PPT ON INSTRUMENT AIR COMPRESSOR

(SCREW TYPE )

11.12.2017

SEMINAR PRESENTED BY
B.NASAR BABU, M.TECH
I & C ENGINEER
ENMAS O & M SERVICES
SITE: SMIORE,HOSPET
32 MW CP
 COMPRESSOR‘S SPECIFICATIONS
IAC SAC

MAKE: ELGI ELGI

MODEL: E 55-9 E 90-5.5
CAPACITY: 10.05 M3/MIN 17.22 M3/MIN
RATED PR: 8.13 KG/CM2 4.59 KG/CM2
 AIR INTAKE SYSTEM
 The filter prevents foreign particles like dust from entering the
air end. the air inlet valve controls the amount of air taken into
the air end. the indicator on the filter turns red when the filter is
to be cleaned or replaced.
 Normally ,when compressed air is being delivered in the
service line, the intake valve is open. when very little or no air
is being supplied, the intake valve is closed.
LOADING & BLOW DOWN VALVE
AIR END
 AIR END
➢ Heart of the compressor is air end, driven by an electric motor.
there are two counter rotating inter-meshed helical screw
elements in the air end, the male rotor and the female rotor
➢ The rotors mesh with each other as they turn .air is trapped
between the flutes and lobes of the rotor, getting progressively
compressed as the rotors turn. the compressed air flows out
towards the discharge port.
➢ Oil is injected in large quantities into the air .it act as a coolant,
remove the heat of compression and lubricates the rotors and
the bearings and gears. the oil is separated from discharge
stream, cooled, filtered and recycled.
⚫ Minimum pressure / check valve (standstill)
⚫ Minimum pressure / check valve (full load)

min. 4 ... 4,5 bar

⚫ Minimum pressure / check valve (unloaded)
 COOLING & LUBRICATION SYSTEM
 The oil separated from the air-oil mixture is cooled in the
oil cooler.
 A thermal switch controls the flow of oil to the cooler,
depending on the temperature of the oil the cooler is
bypassed by the oil if the temp is low enough. Such as in
the initial flow when the compressor is started .
 The oil is passed through an oil filter which removes
dust and other impurities before it is returned to the tank.
The oil circulation circuit is operated solely by the
pressure difference and does not require any separate oil
pump.
 EFFICIENT OIL
SEPARATION WITH “OSBIC”

 It has perfected the ”OSBIC” (oil separation by

impact and centrifugal action) process which
enables efficient separation of air and oil with
minimum pressure drop . the process results in
low oil carry –over (<2ppm) level at the output of
the compressor
 DISCHARGED SYSTEM
 Much of the oil is removed from the air oil separator element
but some oil still remains in the air. To bring the oil content to
with in the desirable limits, below 3 ppm,the lean mixture is
passed through a high efficiency separator element
 The ait temp is still higher than the desired temperature at the
receiver at this stage. So it is cooled in an after –cooler to a few
degrees above the ambient temperatur.The air is passed through
a minimum pressure valve. The minimum pressure valve is
positioned down stream of the oil separator. It maintain a
minimum pressure for safe supply of oil to the compressor unit.
 Before the air is discharged to the external receiver, moisture
is removed from it using a moisture separator. This separator
removes 99 % of the moisture.
 DIGITAL I/O’S
8 NO OF OPTICALLY ISOLATED DIGITAL INPUTS

➢ 01 – emergency stop
➢ 02 – diff pr oil filter
➢ 03 – reverse rotation
➢ 04 – diff pr air filter
➢ 05 – remote start/stop
➢ 06 – high sump pressure
➢ 07 – cooler motor over load
➢ 08 – main motor over load
 8 NO OF OUTPUT RELAYS
(250AC,10A,100000 CYCLE ELECTRIC LIFE)
➢ 01 – main contactor
➢ 02 – star contactor
➢ 03 – delta contactor
➢ 04 – load valve
➢ 05 – cooler fan
➢ 06 – auto drain valve
➢ 07 – dryer (if dryer is connected –else programmable - load,
service, standby,warm,trip,remote,ready )
➢ 08-programble ( load,service,standby,warm,trip,remote,ready)
 ANALOG I/O’S

4 no of analog input channels

➢ 1 no of 4-20 ma channel,0-16 bar for discharge pressure

➢ 1 no of RTD channel ,0-150 deg c for discharge temp

➢ 1 no of 4-20 ma channel ,0-16 bar for sump pressure

➢ 1 no of RTD (pt-100) channel,-50 to 90 deg c for dryer dew

point

2 no of analog outputs
➢ 1-5 v dc ,one for discharge pressure and one programming
pressure
 9 NO OF FUNCTION KEYS

