Maintain the Lubricating Oil between the Low Level and High Level marks on the Oil Level Gauge or Dipstick.Recommended to maintain Oil Level near to high level.

05)If the Oil Pressure Gauge fails to register Oil Pressure,stop the Screw Air Compressor immediately.Rectify the fault before starting the Compressor.

06)Check the tightness of all Nut and Bolts at regular intervals.

07)Do not open the Oil Filter Cap before relieving Air Pressure from Receiver.

08)Keep the Air suction Filter clean.Replace it after regular intervals as recommended by Compressor Manufacturer.This is the most important part of Screw Air Compressor.

09)Servicing of the Air Cleaner is of great importance in prolonging the life of Screw Air Compressor.

10)Never run the Compressor without an Air Filter.

11)Do not operate Screw Compressor beyond 110 Degree Centigrade Air Discharge temperature.Investigate and rectify the cause of High Discharge Air Temperature,if any.

12)Do not restart Compressor unit,until the Pressure in Receiver has fallen to Zero.

13)Do not disturb Safety valve Setting.

14)Preventive Maintains of Electric Motor and Starter to be carried out at regular intervals.This will increase life of Screw Air Compressor.

15)Maintain the general cleanliness of the Electric Screw Air Compressor unit.

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Different Lubrication Devices and its uses in Air Compressor.
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Salient Features of Chicago Pneumatics Reciprocating Air Compressor.

noreply@blogger.com (Prasanna) — Wed, 09 Jul 2008 02:43:00 +0000

01)Vibration Free Running:-

The Symmetrical Reciprocating action,balanced compression ratio in each stage and equal Weight of the moving parts keep the Inertia Force of the Reciprocating Masses in perfect equilibrium,hence Air Compressor runs vibration free.

02)Less Foundation:-

The Air Compressor is smaller in size due to high speed and lesser in weight.The weight of the compressor itself being reduced by 30 to 35% as compared to other models,it offers very easy installation.The arrangement of the Inter-Cooler and After-Cooler effectively reduces the floor space.

03)Easy Accessibility:-

Besides being the Horizontal Type with the cylinder at floor level,the height of the Air Compressor ensures accessibility to all the parts and facilitate the Supervision and Maintenance easy approach of Cylinder Valves makes it very simple for its Maintenance.

04)High Thermal Efficiency:-

The Air Compressor Efficiency is enhanced added to the fact of Accurately Machined Parts,Symmetrically Arranged Valves,Water Cooled Cylinder with adequate water jackets for optimum heat dissipation and efficient cooler.the power consumption is considerably low.

05)Maximum Reliability:-

The accurate selection of Material,its Heat Treatment and the accurate machining of the components gives reliability to the operation of the Air Compressor.All essential sections are designed adequately to make the structure rigid and undergoes the strict tests of quality acceptances tests.

06)Easy Installation:-

Since both the Stages,High Pressure and Low Pressure are mounted on the Frame and each section is minimum in size and weight,the Installation of unit can be done in very quick time.

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How to storage Air Compressor waiting to be Installed.
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How CrankCase Lubrication is completed in Chicago Pneumatic Air Compressor?

noreply@blogger.com (Prasanna) — Tue, 08 Jul 2008 03:11:00 +0000

Every Air Compressor has some rubbing parts which needs lubrication.The most Metallic Parts are fitted in Running Gear which is also known as crank case parts.These parts are mostly Lubricated by Lubrication Oil through Oil pump and Tubes.

A Oil Pump is used to Pump-Up and increase Oil Pressure which we filled in Crankcase Sump.

A Positive Displacement Rotary Pump directly driven by the crankshaft through a Oil Pump Drive Shaft.Oil from the Frame Sump is drawn by the Oil Pump through a fine perforated sheet strainer.

The Oil Pump discharge is taken to Cartridge Paper type Oil Filter and the Filtered Oil through the Copper pipes is led to each Main Bearings,Drive End and Non-Drive End.

The oil from Main Journals of the Crankshaft flows to Crank Pins through the rifle drilling holes and also from Crank Pins to Small End Pins through rifle drilled hole in Connecting Rod.

Facing Belt wheel,having Clockwise direction of Rotation,the left hand Cross Slide which is fitted towards First Stage or Low Pressure Stage is Pressure Lubricated.

