AIR

COMPRESSORS
GUIDED By PREPARED By
NAVJEET SHRMA V PARTHIBAN
LTCDR MCERA II
SI(SAX) MCTRG(SAX)
1
 DEFINITION

▪ A kinetic machine that is used to

increase the pressure of air either by
increasing its kinetic energy or by
reducing its volume.

OR

▪A machine that extracts air from

the atmosphere and compresses it
into a holding chamber.

2
THERMODYNAMICS

3
 THERMODYNAMICS
▪ THERMODYNAMICS DEFINITION
The field of science which deals with energy possessed by
gases and vapors, their conversion in terms of heat, work and their
relationship with properties of system is called thermodynamics.

▪BOYLE’S LAW
The volume of a given mass of a gas varies inversely as its
absolute pressure, provided temperature remains constant.
i.e. When T is constant, V is inversely proportional to P.
i.e. V 1/P (When temperature remains constant)
i.e. V = K/P
i.e. PV=K (Where K is a constant)
4
 THERMODYNAMICS
▪ CHARLES LAW
The volume of a given mass of a gas varies directly as its
absolute temperature provided the pressure remains constant.
i.e. When P is constant V proportional to T
i.e. V  T (when pressure is constant)
i.e. V = KT (where K is a constant)

▪ PERFECT GAS
A perfect gas or an ideal gas is the one, which strictly obeys all
gas laws under all conditions of temperature and pressure.

5
 THERMODYNAMICS
▪ COMPRESSION
It is the process of increasing the pressure of gas by reducing its
volume.

▪ ISOTHERMAL COMPRESSION
Isothermal compression is the process of compression of gas at
constant temperature. In practice this would mean that when the
gas is compressed heat would have to be removed from the gas
at the same rate as it is being received. This would necessitate a
very slow compression or efficient cooling.

6
 THERMODYNAMICS
▪ ADIABATIC COMPRESSION
Adiabatic compression is the process of Compression of a gas
at constant enthalpy Conditions.
Or
If no heat is given to or taken from the gas through the cylinder
walls and all the work done in compressing the gas is stored With in
it. (No exchange of heat energy between the system and
surroundings is called adiabatic compression.)

▪ POLYTROPHIC COMPRESSION
Polytrophic compression is the process of compression where
a partial amount of heat energy exchange takes place between the
air inside the cylinder and outside source. 7
PV DIAGRAM OF RECIPROCATING
COMPRESSOR

8
 PV DIAGRAM OF RECIPROCATING
COMPRESSOR
▪ In previous slide, figure shows a single stage, single acting
reciprocating compressor diagrammatically and its PV Indicator
diagram cycle. Commencing at point a, the cycle of operation is
as follows:-

▪ A to B polytrophic compression of Previously drawn air

into the cylinder with the starting of piston inward stroke.

9
 PV DIAGRAM OF RECIPROCATING
COMPRESSOR
▪ At B discharge valve opens as the pressure inside the cylinder
exceeds the pressure outside the cylinder (valve)

▪ B to C compressed air discharged at constant pressure.

▪ At C piston completes the inward stroke and starts moving

outwards, resulting drop in pressure inside the cylinder clearance
volume acting on the discharge valve, comparing to pressure acting
outside the cylinder on the valve. Hence discharge valve closes.

▪ C to D the air within the clearance volume expands.

10
 PV DIAGRAM OF RECIPROCATING
COMPRESSOR
▪ At D the pressure within the cylinder drops below atmospheric
pressure and the suction valve opens because of higher
atmospheric pressure.

▪ D to A air is drawn inside the cylinder till the end of outward

stroke.

▪ At A the pressure inside and outside the cylinder acting on the

suction valves gets equalized and valves gets closed because of
spring force.

11
 CLEARANCE VOLUME

When the piston is at top dead

center (TDC), the volume within the
cylinder and passage leading to the
suction and discharge valves is
called clearance volume. This
clearance is necessary between
the piston and the cylinder head
and the valves to avoid piston
pumping the cylinder head and
valves during discharge stroke.

12
 COMPRESSOR WITH
NIL CLEARANCE VOLUME

The nil clearance volume will

damage the valve, piston &
cylinder head as the piston will
bang cylinder head, while
moving from BDC to TDC. There
will be no place to accumulate
the compressed medium.