➢ Up, down,left,right,enter,escape,start,stop,reset.
1 NO OF DISPLAY
128*64 back light graphical LCD
9 no of led for visualization alarm & machine status
01- auto 05 – cooler
02 – air filter 06 - pressure
03 – MMO 07 - temp
04 – reverse rotation 08 – diff pr oil filter
01 no of dual led for start/stop indication
 1 no of non volatile memory
(for storage of 30 days report & 99 fault reports)
1 no of real time CLK
(with battery life of about 10 yrs)
4 of COMM ports (RS 485,2 wire)
Serial port 1 :mod bus RTU or SCADA port
2:dedicated FPD port ( for future use)
3:add on i/o interface ( expansion possibility)
4:vfd port
1 no system programming port for program data down
loading and data uploading
Power supply input:24 v ac,50 hz,1 a ( in built protection
present for surge, over current)
 COMMON ROTARY SCREW AIR COMPRESSOR
PROBLEMS
COMPRESSOR WILL NOT START

➢ You press the start button but nothing happens. Either an electrical problem, or
the compressor has tripped on a safety device.
➢ Check supply power. Check for errors on display. Check emergency stop is out.
Check and reset the overload relay. If it’s a new installation, check the phase
sequence.

COMPRESSOR SHUTS DOWN ON HIGH-TEMPERATURE

If your compressor trips on over temperature, it could be any of the following:

➢ Ambient temperature too high or not enough ventilation.
➢ Too low oil level
➢ Wrong type of oil
➢ Dirty oil cooler
➢ Thermostatic valve not not working
➢ Dirt / obstruction in oil lines
 COMPRESSOR RUNS BUT WILL NOT LOAD
➢ A screw compressor can run loaded (‘pumping air’) or unloaded (‘idle’).
The inlet/loading valve opens and closes according to air demand. The inlet
valve is controlled by a solenoid valve that supplies control air to the
inlet/loading valve.
➢ Check electrical power to solenoid valve
➢ Check solenoid valve coil and solenoid valve operation.
➢ Check working of inlet/loading valve
LOW CAPACITY / NOT ENOUGH PRESSURE
➢ First, check that there isn’t a very high air demand, or air leak somewhere.
➢ If the capacity of the air compressor is really too low, check the following:
➢ Does the inlet valve fully open
➢ Check differential pressure over oil separator. Replace separator when
necessary.
➢ Check if inlet filter is clean
➢ Check and replace compressed air filters
 SAFETY VALVE BLOWS / TOO HIGH PRESSURE
➢ Compressor does not unload. Check if pressure switch is correctly
set and working. Check inlet valve and loading solenoid for good
operation.
➢ If the safety valve is located before the oil separator, check
differential pressure of oil separator.
OIL IN COMPRESSED AIR
➢ Oil in compressed air can have various causes:
➢ Oil separator old / saturated
➢ Scavenge line plugged
➢ Too high running temperature
➢ Too high oil level
➢ Wrong type of oil used
➢ Minimum pressure valve not working
 WATER IN COMPRESSED AIR
➢ Water is a natural by product of air compression.
There will always be water in compressed air, unless
we remove it.
➢ Check the condensate trap for good operation. There
should be water coming out every few minutes. If
you open up the manual drain, there should only a
little water be coming out.
➢ If you have a compressed air dryer, check the dew
point.
COMPRESSOR OVERLOAD RELAY TRIPS
➢ Check the current draw with a current clamp meter.
➢ If the motor draws excessive current:
➢ Try to turn the compressor by hand. It should be possible to turn it
around. It should turn around smoothly, without any ‘hiccups’ (be
sure to completely shut down the air compressor!).
➢ Check the isolation of the motor windings. Should be in the mage-
ohms
➢ Check the voltage when the compressor is running. If the voltage
drop significantly when the compressor starts/runs, you have a bad
connection somewhere. Check all relays, fuses and electrical
connections.
➢ Check if all phases are present
➢ If the motor draws it’s normal current, but still trips on overload,
replace the overload relay with a new one (they are known to
sometimes become too sensitive when they get old)
AIR DRYING BASICS
 WHY QUALITY AIR?
pollution in ambient air

pollution in compressed air

 malfunctioning equipment and piping

 deteriorated product quality

 health issues
 POLLUTION
pollution in ambient air

amplify 8 to 13 times

pollution in compressed air

 POLLUTION
 Particles
 Moisture

 Oil

 Smell and taste

 Viruses and bacteria

 POLLUTION/PARTICLES
Why quality air?
 Partly block pipes:
 increasing resistance  increasing energy use
 decreasing performance  increasing operating cost

 chemical or biological clogging

 POLLUTION/PARTICLES
Why quality air?
 Blocking pipes and valves:
system malfunction
down time
cleaning costs
 POLLUTION

 Particles
 Moisture

 Oil

 Smell and taste

 Viruses and bacteria

That’s why…. Quality Air Required

WHY DRYING?

Air contains water...