A Copper Tube Connection is taken through a Tee Connection in Main Oil Line and connected to a Choke which is fitted on the top face side of the Cross Slide.

The lubrication oil through the Choke flows to the centre of the Cross Slide to top of the Cross Head.

The Cross Slide and Cross Head fitted towards Second Stage or High Pressure Stage is Splash Lubricated in case of HX Models.Since the direction of rotation is clockwise when viewed facing the Belt wheel,the splashed oil from the Second Stage Connecting Rod Bearing falls on the top of the Cross Slide.

The top of the Cross Slide is specially built with all around small dam in which the Splashed Oil accumulates and through the drilled hole,falls on top of Cross Head for Lubrication.

In case of HN Model,which has higher capacity than HX Models,the Second Stage Cross Head is Lubricated through Choke.

You may also interested in following.................
How you can remove Cylinder from Reciprocating Air Compressor?
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Some important points about lubrication oil.

Imporatance of Lubrication in Reciprocating Air Compressor.

noreply@blogger.com (Prasanna) — Mon, 07 Jul 2008 06:46:00 +0000

The life of Air Compressor almost depends upon the effectiveness of lubrication and therefore the selection of proper Lubricants must be considered while operating the Machine.

High Quality Industrial Oil must be used for Lubrication of Air Compressor,as experience has shown that it is poor economy to use a cheap oil.

Normally a good quality Non-Detergent Mineral Oil should be used.The Sludge and Other Impurities in the Oil will cause the Oil Strainer to clog,resulting in Lubrication starvation to Bearings.

The ENKLO-220 or SERVO PRESS-220 Grade Oil is best for Frame Lubrication of Reciprocating Air Compressor.

For purpose of Frame Lubrication in Chicago Pneumatic Air Compressor a Oil Pump is used.

The Details about Oil Pump and Pressure is as below.

A Gear type Positive Displacement type Oil Pump is employed.It is therefore absolutely essential that the correct direction of rotation of the Belt Wheel is maintained as per arrow marked on non drive end Bearing Housing.

In case the Air Compressor is run in incorrect direction,the Oil Pump will not pump the Oil,resulting in Seizure and Damage.

The Oil Pressure Regulating valve is housed in the Oil Pump Body and therefore Low Oil Pressure Switch is fitted.The Oil Pressure adjusting screw be turned clockwise to increase the Oil Pressure.

The Oil Pump and Oil Pressure Regulating Valve can be approached by removing front door cover in case of Non-Lubricated Air Compressor.
You have to remove Force Feed Lubricator along with front door cover in case of Lubricated Air Compressor,to reach Oil Pump and Oil Pressure Regulating Valve.

In case the Air Compressor has undergone recent Overhaul or prolonged Storage then it is essential to rotate Belt Wheel several turns to ensure that the Bearings are flooded with Oil.

The Oil Pressure Gauge connection is tapped through drilling in the Frame from the last Bearing on the drive end.

You are suggested to stop the Air Compressor immediately,if Oil Pressure Gauge fails to show the Oil Pressure.Rectify the Fault before starting Compressor.

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Avoid Breakdown of Air Compressor due to Low Water Flow.
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How you can remove Cylinder from Reciprocating Air Compressor?

noreply@blogger.com (Prasanna) — Tue, 01 Jul 2008 01:39:00 +0000

As you know,cylinder is the most important part of any Air Compressor.You can produce Compressed Air with the help of piston assy. in Compressor Cylinder.
In Double Stage Reciprocating Air Compressor,Low Pressure and High Pressure Cylinders by their stages,removal procedure is same for both Cylinder.

Actually,Cylinder is that part of Air Compressor which don't required to be removed for long time or never.Due to some reasons as like Breakdown in Cylinder or cleaning of Inner Head,Cylinder required to be Disassemble from Compressor Unit.

This don't required too much Technical Knowledge but you have to follow some procedure for Disassembling the Cylinder.

The general instructions given in this post for Disassembly and Reassembly of Compressor Cylinder and Valves applies to all stages.

The Important Procedure to be followed for Disassemble the Compressor Cylinder.

01)Close Cooling Water Inlet and Outlet Valves.Drain water from the Cylinder and remove water & oil, and processes piping as required.

