DWARIKESH SUGAR INDUSTRIES LIMITED

Air Compressor & its applications

Submitted By : Under the Guidance of HOD Sir

:
Devendra Singh
Saurabh Singh Mr. Deepak Verma
(Maintenance)
AGM (Maintenance)
 Air Compressor

Contents :
• Definition of Air compressor.
• Working principle of air compressor.
• How does it works.
• Types of Compressors
• Reciprocating compressor
• Parts of Reciprocating Air compressor.
• Advantages and disadvantages of reciprocating air
compressor.
•Screw air compressor
•Working of Screw air compressor
•Parts of Screw Air compressor
•Advantages and disadvantages of Screw air compressor
•Difference B/W reciprocating & Screw air compressor
•Applications of air compressor in our Distillery Plant
•Air compressor maintenance
•Safety
•How to choose the best air compressor
 What is a Air compressor?
Air compressors are devices that convert
natural air into kinetic energy by compressing
and pressurizing air. The compressed air can
then be used for a variety of applications, such
as operating pneumatic equipment , powering
tools, inflating tires.
 Working Principle of Air Compressors:
Every air compressor follows Boyle's and Charles' gas
laws.
According to Boyle's law, “The product of pressure and
volume of the mass of a confined air is constant and
proportional to the temperature.”
PV∝T�
Or
In simple words ,if the temperature is constant (isotherm),
then the product of the pressure and volume are constant.
��.
According to Charles's law , at constant pressure (isobar),
the volume of a gas changes in direct proportion to the
change in temperature.

The general law of state for gasses is a combination of Boyle's and

Charles's laws. This states how pressure, volume and temperature
will affect each other. When one of these variables is changed, this
affects at least one of the other two variables.
 How does it works:

1. The air from the atmosphere is sucked into the

device.
2. The working element compresses the air to high
pressure and decreasing its volume.
3. According to Boyle ’s Law , the temperature is also
increased in this process.
4. Then, the compressed air from the compressor is
delivered to the high-pressure vessel to store the
potential energy in the form of air.
Types of Air Compressors
1). Positive Displacement Compressor:

In positive displacement compression, the air is

drawn into one or more compression chambers,
which are then closed from the inlet. Gradually
the volume of each chamber decreases, and the
air is compressed internally . When the pressure
has reached the designed built-in pressure ratio, a
port or valve is opened.
2). Dynamic compressor:
During dynamic compression, air is drawn between
the blades on a rapidly rotating compression
impeller as it accelerates to a high velocity.
the air is discharged through a diffuser, where the
kinetic energy is transformed into static pressure.
Depending on the main direction of the air flow,
these compressors are called radial or axial
compressors, all of which are designed for large
volume flow rates.
 Difference b/w Dynamic and Positive
displacement
• Operating Principle: Positive Displacement
Compressors: These compressors work by
trapping a volume of gas and then reducing its
volume to increase its pressure..
• Dynamic Compressors: Dynamic compressors
work on the principle of converting kinetic energy
into pressure energy.
 Compression Ratios:
• Positive Displacement Compressors: These
compressors are better suited for applications
where high compression ratios are required.
• Dynamic Compressors: Dynamic compressors
are typically used for applications that require
a continuous flow of gas at a constant
pressure.
 Efficiency
• Positive Displacement Compressors: These
compressors are generally more efficient at higher
compression ratios and are often used in
applications where efficiency is a key
consideration.
• Dynamic Compressors: Dynamic compressors are
more suitable for applications where a continuous
flow of gas is required at a constant pressure and
efficiency is not the primary concern.
 Maintenance
• Positive Displacement Compressors: These
compressors typically have more components that
come into direct contact with the gas being
compressed, which may require more frequent
maintenance and servicing.
• Dynamic Compressors: Dynamic compressors
have fewer moving parts in contact with the gas,
which may result in lower maintenance
requirements compared to positive displacement
compressors
1). Positive Displacement Compressor

Positive Displacement Compressors are divided

into two types

A. Reciprocating compressor
B. Rotary compressor
 Reciprocating Compressor

A reciprocating compressor is a positive displacement

machine in which the compressing and displacing
element is a piston moving linearly within a cylinder.
The reciprocating compressor uses automatic spring-
loaded valves that open when the proper differential
pressure exists across the valve.
There are four kinds of reciprocating compressors