How much water can air contain?
Why is condensation formed?

The water holding capacity of air depends on

PRESSURE & TEMPERATURE.

UN-
SATURATED
 What is a dew point?
It is the temperature (°C) below which condensation occurs
(at a given pressure)

250

200
g/m³

150

100

50

°C
 What does RELATIVE HUMIDITY mean?

250

RH is defined as the ratio

between the water content
200

to the amount of water the 150

100%
air can possibly hold at the g/m³

RH
100

same temperature 50

60%
NOT
0
-10 0 10 20 30 40 SATURATED
50 60 70

°C
 What happens during
Compression

Volume reduces - gm/m3 water vapor

increases in relation
to pressure ratio.
 250

200
g/m³

150

After compression
100

50 Before Compression
0
-10 0 10 20 30 40 50 60 70

°C
 What is the difference between
atmospheric and pressure dew point?
PDP
It is the temperature (°C) below which condensation occurs at the
pressure the air is at.
ADP
It is the temperature (°C) below which condensation occurs after the
air is expanded again to atmosphere.

E.g. Air at 7 bar(e) with a PDP of -40°C

has an ADP of ... -58°C
 HOW TO DRY AIR
(REFRIGERANT DRYING)

Dew points down to 3°C

HEAT EXCHANGER

High efficiency ‘tube in tube’ heat

exchanger. The high quality copper tube
ensures maximum heat transfer
efficiency, corrosion resistance and
minimum pressure drop. The heat
exchanger is filled with PUF for better
insulation and efficiency. It performs the
function of both pre-cooler and
evaporator.
CONDENSER

Highly efficient copper tubed Aluminum

finned condenser. The hot and high
pressure refrigerant enters into the
condenser in gaseous state and
gets cooled through the forced circulation
of cold air using a fan and flows to the
expansion valve in liquid state
CAPILLARY/EXPANSION
DEVICE

Use of capillary refrigerant expander or

mechanical expansion device prior to the
heat exchanger ensures that the
refrigerant flow into the evaporator is
only in the liquid state. High quality
copper ensures minimum due
point fluctuation and maximum heat
transfer efficiency between compressed
air and refrigerant.
PRESSURE SWITCHES
CONTROLLER
THE USE OF MICROPROCESSOR
BASED CONTROLLER ENSURES
HIGHER PERFORMANCE
RELIABILITY OF THE DRIER. THE
CONTROLLER INDICATES THE
PRESSURE DEW POINT FOR
ONLINE MONITORING. SETTING
OPTIONS FOR CONTROLLING THE
CYCLE CONTROLLER AND
AUTOMATIC DRAIN VALVES ARE
PROVIDED.
CYCLE CONTROLLER

The pressure operated 100%

modulating cycle controller provides a
quicker and reliable response to the
inlet air temperature. It ensures
optimum dew point control under all
operating conditions. It is primarily
used to prevent freezing phenomenon
in the evaporator. Mechanical type
cycle controller is used in the higher
flow models and solenoid operated
cycle controller is used
in lower flow models
CONDENSATE DRAIN

High reliability automatic condensate drain

ensures maximum condensate removal form
the system. The drain is solenoid controlled
and the timings of moisture draining
can be set by the user using the
microprocessor based controller. This
controllable feature ensures reliable
moisture cured air even at high humid and
tropical conditions.
 TYPE PF High efficiency General Purpose
Protection: For the removal of
particles down to 1 micron including
coalesced liquid water and oil, providing
a maximum remaining oil aerosol
content of 0.5 mg/m

TYPE CF
Activated Carbon Filtration:
For the removal of oil
vapour and hydrocarbon odour
giving a maximum
remaining oil content of <0.003
mg/m (<0.003 ppm)
0 (excluding methane) @ 21 C.
(Precede type CF with
type FF & PF)
TYPE FF
High Efficiency Oil Removal
Filtration:
For the removal of particles down to 0.01
micron including water and oil aerosols,
providing a maximum remaining oil
aerosol
3 0 content of 0.01 mg/m @ 21 C.
PF – Pre Filter
FF - Fine Filter
CF - Carbon Filter
 The ISO 8573-1 Quality Classes
Q u a lity D ir t W a te r O il
C la s s p a rt ic le s iz e in m a x .c o n c e n - m a x . P D P m a x . c o n c e n -t ra t io n
 m t ra t io n m g / m 3 (°C ) m g /m 3
1 0 ,1 0 ,1 -7 0 0 ,0 1
2 1 1 -4 0 0 ,1
3 5 5 -2 0 1
4 1 5 8 + 3 5
5 4 0 1 0 + 7 2 5
6 - - + 1 0 -

For example: Compressed air to quality class 2.2.2.

Means: Dirt 1micron and 1mg/m3, water -40°C PDP,
oil 0,1 mg/m3
“THANK YOU”