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M02 –Compressors - Theory, Practice and Maintenance

   
 
  • 3 golden rules of Compressed Air usage

  • Compressed air system – Supply side and Demand side

  • Compressed air – One of the most expensive utilities on the shop floor

  • Inappropriate use of compressed air

    • Open blowing

    • Sparging, Aspirating, Atomizing

    • Padding

    • Vacuum generation

    • Hand blowing

    • Unregulated End use

    • Abandoned equipment

  • Potential for energy saving

  • Overview of sub-systems and sub-components of a compressor system

    • Intake Air Filters
    • Compressed Air Filters
    • Why compressor cooling is required
      • Inter stage coolers
      • After coolers
    • Separators
    • Why air drying is essential

      • Air Dryers

      • Deliquescent air dryers

      • Refrigerated Air Dryers

      • Moisture drain traps

    • Air receiver
    • Lubrication
    • Heat recovery
    • Air distribution system

  • Types of compressors

  • Choice of compressors

  • Reciprocating compressor

    • Single acting air cooled
    • Double acting water cooled

  • Rotary compressor

    • Single stage
    • 2 stage
    • Screw Compressors

      • Lubricant injected
      • Oil free

  • Centrifugal air compressors

  • Compressor Prime Movers

  • Comparison of compressors

  • Capacity of a compressor

  • Calculating compressor efficiency
    • Isothermal efficiency

    • Volumetric efficiency

  • Leaks

    • Defining and Quantifying leakage
    • how to calculate leakage
    • Cost of leakage
    • Leak detection

      • Ultrasonic leak detection
    • How to stop leaks

  • Compressed air system performance opportunity roadmap
  • Air quality
  • Air quantity
  • Load profile
  • System pressure

    • Pressure drop and controlling system pressure
    • What causes pressure drop ?
    • Minimizing pressure drop
    • Measurements necessary for pressure profiling a compressed air system
    • Stabilizing system pressure

      • Importance of Primary and Secondary Storage
      • Dedicated compressors

  • Control strategy

    • Matching Demand and Supply
    • System controls
    • Multiple compressor controls
    • Pressure/Flow controllers
    • Variable loads

  • Ensuring efficiency of compressed air end-use applications

  • Heat recovery and compressed air systems
    • Air cooled, rotary screw compressors
    • Water cooled compressors

  • Calculating cost of compressed power

  • The 7 step action plan to analyse and improve compressed air system

  • Tools needed for monitoring and base-lining compressed air system

  • Using Power, Pressure, and Flow to base-line System Performance and Energy Consumption

  • Maintaining air compressors

    • Lubrication
    • Cleaning
    • Belts
    • Air treatment equipment
    • Automatic traps
    • Point-of-use filters, regulators, lubricators
    • Shutting down for maintenance
    • Routine maintenance practices for various periodic frequency

  • Energy saving ideas for compressor air system

    • Energy saving concept – Usage of VFD

Reading nomenclature of compressors

  • Types of valves

    • Plate type

    • Finger type

  • Loading and Unloading characteristics of compressors

  • Types of unloading devices

  • Types of Drainage systems
  • Mounting

    • Horizontal

    • Vertical

  • Type of lubrication

    • Soft

    • Outside

  • Non lubricated compressor

  • Foundation

  • Condition monitoring

    • Temp analysis

    • Vibration analysis

    • Alignment analysis – axial and radial (laser based)

  • Preventive / Predictive maintenance

  • Breakdown maintenance

  • Trouble shooting

  • Checklist

 

 
   
 

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