Compressor Case Study: Classification and Operation

UNIVERSITY OF CAGAYAN VALLEY
COLLEGE OF ENGINEERING
CASE STUDY
ON COMPRESSOR
PRESENTED TO:
ENGR. ROGER AGBISIT JR.
PRESENTED BY:
KARL ANDREW A. NEPOMUCENO
TABLE OF CONTENTS
I. INTRODUCTION
II. CLASSIFICATION
III. APPLICATION
IV. OPERATION
V. COMMON TROUBLES
VI. CONCLUSION
VII. REFERENCES
I. INTRODUCTION
A compressor is a mechanical device that increases the pressure of a
gas by reducing its volume. An air compressor is a specific type of

gas compressor.
Compressors are similar to pumps: both increase the pressure on
a fluid and both can transport the fluid through a pipe. The main
distinction is that the focus of a compressor is to change the density
or volume of the fluid, which is mostly only achievable on gases.
Gases are compressible, while liquids are relatively incompressible,
so compressors are rarely used for liquids. The main action of a
pump is to pressurize and transport liquids.

Many compressors can be staged, that is, the fluid is compressed
several times in steps or stages, to increase discharge pressure.
Often, the second stage is physically smaller than the primary stage,
to accommodate the already compressed gas without reducing its
pressure. Each stage further compresses the gas and increases its
pressure and also temperature (if inter cooling between stages is not
used).The function of compressor is to compress the gases and
vapours from low pressure to high pressure. According to second
law of thermodynamics this is only possible when work is done on
the system, i.e., on the gas or vapour. Compressors have wide
industrial and domestic applications such as compression of
refrigerants in refrigerators and air conditioning plants,
compression of air to fill the air in wheel of automobiles, use of
compressed fluids in non-conventional .A compressor is a
mechanical device that increases the pressure of a gas by reducing
its volume. An air compressor is a specific type of gas compressor.

Compressors are similar to pumps: both increase the pressure on
a fluid and both can transport the fluid through a pipe. The main
distinction is that the focus of a compressor is to change the density
or volume of the fluid, which is mostly only achievable on gases.
Gases are compressible, while liquids are relatively incompressible,
so compressors are rarely used for liquids. The main action of a
pump is to pressurize and transport liquids.
Many compressors can be staged, that is, the fluid is compressed
several times in steps or stages, to increase discharge pressure.
Often, the second stage is physically smaller than the primary stage,
to accommodate the already compressed gas without reducing its
pressure. Each stage further compresses the gas and increases its
pressure and also temperature (if inter cooling between stages is not
used).
II. CLASSIFICATION
Air compressors are categorized as either positive displacement or
dynamic displacement, based on their internal mechanisms. The
four most common types of air compressors are: Rotary Screw

Compressors. Reciprocating Air Compressors.The two main types
of compressors are dynamic and positive displacement. The positive
displacement compressor is probably the one you're familiar with. It
traps gas in a volume and then decreases that volume. The decrease
in volume causes a rise in pressure.
There are two basic types of air compressors:
Positive displacement, and
Dynamic.
Positive Displacement.
In the positive displacement type, a specified quantity of air is
trapped in a compression chamber and the volume which it occupies
is mechanically reduced, causing a corresponding rise in pressure
prior to discharge. Rotary screw, vane and reciprocating air
compressors are the three most common types of air positive
displacement compressors found in small and medium sized
industries.
Dynamic.
Dynamic air compressors include centrifugal and axial machines,
and are used in very large manufacturing facilities. These units are
beyond the scope of this document.
a. Rotary Screw Compressors
Rotary screw compressors have gained popularity and market share
(compared to reciprocating compressors) since the 1980s. These
units are most commonly used in sizes ranging from about 5 to 900
HP. The most common type of rotary compressor is the helical twin,
screw compressor. Two mated rotors mesh together, trapping air,
and reducing the volume of the air along the rotors. Depending on
the air purity requirements, rotary screw compressors are available
as lubricated or dry (oil free) types.

Figure 6 - Cross Section of a Representative Rotary Screw
Compressor
The biggest advantage of screw compressors over small air cooled
reciprocating units is that they can run at full load continuously
where the reciprocating compressors must be used at 60% duty
cycle or below. Rotary screws are also a lot quieter and produce
cooler air that is easier to dry. Be aware that rotary screw

compressors may not be the most efficient choice compared to
start/stop reciprocating compressors. Please refer to Case 3: On/Off
vs. Load/No Load Control on page 101 for an example.
Lubricant Injected Rotary Screw.
The lubricant injected rotary screw compressor is the dominant
type of industrial compressor for a perse set of applications. For
lubricant injected rotary screw compressors, lubricants may be a
hydrocarbon composition or a synthetic product. Typically a
mixture of compressed air and injected lubricant exits the air end
and is passed to a sump where the lubricant is removed from the
compressed air. Directional and speed changes are used to separate
most of the liquid. The remaining aerosols in the compressed air
then are separated by means of a separator element within the
sump, resulting in a few parts per million (ppm) of lubricant
carryover in the compressed air. With two stage compressors,
interstage cooling and the reduced internal losses due to a lower
pressure across each stage increase the compression efficiency.