• Single Acting Reciprocating Air Compressor

• Double Acting Reciprocating Air Compressor

• Single-Stage Reciprocating Air Compressor

• Double Stage Reciprocating Air Compressor

 Single acting
• In this type of compressor, the piston back and
forth inside the cylinder and compress the air

• There are two set of valves that take care of

air intake and exhaust
SINGLE ACTING

COMPRESSOR
 Working

• The compressor takes inside successive amount of

volume of air from intake valve and confined it in closed
surface at that time piston moves downwards the with
the closure of intake valve.
• Then there is compression of air by reducing its volume.
• Now the piston moves upward and compress the air
and then displace the compressed air through exhaust
valve.
 Advantages and Disadvantages
Advantages Disadvantages
• Relatively cheap • Sound too much, you have
• Easy maintenance to arrange a room for it or
• Suitable for high pressure to put it into isolating box.
• Large range of horsepower • High outlet temperature of
compressed air.
• High oil content in the pipe
 Double acting
A double-acting reciprocating air
compressor compresses air on both the forward
and backward strokes of its piston. This design
allows for more efficient compression of air
compared to single-acting reciprocating
compressors, which compress air only during one
stroke of the piston.
Double acting
 Working

A double-acting reciprocating air compressor

compresses air on both the forward and
backward strokes of its piston. This design allows
for more efficient compression of air compared
to single-acting reciprocating compressors,
which compress air only during one stroke of the
piston. Here's a general overview of how a
double-acting reciprocating air compressor
works
Intake Stroke: During the intake stroke, the piston moves away from
the cylinder head, creating a vacuum in the cylinder. The inlet valve
opens, and atmospheric air is drawn into the cylinder.

Compression Stroke (Forward): As the piston reverses direction and

moves towards the cylinder head, the inlet valve closes. The air
trapped in the cylinder gets compressed due to the decreasing
volume. The outlet valve remains closed during this stroke.

Compression Stroke (Backward): Once the piston reaches the

cylinder head, the outlet valve opens. The compressed air is forced
out of the cylinder and into the discharge line.

Discharge Stroke: After the backward compression stroke, the piston

moves away from the cylinder head again. The outlet valve closes,
preventing air from flowing back into the cylinder. The remaining
compressed air in the cylinder is expelled through the discharge
valve and into the air receiver or system.
 Single-Stage Reciprocating Air Compressor

The main function of a reciprocating compressor is to

suck air from the atmosphere, compress it, and deliver
compressed air. It is similar to a diesel engine. However,
as there is no combustion taking place, the cycle reduces
to two strokes: suction and compression

S​ uction stroke: In this stroke, the piston moves from TDC

to BDC creating a partial vacuum inside the casing. At the
same time, the suction valve is opened and the air gets
sucked inside as the piston moves downwards.
Compression stroke: In this stroke, the Inlet valve
closes, the piston moves BDC to TDC and thus air gets
compressed. As the piston reaches near TDC, the
delivery valve opens and compressed air gets
delivered to the desired location. Hence, the working
principle of a single-stage compressor can be seen as
similar to that of two stroke IC engine
 Single stage
Reciprocating compressor
 Double-Stage Reciprocating Air Compressor
A two stage reciprocating air compressor is ideal for demanding,
industrial applications. They are much tougher than single stage
compressors and can handle more pressure and more capacity
Two stage air compressors
With two stage air compressors, the air is compressed in two stage.
In between the stages, the air is cooled.
Stage 1
Air is compressed to medium level. This is the big cylinder/piston. It
moves a high volume of air, but at a low pressure.
Cooler
Air is cooled back to a much lower level. This makes the compressor
more efficient and reduced stress on the high pressure stage.
Stage 2
The air is compressed further to the end pressure. This
is the small cylinder/piston. It moves a lower volume of
air, but at an high pressure.
On some models, you can clearly see the two stages (a
v-shaped pump with a big and a small cylinder). On
other models, they low pressure and the high pressure
cylinder are cast in 1 block. It looks like a single stage
compressor, but it is a two stage compressor.
 Double stage
Reciprocating air compressor
Reciprocating Compressor
 Working of reciprocating compressor
The action of a reciprocating compressor using
a theoretical pressure–volume (PV) diagram. In
position A, the suction valve is open and gas
will flow into the cylinder (from point 1 to
point 2 on the PV diagram) until the end of
the reverse stroke at point 2, which is the start
of compression. At position B, the piston has
traveled the full stroke within the cylinder, and
the cylinder is full of air at suction pressure.
Valves remain closed. The piston begins to move to
the left, closing the suction valve.
In moving from position B to position C, the
piston moves toward the cylinder head,
reducing the volume of gas with an
accompanying rise in pressure. The PV diagram
shows compression from point 2 to point 3. The
piston continues to move to the end of the
stroke (near the cylinder head) until the cylinder
pressure is equal to the discharge pressure,
and the discharge valve opens (just beyond
point 3).
After the piston reaches point 4, the
discharge valve will close, leaving the clearance
space filled with gas at discharge pressure
(moving from position C to position D). As the
piston reverses its travel, the gas remaining within
the cylinder expands (from point 4 to point 1) until
it equals suction pressure, and the piston is again in
position A.
 Environmental Threats to air compreesor
performance

