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SOURCES OF COMPRESSOR MALFUNCTIONS

WATER COOLED COMPRESSORS

SYMPTOMS POSSIBLE CAUSES

1. Intake duct choked

2. Dirty air filter
Compressor fails to deliver 3. Valves in bad condition
4. Broken or worn discs
5. Monitoring equipment not working

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1. Intake duct chocked

2. Dirty air filter
3. Loose valve set screw
Inadequate delivery 4. Worn valves
5. Faulty pressure regulator
6. Speed too low
7. Worn piston rings
8. Worn rod packings
9. Faulty monitoring equipment

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1. Faulty valves
2. Faulty discs
3. Worn discs
4. Loose valve set screw
5. Worn valves
Pressure too low 6. Faulty pressure regulator
7. Excessive air leakage
8. Speed too low
9. Worn piston rings
10. Worn rod packings
11. Air consumption greater than compressor delivery
12. Faulty monitoring equipment

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IT 81A
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1. Worn valves
2. Speed too high
3. Monitoring equipment in poor condition
4. Insufficient water
Temperature too high 5. Temperature of cooling water too high
6. Discharge pressure too high
7. Inadequate cylinder lubrication
8. Motor too weak
9. Belt too tight

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1. Faulty regulating device

Excessive pressure at air receiver 2. Faulty monitoring appliances
3. Monitoring equipment incorrectly mounted

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1. Worn valves
2. Poor regulator2
3. Poor monitoring appliances
4. Monitoring equipment incorrectly mounted
Discharge temperature too high 5. Inadequate water
6. Water temperature too high
7. Discharge pressure too high
8. Poor cylinder lubrication
9. Pressure too high in cooler
10. Fouled cooler
11. Fouled water jackets

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1. Worn valves
2. Faulty regulator
3. Inadequate water
4. Water inlet temperature too high
Cooling water outlet temperature 5. Discharge pressure too high
too high 6. Poor cylinder lubrication
7. Pressure too high in cooler
8. Dirty cooler
9. Dirty water jackets

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1. Faulty regulator
2. Faulty off-loading regulator
3. Unsuitable electrical characteristics
Motor fails to start 4. Motor too weak
5. Belt too tight
6. Voltage too low
7. Incorrect excitation
8. Incorrectly fitted relays

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1. Speed too high

2. Faulty regulator
3. Discharge pressure too high
Motor overheats 4. Poor cylinder lubrication
5. Faulty lubricating mechanism
6. Belt too tight
7. Voltage too low
8. Incorrect excitation

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1. Loose valve set screw

2. Pressure regulator not connected
3. Discharge pressure too high
4. Inadequate cylinder lubrication
5. Faulty lubrication mechanism
Compressor knocks 6. Flywheel improperly secured
7. Excessive bearing play
8. Misalignment
9. Loose piston locking
10. Motor armature improperly anchored to shaft
11. Crosshead slippers loose

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IT 81A
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1. Faulty regulator
2. Excessive leakage in machine
3. Discharge pressure too high
4. Flywheel improperly secured
Compressor vibrates 5. Motor armature improperly anchored to shaft
6. Poor foundation
7. Poor anchorage
8. Wedges left under compressor
9. Misalignment
10. Ducting poorly secured

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1. HP valve discs not working

2. HP valve discs broken
3. Loose HP valve set screw
Pressure too high at cooler 4. Worn HP valve
5. Faulty regulator
6. Wear on HP piston rings
7. Faulty monitoring equipment on HP cylinder

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1. Valves not working (LP)

2. LP valve discs not working
3. LP valve discs broken
4. Loose LP valve set screws
Pressure too low at cooler 5. Worn LP valves
6. Faulty LP cylinder regulator
7. Worn piston rings (LP)
8. Leakage at glands (LP)
9. Faulty monitoring equipment on LP cylinder

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1. Faulty regulator
2. Faulty off-loading regulator
Synchronous motor fails to start 3. Unsuitable electrical characteristics
4. Voltage too low
5. Incorrect excitation
6. Faulty overload relays

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IT 81A