13
COMPRESSOR HAVING SMALL CLEARANCE
VOLUME

14
 COMPRESSOR HAVING EXCESSIVE
CLEARANCE VOLUME
With more clearance volume, the piston
must travel farther in its compression
stroke before the cylinder pressure
exceeds the discharge line pressure
enough to open the discharge valve. The
discharge volumetric efficiency (VEd)
decreases and can be reduced to a point
(especially in high speed machines)
where the compressed gas cannot be
discharged quickly enough and the valve
is forced to close late. A similar reduction
in volumetric efficiency, and therefore in
capacity, can be expected on the suction
valve when the clearance volume is 15
increased
ACTUAL RECIPROCATING COMPRESSOR PV-
DIAGRAM.

16
CLASSIFICATION

17
 CLASSIFICATION OF COMPRESSORS
Compressors are classified mainly on the basis of following :-

▪ Principle of operation

▪ Developed pressure

18
 CLASSIFICATIONS OF COMPRESSORS
Other classification of compressor:-
▪ Mode of operation

▪ Number of compression stages

▪ Number of power cylinders

▪ Method of inter stage cooling

▪ Power drive

▪ Nature of installation

19
 CLASSIFICATION OF COMPRESSORS
PRINCIPLE OF OPERATION

POSITIVE DISPLACEMENT DYNAMIC

CLICK FOR ANIMATION CLICK FOR ANIMATION 20
 CLASSIFICATION OF COMPRESSORS
PRESSURE

LOW PRESSURE HIGH PRESSURE SERVO AIR PRESSURE

21
 LOW PRESSURE AIR COMPRESSORS

▪These compressors develop air

pressure upto 8 kg/cm² or 120 PSI.

▪These have lesser discharge air

temperature.

CLICK FOR ANIMATION

22
 USES OF LOW PRESSURE AIR

▪ Controls of main engines, CPP etc.

▪ Pressure testing of condensers and watertight compartments.

▪ Blowing ship’s siren

▪ Spray painting

▪ Blowing down of sea chest valves

▪ Operation of firefighting systems

▪ Domestic uses. 23
 HIGH PRESSURE AIR COMPRESSORS

▪These compressors develop air

pressure above 8 kg/cm² or 120
PSI.

▪These have higher discharge air

temperature.

CLICK FOR ANIMATION

24
 USES OF HIGH PRESSURE AIR

▪ Starting of main engines and diesel alternators.

▪ Charging/loading of torpedoes.

▪ Torpedo firing

▪ Supply of blast air to guns.

▪ Charging of breathing apparatus sets like ICABA,BASCCA,DCBA etc.

25
 SERVO AIR COMPRESSORS

▪ These are basically low pressure

air compressors but the air
produced by them is used for
pneumatic controls.

▪ Servo air contains less moisture

and impurities as compared to other
types of air.

CLICK FOR ANIMATION

26
CLASSIFICATION ON BASIS OF OPERATION
BASIS OF OPERATION

RECIPROCATING ROTARY
27
RECIPROCATING
COMPRESSOR

28
 RECIPROCATING COMPRESSOR

In this compressor, air is compressed by

means of a piston reciprocating inside a
cylinder. The piston is connected to a
crankshaft that takes drive from a prime
mover.

29
 CLASSIFICATION OF RECIPROCATING
COMPRESSOR

▪ Single acting which

compresses the air at only
one end of the piston.

CLICK FOR ANIMATION

▪ Double acting which

compresses the air at both the
ends of the piston.

CLICK FOR ANIMATION 30

 MAIN COMPONENTS OF RECIPROCATING AIR
COMPRESSOR

CYLINDER HEAD INLET VALVE

CYLINDER DELIVERY VALVE

PISTON

CONNECTING ROD

CRANK SHAFT MAIN BEARING

CRANKCASE

31
 OPERATION OF RECIPROCATING AIR
COMPRESSOR
In this, inside a cylinder, when the
piston moves downwards from top
dead center, the pressure inside the
cylinder falls below the atmospheric
pressure and inlet valve opens. The
atmospheric air is drawn into the
cylinder. On upward movement, the
suction valve gets closed and the
air inside the cylinder is
compressed to a higher pressure.
When the piston is reaching TDC,
the delivery valve opens and CLICK FOR ANIMATION
discharges the compressed air to
the air reservoir. 32
 SALIENT FEATURES OF RECIPROCATING
COMPRESSORS

▪ The maximum delivery pressure may be as high as 1000 bar.

