Operation and Maint of Air Compressor

T H E B E S T D E S E R V E S T H E B E S T
Trai ni ng
ma n u a l
For a f resh approach to f astener trai ni ng.
Mai nt enanc e
and Oper at i on
of
Ai r Compr essor Pl ant s
NAVFAC MO-206
January 1989
SN 0525-LP173-1715
ABSTRACT
This manual is directed to operators and supervisors who
actually perform and supervise operations and maintenance work.
The manual is divided into five chapters with one
covering definitions and
chapter
responsibilities. Chapters two and
three cover positive displacement and
respectively.
dynamic
Chapter
compressors,
four deals with auxiliary
while chapter five covers compressor controls.
equipment,
manual provides guidelines
In general, this
for maintenance and operation of air
compressor plants.
FOREWORD
This publication provides information on the maintenance
and operation of air compressor plants.
For maximum benefit, this manual should be used in
conjunction with equipment manufacturers' manuals, parts lists
and drawings. In case of conflict, manufacturers'
recommendations on use, care, operations, adjustment and repair
of specific equipment should be followed. The manual is a
general guide which establishes standards for the operators,
mechanics, and supervisors who are responsible for carrying out
operations and maintenance functions.
Additional information concerning procedures, suggestions,
recommendations OK modifications that will improve this manual
are continually invited and should be submitted through
appropriate channels to the Commander, Naval Facilities
Engineering Command, (Attention: Code 165), 200 Stovall Street,
Alexandria, VA 22332-2300.
This publication cancels and supersedes NAVAC MO-206 of
January 1964 and any changes thereto. It has been reviewed and
approved in accordance with the Secretary of the Navy
Instruction 5600.16A and is certified as an official publication
of the Naval Facilities Engineering Command.
C. M. MASKELL
Captain, CEC, U.S. Navy
Deputy Commander for
Public Works
CHAPTER 1.
Secti on 1.
Secti on 2.
CHAPTER 2.
Secti on 1.
Secti on 2.
Secti on 3.
Secti on 4.
CONTENTS
DEFI NI TI ONS AND RESPONSI BI LI TI ES
. . . . . . . . . . . . . .
AI R COMPRESSOR PLANT . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .
1 COMPONENTS OF AN AI R COMPRESSOR PLANT . . . . . . . . . . . . . . .
2 AI R COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 AUXI LI ARY EQUI PMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 COOLI NG WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . .
OPERATI ON AND MAI NTENANCE RESPONSI BI LI TI ES . . . . . . . . . . .
1 OPERATI ON . . . . . . . . . . . . . . . . . . . . . . . .
2 DI SASTER CONTROL . . . . . . . . . . . . . . . . . . . . . .
3 OPERATOR MAI NTENANCE . . . . . . . . . . . . . . . . . . .
4 PREVENTI VE MAI NTENANCE
. . . . . . . . . . . . . . . . .
5 BREAKDOWN MAI NTENANCE
. . . . . . . . . . . . . . . . . .
6 COMPRESSED AI R SYSTEM LEAKS
. . . . . . . . . . . . . . . . . . . . . .
POSI TI VE DI SPLACEMENT COMPRESSORS
. . . . . . . . . . . . .
RECI PROCATI NG COMPRESSORS
. . . . . . . . . . . . . . . . .
1 DESCRI PTI ON
. . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY PRECAUTI ONS
. . . . . . . . . . . . . . . . . . .
3 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . .
4 NORMAL OPERATI ON . . . . . . . . . . . . . . . . . . . . .
5 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATI ONAL PREVENTI VE MAI NTENANCE . . . . . . . . . . . . . .
7 PREVENTI VE MAI NTENANCE I NSPECTI ON . . . . . . . . . . . .
8 MAI NTENANCE
. . . . . . . . . . . . . . . . . . . . . . .
ROTARY SLI DI NG VANE COMPRESSORS
. . . . . . . . . . . . . .
1 DESCRI PTI ON
. . . . . . . . . . . . . . . . . . . . . . .
2 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . .
3 NORMAL OPERATI ON
. . . . . . . . . . . . . . . . . . . .
4 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 OPERATI ONAL PREVENTI VE MAI NTENANCE . . . . . . . . . . . . . . .
6 PREVENTI VE MAI NTENANCE I NSPECTI ON . . . . . . . . . . . . . .
7 MAI NTENANCE
. . . . . . . . . . . . . . . . . . . . . . . . . . .
ROTARY TWI N- LOBE COMPRESSORS
. . . . . . . . . . . . . . . .
1 DESCRI PTI ON
. . . . . . . . . . . . . . . . . . . . . . .
2 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . .
3 NORMAL OPERATI ON . . . . . . . . . . . . . . . . . . .
4 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 OPERATI ONAL PREVENTI VE MAI NTENANCE . . . . . . . . . . . . . .
6 PREVENTI VE MAI NTENANCE I NSPECTI ON. . . . . . . . . . . . . . .
7 MAI NTENANCE
. . . . . . . . . . . . . . . . . . . . . . .
ROTARY LI QUI D PI STON COMPRESSORS
. . . . . . . . . . . . . .
1 DESCRI PTI ON
. . . . . . . . . . . . . . . . . . . . . . .
2 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
l - l
l - l
l - l
l - l
l - l
l - 3
l - 4
l - 5
l - 5
l - 5
l - 6
l - 7
l - 7
1- 7
2- l
2- l
2- l
2- l
2- 3
2- 5
2- 5
2- 6
2- 6
2- 8
2- 13
2- 13
2- 13
2- 15
2- 15
2- 16
2- 16
2- 17
2- 19
2- 19
2- 19
2- 21
2- 21
2- 21
2- 21
2- 22
2- 23
2- 23
2- 23
CHAPTER 3.
CHAPTER 4.
Sect i on 1.
Sect i on 2.
Sect i on 3.
Sect i on 4.
Sect i on 5.
Sect i on 6.
CONTENTS ( Cont i nued)
Page
3 NORMAL OPERATI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 23
4 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 23
5 OPERATI ONAL PREVENTI VE MAI NTENANCE . . . . . . . . . . . . . . . . 2- 25
6 PREVENTI VE MAI NTENANCE I NSPECTI ON . . . . . . . . . . . . . . . . . . 2- 25
7 MAI NTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 26
DYNAMI C COMPRESSORS
. . . . . . . . . . . . . . . . . . . . . . . 3- l
1 DESCRI PTI ON . .
. . . . . . . . . . . . . . . . . . . . . . . 3- l
2 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . .
3- 3
3 NORMAL OPERATI ON . . . . . . . . . . . . . . . . . . . . . . . . . .
3- 5
4 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3- 5
5 OPERATI ONAL PREVENTI VE MAI NTENANCE . . . . . . . . . . . . . . . . . . . 3- 7
6 PREVENTI VE MAI NTENANCE I NSPECTI ON
. . . . . . . . . . . . . . . . 3- 8
7 MAI NTENANCE
. . . . . . . . . . . . . . . . . . . . . . . 3- 9
AUXI LI ARY EQUI PMENT . . . . . . . . . . . . . . . . . . . . 4- l
I NTAKE FI LTERS
. . . . . . . . . . . . . . . . . . . . . . . 4- l
1 DESCRI PTI ON
. . . . . . . . . . . . . . . . . . . . . . . 4- l
2 I NSPECTI ON
. . . . . . . . . . . . . . . . . . . . . . . 4- l
3 MAI NTENANCE
. . . . . . . . . . . . . . . . . . . . . . . 4- 2
SI LENCERS
4- 5
1 DESCRI PTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 5
2 I NSPECTI ON AND MAI NTENANCE . . . . . . . . . . . . . . . . . . . . 4- 5
I NTERCOOLERS AND AFTERCOOLERS
. . . . . . . . . . . . . . . 4 - 7
1 DESCRI PTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 7
2 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 8
3 NORMAL OPERATI ON. . . . . . . .
. . . . . . . . . . . . . . . 4 - 8
4 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 9
5 OPERATI ONAL PREVENTI VE MAI NTENANCE . . . . . . . . . . . . . . . . . . 4 - 9
6 PREVENTI VE MAI NTENANCE I NSPECTI ON
. . . . . . . . . . . . 4 - 9
7 MAI NTENANCE
. . . . . . . . . . . . . . . . . . . . . . . 4- 11
SEPARATORS
. . . . . . . . . . . . . . . . . . . . . . . . . 4- 13
1 DESCRI PTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 13
2 OPERATI ON . . . . . . . . . . . . . . . . . . . . . . .
4- 13
3 PREVENTI VE MAI NTENANCE I NSPECTI ON . . . . . . . . . . . . . . . 4- 13
4 MAI NTENANCE
. . . . . . . . . . . . . . . . . . . . . . . 4- 14
TRAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
1 DESCRI PTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
2 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
3 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
4 PREVENTI VE MAI NTENANCE I NSPECTI ON . . . . . . . . . . . . . . . . 4- 15
5 MAI NTENANCE . . . . . . . . . . . . . . . . . . . . . . . 4- 15
AI R RECEI VERS
. . . . . . . . . . . . . . . . . . . . . . . 4- 19
1 DESCRI PTI ON
. . . . . . . . . . . . . . . . . . . . . . . 4- 19
i i
CONTENTS (Continued)
Page
2 NORMAL OPERATION . . . . . . . . . . . . . . . . . 4-19
3 PREVENTIVE MAINTENANCE INSPECTION . . . . . . . . . 4-19
4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . 4-20
Section 7. DRYERS . . . . . . . . . . . . . . . . . . . . . . . 4-21
1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . 4-21
2 TYPES . . . . . . . . . . . . . . . . . . . . . . . 4-21
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . 4-25
CHAPTER 5. CONTROLS.. . . . . . . . . . . . . . ......................
Section 1.
1
2
3
4
5
6
7
PRIME MOVER CONTROLS . . . . . . . . . . . . . . . .
DESCRIPTION . . . . . . . . . . . . . . . . . . . .
STARTUP . . . . . . . . . . . . . . . . . . . . . .
NORMAL OPERATION . . . . . . . . . . . . . . . . .
SHUTDOWN . . . . . . . . . . . . . . . . . . . . .
OPERATIONAL PREVENTIVE MAINTENANCE . . . . . . . .
PREVENTIVE MAINTENANCE INSPECTION . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . .
5-l
5-l
5-l
5-4
5-4
5-4
5-4
5-5
5-5
Section 2. COMPRESSOR CONTROLS . . . . . . . . . . . . . . . . 5-7
1 CAPACITY CONTROL . . . . . . . . . . . . . . . . . 5-7
2 STARTUP . . . . . . . . . . . . . . . . . . . . . . 5-15
4 SHUTDOWN . . . . . . . . . . . . . . . . . . . .
5 OPERATIONAL PREVENTIVE MAINTENANCE
5-15
. . . . . . . . 5-15
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . 5-16
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . Reference-l
APPENDIX A - ABBREVIATIONS AND ACRONYMS . . . . . . . . . . . . A-l
APPENDIX B - EVALUATION OF LOSSES IN COMPRESSED AIR SYSTEMS. . . B-l
1 COMPRESSED AIR SYSTEM LEAKS . . . . . . . . . . . . B-2
2 TEST METHOD . . . . . . . . . . . . . . . . . . . . B-2
3 TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . B-2
4 TEST PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . B-2
5 TEST PROCEDURES . . . . . . . . . . . . . . . . . B-2
6 CORRECTIVE MEASURES . . . . . . . . . . . . . . . . B-6
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index-1
iii
FIGURES
Figure
Page
1-1
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
3-l
3-2
3-3
3-4
3-5
3-6
3-7
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
5-1
5-2
5-3
5-4
5-5
5-6
5-7
B-1
Table
1-1
1-2
B-1
B-2
B-3
Main Components of an Air-Compressor Plant. . . . . . . .
Two-Cylinder, Two-Stage, V-Type Air Compressor . . . . .
Installing Piston Rings . . . . . . . . . . . . . . . . .
Connecting Rod With Wedge Adjusting Bearings . . . . . .
Connecting Rod Assembly . . . . . . . . . . . . . . . . .
Method of Checking the Tension of V-Belts . . . . . . . .
Cross Section of Rotary Sliding Vane Compressor . . . . .
Cutaway View of Two-Stage, Rotary Sliding Vane
Compressor. . . . . . . . . . . . . . . . . . . . . . . .
Impeller Arrangement of Rotary Twin-Lobe Compressor . . .
Rotary Twin-Lobe Compressor . . . . . . . . . . . . . . .
Compression Cycle, Rotary Liquid Piston Compressor. . . .
Functional Elements, Rotary Liquid Piston Compressor. ..
Simple Volute Pump . . . . . . . . . . . . . . . . . . .
Six-Stage Compressor . . . . . . . . . . . . . . . . . .
Impeller Design . . . . . . . . . . . . . . . . . . . . .
Axial Flow Compressor . . . . . . . . . . . . . . . . . .
Rotor and Stator Blades, Axial Compressor . . . . . . . .
Alignment Setup . . . . . . . . . . . . . . . . . . . . .
Coupling Alignment and Misalignment . . . . . . . . . . .
Oil-Bath Intake Filter . . . . . . . . . . . . . . . . .
Compressor Intake Silencer . . . . . . . . . . . . . . .
Air-Cooled Heat Exchanger . . . . . . . . . . . . . . . .
Water-Cooled Heat Exchanger . . . . . . . . . . . . . . .
Centrifugal Type Separator . . . . . . . . . . . . . . .
Baffle Type Separator . . . . . . . . . . . . . . . . . .
Drain Traps . . . . . . . . . . . . . . . . . . . . . . .
Air Receiver . . . . . . . . . . . . . . . . . . . . . .
Flow Diagram of Electric Reactivated Absorption Dryer . .
Deliquescent (Absorption) Dryer . . . . . . . . . . . . .
Flow Diagram of Refrigeration Dryer . . . . . . . . . . .
Automatic Start-Stop Governor . . . . . . . . . . . . . .
Variable Speed, Oil Relay Governor . . . . . . . . . . .
Inlet Valve Unloader . . . . . . . . . . . . . . . . . .
Airflow Diagram of Compressor With Five-Step Control . .
Three-Way Solenoid Valve . . . . . . . . . . . . . . . .
Five-Step Clearance Control . . . . . . . . . . . . . . .
Intake Unloader for Rotary Sliding Vane Compressor . . .
Loss (cfm) vs Pressure (psig) . . . . . . . . . . . . . .
TABLES
Title Page
Maximum Pressures and Capacities of Air Compressors . . . 1-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . 1-8
Amount and Cost of Air Leaks . . . . . . . . . . . . . . B-3
Pressure Test Data . . . . . . . . . . . . . . . . . . . B-4
Calculation of Losses . . . . . . . . . . . . . . . . . . B-4
iv
l-2
2-2
2-9
2-10
2-11
2-11
2-13
2-14
2-20
2-20
2-24
2-25
3-l
3-2
3-2
3-3
3-4
3-11
3-12
4-2
4-5
4-7
4-8
4-13
4-14
4-16
4-19
4-21
4-22
4-23
5-2
5-3
5-8
5-9
5-10
5-11
5-13
B-6
SAFETY SUMMARY
Whenever wor k i s t o be accompl i shed on ai r compr essor pl ant s t her e i s
al ways t he possi bi l i t y of a hazar dous si t uat i on occur r i ng, whi ch coul d r esul t
i n ser i ous i nj ur y t o or deat h of per sonnel . Per f or mance wi t hout i nj ur y i s a
si gn of consci ent i ous wor kmanshi p and pl anned super vi si on. Ther ef or e, saf et y
i s a pr i mar y consi der at i on when oper at i ng, i nspect i ng, or mai nt ai ni ng any of
t he ai r compr essor pl ant s addr essed i n t hi s publ i cat i on.
The f i r st essent i al act i on i s t o r ead and under st and al l publ i cat i ons
associ at ed wi t h t he syst ems and equi pment bei ng used. The manual s expl ai n
saf e and accept ed ways of i nst al l at i on, st ar t up, oper at i on, i nspect i on,
mai nt enance, r emoval , and shut down. I f you do not under st and what you have
r ead, DO NOT at t empt t o per f or mt he i nt ended t ask; get gui dance f r omyour
super vi sor .
The f ol l owi ng saf et y r ul es ar e emphasi zed:
GENERAL
Al l per sonnel shoul d be t r ai ned and qual i f i ed i n car di opul monar y
r esusci t at i on ( CPR) .
Al l per sonnel shoul d wear saf et y shoes.
Al l per sonnel shoul d wear cl ot hi ng appr opr i at e t o t he j ob bei ng
per f or med. El i mi nat e l oose cl ot hi ng, whi ch can get caught i n
machi ner y.
Wear har dhat s when r equi r ed.
Al l per sonnel shoul d wear eye and ear pr ot ect i on pr escr i bed f or t he
t ask bei ng per f or med.
Repor t al l i nj ur i es, even i f t hey seem t o be mi nor .
DO NOT WORK ALONE. At l east one ot her per son shoul d be on hand t o
pr ovi de assi st ance, i f needed.
Al ways use t he cor r ect t ool f or t he j ob.
Pr event ski n r upt ur es and sensor y i nj ur i es when wor ki ng wi t h
compr essed ai r . Cl ose i sol at i on val ves bef or e wor ki ng on l i nes or
f i t t i ngs.
Fol l ow l ockout and t agout pr ocedur es pr escr i bed f or t he pl ant .
Cur r ent and accur at e dr awi ngs of var i ous mechani cal syst ems ar e
essent i al f or oper at i onal saf et y of t he pl ant .
ELECTRI CAL WORK
Do not wear j ewel r y, i ncl udi ng r i ngs, br acel et s, neckl aces, or wr i st
wat ches.
v
Do not wear j acket s wi t h met al zi pper s.
Do not use met al l adder s.
Do not t ake shor t cut s. The st eps r ecommended by a manuf act ur er
usual l y have a mar gi n of saf et y bui l t i nt o t hem.
Do not t r y t o connect met er s t o ci r cui t s unl ess you ar e qual i f i ed.
Wai t f or an el ect r i ci an.
Al ways use i nsul at ed t ool s and gr ounded equi pment . NEVER USE
scr ewdr i ver s or ot her t ool s wi t h met al shanks ext endi ng t hr ough t he
handl e.
Al ways use and obser ve t ags and l ockout s on ci r cui t s bei ng wor ked on.
WARNI NGS AND CAUTI ONS
War ni ngs and caut i ons appear i n equi pment manual s. A CAUTI ON i s a
st at ement r egar di ng an oper at i ng or mai nt enance pr ocedur e, pr act i ce, or
condi t i on whi ch, i f not st r i ct l y obser ved, coul d r esul t i n damage t o, or
dest r uct i on of , equi pment or dat a, l oss of mi ssi on ef f ect i veness, or l ong- t er m
heal t h hazar ds t o per sonnel . A WARNI NG i s a st at ement r egar di ng an oper at i ng
or mai nt enance pr ocedur e, pr act i ce, or condi t i on whi ch, i f not st r i ct l y
obser ved, coul d r esul t i n i nj ur y t o, or deat h of , per sonnel .
The war ni ngs and caut i ons whi ch appear i n t hi s manual ar e r epeat ed her e
f or emphasi s and r ei nf or cement of t hei r need t o be obser ved expl i ci t l y. The
number s i n par ent heses at t he end of each war ni ng and caut i on i ndi cat e t he
page on whi ch i t appear s; f or exampl e, ( 4- 15) r ef er s t o page 4- 15.
