Compressor Replacement Spares Blog - Aeroflon Engineers Pvt. Ltd.

Compressor Lubricants and Compressor Lubrication - Part 1

2009-08-13T12:59:00.006+05:30

Compressor Lubricants and Compressor Lubrication

Cylinder and Packing Oil Recommendations

The following matrix shows recommended oil for a given discharge pressure and type of gas. These lubrication recommendations are general guidelines. If the recommended lubricants or flow rates do not appear to work adequately, flow rates and/or lubricant types may need to be changed. Please contact the lubricant supplier for specific lubricant supplier for specific lubricant recommendations.

MATRIX - Cylinder and Packing Oil Recommendations for Various Gas Stream Components

Base Rate Calculations

There are many different ways to calculate the amount of oil that is injected into the cylinders. Most manufacturers historically have used a specific base amount of oil and factored that by the diameter of the cylinder or piston rod. Other components of the calculated lubrication rate may include piston stroke and speed. The total amount of oil has been specified by a total volume of oil or by the number of drops per minute. B far, the more accurate measure for lubrication is the volume of oil.

Drops per minute only provide the correct amount of oil at a specified temperature. If the temperature is colder or hotter, the size of the drop can change dramatically. This may either inject into the system. The smaller drop of hotter lubricant will not provide the same lubrication as the larger drop of colder lubricant.

A total volume of oil such as pints per day is more accurate because it will inject a consistent amount of oil into the system regardless of the temperature. A base rate set by a number of pints per day per inch of bore diameter is one common calculation method to determine the total amount of oil required by that point. The base rate is determined by:

Base Rate (pints per day) x Bore (inches) = Total pints per day at full rated speed

A second calculation is then needed to determine the cycle time for a given divider block and to modify that rate for reduced speed.
Another calculation method injects one pint per day per 2,000,000 ft2 of cylinder surface area.

(Bore x Stroke x rpm) ÷ 31800 = Pints per day

Again, a second calculation is needed to determine the cycle time for a given divider block.
Once the total pints per day are known for each injection point, the proportion of the total is used to determine the size of distribution block needed. Determining the proportions of the blocks needed is done by using ratios of the required rates and then selecting a block that provides the closest match. Usually a range of 90% to 115% will allow for selection of a block.
Finally, once all the blocks are known, the cycle time can be calculated by the following equation.

Cycle Time = (6 x Sum of all blocks) ÷ Total Quantity of Oil

Energy Efficiency in Air Compressors

2009-07-13T13:00:00.005+05:30

Compressed air is a versatile tool used widely throughout industry for a variety of purposes. Unfortunately, running air compressors often uses more energy than any other equipment.

Air compressor efficiency is the ratio of energy input to energy output. Many air compressors may be running at efficiencies as low as 10 percent. Improving compressor efficiency can yield significant savings to your facility.

When talking about the efficiency of air compressors, it is important to remember that the compressor itself is only one part of the system; therefore it is important to look at the whole system when discussing AC efficiency. Compressed air is the product of a system comprised of the air compressor followed by after-coolers, receivers, air dryers, air storage tanks, supply lines and possibly sequencers and multiple compressor units.

The total energy use of a compressor system depends on several factors. The air compressor type, model and size are important factors in the compressor's energy consumption, but the motor power rating, control mechanisms, system design, uses and maintenance are also fundamental in determining the energy consumption of a compressed air system.

SYSTEM DESIGN

Four aspects of system design are crucial to compressor efficiency.

Save for times of need. The first aspect involves choosing a receiver, or storage tank, to fit the needs of the system demand and prevent system pressure from dropping below minimum required pressure during times of peak demand. A drop in pressure will cause end tools to funtion improperly. The common response to the tool malfunction is to increase the system pressure. The energy used in increasing system pressure could have been saved through the use of a properly sized reciever.

Straighten the path. The second aspect of system design is the layout and design of the air delivery system. Narrow delivery lines, looping and sharp bends in the lines can create pressure drops in the system and reduce end use pressure. The common response to this is to increase compressor pressure and use more energy; this could have been avoided through better system design.

