PUMPS,VALVES AND COMPRESSOR

6.1 Understand pumps concepts.

Irrigation pumps lift water from an existing source, such as surface or groundwater to a higher level.
They have to overcome friction losses during transport of the water and provide pressure for sprinkler and
drip irrigation
Irrigation pumps are mechanical devices which use energy from electrical or combustion motors to
increase the potential and (or) kinetic energy of the irrigation water.
Pumps are used in irrigation systems to impart a head to the water so it may be distributed to different
locations on the farm and used effectively in application systems.
The key requirement in pump selection and design of pump systems for typical irrigation installations is
that there is a correspondence between the requirements of the irrigation system and the maximum
operating efficiency of the pump

6.1.1 List application of pumps.

Pumps are used throughout society for a variety of purposes. Early applications includes the use of the
windmill or watermill to pump water. Today, the pump is used for irrigation, water supply, gasoline
supply, air conditioning systems, refrigeration (usually called a compressor), chemical movement,
sewage movement, flood control, marine services, etc.


6.1.2 Classify types of pumps based on its principle.


i. A Positive Displacement Pump has an expanding cavity on the suction side of the
pump and a decreasing cavity on the discharge side. Liquid is allowed to flow into the
pump as the cavity on the suction side expands and the liquid is forced out of the
discharge as the cavity collapses. This principle applies to all types of Positive
Displacement Pumps whether the pump is a rotary lobe, gear within a gear, piston,
diaphragm, screw, progressing cavity, etc. There are three main classifications of Positive
Displacement Pumps




ii. Rotor dynamic pumps are kinetic machines in which energy is continuously
imparted to the pumped fluid by means of a rotating impeller, propeller, or rotor.
The most common types of rotor dynamic pumps are centrifugal (radial), mixed
flow, and axial flow pumps. These pumps are based on bladed impellors which
rotate within the fluid to impart a tangential acceleration to the fluid and a
consequent increase in the energy of the fluid. The purpose of the pump is to
convert this energy into pressure energy of the fluid to be used in the
associated piping system. Centrifugal pumps use bladed impellers with
essentially radial outlet to transfer rotational mechanical energy to the fluid
primarily by increasing the fluid kinetic energy (angular momentum) and also
increasing potential energy (static pressure). Kinetic energy is then converted
into usable pressure energy in the discharge collector.


There are three main classifications of rot dynamic pumps
c. Radial Flow (Centrifugal Pumps)
d. Mixed Flow (Screw )Pumps
e. Axial Flow (Propeller) Pumps

6.1.3 Assemble and disassemble pump as a practical .As an
examples components can be use is centrifugal pump.

Disassembly pump












































Assemble pump

























































6.1.1 Developed check list pumps maintenance, symptoms and record observations for preventive
maintenance.

Pump Maintenance Concept
Poor maintenance can cause undue wear and tear of fast moving parts, and premature failure of the
equipment. Such premature failure or breakdown causes immense hardship to the consumers and staff,
and avoidable increase in repair cost. The shortcomings in maintenance can also result in increase in
hydraulic and power losses and low efficiency. Inefficient running of the pump increases burden of
power cost. Importance of preventive maintenance, therefore, need not be overstressed. Appropriate
maintenance schedule and procedure need to be prescribed for all electrical and mechanical equipment
based on manufacturers recommendations, characteristics of the equipment, site and environment
conditions i.e. temperature, humidity, dust condition, etc. The maintenance schedule also needs to be
reviewed and revised in the light of experience and analysis of failures and breakdown at the pumping
station. The preventive maintenance schedule shall detail the maintenance to be carried out at regular
intervals i.e. daily, monthly, quarterly, half yearly, annually etc. or operation hours. The schedule shall
also include inspections and tests to be performed at appropriate interval or periodicity



Check List Pump Maintenance, Symptoms and Record Observation For
Preventive Maintenance