Do not use gasol i ne, ker osene, or ot her l ow f l ashpoi nt sol vent s. A
ser i ous expl osi on may r esul t . ( 2- 8, 3- 10, 4- 3, 4- 6, 4- 15, 4- 20,
5- 5, 5- 16)
I f i mpel l er s ar e t o be r ot at ed, keep hands, f eet , l oose cl ot hi ng,
and f or ei gn obj ect s away f r om i nl et and di schar ge openi ngs, as
ser i ous per sonal i nj ur y or damage t o equi pment can occur . ( 2- 19)
Do not oper at e equi pment wi t hout adequat e si l enci ng devi ces. Hi gh
noi se l evel s may cause per manent hear i ng damage. ( 2- 19)
Compr essor equi pment , compr essed ai r , and el ect r i ci t y can be
danger ous. To pr event i nj ur y, bef or e at t empt i ng any mai nt enance be
cer t ai n t he compr essor cannot be st ar t ed acci dent al l y.
( 3- 3)
vi
Pr ot ect i ve devi ces must be wor n t o avoi d damage t o hear i ng. ( 3- 4)
Do not at t empt t o r epai r or r emove any compr essor syst em par t s
wi t hout f i r st r el i evi ng pr essur e f r om t he ent i r e syst em.
( 4- 9,
4- 14, 4- 15, 4- 20, 4- 24, 4- 25, 4- 26)
Never oper at e compr essor i n t he cr i t i cal speed r ange ( i nsuf f i ci ent
vol ume at t he compr essor i nl et t o per mi t st abl e oper at i on) ; sur gi ng
or pumpi ng wi l l occur . Oper at i on under t hese condi t i ons may r esul t
i n equi pment damage.
( 3- 5)
To avoi d damage t o equi pment , af t er shut t i ng down t he dr i ve, keep
auxi l i ar y l ubr i cat i ng oi l pump oper at i ng unt i l bear i ngs have cool ed
t o ambi ent t emper at ur es. ( 3- 5)
To avoi d i nt er nal damage t o equi pment , use onl y synt het i c sponges
when cl eani ng i nt er nal sur f aces and component s. Do not use cl ot h
r ags or cot t on wast e. ( 3- 10)
To ensur e pr oper al i gnment , check al i gnment i n bot h t he hot and col d
condi t i on. Af t er checki ng t he al i gnment i n t he col d condi t i on,
oper at e t he compr essor under f ul l l oad f or 1 hour . Shut down t he
uni t and r echeck t he al i gnment i mmedi at el y. ( 3- 10)
Dr y t ype f i l t er el ement s can easi l y be damaged al l owi ng har mf ul
par t i cul at es t o pass. I f i n doubt about cor r ect cl eani ng
pr ocedur es, r epl ace t he f i l t er el ement .
( 4- 2)
Ensur e al l j oi nt s ar e t i ght t o avoi d ent r y of unf i l t er ed ai r . Di r t
i n t he ai r wi l l cause pr emat ur e wear t o t he compr essor .
( 4- 6)
Never hammer on t he t ubes or use shar p edged scr aper s whi ch may
damage t he t ubes. ( 4- 11)
Chemi cal sol ut i ons used f or cl eani ng shoul d be capabl e of di ssol vi ng
t he scal e or ot her deposi t s wi t hout at t acki ng t he met al . ( 4- 11)
vi i
Do not overrun the uni t. Over r unni ng wi l l r esul t i n t he t ower
becomi ng sat ur at ed and unabl e t o absor b any mor e moi st ur e. Moi st ur e
l aden ai r wi l l t hen be car r i ed over i nt o t he di st r i but i on syst em.
( 4- 23)
On systems where oi l carryover f rom the compressor i s present,
pr ovi si on shoul d be made t o pr ot ect t he desi ccant bed of t he dr yer
f r om becomi ng oi l sat ur at ed. Oi l deposi t s i n t he desi ccant bed
cause a decr ease i n dr yi ng ef f i ci ency and necessi t at e f r equent
r epl acement of t he desi ccant . ( 4- 23)
Do not at t empt t o ser vi ce t he seal ed r ef r i ger at i on uni t ; damage t o
t he uni t may r esul t . Cont act t he manuf act ur er i n t he event of any
mal f unct i on. ( 4- 26)
The oper at or must have a t hor ough under st andi ng of t he cont r ol
syst emand i t s oper at i on. ( 5- 4, 5- 15)
vii
CHAPTER 1. DEFI NI TI ONS AND RESPONSI BI LI TI ES
Sect i on 1. AI R COMPRESSOR PLANT
1 COMPONENTS OF AN AI R COMPRESSOR PLANT. Compr essed ai r i s a f or mof power
t hat has many i mpor t ant uses i n i ndust r i al act i vi t i es. Ai r compr essor pl ant s
ar e used t o pr ovi de an adequat e quant i t y of compr essed ai r at suf f i ci ent
pr essur e t o var i ous poi nt s of appl i cat i on. Di st r i but i on of compr essed ai r i s
f ound i n NAVFAC MO- 209, Mai nt enance of St eam, Hot Wat er , and Compr essed Ai r
Di st r i but i on Syst ems. Component s of a pl ant ar e: ai r compr essor , i nt er cool -
er s, af t er cool er s, moi st ur e separ at or , ai r r ecei ver , and cont r ol s ( f i gur e l - l ) .
2 AI R COMPRESSOR. The ai r compr essor i s t he hear t of a compr essed ai r
pl ant . Compr essor s ar e used t o i ncr ease t he pr essur e of ai r f r omt he i ni t i al
condi t i ons ( ai r i nt ake) t o t he di schar ge condi t i ons ( ai r di schar ge) .
Compr essor s may be used as vacuumpumps. A vacuumpump has an i nt ake t hat i s
bel ow at mospher i c pr essur e and usual l y compr esses t o no hi gher t han
at mospher i c pr essur e. The degr ee of vacuum at t ai nabl e i s dependent upon t he
t ype of syst em, l eakage i nt o t he syst em, and l i mi t at i ons of t he equi pment .
The mai n t ypes of ai r compr essor s ar e posi t i ve di spl acement and dynami c.
2. 1 Posi t i ve Di spl acement Compr essor s. Ther e ar e t wo basi c t ypes of posi t i ve
di spl acement compr essor s. I n one, ai r i s compr essed as t he vol ume of t he
encl osed space i s r educed. I n t he ot her , a def i ni t e quant i t y of ai r i s
t r apped and t r ansf er r ed f r omt he suct i on i nt ake t o t he di schar ge por t wi t hout
r educi ng i t s vol ume. Pr essur e i ncr ease i s caused by backf l ow i nt o t he casi ng
when t he di schar ge por t i s uncover ed. Exampl es of t he f i r st t ype ar e
r eci pr ocat i ng compr essor s, r ot ar y sl i di ng vane compr essor s, and r ot ar y l i qui d
pi st on compr essor s. An exampl e of t he second t ype i s t he r ot ar y t wi n- l obe
compr essor . Ref er t o chapt er 2 f or det ai l s.
2. 2 Dynami c Compr essor s. Dynami c compr essor s oper at e by i mpar t i ng vel oci t y
and pr essur e t o t he admi t t ed ai r , t hr ough t he act i on of a r api dl y spi nni ng
i mpel l er or r ot at i ng vanes. The mai n t ypes of dynami c compr essor s ar e
cent r i f ugal and axi al compr essor s. Ref er t o chapt er 3 f or det ai l s.
2. 3 Maxi mum Pr essur es and Capaci t i es of Ai r Compr essor s. The appr oxi mat e
maxi mumpr essur es i n pounds- f or ce per squar e i nch gauge ( psi g) , and t he
appr oxi mat e maxi mumcapaci t i es i n cubi c f eet per mi nut e ( cf m) f or var i ous
t ypes of compr essor s ar e gi ven i n t abl e l - l .
3 AUXI LI ARY EQUI PMENT. The f ol l owi ng auxi l i ar y equi pment i s r equi r ed f or t he
pr oper oper at i on of an ai r compr essor pl ant .
3. 1 Ai r I nt ake Fi l t er s. Fi l t er s pr event t he admi ssi on of at mospher i c dust t o
t he ai r compr essor . Ref er t o chapt er 4, sect i on 1 f or det ai l s.
3. 2 Si l encer s. Si l encer s r educe obj ect i onabl e compr essor suct i on noi se.
Ref er t o chapt er 4, sect i on 2.
3. 3 I nt er cool er s and Af t er cool er s. I nt er cool er s ar e used bet ween consecut i ve
st ages of mul t i st age compr essor s t o r emove t he heat of compr essi on.
Af t er cool er s ar e i nst al l ed on t he compr essor di schar ge l i nes t o r emove t he
heat of compr essi on af t er compr essi on i s compl et ed. Bot h ar e ef f ect i ve i n
1- 1
FI GURE l - l . Mai n Components of an Ai r Compressor Pl ant
1- 2
TABLE l - l . Maxi mumPr essur es and Capaci t i es of Ai r Compr essor s
Compr essor Maxi mumPr essur e Maxi mumCapaci t y
Type ( psi g) ( cf m)
Reci pr ocat i ng 100, 000 26, 000
Rot ar y sl i di ng vane 400 6, 000
Rot ar y t wi n- l obe 20 32, 800
Rot ar y l i qui d pi st on 100 16, 000
Cent r i f ugal 5, 500 650, 000
Axi al 500 1, 000, 000
r emovi ng moi st ur e and oi l f r om t he compr essed ai r . Ref er t o chapt er 4,
sect i on 3.
3. 4 Separ at or s. Separ at or s r emove and col l ect ent r ai ned wat er and oi l
pr eci pi t at ed f r om t he ai r . Ref er t o chapt er 4, sect i on 4.
3. 5 Tr aps. Tr aps dr ai n condensed moi st ur e and oi l f r om separ at or s,
i nt er cool er s, af t er cool er s, r ecei ver s, and di st r i but i on pi pi ng. Ref er t o
chapt er 4, sect i on 5.
3. 6 Ai r Recei ver s. Ai r r ecei ver s ar e t anks wher ei n compr essed ai r i s
di schar ged and st or ed. They hel p t o r educe pul sat i ons i n t he di schar ge l i ne
and pr ovi de st or age capaci t y t o meet peak demands exceedi ng t he capaci t y of
t he compr essor . Ref er t o chapt er 4, sect i on 6.
3. 7 Ai r Dr yer s. Ai r dr yer s r emove moi st ur e t hat mi ght condense i n ai r l i nes,
ai r t ool s, or pneumat i c i nst r ument s. Ref er t o chapt er 4, sect i on 7.
3. 8 Saf et y Val ves. Saf et y val ves ar e used i n a compr essed ai r or gas
syst em. They must open r api dl y and f ul l y so t hat excessi ve pr essur e bui l dup
can be r el i eved i mmedi at el y t o pr event damage or dest r uct i on of t he syst em
component s. Al t hough t he t er ms saf et y val ve and r el i ef val ve ar e of t en used
i nterchangeabl y, thi s i s techni cal l y i ncorrect. A r el i ef val ve i s used wi t h
l i qui d syst ems. Si nce l i qui ds ar e vi r t ual l y i ncompr essi bl e, a r el i ef val ve i s
desi gned t o open gr adual l y as t he vent i ng of a smal l amount of l i qui d i s of t en
suf f i ci ent t o r el i eve excessi ve pr essur e t hr oughout t he syst em. Ther e i s one
cl ass of val ve known as a saf et y- r el i ef val ve t hat can be used as ei t her t ype
dependi ng upon i nt er nal adj ust ment s. Saf et y val ves ar e f ound i n i nt er st ages,
ai r r ecei ver s, and bet ween a posi t i ve di spl acement compr essor and any shut of f
val ve.
4 CONTROLS. Cont r ol syst ems f or ai r compr essor s var y f r om t he r el at i vel y
si mpl e t o t he ext r emel y sophi st i cat ed. The si mpl er cont r ol syst ems, t hr ough
t he use of sensor s, moni t or t he per f or mance of t he equi pment and, t hr ough t he
l - 3
use of l i ghts and/ or audi bl e si gnal s, al ert an operator that some vari abl e i s
outsi de the normal operati ng range. Most systems automati cal l y i ni ti ate a
shutdown procedure under certai n condi ti ons to prevent equi pment damage. Wi th
i ncreasi ng use of remote, unattended compressor i nstal l ati ons, the demand f or
the hi ghest degree of protecti on and rel i abi l i ty has brought about many
advancements and l essened the need f or operator i nvol vement. Many control
systems provi de a compl etel y automati c sequence f or starti ng, operati ng, and
shutdown of compressors. The more advanced control systems are abl e to
opti mi ze equi pment ef f i ci ency by control l i ng one or more vari abl es to obtai n a
speci f i ed l evel of perf ormance.
5 COOLI NG WATER TREATMENT. Cool i ng water systems are used i n compressed ai r
pl ants to remove heat f romengi nes, ai r compressors, ref ri gerati on condensers,
i ntercool ers, and af tercool ers. These cool i ng systems are cl assi f i ed as
ei ther once- through or reci rcul ati ng. Once- through systems of ten requi re
nothi ng more than chl ori nati on to prevent bi ol ogi cal f oul i ng of heat
exchangers. Treatment i s more cri ti cal i n open reci rcul ati ng systems because
of sol i ds bui l dup due to evaporati on. As hardness and other sol i ds i ncrease,
probabi l i ty of mi neral scal e f ormati on i n heat exchangers i ncreases. To
combat scal e damage, chemi cal addi ti ves are used to keep scal e- f ormi ng sal ts
i n sol uti on. Di ssol ved oxygen and carbon di oxi de are pri me corrosi on
devel opers. Corrosi on control i s provi ded by addi ti on of i nhi bi tors. Sl i me
accumul ati on and f oul i ng may be prevented by the addi ti on of chl ori ne or other
bi oci des. Sol i ds concentrati on i s control l ed by bl owdown. More detai l ed
i nf ormati on on cool i ng water treatment i s contai ned i n the proposed
publ i cati on, NAVFAC MO- 225, I ndustri al Water Treatment.
l - 4
Sect i on 2. OPERATI ON AND MAI NTENANCE RESPONSI BI LI TI ES
1 OPERATI ON. Oper at i on i ncl udes st ar t up, nor mal oper at i on, emer gency
oper at i on, and shut down of pl ant equi pment . Good oper at i on i s saf e, r el i abl e,
and economi cal . Oper at or s and oper at or super vi sor s ar e r esponsi bl e f or saf e
and ef f i ci ent oper at i on of equi pment . Fol l ow t hese basi c r ul es of good
oper at i on.
Al l oper at or s shoul d be t hor oughl y f ami l i ar wi t h t he equi pment and
syst ems t hey oper at e. Car ef ul l y st udy dr awi ngs, di agr ams, i nst r uct i on
manual s, speci al oper at i on pr ocedur es, and emer gency pr ocedur es. Know
t he l ocat i on, met hod of oper at i on, and f unct i on of al l val ves,
swi t ches, el ect r i cal cont r ol s, and ot her cont r ol devi ces.
Per f or m wor k assi gnment s i n a saf e manner i n accor dance wi t h appr oved
oper at i ng pr ocedur es. Use avai l abl e pr ot ect i ve saf et y cl ot hi ng and
equi pment .
Oper at e equi pment and syst ems economi cal l y, saf el y, and r el i abl y.
Teamwor k and cooper at i on ar e essent i al .
Be al er t and concent r at e on your wor k. Er r or s and f or get f ul ness can
cause ser i ous per sonnel i nj ur i es and cost l y damage t o equi pment .
2 DI SASTER CONTROL. Di sast er cont r ol i ncl udes t he pr event i on, mi ni mi zat i on,
and cor r ect i on of oper at i onal and emer gency casual t i es t o pl ant f aci l i t i es and
i nst al l at i ons. Sound desi gn, car ef ul i nspect i on, and ef f ect i ve or gani zat i on
and t r ai ni ng of pl ant per sonnel ar e par t of a di sast er cont r ol pr ogr am. Al l
pl ant per sonnel ar e r esponsi bl e f or di sast er cont r ol as f ol l ows:
( a) The r esponsi bi l i t i es of t he oper at or s ar e:
Oper at i ng t he pl ant equi pment i n a saf e and r el i abl e manner
Handl i ng emer genci es and casual t i es ef f ect i vel y usi ng appr oved
pr ocedur es
Repor t i ng i mmedi at el y t o t hei r super vi sor s any equi pment def ect s
or oper at i onal def i ci enci es
( b) The r esponsi bi l i t i es of t he mai nt enance per sonnel ar e:
Mai nt ai ni ng t he equi pment i n good condi t i on at al l t i mes
Maki ng qui ck ef f ect i ve r epai r s when equi pment br eakdowns occur
( c) The r esponsi bi l i t i es of t he super vi sor y and engi neer i ng per sonnel
ar e:
Sel ect i on of compet ent per sonnel
Pr epar at i on and super vi si on of adequat e per sonnel t r ai ni ng
pr ogr ams
l - 5
Pr epar at i on and super vi si on of an adequat e pl ant mai nt enance,
housekeepi ng, and i nspect i on pr ogr am
Compet ent desi gn and i nst al l at i on of al l pl ant equi pment
Pr epar at i on and super vi si on of nor mal oper at i ng pr ocedur es t hat
ar e saf e, r el i abl e, and economi cal
Pr epar at i on and super vi si on of emer gency and casual t y pr ocedur es
Pr epar at i on and pr ocur ement of t r ai ni ng ai ds, syst em di agr ams,
and manuf act ur er s' manual s f or t he t r ai ni ng and gui dance of
oper at i ng and mai nt enance per sonnel
Pr epar at i on and super vi si on of a per i odi c t est and i nspect i on
pr ogr amf or al l pl ant saf et y devi ces, f i r e f i ght i ng equi pment ,
and ot her emer gency equi pment
3 OPERATOR MAI NTENANCE. Oper at or mai nt enance i s t he necessar y r out i ne,
r ecur r i ng mai nt enance wor k per f or med by t he oper at or s t o keep t he equi pment
oper at i ng at i t s desi gned capaci t y and ef f i ci ency.
3. 1 Responsi bi l i t i es. The oper at or i s an i mpor t ant member of t he mai nt enance
t eam. A wel l - i nf or med and r esponsi bl e oper at or per f or ms t he f ol l owi ng dut i es:
Keeps equi pment i n ser vi ce f or maxi mum per i ods
Det ect s any f l aws so t hat equi pment i s r emoved f r om ser vi ce i n t i me t o
pr event ser i ous damage
Per f or ms mi nor r epai r s on equi pment r emoved f r om ser vi ce t o mi ni mi ze
down t i me
3. 2 Dut i es. Ever yone i n t he oper at i ng chai n shoul d be awar e of t he f ol l owi ng
condi t i ons.
( a) Cl eanl i ness. Di r t i s t he pr i nci pal cause of equi pment f ai l ur e and
shoul d be r emoved i mmedi at el y by t he oper at or .
( b) Lubr i cat i on. Any t wo sur f aces br ought t oget her devel op f r i ct i on.
When not pr oper l y l ubr i cat ed, t hese sur f aces wear down, change cl ear ances, and
cause equi pment br eakdowns.
( c) Temper at ur e Change. Any unusual t emper at ur e change whi ch t he
oper at or cannot cor r ect shoul d be r epor t ed i mmedi at el y t o t he pl ant
super vi sor . When t he t emper at ur e of a pi ece of equi pment r i ses r api dl y,
i mmedi at el y shut i t down.
