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A project report on multi stage air compressor

PROJECT REPORET ONOPERATIONS & MAINTANCE

OF MULTI STAGE AIR

COMPRESSOR

PREPARED BY:-BHUMIT A. VASANT

(Diploma in mechanical 5 th SEM.)(AY-2 roll no.:-36)

ABSTRACT

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A project report on multi stage air compressorMan kinds are very familiar with the air because air is most basic

thing for life. Man knows the power of air in example of storm. They knowthat what air can do?

Before 40 or 50 years man invent an air compressor because herequired the pressure of air production systems the compressor is best wayto give pressure of air.

After the invention of air compressor engineers realized that it is avery necessary thing for mordan industries.

In the time of toddys various types of air compressors areavailable in the market when are going to purchase the air compressor youhave to decided that which type of compressor is more appropriate for theplant.

Generally most of industries are using reciprocating air compressorbecause it gives higher pressure as compare to other types of compressor &it is more economic from other type of compressor.

In this project I have considered all the detail of reciprocating multistage air compressor. For that I have visited m/s. hawa engineers & takeguidenance from the owner MR. Ajay vasant.

Bhumit vasant.

ACKNOWLEDGEMENT

I here by take opportunity to express my deep sense of attitude to PROF. D.D. SHUKLA (head of mechanical

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A project report on multi stage air compressorengineering dept.) for his kind support & timely guidance given to me toreaching my destiny with perfection. I thankful to him for his suggestions &ideas to make this project work even batter.

I my self very much thankful to PROF. D.D. SHUKLA whopermitted me to work on the topic & extended his kind support & help for thesame. The enthusiasm shown by him in my project proved to be a greatsource of inspiration.

I thankful to all the teaching & non-teaching staff membersand friends who helped me directly & indirectly for the successfulcompilation of this project work.

I also thankful to HAWA ENGINEERS (shpar-veraval)& MR. AJAY VASANT owner of HAWA ENGINEERS (shpar-veraval) fortheir all kind support & guidance

Thanking All

Bhumitvasant

(5 th sem.D.M.E.)

INDEX

SR.NO

CONTANT PAGENO

1 INTRODUCTION 13


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2 ABSTRECT 23 ACKNOWLADGEMENT 34 WHAT IS AIR COMPRSSOR 55 CLASSIFICTION OF COMPRESSOR 66 LIMITATION OF SINGLE STAGE AIRCOMPRESSOR 77 WORKING PRINCIPLE OF MULTI STAGE

AIR COMPRESSOR8

8 CONCEPT OF MULTI STAGE AIRCOMPRESSOR

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9 P-V DIAGRAM FOR MULTI STAGE AIRCOMPRESSOR

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10 PRACTICL P-V DIAGRAM 1211 LIFE CYCLE OF COMPRESSOR 1312 LIFE CYCLE COST 1413 ADVANTAGES OF MULTI STAGE AIR

COMPRESSOR15

14 INSTALLATION OF AIR COMPRESSOR 16-22

15 SAFETY FACTOR OF AIR COMPRESSOR 22-29

What is air compressor?

it is a device to make atmospheric air to desirablepressure.

If you've ever had to inflate the tires on your car orbicycle, you've had firsthand experience with an air

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A project report on multi stage air compressorcompressor. Air compressors can be found in gas stations and manufacturingplants, as well as home workshops and garages. Smaller versions can beused to inflate pool toys or even run power tools such as nail guns, sanders,drills, wrenches, staplers and spray guns.

Reducing the size of the space that contains the air increases airpressure. This space is called the air tank, and it is set to hold a certainamount of air at a specific pressure. A conventional compressor also has acrankshaft, a connecting rod and piston, a cylinder and a valve head (seediagram). The crankshaft is powered by an electric motor of gas engine. Asthe piston moves down, it creates a vacuum that allows outside air to pushopen the valve and fill the area above the piston. As the piston moves up,the air above it compresses. This holds the valve shut while air is pressedinto the tank. With each stroke, more air enters the tank, and the pressurerises. The motor turns on and off as needed to maintain pressure in the tank.

Some car manufacturers, like Zero Pollution Motors in France, are developingair-powered cars that operate on the same principle. Compressed air isstored in tanks at high pressure. This air is then fed through an air injector tothe engine and flows into a small chamber, which expands the air. As itexpands, the air pushes down on the pistons and moves the crankshaft,which gives the vehicle power. Such engines can either run on compressedair alone, or serve as a regular internal combustion engine.

