Mohd.

Aqif

Mechanical Engineering

Trainee

Pusa Inst. Of Technology

Training at:-
DMRC Construction site
 Topic:- Air compressor

An air compressor is a device that converts power  (using

an electric motor, diesel or gasoline engine, etc.) into
potential energy ,stored in pressurized air , an air
compressor forces more and more air into a storage tank,
increasing the pressure. When tank pressure reaches its
upper limit the air compressor shuts off. The compressed
air, then, is held in the tank until called into use. The
energy contained in the compressed air can be used for a
variety of applications, utilizing the kinetic energy of the air
as it is released and the tank depressurizes. When tank
pressure reaches its lower limit, the air compressor turns
on again and re-pressurizes the tank.
Classification:-
On the basis of pressure delivered
1. Low pressure (presuure upto 150 psi)
2. Medium pressure (pressure of 151 to 1000psi)
3.High pressure (pressure above 1000psi)

On the basis of working principle

1.Reciprocating type compressor:-
A reciprocating compressor or piston compressor is
a positive-displacement compressor  that uses pistons
driven by a crankshaft  to deliver gases at high pressure.
The intake gas enters the suction manifold, then flows into
the compression cylinder where it gets compressed by a
piston driven in a reciprocating motion via a crankshaft,
and is then discharged.
2.Rotary type compressor:-
A rotary-screw compressor is a type of gas
compressor  that uses a rotary-type positive-
displacement mechanism. They are commonly used
to replace piston compressors  where large volumes
of high-pressure air are needed, either for large
industrial applications or to operate high-power air
tools such as jackhammers.
 Applications
The selecting the type of compressor depends largely on
size, cost, and reliability requirements:

•Rotary compressors:-
Rotary screw compressors in sizes from small (in cars) up
to 500-600 hp are very popular because of their high
reliability and low maintenance requirements. •Centrifugal
compressors are often used in sizes ranging from about
150 hp up to over 10,000 hp. The larger size models are
relatively low in cost and small in physical size compared
to reciprocating compressors.

•Reciprocating compressors:-
These are commonly used today only in sizes up to 25
hp. These compressors are often used for light-duty
applications or in startup industrial enterprises because
they are reliable and low cost.
 Air Compressor Safety Tips.

Always read your owners manual before running your

compressor, there is important information in there!
Improper use is the number one cause for repairs and
personal injury.
Remember to use eye protection and hearing protection
when operating your air compressor.
Try and avoid using air compressors in a wet area. If the
compressor is exposed to water for long periods of time, it
can cause rust to the tank, damage to the tools, and also
cause problems with the electrical circuits.

Hoses:- Ensure that all hose fittings are tight. Loose

fittings can not only damper you compressors
performance, but also cause personal and equipment
damage.
Keep all hoses clean of dirt and debris. This will not only
lengthen the life of your hose, but your air compressor as
well.
Voltage:-

Ensure that the machine is plugged into a properly

grounded outlet. If your machine is plugged into an outlet
without the properly grounded electrical circuits, there may
be damage to the electrical panel of the compressor as
well as the possibility of a fire.
Consult the owners manual for the recommended
extension cord use. Using a longer extension cord than
recommended can result in a loss of power, and can
cause damage to the compressors electrical panel and/or
motor.

Tools:-
Ensure that the machine is plugged into a
properly grounded outlet. If your machine is plugged into
an outlet without the properly grounded electrical circuits,
there may be damage to the electrical panel of the
compressor as well as the possibility of a fire.
Consult the owners manual for the recommended
extension cord use. Using a longer extension cord than
recommended can result in a loss of power, and can
cause damage to the compressors electrical panel and/or
motor.
 Maintenance
Air Compressor Preventive
Maintenance Checks
Air compressor owners often forget that an ounce of
prevention is worth a pound of cure. Maintaining your air
compressor can save you both time and money down the
road. By performing the following checks each time you
operate your air compressor, you are saving yourself a
world of pain in the future.

Checking compressor pump oil level:-

Unless your air compressor is an oil free compressor, do not

operate without lubricant or with inadequate lubricant.
Manufacturers and the company from whom you bought it from
cannot be responsible for failure do to inadequate lubrication.

1. Ensure unit is off and disconnect from the power source

2. Ensure compressor is on a flat and level surface
3. Remove fill cap / plug
4. Inspect the oil in the crankcase assembly and look for dirt or
debris
5. Oil should not exceed the halfway point of the sight glass
Changing compressor pump oil:-
1. Ensure unit is off and disconnect from the power source
2. Ensure compressor is on a flat and level surface
3. Remove fill cap / plug
4. Place collection container underneath the oil drain cap.
5. Remove the oil drain cap, and let the oil drain out.
6. Replace the oil cap and be sure to tighten this nut securely.
White plumbers tape (PTFE) is generally a good idea to help
create a tighter seal. Fill crankcase with appropriate oil, be
sure it does not exceed the halfway point.

Checking air filler element:-

1. Ensure unit is off and disconnect from the power source

2. Allow compressor pump to cool off.
3. Unscrew the filter top from the filter base by turning
(generally) counter-clockwise.
4. Separate the filter top cover from the base.
5. Remove the element from the filter base
6. Blow out dust and debris from the filter element.
7. Replace element if needed.
8. Reconnect filter top to the base and secure filter.
 General Preventive Maintenance Schedule
Procedure Daily Weekly Monthly Annually
(200 Hours)

Check Pump Oil Level X

Oil Leak Inspection X

Drain water in tank X

check for weird noise and vibration X

Inspect all air leaks X

Inspect belts X

Check air filters, clean or replace X

check safety relief valve X

Check belts if necessary X

Check and tighten all bolts X

Check connections for leaks X

Service pump or engine X