COMPRESSORS

USERS BASIC TRAINING PROGRAM

 Ateliers François Compressor Story

1870 - 1890: Coal industry, pneumatic hammers and high speed steam engines.

1890 - 1950: Steel and Coal industry, heavy duty

reciprocating air compressor.

1950 - 1980: Steel, Chemicals, Glass, Breweries & first OIL FREE Piston Air
Compressor.

1980 to PRESENT: Emergence of the pet bottling industry, AF Compressor

commits 100% of its resources to the 40 bar oil free PET
industry.
 Compressor General Basic Description

 The AF compressor is a volumetric, oil-free, reciprocating piston

compressor with 2 or 3 compression stages.
 By using PTFE compression and wearing rings we can produce low or
high air pressure without any presence of oil on the air.
 The compression on 2 or 3 phases keeps the air at a reasonable
temperature. Each cylinder will have an equal suction and discharge
valves number. Between each compression the air is cooled by water
(40°C / 104°F to 60 °C / 140 °F) and the moisture collected on the
separator is automatically dropped.
 The final service pressure as well than the running parameters are
automatically managing by a controller system.
Compressor General Concept.

 3 Stage L - Design Oil free reciprocating air

compressor.
 PTFE Piston Rings to allow for 100% Oil Free
Operation.
 Double Acting Piston for the First Stage for
maximum efficiency with minimum movement.
 Largest & Heaviest Stage is vertical causing
less wear.
 Only two Connecting Rod’s and Crosshead
help to keep maintenance low & cost effective.
 By not using a Packing on the third stage we
do not require sealing against 40 bar thus
reducing stress.
 Compressor Type & Design

MC 244 CE 2 A-B CE 24 A-B

225 M³/Hrs 312 – 390 M³/Hrs 510 – 600 M³/Hrs
600 Rpm/Min 485 - 650 Rpm/Min 570 - 670 Rpm/Min
45 kW 55 – 75 kW 90 – 132 kW

CE 46 XS-S- A CE 46 B

750 – 870 - 1080 M³/Hrs 1320 M³/Hrs

340 - 400 - 500 Rpm/Min 500 Rpm/Min
132 – 160 - 200 kW 250 kW

CE 6 - 68 A CE 68 S - B CE 680 A - B
1700 - 2100 M³/Hrs 2300 - 2600 M³/Hrs 2900 - 3200 M³/Hrs
415 – 480 Rpm/Min 460 – 500 Rpm/Min 480 – 520 Rpm/Min
300 - 350 kW 400 - 450 kW 500 - 550 kW
 Compressor Room General Requirements

1 Soil: Minimum resistances from 2.2 to 3.5 kgf/cm² (see drawings).

Concrete thickness: 150 mm.
Maximum admissible slope: 0.2%.
Compressor room must be clean without dust and sand.

Heat dissipation:
2
Natural. Forced.

Inlet: bottom on the motor side.

Outlet: upper on 3rd stage cylinder side.

1
 Compressor Room General Requirements

Compressor room temperature:

3 ‘Standard’: Between 5°C / 50°F & 40°C / 104°F

‘Optional’: Between 1°C / 33.8°F & 55°C / 131°F
1.2 meter free floured surface
4
around the compressor and 4
annexes

5 Moisture draining collections:

On the compressor.
On the dryer.
On the 40 bar air receiver.
4

5 5
 Compressor Water Cooling System Requirement

 The water cleanness and the temperature are essential to guarantee perfect
compressor and dryer operation as well than low maintenance cost, a close
cooling system is warmly recommended.
 For the characteristic, installation, treatment and protection, please check the
maintenance manual.
 Compressor Water Cooling System Requirement

 The compressor inlet water temperature should include between 10 °C / 50°F

and 30 °C / 86°F. Never equal or lower at 0°C / 32°F (major risk of blocking
refrigerant and the safety valve).
 During operation the water pressure measured after the water pump should be
include between 3 and 5.5 bar. Compressor air
flow direction.

Inlet.

Outlet.
 Compressor Description.

Automatic 1st stage air cooler

air venting. & Tube bundle
Inlet filter casing and filter
cartridges: 10 micron.
4
7 1st stage separator
and safety valve
1 1st Stage cylinder and
piston. (double acting)
8
Air Pressure drop
indicator. 5

2 Discharge Valves, 4
valves cover
3
6
Suction Valves, 6 5
valves cover, 3
unloader system 2 7
6
1
8
3 3
3
6
6
 Compressor Description.

Pulsation dampener. 40 Bar air receiver

2nd Stage cylinder and 2nd ‘vertical or horizontal’
stage piston (single acting). & safety valve.

15
9
12
13
3rd Stage cylinder and 3rd 40 Bar flexible.
stage piston (single acting).

3rd Stage after cooler 16

17
2nd Stage separator & 17
safety valve.
14 40 Bar
11 flexible
support.

2nd Stage 10
air cooler.

11
14
15
9 12
17 16 10
13
 Compressor Description.

Electrical cabinet.
Grooved flywheel.
Dryer & filters.

21 Water pump.

23 24

18

Distance pieces
Anti-vibration Horizontal & Horizontal.
pads.

19
22
Motor & pulley.
22

20 21
18 20 22

24 23
19 19
19 19
 Compressor oil flow - Outside the crankcase.

Oil pump.
Oil filter.
26
25 30

Crankcase.

Oil thermostatic valve.