Air compressors are powerful machines, but they can

be damaged by the elements just like any other tool or
device. Technicians need to keep environmental factors
in mind to ensure they operate effectively. A few
things, in particular, can impact air compressor
performance.
 Temperature
• Air compressor technicians know heat is bad news, especially
when coupled with high humidity. High and low temperatures
can cause numerous problems. Generally, most units perform
best in a sweet spot between 50 and 85 F.
• Performance will start to decline when temperatures rise or
fall outside this window. For example, high heat can lead to
increased water condensation, which is a serious issue for air
compressors. Heat can also worsen other mechanical
problems, leading to overheating and forcing compressors
into automatic shutdown to prevent permanent damage.
Low temperatures can be detrimental to air
compressor performance, as well. For example, the
oil that is crucial for healthy compressor
performance can start to solidify as temperatures
near the freezing point. Water vapor in control
lines will also condensate and eventually freeze.
 How Can I Prevent air Compressor from
Overheating?
• If compressed air is integral to your company’s
daily operations, downtime can be catastrophic.
If your air compressor overheats, it can stop
working and need to be repaired or completely
replaced. While overheating can happen, there
are some steps you can take to prevent common
causes of overheating
Ambient Temperature: Is your air compressor near
windows in the middle of summer? Is it next to other very
hot equipment? Is it in a non-insulated room that is very
small? All of these are preventable issues to keep the
surrounding environment at a lower temperature.
Oil Levels : Another common cause of overheating is
your compressor not having enough oil.
Ventilation : In addition to not only having a room large
enough for your compressor to cool, you must make sure
that the compressor is venting properly.

Thermal Valve : If a thermal valve starts to fail,

overheating can occur.
Moisture

Moisture can be a big problem for air compressors.