In the market the wide rang of compressors are available in themarket according to your applications,

Compressor is classified as under givenBy principle of operationBy construction typeBy stagingBy service dutyLubricated / Non-lubricated

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According to the classification by staging there are twomain types of compressor as under given

Single stage air compressorMulti stage air compressor

single stage air compressor :- Any compressor with cylinders of the same bore size(regardless of the number of the cylinders) may be a singlestage machine. On the suction stroke of the individual piston,air from the atmospheric pressure enters the cylinder throughinlet filter and the valve. On the compression stroke of eachpiston air forced out through the valve and passes into a

common discharge manifold from where it is piped to thereceiver or system. These compressors are useful where lowpressure air is required such as water pumping liquid transferglass industries chemical industries food processing spraypainting etc

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A project report on multi stage air compressorLimitations of a Single-Stage Air Compressor:

Refer to the enclosed diagram, the single stage air-compressor is

compressing from pressure P1 to Pressure P2, completing the cycle 1234,where 3-4 is the clearance air expansion. Also V1-V4 is the effective sweptvolume or the effective volume where the fresh air from atmosphere issucked in. The mass of air flowing through the compressor is controlled bythis effective swept volume V1-V4.

If any restriction is placed on the delivery of the air compressor, for example:the discharge valve throttled, then the delivery pressure of the aircompressor increases. From the diagram, let us say the new deliverypressure is P5. Then the operating cycle will be 1567, where 6-7 is theclearance expansion of air and the effective swept volume is V1-V7. Thus it is

evident that the effective swept volume (V1-V4) is more than (V1-V7). Thuswhen the delivery pressure of the single-stage air compressor is increased,the effective swept volume is reduced.

If the delivery pressure is further increased (assuming the compressor is sostrong to work), the delivery pressure reaches P8, and the compressionfollows the curve 1-8, where there will be no delivery of compressed air. Thus

when the delivery pressure of a single-stage compressor is increased, themass flow rate also increases.

Since the delivery pressure increases, the associated temperature alsoincreases. Thus the temperature of the air after compression is so high as tocause mechanical problems and the amount of heat is actually the energy loss.

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A project report on multi stage air compressorIf a single-stage machine is required to deliver a high-pressure compressedair, then it requires

Working principle of multi stage air compressor:-

Some industries required air pressure more than 35 kg/centimeter square toproduce their product. For example mineral water bottle (pet blowing)requires air pressure more than 40 kg/centimeter square to produce desiredshape of bottle at bottom side. Here Two Stage reciprocating air compressoris not useful, we required the air compressor, who generates air pressureabove 35 kg/centimeter square. This discharge air pressure is achieved bymulti stage air compressor. We normally use three stage reciprocating air

compressors as multi stage air compressor. If we required discharge airpressure above 85 kg/centimeter square then four stage air compressors isuseful.

The working principle of multi stage air compressor is same as double stageair compressor. In three stage air compressor, fresh air from atmosphereenters in first stage (low pressure) cylinder through suction filter. This air iscompressed by piston up to 4 kg/centimeter square & then delivered tosecond stage (middle pressure) cylinder through inter cooler for furthercompression. In this stage suction and compression took place on the bothside of piston

In second stage cylinder low pressure air is compressed up to 14kg/centimeter square & discharge to third stage (high pressure) cylinderthrough second inter cooler to achieve air pressure up to desired deliverypressure. In this stage suction and compression took place on one side of piston.

At high pressure cylinder the 14 kg/centimeter square air pressure isincreased up to desired discharge range from 35 kg/centimeter square to 85kg/centimeter square by the piston reciprocating inside the high pressurecylinder. In this stage suction and compression took place on both side of

piston.

Multi stage reciprocating air compressors are used in few industries like PetBlowing, CNG (Compressed Natural Gas) Center etc.

Concept of multi stage air compressor :-

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A multi-stage compressor is one in which there are several cylinders of different diameters. The intake of air in the first stage gets compressed andthen it is passed over a cooler to achieve a temperature very close toambient air. This cooled air is passed to the intermediate stage where it isagain getting compressed and heated. This air is again passed over a coolerto achieve a temperature as close to ambient as possible. Then thiscompressed air is passed to the final or the third stage of the air compressorwhere it is compressed to the required pressure and delivered to the airreceiver after cooling sufficiently in an after-cooler.

Advantages of Multi-stage compression:1. The work done in compressing the air is reduced, thus power can be

saved2. Prevents mechanical problems as the air temperature is controlled3. The suction and delivery valves remain in cleaner condition as the

temperature and vaporization of lubricating oil is less4. The machine is smaller and better balanced5. Effects from moisture can be handled better, by draining at each stage6. Compression approaches near isothermal7. Compression ratio at each stage is lower when compared to a single-

stage machine8. Light moving parts usually made of aluminum, thus less cost and

better maintenance

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A project report on multi stage air compressorConclusion:

Thus we have seen the actual operation of an Air compressor and itstheoretical P-V diagram. In my next article, we will discuss the work done byand reasons for using multi-stage air compressors. Also you will come toknow some important design reasons that you might have never comeacross or find in any text books.

Operation of an Air Compressor.

Read here to know about both theoretical and practical operation of an aircompressor. Also know about the reasons for your long-lasting question anddoubts on air compressors and its operation. Appreciate the design features

and some reasons which you could never find in text books.