( d) Vi br at i on. Vi br at i on i s a maj or sour ce of equi pment f ai l ur e. ,
Equi pment not pr oper l y secur ed wi l l vi br at e. Thi s vi br at i on causes l ooseni ng
of component s and possi bl e mi sal i gnment of par t s, l eadi ng t o mor e ser i ous
pr obl ems. The oper at or , i n maki ng r ounds, shoul d check t he bear i ngs,
l - 6
compr essor housi ng, and mot or casi ng f or any unusual sound, vi br at i on, or
mot i on. Take i mmedi at e act i on t o cor r ect any pr obl ems.
4 PREVENTI VE MAI NTENANCE. Pr event i ve mai nt enance ( PM) i s a syst emof r out i ne
i nspect i ons of equi pment r ecor ded f or f ut ur e r ef er ence on i nspect i on r ecor ds.
I t s pur pose i s t o ant i ci pat e and pr event possi bl e equi pment f ai l ur es by maki ng
per i odi c i nspect i ons and mi nor r epai r s i n advance of maj or oper at i ng
di f f i cul t i es.
4. 1 Responsi bi l i t i es. PM i s t he r esponsi bi l i t y of t he oper at or s and
speci f i ed mai nt enance cr ews. The oper at or i s expect ed t o do as much
mai nt enance as hi s t echni cal abi l i t i es, t ool s, and t i me al l ows. Speci f i cal l y
assi gned mai nt enance cr ews wor k on equi pment r equi r i ng no oper at or , or wher e
t he wor k t o be done i s beyond t he scope of t he oper at or .
4. 2 Schedul i ng. Schedul i ng PM i s t he r esponsi bi l i t y of t he pl ant
super vi sor . Mai nt ai n a r ecor d car d f or each maj or pi ece of equi pment wi t h
ent r i es of t he PM schedul e, i nspect i ons, and oper at i on. See NAVFAC MO- 322,
I nspect i on of Shor e Faci l i t i es, f or mor e det ai l ed i nf or mat i on.
5 BREAKDOWN MAI NTENANCE. Br eakdown mai nt enance i s t he emer gency r epai r of
i noper abl e equi pment per f or med by oper at or s or mai nt enance cr ews. The pl ant
and mai nt enance super vi sor s ar e r esponsi bl e f or emer gency r epai r s. The
Ut i l i t y and Mai nt enance Shops shoul d devel op a coor di nat ed pl an t o ef f i ci ent l y
handl e emer gency br eakdowns.
5. 1 Tr oubl eshoot i ng. Tr oubl eshoot i ng i s a means of l ocat i ng t he sour ce of
t r oubl e when pr obl ems occur so t hat r epai r s can be made. Compr essor
manuf act ur er s wi l l nor mal l y pr ovi de t r oubl eshoot i ng char t s f or t hei r
equi pment . These char t s can be ver y hel pf ul i n di agnosi ng pr obl ems. Tabl e
l - 2 i s an exampl e of a t ypi cal , but par t i al , t r oubl eshoot i ng char t . Thi s
t r oubl eshoot i ng t abl e i s not meant t o be a compl et e sour ce of i nf or mat i on. I t
i s a composi t e l i st devel oped f r om t he manuf act ur er s of var i ous t ypes of
compr essor s and compr essor syst em component s. The l i st cont ai ns some commonl y
f ound pr obl ems, possi bl e causes, and r emedi es.
6 COMPRESSED AI R SYSTEM LEAKS. A mal f unct i on whi ch may af f ect t he demand
upon a compr essed ai r pl ant i s a l oss of ai r wi t hi n t he di st r i but i on syst em.
A di scussi on of t he eval uat i on of l osses i n compr essed ai r syst ems i s
pr esent ed i n appendi x 8.
l - 7
TABLE l - 2. Troubl eshooti ng Chart
Probl em Possi bl e Cause Remedy
Compressor uni t
wi l l not start
No power to motor. Turn on power.
Unl oaders not operati ng. Repai r unl oaders.
Obstructi on to rotati on.
Repai r or readj ust
cont rol s.
Remove obstructi on.
Mot or Di scharge pressure above
overheati ng r at i ng.
Unl oader setti ng i ncorrect.
I nl et f i l ter cl ogged.
Readj ust control .
Readj ust unl oader.
Cl ean or repl ace f i l ter.
Overheati ng of Di scharge pressure above
compressor rat i ng.
par t s
I ntake f i l ter cl ogged.
Worn or broken val ves.
Leaki ng gaskets.
Lower di scharge pressure.
Cl ean.
Repl ace.
Repl ace.
Unl oader or control def ecti ve. Repl ace.
Unl oader setti ng wrong.
Compressor components worn or
broken.
Cyl i nder head, i ntercool er
di rty.
I nsuf f i ci ent cool i ng water.
V- bel t or coupl i ng mi sal i gn-
ment .
Beari ngs too ti ght.
Oi l l evel too hi gh.
l - 8
Correct.
Repl ace.
Cl ean.
I ncrease quanti ty of
cool i ng water.
Real i gn components.
Adj ust beari ngs.
Correct oi l l evel .
TABLE l - 2. Troubl eshooti ng Chart ( Conti nued)
Oveheati ng of Lubri cati on i nadequate. Correct oi l l evel .
compr essor
par t s
Correct oi l pressure.
( conti nued)
Ensure correct oi l
vi scosi ty i s bei ng used.
Ambi ent temperature too hi gh. Lower ambi ent temperature.
I ncrease venti l ati on.
Val ves di rty. Cl ean val ves.
Bel ts too ti ght. Readj ust bel t tensi on.
Packi ngs too ti ght. Readj ust packi ngs.
Del i very of ai r Systeml eaks excessi ve. Stop l eaks.
l ess than
rated capaci ty I ntake f i l ter cl ogged. Cl ean or repl ace f i l ter as
appl i cabl e.
Val ves worn or broken. Repl ace worn or broken
val ves.
Bel ts sl i ppi ng. Ti ghten.
Speed l ower than rati ng. I ncrease speed.
Compressor components worn or Repl ace.
broken.
Control devi ce i noperati ve or Repai r or adj ust control
mal adj usted. devi ce.
Water quanti ty i nsuf f i ci ent. I ncrease water quanti ty.
I nl et temperature too hi gh. Check water quanti ty and
temperature at i nter-
cool er.
Excessi ve Mounti ng bol ts l oose.
vi brati on of
compressor
Ti ghten mounti ng bol ts.
l - 9
TABLE l - 2. Troubl eshooti ng Chart ( Conti nued)
Excessi ve
vi brati on of
compressor
( conti nued)
Outl et water
temperature
above normal
Mi sal i gnment of bel t pul l eys
or dri ve coupl i ng.
Beari ngs out of adj ustment or
excessi vel y worn.
Real i gn as necessary.
Adj ust or repl ace
beari ngs.
Cyl i nder, head, or i ntercool er Cl ean compressor system
di rty. parts.
Water quanti ty i nsuf f i ci ent. I ncrease cool i ng water
suppl y.
Compressor speed too hi gh. Sl ow down compressor.
Compressor
noi sy or
knocks
Di scharge pressure above
rati ng.
Bel ts sl i ppi ng.
V- bel ts or coupl i ng mi sal i gned.
Pul l ey or f l ywheel l oose.
Dri ve motor or compressor
mounti ng bol ts l oose.
Lubri cati on i nadequate.
I ntercool er vi brati ng.
Lower di scharge pressure.
Readj ust bel ts.
Real i gn.
Ti ghten pul l ey or f l ywheel
mount i ngs.
Ti ghten mounti ng bol ts.
I ncrease oi l l evel or
pressure.
Use correct oi l vi scosi ty.
Check f or l oose mounti ng
har dwar e.
Operati ng cycl e
l asts too l ong
Di scharge pressure above Readj ust control .
rat i ng.
Worn or broken i nternal Repl ace worn or broken,
compressor parts. par t s.
Unl oader or control devi ce Repl ace def ecti ve devi ce
def ecti ve.
1- 10
TABLE l - 2. Tr oubl eshoot i ng Char t ( Cont i nued)
Pr obl em Possi bl e Cause Remedy
Ai r r ecei ver Unl oader or cont r ol def ect i ve. Repai r or r epl ace
pr essur e above def ect i ve par t s.
nor mal
Unl oader set t i ng wr ong. Cor r ect unl oader set t i ng.
Leaks i n cont r ol ai r pi pi ng. St op l eaks.
Cont r ol ai r l i ne cl ogged. Uncl og cont r ol ai r l i nes.
I nt er cool er
pr essur e above
nor mal
Val ves wor n or br oken. Repl ace val ves.
Val ves not seat ed or Reseat or r el ocat e val ves.
i ncor r ect l y l ocat ed.
Unl oader set t i ng wr ong. Cor r ect unl oader set t i ng.
I nt er cool er passages cl ogged. Cl ean i nt er cool er .
I nsuf f i ci ent wat er . I ncr ease wat er suppl y.
I nt er cool er Syst em demand exceeds r at i ng. Upgr ade compr essor .
pr essur e bel ow
nor mal Syst em l eakage excessi ve. St op l eakage.
I nt ake f i l t er cl ogged.
Val ves wor n or br oken.
Unl oader set t i ng wr ong.
Cl ean or r epl ace ai r
f i l t er as appl i cabl e.
Repl ace wor n or br oken
val ves.
Cor r ect unl oader set t i ng.
Ai r i n r ecei ver Moi st ur e separ at or not
t oo moi st dr ai ni ng.
Ai r cool er s i nef f ect i ve.
Uncl og or r epai r separ at or
dr ai n.
Check t emper at ur e of
cool er at di schar ge por t .
I nadequat e cool i ng wat er f l ow Check cool i ng wat er f l ow
r at e. pr essur e.
1- 11
TABLE l - 2. Tr oubl eshoot i ng Char t ( Cont i nued)
Pr obl em Possi bl e Cause Remedy
Oi l i n ai r Cl ogged ai r f i l t er . Cl ean or r epl ace ai r
r ecei ver f i l t er el ement .
Br oken pi st on and/ or r i ngs. Repl ace br oken par t s.
Oi l l evel t oo hi gh. Cor r ect oi l l evel .
Oi l vi scosi t y i ncor r ect . Change l ubr i cant t o pr oper
vi scosi t y.
Oi l wr ong t ype. Change l ubr i cant t o pr oper
vi scosi t y.
Unl oaded r unni ng t i me t oo Use aut o st ar t / st op
l ong. cont r ol .
Sur gi ng of Oper at i ng at l ess t han I ncr ease f l ow of
di st r i but i on desi gned mi ni mum f l ow. compr essor .
ai r
I nst al l sur ge cont r ol
val ve i n di schar ge l i ne.
Cavi t at i on of Feedwat er l evel t oo l ow. I ncr ease f eedwat er l evel
wat er i n i n r eser voi r .
cool i ng suppl y
Ai r l eaks i nt o suct i on pi pi ng. St op l eaks.
1- 12
CHAPTER 2. POSI TI VE DI SPLACEMENT COMPRESSORS
Sect i on 1. RECI PROCATI NG COMPRESSORS
1 DESCRI PTI ON. Reci pr ocat i ng ai r compr essor s ar e manuf act ur ed i n a var i et y
of shapes, si zes, and capaci t i es. Si ngl e- st age machi nes dr aw ai r f r om t he
at mospher e and di schar ge i t i nt o t he r ecei ver or st or age t ank. Two- st age
compr essor s ( f i gur e 2- l ) br i ng t he ai r up t o i nt er medi at e pr essur e i n one
cyl i nder and t o f i nal pr essur e i n a second cyl i nder . Wher e t wo or mor e st ages
ar e empl oyed, t he uni t i s def i ned as a mul t i st age ai r compr essor . Mul t i st age
compr essor s pr oduce hi gher di schar ge pr essur es. St at i onar y ai r compr essor s
ar e usual l y wat er - cool ed, wi t h t he except i on of smal l uni t s t hat ar e
ai r - cool ed. Por t abl e uni t s ar e al so usual l y ai r - cool ed. Ai r - cool ed
compr essor s ut i l i ze f i nned cyl i nder s t o i ncr ease t he r adi at i ng ar ea.
Compr essor dr i ves i ncl ude el ect r i c mot or s, st eam r eci pr ocat i ng engi nes, st eam
t ur bi nes, or i nt er nal combust i on engi nes. Dr i ves may be di r ect connect ed,
connect ed t hr ough r educt i on gear s, or bel t connect ed. Oper at i ng and
mai nt enance i nst r uct i ons f or el ect r i c mot or s, i nt er nal combust i on engi nes,
st eamengi nes, and st eamt ur bi ne dr i ves ar e cont ai ned i n NAVFAC MO- 205,
Cent r al Heat i ng and St eam El ect r i c Gener at i ng Pl ant s.
1. 1 Hi gh- Pr essur e Syst ems. Al t hough hi gh- pr essur e ai r compr essor s can
compr ess ai r t o pr essur es of appr oxi mat el y 100, 000 pounds- f or ce per squar e
i nch gauge ( psi g) , i n t hi s manual di scussi on of hi gh- pr essur e syst ems i s
l i mi t ed t o t he 400- t o 6, 000- psi g r ange. Mul t i st age r eci pr ocat i ng compr essor s
ar e commonl y used f or t hi s ser vi ce. Dependi ng upon t he di schar ge pr essur e,
t he compr essor wi l l have f r omt wo t o f i ve st ages of compr essi on, i nt er cool er s
bet ween st ages, and an af t er cool er . Smal l er compr essor s may be ai r - cool ed or
a combi nat i on of ai r - and wat er - cool ed whi l e l ar ger compr essor s ar e nor mal l y
wat er - cool ed. Power f or l ar ger compr essor s i s usual l y pr ovi ded by el ect r i c
mot or s, al t hough i n some i nst al l at i ons t he compr essor s may be power ed by
di esel or st eam engi nes.
dr i ves may be pr ovi ded.
I n smal l er compr essor appl i cat i ons, gasol i ne engi ne
Power i s nor mal l y t r ansmi t t ed f r om t he power sour ce
t o t he compr essor t hr ough a di r ect dr i ve or V- bel t s. St eam engi nes ar e
usual l y i nt egr al wi t h t he compr essor .
ai r ar e:
Typi cal appl i cat i ons f or hi gh- pr essur e
Test i ng and oper at i ng cat apul t s
Test i ng and l aunchi ng mi ssi l es
Tor pedo wor kshops
Wi nd t unnel s
Ammuni t i on depot s
2 SAFETY PRECAUTI ONS.
2. 1 Expl osi ve Hazar ds. Al t hough compr essed ai r at l ow or medi umpr essur es i s
danger ous i f car el essl y handl ed, t he danger s associ at ed wi t h hi gh- pr essur e
syst ems ar e of much gr eat er consequence. Ser i ous expl osi ons, compl et e
dest r uct i on of f aci l i t i es, and heavy l oss of l i f e have been at t r i but ed t o
unsaf e pr act i ces i nvol vi ng hi gh- pr essur e compr essed ai r syst ems.
A ser i ous
2- l
2
-
2
pot ent i al danger exi st s i n t hese syst ems whenever hi gh- pr essur e ai r i s
suddenl y admi t t ed i nt o pocket s, or dead ends, t hat ar e at or near at mospher i c
pr essur e. The ai r t emper at ur e i n t he conf i ned space i s r ai sed t o t he i gni t i on
poi nt of any f l ammabl e mat er i al t hat may be pr esent . Thi s aut oi gni t i on or
di esel act i on has been i dent i f i ed as t he cause of sever al maj or di sast er s
associ at ed wi t h hi gh- pr essur e ai r syst ems. Such an expl osi on may set up shock
waves t hat can t r avel t hr oughout t he compr essed ai r syst emand possi bl y cause
expl osi ons at r emot e poi nt s. Under t hese condi t i ons, even a smal l quant i t y of
oi l r esi due, a smear of gr ease, or a smal l cot t on t hr ead may be suf f i ci ent t o
cause an expl osi on. Because of t he ser i ous nat ur e of t hese pr obl ems, i t i s
ext r emel y i mpor t ant t hat compet ent per sonnel , exper i enced i n hi gh- pr essur e
syst ems, be empl oyed f or mai nt ai ni ng and oper at i ng such equi pment .
2. 2 Pr event i ve Measur es. As a saf eguar d agai nst expl osi ons i n hi gh- pr essur e
compr essed ai r syst ems, a number of pr ecaut i ons shoul d be t aken.
( a) Use of Sl ow- Openi ng Val ves. These val ves ar e used i n pocket ed
spaces such as l i nes t o gauges and r egul at or s t o pr event a sudden pr essur e
r i se.
( b) El i mi nat i on of Fl ame Ar r est or s. Fl ame ar r est or s, somet i mes used t o
pr event t he spr ead of f l ame i n pi pel i nes, SHOULD NOT be i nst al l ed i n
hi gh- pr essur e ai r syst ems as t hey may cr eat e addi t i onal hazar ds.
( c) Pi pe Col or i ng. Hi gh- pr essur e ai r l i nes ar e i dent i f i ed wi t h a
pai nt ed l i ght gr ay band and adj oi ni ng l i ght gr een ar r owhead poi nt i ng i n t he
nor mal f l ow di r ect i on. These mar ki ngs ar e pl aced on hi gh- pr essur e ai r l i nes
at each poi nt wher e pi pi ng ent er s or emer ges f r oma wal l and i mmedi at el y
adj acent t o al l val ves, r egul at or s, check val ves, st r ai ner s, and ot her
component s.
( d) Locat i on of Equi pment . Hi gh- pr essur e ai r st or age and dr yer
cyl i nder s ar e i sol at ed f r om ot her f aci l i t i es as a pr ecaut i on agai nst damage
t hat coul d r esul t f r om r upt ur e of t he cyl i nder s.
( e) Syst em Test s. Bef or e put t i ng a hi gh- pr essur e syst em i nt o oper at i on,
t he r equi r ed t est i ng of NAVFAC DM- 3. 5, Compr essed Ai r and VacuumSyst ems, must
be accompl i shed by compet ent per sonnel wi t h an engi neer r esponsi bl e f or saf et y.
3 STARTUP.
3. 1 Pr est ar t I nspect i on. Car ef ul l y i nspect t he compr essor i nst al l at i on t o
ensur e t he f ol l owi ng pr est ar t r equi r ement s ar e f ul f i l l ed.
( a) Ver i f y al l i nst al l at i on and r epai r wor k has been compl et ed.
( b) Ensur e syst emhas been cl eaned and t est ed f or l eaks.
( c) Ensur e i nt er st age and di schar ge saf et y val ves ar e oper at i ng pr oper l y.
( d) Ensur e compr essor and dr i ve ar e l ubr i cat ed i n accor dance wi t h t he
manuf act ur er s' i nst r uct i ons. On uni t s f i t t ed wi t h a f or ced mechani cal
l ubr i cat or , pump or cr ank by hand t o see t hat t he oi l i s get t i ng t o al l par t s
r equi r i ng l ubr i cat i on.
2- 3
3. 2 St ar t up Pr ocedur e f or Mot or - Dr i ven Compr essor s. Pr oceed as f ol l ows:
( a) Open al l shut of f val ves bet ween compr essor and r ecei ver .
( b) Make sur e compr essor i s unl oaded. Consul t t he manuf act ur er ' s
i nst r uct i ons f or pr ocedur e.
( c) Tur n on cool i ng wat er , i f pr ovi ded. Thor oughl y vent cyl i nder
j acket s and cool er s i f vent s ar e pr ovi ded.
( d) Tur n compr essor over by hand t o see t hat al l par t s ar e f r ee.
( e) St ar t compr essor mot or . When up t o speed, appl y l oad i f machi ne i s
r unni ng smoot hl y.