Humidity and airborne moisture is not a friend of
electrical systems or metal. Compressors left to
operate for long periods in high humidity can end up
with a rusted tank and pipes. This rust can even
spread to the inside of the system if the intake air is
moist.
 How to reduce moisture from Air
Compressor Room Environment
Ensure the compressor room has plenty of ventilation
to keep temperatures down, reduce moisture buildup
and prevent compressor overheating.
Consider insulating your compressor room for better
temperature control.
Add a dehumidifier to the compressor room.
Fix leaks, and don’t allow water to pool on the floor
near the compressor.
 Air Compressor Maintenance
• Drain the system as needed or maintain automatic drain
valves.
• Maintain all filtration systems and replace the intake and
inline filters as needed.
• Maintain the oil/water separator.
• Perform all required air dryer maintenance and ensure
components work correctly. For instance, check
refrigerant in refrigerated dryers and recharge desiccant
dryers on schedule.
• Ensure the after-cooling system is clean and working
correctly.
 Air Quality
Air can sometimes affect compressor performance. Air
contaminated with moisture and particles can cause
overheating and mechanical issues. Units that take in
large amounts of contaminated air can see buildup of
particulate matter like dust and dirt on the radiator,
cooler and filters.
Basic component of the reciprocating compressor.
Cylinders : The cylinder is a pressure-retaining part of
the reciprocating compressor. The cylinder is house for
both suction and discharge valves. In reciprocating
compressor ,the cylinder is directly connected to
compressor frame.
Piston: The piston is the heart of the reciprocating
compressor. The piston transfers the energy from the
crankcase to the air in the cylinder. In order to avoid
the leakage of compressed air between the piston and
cylinder, the piston is equipped with a set of sliding
seals called piston rings. Usually, the piston rings are
made of a material, that having self-lubricating
property (fluorocarbon ) to reduce the slide friction
force between the cylinder and the piston.
Piston Rod : The piston rod is threaded to the piston
and transmits the reciprocating motion from the
Crosshead to the piston.
 Rod packing
Rod packing is required to prevent the gas leakage
along the piston rod where it passes through the crank
end cylinder closure.
If rod packing cooling needed, the stuffing box is
jacketed for liquid coolant.
CRANKSHAFT: Crankshafts are one of the most
important components to an air compressor. It
is primarily used as the transmission rotary motion to a
linear motion.
 Connecting Rod
• Purpose of the connecting rod is to connect the
crankshaft and the crosshead. The connecting rod
converts the rotary motion into reciprocating motion.
The connecting rod bolts and nuts shall be securely
locked with cotter pins or wire after assembly.
• Like Crankshafts, the connecting rod has drilled hole
for oil passage.
• The connecting rod is made up of forged steel for 150
kW (200 hp) reciprocating compressor. For
compressor less than or equal to 150kW, ductile iron
material is used.
Connecting Rod
 Cross Head
• The compressor can use narrow piston, due to the
use of narrow piston larger valve area for greater
efficiency.
• Permits a longer stroke and greater capacity.
• Separates crankcase from the cylinder, allowing
control of oil carryover into the cylinder.
• Gives greater stability to the piston, eliminating
piston “slap” and reducing ring wear
• Permits stronger piston design and higher operating
pressures.
Cross Head
Valve : Valve is used to manage the compressor's air
compression and control the air pressure.

Reciprocating compressors generally use three types of

valve configurations:

•Plate Type Valve

•Ring Type Valve
•Poppet Type Valve
•Plate Type Valve
The plate type valve contains concentric rings of valve
plates. The concentric ring valve plates are a single
element. Since the valve plate is made of a single element,
flow control is much easier when compared to other types
of valves.
The stress act on the valve plate is higher .
•Ring Type Valve
The ring-type valve consisting of concentric ring valve
uses one or more relatively narrow rings arranged .
These valves have the advantage of a low-stress level
due to the lack of stress concentration points. It is
difficult to maintain uniform flow control across the ring-
type valve.
Poppet valve
The poppet valve is used for low-speed compressor
and gas contain oil particles. The poppet valves are
high lift valves, due to high lift the pressure drop
across the valve is low.
Poppet Valves are not tolerant of uneven flow
distribution. The poppet valve is used in a medium
pressure range compressor. Nowadays these types of
valves are used in hydrocarbon service because of
easy maintenance.
Poppet valves are recommended up to 15 MPa
differential pressure or 30 MPa discharge pressure and
600rpm.
 HEAT EXCHANGERS
• Horizontal or vertical. Shell and tube type, with removable
tube bundle with water through shell and air through
tubes, heat exchangers are fitted on the cylinders at a
height which is easily accessible. Designed for optimum
heat exchange, the heat exchangers cools the air received
from the previous stage discharge effectively before its
entry to the next stage cylinder and so on for successive
stages. Provided with a pulsation bottle on inlet side (in
select models) and an‟ efficient moisture separator on
discharge, the heat exchangers are of counter flow type
and complete with a safety valve and auto drain valve with
bypass arrangement.
OIL PUMP:
Gear type oil pump directly driven by the
crankshaft and fitted on the bearing housing. It
feeds oil to the main bearings connecting rod
bearings and to one cross slide in HX model
(side opposite to crankshaft rotation) and to
both the cross slides through choke in HN
model. The oil pressure is regulated by a
pressure regulating screw provided on the oil
pump body. To increase the pressure,
regulating screw has to be screwed in and vice
versa.
Belt Drive
Air compressor belts are an integral part of the power
transmission system in belt-driven compressors. They connect the
motor to the compressor pump. It helps to transfer power to
generate compressed air. The efficiency of this power transfer
directly impacts the overall performance of the air compressor
Flow diagram
Advantage and Disadvantage of reciprocating compressor
Advantages:
1. Suitable for high pressure ratio
[Link] Maintenance
3. Easy to operate
4. Relatively cheap
Disadvantages:
[Link] machines (Parts) are required
2. Sound too much.
[Link] outlet temp. of compressed air
4. Heavy foundation required
 Rotary compressor

A rotary screw compressor is a type of air compressor that

uses two rotating elements (also known as rotors) to
produce compressed air.