Practical P-V diagram:

In my last article, we have seen the P-V diagram and understood the

operation of an air compressor. But in practice, the diagram is not so perfect. The figure shown here represents the actual practical P-V diagram of an aircompressor. The points, 1234 represents the theoretical diagram. But thereare some shaded portions above and below the work done area. It isnecessary to give certain explanation for these additional areas which addup to the work done by the compressor.

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Referring to the diagram, at point 4, when the clearance air has reduced tothe atmospheric pressure, the inlet valve will not open immediately. Thepressure drops lower than the atmospheric pressure and the inertia of the

valves are overcome by the pressure difference. Thus the valve is forcedopen by the atmospheric air and it rushes into the cylinder chamber. There isa valve bounce and the pressure does not remain constant inside thecylinder. The pressure slightly increases and then decreases after whichreaches somewhat steady intake of air. This negative pressure difference iscalled as the Intake Depression.

The same occurs at the point 2, where the delivery valve delays to open. The compressed air pressure inside the cylinder of compressor reaches a pressure slightly more than the air receiver pressure. The delivery valve then opens causing a slight decrease in pressure but always abovethe air receiver pressure enabling the compressor to deliver air. Then it reaches a stable pointafter some Valve Bounce and then reaches point 3 where the delivery valve closes to continueits cycle. Thus in practice, the compressor requires more power to compensate for the additionalwork done due to the depressions in delayed opening of the valves.

Life cycle of an air compressor:-

1. Heavymoving/workingcomponents tocompress air tosuch a highpressure,

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A project report on multi stage air compressor2. There might be some balancing problems due to heavy moving parts,3. The power requirement for such heavy parts movement is too high,4. There will high torque fluctuations,5. To compensate for the torque fluctuations, a heavy flywheel is

required.6. Better cooling arrangements are required, and7. Lubricating oil which does not get vaporized at such high

temperatures.

Conclusion:

Thus it is clear that a single stage compressor cannot contribute to highdelivery pressure demands. In my next article, let us discuss the effects andadvantages of multi-staging of an air compressor.

Operation of an Air Compressor.Read here to know about both theoretical and practical operation of an aircompressor. Also know about the reasons for your long-lasting question anddoubts on air compressors and its operation. Appreciate the design featuresand some reasons which you could never find in text books.

Air Compressor Life Cycle Costs

According to Best Practices for Compressed Air Systems, Compressed AirChallenge, Second Edition, 2007, energy costs now represent 82-percent of the total operating expenses. Energy savings from Sellers single-stage aircompressors significantly reduce life cycle costs.

Sellers Single-stage Compressors significantly reduce operating and energycosts over the entire compressor life cycle. Contributing to the energysavings is

Sellers proven air end with the low restriction inlet valve

High efficiency fanLow pressure drop air-fluid separation system to prevent energy loss

Solar air compressors designs deliver cost savings for the life of the product.Improved air filtration translates into:

Extended separator lifeImproved fluid filter lifeLess Lubricant contamination

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A project report on multi stage air compressorAnd to reduce fluid disposal costs, Solar air compressor offers biodegradableSoluble 8000-hour fluid, or 24KT, a long-life fluid that never needschanging.

Utilizing the most modern technologies, equipment and advancedmanufacturing techniques, Solar Air Compressors designs, manufactures,assembles, and test the most innovative compressed air products in theindustry. Solar air compressors are known around the world for theiruniversally applicable design, outstanding craftsmanship and superiorquality.

Ring Power is Floridas leading supplier of air compressors, air tools, aircompressor parts and service for over 45 years. We represent the finestelectric compressors and diesel air compressor products in the industrywith names like Solar, Hurricane, and Bellaire. And with over 450 usedand new air compressors and accessories in our inventory, Ring Power iscertain to handle even the largest air compressor project. Portable orindustrial compressed air, high-pressure, or ultra high-pressure, one callsolves your compressed air needs.

What are the Advantages of a Multi Stage AirCompressor?

Multi-stage air compressors are engineered to safely provide hours of coolpressurized air for a multitude of tasks. Harness the power of air to powerthrough difficult cleaning jobs and repairs with an efficient multi-stage aircompressor.

Function

Multi-stage air compressors pressurize air at two levels to improveefficiency on large jobs. These high output compressor units are usuallyfound in the commercial and industrial sector where long-term use isrequired.

Cool Air

Compressed air is cooled in secondary tanks of multi-stage compressorswhen it transfers from a high-pressure tank into a lower-pressure unit.

This cooling effect generates less overall heat than single stagecompressors, making the multi-stage more efficient.

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A project report on multi stage air compressorOutput

Large multi-stage air compressors are capable of pressurizing more cubicfeet of air for a higher output. Big jobs and air tools require these highvolumes and powerful blasts of air.

Wear

Less heat generated by the multi-stage compressor means less wear onyour compressor motor and seals. This adds up to fewer repairs and lessscheduled maintenance for your pressurized air source.