3. 3 St ar t up Pr ocedur e f or St eam- Dr i ven Reci pr ocat i ng Compr essor s. Pr oceed as
f ol l ows:
( a) Open al l shut of f val ves bet ween compr essor and r ecei ver .
( b) Tur n on cool i ng wat er ser vi ces ensur i ng cyl i nder j acket s and cool er s
ar e t hor oughl y vent ed.
( c) Make sur e compr essor i s unl oaded by openi ng t he separ at or dr ai n
val ve or t he compr essor cyl i nder i ndi cat or cocks.
( d) Open val ve chest , exhaust , and st eam cyl i nder dr ai n val ves.
( e) Open t he dr ai n val ve on t he st eamadmi ssi on l i ne above t he t hr ot t l e
val ve. When al l condensat i on has dr ai ned f r om t he l i ne and t he pi pe i s hot ,
cl ose t he dr ai n val ve unt i l i t i s open appr oxi mat el y one- f our t h of a t ur n.
( f ) Cr ack open t he t hr ot t l e val ve and al l ow t he st eamcyl i nder t o war m
up.
( g) Open st eam exhaust val ve.
( h) Sl owl y open t he t hr ot t l e val ve and al l ow t he gover nor t o t ake over
cont r ol .
( i ) Cl ose t he dr ai n val ves when st eamdi schar ge i s f r ee of condensat e.
( j ) When t he compr essor i s up t o speed, sl owl y bui l d up t he l oad.
3. 4 St ar t up Pr ocedur e f or New or Over haul ed Compr essor s. When st ar t i ng a new
compr essor , or one t hat has been over haul ed, al l ow t he compr essor t o r un
unl oaded f or 1 or 2 hour s t o gi ve t he r unni ng sur f aces a pol i shed f i ni sh.
Per i odi cal l y check f or over heat i ng. Bui l d up l oad gr adual l y over a per i od of
sever al hour s. Af t er a f ew days of oper at i on, shut down compr essor and
r echeck al l cyl i nder head, val ve cover , cyl i nder f l ange, shaf t cover , and
f oundat i on bol t s f or t i ght ness.
2- 4
4 NORMAL OPERATI ON. Whi l e t he syst em i s oper at i ng, per f or m t he f ol l owi ng
t asks.
( a) Wat ch f or i r r egul ar compr essor per f or mance; excessi ve vi br at i on; and
over heat i ng of bear i ngs, mot or s, and packi ng.
( b) Mai nt ai n pr oper l ubr i cat i ng oi l l evel s.
( c) Dr ai n i nt er cool er and af t er cool er separ at or s as necessar y.
( d) I f aut omat i c dr ai ner s ar e pr ovi ded, check t hei r oper at i on.
( e) Check t emper at ur es and pr essur es of cool i ng wat er , compr essed ai r ,
and l ubr i cat i ng oi l r egul ar l y.
5 SHUTDOWN. Pr oceed as f ol l ows:
( a) Unl oad t he compr essor bef or e st oppi ng t he dr i ve.
( b) Dr ai n separ at or s, st eam cyl i nder s, and t ur bi nes.
( c) Shut of f cool i ng wat er suppl y i f an aut omat i c shut of f val ve i s not
pr ovi ded.
( d) I f t he compr essor mi ght be subj ect ed t o f r eezi ng t emper at ur es whi l e
shut down, t hor oughl y dr ai n cyl i nder j acket s, cool er s, and dr ai n t r aps.
5. 1 Ext ended Shut down. Any compr essor t aken out of ser vi ce f or an ext ended
per i od wi l l det er i or at e r api dl y f r om r ust and cor r osi on i f not pr oper l y
pr ot ect ed. The manuf act ur er shoul d be cont act ed t o obt ai n t he r ecommended
pr ocedur e f or pr ot ect i ng t he equi pment . Take t he f ol l owi ng pr ecaut i ons i n
addi t i on t o t hose st at ed i n par agr aph 5( a) t hr ough 5( d) .
( a) Dr ai n and r ef i l l t he cr ankcase wi t h a pr eser vat i ve oi l .
( b) Oper at e t he machi ne wi t hout pr essur e f or no l ess t han 15 mi nut es.
Thi s al l ows t hor ough di st r i but i on of t he oi l and el i mi nat i on of any cr ankcase
condensat e.
( c) Whi l e t he machi ne i s r unni ng, spr ay a f og of pr eser vat i ve oi l i nt o
t he compr essor i nt ake.
( d) Remove pi st on r od packi ng and oi l wi per r i ngs f r om t he r od or
cor r osi on of t he pi st on r od may r esul t . Coat t he pi st on r od and oi l wi per
r i ngs wi t h gr ease and wr ap t hem i n wat er pr oof paper .
( e) Tape or pl ug al l openi ngs t o keep out moi st ur e.
( f ) Rel i eve V- bel t s of t ensi on.
( g) Dr ai n t he r ecei ver and af t er cool er .
( h) Dr ai n t he af t er cool er cool i ng wat er , i f used.
2- 5
( i ) Fol l ow t he pr i me mover manuf act ur er ' s i nst r uct i ons f or t he met hod of
pr ot ect i on dur i ng ext ended shut down.
6 OPERATI ONAL PREVENTI VE MAI NTENANCE. Oper at i onal pr event i ve mai nt enance
i ncl udes t he f ol l owi ng t asks.
( a) Keep dai l y oper at i ng l ogs t hat r ecor d pr essur es and t emper at ur es of
ai r and wat er i n t he compr essor , i nt er cool er s and af t er cool er s, and of
compr essor l ubr i cat i ng oi l . Devi at i ons f r omnor mal val ues i ndi cat e t he
cor r ect i ve act i on t hat must be t aken t o r et ur n t he syst emt o nor mal and t o
pr event damage t o t he equi pment f r om i nsuf f i ci ent l ubr i cat i on or i nadequat e
cool i ng.
( b) The oper at i ng l og al so hel ps i n det ect i ng val ve t r oubl es. On
t wo- st age compr essor s, l ow i nt er cool er pr essur e i ndi cat es mal f unct i oni ng of
t he l ow- pr essur e cyl i nder val ves, and hi gh i nt er cool er pr essur e may be due t o
i mpr oper oper at i on of t he hi gh- pr essur e cyl i nder val ves. Locat e def ect i ve
val ve by f eel i ng t he val ve cover pl at es and det er mi ni ng whi ch i s t he hot t est .
Leaki ng hi gh- pr essur e suct i on val ves cause t he i nt er cool er pr essur e t o
f l uct uat e above nor mal val ues. Leaki ng hi gh- pr essur e di schar ge val ves cause
t he i nt er cool er pr essur e t o bui l d up st eadi l y unt i l t he saf et y val ve r el eases
i t . Low- pr essur e di schar ge val ves t hat l eak cause i nt er cool er pr essur e t o
f l uct uat e bel ow nor mal i nt er cool er pr essur e.
( c) Keep compr essor cl ean at al l t i mes. Wi pe t he machi ne dai l y wi t h a
cl ot h. Di r t on t he machi ne wi l l event ual l y wor k i t s way i nt o t he l ubr i cat i ng
syst em. On ai r - cool ed compr essor s, di r t accumul at i ons f or m an i nsul at i ng
bl anket causi ng i ncr eased t emper at ur es wi t hi n t he machi ne and excessi ve wear
on movi ng par t s.
( d) Cl ean i nt ake ai r f i l t er r egul ar l y t o pr event at mospher i c dust f r om
ent er i ng t he compr essor cyl i nder s.
( e) Keep pi st on r od packi ng t i ght enough t o pr event ai r l eakage, but do
not over t i ght en. Over t i ght eni ng causes excessi ve packi ng wear and scor i ng of
t he pi st on r od.
7 PREVENTI VE MAI NTENANCE I NSPECTI ON. The f ol l owi ng i nspect i on schedul es ar e
adequat e f or aver age i nst al l at i ons.
7. 1 Dai l y I nspect i on. I nspect t he compr essor dai l y f or t he f ol l owi ng
condi t i ons:
( a) Unusual noi se or vi br at i on
( b) Abnor mal pr essur es or t emper at ur es of compr essed ai r , cool i ng wat er ,
and l ubr i cat i ng oi l
( c) Pr oper unl oader oper at i on
( d) Abnor mal st uf f i ng box t emper at ur es
( e) Abnor mal bear i ng t emper at ur es
2- 6
( f ) Cor r ect l ubr i cat i ng oi l l evel s
7. 2 Quar t er l y I nspect i on. I nspect t he compr essor ever y 3 mont hs f or t he
f ol l owi ng condi t i ons:
( a) Wear and di r t on, and pr oper seat i ng of , compr essor val ves
( b) Oper at i on of al l saf et y val ves
( c) Wear of packi ng and scor i ng of pi st on r ods
( d) Sl udge accumul at i ons i n cr ankcase
( e) Ti ght ness of cyl i nder head bol t s
( f ) Tensi on, wear , and det er i or at i on of bel t s
( g) Wear of connect i ng r ods and cr ossheads
( h) Wear of , and di r t i n, bear i ngs
( i ) Oper at i on of l ubr i cat or s and oi l cups
7. 3 Annual I nspect i on. Repeat t he quar t er l y i nspect i on out l i ned above and
i nspect f or t he f ol l owi ng condi t i ons:
( a) Wear , scor i ng, and cor r osi on of , and di r t i n, cyl i nder s
( b) Leakage, wear , scor i ng, and secur i t y t o t he pi st on rod of pi stons;
head cl ear ances
( c) Damage, wear , and t i ght ness of , and di r t i n, pi st on r i ngs
( d) Wear at packi ng gl ands of pi st on r ods and secur i t y of pi ston rods to
cr osshead and pi st on
( e) Wear and pr oper oper at i on of cr ankcase and cr ankshaf t bear i ngs
( f ) Wear and pr oper oper at i on of cr ossheads, cr osshead gui des, wedges,
and pi ns
( g) Secur i t y t o shaf t of f l ywheel ; wear and di r t on f l ywheel bear i ngs
( h) Al i gnment of compr essor wi t h dr i ve
2- 7
8 MAI NTENANCE.
8. 1 Lubr i cat i on.
Do not gasol i ne, ker osene, or ot her l ow f l ashpoi nt sol vent s. A
ser i ous expl osi on may r esul t .
Est abl i sh a l ubr i cat i on schedul e f or ai r compr essor s. Nor mal oi l l evel s must
be mai nt ai ned at al l t i mes. Use onl y l ubr i cant s r ecommended by t he
manuf act ur er . Fr equency of oi l changes i s dependent upon sever i t y of ser vi ce
and at mospher i c dust and di r t . The ti me f or oi l changes can best be
det er mi ned by t he physi cal condi ti on of the oi l . When changi ng oi l , cl ean the
i nsi de of t he cr ankcase by wi pi ng wi th cl ean, l i nt- f ree rags. I f thi s i s not
possi bl e, use a good gr ade of f l ushi ng oi l to remove any settl ed parti cl es.
8. 2 Packi ng. When r epl aci ng f i brous packi ng, thoroughl y cl ean the stuf f i ng
box of ol d packi ng and gr ease. Cover each pi ece of new packi ng wi t h t he
r ecommended l ubr i cant . Separ at e t he new r i ngs at t he spl i t j oi nt t o pl ace
t hem over t he shaf t . Pl ace one r i ng of packi ng at a t i me i n t he st uf f i ng box
and t amp f i r ml y i n pl ace. St agger t he j oi nt s of each r i ng so t hey wi l l not be
i n l i ne. Af t er t he l ast r i ng i s i n pl ace, assembl e t he gl and and t i ght en t he
nut s evenl y unt i l snug. Af t er a f ew mi nut es, l oosen t he nut s and r et i ght en
t hemf i nger - t i ght .
8. 3 Cl eani ng.
Cyl i nder j acket s of wat er - cool ed compr essor s shoul d be cl eaned annual l y wi t h
wat er . Di r t accumul at i ons i nt er f er e wi t h wat er ci r cul at i on. Cl eani ng can be
accompl i shed usi ng a smal l hose nozzl e t o pl ay wat er i nt o t he j acket s. On
compr essor s f i t t ed wi t h mechani cal l ubr i cat or s, cyl i nder s may be cl eaned wi t h
a nonf l ammabl e cl eani ng f l ui d.
8. 4 Val ves. Repl ace al l def ect i ve val ve par t s as r equi r ed. When a val ve
di sk or pl at e wear s t o l ess t han one- hal f i t s or i gi nal t hi ckness, i t shoul d be
r epl aced. Val ve seat s may be r esur f aced by l appi ng or r egr i ndi ng. On some
val ve desi gns i t i s necessar y t o check t he l i f t af t er r esur f aci ng. I f t he
l i f t i s f ound t o be mor e t han t hat r ecommended by t he manuf act ur er , t he bumper
must be cut down an equal amount . Fai l ur e t o do t hi s r esul t s i n mor e r api d
val ve and spr i ng wear . Car bon deposi t s shoul d be r emoved and t he val ve
assembl y washed i n nonf l ammabl e cl eani ng f l ui d. Bef or e r epl aci ng val ves, make
sur e t he val ve seat and cover pl at e gasket s ar e i n good condi t i on. I f any
def ect s ar e f ound, r epl ace t he gasket s. Make sur e t he val ve i s r et ur ned t o
2- 8
t he same por t f r om whi ch i t was r emoved. Car ef ul l y f ol l ow t he manuf act ur er ' s
i nst r uct i ons f or val ve r emoval and r epl acement .
8. 5 Pi st on Ri ngs. When r epl aci ng wor n pi st on r i ngs, t he new r i ngs must be
t r i ed i n t he cyl i nder f or f i t . I f t he cyl i nder wal l i s badl y scor ed or out of
r ound, r ebor e t he cyl i nder , or i f cyl i nder l i ner s ar e f i t t ed, r epl ace t hem.
I f necessar y t o f i l e f or end cl ear ance, t ake car e t o f i l e t he ends par al l el .
Cl ean t he r i ng gr ooves and r emove any car bon deposi t s bef or e i nst al l i ng t he
new r i ngs. To i nst al l new r i ngs, pl ace sever al met al st r i ps not mor e t han
0. 032- i nch t hi ck bet ween t he pi st on and r i ngs ( f i gur e 2- 2) . Sl i de t he new
r i ngs over t hese st r i ps unt i l t hey ar e cent er ed over t he gr ooves and t hen pul l
out t he st r i ps. Make sur e t he r i ng i s f r ee by r ot at i ng i t i n i t s gr oove.
St agger t he r i ng gaps of succeedi ng r i ngs so t hey ar e not i n l i ne. Use a r i ng
cl ampi ng devi ce when r ei nst al l i ng t he pi st on. I f t hi s i s not avai l abl e, wi r e
t he r i ngs t i ght l y so t hey ent er t he bor e easi l y. Consul t t he manuf act ur er ' s
i nst r uct i ons f or car bon r i ng r epl acement .
8. 5. 1 Pi st on End Cl ear ance. Al ways check pi st on end cl ear ance af t er
r epl aci ng pi st ons or af t er adj ust ment or r epl acement of mai n, cr ankpi n,
wr i st pi n, or cr osshead bear i ngs. Consul t t he manuf act ur er ' s i nst r uct i ons f or
pr oper cl ear ances and met hod of cl ear ance adj ust ment . To measur e pi st on end
cl ear ance, i nser t a l engt h of l / B- i nch di amet er sol der i nt o t he cyl i nder
t hr ough a val ve por t and t ur n t he compr essor over by hand so t hat t he pi st on
moves t o t he end of i t s st r oke. Remove t he compr essed sol der and measur e i t s
t hi ckness t o det er mi ne t he pi st on end cl ear ance.
FI GURE 2- 2. I nst al l i ng Pi st on Ri ngs
2- 9
8. 6 Bear i ngs. Sl eeve t ype mai n bear i ngs ar e adj ust ed by r emovi ng or addi ng
met al shi ms bet ween t he cap and body of t he bear i ng housi ng. The same number
of shi ms shoul d be added or r emoved f r omeach si de of t he bear i ng. Make sur e
caps ar e t i ght l y secur ed so t hey cannot wor k l oose. Do not over t i ght en as
t hi s causes over heat i ng of t he bear i ng. Consul t t he manuf act ur er ' s
i nst r uct i ons f or adj ust ment of t aper ed r ol l er mai n bear i ngs.
8. 6. 1 Hor i zont al Compr essor Bear i ngs. Many hor i zont al compr essor s have wedge
adj ust i ng cr osshead and cr ankpi n bear i ngs ( f i gur e 2- 3) . Adj ust ment i s made by
t i ght eni ng or l ooseni ng t he adj ust i ng scr ews. Do not over t i ght en t he
bear i ngs. A t i ght f i t at t he cr osshead bear i ng causes t he cr osshead t o r ock,
damagi ng t he cr osshead gui des and shoes.
8. 6. 2 Ver t i cal Compr essor Bear i ngs. Ver t i cal compr essor s ar e usual l y f i t t ed
wi t h aut omot i ve t ype cr ankpi n bear i ngs wi t h babbi t t ed i nser t s ( f i gur e 2- 4) .
These bear i ngs ar e not adj ust abl e and must be r epl aced. When r epl aci ng
bear i ng i nser t s or bushi ngs, make sur e al l par t s ar e t hor oughl y cl ean and t hat
t he oi l hol e i s al i gned wi t h t he oi l hol e i n t he connect i ng r od.
8. 7 V- Bel t Dr i ves. Adj ust t ensi on or r epl ace V- bel t s as r equi r ed. When one
or mor e bel t s i n a set r equi r e r epl acement , r epl ace t he ent i r e set wi t h
mat ched bel t s. I f t hi s i s not done, t he new unst r et ched bel t s, bei ng shor t er
t han t he ol d bel t s, wi l l car r y most of t he l oad and wi l l be subj ect ed t o undue
st r ai n. Removed bel t s t hat appear t o be i n a ser vi ceabl e condi t i on may be
kept f or emer gency use.
FI GURE 2- 3. Connect i ng Rod Wi t h Wedge Adj ust i ng Bear i ngs
2- 10
FI GURE 2- 4. Connecti ng Rod Assembl y
8. 7. 1 Bel t Sheaves. Check condi ti on of bel t sheaves when i nstal l i ng new
bel t s. I f grooves are worn, regroove or repl ace the sheaves. Worn grooves
cause rapi d bel t wear. Sheaves shoul d be cl ean and f ree of oi l or grease.
Bel ts shoul d be i nstal l ed by hand and not pri ed i nto pl ace. Af ter al l bel ts
have been i nstal l ed, adj ust the bel t tensi ons ( f i gure 2- 5) . Proper tensi on i s
i ndi cated when each bel t can be def l ected one bel t thi ckness f or each 48
i nches of unsupported l ength. Af ter bel ts have been tensi oned, check sheave
al i gnment by pl aci ng a strai ght edge across the f aces of the dri vi ng and
dri ven sheaves. The strai ght edge shoul d contact both sheaves squarel y.
FI GURE 2- 5. Method of Checki ng the Tensi on of V- Bel ts
2- 11
INTENTIONALLY LEFT BLANK
2- 12
Sect i on 2. ROTARY SLI DI NG VANE COMPRESSORS
1 DESCRI PTI ON. Rot ar y sl i di ng vane compr essor s ( f i gur es 2- 6 and 2- 7) consi st
of a cyl i ndr i cal casi ng i n whi ch an eccent r i cal l y mount ed r ot or i s l ocat ed.