Use cooler intake air. A third design aspect that may have a significant impact on air compressor efficiency is the intake air temperature. The energy required to compress cool air is much less than that required to compress warmer air. Reducing the intake temperature by moving the compressor intake outside the building and into a shaded area may drastically lower the energy required for compression.

Single vs. Multiple compressors. In some systems it may be more efficient to use a series of smaller compressors rather than one larger compressor. Additional smaller compressors can be brought on-line, or shut down as needed.

Recover waste heat. Recovered waster heat can be used to preheat process and boiler water, for space heating, and more.

USES

Discourage inapporopriate uses. Because compressing air is one the most expensive sources of mechanical energy in the industrial setting, it is often financially beneficial and more energy efficient to use alternative tools or methods when possible. Some common uses of compressed air that may be accomplished by other means are:

Personal Cooling

Cleaning where dry cleanup would be appropriate

Drying

Mixing, atomizing and aspirating

Process cooling

Moving parts

MAINTENANCE

Fix the leaks. This is the area where the most significant changes can occur. In addition to having a great impact on energy use, improvements here are also often relatively cheap and have immediate results.

The number one source of energy loss in an air compressor system can usually be traced to wasted air. Wasted air is lost through leaks in the system. Although leaks are often very small, significant amounts of air can be lost. The air lost is proportional to the size of the orifice and a function of the air compresor supply pressure. The following graph illustrates the amount of the air lost through differen orifice sizes.

Change the filters. Another important element of the system is filters. Filters are located throughout the system to ensure clean air for end uses. Often these filters are not known of or are simply not checked. Dust, dirt, moisture and grease can clog the filters leading to a pressure drop in the system. This pressure drop is not often seen for what it is and more compression energy is used to compensate for the clogged filters resulting in increased energy use.

Checklist

2009-06-17T13:21:00.004+05:30

Source: Hoerbiger India

Posted by Mitul Choksi

What is CFM?

2009-06-17T13:06:00.004+05:30

CFM

This is the usual unit of measure for discharge air from a compressor
CFM is the acronym for Cubic Feet per Minute. A compressor is said to have so many cubic feet of compressed air per minute (CFM) of flow from it's discharge port.
When it comes to using compressed air in your plant or home workshop you will want to know how many cubic feet per minute you can expect from the discharge port of your compressor to help determine if that compressor has sufficient compressed air flow to power your air tools or other air-consuming applications.
To do that you need to know what CFM a particular device or tool will require to function within it's design parameters. The device or tool will require a certain number of CFM at a specific air pressure, to work properly.

A rule of thumg is that 1 HP generates about 4 CFM at the rate of 90 PSI

This is an industry standard, though it doesn't apply to most compressors under 10 HP. For compressors smaller than 10 HP, you will need to read the specifications for that particular unit to determine their flow and pressure rates or use the "guesstimate" of 2 CFM at 90 PSI per HP of electric motor
When you've sized all of your applications and totalled up all of the air you're going to need now and for the future expansion you may be undertaking in the future, and you are out searching for the right air compressor, you would divide the number of CFM you need by 4, and that will give you a rough idea of the horsepower rating of the compressor required.

Be Careful. Not all compressor manufacturers rate their compressor output the same way. You might see a compressor showing a discharge rate at what appears to be an acceptable CFM, but on closer inspection find that the figure is predicated on a much lower pressure than you might need.

Discharge rates in CFM at higher pressures are always quite a bit lower than discharge rates at lower pressures, for that same compressor.

Ensure that the unit you select will give you both the CFM you need, and the pressure your equipment demands to work properly for you.

Posted by Mitul Choksi

Additional Safety Instructions for Air Compressors

2009-06-05T11:08:00.003+05:30

1. AIR NOZZLE
Never aim an air nozzle directly at yourself or others.
Compressed air can break the skin, or enter the bloodstream
through soft tissue or a cut, and cause a stroke or death.

