AIR COMPRESSOR

Introduction
• Air:- A mechanical mixture of gases basically four
part of nitrogen to one part of oxygen minute
quantity of other gas also present
• Air Pressure:-
The force exerted by air when compressed.
Unit of measurement is the ”bar”.
• Air compressor:-
A machine for compressing air
 Principal of air compressor
In the positive displacement compressor, the air is
drawn into a compression chamber which is than closed off
from the inlet.
Its volume is then forcibly reduced, where by the air is
compressed. When the pressure in the compression
chamber has attained the same level as the pressure in the
delivery pipe a valve or port opens and the air in the
compression chamber is discharged at a constant pressure.
Application:- a. Cylinder operation
b. Instrument operation
c. Drilling operation
d. Conveying operation
e. Bag cleaning operation
 Type of compressor

Screw Reciprocating
Compressor Compressor

Non Non
Lubricated Lubricated
Lubricated Lubricated
 Comparison

Screw Compressor Reciprocating Compressor

• Installation is easy. • Installation is difficult.

• Wear and tear is less • Wear and tear is more
than reciprocating than reciprocating.
compressor • Efficiency reduce day by
• Efficiency remains day due to metal to metal
same at all time. contact.

• Easy fault fonding. • Fault fonding difficult.

• There is no require of • Foundation bolt must

foundation bolts. required.
 Screw Compressor Working
• During Unloading:- It the air consumption is less than the
air output of compressor the net pressure an increase reaches
the unloading pressure solenoid valve is de-energized. The
plunger of the valve returns by spring force.
1. The control pressure present in the chambers of loading plunger and
unloading valve is vented to atmosphere via solenoid valve.
2. Loading plunger moves upward and causes inlet valve to close the air
inlet opening.
3. Unloading valve is opened by receiver pressure the pressure from air
receiver is released towards unloader.
4. The pressure is stabilized at low value a small amount of air is kept drawn
in and is blown to the unloader.
Air output is stopped (0%) the compressor runs unload.
 Screw Compressor Working
• During loading:- When the net pressure decrease to the
loading pressure solenoid valve is energized. The plunger
of solenoid valve moves upwards against spring force.
1. Control pressure is fed from air receiver via solenoid valve to
loading plunger and unloading valve.

2. Unloading valve close the air blow-off. Loading plunger moves

down wards and causes inlet valve to open fully.

Air output is resume 100% the compressor runs loaded.

 General Maintenance of Screw Compressor
• Cleaning -
Air filter:- 1. Clean air filter every 3 to 4 days by compressed air.
2. Air filter must be clean inside of filter.
3. During cleaning air pressure not more than 2kg. /cm 2
Oil cooler:- 1. Every week oil cooler to be cleaned with air pressure.
2. Pressure not more than 4kg. /cm 2 /
• Changing Intervale -
Air Filter:- Every 1000 hours air filter to be change.
Oil and Oil Filter:- Every 1500 hours oil and oil filter to be change.
 How to change oil and oil filter
Oil Change
• Stop the compressor.
• Switch off the voltage.
• Close the outlet valve of compressor.
• Release the air of net from moisture traps drain valve.
• Remove the drain plug and drain the oil.
• Tighten the drain plug fill the new oil up to required level.
Oil Filter Change
• Stop the compressor and remove oil filter.
• Clean the filter seat on the manifold. Oil the gasket of new oil filter
element.
• Screw the element into place tighten firmly by hand.
Advice -
• Oil and oil filter to be change at a time.
 Capacity
Capacity F.A.D. using F.A.D. is denoted by C.F.M.
F.A.D. (Free Air Delivery)
C.F.M.(Cubic Feet Per Minute)
Useful conversion
1 bar = 14.5 psi
1000 liter = 1m3
1m 3 / minute = 35.31C.F.M.
 Flow chart
Air Filter

Unloading Valve

Screw Element

Check Valve

Air Oil Receiver/Oil Separator

Minimum Pressure Valve

After Cooler

Discharge
 Trouble Shooting
• Compressor running but dose not load.
• Compressor running but dose not unload.
• Condensate is not discharge from moisture trap during loading.
• Excessive oil consumption, oil carry over through discharge line.
• Compressor capacity or pressure below normal.
• Excessive oil flow through air filter after stopping.
• Compressor over heating.
• Safety valve blows immediately after loading.
• Compressor is unload through air pressure switch but discharge
pressure continues rising slowly safety valve blows.
• Unloading pressure or pressure difference can not be adjusted.
 Air Dryer
A device for extracting moisture from compressed air.
Dew point:- the temperature at which air is fully saturated
with water vapour.
Dew point - 20C to 50C

Type of dryer

Refrigeration Heat less

air dryer air dyer