A project report on multi stage air compressor

PROJECT REPORET ON
OPERATIONS & MAINTANCE
OF MULTI STAGE AIR
COMPRESSOR

PREPARED BY:-
BHUMIT A. VASANT
(Diploma in mechanical 5th SEM.)
(AY-2 roll no.:-36)

ABSTRACT

1
 A project report on multi stage air compressor
Man 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 know
that what air can do?

Before 40 or 50 years man invent an air compressor because he

required the pressure of air production systems the compressor is best way
to give pressure of air.

After the invention of air compressor engineers realized that it is a

very necessary thing for mordan industries.

In the time of toddy’s various types of air compressors are

available in the market when are going to purchase the air compressor you
have to decided that which type of compressor is more appropriate for the
plant.

Generally most of industries are using reciprocating air compressor

because 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 multi

stage air compressor. For that I have visited m/s. hawa engineers & take
guidenance 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
2
 A project report on multi stage air compressor
engineering dept.) for his kind support & timely guidance given to me to
reaching 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 who

permitted me to work on the topic & extended his kind support & help for the
same. The enthusiasm shown by him in my project proved to be a great
source of inspiration.

I thankful to all the teaching & non-teaching staff members

and friends who helped me directly & indirectly for the successful
compilation of this project work.

I also thankful to HAWA ENGINEERS (shpar-veraval)

& MR. AJAY VASANT owner of HAWA ENGINEERS (shpar-veraval) for
their all kind support & guidance

Thanking All

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

INDEX

SR. CONTANT PAGE

NO NO
1 INTRODUCTION 1
3
 A project report on multi stage air compressor
2 ABSTRECT 2
3 ACKNOWLADGEMENT 3
4 WHAT IS AIR COMPRSSOR 5
5 CLASSIFICTION OF COMPRESSOR 6
6 LIMITATION OF SINGLE STAGE AIR 7
COMPRESSOR
7 WORKING PRINCIPLE OF MULTI STAGE 8
AIR COMPRESSOR
8 CONCEPT OF MULTI STAGE AIR 9
COMPRESSOR
9 P-V DIAGRAM FOR MULTI STAGE AIR 10
COMPRESSOR
10 PRACTICL P-V DIAGRAM 12
11 LIFE CYCLE OF COMPRESSOR 13
12 LIFE CYCLE COST 14
13 ADVANTAGES OF MULTI STAGE AIR 15
COMPRESSOR
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 desirable

pressure.

If you've ever had to inflate the tires on your car or

bicycle, you've had firsthand experience with an air

4
 A project report on multi stage air compressor
compressor. Air compressors can be found in gas stations and manufacturing
plants, as well as home workshops and garages. Smaller versions can be
used 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 air
pressure. This space is called the air tank, and it is set to hold a certain
amount of air at a specific pressure. A conventional compressor also has a
crankshaft, a connecting rod and piston, a cylinder and a valve head (see
diagram). The crankshaft is powered by an electric motor of gas engine. As
the piston moves down, it creates a vacuum that allows outside air to push
open 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 pressed
into the tank. With each stroke, more air enters the tank, and the pressure
rises. The motor turns on and off as needed to maintain pressure in the tank.

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

In the market the wide rang of compressors are available in the

market according to your applications,

 Compressor is classified as under given

 By principle of operation
 By construction type
 By staging
 By service duty
 Lubricated / Non-lubricated

5
 A project report on multi stage air compressor

 According to the classification by staging there are two

main types of compressor as under given

 Single stage air compressor

 Multi 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 single
stage machine. On the suction stroke of the individual piston,
air from the atmospheric pressure enters the cylinder through
inlet filter and the valve. On the compression stroke of each
piston air forced out through the valve and passes into a
common discharge manifold from where it is piped to the
receiver or system. These compressors are useful where low
pressure air is required such as water pumping liquid transfer
glass industries chemical industries food processing spray
painting etc

6
 A project report on multi stage air compressor
Limitations 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 swept
volume or the effective volume where the fresh air from atmosphere is
sucked in. The mass of air flowing through the compressor is controlled by
this 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 air
compressor increases. From the diagram, let us say the new delivery
pressure is P5. Then the operating cycle will be 1567, where 6-7 is the
clearance 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). Thus
when 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 so

strong to work), the delivery pressure reaches P8, and the compression
follows 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, the
mass flow rate also increases.

Since the delivery pressure increases, the associated temperature also

increases. Thus the temperature of the air after compression is so high as to
cause mechanical problems and the amount of heat is actually the energy
loss.