Rotary compressor are divided into two types

A). Screw Air Compressor

B). Blower Compressor
 Screw air compressor
A rotary screw air compressor is a type of air
compressor which uses a rotary type mechanism. Screw
compressor works with a male and female rotor that
rotate in the opposite direction. Screw compressors
generally found where large volumes of high-pressure
air are in need. When your application requires
continuous air demand, a screw compressor is the way
to go.
Screw compressor
 Working of screw compressor
1. An opening valve sucks air into the compressor chamber.
Located in the chamber are the two screw rotors; when the
machine is on, they will rotate at high speeds.

2. As the screws rotate, they trap and isolate air in the

cavities between the rotors, thus moving the air down the
chamber.

3. The chamber decreases in size and is moved away from

the opening valve. As the volume decreases, the pressure
increases.
4. Air pressure will trigger the compressor’s discharge
valve to open, allowing the pressurised air to enter a
receiver or other holding tank.

5. Air is compressed and can be transferred to downstream

equipment such as dryers .
Flow diagram
 Basic Parts of the Screw compressor
Air filters : Air filters are one of many layers of filters
within the rotary compressor. The air filter sits inside the
compressor’s opening valve where it catches dust,
particles, and moisture. This prevents them from damaging
to the inside of the machine. The material of air filter is
steel and polyester, it is a kind of plastic it is popular for
high strength and durability.
Intake Valve: The main function of the intake valve is to
control the amount of air that is sucked in by the screw air
compressor. When the intake valve is wide open, air will
enter inside the compressor, the pressure of the air inside
will begin to rise. Intake valve operates with the help of
solenoid operated Valve(SOV).
Rotary screw element: Air is sucked and compressed
between the rotors while the spinning continues. The air
will be transformed to a fully compressed state once the
grooves will reach the finishing of the rotation length.
Lastly, the compressed air will be released through the
discharge valve into the storage tank.
Air Oil Separator : An Air Oil Separator plays a key role in
the separation process. It ensures that only the air and no
oil is delivered to the outlet. Hence it is important that the
separator should be replaced from time to time.
Minimum pressure valve (MPV) : In a rotary screw air
compressor, the minimum pressure valve maintains a
minimum pressure , it maintain 4 kg/cm2 pressure in the
air-oil separator to transfer oil and Compressed air.
Air cooler: An after cooler is a mechanical heat exchanger
that is designed to remove the heat & excess moisture of
compressed air.
Gaskets : Gaskets provide a seal between various compressor
components, preventing air leaks and ensuring efficient operation.
Over time, they can wear out or degrade, so regular checks and
replacements are essential.
Vibration Pads : To reduce noise and prevent wear and tear from
constant vibrations, many compressors are mounted on vibration
pads. These pads absorb and dampen vibrations, leading to quieter
operation and increased component longevity.
Oil cooler

• The air compressor cooler is a heat exchanger

used to cool the lubricating oil flowing from
the oil separator, which reduces the oil
temperature.

• They use the same working principle that a

radiator uses; hot oil flows through some
tubes with fins that join them.
Thermostatic Valve
• A thermostatic valve is a device that controls the
temperature of compressed air by regulating the oil flow
to the cooling jacket around the rotating elements. It
works by sensing the temperature of the compressed air
and adjusting the oil flow accordingly.
Oil Filter: The Air Compressor Oil Filter consists of a
paper filter element , which is use for removing dirt, rust,
sand, metal filings, calcium, or other impurities from oil
that can damage other components of the air compressor.
Safety Valve -It's a pressure releasing valve that
automatically opens when the air pressure within the
system exceeds a set limit. The function of the Safety Valve
is to protect life and property against failure to control
system pressures.
Valve closed (p < pset)
Fp < Fs Valve opend (p > pset)
Fp > Fs
Fs = Spring force
Fp = Force by pressure Fs = Spring force
Fp = Force by pressure
Blowdown Pressure - Blowdown is the difference between set
pressure and reseating pressure of a safety valve .