The r ot or i s f i t t ed wi t h bl ades t hat ar e f r ee t o sl i de i n and out of
l ongi t udi nal sl ot s. I n oper at i on, t he bl ades ar e f or ced out war d by
cent r i f ugal f or ce and f or mcompar t ment s wher e ai r i s compr essed. Each
compar t ment var i es f r oma maxi mumvol ume on t he suct i on si de of t he r evol ut i on
t o a mi ni mumvol ume on t he compr essi on hal f of t he r evol ut i on. Thi s gi ves a
posi t i ve di spl acement t ype suct i on and pr essur e ef f ect . Rot ar y sl i di ng vane
machi nes ar e nor mal l y di r ect l y connect ed t o el ect r i c mot or s or i nt er nal
combust i on engi nes. Oper at i ng and mai nt enance i nst r uct i ons f or el ect r i c
mot or s and i nt er nal combust i on engi nes ar e cont ai ned i n NAVFAC MO- 205, Cent r al
Heat i ng and St eam El ect r i c Gener at i ng Pl ant s.
2 STARTUP.
( a) Al l i nst al l at i on and r epai r wor k has been compl et ed.
( b) I nst al l at i on has been cl eaned and t est ed f or l eaks.
( c) Al i gnment has been checked.
( d) Uni t i s pr oper l y l ubr i cat ed; cr ank l ubr i cat or by hand t o cl ear l i nes
of ai r and t o assur e oi l suppl y f or st ar t up.
FI GURE 2- 6. Cr oss Sect i on of Rot ar y Sl i di ng Vane Compr essor
2- 13
FI GURE 2- 7. Cut away Vi ew of Two- St age, Rot ar y Sl i di ng Vane Compr essor
2- 14
( e) Compr essor t ur ns f r eel y by hand.
( f ) Di r ect i on of mot or r ot at i on i s cor r ect .
( g) Unl oader oper at i on has been checked.
( h) Saf et y val ve oper at i on has been checked.
2. 2 St ar t up. Pr oceed as f ol l ows:
( a) Open di schar ge shut of f val ve.
( b) Tur n on cool i ng wat er suppl y. Thor oughl y vent j acket s and
i nt er cool er .
( c) Set r egul at i ng devi ce t o unl oaded posi t i on.
( d) St ar t mot or and br i ng uni t up t o speed.
( e) Check and adj ust l ubr i cat or f eed r at e i n accor dance wi t h
manuf act ur er ' s i nst r uct i ons.
( f ) Load t he compr essor i f machi ne i s r unni ng smoot hl y.
t asks.
( a) Mai nt ai n pr oper l ubr i cat i ng oi l l evel s.
( b) Dr ai n oi l separ at or and r ecei ver .
( c) Check aut omat i c t r aps f or pr oper oper at i on.
( d) Check compr essed ai r and cool i ng wat er pr essur es and t emper at ur es
dai l y.
4 SHUTDOWN. Pr oceed as f ol l ows:
( a) Unl oad compr essor .
( b) St op mot or .
( c) Shut of f cool i ng wat er suppl y.
( d) I f t he compr essor i s t o be subj ect ed t o f r eezi ng t emper at ur es,
t hor oughl y dr ai n cyl i nder j acket s, cool er s, and dr ai n t r aps.
4. 1 Ext ended Shut down. Rot ar y sl i di ng vane compr essor s shoul d not be l ef t
i dl e f or l ong per i ods of t i me. Rust and cor r osi on wi l l cause r api d
det er i or at i on i f t he machi ne i s not pr oper l y pr ot ect ed. Rot or bl ade
expansi on, caused by t he absor pt i on of moi st ur e, i s anot her pot ent i al
pr obl em. Obser vat i on of t he f ol l owi ng pr ocedur e shoul d adequat el y pr ovi de t he
pr oper pr ot ect i on.
2- 15
( a) Ever y 2 weeks, t ur n t he compr essor over by hand t o di st r i but e oi l t o
t hose ar eas r equi r i ng l ubr i cat i on, t hen oper at e t he compr essor f or a mi ni mum
of 2 hour s. Thi s wi l l keep t he i nt er i or dr y, wel l l ubr i cat ed, and pr event
absor pt i on of moi st ur e by t he bl ades.
( b) Do not al l ow cool i ng wat er t o r un af t er shut down. Thi s causes
i nt er nal condensat i on t hat can be absor bed by t he bl ades.
( c) I f t he compr essor i s t o be subj ect ed t o f r eezi ng t emper at ur es,
t hor oughl y dr ai n cyl i nder j acket s, cool er s, and dr ai n t r aps.
( a) Keep a dai l y l og of compr essed ai r and cool i ng wat er t emper at ur es
and pr essur es, and l ubr i cat i ng oi l addi t i ons t o det ect any devi at i ons f r om
nor mal oper at i ng val ues. On t wo- st age machi nes, l ow i nt er st age pr essur e
i ndi cat es a mal f unct i on i n t he f i r st st age or st oppage of t he i nt ake f i l t er .
Hi gh i nt er st age pr essur e may i ndi cat e t hat t he second st age i s not oper at i ng
pr oper l y or t hat t he ai r f r omt he f i r st st age i s not bei ng cool ed suf f i ci ent l y
by t he i nt er cool er .
( b) Keep t he machi ne cl ean at al l t i mes by wi pi ng dai l y wi t h a cl ot h.
Di r t accumul at i ons wi l l event ual l y wor k t hei r way i nt o t he machi ne and cause
accel er at ed wear .
( c) Do not oper at e a compr essor beyond i t s r at ed capaci t y. Over l oad
oper at i on r esul t s i n over heat i ng and damage t o r unni ng sur f aces.
( d) Do not over t i ght en packi ng gl and. Thi s r esul t s i n r api d packi ng
wear and shaf t scor i ng. Gl and shoul d be pul l ed up f i nger - t i ght and some oi l
l eakage shoul d be pr esent .
( e) Check l ubr i cat or weekl y f or pr oper dr op r at e.
6. 1 Dai l y I nspect i on. The oper at or shal l i nspect t he i nst al l at i on dai l y f or
t he f ol l owi ng condi t i ons:
( b) Abnor mal pr essur es or t emper at ur es
( c) Pr oper l ubr i cat i ng oi l l evel s
( d) Abnor mal st uf f i ng box t emper at ur es
( e) Abnor mal bear i ng t emper at ur es
( f ) Over heat i ng of mot or
2- 16
6. 2 Quar t er l y I nspect i on. I nspect t he compr essor ever y 3 mont hs f or t he
f ol l owi ng condi t i ons:
( a) Oper at i on of al l saf et y val ves
( b) Pr oper oper at i on of al l cont r ol s
6. 3 Semi annual I nspect i on. I nspect f or t he f ol l owi ng condi t i ons:
( a) Al i gnment of t he compr essor t o t he dr i ve
( b) On t wo- st age uni t s, al i gnment of t he out boar d compr essor t o t he
i nboar d one
( c) Condi t i on of packi ng, i f pr ovi ded
6. 4 Annual I nspect i on. Once a year or mor e of t en, dependi ng on t he sever i t y
of ser vi ce, di smant l e t he compr essor and i nspect f or t he f ol l owi ng condi t i ons:
( a) Bear i ngs f or wear and di r t
( b) Shaf t f or wear at seal s
( c) Mechani cal seal s f or damage, i f t hey ar e pr ovi ded
( d) Rot or bl ades; r emove and i nspect f or wear
( e) Wear and scor i ng of cyl i nder bor e
( f ) Damage t o gasket s
7 MAI NTENANCE.
7. 1 Rot or Bl ades. Rot or bl ades shoul d be r epl aced i f t he bl ade t hi ckness at
any poi nt i s l ess t han 85 per cent of t he r ot or sl ot wi dt h; i f t he bl ade wi dt h
i s l ess t han 90 per cent of t he r ot or sl ot dept h; or i f t her e i s any char r i ng,
spl i t t i ng, or chi ppi ng on t he r unni ng edge of t he bl ades.
( a) Thor oughl y cl ean t he r ot or sl ot s when r epl aci ng or i nst al l i ng new
bl ades.
( b) Thor oughl y cl ean and oi l bl ades bef or e i nst al l at i on.
7. 2 Cyl i nder s. Thor oughl y cl ean cyl i nder i nt er i or annual l y as f ol l ows:
( a) Bl ow out al l oi l hol es ensur i ng t hey ar e open and f r ee of sl udge.
( b) Fl ush out cyl i nder j acket s wi t h a wat er hose t o r emove di r t
accumul at i ons.
( c) St one r ough spot s on cyl i nder wal l s, cyl i nder heads, and r ot or .
2- 17
( d) When r eassembl i ng, oi l each par t wi t h cl ean l ubr i cat i ng oi l .
( e) Repl ace def ect i ve gasket s.
7. 3 Bear i ngs. Repl ace wor n or def ect i ve bear i ngs as r equi r ed. I f bear i ng
r epl acement becomes necessar y,
heat i ng i t wi t h a t or ch.
t he i nner r ace may be r emoved f r omt he shaf t by
not t he shaf t .
Car e must be t aken t o heat t he i nner r ace onl y and
The i nner r ace i s shr unk ont o t he shaf t , so t hat heat i ng bot h
par t s wi l l not f r ee t he bear i ng. Never at t empt t o pul l t he i nner r ace of f t he
shaf t wi t hout heat , as damage t o t he shaf t wi l l r esul t . To i nst al l a new
i nner r ace, i t i s necessar y f or i t t o be t hor oughl y heat ed i n an oi l bat h t o a
t emper at ur e of 200F t o 300F dependi ng on manuf act ur er ' s i nst r uct i ons. I t
wi l l t hen sl i p easi l y ont o t he shaf t .
t he bear i ngs. Cl ear ances must be cl osel y hel d f or pr oper oper at i on of t he
compr essor . Cl ear ances ar e nor mal l y gi ven on t he compr essor namepl at e.
Fol l ow t he manuf act ur er ' s i nst r uct i ons car ef ul l y f or set t i ng cl ear ances.
7. 4 Cl ear ances. Each t i me t he compr essor i s i nspect ed i nt er nal l y or
di sassembl ed f or r epai r , cl ear ances must be checked. These i ncl ude cl ear ances
bet ween t he r ot or and cyl i nder , t he r ot or ends and t he cyl i nder heads, and i n
7. 5 Lubr i cat i on. Rot ar y sl i di ng vane compr essor s ar e nor mal l y f i t t ed wi t h
mechani cal f or ce- f eed l ubr i cat or s dr i ven f r om t he compr essor shaf t . On new
compr essor s,
mor e oi l t han
or compr essor s t hat have been over haul ed, f eed about 25 per cent
nor mal f or about 2 weeks unt i l t he compr essor has been r un- i n.
For nor mal oper at i on, t he f eed shoul d be adj ust ed t o t he dr i p r at e i ndi cat ed
on t he l ubr i cat or namepl at e.
i ndi cat or s.
Rat e of f l ow can be obser ved i n t he si ght f l ow
2- 18
Sect i on 3. ROTARY TWI N- LOBE COMPRESSORS
1 DESCRI PTI ON. Rot ar y t wi n- l obe compr essor s ( bl ower s) consi st of t wo
i mpel l er s mount ed on par al l el shaf t s t hat r ot at e i n opposi t e di r ect i ons wi t hi n
a housi ng ( f i gur e 2- B) . As t he i mpel l er s r ot at e, t hey t r ap a quant i t y of ai r
bet ween t hemsel ves and t he bl ower housi ng and move t he ai r f r om t he i nl et t o
t he di schar ge por t . The oper at i ng pr i nci pl e of t hi s t ype compr essor i s
unusual si nce t he i mpel l er s do not compr ess t he ai r whi l e movi ng i t . I nst ead,
as each i mpel l er uncover s t he di schar ge por t , t he pr essur i zed ai r i n t he
di schar ge l i ne f l ows back i nt o t he compr essor compr essi ng t he ai r bet ween t he
di schar ge por t and t he next l obe of t he i mpel l er . As t he i mpel l er s t ur n, t hey
f or ce t hi s pr essur i zed ai r i nt o t he di schar ge l i ne and i mmedi at el y st ar t a new
cycl e, as shown i n f i gur e 2- B. Thi s act i on t akes pl ace f our t i mes per
r evol ut i on, t wi ce f or each i mpel l er . The i mpel l er s ar e posi t i oned i n r el at i on
t o each ot her by t i mi ng gear s l ocat ed at t he end of each shaf t and ext er nal t o
t he bl ower housi ng. Rot ar y t wi n- l obe compr essor s ( f i gur e 2- 9) ar e nor mal l y
el ect r i c mot or dr i ven t hr ough V- bel t s or by di r ect connect i on. Oper at i ng and
mai nt enance i nst r uct i ons f or el ect r i c mot or s ar e cont ai ned i n NAVFAC MO- 205,
Cent r al Heat i ng and St eam El ect r i c Gener at i ng Pl ant s.
2 STARTUP.
I f i mpel l er s ar e t o be r ot at ed, keep hands, f eet , l oose cl ot hi ng,
and f or ei gn obj ect s away f r om i nl et and di schar ge openi ngs, as
ser i ous per sonal i nj ur y or damage t o equi pment can occur .
Do not oper at e equi pment wi t hout adequat e si l enci ng devi ces. Hi gh
noi se l evel s may cause per manent hear i ng damage.
( d) Compr essor and dr i ve have been pr oper l y l ubr i cat ed.
( e) Oper at i on of saf et y val ves has been checked.
( f ) Compr essor di schar ge val ves ar e open.
( a) Tur n compr essor over by hand t o see t hat i t t ur ns f r eel y.
2- 19
FI GURE 2- B. I mpel l er Arrangement of Rotary Twi n- Lobe Compressor
FI GURE 2- 9. Rotary Twi n- Lobe Compressor
2- 20
( b) Check mot or f or cor r ect di r ect i on of r ot at i on.
( c) Tur n on cool i ng wat er t o oi l cool er , i f pr ovi ded.
( d) St ar t t he compr essor .
t asks.
( a) Mai nt ai n cor r ect oi l l evel s.
( b) Check ai r di schar ge and l ubr i cat i ng oi l pr essur es.
( c) Wat ch f or i r r egul ar compr essor per f or mance and any unusual noi se or
vi br at i on.
4 SHUTDOWN. When t he compr essor i s t o be out of ser vi ce f or an ext ended
per i od, coat t he i mpel l er s and t he i nsi de of t he housi ng wi t h a heavy oi l or
gr ease t o pr event r ust i ng and cor r osi on. Bef or e r et ur ni ng t he uni t t o
ser vi ce, t hor oughl y cl ean al l oi l or gr ease f r om t he compr essor i nt er i or .
( a) Oper at e t he compr essor wi t hi n t he r at ed capaci t y, ot her wi se
over heat i ng of t he compr essor and dr i ve may occur .
( b) On uni t s f i t t ed wi t h oi l cool er s, ensur e t hat t he t emper at ur e of t he
oi l t o t he gear s and bear i ngs i s wi t hi n t he l i mi t s r ecommended by t he
manuf act ur er .
( c) Mai nt ai n oi l l evel s wi t hi n t he l i mi t s i ndi cat ed on t he oi l l evel
gauge. I nsuf f i ci ent oi l wi l l r esul t i n i mpr oper l ubr i cat i on. Too much oi l
wi l l cause over heat i ng of bear i ngs and gear s.
6. 1 Dai l y I nspect i on. The oper at or shal l i nspect t he compr essor dai l y f or
t he f ol l owi ng condi t i ons:
( b) Abnor mal suct i on or di schar ge pr essur e or t emper at ur e
( c) Abnor mal oi l pr essur e when f or ce- f ed l ubr i cat i on i s pr ovi ded
( d) Abnor mal bear i ng t emper at ur es
( e) Over heat i ng of mot or
( f ) Oi l l eaks
2- 21
6. 2 Annual I nspect i on. Once a year or as r equi r ed, dependi ng on t he sever i t y
of ser vi ce, cl ean and i nspect t he compr essor f or t he f ol l owi ng condi t i ons:
( a) Cor r osi on or er osi on of par t s
( b) Pr oper cl ear ances
( c) Cor r ect al i gnment
( d) Wor n or br oken t i mi ng gear s
( e) Ti mi ng gear set t i ng
( f ) Oper at i on and set t i ng of saf et y val ves
( g) Wear of shaf t s at seal s
7 MAI NTENANCE.
7. 1 Lubr i cat i on. Est abl i sh a def i ni t e l ubr i cat i on schedul e f or t he
compr essor , and est abl i sh speci f i c r esponsi bi l i t i es f or car r yi ng out per i odi c
l ubr i cat i on. Fr equency of l ubr i cat i on and t ype of l ubr i cant shoul d be as
r ecommended by t he manuf act ur er .
7. 2 Ti mi ng Gear s. Ti mi ng gear s mai nt ai n t he compr essor i mpel l er s i n pr oper
r ot at i ve posi t i on and hol d i mpel l er cl ear ances. They must be secur el y l ocked
t o t hei r shaf t s i n pr oper posi t i on. Gear s or i mpel l er s t hat have been r emoved
f or r epai r must be r et ur ned t o t hei r or i gi nal posi t i ons. When i nst al l i ng new
or r epai r ed par t s, car ef ul l y f ol l ow t he manuf act ur er s' i nst r uct i ons f or
set t i ng cl ear ances. Cl ear ances must be set accur at el y or damage t o t he
machi ne may r esul t f r om i mpel l er r ubbi ng.
7. 3 Seal s. Rot ar y t wi n- l obe compr essor s ar e nor mal l y f i t t ed wi t h mechani cal
seal s. Seal s shoul d be kept f r ee of di r t , dust , and f or ei gn mat t er t o ensur e
l ong l i f e. Seal i ng f aces ar e l apped t oget her dur i ng manuf act ur e and t he
ent i r e assembl y must be r epl aced when def ect i ve seal s ar e f ound. Use ext r eme
car e when i nst al l i ng seal s t o pr event mar r i ng of t he seal i ng f aces. Be sur e
t hat t he l apped seal i ng f aces ar e f r ee of scr at ches, dust , or f i nger mar ks
bef or e i nst al l at i on. Car ef ul l y f ol l ow t he manuf act ur er s' i nst r uct i ons when
r epl aci ng mechani cal seal s.
7. 4 Bear i ngs. Rot ar y t wi n- l obe compr essor s ar e nor mal l y f i t t ed wi t h
ant i f r i ct i on bal l or r ol l er bear i ngs. Wor n or def ect i ve bear i ngs shoul d be
r epl aced. Wear t o bear i ngs may al l ow t he i mpel l er shaf t t o shi f t posi t i on
unt i l a cyl i nder r ub devel ops or t he i mpel l er s begi n r ubbi ng. Car ef ul l y
f ol l ow t he manuf act ur er s' i nst r uct i ons when r epl aci ng bear i ngs.
2- 22
Sect i on 4. ROTARY LI QUI D PI STON COMPRESSORS
1 DESCRI PTI ON. Rot ar y l i qui d pi st on compr essor s ( f i gur es 2- 10 and 2- 11)
ut i l i ze a l i qui d ( wat er or ot her l ow vi scosi t y l i qui d) as t he compr essant .