7
 A project report on multi stage air compressor
If a single-stage machine is required to deliver a high-pressure compressed
air, then it requires

 Working principle of multi stage air compressor:-

Some industries required air pressure more than 35 kg/centimeter square to

produce their product. For example mineral water bottle (pet blowing)
requires air pressure more than 40 kg/centimeter square to produce desired
shape of bottle at bottom side. Here Two Stage reciprocating air compressor
is not useful, we required the air compressor, who generates air pressure
above 35 kg/centimeter square. This discharge air pressure is achieved by
multi stage air compressor. We normally use three stage reciprocating air
compressors as multi stage air compressor. If we required discharge air
pressure above 85 kg/centimeter square then four stage air compressors is
useful.

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

In second stage cylinder low pressure air is compressed up to 14

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

At high pressure cylinder the 14 kg/centimeter square air pressure is

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

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

 Concept of multi stage air compressor :-

8
 A project report on multi stage air compressor

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 and
then it is passed over a cooler to achieve a temperature very close to
ambient air. This cooled air is passed to the intermediate stage where it is
again getting compressed and heated. This air is again passed over a cooler
to achieve a temperature as close to ambient as possible. Then this
compressed air is passed to the final or the third stage of the air compressor
where it is compressed to the required pressure and delivered to the air
receiver 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
saved
2. Prevents mechanical problems as the air temperature is controlled
3. The suction and delivery valves remain in cleaner condition as the
temperature and vaporization of lubricating oil is less
4. The machine is smaller and better balanced
5. Effects from moisture can be handled better, by draining at each stage
6. Compression approaches near isothermal
7. Compression ratio at each stage is lower when compared to a single-
stage machine
8. Light moving parts usually made of aluminum, thus less cost and
better maintenance

9
 A project report on multi stage air compressor
P-V diagram:

Referring to the diagram, the theoretical air compressor P-V diagram can be
understood.

Fig. multi stage compresson on p-v diagram

4-1

The air compressor draws in air from the atmosphere. The atmospheric
pressure is P1. The initial volume when the piston is at top is zero (Assuming
there is no bumping clearance). Thus as the piston moves from top to
bottom, a volume of air V1 is drawn into the compressor. The temperature of
air is T1.

1-2:

As the piston moves up, the air is compressed polytropically (PV^n= C). The
pressure of air increases from P1 to P2. The volume decreases from V1 to V2.
The temperature increases from T1 to T2.

2-3:

The compressed air at the pressure P2, volume V2 and temperature T2 is

delivered out of the compressor to the air receiver.
10
 A project report on multi stage air compressor
Conclusion:

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

 Operation of an Air Compressor.

Read here to know about both theoretical and practical operation of an air
compressor. Also know about the reasons for your long-lasting question and
doubts 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 air
compressor. The points, 1234 represents the theoretical diagram. But there
are some shaded portions above and below the work done area. It is
necessary to give certain explanation for these additional areas which add
up to the work done by the compressor.

11
 A project report on multi stage air compressor

Referring to the diagram, at point 4, when the clearance air has reduced to
the atmospheric pressure, the inlet valve will not open immediately. The
pressure drops lower than the atmospheric pressure and the inertia of the
valves are overcome by the pressure difference. Thus the valve is forced
open by the atmospheric air and it rushes into the cylinder chamber. There is
a “valve bounce” and the pressure does not remain constant inside the
cylinder. The pressure slightly increases and then decreases after which
reaches somewhat steady intake of air. This negative pressure difference is
called 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 above
the air receiver pressure enabling the compressor to deliver air. Then it reaches a stable point
after some “Valve Bounce” and then reaches point 3 where the delivery valve closes to continue
its cycle. Thus in practice, the compressor requires more power to compensate for the additional
work done due to the depressions in delayed opening of the valves.

 Life cycle of an air compressor:-

1. Heavy
moving/working
components to
compress air to
such a high
pressure,

12
 A project report on multi stage air compressor
2. 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, and
7. Lubricating oil which does not get vaporized at such high
temperatures.

Conclusion:

Thus it is clear that a single stage compressor cannot contribute to high

delivery pressure demands. In my next article, let us discuss the effects and
advantages of multi-staging of an air compressor.

Operation of an Air Compressor.

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

 Air Compressor Life Cycle Costs

According to Best Practices for Compressed Air Systems, Compressed Air

Challenge, Second Edition, 2007, energy costs now represent 82-percent of
the total operating expenses. Energy savings from Seller’s single-stage air
compressors significantly reduce life cycle costs.