▪ The maximum air discharge is about 300 m³/ min.

▪ They are suitable for low discharge of air at very high pressure.

▪ The speed of air compressor is low.

▪ The air supply is intermittent.

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 DISADVANTAGES OF COMPRESSOR
▪ The size of air compressor is large for the given discharge.

▪ The balancing is a major problem.

▪ Lubricating system is complicated.

▪ The air delivered is less clean as compared to rotary

compressors, as it comes in contact with lubricating oil.

▪ Isothermal efficiency is used for all sorts of calculations.

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 SINGLE STAGE COMPRESSION

▪When the air compressor

increases the pressure of air in
one working stage, the process is
called single stage compression.

▪It is suitable for only low ranges

of air pressure.

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 DRAWBACKS OF SINGLE STAGE
COMPRESSION
▪ The size of the cylinder will be too large.

▪ Due to compression, there is a rise in the temperature of air. It is

difficult to reject heat from air in the small time available during
compression.

▪ Sometimes, the temperature of air, at the end of compression, is

too high which may heat up the cylinder head or burn the lubricating
oil.

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 MULTISTAGE COMPRESSION

▪ When the process of compression takes place in more than one

working stage, it is known as multistage compression.
▪ It is suitable for higher ranges of pressure.

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 ADVANTAGES OF MULTISTAGE COMPRESSION

▪The work done per unit mass of air is reduced in multistage

compression with intercooler as compared to single stage
compression for the same delivery pressure.

▪It improves the volumetric efficiency for the given pressure ratio.

▪The size of the two cylinders (i.E. High pressure and low
pressure) may be adjusted to suit the volume and pressure of the
air.

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 ADVANTAGES OF MULTISTAGE COMPRESSION

▪ It reduces the leakage loss considerably.

▪ It gives more uniform torque and hence a smaller size flywheel is

required.

▪ It provides effective lubrication because of lower temperature range.

▪ It reduces the cost of compressor

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MULTISTAGE COMPRESSION WITH
INTERSTAGE COOLING

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40
 INTERSTAGE COOLING

▪It is the process of cooling of

discharge air in between intermediate
stages of an air compressor.

▪It can be carried out either by air,

water or any other available cooling
medium.

CLICK FOR ANIMATION

41
 FUNCTION OF INTERSTAGE COOLING IN
COMPRESSION

▪ Inter stage cooling decreases the

volume and temperature of
compressed air after each stage of
compression. It results in saving of
work required to compress the air
in the next stage.

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 ADVANTAGES OF INTERSTAGE COOLING IN
COMPRESSION
▪ Work done is reduced.

▪ Temperature can be brought back to ambient air temperature.

▪ Material of lesser strength can be used as the temperature is

reduced drastically.

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 SINGLE ACTING SINGLE STAGE
RECIPROCATING AIR COMPRESSOR

It is the compressor in which

air compression takes place in
a single stage and it is carried
out at only one side of the
piston. This compressor is
used to supply low pressure
air.

CLICK FOR ANIMATION

44
 TWO STAGE RECIPROCATING AIR
COMPRESSOR
In this compressor, air
compression takes place in two
working stages. Intercooler and
after cooler may be fitted as per
the required volume and
pressure of air supplied. The
discharge pressure of first stage
is considered equal to the
suction pressure of second
stage neglecting the pressure
drop occurring in the intercooler .

45
VARIOUS PARTS OF A TWO STAGE
RECIPROCATING COMPRESSOR

1. Intercooler
2. Fan and belt
3. Piston and pin
4. Crankshaft
5. Main bearing
6. Drive shaft
7. Oil pump

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THREE STAGE RECIPROCATING AIR
COMPRESSOR WITH SYSTEM

47
FOUR STAGE RECIPROCATING AIR
COMPRESSOR.

48
 SECTIONED VIEW OF FOUR STAGE
RECIPROCATING AIR COMPRESSOR.

1. Air inlet
2. 1st stage intercooler
3. 2nd stage intercooler
4. 3rd stage piston
5. 3rd stage intercooler
6. After cooler (Discharge)
7. Compressed air outlet

49
 SULZER ( S 5 W 2 17 L) HIGH PRESSURE AIR
COMPRESSOR
This compressor is a five
stage, v-type, Single acting,
water cooled, electric Motor
driven air compressor with two In
number first stages. Inter stage
Coolers are provided after each
stage for maintaining appropriate
inlet air temperature to each
stage.