For Ex.
Set pressure – 12 kg/cm2
Reset pressure – 10 kg/cm2

Blow down pressure = Set pressure-reset pressure, 12-10= 2kg/cm2

Blowdown Pressure % = blowdown pressure/set pressure X 100
= 2/12 X 100
=16.66%
Manual drain valve:
Drain valves allow excess water vapor to exit the tank and
reach the atmosphere. Condensation buildup can result in
corrosion that damages the compressor, shortening its life
span. By removing the extra moisture, you reduce wear on
equipment powered by compressed air systems.
 Advantages of Screw Compressors

• Noise Levels: Due to the smooth movement of the

rotating shaft, screw compressors produce much less
noise.

• Durable and long lasting : Rotary screw air

compressors have a reputation for their long life
which is much longer than other air compressors. If
you buy a rotary screw air compressor , you can expect
a typical lifetime around 60,000 to 80,000 hours with
little to no capacity reduction.
• Low Vibration: The rotational nature of the screw
means that vibrations are minimal, making it an
excellent solution for sensitive environments where
vibrations can interfere with equipment.

Energy efficient : Screw air compressors are more

energy efficient than other types of air compressor
and they generate much less heat too.
• low maintenance : Unlike piston compressors,
screw compressors have little wear and tear
because of the continual, smooth rotation of the
central screw shaft. This results in few repairs and
even fewer replacements being needed.
 Disadvantages of Screw Compressors

• Cost: Due to their more advanced design, screw

compressors often cost more than their piston
counterparts.

• Required skilled manpower for Maintenance: Although

maintenance is less frequent for a screw compressor, it
can also be more complicated. If something does need
repaired, this can often result in the need for reassembly
and alignment of the screw shaft.
• Little bit oil in the air : A little oil goes away with
compressed air, due to which direct air cannot be used
in critical equipment ( instrument).
Difference b/w Reciprocating & Rotary Screw Compressor

Efficiency:
Rotary screw compressors are generally more
efficient in electricity consumption and cost than
reciprocating compressors. They use two meshing
helical screws to compress the air, which results in a
more continuous flow of compressed air and less
energy loss compared to the piston movement in
reciprocating compressors.
Design:
Rotary screw compressors use two meshing helical screws
(rotors) to compress the air, while reciprocating
compressors use pistons driven by a crankshaft.

Noise level:
Rotary screw compressors are known for their quiet
operation, reciprocating compressors which generate more
noise due to the movement of the pistons. The noise level
of a rotary screw compressor typically ranges between 60-
70 dB(A), while a reciprocating compressor can produce
noise levels of around 70-90 dB(A), depending on the size,
model, and brand.
Airflow:
The air flow rate of rotary screw compressor is high
to compare of reciprocating air compressor.

Air pressure:
In Rotary screw compressors the air pressure is low
compare of Reciprocating air compressor, usually up to 150
psi (10.3 bar).
On the other hand, reciprocating compressors are designed
to generate compressed air at higher pressures, frequently
reaching up to 200 psi (13.8 bar) or more.
Maintenance:
Rotary screw air compressors are generally easier to
maintain than reciprocating compressors. They have fewer
moving parts, which results in less wear and tear. Moreover,
the lack of piston rings in rotary screw compressors means
there is less need for regular oil changes and less potential
for oil leaks.

Despite being less easy to operate, reciprocating is still a

popular choice amongst several businesses because of its
low initial cost and compact design and easy to
maintenance (semi skilled person can do).
 Air Compressors in our Distillery Plant

According to Working of Compressor there are two types

of compressor in our distillery plant
 Reciprocating Air Compressor (1x2)
 Screw Air Compressor(5X2)