Seller’s Single-stage Compressors significantly reduce operating and energy

costs over the entire compressor life cycle. Contributing to the energy
savings is

 Seller’s proven air end with the low restriction inlet valve
 High efficiency fan
 Low 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 life

 Improved fluid filter life
 Less Lubricant contamination

13
 A project report on multi stage air compressor
And to reduce fluid disposal costs, Solar air compressor offers biodegradable
Soluble™ 8000-hour fluid, or 24KT™, a long-life fluid that never needs
changing.

Utilizing the most modern technologies, equipment and advanced

manufacturing techniques, Solar Air Compressors designs, manufactures,
assembles, and test the most innovative compressed air products in the
industry. Solar air compressors are known around the world for their
universally applicable design, outstanding craftsmanship and superior
quality.

 Ring Power is Florida’s leading supplier of air compressors, air tools, air
compressor parts and service for over 45 years. We represent the finest
electric compressors and diesel air compressor products in the industry
with names like Solar, Hurricane, and Bellaire. And with over 450 used
and new air compressors and accessories in our inventory, Ring Power is
certain to handle even the largest air compressor project. Portable or
industrial compressed air, high-pressure, or ultra high-pressure, one call
solves your compressed air needs.

What are the Advantages of a Multi Stage Air

Compressor?
Multi-stage air compressors are engineered to safely provide hours of cool
pressurized air for a multitude of tasks. Harness the power of air to power
through difficult cleaning jobs and repairs with an efficient multi-stage air
compressor.

Function

Multi-stage air compressors pressurize air at two levels to improve

efficiency on large jobs. These high output compressor units are usually
found in the commercial and industrial sector where long-term use is
required.

Cool Air

Compressed air is cooled in secondary tanks of multi-stage compressors

when it transfers from a high-pressure tank into a lower-pressure unit.
This cooling effect generates less overall heat than single stage
compressors, making the multi-stage more efficient.

14
 A project report on multi stage air compressor
Output

Large multi-stage air compressors are capable of pressurizing more cubic

feet of air for a higher output. Big jobs and air tools require these high
volumes and powerful blasts of air.

Wear

Less heat generated by the multi-stage compressor means less wear on

your compressor motor and seals. This adds up to fewer repairs and less
scheduled maintenance for your pressurized air source.

Features

Multi-stage air compressors come with a variety of features to make it

more controllable, more portable and more useful. Compressors are
available with wheels, digital gauges and a variety of compatible air tools.

Compressor: How to install Air Compressor?

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

The Rate of Corrosion varies with Climatic Conditions. Variance in Climatic

Condition 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 find
your own ways. As I spend many years in compressor engineering, I have
some knowledge which I like to share with you.

Procedure to install Air Compressor

01) Open top cover from crankcase and lean Crankcase from inside with
help of cloth. Never use cotton waste for cleaning purpose.
15
 A project report on multi stage air compressor

02) Fill H.P.Rustop-286 or any other Anti-Corrosive Oil in Crankcase and

rotate Compressor belt wheel for several times. This will ensure the
circulation of Anti-Corrosive Oil to all moving parts, Cross-Slide and
Guide.00000oo

03) Clean low pressure and high pressure cylinders and spray sufficient
quantity 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 Air
Compressor is Non-Lubricated type. Now a days Teflon spray is used to
prevent valve from corrosion. Don’t remove this material.

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

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

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

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 not
enter 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 many
parts. In air compressor engineering various parts and components are used
to assemble air compressor. All the parts are important for working of air
compressor but here I will share the information about major parts. The
information of parts I am sharing with you is used in the reciprocating air
compressor manufactured by Chicago Pneumatics, Ingersoll Rand, Atlas Cop
co, etc. and used in large engineering units where huge quantity of
compressed air is required. If you are interested in compressor technology
then I hope the information below will help you.

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

 Crank Shaft: -

High grade S.G. Iron crank shaft in one piece in design, dynamically balanced
with 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 cylinders designed with water jacket in water cooled air
compressor to remove heat generated during compression. Designed for
streamlined air passage & maximum numbers of valves, cylinder provides
smooth flow of air, there by minimizing the pressure drop.

 Pistons: -

Special Aluminum alloy pistons for non-lubricated air compressor and graded
cast iron pistons are used for lubricated models. Piston Rings are used for
sealing to cylinder.