(a) Routine observations of irregularities

The pump operator should be watchful and should take appropriate action on any irregularity noticed in
the operation of the pumps. Particular attention should be paid to following irregularities.

i. Changes in sound of running pump and motor
ii. Abrupt changes in bearing temperature.
iii. Oil leakage from bearings
iv. Leakage from stuffing box or mechanical seal
v. Changes in voltage
vi. Changes in current
vii. Changes in vacuum gauge and pressure gauge readings
viii. Sparks or leakage current in motor, starter, switch-gears, cable etc.
ix. Overheating of motor, starter, switch gear, cable etc.
(b) Record of operations and observations

A log book should be maintained to record the hourly observations, which should cover the following
items.
i. Timings when the pumps are started operated and stopped during 24 hours.
ii. Voltage in all three phases.
iii. Current drawn by each pump-motor set and total current drawn at the
installation.
iv. Frequency.
v. Readings of vacuum and pressure gauges.
vi. Motor winding temperature.
vii. Bearing temperature for pump and motor.
viii. Water level in intake/sump.
ix. Flow meter reading.
x. Any specific problem or event in the pumping installation or pumping
system (burst in pipeline, tripping or fault, power failure).






Pump Maintenance Procedure
Daily Maintenance

Clean the pump, motor and other accessories.
Check coupling bushes/rubber spider.
Check stuffing box, gland etc
Monthly Maintenance
i. Check free movement of the gland of the stuffing box, check gland packing and
replace if necessary.
ii. Clean and apply oil to the gland bolts.
iii. Inspect the mechanical seal for wear and replacement if necessary.
iv. Check condition of bearing oil and replace or top up if necessary.






Quarterly Maintenance

i. Check alignment of the pump and the drive. The pump and motor shall be
decoupled while correcting alignment, and both pump and motor shafts shall be
pushed to either side to eliminate effect of end play in bearings.
ii. Clean oil lubricated bearings and replenish with fresh oil. If bearings are grease
lubricated, the condition of the grease should be checked and
replaced/replenished to the correct quantity. An anti-friction bearing should have
its housing so packed with grease that the void space in the bearing housing
should be between one third to half. A fully packed housing will overheat the
bearing and will result in reduction of life of the bearing.
iii. Tighten the foundation bolts and holding down bolts of pump and motor
mounting on base plate or frame.
iv. Check vibration level with instruments if available; otherwise by observation.
v. Clean flow indicator, other instruments and appurtenances in the pump
house.

















6.2 Understand valve concept.

A valve is a device regulates directs or controls the flow of a fluid (gases, liquids, fluidized solids) by opening,
closing.

6.2.1 Application of valves

Gas system
Crude oil industry
Refinery plant
6.2.2 Classify types of valves.
Common valve type in usage.
Ball valve
Butterfly valve
Gate valve
Globe valve


Figure 6.2.1 Ball valve




Figure 6.2.2 Butterfly valve













Figure 6.2.3 Gate valve




Figure 6.2.4.Globe Valve

Valves can be categorized into the following basic types:

Ball valve, for on/off control without pressure drop, and ideal for quick shut-off, since a 90 turn
offers complete shut-off angle, compared to multiple turns required on most manual valves.

Butterfly valve, for flow regulation in large pipe diameters.

Gate valve, mainly for on/off control, with low pressure drop.

Globe valve, good for regulating flow.


Figure 6.2.6.Butterfly valve function.


















Gate valve

Gate valves are used straight line, laminar fluid flow, and minimum restrictions are needed. These valves
use a wedge-shaped sliding plate in the valve body to stop, throttle, or permit full flow of fluids through
the valve. When the valve is wide open, the gate is completely inside the valve bonnet. This leaves the
flow passage through the valve fully open with no flow restrictions, allowing little or no pressure drop
through the valve. Gate valves are not suitable for throttling the flow volume unless specifically authorized
for this application by the manufacturer. They generally are not suitable because the flow of fluid through
a partially open gate can cause extensive damage to the valve.



Figure 6.2.7. Gate valve function.