2. AIR COMPRESSOR STORAGE
DO NOT store the compressor while plugged into power. If a leak develops, the compressor may run continuously, causing overheating and possibly a fire .

3. UNATTENDED TOOLS
DO NOT leave before relieving the tool of air pressure and
disconnecting it from the air hose.

4. AVOID BURNS
DO NOT touch the motor or the air supply pipe,
they will become hot during operation.

5. COMPRESSED AIR USE
Do Not use the compressor for filling breathing or diving tanks.
Compressed air from this compressor cannot be used for pharmaceutical, food or health applications.

6. AIR HOSE
Make sure your air hose has a PSI rating exceeding the
maximum PSI of your compressor, is in good condition, and is long enough to reach your work without stretching. Make sure the air lines and power cord do not come in contact with sharp or abrasive objects.

7. PLASTIC (PVC) PIPE
DO NOT use plastic pipe for high pressure air lines. It could shatter, resulting in serious injury.

8. TANK CORROSION
Drain the tank after each use to prevent corrosion and possible tank rupture. Inspect the tank for unsafe conditions such as rust, pin holes and cracks.NEVER weld or drill holes in an air tank.

9. SAFETY VALVE OR PRESSURE SWITCHES
NEVER adjust safety valve or pressure switch to allow the
compressor to build higher PSI than rated.
Keep safety valve free from paint and other accumulations to
provide safety against over-pressure.

There is danger associated with the use of air compressors. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this air compressor with respect and caution to lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur.

For any further details feel free to contact us

Aeroflon Engineers Pvt. Ltd.
B-505, Premium House,
Opp. Gandhi Gram Railway Station,
Ahmedabad - 380 009 Gujarat (India)

Phone: 079 - 26589712
Fax: 079 - 26586954
Email: info@aeroflon.com / aeroflon@vsnl.com/ aeroflon@gmail.com
Web: http://www.aeroflon.com/
Our Blog: http://blog.aeroflon.com/

Check List & Service Schedule for Air Compressor

2009-05-22T17:02:00.015+05:30

CLICK ON TABLE TO ENLARGE

For further any queries please feel free to contact us..

Aeroflon Engineers Pvt. Ltd.
B-505, Premium House,
Opp. Gandhi Gram Railway Station,
Ahmedabad - 380 009 Gujarat (India)

Phone: 079 - 26589712
Fax: 079 - 26586954
Email: info@aeroflon.com /aeroflon@vsnl.net /aeroflon@gmail.com
Web: http://www.aeroflon.com/
Our Blog: http://blog.aeroflon.com/

Troubleshooting & Solutions

2009-05-06T14:20:00.024+05:30

aeroflon@gmail.com
Web: http://www.aeroflon.com/
Our Blog: http://blog.aeroflon.com/

Trouble shooting & solutions of Air Compressor

2009-04-23T14:42:00.021+05:30

→In reciprocating air compressor, safety devices are most important parts of operating the machine. It should be checked every month.

Oil pressure should be more than 20 PSI [1.2kg/cm²] please check it.
Water pressure [In all water cooled machines] should be more than 2.5 kg/cm² . Check it.
Oil level should be proper as per indicated in gauge class.
Please check the function of low oil & water pressure switch.
Please check the function of Inter stage & receiver safety valve & auto drain valve
Please check the function of motor relay tripping for any overload.
Please check the function of pressure switch for load-unload.
Please check the function of all pressure gauge.
Please check function of NRV.
Please calibrate receiver tank periodically.

Mr. Jagdish Joshi

(Head- Engineering Team )

For further any queries please feel free to contact us .