Consequently, less energy is required to compress the air to the final
pressure.
Dry Type Rotary Screw.
In the dry type, the intermeshing rotors do not contact one another,
and their relative clearances are maintained to very close tolerances
by means of external lubricated timing gears. Most designs use two
stages of compression with an intercooler and aftercooler. Lubricant
free rotary screw compressors have a range from 25 to 1,200 HP or
90 to 5,200 cfm.
b. Reciprocating Compressors
Reciprocating compressors have a piston that is driven through a
crankshaft and by an electric motor. Reciprocating compressors for
general purpose use are commercially obtainable in sizes from less
than 1 HP to about 30 HP. Reciprocating compressors are often
used to supply air to building control and automation systems.

Large reciprocating compressors still exist in industry, but they are
now no longer commercially available, except for use in specialized
processes such as high pressure applications.
c. Vane Compressors
A rotary vane compressor uses an elliptical slotted rotor situated
within a cylinder. The rotor has slots along its length, each slot
contains a vane. The vanes are forced outwards by centrifugal force
when the compressor is rotating, and the vanes move in and out of
the slot because the rotor is eccentric to the casing. The vanes sweep
the cylinder, sucking air in on one side and ejecting it on the other.
In general, vane compressors are used for smaller applications
where floor space is an issue; however, they are not as efficient as
rotary screw compressors.
d. Compressor Motors
Electric motors are widely used to provide the power to drive
compressors. As a prime mover, the motor needs to supply sufficient

power to start the compressor, accelerate it to full speed, and keep
the unit operating under various design conditions. Most air
compressors use standard, three phase induction motors.
For new or replacement air compressors, premium high efficiency
motor should be specified over a standard ones. The incremental
cost of the premium high efficiency motor is usually recovered
quickly from the consequential energy savings.
e. Compressor Controls and System Performance
As air systems seldom operate at full load all of the time, the ability
to efficiently control flow at part loads is essential.
Consideration should be placed to both compressor AND system
control selection as they are important factors affecting system
performance and energy efficiency.
Various inpidual compressor control strategies exist including the
following:
Start/Stop. This is the simplest and most efficient control strategy. It
can be applied to either reciprocating or rotary screw compressors.
Essentially, the motor driving the compressor is turned on or off in
response to the discharge pressure of the machine. For this strategy,
a pressure switch provides the motor start/stop signal. Start/Stop
strategies are generally appropriate for compressors smaller than 30
horsepower in size.
Repeated starts may cause the motor to overheat and place greater
maintenance demands on compressor components. For this reason,
care should be taken in sizing storage receivers and maintaining
wide working pressure bands to keep motor starts within allowable
limits.
Load/Unload. This control mode is sometimes called online/offline
control. It keeps the motor running continuously, but unloads the
compressor when the discharge pressure is adequate. Unloaded
rotary screw compressors typically consume 15-35% of their full
load power demand, while producing no useful compressed air

output. Optional unload timers are available that will save energy
by automatically turning off the compressor and placing it in
standby if the unit runs unloaded for a period of time (usually 15
minutes).
Load/unload control strategies require significant control storage
receiver capacity for efficient part load operation.
Figure 7 - Average Power vs. Capacity for Rotary Screw
Compressor
Modulating Control. This mode of control varies the compressor
output to meet flow requirements by adjusting the inlet valve,
resulting in air restrictions to the compressor. Even fully modulated
at zero flow rotary screw compressors typically consume about 70%
of their full load power demand. The use of pressure switch
activated unloading controls can reduce the unloaded power
consumption to 15 to 35%. Modulating control is unique to
lubricated screw compressors and is the least efficient way to
operate these units.
Compressor controls have a significant impact on energy
consumption, especially at lower flows, where start/stop controls are
generally the most energy efficient.
Figure 8 illustrates a typical performance curves for compressors
where inlet valve modulation is used with and without unloading the
compressor.
Figure 8 - Rotary Screw Compressor with Inlet Modulation Control
Variable Displacement.
Some lubricated rotary screw compressors vary their output
capacity using special capacity control valves, also called spiral, turn
or poppet valves. With a variable displacement control scheme, the
output pressure and compressor power consumption can be closely
controlled without having to start/stop or load/unload the
compressor. This control method has good efficiency at points above

