Compressors
Basic Classification and design overview
And maintenance
What are
compressors?
Compressors are mechanical devices that
compresses gases. It is widely used in
industries and has various applications
How they are different from pumps?
Major
difference is that compressors handles the gases and pumps handles
the liquids.
As
gases are compressible, the compressor also reduces the volume of gas.
Liquids
are relatively incompressible; while some can be compressed
Centrifugal pump
What are its applications?
Compressors have many everyday uses, such as in :
Air
conditioners, (car, home)
Home
and industrial refrigeration
Hydraulic
Air
compressors for industrial machines
compressors for industrial manufacturing
Refrigeration compressor
What are its various types?
Compressor classification can be described by following flow chart:
What are dynamic
compressors?
The dynamic compressor is continuous flow compressor is characterized by rotating
impeller to add velocity and thus pressure to fluid.
It is widely used in chemical and petroleum refinery industry for specific services.
There are two types of dynamic compressors
Centrifugal Compressor
Axial Flow Compressor
Centrifugal Compressor
Achieves
compression by applying inertial forces to the gas by means of
rotating impellers.
It
is multiple stage ; each stage consists of an impeller as the rotating
element and the stationary element, i.e. diffuser
Fluid flow enters the impeller axially and discharged radially
The gas next flows through a circular chamber (diffuser), where it loses
velocity and increases pressure.
Axial flow compressor
Working fluid principally flows parallel to the axis of rotation.
The energy level of air or gas flowing through it is increased by the
action of the rotor blades which exert a torque on the fluid
Have the benefits of high efficiency and
large mass flow rate
Require several rows of airfoils to achieve
large pressure rises making them complex and
expensive
Why multistage compressor?
High
temp rise leads into limitation for the maximum achievable pressure
rise.
Discharge temperature shall not exceed 150C and should not exceed 135 0C
for hydrogen rich services
A multistage centrifugal compressor compresses air to the required
pressure in multiple stages.
Intercoolers are used in between each stage to removes heat and decrease
the temperature of gas so that gas could be compressed to higher pressure
without much rise in temperature
Intercooler
What are positive displacement
compressors?
Positive displacement compressors causes movement by trapping a fixed amount
of air then forcing (displacing) that trapped volume into the discharge pipe.
It can be further classified according to the mechanism used to move air.
Rotary Compressor
Reciprocating compressor
Rotary compressors
The
gas is compressed by the rotating action of
a roller inside a cylinder.
The
roller rotates off-centre around a shaft so
that part of the roller is always in contact with
the cylinder.
Volume of the gas occupies is reduced and the
refrigerant is compressed.
High
efficient as sucking and compressing
refrigerant occur simultaneously.
Reciprocating compressor
It is a positive-displacement compressor that
Uses pistons driven by a crankshaft to deliver
at high pressure.
The
gases
intake gas enters the suction manifold, then flows
into the compression cylinder
It
gets compressed by a piston driven in a
reciprocating motion via a crankshaft,
Discharged
at higher pressure
Maintenance
Location : should be dry ,
clean , cool
FAILURE TO MAKE THESE RECOMMENDED CHECKS COULD RESULT IN
SERIOUS INJURY, PROPERTY DAMAGE, AND MECHANICAL FAILURE.
1. Remove all loose pieces and tools around the compressor installation.
2. Check oil level in crankcase.
3. Check motor and compressor pulley for alignment and tightness on shaft
4. Be absolutely certain that all mounting bolts are tight.
5. Manually rotate compressor through enough revolutions to be certain there are
no
mechanical interferences.
6. Check belt tension, it should be neither too loose nor too tight.
7. Check all pressure connections for tightness.
8. Check to make sure all safety relief valves are in place.
9. Check to be sure all guards are in place and securely mounted.
10. Check fuses, circuit breakers and thermal overloads for proper size.
11. Open all manual shutoff valves (block valves) at and beyond the compressor
discharge.
12. After all of the above conditions have been satisfied, jog the starter switch
button to
check the rotational direction of the compressor, it should agree with the rotation
arrow
on the unit.
Periodic protective maintenance
We will discuses steps and actions in following tables :
annually
Semiannually
monthly
weekly
daily
check
1. Check Low oil level. Maintain between
High and level masks on gauge.
CAUTION: Do not overfill!
2. Drain moisture accumulation from the air
receiver
3. Drain drop legs and u in air distribution
system.
4. Give compressor an overall visual
inspection and be sure safety guards are in
place
Check for any unusual noise or vibration. 5
.Check for oil leaks. 6
7. Operate the safety valves to be certain
they are functioning
8. Clean the cooling surfaces of the
intercooler, aftercooler and compressor
9. Replace more or clean air intake filter.
Check more often if dirty conditions exist.
10. Check the air distribution system for air
leaks
11. Inspect oil for contamination and
change if necessary. Check more often
under dirty conditions.
.Check belt tension. 12
13. Check pulley and pulley clamp screws or
set screws for tightness.
.Inspect compressor valves. 14
Some problems and solution
Solutions
Causes
Anomalies
Invert the phase wires, press the
RESET button on the electronic
.board and start again
The compressor fails to start, the
screw unit is running in the wrong
Direction.
The compressor runs in the wrong
direction. Message on display
.ROTATION ALARM
Check the electric connections of
the probe. Check the oil level,
check
if the radiator is clean, check if the
pre anti-dust filter is clean, check
the
ambient temperature, check the
minimum distance of the
compressor
from the walls of the room
Excessive temperature of air/oil
mix outlet from the screw (105
C).
Oil alarm triggers and the machine
stops (red LED).
Message on display TEMPERATURE
ALARM.
Check the temperature on the
display.
Check if the electric power supply
is correct, check if the 3 power
supply phases are roughly the
same value. Check if the cables
are firmly connected to the terminal
board, check if the electric cables
have melted. Check if the suction
grid of the cooling fan of the motor
is clean and not clogged with
anything (paper, leaves, rags). To
start the machine again
The trip switch that protects the
compressor motor has tripped.
The trip switch of the compressor
motor trips and the machine stops
(red LED).
Message on display COMP.
TRIP SWITCH ALARM
Solutions
Causes
Anomalies
Check if the electric power supply
is correct, check if the 3 power
supply phases are roughly the
same value. Check if the cables
are firmly connected to the terminal
board, check if the electric cables
have melted check FV fuses.
Check if the suction grid of the
cooling fan of the motor is clean
and not clogged with anything
(paper, leaves, rags). To start the
machine again, disconnect it from
the mains, open the front panel of
the compressor, press the reset
key in the electric cabinet (see
button 3 sect. 5.2.3) and press
RESET on the board
The trip switch that protects the
fan motor has tripped
The trip switch of the fan motor
trips and the machine stops (red
LED).
Message on display FAN TRIP
SWITCH ALARM
Thank You