Aeroflon Engineers Pvt. Ltd.
B-505, Premium House,
Opp. Gandhi Gram Railway Station,
Ahmedabad - 380 009 Gujarat (India)

Phone: 079 - 26589712
Fax: 079 - 26586954
Email: info@aeroflon.com / aeroflon@vsnl.com / aeroflon@gmail.com
Web: http://www.aeroflon.com/
Our Blog: http://blog.aeroflon.com/

Introduction to How Compressor works

2009-04-08T04:46:00.005+05:30

Part-1

CLICK IMAGE TO ENLARGE

A lightweight single-cylinder, oil less compressor shares many features with larger units. The pressure switch controls maximum tank pressure while the regulator sets the pressure to the air hose. The valves are thin metal flaps that open and shut with air pressure and the cooling fins dissipate heat produced by compression.
Years ago, it was common for shops to have a central power source that drove all the tools through a system of belts, wheels and driveshafts. The power was routed around the work space by mechanical means. While the belts and shafts may be gone,

many shops still use a mechanical system to move power around the shop. It's based on the energy stored in air that's under pressure, and the heart of the system is the air compressor.

You'll find air compressors used in a wide range of situations—from corner gas stations to major manufacturing plants. And, more and more, air compressors are finding their way into home workshops, basements and garages. Models sized to handle every job, from inflating pool toys to powering tools such as nail guns, sanders, drills, impact wrenches, staplers and spray guns are now available through local home centers, tool dealers and mail-order catalogs.
The big advantage of air power is that each tool doesn't need its own bulky motor. Instead, a single motor on the compressor converts the electrical energy into kinetic energy. This makes for light, compact, easy-to-handle tools that run quietly and have fewer parts that wear out.

While there are compressors that use rotating impellers to generate air pressure, positive-displacement compressors are more common and include the models used by homeowners, woodworkers, mechanics and contractors. Here, air pressure is increased by reducing the size of the space that contains the air. Most of the compressors you'll run across do this job with a reciprocating piston.
Like a small internal combustion engine, a conventional piston compressor has a crankshaft, a connecting rod and piston, a cylinder and a valve head. The crankshaft is driven by either an electric motor or a gas engine. While there are small models that are comprised of just the pump and motor, most compressors have an air tank to hold a quantity of air within a preset pressure range. The compressed air in the tank drives the air tools, and the motor cycles on and off to automatically maintain pressure in the tank.
At the top of the cylinder, you'll find a valve head that holds the inlet and discharge valves. Both are simply thin metal flaps–one mounted underneath and one mounted on top of the valve plate

As the piston moves down, a vacuum is created above it. This allows outside air at atmospheric pressure to push open the inlet valve and fill the area above the piston. As the piston moves up, the air above it compresses, holds the inlet valve shut and pushes the discharge valve open. The air moves from the discharge port to the tank. With each stroke, more air enters the tank and the pressure rises.
Typical compressors come in 1- or 2-cylinder versions to suit the requirements of the tools they power. On the homeowner/contractor level, most of the 2-cylinder models operate just like single-cylinder versions, except that there are two strokes per revolution instead of one. Some commercial 2-cylinder compressors are 2-stage compressors–one piston pumps air into a second cylinder that further increases pressure.

PART-2

Compressors use a pressure switch to stop the motor when tank pressure reaches a preset limit–about 125 psi for many single-stage models. Most of the time, though, you don't need that much pressure. Therefore, the air line will include a regulator that you set to match the pressure requirements of the tool you're using. A gauge before the regulator monitors tank pressure and a gauge after the regulator monitors air-line pressure. In addition, the tank has a safety valve that opens if the pressure switch malfunctions. The pressure switch may also incorporate an unloader valve that reduces tank pressure when the compressor is turned off.
Many articulated-piston compressors are oil lubricated. That is, they have an oil bath that splash-lubricates the bearings and cylinder walls as the crank rotates. The pistons have rings that help keep the compressed air on top of the piston and keep the lubricating oil away from the air. Rings, though, are not completely effective, so some oil will enter the compressed air in aerosol form.
Having oil in the air isn't necessarily a problem. Many air tools require oiling, and inline oilers are often added to increase a uniform supply to the tool. On the down side, these models require regular oil checks, periodic oil changes and they must be operated on a level surface. Most of all, there are some tools and situations that require oilfree air. Spray painting with oil in the airstream will cause finish problems. And many new woodworking air tools such as nailers and sanders are designed to be oilfree so there's no chance of fouling wood surfaces with oil. While solutions to the airborne oil problem include using an oil separator or filter in the air line, a better idea is to use an oilfree compressor that uses permanently lubricated bearings in place of the oil bath.
A variation on the automotive-type piston compressor is a model that uses a one-piece piston/connecting rod. Because there is no wrist pin, the piston leans from side to side as the eccentric journal on the shaft moves it up and down. A seal around the piston maintains contact with the cylinder walls and prevents air leakage.
Where air requirements are modest, a diaphragm compressor can be effective. In this design, a membrane between the piston and the compression chamber seals off the air and prevents leakage.