Globe valve

A disk attached to the valve stem controls flow in a globe valve. Turning the valve stem until the disk is
seated closes the valve. The edge of the disk and the seat are very accurately machined to provide a tight
seal. It is important for globe valves to be installed with the pressure against the disk face to protect the
stem packing from system pressure when the valve is shut. While type of valve is commonly used in the
fully open or fully closed position, it also may be used for throttling.



Figure 6.2.8 Globe valve function










6.2.3 Determine valve maintenance concept.
Ball Valve
There are specific cleaning agents that should be used with the valve parts that are made of plastic,
rubber, and metal. The appropriate cleaning agent should be used to avoid reaction of the cleanser with
the parts. This can prevent any damages that can be brought by corrosive reactions. Cleansing sprays
made of gas perfectly works for metal parts where gas is the working medium. Alcohol or water or a
mixture of the two can be applied on non-metal parts. However, there are manufactured cleansers that
are especially formulated for valve parts.


Butterfly Valve

Following proper directions and instructions is and will always be a nice thing to do, even in installing a
butterfly valve inside the house. No kidding. This valve is widely used in day-to-day life such as in the
carburettor of a car. These valves are mainly used in controlling a certain object, in the case of a
carburettor, and then the entrance of air in the car is being decreased or increased through the use of the
valve. Simply put, this is used to regulate the flow which in this case, is the air. Due to this high end
function, proper and constant maintenance of this valve is a must. This valve is operated similar to that of
a ball valve.

Gate valve

The proper maintenance of a gate valve, or any valve for that matter, is important in ensuring that it will
last for many years and work as efficiently as it should. Thinking that it can simply be installed and left
alone afterwards is the beginning of the end since the time will definitely come that the valve will either
have to be repaired or totally replaced due to lack of maintenance. So, if you want to spare yourself a few
headaches and several dollars in repair or replacement costs, learn how to maintain your gate valves
effectively.





6.2.4 Developed check list valve maintenance symptoms and record observation for preventive
maintenance.
Control/Shut-Off Valve - Inspection Form
General Information:

Date of Site Visit: Unit No._

Plant Name:

Source/s of data:

Valve Manufacturer: _Age of Valve: ___

Size of Valve: Size of Penstock

System Pressure (PSI):

Control/Shut-Off Valve Description:_ __







Maintenance History / Major Repairs Description:










Control/Shut-Off Valve:

Valve Manufacturer/Model:

Rated Operating Pressure:

Addition specification data:

Valve Operator:

Make:_ Model: _

Addition specification data:

























































4
Control/Shut-Off Valve Check List
Topic Yes No N/A Comments/Details
Maintenance & Major Repair History
Are there plant preventive maintenance procedures for the
Control/Shut-off Valve? Are they routinely carried out?

Has there been any valve and/or penstock repair?
Has the Valve been rebuilt?
Has the valve operator been rebuilt?
If parts of valve require lubrication, are there records of
lubricant application?

Have all plant records regarding valve repairs, operating
conditions, etc. been requested/gathered?


Control/Shut-Off Valve Check List - Continued
Topic Yes No N/A Comments/Details
Equipment Condition Assessment
What is condition of the exterior of the valve?

Can the interior of the Valve be accessed?

What is the condition of the interior of the valve?
What is the condition of the valve operator?
Are differential pressure indicators or transmitters present?
Are differential pressure indicators or transmitters
operational?


Control/Shut-Off Valve Check List - Continued
Topic Yes No N/A Comments/Details
Equipment Condition Assessment - Continued
Is there a valve position indicator?

Does the valve position indicator function correctly?
Local and/or remote?

Have valve malfunctions been noted as the cause of unit
outages or unit deratings? If so, how many megawatt hours
lost (MWHL) have been attributed to valves?

Does the valve have packing leaks?

Does the valve have flange gasket leaks?
Is the valve insulated?
If so, does the insulation contain asbestos fiber?