60% loading. Use of pressure switch activated unloading controls at
flows below 40% capacity can significantly reduce power
consumption at lower flows.
Figure 9 - Rotary Screw Compressor with Variable Displacement
(Courtesy Compressed Air Challenge)
Variable Speed Drive (VSD).
This control method varies the speed of the compressor to respond
to changes in air demand. Both lubricated and oil free screw
compressors can be purchased equipped with variable speed drive
controls that continuously adjust the drive motor speed to match the
variable demand requirements and maintain constant pressure.
These compressors usually operate in on/off or load/unload control
when air loading drops below the minimum speed of the drive.
In most cases a variable speed drive compressors offers the most
efficient part load operation. Ideally, when there are multiple air
compressors at a facility. One or more fixed speed compressors
would supply the base load compressed air, and a VSD compressor
would be used to supply the fluctuating or trim load.
Figure 10 - Variable Speed Rotary Screw Power Curve

To benefit from VSD compressors, the appropriate amount of air
receiver storage volume needs to be evaluated for different flow and
control scenarios.
Variable speed drive (VSD) compressors should be considered for
trim (or swing) duty as they are typically the most efficient unit to
supply partial loads. Capable of supplying a constant pressure
through a wide control range, the energy consumption and flow of a
VSD compressor is almost directly proportional to the speed. This
can result in energy savings over comparable fixed speed units when
compressors are partially loaded. Be aware, however, that at full
loads, the VSD will use slightly more energy compared to a similar
sized constant speed motor drive.
Operating Cost Comparison of Different Control Modes
The compressor control mode can have a big effect on operating
costs. In modulating mode the compressor would use 90% of full
load power. For load/unload with minimal air storage (1 US Gal per
cfm), the compressor would use about 92% of full power. By

increasing the air storage to 10 US Gal per cfm, the load/unload
compressor will use about 77% of full power. With variable speed
drive control, the same size compressor will use about 66% of full
power.
Figure 11 - Approximate Annual Cost for a 100 HP Compressor at Different Control Modes*
Load/Unload with Load/Unload with
% Load Modulating 1 gal/cfm Receiver 10 gal/cfm Receiver
100 $36,130 $36,130 $36,130
75 $33,420 $34,680 $29,350
65 $32,330 $33,240 $27,820
50 $30,710 $31,070 $24,200
25 $28,000 $24,930 $16,800

Figure 11 - Approximate Annual Cost for a 100 HP Compressor at Different Control Modes*
Load/Unload with Load/Unload with
% Load Modulating 1 gal/cfm Receiver 10 gal/cfm Receiver
10 $26,370 $16,620 $11,740
*Based on 10 cents per kWh and 4,250 hours per year.
f. Multiple Compressor System Controls
The goal in controlling multiple compressors is to automatically
maintain the lowest and most constant pressure, through all flow
conditions, while ensuring all running compressors except one are
either running at full load or off. The remaining compressor (trim
unit) should be the one most capable of running efficiently at partial
loads.
Local compressor controls independently balance the compressor
output with the system demand and are always included in the
compressor package. To achieve the stated goals, systems with
multiple compressors require more advanced controls or control
strategies (cascaded pressure bands, network or system master
controls) to coordinate compressor operation and air delivery to the
system.
Proper coordination is required to maintain adequate system
pressures and increased efficiency whenever more than one
compressor is required to run in a compressed air system.
Because compressor systems are generally sized to meet a facility’s
maximum demand, but are normally running at partial loads, a
method of control is required to ensure the running compressors are
at their maximum efficiency. A description of some common control
methods follows:
Cascaded Pressure Band Control. This type of control is the
simplest method of coordinating multiple compressors. With this

control strategy the local compressor pressure switch controls are
arranged in an overlapping or cascaded pattern (see Figure 12).
This method of control will unload and/or load compressors at
varying system pressures as the load decreases or increases. The
cascaded control method results in higher than necessary system
pressures during partial loads which causes higher than required
energy consumption. Also, as the number of coordinated
compressors increases, it becomes more and more difficult to
achieve accurate compressor control without exceeding the pressure
rating of the connected compressors at low loads or experiencing
low system pressure at high loads.