A positive displacement compressor compresses air by reducing the size of the space that contains the air. In most cases, this is achieved with a piston. Piston type and lubrication method are two variables that affect compressor design and application.

Compressor power

One of the factors used to designate compressor power is motor horsepower. However, this isn't the best indicator. You really need to know the amount of air the compressor can deliver at a specific pressure.
The rate at which a compressor can deliver a volume of air is noted in cubic feet per minute (cfm). Because atmospheric pressure plays a role in how fast air moves into the cylinder, cfm will vary with atmospheric pressure. It also varies with the temperature and humidity of the air. To set an even playing field, makers calculate standard cubic feet per minute (scfm) as cfm at sea level with 68 degrees F air at 36% relative humidity. Scfm ratings are given at a specific pressure–3.0 scfm at 90 psi, for example. If you reduce pressure, scfm goes up, and vice versa.
You also may run across a rating called displacement cfm. This figure is the product of cylinder displacement and motor rpm. In comparison with scfm, it provides an index of compressor pump efficiency.
The cfm and psi ratings are important because they indicate the tools that a particular compressor can drive. When choosing a compressor, make sure it can supply the amount of air and the pressure that your tools need.

Aeroflon Engineers Pvt. Ltd.
B-505, Premium House,
Opp. Gandhi Gram Railway Station,
Ahmedabad - 380 009 Gujarat (India)

Phone: 079 - 26589712
Fax: 079 - 26586954
Email: info@aeroflon.com /aeroflon@vsnl.com /aeroflon@gmail.com
Web: http://www.aeroflon.com/
blog: http://blog.aeroflon.com/

Introduction

2009-03-04T14:48:00.001+05:30

AEROFLON ENGINEERS PVT. LTD. - An ISO 9001:2000 Company

At our best when things are at their worst..!"

Company Profile

We, Aeroflon Engineers Private Limited are please to introduce ourselves as a manufacturer of replacement spares of reciprocating air compressors.

Aeroflon Engineers Private Limited is a professionally managed company It is one of the few compressor replacement spare providers that has the ISO 9001-2000 certification. This makes the company stand tall in the industry with core competency in marketing and quality and services.

We are please to inform you that Aeroflon is the one and only organization in our country who has been certified as ISO 9001-2000 organization for compressor replacement spares and engineering fabrication work.

We are mainly dealing in following genuine spares of all reciprocating air compressor...

All PTFE (Teflon ®) spares like Piston Rings, Rider Rings , Packing Sets
Piston Assemblies , Crank Shafts and all Valve Spares & Bearings
Ingersoll Rand
CPT (Chicago Pneumatics Tools)
Kirloskar
Khosla
ELGI

All the replacement spares of reciprocating air compressor as well as maintenance is provided in all makes and all model by Aeroflon. We also offer overhauling of compressors which is performed by our team of expert engineers and technicians.

For any further queries or information please feel free to contact us

Aeroflon Engineers Pvt. Ltd.
B-505, Premium House,
Opp. Gandhi Gram Railway Station,
Ahmedabad - 380 009 Gujarat (India)

Phone: 079 - 26589712
Fax: 079 - 26586954
Email: info@aeroflon.com / aeroflon@vsnl.com
Web: http://www.aeroflon.com
Our Blog: http:// blog.aeroflon.com