The uni t consi st s of a r ound mul t i bl ade r ot or t hat r ot at es i n an el l i pt i cal
casi ng par t i al l y f i l l ed wi t h l i qui d. The l i qui d i s car r i ed ar ound by t he
r ot or and f ol l ows t he cont our of t he casi ng. The r ot or bucket s ar e f i l l ed
wi t h ai r , t hr ough t he i nt ake por t , by t he suct i on cr eat ed when t he l i qui d i s
f or ced t o r ecede f r om t he r ot or bucket s at t he wi de poi nt of t he el l i pt i cal
casi ng. As t he l i qui d r eaches t he nar r ow poi nt of t he el l i pse, i t r eent er s
t he bucket s, compr esses t he ai r , and passes i t out t hr ough t he di schar ge
por t s. The cycl e i s r epeat ed t wi ce f or each r evol ut i on of t he r ot or . Li qui d
i s suppl i ed cont i nuousl y t o t he compr essor t o t ake up t he heat of
compr essi on. Excess wat er i s di schar ged f r om t he compr essor wi t h t he ai r and
i s r emoved by a separ at or connect ed t o t he compr essor di schar ge. Oper at i ng
and mai nt enance i nst r uct i ons f or el ect r i c mot or dr i ves ar e cont ai ned i n NAVFAC
MO- 205, Cent r al Heat i ng and St eam El ect r i c Gener at i ng Pl ant s.
2 STARTUP.
2. 1 Pr est ar t I nspect i on. Car ef ul l y i nspect t he i nst al l at i on t o ensur e t he
f ol l owi ng pr est ar t r equi r ement s ar e f ul f i l l ed.
( d) Saf et y val ve has been t est ed f or pr oper oper at i on.
( e) Compr essor i s pr oper l y l ubr i cat ed.
( a) Open compr essor di schar ge val ves.
( b) Tur n on compr essor seal i ng- wat er .
( c) St ar t t he compr essor .
3 NORMAL OPERATI ON. Whi l e t he syst emi s oper at i ng, per f or mt he f ol l owi ng
t asks.
( a) Mai nt ai n cor r ect seal i ng- wat er f l ow r at e.
( b) Check ai r di schar ge pr essur es.
( c) Wat ch f or i r r egul ar per f or mance of t he compr essor .
4 SHUTDOWN. When r emovi ng t he compr essor f r omser vi ce f or an ext ended
per i od, t hor oughl y dr ai n t he casi ng of al l seal i ng- wat er . Run a f l ushi ng oi l
t hr ough t he compr essor t o pr event r ust i ng and cor r osi on. Repack gr ease
l ubr i cat ed bear i ngs wi t h new gr ease and f i l l oi l l ubr i cat ed bear i ngs wi t h
2- 23
Starti ng at poi nt A, the chambers of the rotor are f i l l ed wi th
water. Thi s water rotates wi th the rotor, but f ol l ows the contour
of the casi ng. The water, whi ch enti rel y f i l l s the rotor chamber
at poi nt A, recedes i nto the casi ng as the rotor advances, unti l
at poi nt C, the rotor chamber i s empty. The convergi ng casi ng
f orces the water back i nto the rotor chamber, unti l at poi nt D,
the chamber i s agai n f ul l . Thi s cycl e occurs once duri ng each
revol uti on of the rotor. As water recedes f romthe rotor chamber
at poi nt B, the water i s repl aced by ai r drawn through an i nl et
port i n the stati onary coni cal casi ng that connects to the
compressor i nl et. As the rotor turns through 360 and water i s
f orced by the casi ng back i nto the rotor chamber, the ai r that has
f i l l ed the chamber i s f orced through di scharge ports i n the
coni cal casi ng to the compressor di scharge. The water used as the
l i qui d compressant al so serves to seal cl earances between the
rotor and the cone and i s ref erred to as seal water.
FI GURE 2- 10. Compressi on Cycl e, Rotary Li qui d Pi ston Compressor
2- 24
FI GURE 2- 11. Funct i onal El ement s, Rot ar y Li qui d Pi st on Compr essor
f r esh oi l . Remove shaf t packi ng. Tur n t he compr essor over by hand once a
week t o keep a coat i ng of oi l on t he bear i ngs.
shal l i ncl ude t he f ol l owi ng t asks.
( a) Never r un a l i qui d pi st on compr essor dr y. Oper at i on wi t hout
seal i ng- wat er r esul t s i n ser i ous damage t o t he compr essor .
( b) Mai nt ai n cor r ect seal i ng- wat er f l ow r at e. I nsuf f i ci ent seal i ng- wat er
wi l l r esul t i n a l oss of capaci t y. Excess seal i ng- wat er over l oads t he
compr essor dr i ve. Consul t t he manuf act ur er ' s i nst r uct i ons f or cor r ect
seal i ng- wat er quant i t i es.
( c) Do not over t i ght en t he packi ng on uni t s wi t h st uf f i ng boxes. Thi s
r esul t s i n r api d packi ng wear and scor i ng of t he shaf t .
6. 1 Dai l y I nspect i on. The oper at or shal l i nspect t he compr essor i nst al l at i on
dai l y f or t he f ol l owi ng condi t i ons:
( b) Abnor mal di schar ge pr essur es
( c) Over heat i ng of mot or
2- 25
( d) Abnor mal bear i ng t emper at ur es
( e) Cor r ect seal i ng- wat er f l ow and pr essur e
6. 2 Semi annual I nspect i on. I nspect t he f ol l owi ng i t ems:
( a) Al i gnment s
( b) Wear of packi ng and scor i ng of shaf t at packi ng or seal s
( c) Set t i ng and oper at i on of saf et y val ves
6. 3 Annual I nspect i on. Once a year or as r equi r ed, dependi ng upon t he
sever i t y of ser vi ce, i nspect f or t he f ol l owi ng condi t i ons:
( a) Bear i ngs f or wear and di r t
( b) Cor r osi on or er osi on of par t s
( c) Cor r ect cl ear ances
( d) Compr essor i nt er nal s f or scal e deposi t s
( e) Gasket s f or damage
( f ) Mechani cal seal s, i f pr ovi ded, f or damage
7 MAI NTENANCE.
7. 1 Lubr i cat i on. Est abl i sh a def i ni t e l ubr i cat i on schedul e, i n accor dance
wi t h t he manuf act ur er ' s r ecommendat i ons, f or al l l i qui d pi st on compr essor s.
Assi gn r esponsi bi l i t i es f or car r yi ng out t he l ubr i cat i on schedul e. Fol l ow t he
manuf act ur er ' s r ecommendat i ons f or t he t ypes of l ubr i cant s t o be used.
7. 2 Packi ng. When r epl aci ng f i br ous packi ng, t hor oughl y cl ean t he st uf f i ng
box of ol d packi ng and gr ease. Cover each pi ece of new packi ng wi t h t he
r ecommended l ubr i cant . Separ at e t he new r i ngs at t he spl i t j oi nt t o pl ace
t hem over t he shaf t . Pl ace one r i ng of packi ng at a t i me i n t he st uf f i ng box
and t amp f i r ml y i n pl ace. St agger t he j oi nt s of each r i ng so t hey ar e not i n
l i ne. Af t er t he l ast r i ng i s i n pl ace, assembl e t he gl and and t i ght en t he
nut s evenl y unt i l snug. Af t er a f ew mi nut es, l oosen t he nut s and r et i ght en
t hem f i nger - t i ght .
7. 3 Bear i ngs. Wor n or def ect i ve bear i ngs shoul d be r epl aced. Bear i ngs ar e
mount ed i n br acket s on each end of t he housi ng and ar e at t ached t o t he r ot or
shaf t by l ocknut s. When bear i ngs ar e r epl aced on bel t - dr i ven uni t s,
car ef ul l y check and set t he bel t t ensi on. Keep t he bel t as l oose as possi bl e
wi t hout sl i ppage. Excessi ve bel t t i ght eni ng wi l l put an unnecessar y st r ai n on
t he compr essor bear i ngs. When mount i ng pul l eys or coupl i ngs t hat r equi r e a
dr i ve f i t on t he compr essor shaf t , back up t he opposi t e end of t he shaf t t o
absor b t he dr i vi ng f or ce. Unl ess t hi s i s done, t her e i s danger of damagi ng
t he bear i ngs. Mai nt enance i nst r uct i ons f or ant i f r i ct i on bal l and r ol l er
bear i ngs ar e cont ai ned i n NAVFAC MO- 205, Cent r al Heat i ng and St eamEl ect r i c
Gener at i ng Pl ant s.
2- 26
CHAPTER 3. DYNAMI C COMPRESSORS
1 DESCRI PTI ON. Cent r i f ugal and axi al f l ow compr essor s ar e bot h cat egor i zed
as dynami c compr essor s. Dynami c compr essor s move gases by a pr ocess of
accel er at i on. The di r ect i on of ai r f l ow i n t he cent r i f ugal compr essor i s
r adi al wi t h r espect t o t he axi s of r ot at i on. I n t he axi al f l ow compr essor
ai r f l ow i s par al l el t o t he axi s of r ot at i on. Cent r i f ugal and axi al f l ow
compr essor s ar e dr i ven by el ect r i c mot or s or st eamt ur bi nes. Oper at i ng and
mai nt enance i nst r uct i ons f or el ect r i c mot or and st eamt ur bi ne dr i ves ar e
cont ai ned i n NAVFAC MO- 205, Cent r al Heat i ng and St eam El ect r i c Gener at i ng
Pl ant s.
1. 1 Cent r i f ugal Compr essor . The maj or component s of a cent r i f ugal compr essor
ar e: i mpel l er , shaf t , casi ng, and di f f user / vol ut e ( f i gur es 3- l and 3- 2) . I n
t he cent er of t he i mpel l er i s t he suct i on eye ar ea, t he cent er of l ow pr essur e
when t he i mpel l er i s r ot at i ng. Fi gur e 3- 3 i l l ust r at es t hr ee basi c i mpel l er
desi gns. Ai r ent er i ng t he suct i on eye i s moved out war d al ong t he i mpel l er
bl ades by cent r i f ugal f or ce wi t h i ncr easi ng vel oci t y. The ai r l eaves t he
i mpel l er t hr ough t he di f f user t o t he vol ut e wher e t he ai r i s sl owed and t he
vel oci t y component of t he ai r mass i s par t i al l y conver t ed i nt o pr essur e. I n a
mul t i st age compr essor t he ai r exi t i ng t he vol ut e i s f ed t o anot her i mpel l er -
di f f user - vol ut e ser i es t o f ur t her i ncr ease t he ai r pr essur e.
1. 2 Axi al Fl ow Compr essor . The maj or component s of an axi al f l ow compr essor
ar e: r ot or wi t h r ows of bl ades, and a st at or wi t h r ows of st at i onar y bl ades
( f i gur es 3- 4 and 3- 5) . The movi ng bl ades accel er at e t he ai r , and t he
st at i onar y bl ades di r ect t he f l ow of ai r i nt o t he next r ow of movi ng bl ades.
FI GURE 3- l . Si mpl e Vol ut e Pump
3- 1
FI GURE 3- 2. Si x- Stage Compressor
FI GURE 3- 3. I mpel l er Desi gn
3- 2
Thi s sequence conti nues unti l the ai r has passed through al l the rows of
movi ng bl ades. The stati onary bl ades al so of f er a smal l amount of f l ow
resi stance, whi ch sl ows down the ai r and i ncreases i ts pressure. I n an axi al
f l ow compressor, i t i s the conti nual process of accel erati ng the ai r and then
sl owi ng i t down that bui l ds up the ai r pressure.
2 STARTUP.
2. 1 Prestart I nspecti on. Caref ul l y i nspect the compressor i nstal l ati on,
perf ormi ng the f ol l owi ng prestart tasks.
Compressor equi pment, compressed ai r, and el ectri ci ty can be
dangerous. To prevent i nj ury, bef ore attempti ng any mai ntenance be
certai n the compressor cannot be started acci dental l y.
( a) Ensure power swi tch i s i n OFF posi ti on and tag, or veri f y that power
shutof f val ve i s i n OFF posi ti on and tag.
( b) Veri f y compl eti on of al l i nstal l ati on or repai r work.
( c) Ensure i nstal l ati on has been cl eaned.
( d) Veri f y that systemhas been tested f or l eaks.
FI GURE 3- 4. Axi al Fl ow Compressor
3- 3
FI GURE 3- 5. Rot or and St at or Bl ades, Axi al Compr essor
( e) Check coupl i ng al i gnment ( r ef er t o par agr aph 7. 2) .
( f ) Check l ubr i cat i ng oi l l evel s and t op of f , i f r equi r ed.
( g) Check al l saf et y devi ces and cont r ol s f or pr oper oper at i on.
( h) Tur n compr essor over by hand t o see t hat i t r ot at es f r eel y.
( i ) Open al l compr essor , dr ai n val ves, dr ai n of f al l l i qui d, and cl ose
dr ai n val ves.
2. 2 St ar t up Pr ocedur e. Pr oceed as f ol l ows:
Pr ot ect i ve devi ces must be wor n t o avoi d damage t o hear i ng.
( a) Remove t ag f r om el ect r i c power swi t ch and swi t ch t o ON posi t i on, or
r emove t ag f r om power shut of f val ve and t ur n t o ON posi t i on.
( b) Tur n on cool i ng wat er .
( c) St ar t oi l pump and check oi l pr essur e.
( d) Tur n on seal i ng ai r t o seal s, i f pr ovi ded.
( e) Open suct i on and di schar ge val ves.
3- 4
Never oper at e compr essor i n t he cr i t i cal speed r ange ( i nsuf f i ci ent
vol ume at t he compr essor i nl et t o per mi t st abl e oper at i on) ; sur gi ng
or pumpi ng wi l l occur . Oper at i on under t hese condi t i ons may r esul t
i n equi pment damage.
( f ) St ar t compr essor dr i ve mot or as f ol l ows, dependi ng on t ype:
( 1) Si ngl e Speed Mot or . St ar t and st op t he mot or qui ckl y and al l ow
t he compr essor t o coast t o a st op. Check f or f r eedom of r ot at i on and any
unusual noi se or vi br at i on. I f uni t r uns smoot hl y, st ar t t he mot or and br i ng
up t o speed.
( 2) Var i abl e Speed Mot or . St ar t t he mot or and br i ng i t sl owl y up
t o speed, obser vi ng t he oper at i on car ef ul l y f or unusual noi se or vi br at i on.
t asks.
( a) Check and r ecor d oper at i onal dat a at pr escr i bed i nt er val s
( par agr aph 5) .
( b) Wat ch f or i r r egul ar per f or mance of t he compr essor and dr i ve.
( c) Mai nt ai n pr oper l ubr i cat i ng oi l l evel s.
4 SHUTDOWN.
4. 1 Shor t - Ter mShut down. Pr oceed as f ol l ows:
To avoi d damage t o equi pment , af t er shut t i ng down t he dr i ve, keep
auxi l i ar y l ubr i cat i ng oi l pump oper at i ng unt i l bear i ngs have cool ed
t o ambi ent t emper at ur es.
( a) Shut down compr essor dr i ve.
( b) Cl ose suct i on and di schar ge val ves.
( c) Shut of f cool i ng wat er suppl y.
( d) Shut of f seal ai r , i f pr ovi ded.
( e) Open compr essor dr ai n val ves and dr ai n of f any l i qui d pr esent .
( f ) Shut of f l ube oi l pump af t er bear i ngs have cool ed t o ambi ent
t emper at ur e.
3- 5
4. 2 Long- Ter mShut down. Long- t er m shut down pr ocedur es r equi r e ext ensi ve
di sassembl y. Consul t t he manuf act ur er f or compl et e det ai l s f or speci f i c
compr essor s. I n t he absence of speci f i c pr ocedur es, use t he f ol l owi ng
pr ocedur es wher e appl i cabl e.
( a) Cent r i f ugal Compr essor s. Pr oceed as f ol l ows:
( 1) Shut down syst emas descr i bed i n par agr aph 4. 1.
( 2) Open t he compr essor case, r emove i nt er cool er s, di f f user s,
di f f user cover s, r ot or s, bear i ngs, and dr ai n t r aps.
( 3) Remove t he pl ai n and t hr ust bear i ngs.
( 4) Bl ow dr y ai r t hr ough t he wat er mani f ol ds, i ncl udi ng t he oi l
cool er s. Spr ead vapor phase i nhi bi t or ( VPI ) cr yst al s i n t he cool i ng wat er
mani f ol ds.
( 5) I dent i f y each r ot or and i mpel l er i f appl i cabl e. Coat each r ot or
component wi t h a r ust i nhi bi t or and pack secur el y i n a car t on.
( 6) Wi pe and dr y al l unpr ot ect ed i nt er nal machi ned sur f aces. Coat
al l sur f aces wi t h a r ust i nhi bi t or , i ncl udi ng di f f user and i nt er cool er bor es.
( 7) Thor oughl y dr y t he i nt er cool er s and r ei nst al l t hem.
( 8) Rei nst al l di f f user cover s, di f f user s, and i nt er cool er s.
Di st r i but e VPI cr yst al s t hr oughout and cl ose t he machi ne.
( 9) Al l openi ngs must be adequat el y seal ed wi t h gasket ed f l anges,
pl ugs, or pol y wr aps t o pr event l oss of VPI vapor s, i ncl udi ng t he seal ai r
casi ng vent s and dr ai ns.
( 10) Remove t he r eser voi r br eat her and seal t he openi ng. Coat t he
exposed por t i on of t he shaf t and coupl i ng hub wi t h pr eser vat i ve.
( 11) Remove i nl et and bypass cont r ol val ves and t he check val ve.
Cl ean, dr y, and box.
( 12) Remove al l pr obes and cabl es and box adequat el y.
( 13) Repl ace t hr ust bear i ng and cover s and cl ose up ALL openi ngs
usi ng pi pe pl ugs or bl ank f l anges wi t h gasket .
( 14) Seal t he bot t om of t he cont r ol cabi net i f i t i s of t he open
desi gn.
( 15) Coat mai n dr i ve coupl i ng spacer wi t h pr eser vat i ve and pack i n
separ at e box.
( 16) Coat al l ext er nal machi ned unpai nt ed sur f aces wi t h pr eser vat i ve.
3- 6
( b) Axi al Fl ow Compr essor s. I t i s i mpor t ant t o i mpl ement pr oper
l ong- t er mst or age ( LTS) pr ocedur es accor di ng t o t he speci f i c model of
compr essor . I n si t uat i ons wher e LTS i s pl anned, t he manuf act ur er must be
cont act ed t o pr ovi de LTS pr ocedur es. I n most i nst ances, LTS wi l l i ncl ude
speci f i c var i at i ons of t he f ol l owi ng:
( 1) Par t i al di sassembl y
( 2) Per i odi c r ot at i on of mai n shaf t
( 3) Use of desi ccant s
( 4) Speci al i zed bear i ng mai nt enance accor di ng t o bear i ng t ypes
( 5) Pr oper t aggi ng
4. 3 Col d Cl i mat e Shut down. I f t he compr essor mi ght be subj ect ed t o f r eezi ng
t emper at ur es whi l e shut down, per f or m t he f ol l owi ng st eps as appl i cabl e.
( a) Per f or m st eps 4. 1( a) t hr ough 4. 1( f ) .
( b) Dr ai n wat er f r om oi l cool er .
( c) Dr ai n al l st eam l i nes.
( d) Dr ai n al l cool i ng l i nes.
( e) Dr ai n wat er - cool ed di aphr agms.
( f ) Tag equi pment cont r ol s.
( a) Keep a dai l y oper at i ng l og t o ai d i n det ect i ng equi pment
mal f unct i ons. The f ol l owi ng l i st may be hel pf ul i n desi gni ng a si t e speci f i c
oper at i ons l og f or col l ect i ng and devel opi ng a usef ul dat a base:
( 1) Log- i n t i me
( 2) Vi br at i on moni t or r eadi ng at each compr essor st age
( 3) War ni ng l i ght s
( 4) I nl et t emper at ur e
( 5) I nl et f i l t er pr essur e
( 6) Pr essur e and t emper at ur e of each compr essor st age
( 7) Condi t i on of condensat e t r ap at each compr essor st age
( 8) Ai r cool er s t emper at ur e i n and out
3- 7
( 9) Oi l pr essur e
( 10) Oi l cool er t emper at ur e i n and out
( 11) Oi l l evel at mot or
( 12) Oi l l evel at oi l r eser voi r
( 13) Dr ai n dr i p l egs
( 14) Hour s on uni t
( 15) Bear i ng t emper at ur es
( 16) Compr essor speed
( b) Wi pe down machi ne dai l y wi t h cl ean, l i nt - f r ee r ag.