 Connecting Rod:-

Forged alloy steel connecting rod is duly normalized, are designed to provide
minimum thrust on cross head bearing surface.

 Main Bearings & Big End Bearings: -

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

 Cross Slide & Cross Head:-

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

 Piston Rod: -

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

17
 A project report on multi stage air compressor
 Suction & Discharge Valves: -

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

 Oil Pump: -

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

Along with above parts some small parts as like oil seal ring, small end
bushing, Suction filter element, cross head pin; heads, belts nut and bolt,
gaskets etc. are used. You are suggested to add the knowledge you have
about compressor.

Water: Requirement of Cooling Water in Air Compressor

Which air compressor you are using your engineering plant? Are you
using water cooled compressor? Do you have any education about cooling
water? I know you have answer in “YES” or “NO”. I have commissioned and
service too many water cooled air compressors at various sites. In water
cooled air compressor the quality and quantity of cooling water plays the
vital role in performance of machine. Many times I found that utility or
maintenance engineers or mangers are careless about cooling water
supplied to machine. They are interested in compressed air only. Many major
breakdowns may occur due to negligence of cooling water. To increase the
life and performance of air compressor below points must be taken into
consideration.

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

02) Good clean water should be provided for cooling. If the cooling water has
a high percentage of lime sulphur, slit, mud or other water impurities, these
will be deposited in the cylinder jackets, head, inter-cooler, after-cooler's
tube and shell. The scale deposited unless are removed, will obstruct the
flow of water, lower the rate of heat transfer and may result in damage to
the air compressor. The cleaning doors are provided in the side of cylinder
for cleaning of jackets and cylinder heads. Periodically the cylinder jackets,
cylinder heads, inter-cool, after-cooler tubes and inside of the shell should be
inspected and cleaned.
18
 A project report on multi stage air compressor
03) It is preferable that the outlet water from each cylinder, inter-cooler and
after-cooler should empty into the funnels to facilitate the operator to
observe 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 an
underground pit tank and pumped to cooling tower. In case you are using
closed water system then a visible Flow Indicator must be installed in each
water outlet pipe. It is also suggested to clean flow indicator glass
periodically 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 be
maintained between minimum 2.5 kilogram/centimeter square and
maximum 4 kilogram/centimeter square. The inlet water temperature must
not exceed 40 degree centigrade and this should be very strictly taken care
off. The water temperature differential between inlet and outlet should not
exceed 7 to 8 degree centigrade and should preferably be lower.

05) Over a time of period, water pipe/tube got rusted or clogged from inside
so 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 the
water flowing into the outlet funnel. A small pin hole will cause air bubble in
the water and a larger hole will cause the outlet water spurt. Whenever such
a 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) I
am giving you details about Low Cooling Water Flow Switch (LCWFS).Why I
am 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 70
switch is used as LOPS & LCWPS, the only difference is "LCWPS" used in
discharge (outlet) water line of closed circuit system or in water inlet
(between inlet valve & compressor) for open drain type system of air
compressor. 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 is
actuated 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 cooling

water pipe. Where there is a straight horizontal of at least five pipe
19
 A project report on multi stage air compressor
diameters on either side of the flow switch. Weld a socket of 1" BSP thread
on water inlet line, for free movement of the flapper in pipe without rubbing
the side. Open the instrument cover, remove spring hook from the horizontal
balancing arm & refit after the instrument is mounted on the pipe. The
flapper of LCWFS must be in right angle to the flow & the arrow mark on the
body is in same direction of water flow. Check the operation of flow switch to
ensure that the flapper is free to move inside the water pipe line.

This is a important safety of Air Compressor Engineering. LCWFS must be in

working condition to avoid any breakdown to the compressor. Now know
about operation.

The pressure applied at the sensor creates a force against the balance plate
through the operating rod. The upward movement of the balance plate is
countered by a continuously adjustable range spring, which is used for
setting 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 & rotate
the 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 the
water flow to the fair requirement, now this NO (Normal Open) contact must
close, 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 minimum
requirement. The contact must open, and close when the flow reaches fair
requirement.
Do not avoid safety switches .It will protect your Air Compressor from
breakdown.

 There are some special problems of multi stage air compressor?

 Pressure variation in inter stage

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

 Inter stage cooler pipe damage

20
 A project report on multi stage air compressor
• Chock up of carbon formation in manifold
• 3rd stage or 4th stage discharge valve lickage
• NRV lickage & chock up
• 2nd or 3rd 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 the
safety precautions as per the specification in the case of
compressor there are two types of safety

 Safety of machine
 Safety of operator

How to safeguard machine?