50
 FREE PISTON AIR COMPRESSOR (DK 10)

The diesel driven compressor comprises a horizontal four

stage reciprocating piston type HP air compressor and a single
cylinder two stroke free piston compression ignition engine built
as a single set in a common housing.

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51
 SPECIAL FEATURES OF DK-10 COMPRESSORS

▪ Stroke length of pistons is not constant, i.e. Increase and

reduction in the quantity of fuel injected varies the stroke length
(directly proportional).

▪ Self adjustment of moving pistons without any external

arrangement, i.e. Movement of piston to outer dead center and
back to inner dead center. This helps to get the compressor
stopped when quantity of fuel injected is reduced to 60 - 50 %.

▪Speed increases with increase in load i.e. Increase in number of

working cycle with increased compressed air in clearance
volume.
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SPECIAL FEATURES OF DK-10 COMPRESSORS

▪ Starting should be instantaneous upon the first return stroke.

▪ Seizure or breakage of critical parts will not cause any

breakdown of serious consequences as compressor comes to an
instant stoppage.

▪ Better balanced, hence special foundation is not required.

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 ROTARY
COMPRESSORS

54
 ROTARY COMPRESSORS

In this type of compressor, air

is compressed by a rotating
component that reduces the
volume of air inside a cavity. It
gets its drive from a prime
mover.

CLICK FOR ANIMATION

55
 SALIENT FEATURES OF ROTARY
COMPRESSORS
▪ The maximum delivery pressure is 10 bar only.

▪ The maximum free air discharge is as high as 3000 m³/min.

▪ They are suitable for large discharge of air at low pressure.

▪ The speed of air compressor is high.

▪ Air supply is continuous.

56
 SALIENT FEATURES OF ROTARY
COMPRESSORS

▪ The size of air compressor is small for the same discharge.

▪ There is no balancing problem.

▪ Lubricating system is simple.

▪ Air delivered is cleaner as compared to reciprocating

compressor as it does not come in direct contact with lubricating
oil.

▪ Isentropic efficiency is used for all sorts of calculations.

57
 ROTARY COMPRESSORS

In this compressor the compression of air is effected by the

rotation of an impeller or vane. Various types of rotary air
compressors are :-

▪ Roots blower or lobe type compressor

▪ Vane type compressor
▪ Screw compressor or helical lobe compressor
▪ Scroll Compressors

58
 LOBE TYPE AIR COMPRESSOR
▪One of the rotors is driven by the motor
or engine and the other is geared to the
driven one. When one spins, the other
spins in the opposite direction with very
precise timing and clearances.

▪Air is sucked into the inlet, and it is

forced around by the lobes, and then
pushed out of the discharge. A very
small amount can escape back through
the clearance in the rotors, and this is
called the "slip." The slip is why blowers
are only used for very low pressures. CLICK FOR ANIMATION
59
 VANE BLOWER COMPRESSOR

It consists of a rotor disc rotating

eccentrically in an airtight casing
with inlet and outlet ports. Either the
rotor disc or the casing has a
number of slots (generally 4 to 8)
containing vanes. The rotor rotates
eccentric in the casing thereby
pressing or squeezing all the vanes.
Drive is taken from the prime mover
through a shaft.

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60
 TYPES OF VANE BLOWER COMPRESSOR

Fixed vane rolling piston type Rotating vane type where vanes
where vanes are stationary rotate with the rotor disc.

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61
 SCREW COMPRESSOR

These consist of either a single

screw driven in a close cavity or
two screws meshing in a casing in
which drive is transmitted to one
screw and the rest are driven by
the driver screw. As the screws are
rotated at high rpm, they create a
low pressure region at the inlet of
the compressor. The air is trapped
in the helical grooves of the screw
and is delivered at a higher
pressure at the outlet.