02)Close Discharge Air Service Valve and Unloading Air Valve.Remove all Air from Air receiver,if Compressor has separate Air Receiver.

03)Remove Inter-Cooler and After-Cooler,if fitted.

04)Remove Suction Filter and Discharge Pipe,if Compressor has only one Cylinder.If you have to remove High Pressure Cylinder,remove only Discharge Pipe and if you have to remove Low Pressure Cylinder,remove suction filter only,if the Compressor is Double Stage.

05)Mark Suction and Discharge side on Cylinder and remove all Suction and Discharge Valves.

06)Remove Nut and Bolts from Outer Head and remove Outer Head from Cylinder.

07)Loosen Cross head Nut and turn compressor piston rod out of the Cross head and remove the Nut from the Rod.

08)Push Piston from Cylinder with block between Cross head and Piston Rod.Remove Piston Assy. out of cylinder with the help of two or three person, as applicable

09)Remove Nut and Bolts of Inner head or Frame End.Remove Compressor Cylinder from unit along with Inner head.

10)Remove Inner head from Cylinder.

This way you can Disassemble the Compressor Cylinder for purpose of Re-Conditioning or Rectification of Faults.

Use Overhead Crane or Chain Pulley Block for removal and lifting heavy parts,don't take chances.

Reassembly of the Compressor Cylinder can be accomplished by reversing the procedure of Disassembly.

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Different Lubrication Devices and its uses in Air Compressor.

noreply@blogger.com (Prasanna) — Mon, 30 Jun 2008 04:23:00 +0000

Any moving parts must required some sort of lubrication to reduce Friction between the Moving Parts.In Air Compressor Oil is used as Lubrication Media,to lubricate the Crank Case parts and Air Cylinders.

The quality of Lubrication will depends upon the various Devices which are used in Lubrication System.I will cover some in this post.

A)Lube Oil Cooler:-

This Oil Coolers are of Shell and Tube type.The water is used as Cooling medium,which is circulated through the tubes,while the Lubrication Oil forced through the Shell side of the Oil Cooler.

You should have to remove Headers to inspect the tube or water side of the Oil Cooler.Dirt and Foreign matter can be removed either by Chemical cleaning or brush.The Shell of Oil Cooler should be cleaned in Trichlonthylen Bath and Flushed with Clean Air.

B)Lube Oil Strainer:-

This is located on the Lube Oil Suction Pipe in the Crankcase Sump.A build-up of Foreign matter or Dirt around the Strainer will cause a drop in Oil Pressure,that's why Strainer must be kept clean at all times.
This Strainer must be cleaned at every Oil change in Sump.To clean,unscrewing it from Lube Oil suction Line and then wash it in Solvent.

C)Oil Filter Element:-

The Oil Filter used in Air Compressor Lubrication System is of Cartridge Type.It is use and throw-away type Oil Filter.It should be replaced each time,the Oil is changed in Air Compressor.
While fitting the Lube Oil Filter Element,fill it fully before Screwing it to the Filter Body.

Follow all the Instructions which are printed on the Filter Element at the time of Replacing.

Some other Devices Such as Oil Pump,Forced Feed Lubricator etc. will be cover in another posts.

Method of V-Belt Tensioning in Reciprocating Air Compressor.

noreply@blogger.com (Prasanna) — Sun, 29 Jun 2008 01:06:00 +0000

The method of V-Belt tensioning may be same for all Belt Driven Air Compressors but I will cover the most useful method for Air Compressor which have a Capacity of 100 C.F.M. and above.

Installation of V-Belts.

In Assembling the Drive,the Electric Motor or Prime Mover should be moved towards the Air Compressor Belt wheel.By this way you can put the V-Belts in their respective Grooves by hands.The allowance must be available for adjustment of Centre Distance.

Under no circumstances should V-Belts be forced on to the Pulley with Crowbars,Wedges,Screw Driver or any other type of implement.Such procedure would tend to cause rupture to outside jacket or inside cords.
It is possible for the inside load carrying cords to be broken by forcing over the Grooves,such V-belt will fail completely during the first few hours of running of Air compressor.