6 PREVENTI VE MAI NTENANCE I NSPECTI ON. An i nspect i on and mai nt enance pr ogr am
i s i mpor t ant t o ensur e sat i sf act or y per f or mance. One of t he most i mpor t ant
aspect s of any mai nt enance pr ogr am i s pr udent use of t he oper at i onal dat a base
compi l ed f r oma dai l y oper at i ng l og [ par agr aph 5( a) ] . An oper at i onal l og
pr ovi des an i ndi cat i on of per f or mance, need f or revi si ng the mai ntenance
schedul e, and, i ndi r ect l y, spar e par t s r equi r ement s. Gener al i zed pr ocedur es
ar e pr esent ed her ei n, but f r equency of i nspect i ons wi l l var y and must r ef l ect
each i nst al l at i on' s oper at i ng condi t i ons and envi r onment .
6. 1 Dai l y I nspect i on. Pr event i ve mai nt enance i nspect i ons shal l i ncl ude t he
f ol l owi ng t asks.
( a) Revi ew t he cur r ent oper at i ng l og f or si gni f i cant devi at i ons i n t he
dat a such as:
( 1) Abnor mal pr essur es or t emper at ur es of l ubr i cat i ng oi l
( 2) Abnor mal appear ance or pr esence of wat er i n l ubr i cat i ng oi l
( 3) Lubr i cat i ng oi l l evel s
( 4) Abnor mal bear i ng t emper at ur es
( 5) I ncr eased i nl et f i l t er pr essur e
( b) Li st en f or unusual noi ses.
( c) Li st en and f eel f or unusual vi br at i ons.
( d) Vi sual l y i nspect t he compl et e compr essor pl ant f or l eaki ng f i t t i ngs
or l oose f ast ener s.
6. 2 Semi annual I nspect i on. I n addi t i on t o per f or mi ng i nspect i ons speci f i ed
i n par agr aph 6. 1, per f or m t he f ol l owi ng t asks.
( a) Check l ubr i cat i ng oi l f or det er i or at i on and/ or pr esence of wat er .
3- 8
( b) Test saf et y cont r ol s t o ensur e pr oper f unct i oni ng.
6. 3 Annual I nspect i on. I n addi t i on t o per f or mi ng i nspect i ons speci f i ed i n
par agr aphs 6. 1 and 6. 2, per f or m t he f ol l owi ng pr ocedur es wher e appl i cabl e.
( a) Check j our nal and t hr ust bear i ngs f or wear . Adj ust or r epl ace as
r equi r ed.
( b) Check al i gnment and coupl i ng condi t i on. Vi sual l y i nspect coupl i ng
condi t i on and use di al i ndi cat or t o r eal i gn coupl i ng wi t hi n speci f i ed
t ol er ances ( par agr aph 7. 2) .
( c) Cl ean and r epai nt al l ar eas of cor r osi on or peel i ng pai nt on
compr essor case.
( d) Check compr essor bol t s f or t i ght ness. Ret i ght en l oose bol t s t o
speci f i ed t or que val ues.
6. 4 I nt er nal I nspect i on. I f compr essor per f or mance has f al l en of f , or noi se
or dr i ver over l oad i ndi cat e i nt er nal t r oubl e, di smant l e t he compr essor and
make t he f ol l owi ng i nspect i on.
( a) Exami ne casi ng or st at or f or cor r osi on or er osi on damage and di r t .
( b) Check case f or wat er l eaks i f di aphr agm cool i ng i s pr ovi ded.
( c) I nspect r ot or f or cor r osi on or er osi on damage t o i mpel l er s or bl ades.
( d) Check r ot or f or bal ance.
( e) Check cl ear ances and condi t i on of r ot or , bear i ngs, and seal s.
Recor d al l measur ement s. I f t he need f or bear i ng r epl acement i s i ndi cat ed,
r ef er t o par agr aph 7. 3.
( f ) Per f or ml ubr i cat i on syst emmai nt enance ( par agr aph 7. 1) .
7 MAI NTENANCE.
7. 1 Lubr i cat i on Syst em. Lubr i cat i on syst em mai nt enance must be per f or med at
i nt er val s pr escr i bed f or each speci f i c i nst al l at i on. I n addi t i on, l ubr i cat i on
syst emmai nt enance shal l be per f or med at t i mes of i nt er nal i nspect i on and
r epai r . Lubr i cat i on syst em mai nt enance i ncl udes t he f ol l owi ng t asks.
( a) Cl ean oi l f i l t er s and st r ai ner s or r epl ace car t r i dges.
( b) Change oi l i f i t i s war r ant ed by a chemi cal anal ysi s or per i odi c
schedul e. To change oi l per f or m t he f ol l owi ng t asks.
( 1) Tag equi pment cont r ol s.
( 2) Dr ai n oi l f r omal l syst ems.
3- 9
To avoi d i nternal damage to equi pment, use onl y syntheti c sponges
when cl eani ng i nternal surf aces and components. Do not use cl oth
rags or cotton waste.
( 3) Thoroughl y cl ean beari ng chambers and oi l reservoi rs.
Do not use gasol i ne, kerosene, or other l ow f l ashpoi nt sol vents. A
seri ous expl osi on may resul t.
( 4) Fl ush out compl ete l ubri cati ng systemwi th f l ushi ng oi l .
( 5) I nspect oi l pumps f or corrosi on, erosi on, and wear.
( 6) Remove tube bundl es f romoi l cool ers, i f appl i cabl e, and
thoroughl y cl ean tubes.
( 7) Ensure cl osure of al l drai n val ves, rei nstal l ati on of pl ugs,
and rei nstal l ati on of sump covers.
( 8) Ref i l l l ubri cati ng oi l reservoi rs to proper l evel .
( 9) Remove tag f romcontrol s.
( 10) Fol l ow procedures f or startup provi ded i n paragraph 2. 2.
7. 2 Al i gnment. Al i gnment of the uni t may be checked wi th a di al i ndi cator.
Ref er to speci f i c i nstal l ati on manual f or appl i cabl e tol erances. To al i gn the
coupl i ng, perf ormthe f ol l owi ng procedure.
To ensure proper al i gnment, check al i gnment i n both the hot and col d
condi ti on. Af ter checki ng the al i gnment i n the col d condi ti on,
operate the compressor under f ul l l oad f or 1 hour. Shut down the
uni t and recheck the al i gnment i mmedi atel y.
NOTE
When usi ng the di al i ndi cator, make sure the compressor shaf t end
pl ay i s hel d constant i n one di recti on.
( a) Attach i ndi cator bracket to compressor hub of coupl i ng. Fi gure 3- 6
i l l ustrates two methods of attachi ng the i ndi cator mounti ng bracket to the
coupl i ng.
3- 10
( b) At t ach di al i ndi cat or t o mount i ng br acket wi t h t he poi nt er
cont act i ng t he shoul der on t he coupl i ng hub.
( c) Rot at e compr essor shaf t and t ake r eadi ngs 90 apar t .
( d) Cor r ect axi al mi sal i gnment by addi ng or r emovi ng shi ms under t he
dr i ver t o br i ng compr essor and dr i ve cent er l i nes i nt o al i gnment .
( e) To check angul ar al i gnment , f ol l ow t he above pr ocedur e, but t ake
i ndi cat or r eadi ngs on t he coupl i ng hub f ace ( f i gur es 3- 6 and 3- 7) .
( f ) To cor r ect angul ar mi sal i gnment , par al l el t he coupl i ng f aces by
shi f t i ng t he dr i ve on i t s base and addi ng or r emovi ng shi ms under t he dr i ver
base.
7. 3 Bear i ngs. Cent r i f ugal and axi al f l ow compr essor s ut i l i ze many bear i ng
t ypes such as: spl i t sl eeve, st eel backed babbi t i nser t s, t i l t i ng pad, and
ant i f r i ct i on r ol l er and bal l bear i ngs. Use speci f i c manuf act ur er ' s
i nf or mat i on f or bear i ng wear , adj ust ment , and r epl acement consi der at i ons.
FI GURE 3- 6. Al i gnment Set up
3- 11
FI GURE 3- 7. Coupl i ng Al i gnment and Mi sal i gnment
3- 12
CHAPTER 4. AUXI LI ARY EQUI PMENT
Sect i on 1. I NTAKE FI LTERS
1 DESCRI PTI ON. Ai r f i l t er s ar e pr ovi ded on ai r compr essor i nt akes t o pr event
at mospher i c dust f r om ent er i ng t he compr essor and causi ng scor i ng and
excessi ve wear . Ther e ar e t wo t ypes of ai r f i l t er s, t he dr y t ype and t he
oi l - wet t ed t ype. Gener al l y, dr y t ype f i l t er s ar e mor e ef f i ci ent t han
oi l - wet t ed t ypes i n t r appi ng and r emovi ng ver y f i ne, sol i d par t i cl es f r omt he
i ncomi ng ai r . However , dr y t ype f i l t er s must be cl eaned and r epl aced mor e
of t en t han oi l - wet t ed t ypes. Oi l - wet t ed t ypes ar e of t en used wher e t her e ar e
heavy dust concent r at i ons pr esent i n t he at mospher e.
1. 1 Dr y Type Fi l t er . Dr y f i l t er s empl oy many di f f er ent mat er i al s f or t he
f i l t er medi a. Paper , pol yest er f el t , and f i ne wi r e mesh ar e a f ew exampl es.
The f i l t er medi a can be f ol ded, wr apped, and l ayer ed i n many conf i gur at i ons t o
achi eve t he desi r ed ef f i ci ency. Al t hough t he dr y f i l t er i s mor e ef f i ci ent
t han t he wet t ed t ype f i l t er , t he por es i n t he dr y f i l t er medi a become cl ogged
and r esul t i n a pr essur e dr op acr oss t he f i l t er . Dr y t ype f i l t er s cannot be
used successf ul l y wher e i nt ake ai r cont ai ns moi st ur e or vapor s i n amount s t hat
woul d cause di si nt egr at i on of t he f i l t er i ng medi a. The mai n advant ages of t he
dr y t ype f i l t er , when used i n an appr oved appl i cat i on, i s i t s hi gh ef f i ci ency
and ease of mai nt enance.
1. 2 Oi l - Wet t ed Type Fi l t er . Wet f i l t er s have f i l t er el ement s t hat ar e coat ed
wi t h a f i l mof oi l . The oi l f i l mcat ches ai r bor ne par t i cul at es bef or e t hey
r each t he act ual f i l t er el ement medi a. Wet t ed t ype f i l t er s ar e of t wo
desi gns, oi l - wet t ed and oi l - bat h f i l t er s. I n an oi l - wet t ed f i l t er , a coat i ng
of oi l i s deposi t ed on t he f i l t er el ement , whi ch i s usual l y made of l ayer s of
wi r e mesh. The oi l coat i ng i s i nt ended t o adher e t o t he el ement f or a f ai r l y
l ong ser vi ce per i od. The ai r bor ne par t i cul at es ar e i mpi nged or t r apped on t he
f i l t er el ement whi ch has been cover ed wi t h a f i l m of oi l . I n an oi l - bat h
f i l t er ( f i gur e 4- l ) , t he same vi scous i mpi ngement pr i nci pl e i s empl oyed.
However , t he ai r f l ow i s di r ect ed t hr ough t he oi l sump, car r yi ng oi l wi t h i t t o
t he f i l t er el ement wher e t he oi l col l ect s and washes t he i mpi nged par t i cl es
down t o t he oi l sump, f or mi ng sl udge. The sel f - washi ng aspect of t he oi l - bat h
f i l t er ext ends t he t i me bet ween mai nt enance r out i nes.
2 I NSPECTI ON. Ai r f i l t er i nspect i ons ar e t o be per f or med when any of t he
f ol l owi ng condi t i ons exi st .
( a) Pr escr i bed t i me i nt er val on t he mai nt enance schedul e has el apsed.
( b) Pr essur e dr op acr oss t he f i l t er el ement i ndi cat es a mai nt enance
r equi r ement .
( c) One- f our t h i nch of sl udge has bui l t up i n t he oi l sump of t he
oi l - bat h t ype f i l t er .
4- l
FI GURE 4- l . Oi l - Bat h I nt ake Fi l t er
3 MAI NTENANCE. Mai nt enance met hods di f f er f or each t ype of ai r f i l t er . Use
t he appr opr i at e met hod f or t he f i l t er under goi ng mai nt enance per t he f ol l owi ng
par agr aphs.
Dr y t ype f i l t er el ement s can easi l y be damaged al l owi ng har mf ul
par t i cul at es t o pass. I f i n doubt about cor r ect cl eani ng
pr ocedur es, r epl ace t he f i l t er el ement .
3. 1 Dr y Type Fi l t er . Ser vi ce t he f i l t er assembl y as f ol l ows:
( a) Shut down compr essor and t ag cont r ol s.
( b) Remove t op of f i l t er assembl y.
( c) Remove f i l t er el ement and cl ean as pr escr i bed by manuf act ur er or
r epl ace.
( d) Reassembl e f i l t er el ement and t op t o f i l t er assembl y.
( e) Remove t ag f r om cont r ol s.
3. 2 Oi l - Wet t ed Type Fi l t er . Cl ean t he f i l t er assembl y as f ol l ows:
4- 2
( b) Remove t he t op and f i l t er el ement f r omf i l t er assembl y.
( c) Wash f i l t er el ement wi t h appr oved sol vent or det er gent and wat er
sol ut i on.
( d) Dr y f i l t er el ement t hor oughl y.
( e) Appl y f r esh oi l by spr ay or di p and l et excess oi l dr ai n. Use oi l
t ype suggest ed by manuf act ur er .
( f ) Cl ean f i l t er body.
( g) Rei nst al l f i l t er el ement and t op t o f i l t er assembl y.
( h) Remove t ag f r om cont r ol s.
3. 3 Oi l - Bat h Fi l t er . Cl ean t he f i l t er assembl y as f ol l ows:
( b) Remove f i l t er assembl y f r om compr essor .
( c) Wash f i l t er el ement wi t h appr oved sol vent or det er gent and wat er
sol ut i on.
( d) Dr y f i l t er el ement t hor oughl y.
( e) Cl ean and dr y f i l t er oi l sump.
( f ) Add oi l t o oi l sump t o i ndi cat ed l evel .
( g) Rei nst al l f i l t er el ement and t op on f i l t er assembl y.
( h) Rei nst al l f i l t er assembl y on compr essor .
( i ) Remove t ag f r omcont r ol s.
4- 3
4- 4
Sect i on 2. SI LENCERS
1 DESCRI PTI ON. Compr essor syst emsi l encer s ar e sound- absor bi ng accessor i es
at t ached t o t he syst emat t he i nt ake and out put of t he compr essor . The
si l encer s absor b noi se pr oduced by t he compr essor i n or der t o r educe t he noi se
out put t o an accept abl e l evel . I n general , ai r noi se si l encers are
cyl i ndr i cal housi ngs cont ai ni ng acoust i cal l y t uned baf f l es and sound- absor bi ng
mat er i al ( f i gur e 4- 2) .
2 I NSPECTI ON AND MAI NTENANCE. At i nt er val s pr escr i bed by t he manuf act ur er ' s
mai nt enance schedul e, i nspect and per f or mmai nt enance on t he si l encer as
f ol l ows:
( a) Shut down syst em and t ag cont r ol s.
( b) I nspect i nt er nal par t s f or damage or l ooseni ng f r om cor r osi on or
vi br at i on.
( c) I nspect i nt er i or of si l encer and, i f di r t i s pr esent , cl ean as
f ol l ows:
( 1) Remove si l encer f r om i nt ake syst em and l ook f or sour ces of di r t
ent r y i nt o si l encer .
FI GURE 4- 2. Compr essor I nt ake Si l encer
4- 5
( 2) Cl ean si l encer usi ng appr oved sol vent or det er gent and wat er
sol ut i on.
( 3) Dr y si l encer t hor oughl y.
Ensur e al l j oi nt s ar e t i ght t o avoi d ent r y of unf i l t er ed ai r . Di r t
i n t he ai r wi l l cause pr emat ur e wear t o t he compr essor .
( 4) Rei nst al l si l encer i nt o compr essor syst em usi ng new gasket s and
seal s.
( d) Check al l ext er nal sur f aces f or cor r osi on, peel i ng, or damaged
pai nt . Repai nt as necessar y.
( e) Remove t ag f r om cont r ol s.
4- 6
Secti on 3. I NTERCOOLERS AND AFTERCOOLERS
1 DESCRI PTI ON. I ntercool ers and af tercool ers are heat exchangers empl oyed to
di ssi pate the heat generated i n compressi on. There are two types of heat
exchangers used on ai r compressors, ai r- cool ed and water- cool ed.
1. 1 Ai r- Cool ed Heat Exchanger. Ai r- cool ed heat exchangers are most of ten
used on smal l compressors. The ai r- cool ed heat exchanger i s a f i nned, tubul ar
radi ator ( f i gure 4- 3) .
1. 2 Water- Cool ed Heat Exchanger. The most common desi gn of water- cool ed heat
exchangers, shel l and tube type, consi sts of a si ngl e bundl e of tubes encl osed
i nsi de a cyl i ndri cal shel l ( f i gure 4- 4) . The ai r to be cool ed passes through
the tubes whi l e the water passes over the tubes. Baf f l es are of ten provi ded
i n the tube bundl e to di rect the waterf l ow across the heat exchanger tubes i n
the most ef f i ci ent manner.
( a) The i ntercool er i s l ocated between the di scharge of one cyl i nder and
the i ntake of the next cyl i nder of mul ti stage compressors. The i ntercool er
reduces the temperature and the vol ume of the compressed ai r f or del i very to
the next compressi on stage.
( b) The af tercool er i s l ocated at the di scharge of the l ast cyl i nder to
cool the ai r, reduce i ts vol ume, and to l i qui f y any condensabl e vapors.
FI GURE 4- 3. Ai r- Cool ed Heat Exchanger
4- 7
FI GURE 4- 4. Water- Cool ed Heat Exchanger
2 STARTUP.
2. 1 Prestart I nspect i on. Caref ul l y i nspect the i ntercool er or af tercool er,
ensuri ng the f ol l owi ng prestart requi rements have been f ul f i l l ed.
( a) Veri f y compl eti on of al l i nstal l ati on or repai r work.
( b) Ensure equi pment has been cl eaned and tested f or l eaks.
( c) Ensure thermometers, pressure gauges, and control s are i n good
operati ng condi ti on.
( d) Ensure saf ety val ves are operati ng.
2. 2 Startup Procedure.
wat er f l ow bef or e st ar t i ng t he ai r compr essor . Pr oceed as f ol l ows:
Al ways start i ntercool er and af tercool er cool i ng
( a) Open ai r vent val ves on watersi de of cool er.
( b) Open cool i ng water i nl et and outl et val ves.
( c) Cl ose watersi de vent val ves af ter al l ai r has been di spl aced.
3 NORMAL OPERATI ON.
Mai ntai n rated cool i ng waterf l ow. Check ai rsi de drai n
peri odi cal l y to see that i t i s operati ng properl y and uni t i s f ree of
condensate.