62
 TYPES OF SCREW COMPRESSORS
BASIS OF OPERATION

SINGLE SCREW TWIN-SCREW TRIPLE SCREW

COMPRESSOR COMPRESSOR COMPRESSOR
CLICK FOR ANIMATION CLICK FOR ANIMATION CLICK FOR ANIMATION

63
 SCROLL COMPRESSOR
▪A scroll compressor uses two
interleaving scrolls to compress or
pressurize medium such as air or gases.
The vane geometry may be involute,
Archimedean spiral , or hybrid curves.[
▪ Often, one of the scrolls is fixed, while
the other orbits eccentrically without
rotating, thereby trapping and
compressing pockets of medium between
the scrolls. Another method for producing
the compression motion is co-rotating the
scrolls, in synchronous motion, but with
offset centers of rotation. The relative CLICK FOR ANIMATION
motion is the same as if one were orbiting. 64
AIR COMPRESSOR VALVE

CLICK FOR ANIMATION

65
 DYNAMIC
COMPRESSORS

66
 DYNAMIC COMPRESSORS

In these compressors, energy is

continuously added to increase the
gas velocity within the compressor
casing and at the discharge the
velocity is dropped suddenly by
means of diffuser that results in
pressure rise.

67
 TYPES OF DYNAMIC COMPRESSORS
DYNAMIC COMPRESSORS

CENTRIFUGAL COMPRESSORS AXIAL FLOW COMPRESSORS

68
 TYPES OF CENTRIFUGAL COMPRESSORS
▪ Single stage compressor.
▪ Multistage centrifugal compressor.
▪ Multistage with inter cooler centrifugal compressor.
▪ Multistage with double flow compressor.

CLICK FOR ANIMATION CLICK FOR ANIMATION

69
 APPLICATION OF CENTRIFUGAL
COMPRESSORS
▪Process industries such as to make coke out of coal where it is
used to draw off gas from the coke ovens.

▪Air conditioning plants.

▪Internal combustion engine supercharger.

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AXIAL FLOW COMPRESSOR

CLICK FOR ANIMATION

71
 ADVANTAGES OF AXIAL FLOW COMPRESSORS

▪ Volume of air handled by these is more as compared to

reciprocating compressors.

▪ Their efficiency is as high as 80%.

▪ They can be run at high speed from 3000 rpm to 18,000 rpm
hence can be connected directly to steam and gas turbines.

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 ADVANTAGES OF AXIAL FLOW COMPRESSORS

▪Capacity of compressor ranges between 1000 CFM to 150,000

CFM.

▪Have less moving parts, hence less wear down, long life and less
maintenance.

▪No vibration as there is no unbalanced mass.

▪Silent in operation, hence less noise pollution.

73
 DISADVANTAGES OF AXIAL FLOW
COMPRESSORS
▪Per stage pressure raise is very less.

▪Capacity is limited above 1000 CFM as more efficient compressors

are available for lesser capacities.

▪Compressor starts surging with dirty filters.

▪Fouled impellers cause vibration.

74
SAFETY & CONTROL
DEVICES

75
 SAFETY DEVICES

▪ Low lub oil pressure control

▪ High first stage air temperature cutout

▪ Safety valve

▪ Bursting disc

76
 SAFETY DEVICES
LOW LUB OIL PRESSURE CUTOUT
▪ In a forced lubricated air compressor when the lub
oil pressure falls below the desired minimum pressure
a pressure switch is set to trip the compressor motor.
With the tripping of motor a warning with light
indication comes on the control panel.
HIGH 1ST STAGE AIR TEMPERATURE CUTOUT
▪In a water cooled multistage air compressor when
the first stage air temperature exceeds maximum limit
a thermostatic switch trips the compressor motor. A
warning with light indication comes on the control
panel. Temperature rise in compressor indicates
improper or insufficient cooling of compressor and
77
compressed air.
 SAFETY DEVICES
SAFETY VALVE
▪ After each stage of compression, a relief
valve will normally be fitted to release the
excess pressure between stages.
Regulations only require the fitting of a relief
valve on the high pressure stage.

