Compressor air necessary

during all situations whether it is

• Project activities
• Commissioning activities
• Normal operation of plant
• Overhaul & general operation of plant.

Instrument air used for most of the instruments,

valves & electrical breakers on-off operation.
Service air is used to operate many pneumatic
equipments, air operated hand tools and for other
general purpose.
 classification

Dynamic type Positive displacement

Radial flow centrifugal Reciprocating

Rotory
Axial flow compressor

Mix flow compressor

1/2mv2 kinetic energy is

converted into pressure energy
• One can say that IA & SA system is life line of
power station like AC/DC electric supply
system. Non availability of air supply may lead
to shutting down of unit.
• In most of the power plant generally
1. Single or multi cylinder
2. Multistage, double acting
3. Vertical or balanced opposed reciprocating
compressors are used.
• Piston execute reciprocating motion.
• Head which contain valves.
• Piston rings are for sealing the piston.
• Piston is connected to the driving mechanism.
 Following important elements are common

• Main compressor system. (Cylinder, head, air

valves & piston.)
• Driving unit.
• Cooling system. (Jacket cooling, Inter cooler, after
cooler.)
• Lubricating system.
• Regulating system
• Unloading system.
• Air dryers.
• Assuming clearance and leakage to be absent total
work done on reciprocating compressor is given
by
• W=S P2
P1 vdp
• = (r/r-1)P1V1[(P2/P1)r-1/r-1
• R = ratio of specific heats
• Ideal intercooler pressure p2 for two stage poly
tropic compression operating between pressure p1
& p3 is given by, p2 = ( p1.p3)1/2
• Volumetric efficiency of compressor considering
the clearance. =1-Vc/Vs[(p2/p1)1/n-1]
• Preventive Maintenance
• Weekly- Checking oil, Cleaning air filter.
• Monthly- Checking abnormalites and attending.
• Quarterly- Removing all SVs & DVs checking &
replacing damaged plates / parts. Replacing oil
(Enklo-150/Barat cobol-150/servo press-150) as a
general rule, the supply of lube oil to each cylinder
is arround 2-3 drops per minits.
• If knocking sound observed near the head, it is due
to less clearance betwn head & piston.
• If SVs or DVs valve plate broken, increase of vave
body temperature observe.
• If air leakage or vibration near valve cover
observed, it may cause due to damage of “O” ring
• Assem. Max
Allo.
• Diametrical clearance of the shaft main bearing 0.08-0.15 0.3
• Diametrical clearance of the connecting rod big end brg. 0.07-0.13 0.3
• Diametrical clearance of the connecting rod small end bush 0.05-0.10 0.2
• Diametrical clearance betwn cross head guide & cross head 0.18-0.26 0.6
• Side clearance of crank shaft 0.45-0.60 0.9
• Side clearance of connecting rod big end. 0.33-0.42 0.6
• End clearance piston ring per 100 mm dia. 0.3
1.0
• Diametrical clearance of betwn piston & comp. Cylinder. 0.1 0.4
• (CI piston / Aluminum piston per 100 mm)
• Piston end clearance free end. 2 mm min.
• Piston end clearance crank end 1.5 mm min.
• Tightening torque
1. Connecting rod big end bolt. ------------------ 25 mkgs
2. Main bearing stud nut ------------------- 17 mkgs
3. Blocking nut of piston rod -------------------- 25 mkgs
4. Piston rod crosshead nut ----------------------- 25 mkgs