Features

Multi-stage air compressors come with a variety of features to make itmore controllable, more portable and more useful. Compressors areavailable with wheels, digital gauges and a variety of compatible air tools.

Compressor: How to install Air Compressor?

Air CompressorIn engineering units, store is the place where machines and spare pars arestored. Actually air compressor is not a machine to keep in store but due tosome reasons it requires to be storage for some time. Any air compressor,which is not in service, whether it is installed or not, the unpaintedCompressor surface are subjected to Rust and Corrosion. If this occurs toyou, you have to take care of that air compressor up to commissioning.However every Compressor going out of factory is always processed withRust Preventive Oil. This Rust Preventive Oil will work better up to one monthand if your requirement is more than this period then you should have totake extra preventive steps.

The Rate of Corrosion varies with Climatic Conditions. Variance in ClimaticCondition makes it impossible to state the length of time; in very humid

climate rust formation is fast and in dry climate it is slow.No one will give you education about storage of compressor; you have to findyour own ways. As I spend many years in compressor engineering, I havesome knowledge which I like to share with you.

Procedure to install Air Compressor

01) Open top cover from crankcase and lean Crankcase from inside withhelp of cloth. Never use cotton waste for cleaning purpose.

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02) Fill H.P.Rustop-286 or any other Anti-Corrosive Oil in Crankcase androtate Compressor belt wheel for several times. This will ensure thecirculation of Anti-Corrosive Oil to all moving parts, Cross-Slide andGuide.00000oo

03) Clean low pressure and high pressure cylinders and spray sufficientquantity of H.P.Rustop-286 and rotate Air Compressor several revolutions.

04) Place Silica Gel bags in valve ports and refit valve covers if the AirCompressor is Non-Lubricated type . Now a days Teflon spray is used toprevent valve from corrosion. Dont remove this material.

05) Drain water from Cylinder Jackets, Inter-Cooler and After-Cooler andthoroughly flush with clean water with H.P. Radiator Cleaner. Refilled thesystem with 10:1 mixture of Water and H.P. Radiator Cleaner and keep it for4 to 5 days. Remove it after the said period. In cold condition, where WaterFreezing may occur, in that case drain the mixture immediately.

06) Drain H.P.Rustop-286 or any other Anti-Corrosive Oil from Frame andForce Feed Lubricator.

07) If V-Belts are fitted, remove these completely and store it at separateplace.

08) Apply sufficient quantity of preservative grease on piston rod.

09) Plug and seal all openings thoroughly so as the Moist-Air and Dirt do notenter inside any part of the compressor .

10) Store Air Compressor in dry place under shade or in any separate room.

Constriction features of multi stage air compressor :-

Can you manufacture any machine without parts? NO, you require manyparts. In air compressor engineering various parts and components are usedto assemble air compressor. All the parts are important for working of aircompressor but here I will share the information about major parts. Theinformation of parts I am sharing with you is used in the reciprocating aircompressor manufactured by Chicago Pneumatics, Ingersoll Rand, Atlas Copco, etc. and used in large engineering units where huge quantity of compressed air is required. If you are interested in compressor technologythen I hope the information below will help you.

Frame/Crankcase: -16
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A project report on multi stage air compressor Totally enclosed rigid cast iron body in square or rectangle shape. Bearinghousing is fitted on crank case with accurately bored to fit main bearings so,misalignment or eccentricity is avoided. It gives better support to the crankshaft..

Crank Shaft: -

High grade S.G. Iron crank shaft in one piece in design , dynamically balancedwith counter weights, avoid any twisting. Crank pin & journals duly ground &polished ensure long life of bearings. A flywheel is fitted on crank shaft.

Cylinders :-

Graded cast iron cylinder s designed with water jacket in water cooled aircompressor to remove heat generated during compression. Designed forstreamlined air passage & maximum numbers of valves, cylinder providessmooth flow of air, there by minimizing the pressure drop.

Pistons: -

Special Aluminum alloy piston s for non-lubricated air compressor and gradedcast iron pistons are used for lubricated models. Piston Rings are used forsealing to cylinder.

Connecting Rod:- Forged alloy steel connecting rod is duly normalized, are designed to provideminimum thrust on cross head bearing surface.

Main Bearings & Big End Bearings: -

Copper lead alloy designed for long life . It gives perfect rigidity to runninggear.

Cross Slide & Cross Head:-

Manufactured from high grade S.G. Iron material. Its low inertia along withlow friction cross slide ensure perfect running of cross head.

Piston Rod: -

Alloy Steel piston rods fitted with wear resistant packing rings of antifrictiontype to prevent any possibility of compressed air leakage.

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A project report on multi stage air compressorSuction & Discharge Valves: -

Stainless Steel plate type or spring type valves are arranged symmetricallyin suction & discharge provides longer life

Oil Pump: -

It feeds oil to main bearings, connecting rod bearings & to cross slides. Theoil pump regulates the oil pressure by pressure regulating screw .

