PLANT MAINTENANCE

(ME-426)

Installation, Maintenance and

Troubleshooting of Compressor

Adeel Ahmed Khan, Assistant Professor

(MED)
COMPRESSOR:
• Compressor is a machine which increases the pressure
of a fluid by mechanically decreasing its volume (i.e.
by compressing it).(The fluid here is generally air
since liquids are theoretically incompressible).
• Air compressor is an application based equipment
which is used for various like painting & polishing
workshops, automobile garage & various small
medium industries.
• Painting vehicles in an auto body shop, Sandblasting
in a machine shop and manufacturing facilities,
Operating air tools on production lines, In running
Gas turbine etc.

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 TYPES OF COMPRESSOR :
• Positive displacement
 Rotary screw compressor

 It consists of two screws one is main rotor(screw) and other is secondary rotor (screw).
 Main rotor has helical lobes where as secondary rotor has helical grooves.
 Air passes through the clearance between the two rotors.
 Compression is accomplished by the minimizing the clearance along the flow direction.

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 • Positive displacement
 Rotary screw compressor

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• Positive displacement
 Reciprocating compressor

 The reciprocating compressors use a piston in a chamber called a cylinder to decrease the volume
and increase the pressure.
 The cylinder in the reciprocating machines may be air cooled or water cooled. Water cooling is
used on the larger units. This cooling action is very important to increase compressor life and to
keep maintenance and repairs low.

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TYPES OF COMPRESSOR :
• Centrifugal
 Operates on the principle of non-positive displacement.
 Axial suction through a rotating impeller which guides the air to the involute shaped casing and is
finally pushed radially outward at a higher speed.
 Increased speed results in pressure drop so diffuser is added to increase the pressure.
 Guide vanes at inlet controls the mass flow rate of air.
 The compressed air after passing through the involute gets hot due to compression, so intercooler
is used for cooling purpose.

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INSTALLATION:
• Location
 The air compressor location should be as close as possible to the point where the compressed air is
to be used.
 It is important to locate the compressor in a dry, clean, cool, well lighted and well-ventilated area.
 Allow space on all sides for air circulation and for ease of maintenance.
 Flywheel side of the unit should be placed toward the wall and protected with a totally enclosed
belt guard.
 Overhead lifting capability is highly advantageous when overhaul is required.

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INSTALLATION:
• Ventilation
If the compressor is air-cooled it requires a large amount of cooling air to reject
the heat loads.
The compressor must not be operated at full load for extended periods of time in
ambient temperature.
The inlet grids and ventilation fan should be installed in such a way that any
recirculation of cooling air to the compressor is avoided.

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INSTALLATION:
• Foundation
 An adequate compressor foundation is a necessity for
satisfactory operation and maintenance of a compressor.
 A foundation that is designed without sufficient mass and
bearing surface will cause vibration of the compressor,
resulting in discharge-, suction-, and waterline breakage and
excessive wear of compressor parts.
 To prevent vibration the compressor should be supported at
all base bolt locations on a level surface.

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INSTALLATION:
• Air Receiver Tank
 An air receiver tank is an integral and important part of any
compressed air system.
 In a compressed air system, a receiver tank provides the
following benefits:
 The receiver tank acts as a reservoir of compressed air
for peak demands.
 The receiver tank will help remove water from the
system by allowing the air a chance to cool.
 The receiver tank minimizes pulsation in the system
caused by a reciprocating compressor or a cyclic
process downstream.

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AIR COMPRESSOR MAINTENANCE:
• Checking Compressor Pump Oil
Level:
 Ensure unit is off and disconnect from the power
source
 Ensure compressor is on a flat and level surface
 Remove fill cap / plug
 Inspect the oil in the crankcase assembly and look for
dirt or debris
 Oil should not exceed the halfway point of the sight
glass

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AIR COMPRESSOR MAINTENANCE:
• Changing Compressor Pump Oil:
 Ensure unit is off and disconnect from the power source
 Ensure compressor is on a flat and level surface
 Remove fill cap / plug
 Place collection container underneath the oil drain cap.
 Remove the oil drain cap, and let the oil drain out.
 Replace the oil cap and be sure to tighten this nut securely. White plumbers tape (PTFE)
(Polytetrafluoroethylene) is generally a good idea to help create a tighter seal. Fill crankcase with
appropriate oil, be sure it does not exceed the halfway point.