There is two types of main hazards occurs in machine

 Due to exciting vibrations

 Due to other rimidities

How to Safeguard Air Compressor from Excessive

Vibrations?

It is also important to protect your compressor from excessive vibrations

developed due to operation or any other reasons. Unfortunately many plants
are not using this safety switch on their compressor. If you are using or
interested to install Excessive Vibration switch, this post will help you to
increase your engineering knowledge. Many different Vibration Switches are
available in market but in old days a very accurate switch "Roberts’s haws"
21
 A project report on multi stage air compressor
made in USA make VIBRASWITCH is adopted by various plants. The details
are as below.

The switch is to protect the crankcase/crankshaft against any damage from

malfunctions that can be detected as an increase in vibration. This is
mounted on crankcase of compressor. It is sensitive to vibration in the
direction perpendicular to its mounting base.

It contains a vibration detecting mechanism, which also function as a

"Mechanical Amplifier" to activate a snap-action switch when the selected
level of vibration is exceeded and the detecting mechanism "Trips".

The mechanism may be reset manually, by depressing the reset button to

make the armature away from latching magnet until it is held against the
stop 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 in
good 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 & press
the reset button. Then turn the set point adjustment screw slowly clockwise
until actuation occurs. This is the zero vibration point or actuating point,
when the compressor not in running condition. A mark should made to
permanently record this "Zero Vibration point". Subsequent measurements
are made relative to this point.
 Normal G-Level measurement:-
When the compressor is in operating condition, back off the set point
adjustment screw one turn counter clockwise and reset. If it will not reset,
back-off slowly until reset. Again turn the set point adjustment screw slowly
clockwise until actuation occurs, mark the position. The difference between
the 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 1.0g
 Fine Set Point Adjustment:-
Rotate the set point adjustment screw one full turn counter clockwise from
the 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 this
important engineering utility. we cannot keep one operator for full time near
to compressor & keep watching performance. That is why it is necessary to
provide some safety switches in control panel. These safety devices will work

22
 A project report on multi stage air compressor
in abnormal condition & stop electric motor and further prevent any
breakdown in Air Compressor.

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

The details of LOPS is as below INDFOS make IPS-70 switch is commonly

used & the function of this switch is to monitor the oil pressure in the
crankcase of air compressor. This switch is connected in the oil pressure
sensing 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 spindle
is moved upwards until the spring pressure balance the bellow pressure. The
spindle has guiding knob and differential adjusting nut which jointly transmit
the spindle movement to the switch.

The differential pressure has to be set at zero (Indicator scale at extreme

left, facing to LOPS) and the main scale is set to required pressure. (Minimum
oil pressure required by the compressor. i.e. 14 PSIG for reciprocating air
compressor & 35 PSIG for rotary air compressor).The pressure on main scale
can 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 observe
the switch operation. Start the compressor and watch the oil pressure at
which contacts closes, then stop the compressor to see at what oil pressure
contacts opens. By adjusting the knob further fine adjustment can be done to
the exact pressure required. So confirm the setting by starting & stopping
the compressor. Since the switch remains open during starting, a normal
close 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 its
timing cycle and the compressor oil pressure also start building up in 60 sec.
timer contacts will becomes open. Due to developed oil pressure in sensing
line, LOPS contacts closes & continued the healthy running condition of air
compressor.

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

23
 A project report on multi stage air compressor

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 this
important engineering utility. We cannot keep one operator for full time near
to compressor & keep watching performance. That is why it is necessary to
provide some safety switches in control panel. These safety devices will work
in abnormal condition & stop electric motor and further prevent any
breakdown in Air Compressor.

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

The details of LOPS is as below INDFOS make IPS-70 switch is commonly

used & the function of this switch is to monitor the oil pressure in the
crankcase of air compressor. This switch is connected in the oil pressure
sensing 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 spindle
is moved upwards until the spring pressure balance the bellow pressure. The
spindle has guiding knob and differential adjusting nut which jointly transmit
the spindle movement to the switch.