Along with above parts some small parts as like oil seal ring, small endbushing, Suction filte r element, cross head pin; heads, belt s nut and bolt,gaskets etc. are used. You are suggested to add the knowledge you haveabout compressor.

Water: Requirement of Cooling Water in Air CompressorWhich air compressor you are using your engineering plant? Are you

using water cooled compressor ? Do you have any education about coolingwater? I know you have answer in YES or NO. I have commissioned andservice too many water cooled air compressors at various sites. In watercooled air compressor the quality and quantity of cooling water plays thevital role in performance of machine. Many times I found that utility ormaintenance engineers or mangers are careless about cooling watersupplied to machine. They are interested in compressed air only. Many majorbreakdowns may occur due to negligence of cooling water. To increase the

life and performance of air compressor below points must be taken intoconsideration.

01) The cooling water piping connections for the compressor cylinder, inter-cooler and after-cooler should be arranged as shown on the generalarrangement drawing and water piping diagram. A main stop valve should besituated in the water pipe, inlet header and flow regulating valve in thesupply line to each cylinder, inter-cooler and after-cooler (means parallelwater circuit.)

02) Good clean water should be provided for cooling. If the cooling water hasa high percentage of lime sulphur, slit, mud or other water impurities, thesewill be deposited in the cylinder jackets, head, inter-cooler, after-cooler'stube and shell. The scale deposited unless are removed, will obstruct theflow of water, lower the rate of heat transfer and may result in damage tothe air compressor. The cleaning doors are provided in the side of cylinderfor cleaning of jackets and cylinder heads. Periodically the cylinder jackets,cylinder heads, inter-cool, after-cooler tubes and inside of the shell should beinspected and cleaned.

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A project report on multi stage air compressor03) It is preferable that the outlet water from each cylinder, inter-cooler andafter-cooler should empty into the funnels to facilitate the operator toobserve whether the water is flowing or not and also to control the flow of water (open water system). The outlet water can be then taken to anunderground pit tank and pumped to cooling tower. In case you are usingclosed water system then a visible Flow Indicator must be installed in eachwater outlet pipe. It is also suggested to clean flow indicator glassperiodically or according to requirement .

04) A sufficient amount of cooling water should be provided to each cylinder,inter-cooler and after-cooler. The flow to each of them should be capable of individual adjustment. The inlet water pressure is recommended to bemaintained between minimum 2.5 kilogram/centimeter square andmaximum 4 kilogram/centimeter square. The inlet water temperature mustnot exceed 40 degree centigrade and this should be very strictly taken careoff. The water temperature differential between inlet and outlet should notexceed 7 to 8 degree centigrade and should preferably be lower.

05) Over a time of period, water pipe/tube got rusted or clogged from insideso they must be replaced by new one. The leaky tube. "O" ring and gasket of inter-cooler or after-cooler or cylinder head can be detected by observing thewater flowing into the outlet funnel. A small pin hole will cause air bubble inthe water and a larger hole will cause the outlet water spurt. Whenever sucha leaky tube is found it should be repaired or replaced without delay.

Maintance of multi stage air compressor:-

What steps to be taken to avoid break down?

Instate of giving details about Low cooling water pressure switch (LCWPS) Iam giving you details about Low Cooling Water Flow Switch (LCWFS).Why Iam doing this? not to any particular reason, but the operation & setting of LCWPS is same as LOPS (Low Oil Pressure Switch).Same INDFOS Make-IPS 70switch is used as LOPS & LCWPS, the only difference is "LCWPS" used indischarge (outlet) water line of closed circuit system or in water inlet(between inlet valve & compressor) for open drain type system of aircompressor. Find the details about LOPS from previous post .

Details about Low Cooling Water Flow Switch:-Flow switch consist of a micro-switch, mounted outside the stream isactuated by a metallic bellows sealed pivoted flapper. A SWITZER Make,

Type-CR25MV is the common switch used as LCWFS. The Location and Installation of LCWFS: -

Flow switch should preferably be mounted in a horizontal section of coolingwater pipe. Where there is a straight horizontal of at least five pipe

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A project report on multi stage air compressordiameters on either side of the flow switch. Weld a socket of 1" BSP threadon water inlet line, for free movement of the flapper in pipe without rubbingthe side. Open the instrument cover, remove spring hook from the horizontalbalancing arm & refit after the instrument is mounted on the pipe. Theflapper of LCWFS must be in right angle to the flow & the arrow mark on thebody is in same direction of water flow. Check the operation of flow switch toensure that the flapper is free to move inside the water pipe line.

This is a important safety of Air Compressor Engineering . LCWFS must be inworking condition to avoid any breakdown to the compressor. Now knowabout operation.