Figure 12 - Multiple Compressor Cascading Control
Network Control. This type of control uses the optional feature of
the local compressor control to communicate with other
compressors to form a chain of communication that makes decisions
to stop/start, load/unload, modulate, and vary speed. One
compressor generally assumes the primary lead with the others
being secondary to the instructions from this compressor. This type
of control can accommodate many compressors while maintaining
system pressure within a single lower pressure band for all flow
conditions. Typically these types of controls can only interconnect
compressors of the same manufacturer.
System Master Controls. (Also called automatic sequencers). Similar
to network controls these externally installed controls interface with
the local compressor controller to ensure system pressure remains
within a single more efficient lower pressure band. Most system
master controls can accommodate different manufacturers and
types of compressors in the same system. Some newer system master

controls have many extra capabilities, including the ability to
monitor and control important parameters in the system.
Multiple Controls with Variable Speed Drives (VSD). One or more
VSD compressor(s) can be incorporated in the compressor control
strategies previously indicated. In doing so it is important to ensure
that the variable capacity is equal to or larger than the largest fixed
speed compressor or a control gap will result. A control gap is
where, under certain conditions, neither the base capacity nor the
VSD will satisfy system loading. This control gap will cause the base
and VSD compressors to fight for lead position and will lower
system efficiency. Your compressor provider can assist you with
properly sizing your VSD compressors.
To benefit from multiple compressor control, the appropriate
amount of air receiver storage volume needs to be installed to slow
system pressure changes and allow time to start and stop
compressors. Storage is most important for load/unload control but
is also required for systems using VSD compressors.

III. APPLICATION
Compressors are used throughout industry to provide shop or
instrument air; to power air tools, paint sprayers, and abrasive blast
equipment; to phase shift refrigerants for air conditioning and
refrigeration; to propel gas through pipelines; etc.
Reciprocating compressors are typically used where high
compression ratios (ratio of discharge to suction pressures) are
required per stage without high flow rates, and the process fluid is
relatively dry.
Screw compressors: Trailer mounted diesel powered units are often
seen at construction sites, and are used to power air operated
construction machinery.
P.E.T bottling industries, gas filling stations usually use
reciprocating compressors. Processing equipment, Oxygen
Generators Oil
Atomization use compressors of required capacity.

Air compressors: a compressor that takes in air at atmospheric
pressure and delivers it at a higher pressure.
Compressors serve the basic necessities & form an integral part of
the company .
Pneumatic brakes
Pneumatic drills
Pneumatic jacks
Pneumatic lifts
Spray painting
Shop cleaning
Injecting fuel in Diesel engines
Refrigeration and Air conditioning systems.Sometimes a compressor
application has more than one suction or discharge pressure level.
For example, in an oil field gas system, the compressor may take
different quantities of gas from the separator at two pressures, say

40 and 250 psig (275–1724 kPa). This machine could also be
required to deliver a portion of the gas at 1000 psig (6895 kPa)
for gas lift, and the remainder at 2500 psig (17,237 kPa) for injection
back into the formation. In this case, these pressures would set the
interstage pressures so that the sidestreams are accomplished. Note
also that two stages might be required between the 40 and 250 psig
(275–1724 kPa) levels (depending on suction temperature and k
value) to stay below the discharge temperature limits.

IV. OPERATION
Air compressors work by forcing atmospheric air under pressure to
create potential energy that can be stored in a tank for later use.
Just like an open balloon, the pressure builds up when the
compressed air is deliberately released, converting the potential
energy into usable kinetic energy.In the modern world of
pneumatics, air compressors are vital to the operations of factories
and workshops across the globe. But they haven’t always been. Air
compressors are a relatively recent invention in the context of
machine-age history.
Before air compressors, many tools got their power from
complicated systems with belts, wheels and other large components.
This machinery was massive, heavy and costly, and typically out of
reach for many small operations. Today, air compressors come in
many shapes and sizes, and you can find them in large shop floors,
auto workshops and even your neighbor’s garage. In this guide,
we’ll discuss how air compressors work — from their basic

functionality to the various ways different compressors handle air
displacement.
Air compressors work by forcing atmospheric air under pressure to
energy into usable kinetic energy. From there, this energy transfer
can be harnessed to power various pneumatic tools.
Industrial air compressors work similarly to combustion engines.
Generally, air compressor operation requires a pump cylinder,
piston and crankshaft to transfer energy for a wide variety of
tasks. These basic components can help supply air for filling up
objects like tires or inflatable pool toys, or they can supply power
for operating tools such as drills, nail guns, grinders, sanders and
spray guns.
From impact wrenches to AC units, many versatile air-powered
tools and machines are responsible for the comfort, shelter,