Control/Shutoff Valve Data Collection Sheet
Topic Data Input




























Symptom and corrective action for ball valve.


SYMPTOMS REASON ACTION


Symptom and corrective action for butterfly valve.

SYMPTOMS REASON ACTION
Symptom and corrective action for globe valve.

SYMPTOMS REASON ACTION










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6.3.1 Type of compressor

It can be divided into two main categories:-
i. Dynamic
ii. Positive displacement








Dynamic Centrifugal




Positive
Displacement
Rotary
Reciprocating

Figure 6.3.1 type of compressor



6.3.2 Principle and Characteristic of Compressor


i) Dynamic

This type of compressors uses the phenomenon of velocity to generate energy. It happens
by creating high speed energy through a rapidly moving piece. This fast moving piece then
propels the basic unit of the air compressor to generate power which is then used for mechanical
purposes. The dynamic compressor is characterized by rotating impeller to add velocity and
pressure to fluid. Compare to positive displacement type compressor, dynamic compressor are
much smaller in size and produce much less vibration. Although the dynamic air compressors are
very useful they are not as common as the positive displacement compressors and their use is
mostly restricted to various industries and is not used at homes. It is widely used in chemical
and petroleum refinery industry for specifies services. They are also used in other industries such
as the iron and steel industry, pipeline booster, and on offshore platforms for reinjection
compressors.



a) Centrifugal Compressor





















Figure 6.3.2 centrifugal pumps

A centrifugal compressor is a dynamic type of compressor. It has a continuous flow of
fluid which receives energy from integral shaft impellers. In a centrifugal compressor the
mechanical energy is increased by centrifugal action. The gas enters the suction eye of a high
speed rotary element called the impeller which carries radial vanes integrally cast in it. As the
impeller rotates, the blades of the impeller force the gas outward from the center the impeller to
the outer rim of impeller, the increase in velocity of the gas creates a flow pressure area at the
eye of the impeller. The gas at the outer rim of the impeller is forced in to a passage way called a
diffuser where the velocity decreases in the pressure of the gas. The maximum pressure rise for
centrifugal compressor mostly depends on the rotational speed (rpm) of the impeller and the
impeller diameter. But the maximum permissible speed is limited by the strength of the structural
materials of the blade and the sonic velocity of fluid and it will leads into limitation for the
maximum achievable pressure rise.














Advantages

a) Reliable
b) Compact
c) Robust
d) High reliability, eliminating the need for multiple compressors and installed standby
capacity.
e) For the same operating conditions, machine prices are lower for high volume flow rates.
f) Less plot area for installation for a given flow rate.
g) Machine is small and light weight with respect to its flow rate capacity.
h) Installation costs are lower due to smaller size
i) Low total maintenance costs
j) When a turbine is selected as a driver, the centrifugal compressor's speed level allows
direct drive thereby minimizing equipment cost, reducing power requirements, and
increasing unit reliability.
k) Flow control is simple, continuous, and efficient over a relatively wide flow range.
l) No lube oil contamination of process gas.
m) Absence of any pressure pulsation above surge point.
n) Can reach pressure up to 1200 psi.
o) Completely package for plant or instrument air up through 500 hp.
p) Does not require special foundations

Disadvantages

a) Lower efficiency than most positive displacement types for the same flow rate and
pressure ratio.
b) Due to recycle not efficient below the surge point.
c) Very sensitive to changes in gas properties, especially molecular weight
d) Not effective for low molecular weight gases. The pressure ratio capability per stage is
low, tending to require a large number of machine stages, hence mechanical complexity.
e) High initial cost
f) Complicated monitoring and control systems
g) High rotational speed require special bearings and sophisticated vibration and clearance
monitoring
h) Specialized maintenance considerations














ii) Positive Displacement Compressor

Positive displacement compressors types deliver a fixed volume of air at high pressures
condition. It can be divided into two types which are rotary compressors and reciprocating
compressors. In this type of compressor a certain inlet volume of gas is confined in a given space
and subsequently compressed by reducing this confined space or volume. At this elevated
pressure, the gas is expelled into discharge piping or vessel system.

a) Rotary Compressor
















Figure 6.3.3 Rotary Compressor

Rotary compressor is a group of positive displacement machines that has a central,
spinning rotor and a number of vanes. It also generally classified as screw compressor, vane type
compressor, and lobe and scroll compressor. The difference between each type is their rotating
device.

