Field Operator Certifi cation

Piston Compressors
Learner Guide
 Piston Compressors – Learner Guide

Introduction
This lesson on Piston Compressors, as with your other lessons on Auxiliary Equipment, consists of
two main learning components a self-directed/in-class component and an on-the-job component.
You are expected to complete both components as part of your Certification Program.

Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.

Objectives
Your learning objectives are broken down into two categories learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.

Self-Directed/In-Class Learning Objectives

 State purpose for Piston Compressors
 List main components of the Piston Compressor
 Explain principle of operation for Piston Compressors
 List the types of operation for the Piston Compressor
 Describe the cooling components used for Piston Compressors
 List the regulator types used on Piston Compressors
 State applications for the Piston Compressor
 Describe running & static inspection points for Piston Compressor
 Describe 2 troubleshooting methods for common Piston Compressor problems
 State safety concerns related to Piston Compressors

On-the-job Learning Objectives

 Perform a running inspection on a Piston Compressor
 Perform a static inspection on a Piston Compressor

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Lesson Outline
The first portion of the lesson, the self-directed/in-class portion, involves reviewing the following
information:

 The purpose and basic principle of operation of the Piston Compressor

 A listing and description of the various components of the Piston Compressor
 Various applications of the Piston Compressor
 Basic troubleshooting of the Piston Compressor
 Safety concerns related to Piston Compressors
Pictures and graphics are included where appropriate to help you understand how the Piston
Compressor functions. At the end of this section, there are a series of questions that you will be
required to answer and review with your Instructor.

The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Piston Compressors, including both a running and static inspection. When you
are ready to perform these inspections, inform your Instructor.

If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.

 Step One
 Your Instructor will ‘walk through’ an inspection procedure with you. At that time you
can ask questions and take down any notes required.
 This walkthrough may be completed out in the field or during a meeting with your
Instructor.
 Step Two
 Your Instructor will demonstrate an inspection procedure in the field.
 Step Three
 You will conduct an inspection procedure in the field under the supervision of your
Instructor.
 Your Instructor will provide you with feedback about your performance during the
inspection.
 Step Four
 You will complete a full inspection procedure without any assistance from your
Instructor.

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 This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor and you may only be required to actually complete
Step Four as discussed above.

Reference Material
 NA

Pre-requisites
 NA

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Piston Compressors – Learning Content

Purpose
 The purpose of the Piston Compressor is to generate large volumes of compressed air at
relatively low pressure.

PISTON COMPRESSOR

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Components
 Belt Wheel  Intercooler Manifold
 Centrifugal Unloader  Intercooler Safety Valve
 Crankshaft  Oil Seal
 Drive motor  Outer Bearing
 Inlet Filter/Silencer  Pilot Valve
 Inner Bearing  Shaft End Cover
 Intercooler  Snap Ring

P ISTON C OMPRESSOR

Intercooler Safety Valve

Inlet Filter/Silencer

Intercooler Manifold

Belt Wheel

Snap Ring

Oil Seal

Outer Bearing
Bearing
BBearing Pilot Valve
Shaft End Cover

Intercooler Inner Bearing Centrifugal Unloader

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Components (continued)

 Air Head Valve  H.P. Cylinder

 Breather Tube  L.P. Cylinder
 Connecting Rod  Piston
 Cylinder  Piston Rings
 Cylinder Relief Valve  Safety Valve
 Frame

T WO S TAGE , T HREE C YLINDER C OMPRESSOR

L.P. Cylinder

Breather Tube
L.P. Cylinder

Air Head

Valve

Connecting Rod
Piston Rings
Rings
Piston

Cylinder

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Principles of Operation

 The piston compressor can be either a single stage or a two stage operation.

 While there are many different types and manufacturers of piston compressors, the principle
operation is the same.

 Compressors are equipped with a drive motor or motors and are fitted with belts from the
motor pulley to the belt wheel on the end of the crankshaft of the compressor.

 The crankshaft rides in an inner and outer bearing and as the crankshaft turns this causes the
up and down motion of the connecting rod and piston within the cylinder, thus compressing
the air within.

Types of Operation
SINGLE STAGE
 Air is compressed once before it is sent to the receiver.

 Air enters the cylinder on the suction stroke of the piston through the inlet filter and valve
located in the air head.
 On compression stroke of the piston, air is forced out through the valve, passes into a
manifold, and is piped to the receiver tank at a higher pressure.

TWO STAGE
 This is type of compressor commonly used here.

 Air is compressed twice before it is passed to the receiver.

 .Air enters in same manner as single stage on suction stroke, but on the compression stroke
air is compressed to an intermediate pressure, is discharged through the valve, and is drawn
into the second stage cylinder on its suction stroke.
 The compression stroke then compresses the air to the final discharge pressure. Air is then
forced out through the outlet valve into the receiver.

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Compressor Cooling
INTERCOOLER TUBES
 Two stage compressors are equipped with highly efficient intercooler tubes, used to cool the
air as it passes from the first stage of compression to the second stage cylinder.
 Heat is removed by the action of the belt wheel fan passing cool air over the intercooler
tubes.

AFTER COOLERS
 After coolers are installed if the cooling of the final (second stage) discharge air is required.

 The after coolers can be either water or air cooled, and are installed between the compressor
discharge and the receiver.