BURSTING DISC
▪ Bursting discs are fitted on to the water side
of stage coolers so that in the event of a
compressed air carrying tube bursting, the
sudden rise in pressure of the surrounding
water will not fracture the cooler casing. 78
 CONTROL DEVICES

▪ Cut in and cut off pressure switch (start/stop control)

▪ Blowing down valve

▪ Constant running control (unloading device).

▪ Automatic drain

79
 CONTROL DEVICES
CUT IN AND CUT OFF PRESSURE SWITCH
(START/STOP CONTROL):-
This is only suitable for small
electrically driven compressors. A
pressure switch attached to the
compressor discharge line is set to
desired maximum/minimum pressure
which would switch the electric current
to the electric motor off or on
respectively. To reduce the number of
starts and stops of the compressor per
unit time, the air bottles (receiver) are
to be large. It must be remembered
always starting current is more than
the running current.
80
 CONTROL DEVICES
BLOWING DOWN VALVE
These are fitted between each stage and
on discharge of the compressor to totally
unload the compressor during starting and
stopping. Also it drains out the condensate
water and oil from oil and water separators
during starting, stopping and running as per
setting of timer.

AUTOMATIC DRAIN
These drain traps are fitted to drain off
condensate water as and when water gets
accumulated in a oil and water separator. 81
 CONTROL DEVICES

CONSTANT RUNNING CONTROL (UNLOADING DEVICE):-

This method of control is the one most often used. The compressor
runs continuously at a constant speed and when the desired air pressure
is reached, the air compressor is unloaded in such a way so that no air is
delivered and practically no work is done in the compressor cylinders.

THE METHODS OF UNLOADING:-

▪Closing of suction valve. (No suction no delivery)
▪Lifting of suction valve. (Suction and discharge through same valve)

82
OPERATION

83
 STARTING PROCEDURE
▪ Check the surrounding and turn the compressor for freeness.

▪ Check the lub oil level in the sump and check the condition of oil also.

▪ Open the drain valves of the entire oil and water separator.

▪ Open the compressor discharge valve to mains (air bottles).

▪ Open the required air bottle filling valve for charging.

▪ Open the cooling water valve.

▪ Start the compressor motor or engine. 84

 STARTING PROCEDURE
▪Purge cooling water system by opening purging cocks.

▪Check the lub oil pressure and cooling water pressure.

▪Close the oil water separator drain valves one by one and see the
stage pressure for the limits.

▪The temperature of discharge air between stages should not be

much above the cooling water temperature.

▪Check for any external leakage of lub oil, cooling water and air.

▪Check lub oil, sea water and inter stage air pressure for their limits;
if found abnormal, rectify the defect. 85
 PRECAUTIONS WHILE RUNNING

▪When the compressor is settled down keep a regular check on

the compressor and its pressure indicated by gauge.

▪The normal lp stage pressure about 120 psi. When compressor

pressure reaches 1200 psi on the HP stage, for the best
efficiency, the water supply is to be regulated so that the
temperature of water leaving the jacket is about 90ºf to 95 f. The
temperature always varies with variation in the sea water
temperature

▪The drain cock on the inter cooler and separator should be

opened for a minute or two in order to clean the moisture and oil
out of the system before compressor is stopped. Close all air stop
valves after stopping.
86
 STOPPING PROCEDURE

▪ Stop the compressor.

▪ Drain the water jacket.

▪ Drain the bottom of after cooler.

▪ Drain the compressor from drain cock.

87
TROUBLESHOOTING

88
 LUB OIL PRESSURE FALLS/ FAILS
CAUSES
▪ Low lub oil level in the sump.
▪ Oil strainers choked.
▪ Faulty pressure gauge.
▪ Pressure gauge line choked.
▪ Pump relief valve is faulty.
▪ Leakage in lubrication system.
▪ Lub oil pump drive broken or slipped.
▪ Lub oil pump defective
89
 LUB OIL PRESSURE FALLS/ FAILS
REMEDIES
▪ Fill up oil in sump up to required level.

▪ Clean the strainers.

▪ Check and renew the gauge.

▪ Clean the gauge line.

▪ Reset/renew the relief valve.

▪ Rectify the leakage.

▪ Repair/renew the drive.