This compressor gains the pressurizing ability from a spinning component. These types
of compressor are compact, relatively inexpensive, and require a minimum of operating attention
and maintenance. The compressor increased the pressure of the gas by trapping it between vanes
which reduce the volume when the impeller rotates around an axis eccentric to the casing as
show in the figure 6.3.4 below:
























Figure 6.3.4 Rotary Compressor Gas Compressing Principle

The volume can be varied by changing the speed or by bypassing or wasting some of the
capacity of the machine. The discharge pressure will can be control with the resistance on the
discharge side of the system.

Advantages

a) Simple design
b) Low to medium initial and maintenance cost
c) Two-stages design provide good efficiencies
d) Easy to install
e) Few moving parts

Disadvantages

a) High rotational speed
b) Shorter life expectancy than any other designs
c) Single-stage designs have lower efficiency
d) Difficulty with dirty environment












b) Reciprocating compressor





























Figure 6.3.5 Reciprocating Compressor

The reciprocating or also called as piston compressor, is another type of common positive
displacement compressor. It uses the movement of a piston within a cylinder to increase the
pressure of the gas from lower pressure level to higher pressure level. It can be considered as
single acting, when the compressing is accomplished using only one side of the piston, or double
acting when it is using both sides of the piston. This machine is used when high-pressure head is
required at a low flow. Generally, the compression ratio will determine the maximum allowable
discharge-gas temperature. It can be single-stage or multistage compressor. Typical compression
ratios for the compressor are about 3 per stage in order control the discharge temperatures from
300of to 350f. Some reciprocating compressors have as many as six stages that can provide a
total compression ratio over 300.






































Figure 6.3.6 Reciprocating Compressor Working Principle

As shown in the figure 1.6 above the gas enters the suction manifold into the cylinder
cause by the vacuum condition that is created inside the cylinder as the piston moves downward.
When the piston reaches its bottom position it begins to move upward. So the intake valve closes
and trapping the gas fluid inside the cylinder. After that the piston continues to move upward and
compresses the gas and the pressure will increase. The high pressure in the cylinder pushes the
piston downward cause by the higher pressure that occurs in the cylinder. As the piston is
reaching near the bottom of the cylinder, the exhaust valve opens and releases high pressure gas
fluid.

Advantages

a) Simple design, easy to install
b) Lower initial cost
c) Large range of horsepower
d) Special machines can reach extremely high pressure
e) Two stages models offer the highest efficiency

Disadvantages

a) Higher maintenance cost
b) Many moving parts
c) Potential for vibration problems
d) Foundation may be required depending on size
e) Many are not designed to run at full capacity







6.3.3 Compressor Maintenance Concept

In order to maintain an air compressor system it requires well care of the equipment,
paying attention to changes and trends, and responding promptly to maintain operating
reliability and efficiency. To assure the maximum performance and service life of your
compressor, a routine maintenance schedule should be developed. Proper maintenance requires
daily, weekly, monthly, quarterly, semi-annual, and annual procedures. Monitoring operating
conditions on a daily or shift change base is good practice. It allows the operators to become
familiar with a smooth running machine which will lead to early detection of potential
problems. Excellent maintenance is the key to good reliability of a compressed air system;
reduced energy costs are an important and measurable by product. The benefits of good
maintenance far outweigh the costs and efforts involved. Good maintenance can save time,
reduce operating costs, and improve plant manufacturing efficiency and product quality

Just as with any other type of machinery, compressors are subject to operational
changes from environmental conditions, wear, or neglect. A plugged condensate drain, unusual
noises, temperature or vibration increases, discolored oil, and/or fluid leaks are some
examples of operational changes that may signal beginning of potential problems.
Recognizing any changes in operation and appropriately responding to those changes can
prevent undesirable consequences such as unscheduled shutdown and/or the expense of
unanticipated repairs.


























