WH40H3N

Training material purpose

 • Compressor overview
• Compressor identification
• Operating data

Title and Content Layout with List

 • How it work ?

Compressor Overview
 • Reciprocating compressor?
Reciprocating compressors are commonly called piston
compressors.

reciprocating compressors are positive displacement

compressors that use a piston in a chamber called a
cylinder to decrease the volume and increase the
pressure.
That was then broken down into double-acting, single-
acting, and diaphragm.

They're called "reciprocating" because the piston goes

back and forth in a reciprocal motion.

Compressor Overview
There is an inlet or suction valve and a discharge valve. Both are one way valves and both are spring
loaded so it takes a certain amount of force to open them. The inlet valve will only let air come into the cylinder
and the discharge valve will only let air out. As the piston moves downward through the cylinder, air is sucked in
the inlet valve. When the piston moves up through the cylinder the inlet valve closes and the discharge won't
open until a certain amount of force is applied. This causes the air to be trapped inside while the volume is
reduced, increasing the pressure. When the pressure is enough to open the discharge valve, then the air goes
out at the higher pressure.

Single-acting recip compressors only have valves on top of the cylinder, so there is one compression cycle for
every turn of the crankshaft.

Single-Acting Reciprocating Compressors

Double-acting recip compressor are similar to single-acting, but they have inlet and discharge valves on
both sides of the cylinder. This gives you two compression cycles for every turn of the crankshaft.

Double-acting recips are some of the most efficient compressors ever built, but they're not as common as
they used to be. They're still around, but they're extremely large. You rarely see one under 100 hp. Back in
the days, they used to be called earth-movers, because being around one felt like you were in an
earthquake. If the compressor didn't have the right foundation and vibration isolation, it could tear down the
building it was in. These used to be the workhorses in manufacturing plants, but in the last 20-30 years that
role was taken over by rotary screw compressors.

Double-Acting Reciprocating Compressors

As the compressor piston moves to
compress gas, the differential
pressures acting on the piston and
stationary components result in gas
forces illustrated in Figure 2. An
ideal pressure versus time diagram
for a typical double acting
compressor cylinder is shown in
Figure 3. The pressures acting on
the piston faces (head end and
crank end) result in forces on the
piston rod. The force acting on the
piston rod due to the cylinder
pressures alone alternates from
tension to compression during the
course of each crankshaft
revolution.
 • How it work ?

Compressor Overview
Compressor identification
 • Crankcase
• Oil Pump
• Connecting Rods
• Crossheads
• Cylinders, Pistons and
Piston Rod Packings
• Valves
• Motor and Couplings
• Control Panel and Controls
• Safety Equipment and Systems

Compressor identification
 • Crankcase
• The crankcase forms the lubricating oil sump, and is complete with tapped holes for the oil
level window nut, the oil pump suction feed pipe, the crankcase drain plug and the oil cooler.

Compressor identification
 • Oil Pump
• gear type oil pump driven via a coupling off the non-drive
end of the crankshaft is driven via a coupling off the non-
drive end of the crankshaft
Oil is drawn by the pump from the
crankcase sump through a wire mesh
strainer and external pipe. The oil is
delivered through a full-flow fine-mesh
cartridge filter to the oil ways in the
crankshaft.
Any excess oil output is by-passed back
to the sump by a spring-loaded
pressure relief valve mounted on the
crankcase main bearing housing.