Low Oil Oil pressure
temperature. sensor. 29
31

Warm Oil
temperature.

32 27
Pre-grassing electrical Oil pump. Oil level box.
Oil Radiator. 28
(For special configuration)
 Compressor oil flow - Inside the crankcase.

Oil deflector.

38 Crosshead &
Crosshead guide.
Oil scrappers.
37
Piston rod.
36
Crosshead &
Crosshead guide.

35
35
Connecting rods.

34
26 Crosshead &
Crosshead pin.
Oil pump.

33
Crankcase.
Crosshead pin.
Crankshaft.
Grooved
25
flywheel.

21
 1st stage cylinder (LP) compressor air flow.

Discharge 1st stage

temperature sensor.

40
Cold Water Inlet.

Warm water outlet.

Inlet filter.
39 1st stage 7
1 air cooler. 41
1st stage safety valve.

1st stage packing 43

rings 2nd stage air inlet
39 thermometer. 42
44 1st stage air
1st stage air
separator. pressure gage.
8
45
Moisture drains
The 1st stage sealing piping.
rings keep the pressure 42
on the cylinder.
Demister pad.
 2nd & 3rd stage cylinder (HP) compressor air flow.
2nd stage safety valve.
2nd stage air
2nd stage separator. 47
cylinder.
9
3rd stage 11
cylinder.
3rd stage air
12 inlet
thermometer.
48
50
Moisture 49
drains
piping. 2nd stage air
pressure gage.
10
2nd Stage
air cooler.

Discharge 2nd stage

temperature sensor.
2nd stage 46
packing rings
Discharge 3rd stage
temperature sensor.

51

The 2nd stage sealing

rings keep the pressure
on the cylinder. 13
52
Pulsation dampener. 40 bar pressure releasing valve.
 After cooler & way out compressor air flow.

Water safety valve.

51

40 bar pressure
3rd Stage after cooler sensor.
14 After cooler air 53
temperature sensor. 52
54
55
40 Bar
flexible.
40 bar receiver.
Dryer. 16 15

24 17
40 Bar flexible support.

40 bar safety valve.

53
40 Bar After cooler air 52
pressure gage.55 54
flexible.
Dryer.
16 40 bar junction piping. 51
24 17
40 Bar flexible support.
 Inlet & outlet valve suction operation.

Inlet valve. Outlet valve.

3
6
 Inlet & outlet valve discharge operation.

Inlet valve. Outlet valve.

 Inlet & outlet valve automatic loading operation.

Inlet valve
Suction operation.

Outlet valve
Discharge operation.

Inlet valve Outlet valve

Discharge operation. Discharge operation.
 Inlet valve automatic
loading & unloading operation.

40 bar Low
pressure reducer Low air pressure
purging valve. Suction operation.
56
Low air pressure
57 Filter. 62 safety valve. 63
58 Pressure gage. 64 61
60
7-5 bar low
pressure Purging solenoid
receiver. valves.
59
Loading - unloading
solenoid valves
Unloader. (1st & 2nd-3rd stage).
63
Aircon Controller.

Discharge operation.

63
64

36.5
 Inlet valve automatic
loading & unloading operation.

Suction operation.

Discharge operation.

39.5
39.4
39.3
39.2
39.1
39.0
38.5
38.0
37.5
37.0
36.9
36.8
36.7
36.6
36.5
 Inlet valve automatic
loading & unloading operation.

Suction operation.

Discharge operation.

39.5
 Inlet valve automatic
loading & unloading operation.

Suction operation.

Discharge operation.

36.5
36.6
36.7
36.8
36.9
37.0
37.5
38.0
38.5
39.0
39.1
39.2
39.3
39.4
39.5
Moisture purging 1st & 2nd stage separators.

1st stage air

separator.

1st stage pneumatic

purging valve. 11
2nd stage air
separator.
65

2nd stage
Bekomat.

66
 Moisture purging 2nd stage outlet, receiver & dryer.

Dryer.

24

2nd stage outlet

67 elbow piping.

2nd stage outlet elbow 40 bar Bekomat.

piping purging
Main motor.
solenoid valve.
70
69 68
15

5 Sec
4
3
2
1
40 bar receiver.

15
 Dryer basic functioning description.
Air hot & wet
40 bar air status
Inlet air (from the Air cool (+/-1°C) & wet
compressor) Air cool (+/- 1°C & dry)
1
Outlet air (to the Air warm & dry
user) 2
6 Air Inlet - air outlet
(heat exchanger)

Filter - moisture
separator. 3
Air - refrigerant
5 4 (heat exchanger)
40 bar Bekomat
or
solenoid draining
system.
Accumulator. G Thermo -
Refrigerant expansion valve.
bypass valve.
H J
Cooling water outlet. Freon gas status
Radiator heat
E exchanger Freon gas very hot
BW & high pressure
Refrigerant heat BA
exchanger Freon gas cool
A Refrigerant
& high pressure
compressor Freon gas +/- 1°C
D
& low pressure
Cooling water inlet. C
F Freon gas warm
Cooling water control & low pressure
valve & strainer. Receiver.
 Compressor Maintenance Requirement

Dedicated lifting equipment such as traveling A-Frame or overhead rail system

capable of lifting heavy components (cylinder, piston …). The hook can be moved
from the up to the 1st stage cylinder center and from the up to the 3rd stage cylinder
inlet flange to outside the compressor frame. Any part from the compressor can be
moved.