6.3.4 Maintenance Check List, Compressors Failure Symptom and Preventive
Maintenance Observation

Maintenance Check List
Daily inspection
A daily inspection takes only a short time, but it will allow the operator to develop a
definite sense of the appearance, sounds, and other operating conditions of a smoothly
performing compressor. Any changes can be investigated and be given attention before major
problems develop.

Daily operator inspection checklist
Warning: exercise care when in the vicinity of hot surfaces, pressurized air, and high
voltages.
Procedures accompanied by the alert symbol (!) Require special precautions as
indicated.
() Operating data log
Operating parameters recorded and within specifications
Setpoints recorded
Gearcase (high surface temperatures)
External surfaces wiped clean
No unusual noise or vibrations
No oil leaks
No water leaks
No frayed or worn electrical cables
Intercoolers and aftercooler (pressurized air, high surface temperatures)
External surfaces wiped clean
Condensate drains functioning properly
No cooling water leaks
No air leaks
Lubrication system (high voltages at heater, pump motor)
External surfaces wiped clean
Proper oil level in oil reservoir
Proper oil color
No mist from ejector system
No oil cooler water leaks
No oil leaks
No frayed or worn electrical cables
Compressor drive motor (inspect visually onlyhigh voltages, temperatures)
External surfaces wiped clean
Properly ventilated
No erratic or noisy operation
No frayed or worn electrical cables
Inspected in accordance with manufacturers recommendations

Table 6.3.1 Example of Daily Operator Inspection Checklist


Scheduled maintenance

Table 1-2 below lists suggested intervals for prescribed scheduled maintenance
procedures such as those involving filters, lubrication, and other inspections and/or adjustments.
Bear in mind, however, that these intervals may vary with operating conditions and/or actual
hours of machine operation. Some items may require attention more or less frequently as
circumstances dictate.

Scheduled maintenance procedures
() Weekly:
(or after about 150 hours of operation)
Inlet air filter elements inspected, replaced if required
Oil reservoir venting system filter elements inspected, replaced if required
Bypass valve filter checked (if supplied)
Every six months:
(or after about 4000 hours of operation) Oil reservoir venting system filter element changed
Oil system filter element changed
Lubrication system oil tested and changed if required
Coolant chemically tested
Bypass valve lubricated (if required check instructions)
Inlet guide vane assembly drive screw lubricated
Main drive coupling inspected and lubricated.
Drive motor ball bearings lubricated with recommended grease.
Oil pump motor lubricated with recommended grease
Discharge air check valve inspected

Table 6.3.2 Example of Scheduled Maintenance Checklist
Professional inspection

A substantial part of any good preventative maintenance program also involves
professional inspection and replacement of common maintenance components after an
established interval. Such in-depth inspection is particularly important when an unscheduled
and/or long-term shutdown would seriously affect production. Table 1.3 below lists the items
which require a professional service inspection whenever environmental or operational
conditions dictate. Contact a authorized service representative for those procedures and for
professional advice.

Service inspection checklist
To be performed with a manufacturer authorized representative:
() Gearcase
Impellers, inlets, and diffusers cleaned
Impellers, inlets, and diffusers inspected
Gearing visually checked
Gearing backlash clearances measured
Axial pinion float checked
Clearances between impellers and inlets checked
Intercoolers and aftercooler
Bundle tubes inspected, cleaned if required
Bundle fins inspected, cleaned if required
Cooler cavities cleaned and inspected
Lubrication system
Piping connections checked for leaks
Oil visually inspected
Oil cooler inspected
Filters
All filter elements inspected
Control panel
Inspected for proper operation
Control valves
Inlet guide vane inspected
Bypass valve inspected
Discharge air check valve inspected
Drive motor
Main drive coupling inspected and re-greased
Motor inspected in accordance with manufacturers instructions

Table 6.3.3 Example of Service Inspection Checklist by Professional
Compressors Failure Symptom

For compressor itself there are several common failure symptoms that must be pay
attention in order to detect the problems, so that correction step can be done to prevent severe
damage to occur. In the table below show the common symptom, cause and correction step for
each symptom.