automation and efficiency of everyday life. The compressors
themselves are more compact and lightweight than other centralized
power sources. They are also long-lasting, require less maintenance
and are easier to move than other old-fashioned machinery.Air
compressors work by forcing atmospheric air under pressure to
energy into usable kinetic energy. From there, this energy transfer
can be harnessed to power various pneumatic tools.
Industrial air compressors work similarly to combustion engines.
Generally, air compressor operation requires a pump cylinder,
piston and crankshaft to transfer energy for a wide variety of
tasks. These basic components can help supply air for filling up
objects like tires or inflatable pool toys, or they can supply power
for operating tools such as drills, nail guns, grinders, sanders and
spray guns.
From impact wrenches to AC units, many versatile air-powered
tools and machines are responsible for the comfort, shelter,
automation and efficiency of everyday life. The compressors
themselves are more compact and lightweight than other centralized
power sources. They are also long-lasting, require less maintenance
and are easier to move than other old-fashioned machinery.

V.COMMON TROUBLES
A variety of problems can cause a rotary screw air compressor to
fail well short of its full life expectancy. Issues such as air leaks,
filter clogs, and inadequate lubrication can all serve as warning
signs of a gradually failing system.
While you should always carry out compressor maintenance
according to schedule, the problems associated with system failure
can still take root if certain issues and their symptoms go
unrecognized. The following issues are among the main problems to
look for as you proceed with your air compressor troubleshooting
efforts.
Air Leaks
Leaks along a system are often the cause of air compressor failure.
These leaks can form as parts wear down with age. As cracks form
along one of the pipes or hoses, the loss of air can be a slow but
gradual process. Little by little, the crack will render your system
far less efficient. When a leak becomes large, it might become an

audible problem that isn’t difficult to trace (if you follow the noise).
In a lot of cases, however, it takes ultrasonic equipment to isolate the
source of the problem. In any case, air leaks can be a costly problem
due to the lost productivity resulting from decreased volumes of
compressed air in a given set of operations.
Exceeded Pressure Limits
Compressor failure is also often the result of excess pressure. When
system operators run compressors at pressure levels beyond the
recommended limits, the effect of this excess pressure puts undue
strain on system components. Basically, air compressors have their
limits for a reason.

Pressure limits can get exceeded when a single air compressor
conducts too many simultaneous operations. If you are using a small
machine to handle a multitude of high-powered tasks, you are liable
to shorten the life of the air compressor. While it might seem as
though you are saving money by overworking one air compressor,
you might actually save in the long run by investing in a second
compressor and evening out the workloads.
The costs associated with excess pressure levels can be financially
draining in several ways, as excess pressure leads to wasteful energy
usage, shortened service intervals, increased occurrences of
downtime, and earlier compressor failure.
Clogged Air Filters
The air filters are among the most important components of a
compressed-air system. If not for the air filters, the compressed air
your system generates would get corrupted with dust and dirt as it
travels to each endpoint application. However, air filters themselves
get dirty and need frequent monitoring.

As dirt and dust collect on the air filters, impurities move through
the system and degrade the quality of compressed air. Moreover,
dirty air filters impede system performance and force the system to
exert more energy just to perform basic functions. If the problem
persists, dirty air filters can lead to excess energy consumption,
costly maintenance, and downtime. Rotary screw air compressor
overheating is also sometimes the result of clogged air filters.
Infrequent Maintenance
Another oversight that can lead to premature compressor failure is
insufficient maintenance. If you have not established a maintenance
schedule for your air compressor and its assorted attachments,

issues could easily emerge, some of which are liable to spread before
they even come to your attention. In some cases, the issues might
start from simple problems you could rectify within minutes during
a routine checkup.
For example, you can remedy the build-up of dirt and the gradual
wear-down of system resources with daily inspections of the filters
and valves. At times when nobody is using the system, make sure to
turn off the compressor and close it at the valves. Moreover, you
should monitor system noises regularly to ensure no irregular
patterns emerge. It’s a best practice to establish a day of the week or
month for each area of system maintenance.
Insufficient Lubrication
As with motor vehicles, air compressors need sufficient oiling and
lubrication to function as intended. Some of the most common
causes of compressor failure are irregular oil changes and negligent
lubrication intervals. When you fail to lubricate the internal

components of an air compressor sufficiently, friction occurs
between the metal surfaces.
As lubrication ages, it loses its viscosity due to prolonged exposure
to heating and cooling cycles. If the working environment becomes
excessively humid, grease can liquefy and lose its ability to lubricate
the moving parts properly. Likewise, if extremely cold temperatures
permeate the workspace, the lubricant can become icy and
ineffective. Alternatively, if you leave a lubricant to age beyond its
usefulness, its properties can become acidic and have a varnishing,
corrosive effect on the interior parts.
When you replace the oil and lubrication in your air compressor, it
is important to remove the old oil. When old and new oils mix, the
former can degrade the latter’s quality. For example, when you
refill a dirty oil tank, the acidity of the older oil lining the interior
can corrupt the new oil supply and reduce its freshness. Soon
enough, problems associated with old oil will resurface. A similar