The differential pressure has to be set at zero (Indicator scale at extreme

left, facing to LOPS) and the main scale is set to required pressure. (Minimum
oil pressure required by the compressor. i.e. 14 PSIG for reciprocating air
compressor & 35 PSIG for rotary air compressor).The pressure on main scale
can 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 observe
the switch operation. Start the compressor and watch the oil pressure at
which contacts closes, then stop the compressor to see at what oil pressure
contacts opens. By adjusting the knob further fine adjustment can be done to
the exact pressure required. So confirm the setting by starting & stopping
the compressor. Since the switch remains open during starting, a normal
close 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 its
timing cycle and the compressor oil pressure also start building up in 60 sec.
timer contacts will becomes open. Due to developed oil pressure in sensing
line, LOPS contacts closes & continued the healthy running condition of air
compressor.

24
 A project report on multi stage air compressor

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

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 your
Engineering Production. You have to bear production loss due to breakdown
of machine. Many safety switches as like LOPS, LCWPS, HDATS etc. are
installed for safety of compressor.. High Discharge Air Temperature Switch
(HDATS) is also one of the most essential safety major has to be taken to
prevent any abnormal to your valuable utility. If the temperature of
discharge air (i.e. leaving compressed air from high pressure cylinder) is
more, than the requirement, it could stick the piston inside the cylinder,
which causes a breakdown of compressor. A working HDATS will safeguard
your compressor from this problem.

A INDFOS Make RT-120 high discharge air temperature switch is normally

used for safety of Air Compressor. This switch having 2 mtr. Long capillary
connecting the switch and the bulb, with thermo well to fit the bulb. Fit the
thermo well in air discharge line in the direction of discharge air flow in
angular direction, in between the compressor and AFTER-COOLER, closer to
the cylinder discharge. So the discharge air temperature safety can be done.
If it has to monitor the air temperature before AFTER-COOLER. Fit the HDATS
after 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 by
manufacturer that is why it is essential to set the temperature switch outside
in an oil bath, having steady required temperature at the switch to be set.
Keep the differential setting at zero, connect an Ohm meter across Normal
close (NC) contact of the switch. Immerse the bulb and thermometer in the
oil bath, keep stirring. Set the high Discharge Air Temperature Switch at 170
degree centigrade, on the main scale. Control the steady temperature 170
degree centigrade of oil bath, now close contact of switch should change &
the Ohm meter pointer should show infinity, if not, reduce the setting till the
contact changes to open. Increase the temperature setting if the contact

25
 A project report on multi stage air compressor
opened before 170 degree centigrade till it closes and opens. Now the switch
is set at 170 degree centigrade.

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

After setting the switch, install near the thermo well, fill compressor oil in the
thermo well and insert the bulb of temperature switch slowly. Wire the
control 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 not
possible to install all the safety due to cost or technical problem but still I
recommend installing Low Oil Pressure Switch, Low water Pressure Switch,
and High Discharge Temperature Switch & Motor Overload Relay. This four
safety switches are most essential to run your Air Compressor without
trouble.

 Installing process for new air compressor

Coupling: How to Couple Compressor with Electric Motor?

Electric motor or diesel engine is used to operate the engineering

compressors. Various methods are used to couple the Air Compressor. Some
compressors are run by tire couplings some run by direct coupling, some run
by V-Belts. Many times customer phoned me about abnormal sound from
compressor 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 my
servicing 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 Compressors
and mostly fanner belts are used. I will cover the most useful method for air
compressor 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 moved
towards the Air Compressor Belt wheel. The sliding rails are provided for this
purpose. By this way you can put the V-Belts in their respective grooves by
hands. The allowance must be available for adjustment of centre distance.
When V-belts have been placed on belt wheel and pulley grooves, the
electric motor or prime mover should then be, moved away from the
compressor, until to apply uniform tension to the V-Belts.
Under no circumstances should V-Belts be forced on to the pulley or belt
wheel with Crowbars, Wedges, Screw Driver or any other type of implement.
26
 A project report on multi stage air compressor
Such procedure would tend to cause rupture to outside jacket or inside
cords. It is possible for the inside load carrying cords to be broken by forcing
over 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 in
millimeter (mm).
02) Set the lower marking ring at the allowable deflection distance required in millimeter on the
lower 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 at
right angle to the belt deflecting it to the point where the lower marker ring is level with the top
of 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 belt
tension indicator. If the measure force falls within the value given the drive should be
satisfactory.
07) A measured force below the lower value indicates under tensioning and upper value indicates
over tensioning. Make corrections accordingly.
08) The new belts should be tensioned to the higher value to allow for the normal drop in tension
during 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 the
grooves and the V-Belts tension should be rechecked. Make adequate provision for tensioning
the belts during its life.

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

27
A project report on multi stage air compressor

28