SYMPTOM CAUSE CORRECTION





High
Discharge
Temperature
Sump lubricant low. Fill lubricant.


Clogged or varnished heat
exchanger/oil cooler.
Inspect lubricant lines for
blocks.
Analyze lubricant.
If varnish is present, flush with
cleaner.
Faulty thermal by-pass valve. Rebuild or replace by-pass valve.
Restriction of heat exchanger air
flow.
Remove restrictions.
Insufficient air circulation at oil
cooler.
Check location and make sure there
is no restriction of cool fresh air.
Plugged oil filter element. Replace oil filter elements



Premature
Lubricant
Breakdown
Compressor operating too hot. See corrections for high discharge
temperature.
Chemically active gases present.
Review plant/operations/make-
up air.
Analyze oil and correct inlet air
source as needed.
Improper receiver condensate
draining.
Periodically drain receiver
condensate.

Inspect auto-drains, drain lines
and valves.
Mixing incompatible lubricants. Drain, replace and analyze oil.
Flush compressor with cleaner.

Frequent
Separator
Plug-Up /
Collapse
Incompatible oil in compressor. Review and analyze oil.
Replace with proper lubricant.
Minimum pressure valve sticking. Rebuild or replace valve.
Ruptured intake air path filter.
Inspect inlet filter and air path,
checking for voids.
Replace and repair as needed.



Decreased
Discharge
Pressure
Excessive air demand. Check plant air demand and inspect
plant for air leaks.
Service valve open. Close valve.
Leaky service line. Fix leaks.
Plugged inlet air filter. Clean or replace filter.
Inlet valve partially closed. Check inlet valve assembly and
rebuild as needed.

Failure To
Start
Safety shut-down tripped. Re-set compressor safety.
Disconnected main switch. Check switch and verify that power
is ON.
Power failure. Check power supply.


High Power
Consumption
Plugged air/oil separator Change separator element.
Wrong air pressure setting. Adjust setting.
Obstructed after cooler. Clean after cooler.
Plugged inlet air filter. Inspect and replace as needed.
Lubricant viscosity issues. Test and replace oil as needed.





Excessive
Lubricant
Consumption
Overfilled lubricant sump. Drain receiver to proper level
Broken lubricant line .Replace lubricant line.
High compressor discharge
temperature.
Inspect and clean coolers.
Inspect temperature control valve.
Improperly positioned lubricant
return scavenges line.
Plugged scavenge line.
Check scavenges line connections.
Make sure that scavenge line is
cut at 45 angle, reaches the bottom
of the separator and isnt blocked.
Table 6.3.4 Common Failure System, Cause and Correction Step








.
Preventive Maintenance Observation

Preventive maintenance is very important in order to maintain the compressor in their
best condition. Listed below is the general preventive maintenance that can be done in order to
maintain the compressor to work in their best condition.

1. Foundation
Annual. Examine concrete for cracks and spalling.

2. Frame
Annual. Examine metal for corrosion and cracks. Clean and paint if required.

3. Compressor Drive
Weekly. Check v-belts for slippage, chains for looseness, and shaft couplings for excessive run
out or vibration. Dress or tighten v-belts if required. Tighten coupling bolts and lubricate
coupling if required.
Annual. Check v-belts for signs of wear or aging and replace as needed. Check shaft run out of
direct coupled machines with dial indicator and check shaft alignment if run out is excessive.