C OMPRESSOR C OOLING S YSTEM

Belt Guards
Air Inlet Filters
After
Coolers
Crankcase Heater
& Thermostat

Isolation & Safety

Inspection Holes Valves

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Regulator Types

AUTOMATIC STOP & START CONTROL

 This type of controller either makes or breaks the electrical contact, causing the compressor
to shut down at a predetermined pressure.
 This type of regulator is used when the
demand for air is small or intermittent,
but where pressure must be
continuously maintained.

T YPICAL C ONSTANT S PEED C ONTROL

CONSTANT SPEED CONTROL ARRANGEMENT FOR TWO STAGE UNITS

 Unloads the compressor at a Constant speed

predetermined pressure while the motor unloader
continues to operate.
 This type of regulator is used when the
demand for air is practically constant at the
capacity of the compressor.
DUAL CONTROL
 Permits a manual selection between automatic
start/stop control and constant speed control,
depending upon the air requirements.

Auxiliary valve
Air Receiver

C ONSTANT S PEED U NLOADER

(A PPLIES TO C ONSTANT S PEED AND D UAL C ONTROL O NLY

Constant Speed
Unloader

Air Head
Cylinder
Valve

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Applications

 Finish Grind
 Raw Grind
 Pyroprocessing

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Inspection Points

Piston Compressor – Running Inspection

Check For OK

 Listen for abnormal noise or vibration in the Compressor and drive system

 Check drive belts for proper tensioning

 Inspect the condition of the drive belts, sheaves, or drive coupling
 Check for proper air pressure, 90 PSI
 Check condition of filters, both inlet and outlet when present
 Check for leaking oil and air lines
 Check oil level, add when needed.
 Inspect the drive’s mounting base for damage, cracks, loose bolts
 Inspect the condition of drive components (motor to reducer). V-belt condition and tensioning,
sheaves, direct coupling condition, fluid coupling, intermediate shafts and bearings
 Inspect the general condition of the equipment—cleanliness, damage
 Inspect the condition and support integrity of all safety guards
 Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen. Remove
build-up if applicable
 Palm test the motor and compressor casing temperature- If too hot to touch, record temperature with
hand pyrometer or contact thermometer
 Inspect drive motor electrical connections for damage or strain—if applicable
 Inspect the condition and support integrity of all pressure gauges
 Open drain at the bottom of the receiver tank to remove moisture

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Piston Compressor – Static Inspection

Check For OK

 Check drive belts for proper tensioning

 Inspect the condition of the drive belts, sheaves, or drive coupling
 Check for proper air pressure, 90 PSI
 Check condition of filters, both inlet and outlet when present
 Check for leaking oil and air lines
 Check oil level, add when needed.
 Inspect the drive’s mounting base for damage, cracks, loose bolts
 Inspect the condition of drive components (motor to reducer). V-belt condition and tensioning,
sheaves, direct coupling condition, fluid coupling, intermediate shafts and bearings
 Inspect the general condition of the equipment—cleanliness, damage
 Inspect the condition and support integrity of all safety guards
 Inspect the drive motor for material build up on cooling fins and cooling fan inlet screen. Remove
build-up if applicable
 Palm test the motor and compressor casing temperature- If too hot to touch, record temperature with
hand pyrometer or contact thermometer
 Inspect drive motor electrical connections for damage or strain—if applicable
 Inspect the condition and support integrity of all pressure gauges

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Troubleshooting
The following troubleshooting information has been prepared to help you resolve common
operating problems associated with the Piston Compressor

T ROUBLESHOOTING

Problem Actions to Take

 Will Not Start Visually inspect the compressor
If compressor looks correct, Check oil. Put in oil if low.

If oil is okay, Check and reset temperature and motor

Pressure switch may be
indicating high air pressure
Once reset, attempt to restart.
overloads.
Check the pressure switch to ensure that it is not
stuck and working properly
If will not restart, contact mechanical
maintenance.

 Low Air Pressure Visually inspect the compressor (observe belt tension)
Listen for abnormal operation.
If repairs are required, Shut down and notify mechanical maintenance.

If visual and audio inspections Check inlet air filters.

are okay,
If air filters are okay, 
If no air leaks are located,
If dirty, clean and replace
Check for air leaks in piping (on machine) or in
outside system piping.
If leak detected, isolate and repair if possible or
notify mechanical maintenance of description
and location of problem.
Observe and notify mechanical maintenance of
possible internal compressor problems.

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Safety – Work Page

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Safety
 Always lockout before performing work on Piston Compressors
 Be sure all guards are in place.
 Make sure to isolate compressor if it is inline with other compressors.
 Shutdown the compressor to add oil or check oil level and relieve the pressure inside the oil tank
by slowly removing the cover(cap)

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Review Exercise
Complete each of these questions and review your answers with your Instructor.

1. What is the main purpose of a Piston Compressors?

2. List 4 of the main components of the Piston Compressor

3. Describe the principle of operations of the Piston Compressor.

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4. List the types of operations for Piston Compressors.

5. Describe the cooling components used for Piston Compressors.

6. List the regulator types used on Piston Compressors.

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7. State applications for the Piston Compressor.

8. Describe 5 running inspection points for Piston Compressors.

9. Describe 2 troubleshooting methods related to Piston Compressor low air pressure

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10. State three safety concerns related to Piston Compressors.

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