effect can occur when you apply fresh lube over old, hardened
lubricant.
Dirty Air/Oil Separator
For compressed air to be clean and pure when it reaches the
endpoint, oil from the system needs to be filtered out before the air
leaves the machine and travels through the hoses. Oily compressed
air can seriously degrade the quality of pneumatic operations such
as sanding, spray painting, and air drying.
The component that prevents compressed air from becoming
saturated with oil mist is the air/oil separator, which extracts oil
from the air before the latter leaves the compressor. However, the
air/oil separator can only hold so much oily build-up, which can
ultimately spread to adjacent parts and have a detrimental effect on
the system as a whole. Therefore, you need to replace the air/oil
separator periodically, preferably after 800 hours of use.The screw
component of a rotary compressor—alternately called the pump or
airend—is the principal piece of the system’s functionality.

However, the pump can wear down and require maintenance long
before it reaches the end of its life expectancy. Therefore, screw
compressor troubleshooting is often necessary in this area.
Issues that can lead to pump failure include overheating and excess
system pressure. If condensation build-up persists within the
machine, the effects of the moisture can be detrimental to the
airend. The impact of vibrations and the effects of oily residue can
also wear down on the screw component. When the air compressor
lags, stalls, or appears defective, this area is often the root of the
problem. Signs of an advanced problem include leaks from the oil
seal and strange bearing noises.
Drive Train Issues

In belt-driven models, the belts and sheaves should be inspected
after every 500 hours of use. Direct-coupled rotary screw models
need alignments when the motor and airend are aligned improperly.
If alignments are off, motor and airend bearings are liable to wear
down and cause the compressor to fail. To ensure proper alignment,
it is generally best to contact an air compressor service professional.
Improperly Greased Motor Bearings
The bearings in the compressor motor enable the system to operate.
Sufficient amounts of grease applied periodically help the bearings
move around smoothly. If the grease is insufficient, the bearings are
liable to cause friction and degrade the overall performance of the
motor.
To ensure proper functioning of the motor bearings, you must
grease them with a lubricant of the proper grade and viscosity.
Failure to do so could lead to system overheating, excess energy
consumption, and premature system failure. Do not mix different
types of motor grease or alternately apply them to the bearings, as

the properties of each lubricant could come into conflict and have a
corrosive effect.
How To Prevent Rotary Screw Compressor Failure
Air compressor problems are easiest to remedy when you identify
them at an early stage. Nonetheless, you can rectify even the more
advanced problems if you follow a rotary screw troubleshooting
guide and service or replace the affected parts.
That said, you should read any symptom associated with air
compressor failure as a warning sign to shut down the system and
service it immediately. Failure to act now could ultimately prove to
be a costly mistake down the line. Therefore, you should have an air
compressor troubleshooting chart available, complete with a list of
actions to perform for each of the following pre-failure symptoms.
Air Compressor Fails To Start
If you press the power button and the compressor fails to activate,
the problem will typically be related to an electrical issue. In some
cases, the machine will have tripped on a safety device. Either way,
the first thing to do is check for the following errors:
Disconnected power supply

Errors on the display
Failed emergency stop
Inspect the overload relay and reset if necessary. There might be an
issue with the phase sequence if the installation was recent. In any
case, it is always best to inspect for simple problems before you
consider the possibility of more serious issues.
Compressor Powers Off At High Temperatures
If your compressor shuts down abruptly as it reaches a certain
temperature, the problem is likely due to one of the following issues:
Overbearing ambient temperature
Poorly ventilated workspace
Poorly ventilated workspace
Dirty oil cooler
Malfunctioning thermostatic valve

Blocked/dirty oil lines
The biggest cause of compressor burnout is overheating, which can
occur when there is too much humid air trapped in the work area—
especially in compressors with obstructed vents. If the machine is up
against a wall and the vents lack breathing space, consider moving
the compressor to a better-ventilated area. Also, check the oil and
clean out the cooler and oil lines if necessary. If oil corrodes and
loses its proper viscosity, internal machine parts will start to grind,
causing friction and overheating.
Compressor Runs But Fails To Load