▪ Repair/overhaul the pump. 90

 RAPID RISE IN LUB OIL TEMPERATURE
CAUSES

▪ Defective temperature gauge.

▪ Overheated bearing.

▪ Improper lubrication due to air in the system or choked pipes

and passages.

▪ Failure of lub oil cooling.

91
 RAPID RISE IN LUB OIL TEMPERATURE
REMEDIES

▪ Replace temperature gauge.

▪ Check the compressor alignment and align if required. Replace

bearings if necessary.

▪ Examine the system for air lock and choked pipes and
passages. Clear air lock and choked passages.

▪ Check cooling water supply to oil coolers.

92
 COOLING WATER PRESSURE FALLS
CAUSES

▪Pressure gauge faulty.

▪Air lock in the pump or system.

▪Pump drive broken.

▪Pump defective.

▪Suction strainer choked.

93
 COOLING WATER PRESSURE FALLS
REMEDIES

▪ Check and renew the gauge.

▪ Remove the air lock.

▪ Replace the drive.

▪ Refit/renew the pump.

▪ Clean the suction strainer 94

 COMPRESSOR SPEED LOW
CAUSES

▪ Compressor overloaded.

▪ Overheated bearings.

▪ Low electric supply voltage or frequency.

▪ Belts worn out or slipping (if belt driven)

95
 COMPRESSOR SPEED LOW
REMEDIES

▪ Examine the moving components and discharge pressure.

▪ Align/replace the bearings.

▪ Correct voltage and frequency.

▪ Renew or tighten up the belts

96
 LOW OR REDUCED COMPRESSOR CAPACITY
CAUSES

▪ Too much clearance volume.

▪ Sluggish operation of suction and discharge valves.

▪ Cylinder, piston or piston rings worn out.

▪ Inlet air temperature is too high.

▪ Choked or dirty inlet strainers

▪ Insufficient compressor cooling 97

 LOW OR REDUCED COMPRESSOR CAPACITY
REMEDIES
▪ Replace the cylinder head gasket to correct thickness.

▪ Renew suction and discharge valves or clean the valves.

▪ Renew piston rings/cylinder.

▪ Reduce the air temperature by keeping compartment blower on.

▪ Clean the filters or renew them.

▪ Clean the cooling water system. 98

 STAGE PRESSURE TOO LOW
CAUSES

▪ Suction valve defective.

▪ Piston rings worn out.

▪ Cylinder liner worn out.

▪ Defective relief valve.

99
 STAGE PRESSURE TOO LOW
REMEDIES

▪ Examine/refit the suction valve.

▪ Renew piston rings.

▪ Renew cylinder liner.

▪ Reset/renew relief valves.

100
 STAGE PRESSURE TOO LOW
CAUSES
▪ Faulty suction valve on next stage.

▪ Leaky piston rings/worn out cylinder of higher stage in case of

combined pistons

REMEDIES
▪ Repair/renew the valve.

▪ Renew the piston liners or piston rings as required.

101
MAINTENANCE

102
 MAINTENANCE ROUTINES
DAILY ROUTINE

▪ Check oil level in the sump or tank.

▪ Check for leakages of water, oil, air etc.

MONTHLY ROUTINE

▪ Check all securing nut and bolts.

▪ Check s & v mountings for perfect condition.

▪ Test lubricating oil.

103
 MAINTENANCE ROUTINES
FOUR MONTHLY

▪ Exchange lub oil and clean oil filter.

▪ Clean air filter.

▪ Check zinc protector.

▪ Clean electric starter contactor.

▪ Check all control & safety devices 104

 MAINTENANCE ROUTINES

100 HOURLY ROUTINE

▪ Check suction and discharge valves for carbonization.

▪ Change lub oil and clean oil filter after first 100 hrs of
running.

105
 MAINTENANCE ROUTINES
300 HOURLY ROUTINE
▪ Change lub oil and clean oil filter.

▪ Clean air filter.

▪ Check drive of compressor.

▪ Check function of cooling water pump.

▪ Check safety valves and if necessary renew safety valves.

▪ Check hand operated drain valve.

▪ If necessary renew suction and delivery valves.

106
GUIDED By
NAVJEET SHRMA
LTCDR
SI(SAX)

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V PARTHIBAN
MCERA II
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