When V-belts have been placed on Belt Wheel and Pulley Grooves,the Electric Motor or Prime Mover should then be,moved away from the Compressor,until to apply uniform tension to the V-Belts.

Methods of V-Belt Tensioning.

01)Multiply the Centre Distance in between the compressor Belt Wheel and Electric Motor Pulley (in Meter) by 16 to obtain the Deflection Distance in mm.

02)Set the Lower Marking Ring at the Deflection Distance required in mm on the Lower Scale of Belt Tension Indicator.

03)Set the Upper Marker Ring against the bottom edge of the top tube.

04)Place the Belt Tension Indicator on top of the Belt at the Centre of Spam,and apply a Force at Right Angle to the Belt Deflecting it to the point where the Lower marker Ring is level with the top of the adjacent by the top edge.

05)Read off the Force Value indicated by the top edge of the Upper Marking Ring.

06)Compare this Force Value to the Kgf Value in the Standard Table which is provided with Belt Tension Indicator.If the measure Force falls within the Value given the Drive should be satisfactory.

07)A Measured Force below the Lower Value indicates under Tensioning.

08)A new Drive should be tensioned to the Higher Value to allow for the normal drop in Tension during the running period of Air Compressor.

09)Run the Compressor under Load for 30 minutes,stop the Compressor,check the Tension,re-setting to the required value,if necessary.

10)After the Air Compressor has been running for few days the V-Belts will have seated in the Grooves and the V-belts Tension should be rechecked. Make adequate provision for tensioning the Belts during the Life.

How to storage Air Compressor waiting to be Installed.

noreply@blogger.com (Prasanna) — Sat, 28 Jun 2008 03:20:00 +0000

Any Air Compressor,which is not in service,whether it is Installed or not,the unpainted compressor surface are subjected to Rust and Corrosion.

Actually Air Compressor is not a machine to keep in store but due to some reasons it requires to be storage for some time.

If this occurs to you,you have to take care of that Air Compressor up to Commissioning.However every Compressor going out of factory is always processed with Rust Preventive Oil.This Rust Preventive Oil will work better up to one months.What after that period?

The Rate of Corrosion varies with Climatic Conditions.Variance in Climatic Condition makes it impossible to state the length of time,any Air Compressor can be stored without Rust and Corrosion damage.

Basic Method of preparing the Air Compressor for long period.

01)Clean Crankcase from inside with help of cloth.

02)Fill H.P.Rustop-286 or any other Anti-Corrosive oil in Crankcase and rotate Compressor Belt Wheel for several times.This will ensure the circulation of Anti-Corrosive Oil to all moving parts,Cross-Slide and Guide.

03)Clean Low Pressure and High Pressure cylinder and spray sufficient quantity of H.P.Rustop-286 and rotate Air Compressor several revolutions.

04)Place SillicaGel bags in valve Ports and Refit Valve Covers if the Air Compressor is Non-Lubricated type.

05)Drain water from Cylinder Jackets,Inter-Cooler and After-Cooler and thoroughly flush with clean water with H.P.Radiator Cleaner.Refilled the system with10:1 mixture of Water and H.P.Radiator Cleaner and keep it for 4 to 5 days.Remove it after the said period.In cold condition,where Water Freezing may occur,in that case drain the mixture immediately.

06)Drain H.P.Rustop-286 or any other Anti-Corrosive Oil from Frame and Force Feed Lubricator.

07)If V-Belts are fitted,remove these completely.

08)Apply sufficient quantity of Preservative Grease on piston Rod.

09)Plug and seal all openings thoroughly so as the Moist-Air and Dirt do not enter inside.

10)Store Air Compressor in Dry place under shade.

If you are really interested to store your Air Compressor very safely for long period,follow all the above guidelines.

How should be the Discharge Pipeline of your Air Compressor?

noreply@blogger.com (Prasanna) — Fri, 27 Jun 2008 11:32:00 +0000

In my earlier post you come to know about Important Guidelines for Air Intake Piping of Air Compressor.It is also important to be a best designed Air Discharge Pipeline for Air Compressor Operations.

A faulty Discharge Pipeline may produce extra Stress and Strain on Compressor Valves.So,below are few points must be taken into consideration while Designing the Discharge Pipeline.

01)The Discharge Pipeline should connected as Direct as possible to the middle or lower part of the Receiver.