There are 6 types of air compressors in distillery plant

according to their Capacity.
The numbers of total air compressors are 12 NOS (6x2).
Compressor No.1
Model No. – NS PX 60-7-W
Type- Reciprocating Air Compressor
Number of compressor in plant – 2 NOS
Max. Discharge pressure – 7.0 kg/cm2
Capacity- 332 CFM
Lubricant oil- Recip Lube
Motor Power – 45 HP
Motor rpm - 14
Application in plant – Use for operate instrument
equipments like control valve
Compressor Location – Power House
Compressor No.2
Model No. – CPE 100
Type- Screw Air Compressor
Number of compressor in plant – 2 NOS
Max. Discharge pressure– 7.0 kg/cm2
Capacity- 517 CFM
Lubricant oil- Rotair Excellence
Motor Power- 100 HP
Application in plant – Use for Ash Handling.
Compressor Location – Power House
Compressor No.3
Model No. – CPB TMD 25 08
Type- Screw Air Compressor
Number of compressor in plant – 2 NOS
Max. Discharge pressure– 8.1 kg/cm2
Capacity- 105 CFM
Lubricant oil- Rotair Advance
Motor Power- 25 HP
Application in plant – Use for purging of Beg filter.
Compressor Location – Power House
Compressor No.4
Model No. – CPB 20
Type- Screw Air Compressor
Number of compressor in plant – 2 NOS
Max. Discharge pressure– 8 kg/cm2
Capacity- 84 CFM
Lubricant oil- Rotair Advance
Motor Power- 20 HP
Application in plant – Use for operate instrument
equipments like control valve etc
Compressor Location – Distillation 100KL
Compressor No.5
Model No. – CPA 10 TMD
Type- Screw Air Compressor
Number of compressor in plant – 2 NOS
Maximum Discharge pressure – 7.2 kg/cm2
Capacity- 42 CFM
Lubricant oil- Rotair Advance
Motor Power- 10 HP
Application in plant – Use for operate instrument
equipments like control valve etc
Compressor Location – Distillation 30KL
Compressor No.6
Model No. – CPM 4D
Type- Screw Air Compressor
Number of compressor in plant – 2 NOS
Max. Discharge pressure– 10 kg/cm2
Capacity- 11CFM
Lubricant oil- Rotair Advance
Motor Power- 04 HP
Application in plant – Use for operate instrument equipments
like contol valve etc
Compressor Location – CPU Plant
 What is CFM (Cubic feet per minute) : It is a unit of
volume flow rate of air compressor
CFM = Tank Volume in cubic feet X standard pressure
during a cycle (ATM) X Cranks per minute
Standard Pressure:
it is the pressure difference during load and unload Condition.

Cranks per minute:

it is the time taken (in minutes) by compessor from loading to
unloading Condition.
Example :
A 15 HP Compressor with a 500 litres tank rated for 125 PSI

Tank Volume – 500 letters= 500/28.317 = 17.65 cubic feet

( 1 Cubic feet =28.317 litres)
Loading Pressure- 80PSI
Unloading Pressure- 120 PSI
Standard pressure- 120-80= 40 PSI = 40/14.7 = 2.72 ATM
(1 ATM = 14.7 PSI) , 1ATM= 1.033kg/cm2
Suppose it takes 1 min 8.4 sec = 1.14 minutes

Compressor CFM = 17.65X2.72X1.14

= 54.73 CFM
Lubrication oil : Air compressors lubrication oil plays a
critical role in the operation, performance, and overall
health of compressor.

In our compressors we are using 3 types of lubricant oil

A). Recip Oil
B). Rotair Advance
C). Rotair Excellence
 A). Recip Oil:
Lubricant Properties:
Viscosity @ 40°C – 105 mm²/s
Viscosity @ 100°C– 12.2 mm²/s
Flash point – 240°C
Pour point- -39°C
B). Rotair Excellence
Viscosity @ 40°C – 88 mm²/s
Viscosity @ 100°C– 10.6 mm²/s
Flash point – 220°C
Pour point- -42°C
C). Rotair Advance
Viscosity @ 40°C – 46 mm²/s
Viscosity @ 100°C– 7.3 mm²/s
Flash point – 210°C
Pour point- -57°C
Properties of lubricant Oil:

1). Viscosity: it is defined as resistance of flow

Viscosity of lubricant oil is defined as SAE No.

SAE- Society of Automotive Engineers

SAE 10, SAE20 – Mono grade type

SAE 20W40 , SAE 10W30 - Multi grade type

Multi grade type - can change its Viscosity properties (best for both
condition Summer & winter)
Mono grade type - can not change its Viscosity properties (best for
one condition )
SAE 20W40
In this 20 represent oil Viscosity at 0°F
W- winter
40 represent oil Viscosity at 212°F

SAE20
In this 20 represent oil Viscosity at 212°F

Viscosity range of gearoil – 92-140 mm²/s

Viscosity range of engine oil - 20-40 mm²/s
2. Flash Point – Maximum working temp. where lubricant oil work
without any failure.
(The Flash Value for best lubricant oil should be maximum)