Rotary screw compressors run in two load modes: the loaded or
“pumping air” mode, and the unloaded or “idle” mode. Depending
on air demand, the inlet valve—through which the air loads—will
either open or close. The solenoid valve supplies this same valve with
controlled air. If the compressor fails to load, inspect the following:
The solenoid valve power source
The solenoid valve coil
The solenoid valve performance
The inlet valve performance
Make sure the solenoid valve receives power, and that both the
solenoid and inlet valves perform free of obstructions.
Insufficient Pressure
If your air compressor generates air pressure at low capacity, check
the current air demand. In some cases, the demands of assorted
tools are too low to merit normal pressure levels. Be sure to check
for the possibility of a leak somewhere along the compressed air
system as well. If the air pressure is indeed insufficient for your
current round of operations, perform the following steps:
Inspect the inlet valve for obstructions.
Inspect the inlet filter for dust or dirt.
Inspect the condition of the air filters.
Inspect the oil separator.
Replace the air filters and oil separator if necessary. Clean the inlet
filter as needed and make sure the valve is fully open.
Safety Valve Fails
If the compressor fails to unload, inspect the pressure switch to
ensure it functions properly at the correct setting. Also, inspect the
performance of the inlet and solenoid valves. If the oil separator is
placed after the safety valve, inspect the former’s differential
pressure.
Compressed Air Saturated With Oil
If any trace of oil gets past the separator, it can degrade the quality
of your endpoint applications. When oil does saturate the
compressed air, the problem is typically due to one of the following
issues:
The oil separator is worn out and dirty.
The scavenge line is clogged.
Operating temperature is too high.
Oil level is excessively high.
The oil type is ill-suited to the compressor.
The minimum pressure valve is malfunctioning.

If the oil separator is old and dirty, replace it with a new one. If the
oil has thinned out, replace it with a more appropriate brand of
proper viscosity.
Moisture In Compressed Air
Water particulates comprise a portion of all ambient and
compressed air. As such, there is no way to guarantee compressed
air with zero moisture content. That said, a properly functioning
compressor should keep the water content down to a minimum level.
If water content rises at the expense of endpoint functions, inspect
the condensate trap. Does it appear to trap water at normal levels?
Every couple of minutes, water should come out. When you use the
manual drain, little—if any—water should come out. If your system
includes an air dryer, make sure the dewpoint is ideal.
Failure Of The Overload Relay

If the overload relay trips, inspect the current draw and clamp
meter on your air compressor. If the motor draws excessive current
levels, perform the following steps:
Physically turn the compressor, but only with the power off.
Inspect the isolation of the motor windings.
Check the running-time voltage of the compressor.
Make sure you can turn the compressor without it making hiccup
noises. If the voltage plummets each time the compressor is
activated, the connection is weak. If overload still causes the
compressor to trip despite a normal current, replace the overload
relay.
Rotary screw models are used across a vast range of assembly
applications, the results of which are everyday fixtures of
contemporary living. From the automobiles and aircraft that fill the
world’s roads and airways to the appliances, furnishings, and
consumable products found on the shelves of every supermarket,

companies have used compressed air to mold, attach, and fasten
product parts and can, bottle, seal, and label foods and beverages.
Today’s increasingly eco-conscious world relies on compressed air
more than ever as an alternative power source for a variety of high-
tech applications, the likes of which would otherwise consume
enormous amounts of energy. On this and numerous other fronts,
Kaishan Compressor leads the way by offering air compressors that
preserve energy while providing more air per unit of power.
At Kaishan Compressor, we offer a range of rotary screw air
compressors, from the 10-50 HP belt-drive KRSB to the 100-500 HP
two-stage KRSP 2. We back the main screw airend component with
a lifetime warranty, while we offer a five-year warranty on the other
major components.
Whether you run a large or small production facility, compressed
air can serve as a vital utility that could easily supplant the use of
electrical power in several areas. For numerous processes and
assembly tasks, air-powered pneumatic tools and machinery can

accomplish levels of productivity at volumes human hands could
never match.
Whether you are looking to buy your first compressor or replace an
old, outdated model, there are rotary compressors for all demands
and tasks in the Kaishan Compressor inventory. Browse our catalog
and contact us today for more information on high-quality air
compressors.
V.CONCLUSION
It was identified that compressed air systems contribute
significantly to worldwide electricity consumption. Compressed air
systems at South African mines were identified as a focus area to
reduce electricity consumption. Mines are very dependent on
adequate compressed air supply due to its flexibility and ease of use.
A brief overview of mine compressed air systems revealed that these
systems are very complex. A lack of extensive knowledge and the
complexity of the mine compressed air systems resulted in the
inefficient operation of the systems. An opportunity was identified to
reduce electricity consumption by improving mine compressed air
systems. Existing energy efficiency projects on industrial projects
revealed that mine compressed air systems are generally larger and
more complex than most industrial systems. Analysis of existing
energy saving initiatives implemented on compressed air systems
revealed that most projects are done unsystematically. This is
largely due to a misunderstanding of compressed air systems.