The pressure applied at the sensor creates a force against the balance platethrough the operating rod. The upward movement of the balance plate iscountered by a continuously adjustable range spring, which is used forsetting pressure values. When the input force overcomes the spring tension,the balance plate just moves and operates the micro-switch. On reduction of the applied pressure of the flow, the micro-switch is automatically reset &balance plate is restored to its original position.

How to set the LCWFS in water pipe line?

Identify the NO & NC contact of the micro-switch and check the function of switch by moving flapper to and fro. Fit the Switch in pipe, open water inlet &outlet valve fully, at this maximum flow Normal Open (NO) contact will close.Reduce the water flow to minimum requirement of Air Compressor & rotatethe adjusting range spring, so that the switch is to be set this range as its

normal condition i.e. Normal Open contact remain open. Then increase thewater flow to the fair requirement, now this NO (Normal Open) contact mustclose, if not, adjust the screw.Check the actual operation of the micro-switch by gradually opening &closing the water outlet valve. So that as the water flow falls to the minimumrequirement. The contact must open, and close when the flow reaches fairrequirement.Do not avoid safety switches .It will protect your Air Compressor frombreakdown.

There are some special problems of multi stage air compressor?

Pressure variation in inter stage

Check the suction valve of both 1 st & 3 rd stage cylinder. Check the discharge of both 1 st & 2 nd both.

Inter stage cooler pipe damage

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A project report on multi stage air compressor Chock up of carbon formation in manifold 3 rd stage or 4 th stage discharge valve lickage NRV lickage & chock up 2 nd or 3 rd stage inlet valve chock up

Over heating of discharge valve(Exissive discharge temperature)

Inter cooler & after cooler is chock up Oil pumping is more from the piston ring Piston ring is worn out

While you are working with any machines you must follow thesafety precautions as per the specification in the case of compressor there are two types of safety

Safety of machineSafety of operator

How to safeguard machine?

There is two types of main hazards occurs in machine

Due to exciting vibrationsDue to other rimidities

How to Safeguard Air Compressor from ExcessiveVibrations?

It is also important to protect your compressor from excessive vibrationsdeveloped due to operation or any other reasons. Unfortunately many plantsare not using this safety switch on their compressor. If you are using orinterested to install Excessive Vibration switch, this post will help you toincrease your engineering knowledge. Many different Vibration Switches areavailable in market but in old days a very accurate switch "Robertss haws"

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A project report on multi stage air compressormade in USA make VIBRASWITCH is adopted by various plants. The detailsare as below.

The switch is to protect the crankcase/crankshaft against any damage frommalfunctions that can be detected as an increase in vibration. This ismounted on crankcase of compressor. It is sensitive to vibration in thedirection perpendicular to its mounting base.

It contains a vibration detecting mechanism, which also functio n as a"Mechanical Amplifier" to activate a snap-action switch when the selectedlevel of vibration is exceeded and the detecting mechanism "Trips".

The mechanism may be reset manually, by depressing the reset button tomake the armature away from latching magnet until it is held against thestop pin.

Adjustment of operating set point. The operating set point for the "Vibrato-switch" varies with the type of Air Compressor & its location on the machine.

The set point adjustment suggested here are for machine which is working ingood or normal condition.

The switch is adjusted by three step procedure, for making the adjustment;cover must be removed to gain access to the set point adjustment screw.

Zero Vibration Level Measurement:-When the compressor on which the Vibra-switch is mounted, not operating,back-off the set point adjustment screw counter clockwise two turns & pressthe reset button. Then turn the set point adjustment screw slowly clockwiseuntil actuation occurs. This is the zero vibration point or actuating point,when the compressor not in running condition. A mark should made topermanently record this "Zero Vibration point". Subsequent measurementsare made relative to this point.

Normal G-Level measurement:-When the compressor is in operating condition, back off the set pointadjustment screw one turn counter clockwise and reset. If it will not reset,back-off slowly until reset. Again turn the set point adjustment screw slowlyclockwise until actuation occurs, mark the position. The difference betweenthe two actuating points in step 01 & step 02 is the normal G-level of the Air Compressor , in scale divisions. One scale division is 0.1g & one full revolution

is 1.0gFine Set Point Adjustment:-Rotate the set point adjustment screw one full turn counter clockwise fromthe point where actuation occurred in above step 02.It is very important that the air compressor should run in good working condition to deliver best result, for this we have to take care of thisimportant engineering utility. we cannot keep one operator for full time nearto compressor & keep watching performance . That is why it is necessary toprovide some safety switches in control panel. These safety devices will work

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A project report on multi stage air compressorin abnormal condition & stop electric motor and further prevent anybreakdown in Air Compressor.

Many safety switches are used to avoid any accident to air compressor. Outof that the most important safety switch is "Low oil pressure switch" in shortLOPS as the name indicates; this switch will operate in condition, when oilpressure in crankcase is lower than set limit & stops the compressor.