02)It should be the same size as shown on the General Arrangement and should have few turns as possible.

03)It is advisable to design Discharge Pipe system to prevent Resonance and excessive Pulsations.

04)The Discharge Pipeline must be supported at frequent distance.

05)In order to avoid Stresses,the Discharge Pipe System must be free from expansion.

06)It is good practise to increase the Pipe by one size for every 100 feet length from Air Compressor Discharge.

07)It is essential that the Pipe size should be sized to prevent excessive pressure Drop to avoid Power Loss.

08)Use long Radius Elbows to reduce Air Friction.It is suggested to make all pipes as direct and short as possible.

09)Never place a Shut-off valve in Discharge line between Receiver and the Compressor unless a Safety Valve is inserted between the Valve and the compressor.

10)Place a Shut-off Valve in each Discharge line near to cylinder Discharge,if two or more Air Compressors are connected to the same System.

You can add to the list,if you know something about the subject.

Important Guidelines for Air Intake Piping of Air Compressor.

noreply@blogger.com (Prasanna) — Wed, 25 Jun 2008 16:08:00 +0000

In any Air Compressor,the performance of the Compressor is mostly depends upon the quality of Air which has been sucked by Air Suction Filter Element. The Air Compressor will give best result when a clean air has entered inside the Cylinder.

As it is imperative that the air sucked by Air Compressor should be clean,dry and cool so it is advisable to fit an Air Intake Pipe to be taken towards clean atmosphere and then mount the Air Suction Filter.

Below are the few Important Guidelines for Air Intake Piping.

01)The Air Intake Pipe should not be locate in the vicinity of any Delivery Pipe Line which is normally hot.It is advisable that the Compressor should sucks Air as cold as possible.

02)The Air Intake Pipe System should be sized so as to give a Low Pressure Drop.

03)The Velocity of Air through the Intake Pipe Line should be about 400 meter per minute.

04)Avoid unusually long pipe line as it will increase the Resistance to Flow of Air and increase Pressure Drop,thereby resulting in loss of Air Compressor Capacity.

05)It is advisable to use Large Radius Bends which gives Minimum Resistance to Air Flow.

06)Air Intake Pipe should be painted with a Rust-Preventive from inside to avoid any Rust or Foreign Particles to be sucked inside the cylinder.

07)At certain critical lengths of intake Pipe Resonance may occur,it is imperative therefore to correctly design the Intake pipe.Specially consider pipe Length and Diameter to eliminate Resonance.

08)The Air Intake Pipe should be properly supported so that it does not transmit any undue load to the Compressor.

09)To avoid the Vibrations,which may Transmitted to the wall and building ,Intake pipe must not be rigidly attached to walls or ceilings.

10)It is advisable to have independent Air Intake Pipe Lines for each Air Compressor.

You can add to the list,if you know something about the subject.

Some important points about lubrication oil.

noreply@blogger.com (Prasanna) — Thu, 29 May 2008 09:26:00 +0000

In Lubricated or non-lubricated Air Compressor lubrication of crankcase parts such as Main Bearings,Connecting Rod Bearings,Cross slide etc. are done by lubrication oil with the use of Oil Pump,Strainer,Oil filter etc.

Oil is the important media of lubrication in any Air Compressor so,due care must be taken about lubrication oil and its level.

In many Air Compressor two numbers of Visual Screw (Indicators) are provided.Lower Indicator indicates lower level while upper indicator indicates full level.

Now a days only one oil level indicators are provided,in which we have to maintain oil level up to Red Mark or at half level.This much oil in crankcase is more than sufficient.

Some Important points to remember about Lubrication Oil.

01)Never mix two different Brands of oil.If you want to use other Brand of oil,drain existing oil completely and cleaned frame thoroughly before filling other brand of oil.

02)Maintain correct oil level.Low oil level will cause foamimg due to mixture of air and oil.Higher oil level will cause excessive high oil temperature.The normal working oil temperature will be 70 degree Centigrade.

03)It is necessary to drain periodically condensed water,sludge and other impurities accumulated at the bottom of the crankcase,before making up the required level of oil.