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AIR COMPRESSOR MAINTENANCE:
• Checking the air filer element:
 Ensure unit is off and disconnect from the power
source
 Allow compressor pump to cool off.
 Unscrew the filter top from the filter base by turning
(generally) counter-clockwise.
 Separate the filter top cover from the base.
 Remove the element from the filter base
 Blow out dust and debris from the filter element.
 Replace element if needed.
 Reconnect filter top to the base and secure filter.

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TROUBLESHOOTING PROCEDURE:
1- COMPRESSOR IS DEAD – NOTHING
HAPPENS
Check:
• If there is power and all fuses are ok.
• Pressure switch and the actual pressure in the tank.
• The low oil level or high temperature safety switch.
 Pressure Switch:The air compressor pressure switch helps to
measure the pressure inside your air tank and then is used to shut
off your compressor when your air tank reaches the desired air
pressure.
 Safety valve :A Safety valve (pressure relief valve) for an air
compressor helps to keep you protected if the pressure of the
compressor gets too high.
 Regulator :The regulator is designed to lower the pressure setting
that the downstream hose and tool receives, and maintain that
lower air pressure regardless of how high the air pressure stored
in the compressor tank is.
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TROUBLESHOOTING PROCEDURE:
2- COMPRESSOR NOT BUILDING PRESSURE AND
AIR BLOWING OUT OF THE INLET FILTER

• The inlet check valves / plates are broken, worn or dirty.

3- PRESSURE BUILDS UP VERY SLOWLY (LOW

CAPACITY)
Check:
 Air leaks.
 Inlet/outlet valves (inside compressor head).
 Head gasket.
 Inlet air filter.

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TROUBLESHOOTING PROCEDURE:
4- COMPRESSOR IS MAKING NOISE
•Look for loose belts, loose bolts, and loose pulleys.
•Check for the rubber damping feet.
•Check the oil level.
•Check the inlet/outlet valves, piston rings.
•Check the main bearings or connecting rod bearings.

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TROUBLESHOOTING PROCEDURE:
5- COMPRESSOR CANNOT START (BUT TRIES HARD)
• Problem with the unloader valve
• Unloader valve blows-off the exhaust pipe of the air compressor.
Unloader Valve:
 The output of the piston compressor is connected through a pipe to the air
receiver.
 When the compressor stops, the pressure in this pipe is blown off to 0 bar
(atmosphere).
 This is the ssssssshhh sound you will here when the compressor stops. At
the same time, a check-valve makes sure that not the whole air receiver
(tank) flows empty, but only this small pipe.
 Why? When the compressor starts up again, and this pipe would still be
under pressure, the electric motor will not be strong enough to turn the
compressor.

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TROUBLESHOOTING PROCEDURE:
6- AIR IS LEAKING OUT OF THE UNLOADER VALVE/PRESSURE SWITCH
• Problem with the check-valve on the air receiver.
• Check valve makes sure that the air in the air receiver stays in the air receiver.

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TROUBLESHOOTING PROCEDURE:
7- HIGH OIL CONSUMPTION / LOW OIL LEVEL
Check:
• Oil leak
• High oil carry over = oil in compressed air
• The drain valve/plug and the shaft seal.

8- OIL IN COMPRESSED AIR

Oil with a too low viscosity
A higher temperature will lower the oil viscosity.
Worn piston rings or wrongly installed or worn cylinder surface.

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TROUBLESHOOTING PROCEDURE:
9- HIGH CYLINDER TEMPERATURE
Can be any of the following:
 High ambient temperature.
 Broken cylinder head gasket.
 Leaking/broken/dirty intake/exhaust valves.

10-WATER IN COMPRESSED AIR

•Drain the drain valve until all the water is out.
•For an automatic drain valve, check if it is working correctly.

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TROUBLESHOOTING PROCEDURE:
11- THERMAL RELAY / OVERLOAD RELAY TRIPS
•Could be either an electrical problem or a mechanical problem.
•Check how much amps the motor draws and compare.
•Check by hand to turn the compressor.

12-LOW VOLTAGE/ VOLTAGE DROP DURING

THE RUN
•If the voltage is too low, it can result in overload/overheating.
•If the voltage drops significantly during the run, it may be because of
a too long extension cord, or too thin electrical wiring.

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