The details of LOPS is as below INDFOS make IPS-70 switch is commonlyused & the function of this switch is to monitor the oil pressure in thecrankcase of air compressor. This switch is connected in the oil pressuresensing line coming from the crankcase to the oil pressure gauge, through

Tee connection.

The main spring can be set to balance different pressure on the bellows.When the pressure increases, the bellow is affected so that the main spindleis moved upwards until the spring pressure balance the bellow pressure . Thespindle has guiding knob and differential adjusting nut which jointly transmitthe spindle movement to the switch.

The differential pressure has to be set at zero (Indicator scale at extremeleft, facing to LOPS) and the main scale is set to required pressure. (Minimumoil pressure required by the compressor. i.e. 14 PSIG for reciprocating air compressor & 35 PSIG for rotary air compressor).The pressure on main scalecan be set by rotating the knob given at top of the switch.

How to set & test Low Oil Pressure Switch.Connect an Ohmmeter across normal open contact of the switch to observethe switch operation. Start the compressor and watch the oil pressure atwhich contacts closes, then stop the compressor to see at what oil pressurecontacts opens. By adjusting the knob further fine adjustment can be done tothe exact pressure required. So confirm the setting by starting & stoppingthe compressor. Since the switch remains open during starting, a normalclose contact of the timer is connected across the normal open contact of LOPS. The timer is set for 60 sec. As the compressor starts, timer starts itstiming cycle and the compressor oil pressure also start building up in 60 sec.

timer contacts will becomes open. Due to developed oil pressure in sensingline, LOPS contacts closes & continued the healthy running condition of aircompressor.

In case the oil pressure does not build due to any reason, this contactremains open and compressor will trip in 60 sec. time span. An indicatorlamp on Solid State Annunciation or any other indication device will flash &hooter starts blowing, rush to compressor immediately & rectify theproblem .

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Safety: How to Safeguard Air Compressor?It is very important that the air compressor should run in good working condition to deliver best result, for this we have to take care of thisimportant engineering utility. We cannot keep one operator for full time nearto compressor & keep watching performance . That is why it is necessary toprovide some safety switches in control panel. These safety devices will workin abnormal condition & stop electric motor and further prevent anybreakdown in Air Compressor.

Many safety switches are used to avoid any accident to air compressor. Outof that the most important safety switch is "Low oil pressure switch" in shortLOPS as the name indicates; this switch will operate in condition, when oilpressure in crankcase is lower than set limit & stops the compressor.

The details of LOPS is as below INDFOS make IPS-70 switch is commonlyused & the function of this switch is to monitor the oil pressure in thecrankcase of air compressor. This switch is connected in the oil pressuresensing line coming from the crankcase to the oil pressure gauge, through

Tee connection.

The main spring can be set to balance different pressure on the bellows.When the pressure increases, the bellow is affected so that the main spindleis moved upwards until the spring pressure balance the bellow pressure . Thespindle has guiding knob and differential adjusting nut which jointly transmitthe spindle movement to the switch.

The differential pressure has to be set at zero (Indicator scale at extremeleft, facing to LOPS) and the main scale is set to required pressure. (Minimumoil pressure required by the compressor. i.e. 14 PSIG for reciprocating aircompressor & 35 PSIG for rotary air compressor).The pressure on main scalecan be set by rotating the knob given at top of the switch.

How to set & test Low Oil Pressure Switch .Connect an Ohmmeter across normal open contact of the switch to observethe switch operation. Start the compressor and watch the oil pressure atwhich contacts closes, then stop the compressor to see at what oil pressure

contacts opens. By adjusting the knob further fine adjustment can be done tothe exact pressure required. So confirm the setting by starting & stoppingthe compressor. Since the switch remains open during starting, a normalclose contact of the timer is connected across the normal open contact of LOPS. The timer is set for 60 sec. As the compressor starts, timer starts itstiming cycle and the compressor oil pressure also start building up in 60 sec.timer contacts will becomes open. Due to developed oil pressure in sensingline, LOPS contacts closes & continued the healthy running condition of aircompressor.

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In case the oil pressure does not build due to any reason, this contactremains open and compressor will trip in 60 sec. time span. An indicatorlamp on Solid State Annunciation or any other indication device will flash &hooter starts blowing, rush to compressor immediately & rectify theproblem .

To take more safety precaution the under given steps are to be taken.

Safety: HDATS used for safety of Air Compressor.

It is most important to prevent your Air Compressor from any breakdown,because breakdown not only increase maintenance cost but also suffers yourEngineering Production. You have to bear production loss due to breakdownof machine. Many safety switches as like LOPS , LCWPS, HDATS etc. areinstalled for safety of compressor.. High Discharge Air Temperature Switch(HDATS) is also one of the most essential safety major has to be taken toprevent any abnormal to your valuable utility. If the temperature of discharge air (i.e. leaving compressed air from high pressure cylinder ) ismore, than the requirement , it could stick the piston inside the cylinder ,which causes a breakdown of compressor. A working HDATS will safeguardyour compressor from this problem.