Compressor identification
Compressor identification
 • Lubrication system

Compressor identification
 • Connecting Rod

Compressor identification
 • Crosshead

4 2
5
1

3
3
Compressor identification
 • Cylinders, Pistons and Piston Rod Packings

Cylinder

Compressor identification
 • Cylinders, Pistons and Piston Rod Packings

Compressor identification
Compressor identification
Compressor identification
Compressor identification
Compressor identification
 • Valves

Compressor identification
• function
The compressor unloader is
used to remove all the
compression load from the
compressor while unit is
starting and applies the
load after the compressor
is up to speed.
The unloading system is
also used on air
compressors to regulate
output if the compressor
run continuously.
Unloading the reciprocating
air compressor may be
accomplished by:
Closing or throttling the
compressor intake.
Holding the intake valves off
their seats.
Relieving the intercoolers to
unloader
atmosphere.
Opening a bypass from the
 • Unloading assembly

diffuser

Compressor identification
 • Unloading assembly

Compressor identification
Compressor identification
 • Motor and Couplings

Compressor identification
 • Control Panel and Controls

Operator interface
 display :
Reset Emergency Stop “Reset Emergency Stop”
Lakukan :
Dengan mereset push button dan
menekan tombol emergency stop reset

Display :
Informasi bahwa dryer HAC belum normal
DRYER TRIP
(status off/alarm).
Lakukan :
On kan dryer atau reset alarm dryer

ALARM INFORMATION
 Menekan F2 akan menstart
compressor dan display akan
berubah menjadi :

Display ini akan selalu

RUNNING F3 = STOP ditampilkan selama compressor
running, dengan menekan F3
maka compressor akan stop

Dengan menekan COUNTERS maka menu screen

akan menampilkan HOURS RUN DATA
Data counter yang dicatat dalam run hours daily
ceklist /jam adalah HOUR TUN TOTAL
 F10

F9=LOAD
F9

Change settings
Default password : 1966

• Safety Equipment and Systems
Compressor identification
Pressure relief valve (PRV) adalah sebuah alat
instrument yang bekerja saat adanya over pressure pada
inlet nozzle. Di desain untuk terbuka secara proporsional
saat adanya abnormal (dalam hal ini over pressure) pada
sebuah plant dan akan menutup saat plant kembali
normal (normalpressure)
 • Pressure gauge arrangement

AMOT model 4140 switches are available as a single

(4140C & F), dual step pressure or temperature switch
(4140D & E), or a combined pressure and temperature
switch (4140A). Model 4140 temperature switches and
combined switches are supplied with a thermal well or
slip coupling and are mounted by inserting the
temperature sensing element into a properly located
pipe boss.
•Gold and silver plated contacts - for use in I/S circuits
•Weatherproof enclosure IP56
•Single and dual set points - alarm and shutdown capabilities in one unit
•Combined temperature and pressure with independent, fully adjustable set points - for use in diverse
applications

Compressor identification
 Intercooler
Intercoolers and aftercoolers are used on reciprocating
air compressors improve overall compressor efficiency.

Intercoolers and aftercoolers are also used to remove

moisture in the air

Intercooler
 • A/Cooler Assembly

Compressor identification
 • The compressed air system receivers are
classified as an unfired pressure vessel.
• The air receiver must be protected with a
relief valve.
• The air receiver must be open for internal
inspection at the C.O.I. Inspection every two
years.
• The air receiver must have a drain valve to
remove water.
• The air receiver stores air for the system and
also dampens pulsations in the system.

Vessel
Compressor identification
Compressor identification
 in

out

• Cooling method (water)

cooling Cooling water in -> oil cooler
Water cooling is a method of heat removal -> after cooler
from components and industrial equipment. -> 2nd stage intercooler
As opposed to air cooling, water is used as -> 1st stage intercooler
the heat conductor.
1st stage double act cyl -> 2nd st.double act cyl ->3rd st.double act cyl -> cooling water out
 outlet inlet

Oil cooler

After cooler

Cooling water
Compressor operating data
PRE TEST / POST
TES 1 1
1. Berdasarkan klasifikasi
compressor maka WH40H3N
termasuk tipe compressor?
2. Berdasarkan tipe silinder
WH40H3N termasuk tipe?
3. Sebutkan nama komponen
pada gambar disamping :
No. 1 ___________
Fungsi komponen tersebut adalah :

2
No.2____________
Fungsi komponen tersebut adalah :