3. Pour Point – It is the minimum temperature ,where lubricant oil

can not move.
(The Pour Value for best lubricant oil should be minimum)
 The risk of not using original lubricants

Problem
Sludge and deposit formation

Cause
Low oxidation resistance properties

Impact
• Lower lubricant lifetime
• Compression block break- down
Other parts such as oil separators suffer from clogging and
valves being blocked
Problem
Metal to metal contact between
rotors and bearings, resulting in
scratches and premature wear

Cause
Low anti-wear properties
Not right oil film thickness

Impact
Replacement of the element
Gear damage because of scuffing, requiring replacement
Problem
High temperature in the
compression block – risk of metal
to metal contact

Cause
Oil viscosity

Impact
• Compressor shutdowns due to high outlet temperature
• Lower performance in mild and demanding conditions
 Air compressor maintenance
DAILY
Monitor all gauges and indicators for normal operation
Check the oil level
Look for oil leaks
Listen and feel for any abnormal noises or vibrations
Inspect - Belt Tension

Every 500 hours

 Clean Suction filter element
 Check leakage of oil
 Inspect - Belt Tension
Every 2000 hours
Clean Intake filter, Replace it if necessary
 Check oil filter and replace if necessary
 Check belt tension
 Check Radiator surface area. Clean it if necessary.
 Check for nut bolt tightness.
 Check oil level
 Inspect leaks - Air, Water , Oil
 Check piston clearance
Every 4000 hours
 Change sump oil.
 Replace oil filter.
 Replace suction filter element.
 Inspect and replace compressor valves as required.
Check piston ring and rider ring wear replace if necessary.
 Grease electrical motors if necessary.
Check electrical connections at control panel motor
terminals.
 Safety

Safety icons explanation

Danger for life
Warning
Important note
Use hearing protection

Use Eye protection

 Operating Safety
Air hoses pipe shall be of correct size and suitable for
the working pressure. Never use over size , damaged
hoses pipes. Use only the correct type and size of hose
and fittings and connections.
Never operate the compressor at pressures over of its
limit ratings as indicated on the Principal Data sheet

Keep all bodywork doors shut during operation. The

doors may be opened for short period any e.g. to carry
out checks. Wear ear protectors when opening a door.
Never operate the unit when there is a possibility of
taking in flammable or toxic fumes
People staying in environments or rooms where the
sound pressure level reaches or exceeds 90 dB (A) shall
wear ear protectors

Periodically check that:

All guards are in place and securely fastened
All hoses and / or pipes inside the unit are in good
condition.
There are no leaks of oil and air.
All fasteners are tight condition.
All electrical leads are secure and in good order.
Maintenance Safety
Maintenance and repair work shall only be carried out under
supervision of someone qualified for the job.

Use only the correct tools for maintenance and repair work.

Use only genuine spare parts

All maintenance work, other than routine attention, shall

only be undertaken when the unit is stopped, the main
power supply is switched off and the machine has cooled
down.
Make sure that after maintenance work no tools, loose parts are
left in or on the compressor.

Make sure that all sound-damping material, e.g. on the

bodywork and in the air inlet and outlet systems of the
compressor, is in good conditions. If damaged, replace it by
genuine material to prevent the sound pressure level from
increasing.

Protect the motor, air filter, electrical and etc. to prevent

moisture from entering.
How to choose the best air compressor to meet your needs?

When choosing an air compressor, there are a few things

you should keep in mind, such as:

1. The type of air compressor : There are two main

types of air compressors : piston , and screw . Each type
has its own set of benefits and drawbacks, so it’s
important to choose the one that best meets your
needs.
2. The size of the air compressor: Air compressors
come in a variety of sizes, from small portable units
to large industrial units. It’s important to choose
the right size for your needs.

3. The pressure: Air compressors are available in a

variety of pressures , from low-pressure units to
high-pressure units. It’s important to choose the
right pressure for your needs.
4. The power source: Air compressors can be powered
by electricity , gasoline , or diesel. Each power source
has its own set of benefits and drawbacks, so it’s
important to choose the one that best meets your
needs.

5. The location where it will be used: Air compressors

can be used in a variety of locations , from small
workshop to large industrial facilities. It’s important to
choose the right location for your needs.
6. The capacity: Air compressors come in a
variety of capacities, from small portable units to
large industrial units. It’s important to choose
the right capacity for your needs.
Thank you