04)Replace crankcase oil after 50 working hours when Air Compressor is newly commissioned.It is not practical to state definitely how often the frame oil should be changed because operating conditions vary from site to site.However,it is recommended to replace frame oil after every 3000 working hours or every six months,whichever is earlier.

05)Always keep close watch on oil pressure shown in oil pressure gauge.Any indication of low oil pressure must be investigated and rectified at earliest.Oil filter must be replaced after every 1500 working hours or after every 3 months.

How to Start and Stop Air Compressor.

noreply@blogger.com (Prasanna) — Wed, 28 May 2008 08:16:00 +0000

Air Compressor will give the best performance when it is operated by due care taken.Every machine has its own requirement of starting and stopping.This is the machine which may run for several weeks without stopping or some times required to keep idle for many days or week.Every operator must have to know the routine stating and stopping of Air Compressor,to obtain best result from the machine.Here i will cover most of them,follow it.

Routine Starting of Air Compressor.
01)Keep Air Compressor at Unload condition by use of Unloaders.
02)Turn on cooling water to remove air lock from water cooling system.
03)Ensure belt wheel is free to rotate by rotating it by hand,for several rotations.
04)If force feed lubricator if fitted,check oil level and operate it for 8-10 turns.
05)Check position of safety shut down switches.
06)Drain Condensate from Inter cooler & After cooler.
07)Check V-belt tightness.
08)Check position of stop valve,open it,to flow compressed air to receiver. 09)Start Air compressor.
10)Check oil pressure.
11)Check oil flow from each lubricator Pump.
12)Load Air Compressor after 3 to 5 minutes of operation.
13)Regulate water flow to cylinder,inter cooler and after cooler.
14)Check Inter stage Pressure.
15)Check for leaks in Air,Water and oil lines.
16)Check Voltage available to each terminals and current drawn by the motor.
17)Check Discharge air temperature.
18)Drain condensed water from Air Receiver,Pulsation bottles and moisture separators.
19)Check for loose nut and bolts,tighten if required.
20)Check for unusual noises.

Procedure for stopping the Air Compressor.
01)Unload Air compressor by using unloader and allow compressor to run for 5 minutes.
02)Stop Electric Motor.
03)Shut off Cooling water
04)Drain condensed water from collection points.
05)Discontinue Power supply to starter.

If any one follow above precautions,there Air Compressor will give best performance for long period.

Important precautions for Unlubricated Cylinders fitted with Air Compressor.

noreply@blogger.com (Prasanna) — Sat, 24 May 2008 06:26:00 +0000

Air compressors are mainly lubricated or non-lubricated types.This is defined by the lubrication of the Air Cylinder fitted with Air Compressor.In many industries clean,oil free compressed air is the main requirement for product production.

In old days lubricated Air Compressor vastly used due to efficiency reasons,but in pharmaceutical industries oil free compressed air is the standard requirement.This can be achieved by non-lubricated Air Cylinder.

As there is no lubrication to Air Cylinder,some particular care must be taken for Air Compressor fitted with non-lubricated cylinders than lubricated cylinders.Corrosion formation on non-stainless steel elements requires thorough investigation.As compressor works,some condensation are formed.

The lack of an oil film on the non-lubricated Air Cylinder walls are subjected to severe corrosion caused by condensation.

You may face some problems due to corrosion in cylinder walls while using the compressor.The first drawback is wear-out ratio of piston rings are high.Therefore the cylinder walls must be protected against corrosion and the cause of condensation must be eliminated.We should not neglect condensation.

You may not observe problem in running condition,but when Air Compressor is idle for long time,corrosion will create severe problem.To avoid this some care must be taken before stopping the compressor.

Precautions to be taken before stopping the Air Compressor.(Fitted with non-lubricated cylinder)

01)It is recommended that water safety device must be fitted but due to any reason,when there is no water safety device fitted,stop the water supply a few minutes before stopping the Air Compressor and allow the compressor to run unloaded.This allows the condensation to drain.

02)Do not keep Air Compressor idle for long time,it should be run for at least half an hour every week.

03)Unloading piston in suction valve cover be cleaned at least once in a month.Apply slight grease or silicon to avoid sticking.

04)The Air Cleaner Element must be kept clean at all times,clean it every 500 working hours from inside out.

You are suggested to add in this list,if you know something about this.