4. Cooling System
Weekly. Check flow of water or coolant through compressor and after cooler.
Check for accumulation of dirt and lint on cooling fins of air-cooled compressors and radiators
or water-cooled compressors.
Annual. Check for corrosion and scale buildup and clean or flush as required.
Thoroughly clean cooling fins of air-cooled compressors and radiators of water-
cooled compressors.

5. Air Intake
Weekly. Check condition of filter and intake for obstructions. Replace filter as required.

6. Piping and Valves
Annual. Check piping for corrosion. Clean and repaint or replace piping as required. Repack and
reseat valves as required.

7. Aftercoolers
Not Scheduled. Check for leaks and for adequate water flow. Disassemble and check for internal
corrosion and scale buildup. Clean as required.

8. Separators
Not Scheduled. Check for leaks. Disassemble and check for corrosion and scale buildup. Clean
as required.

9. Traps
Weekly. Operate manual drains.
Annual. Check automatic traps for leaks and proper operation. Clean strainer and check for
corrosion or scale buildup.

10. Dryers
Annual. Replace dryer elements as required on deliquescent dryers. Check operation of
refrigerated and desiccant types.
11. Pressure Regulating Valves
Annual. Check operation and verify that regulating valves are providing correct pressure
downstream from valve.

12. Pressure Relief Valves
Annual. Verify operation and setting. Check for signs of leaking, rust or corrosion, deposits, or
mineral buildup. Perform operational test of relief valve either in service or remove and perform
test on test stand. If a valve is found to be not functioning properly, the system immediately
should be taken out of service until the valve can be repaired or a new valve can be installed. The
relief valve setting should not be changed by plant personnel. The setting of a pressure relief
valve can only be certified by an accredited repair facility.

13. Receiver Tanks and Other Pressure Vessels
Weekly. On air receiver tanks, open the receiver drain valve and blow down until water is
removed from tank. Check for leaks on all pressure vessels. Annual. Make thorough inspection
of exterior of the tank, paying close attention to joints, seams, and fittings. The inspection should
be performed by a qualified inspector.

14. Gauges
Weekly. Check operation of gauge. Look for loose or stuck pointer. If there is any doubt about
the accuracy of gauge, remove and check calibration or replace with new gauge. Biannual.
Remove gauge and calibrate. Make any necessary repairs or replace with new gauge if gauge is
not repairable.



15. Pressure and Temperature Switches
Monthly. See that pressure switches cut in and out at proper pressures. Check setting of
temperature switches. Annual. Check switch calibration and set points.

16. Unloader
Monthly. Check that compressor is not being loaded until operating speed is reached in starting
and that it unloads at the proper pressure. Annual. Inspect valves and air lines for leaks and
valves for proper seating. Lap valves if required. Examine solenoid for deteriorated insulation or
loose connections.

17. Bearings
Weekly. Check antifriction bearing for excessive vibration or noise and schedule replacement as
required. Check for adequate lubrication. Not Scheduled. Disassemble compressor and inspect
condition of all bushings and babbitt-lined bearings. Repair or replace as required.


REFERENCE
1. R. Keith Mobley (2008). Maintenance Engineering Handbook 7
th
.Ed.McGraw-Hill,
USA. ISBN 978-0-07-154646-1

2. Ling. A. L. and Viska Mulyandasari (2011) .Compressor Selection and Sizing
(Engineering Design Guidelines) KLM Technology Group, Johor Bharu.

3. Roger Cline, John Germann and Bill McStraw(2009). Maintenance Scheduling for
Mechanical Equipment Facilities Instructions, Standards and Techniques, Volume 4-1A
Revised 2009, U.S. Department of the Interior, Bureau of Reclamation, Denver,
Colorado.

4. Glenn K. Moore. (2009) Field Service Notes (Why Compressors Fail), Danfoss Ltd.
Denmark.

5. R. Keith Mobley (2008). Maintenance Engineering Handbook 7
th
.Ed.McGraw-Hill,
USA. ISBN 978-0-07-154646-1