Typical mistakes identified include the assumption that a project
that reduces the demand for compressed air will automatically
result in a direct reduction in compressor power consumption. It
was proved that some techniques realised insignificant savings
because they did not manage a reduction in compressor power
consumption. Analysis of complex mine compressed air systems can
be very time consuming. Simplified approximation methods were
developed to evaluate possible energy saving initiatives without
using complex equations and simulations packages. These
approximation methods were derived from theoretical equations
and verified with actual system data. These approximation methods
are summarised in Table 13. The approximation methods provided
results with accuracies of more than 90% for some projects.

VI.REFERENCES
1.Perry, R.H.; Green, D.W., eds. (2007). Perry's Chemical
Engineers' Handbook (8th ed.). McGraw Hill. ISBN 978-0-07-
142294-9.
2.Bloch, H.P.; Hoefner, J.J. (1996). Reciprocating Compressors,
Operation and Maintenance. Gulf Professional Publishing. ISBN 0-
88415-525-0.
3. Reciprocating Compressor Basics Archived 2009-04-18 at
the Wayback Machine Adam Davis, Noria Corporation, Machinery
Lubrication, July 2005.
4. Screw Compressor Archived 2008-01-10 at the Wayback
Machine Describes how screw compressors work and include
photographs.
5.Technical Centre Archived 2007-12-13 at the Wayback
Machine Discusses oil-flooded screw compressors including a
complete system flow diagram


Compressor Case Study: Classification and Operation

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UNIVERSITY OF CAGAYAN VALLEY

ENGR. ROGER AGBISIT JR.

KARL ANDREW A. NEPOMUCENO

A compressor is a mechanical device that increases the pressure of a

gas by reducing its volume. An air compressor is a specific type of

Compressors are similar to pumps: both increase the pressure on

distinction is that the focus of a compressor is to change the density

or volume of the fluid, which is mostly only achievable on gases.

Gases are compressible, while liquids are relatively incompressible,

so compressors are rarely used for liquids. The main action of a

pump is to pressurize and transport liquids.

Many compressors can be staged, that is, the fluid is compressed

several times in steps or stages, to increase discharge pressure.

to accommodate the already compressed gas without reducing its

used).The function of compressor is to compress the gases and

vapours from low pressure to high pressure. According to second

law of thermodynamics this is only possible when work is done on

the system, i.e., on the gas or vapour. Compressors have wide

industrial and domestic applications such as compression of

refrigerants in refrigerators and air conditioning plants,

compression of air to fill the air in wheel of automobiles, use of

compressed fluids in non-conventional .A compressor is a

mechanical device that increases the pressure of a gas by reducing

its volume. An air compressor is a specific type of gas compressor.

Compressors are similar to pumps: both increase the pressure on

distinction is that the focus of a compressor is to change the density

or volume of the fluid, which is mostly only achievable on gases.

Gases are compressible, while liquids are relatively incompressible,

so compressors are rarely used for liquids. The main action of a

pump is to pressurize and transport liquids.

Many compressors can be staged, that is, the fluid is compressed

several times in steps or stages, to increase discharge pressure.

to accommodate the already compressed gas without reducing its

Air compressors are categorized as either positive displacement or

dynamic displacement, based on their internal mechanisms. The

four most common types of air compressors are: Rotary Screw

Compressors. Reciprocating Air Compressors.The two main types

of compressors are dynamic and positive displacement. The positive

displacement compressor is probably the one you're familiar with. It

in volume causes a rise in pressure.

There are two basic types of air compressors:

Positive displacement, and

In the positive displacement type, a specified quantity of air is

trapped in a compression chamber and the volume which it occupies

is mechanically reduced, causing a corresponding rise in pressure

prior to discharge. Rotary screw, vane and reciprocating air

compressors are the three most common types of air positive

displacement compressors found in small and medium sized

Dynamic air compressors include centrifugal and axial machines,

beyond the scope of this document.

a. Rotary Screw Compressors

Rotary screw compressors have gained popularity and market share

(compared to reciprocating compressors) since the 1980s. These

screw compressor. Two mated rotors mesh together, trapping air,

the air purity requirements, rotary screw compressors are available

as lubricated or dry (oil free) types.

Figure 6 - Cross Section of a Representative Rotary Screw

The biggest advantage of screw compressors over small air cooled

reciprocating units is that they can run at full load continuously

where the reciprocating compressors must be used at 60% duty

cooler air that is easier to dry. Be aware that rotary screw

compressors may not be the most efficient choice compared to

start/stop reciprocating compressors. Please refer to Case 3: On/Off