A INDFOS Make RT-120 high discharge air temperature switch is normallyused for safety of Air Compressor. This switch having 2 mtr. Long capillaryconnecting the switch and the bulb, with thermo well to fit the bulb. Fit thethermo well in air discharge line in the direction of discharge air flow inangular direction, in between the compressor and AFTER-COOLER, closer tothe cylinder discharge. So the discharge air temperature safety can be done.If it has to monitor the air temperature before AFTER-COOLER. Fit the HDATSafter the AFTER-COOLER, if it is to monitor the air temperature after AFTER-COOLER.

How to set HDATS?HDATS has to be set for some high value which is recommended bymanufacturer that is why it is essential to set the temperature switch outsidein an oil bath, having steady required temperature at the switch to be set.Keep the differential setting at zero, connect an Ohm meter across Normalclose (NC) contact of the switch. Immerse the bulb and thermometer in theoil bath, keep stirring. Set the high Discharge Air Temperature Switch at 170degree centigrade, on the main scale. Control the steady temperature 170degree centigrade of oil bath, now close contact of switch should change &the Ohm meter pointer should show infinity, if not, reduce the setting till thecontact changes to open. Increase the temperature setting if the contact

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A project report on multi stage air compressoropened before 170 degree centigrade till it closes and opens. Now the switchis set at 170 degree centigrade.

Confirm the setting once again by heating oil bath after the oil attains theambient temperature or take fresh oil & continue the process.

After setting the switch, install near the thermo well, fill compressor oil in thethermo well and insert the bulb of temperature switch slowly. Wire thecontrol cable in control panel to Normal Close (NC) Contact of the switch.

Your Air compressor is safer if you provide more safety devices. It is notpossible to install all the safety due to cost or technical problem but still Irecommend installing Low Oil Pressure Switch, Low water Pressure Switch,and High Discharge Temperature Switch & Motor Overload Relay. This foursafety switches are most essential to run your Air Compressor withouttrouble.

Installing process for new air compressor

Coupling: How to Couple Compressor with Electric Motor?

Electric motor or diesel engine is used to operate the engineeringcompressors. Various methods are used to couple the Air Compressor. Somecompressors are run by tire couplings some run by direct coupling, some runby V-Belts. Many times customer phoned me about abnormal sound fromcompressor when I reach to inspect, I found that sound is due to loose v-

belts on pulley and belt wheel. I tried to educate many people in myservicing job and this last chance I am taking to share education with you. The method of V-Belt tensioning is same for all Belt Driven Air Compressorsand mostly fanner belts are used. I will cover the most useful method for aircompressor which has a capacity of 100 cfm or above.

How to Install V-Belts?

In assembling the drive, the electric motor or prime mover should be movedtowards the Air Compressor Belt wheel. The sliding rails are provided for thispurpose. By this way you can put the V-Belts in their respective grooves byhands. The allowance must be available for adjustment of centre distance.When V-belts have been placed on belt wheel and pulley grooves, theelectric motor or prime mover should then be, moved away from thecompressor, until to apply uniform tension to the V-Belts.Under no circumstances should V-Belts be forced on to the pulley or beltwheel with Crowbars, Wedges, Screw Driver or any other type of implement.

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A project report on multi stage air compressorSuch procedure would tend to cause rupture to outside jacket or insidecords. It is possible for the inside load carrying cords to be broken by forcingover the grooves, such V-Belt will fail completely during the first few hours of running compressor.

How to give Tension to V-Belts?

Belt Deflection

01) Measure the centre distance in between the compressor belt wheel and electric motor pulley(in meter). Multiply this distance by 16 to obtain the allowable deflection distance of belts inmillimeter (mm).02) Set the lower marking ring at the allowable deflection distance required in millimeter on thelower scale of Belt Tension Indicator.03) Set the upper marker ring against the bottom edge of the top tube.04) Place the belt tension indicator on top of the belt at the centre of spam, and apply a force atright angle to the belt deflecting it to the point where the lower marker ring is level with the topof the adjacent by the top edge.05) Read off the force value indicated by the top edge of the upper marking ring.06) Compare this force value to the Kgf value in the standard table which is provided with belttension indicator. If the measure force falls within the value given the drive should besatisfactory.07) A measured force below the lower value indicates under tensioning and upper value indicatesover tensioning. Make corrections accordingly.08) The new belts should be tensioned to the higher value to allow for the normal drop in tensionduring the running period of Air Compressor.09) Run the compressor under load for 30 minutes, stop the compressor, and check the tension,re-setting to the required value, if necessary.10) After the air compressor has been running for few days the V-Belts will have seated in thegrooves and the V-Belts tension should be rechecked. Make adequate provision for tensioningthe belts during its life.

If you follow the above procedure and rules then there is no doubt that you will get maximumlife from your v-belts. What you think about the information I share with you? Will it sufficientor not?

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