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PROFILE

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

→ 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

• vLeaks

→ 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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