4- 8
4 SHUTDOWN. I f t he compr essor i s goi ng t o be shut down, per f or mt he
f ol l owi ng pr ocedur es.
( a) Mai nt ai n cool i ng wat er f l ow unt i l cool er s have r eached ambi ent
t emper at ur e.
( b) Dr ai n al l wat er f r omcool i ng syst emi f t he cool er wi l l be exposed t o
f r eezi ng t emper at ur es.
5 OPERATI ONAL PREVENTI VE MAI NTENANCE. Obser ve t he f ol l owi ng pr ocedur es
dur i ng nor mal oper at i on.
( a) Mai nt ai n r at ed cool i ng wat er f l ow. Avoi d excessi ve wat er f l ow whi ch
mi ght cause er osi on.
( b) Adj ust wat er f l ow r at es sl owl y t o avoi d sudden t emper at ur e changes i n
t he cool er .
( c) Shut down compr essor i f condensat e t r ap i s col l ect i ng excessi ve
amount s of wat er . Cool er t ubes may be l eaki ng.
( d) Shut down compr essor i f cool er ai r t emper at ur e i s abnor mal l y hi gh.
Leak i n cool er t ubes coul d be al l owi ng ai r t o di spl ace cool i ng wat er i n
wat er si de of cool er .
6 PREVENTI VE MAI NTENANCE I NSPECTI ON.
6. 1 Dai l y I nspect i on. I nspect t he cool er dai l y f or t he f ol l owi ng condi t i ons:
( a) Pr oper oper at i on of t he aut omat i c cont r ol s and i nst r ument s
( b) Wat er l eaks, t emper at ur e, and f l ow r at e
( c) Any devi at i ons f r om nor mal t emper at ur e or pr essur e dr ops acr oss t he
cool er
6. 2 Per i odi c I nspect i on. I nspect t he f ol l owi ng i t ems at i nt er val s pr escr i bed
by t he manuf act ur er ' s mai nt enance schedul e.
( a) Check cool er f or cor r osi on and peel i ng pai nt .
wi t hout f i r st r el i evi ng pr essur e f r omt he ent i r e syst em.
( b) Check saf et y val ves f or set t i ng and pr oper oper at i on.
( c) Check manual and aut omat i c val ves f or l eakage and cor r osi on.
4- 9
( d) Remove t he t ube bundl e f r om t he cool er and car ef ul l y i nspect t he
i nt er nal s of t he uni t f or t he f ol l owi ng condi t i ons.
( 1) Cor r osi on t o t ubes, t ube sheet s, and baf f l es: Cor r osi on and
el ect r ol ysi s ( gal vani c cor r osi on) may appear ver y si mi l ar , but t hey ar e
di f f er ent and occur because of t he pr esence of ent i r el y di f f er ent el ement s.
Si nce car bon di oxi de and oxygen ar e t he mai n causes of cor r osi on, any
oper at i ng met hod t hat r educes t he cont ent of car bon di oxi de and/ or oxygen wi l l
r educe cor r osi ve ef f ect s. One met hod t o cont r ol CO2, and 02 l evel s i n t he
cool ant i s t o r educe cool ant l osses wher ever possi bl e. Thi s r educes t he ent r y
of addi t i onal f r ee CO2 and 02 pr esent i n most makeup wat er . Di f f er ent
pr et r eat ment s of makeup wat er may be r equi r ed such as: l i me soda sof t eni ng,
hot l i me zeol i t e sof t eni ng, aci d cycl e sof t eni ng, and sal t spl i t t i ng. Al l
t ypes r educe t he quant i t y of CO2. I nt er nal l y, cor r osi on of pi pi ng can be
cont r ol l ed by t he use of cor r osi on i nhi bi t or s. For mor e i nf or mat i on, r ef er t o
NAVFAC MO- 225, I ndust r i al Wat er Tr eat ment .
( 2) El ect r ol ysi s of t ubes, t ube sheet s, and baf f l es: El ect r ol ysi s
i s an el ect r ochemi cal cor r osi on associ at ed wi t h t he cur r ent caused by
di ssi mi l ar met al s i n an el ect r ol yt e ( cool ant ) . I t r esembl es er osi on i n
appear ance, but t he l oss of mat er i al i s due t o t he exposur e of t wo met al s of
di f f er ent composi t i ons ( such as st eel and br onze or st eel and al umi num) t o an
el ect r ol yt e ( cool ant ) . Two met hods used f or cont r ol l i ng t he ef f ect s of
el ect r ol ysi s ar e el ect r oni c cat hodi c syst ems and sacr i f i ci al anode pl acement
wi t hi n t he syst em( such as zi nc compound pl ugs) .
( 3) Er osi on t o t ubes, t ube sheet s, and baf f l es: Er osi on may be
evi dent at mat er i al edges, t ube ends, and baf f l es, due t o excessi ve f l ow r at es
and cool ant i mpur i t i es. Evi dence of er osi on i s r ounded edges or depr essi ons
i n mat er i al sur f aces at l ocat i ons wher e t he f l ow changes di r ect i on or r at e.
( 4) Leaki ng t ubes: Any l eaks i n t he cool er bet ween t he t ubes
car r yi ng cool ant and t he t ubes car r yi ng compr essed ai r i s det r i ment al t o t he
syst em. I f a l eak i s f ound dur i ng a di sassembl y i nspect i on i t shoul d be
r epai r ed bef or e r eassembl y. I n many i nst ances when t he wat er pr essur e i s
gr eat er t han t he ai r pr essur e, t he f i r st i ndi cat i on of a l eak i s t he sudden
i ncr ease of moi st ur e at t he separ at or or r ecei ver . I f t he ai r pr essur e i s
hi gher t han t he wat er pr essur e, ai r t hen ent er s t he cool ant syst emr esul t i ng
i n hi gher t emper at ur es.
( 5) Pl ugged t ubes: I f t ubes become pl ugged, i t i s an i ndi cat i on of
an i mbal ance i n t he cool ant - equi pment r el at i onshi p and condi t i oni ng of t he
cool ant shoul d be consi der ed. Pl ugged t ubes, dependi ng on t he number , usual l y
r esul t i n hi gher syst em t emper at ur es. Most pl ugged t ubes can be cl eaned
wi t hout causi ng damage t o t he t ube. Consul t t he manuf act ur er ' s i nst r uct i ons
f or det ai l s.
( 6) Scal e deposi t s: Scal e deposi t s ar e an i ndi cat i on of an
i mbal ance bet ween t he cool ant - equi pment r el at i onshi p. Condi t i oni ng of t he
cool ant shoul d be consi der ed. Scal e r esul t s i n hi gher syst em t emper at ur es.
Ref er t o t he manuf act ur er ' s i nst r uct i ons f or cor r ect i onal pr ocedur es.
4- 10
7 MAI NTENANCE.
Never hammer on t he t ubes or use shar p edged scr aper s whi ch may
damage t he t ubes.
Chemi cal sol ut i ons used f or cl eani ng shoul d be capabl e of di ssol vi ng
t he scal e or ot her deposi t s wi t hout at t acki ng t he met al .
7. 1 Cl eani ng. Tube i nt er i or s may be cl eaned by f l ushi ng a st r eamof wat er
t hr ough t hem. For mor e per si st ent deposi t s,
t ool s may be r equi r ed.
br ushes, r ods, or ot her cl eani ng
hot wat er .
Tube ext er i or s can be cl eaned by hosi ng wi t h st eamor
A st i f f br i st l e br ush wi l l ai d i n r emovi ng deposi t s f r ombet ween
t ubes. Cool er i nt er i or s may be cl eaned wi t hout di smant l i ng t he uni t by
ci r cul at i ng a chemi cal sol ut i on t hr ough i t . Al l chemi cal s shoul d be
t hor oughl y washed out of t he cool er bef or e r et ur ni ng i t t o ser vi ce.
7. 2 Tube Repl acement and Repai r . Cool er s wi t h l eaki ng t ubes must be r epai r ed
i n accor dance wi t h manuf act ur er s' r ecommendat i ons. Ref er to speci f i c
manuf act ur er ' s ser vi ce manual f or t ube r epai r and r epl acement i nst r uct i ons.
4- 11
4- 12
Sect i on 4. SEPARATORS
1 DESCRI PTI ON. Separ at or s ar e used on compr essor i nst al l at i ons t o r emove
ent r ai ned wat er and oi l f r om t he compr essed ai r . Fi gur e 4- 5 shows a
cent r i f ugal t ype moi st ur e separ at or wher e ai r i s di r ect ed i nt o t he uni t so
t hat i t obt ai ns a swi r l i ng mot i on. Cent r i f ugal act i on f or ces t he moi st ur e
par t i cl es agai nst t he wal l of t he separ at or wher e t hey dr ai n t o t he bot t om.
I n t he baf f l e t ype separ at or ( f i gur e 4- 6) t he ai r i s subj ect ed t o a ser i es of
sudden changes i n di r ect i on. The heavi er moi st ur e par t i cl es st r i ke t he
baf f l es and wal l s of t he separ at or and dr ai n t o t he bot t om of t he uni t .
2 OPERATI ON. Dr ai n separ at or s r egul ar l y i f aut omat i c dr ai ner s ar e not
pr ovi ded. Fr equency of dr ai ni ng i s best det er mi ned by exper i ence wi t h t he
i nst al l at i on. I mpr oper l y dr ai ned separ at or s r esul t i n moi st ur e car r yover i nt o
t he ai r di st r i but i on syst em.
3 PREVENTI VE MAI NTENANCE I NSPECTI ON. I nspect t he separ at or at per i odi c
mai nt enance i nt er val s f or t he f ol l owi ng condi t i ons:
( a) Ext er nal l y f or r ust , cor r osi on and peel i ng pai nt
( b) I nt er nal l y f or cor r osi on and accumul at i ons of di r t and oi l
( c) Gasket s f or damage
FI GURE 4- 5. Cent r i f ugal Type Separ at or
4- 13
FI GURE 4- 6. Baf f l e Type Separ at or
4 MAI NTENANCE. Per f or mt he f ol l owi ng mai nt enance t asks.
( a) Remove cor r osi on and peel i ng pai nt .
( b) Pr i me and pai nt pr epar ed sur f aces.
( c) Thor oughl y cl ean separ at or i nt er nal s.
( d) Repl ace def ect i ve gasket s.
4- 14
Sect i on 5. TRAPS
1 DESCRI PTI ON. Tr aps dr ai n condensed moi st ur e f r om i nt er cool er s,
af t er cool er s, r ecei ver s, and di st r i but i on pi pi ng. The most common t r aps ar e
t he bal l f l oat t r ap, bucket t r ap, and i nver t ed bucket t r ap ( f i gur e 4- 7) . An
i n dept h di scussi on of t r aps i s f ound i n NAVFAC MO- 209, Mai nt enance of St eam,
Hot Wat er , and Compr essed Ai r Di st r i but i on Syst ems.
2 STARTUP. Some compr essed ai r dr ai n t r aps must be pr i med bef or e pl aci ng
t hem i n ser vi ce. Thi s i s done by f i l l i ng t he t r ap hal f f ul l wi t h f r eshwat er .
3 SHUTDOWN. I f t he compr essed ai r syst em i s not i n oper at i on and t he dr ai n
t r aps mi ght be subj ect ed t o f r eezi ng t emper at ur es, t hor oughl y dr ai n t he t r aps
of al l condensat e t o pr event damage f r omf r eezi ng.
4. 1 Dai l y I nspect i on. Check t he oper at i on of dr ai n t r aps dai l y. Make sur e
t he t r ap i s dr ai ni ng pr oper l y and not bl owi ng ai r .
4. 2 Per i odi c I nspect i on. At i nt er val s pr escr i bed by t he manuf act ur er ' s
mai nt enance schedul e, di smant l e t he t r ap. Par t s shoul d be cl eaned and
eval uat ed as t o t hei r abi l i t y t o per f or msat i sf act or i l y unt i l t he next
schedul ed per i odi c i nspect i on. I nspect t he t r ap f or t he f ol l owi ng condi t i ons:
( a) Cor r osi on and er osi on
( b) Damaged or excessi vel y wor n val ves and seat s
( c) Def ect i ve f l oat or bucket
( d) Loose, damaged, or excessi vel y wor n l i nkage and pi vot poi nt s
5 MAI NTENANCE.
Do not at t empt t o r epai r or r emove any compr essor syst empar t s
5. 1 Cl eani ng. Fr equency of cl eani ng depends upon t he condi t i on of t he syst em
and whet her or not a st r ai ner i s i nst al l ed ahead of t he t r ap. Thor oughl y
cl ean t r ap i nt er nal s. Remove al l di r t accumul at i ons f r om t he t r ap body and
mechani sm, usi ng det er gent and wat er , or an appr oved sol vent i f necessar y.
Val ve seat s may be cl eaned usi ng a smal l spi r al br ush.
4- 15
FI GURE 4- 7. Dr ai n Tr aps
4- 16
FI GURE 4- 7. Dr ai n Tr aps ( Cont i nued)
5. 2 Val ves and Seat s. Repl ace badl y wor n or gr ooved val ves and seat s. I f
ei t her t he val ve or t he seat i s wor n, r epl ace bot h as t hey ar e mat ched par t s.
Ensur e t hat t he val ve and seat ar e cl ean bef or e i nst al l at i on. For ei gn mat t er
wi l l i nt er f er e wi t h pr oper seat i ng.
5. 3 Lever s. Lever s and l i nkages wear at pi vot poi nt s.
I f excessi ve pl ay i n
t he l i nkages i s f ound, t hey shoul d be r epl aced. Wor n l ever s af f ect t he bucket
or f l oat t r avel and r esul t i n a l oss of capaci t y.
Repl ace cor r oded or wor n
pi ns.
5. 4 Bucket s and Fl oat s. Repl ace cor r oded or damaged bucket s or f l oat s.
4- 17
4- 18
Sect i on 6. AI R RECEI VERS
1 DESCRI PTI ON. Ai r r ecei ver s ( f i gur e 4- 8) ser ve as r eser voi r s f or t he
st or age of compr essed ai r so t hat ai r i s avai l abl e t o meet peak demands i n
excess of t he compr essor capaci t y. They al so f unct i on as pul sat i on damper s on
r eci pr ocat i ng compr essor i nst al l at i ons. Ai r r ecei ver s ar e usual l y ver t i cal l y
mount ed, but may be hor i zont al i n t he smal l er si zes. Recei ver s ar e f ur ni shed
wi t h a r el i ef val ve, pr essur e gauge, dr ai n val ve, and i nspect i on openi ngs.
2 NORMAL OPERATI ON. Dr ai n r ecei ver s of accumul at ed condensat e at l east once
each shi f t i f an aut omat i c dr ai ner i s not pr ovi ded.
3. 1 Dai l y I nspect i on. Check aut omat i c dr ai ner f or pr oper oper at i on, i f one
i s pr ovi ded.
3. 2 Per i odi c I nspect i on. Pr oceed as f ol l ows at i nt er val s pr escr i bed by t he
manuf act ur er ' s mai nt enance schedul e.
( a) Check oper at i on of saf et y val ve.
( b) Exami ne r ecei ver f or cor r osi on and peel i ng pai nt .
( c) I nspect t he r ecei ver i nt er nal l y f or cor r osi on and di r t accumul at i on.
( d) Ref er t o NAVFAC MO- 324, I nspect i on and Cer t i f i cat i on of Boi l er s and
Unf i r ed Pr essur e Vessel s.
FI GURE 4- 8. Ai r Recei ver
4- 19
4 MAI NTENANCE. Pr oceed as f ol l ows:
( a) Thor oughl y cl ean t he r ecei ver i nt er nal s annual l y.
( b) Cal i br at e pr essur e gauge semi annual l y.
( c) Repai nt ext er i or of r ecei ver wher e t her e i s cor r osi on or damaged
pai nt .
4- 20
1 DESCRI PTI ON. Compr essed ai r dr yer s r emove moi st ur e t hat mi ght ot her wi se
condense i n ai r l i nes, ai r t ool s, and pneumat i c i nst r ument s. Thi s condensat e
can cause damage t o equi pment f r om cor r osi on, f r eezi ng, and wat er hammer , and
can cause mal f unct i oni ng of i nst r ument s and cont r ol s.
2. TYPES. Thr ee t ypes of ai r dr yer s ar e avai l abl e: adsor pt i on, del i quescent ,
and r ef r i ger at i on.
2. 1 Adsor pt i on Type. The adsor pt i ve or desi ccant dr yer cont ai ns a bed of an
i ner t desi ccant mat er i al , ei t her si l i ca gel or act i vat ed al umi na, whi ch has
hi gh adsor pt i ve sur f ace ar ea f or a gi ven wei ght and vol ume. Thi s ar ea i s i n
submi cr oscopi c cavi t i es t hat can hol d wat er vapor r emoved f r omt he ai r . When
t he adsor pt i ve desi ccant i s compl et el y sat ur at ed wi t h wat er , t he wat er can be
dr i ven of f agai n by heat i ng. An ai r st r eam passed t hr ough t he desi ccant wi l l
car r y away t he r el eased wat er vapor r est or i ng t he desi ccant t o i t s i ni t i al
adsor pt i ve condi t i on. Adsor pt i on t ype dr yer s ( f i gur e 4- 9) gener al l y consi st
of t wo dr yi ng t ower s, each cont ai ni ng an adsor bent , pl umbed i n par al l el . The
dr yer t ower s ar e cycl ed ei t her manual l y, semi aut omat i cal l y, or aut omat i cal l y,
so t hat one dr yi ng t ower i s on st r eam whi l e t he ot her t ower i s bei ng
r eact i vat ed. React i vat i on i s accompl i shed by means of el ect r i c or st eam
heat er s embedded i n t he adsor bent or by passi ng dr i ed pr ocess ai r t hr ough t he
uni t .
Sect i on 7. DRYERS
FI GURE 4- 9. Fl ow Di agr am of El ect r i c React i vat ed Adsor pt i on Dr yer
4- 21
2. 2 Del i quescent ( Absor pt i on) Type. The del i quescent or absor pt i on dr yer i s
l owest i n i ni t i al cost but r equi r es cont i nual r epl eni shment of t he dr yi ng
medi um ( f i gur e 4- 10) . Si mpl e i n desi gn, t hi s t ype of dr yer i s a pr essur e
vessel i n whi ch a bed of cr yst al l i ne sol i ds i s pl aced on t op of a scr een whi ch
i s l ocat ed cl ose t o t he bot t om of t he vessel . Wet ai r f r om t he af t er cool er
and separ at or ent er s t he bot t omof t he vessel and f l ows upwar d t hr ough t he
bed. As i t passes t hr ough t he bed, t he l i qui d wat er and vapor pr esent i n t he
ai r , di ssol ve t he dr yi ng medi um i n what i s t er med a del i quescent ef f ect . The
r esul t i ng sol ut i on t r i ckl es t o t he bot t omof t he dr yer wher e i t i s r emoved by
a t r ap. The f r equency wi t h whi ch t he cr yst al l i ne absor bent mat er i al must be
r epl aced i s a f unct i on of t he desi gn t hi ckness of t he bed and t he amount of
wat er and vapor pr esent i n t he ai r ent er i ng t he dr yer .
2. 3 Ref r i ger at i on Type. Dr yer s t hat r emove moi st ur e f r omt he ai r by
condensat i on i ncor por at e a mechani cal r ef r i ger at i on uni t ( f i gur e 4- 11) or col d
wat er , i f avai l abl e. I nl et ai r passes t hr ough t he pr ecool er / r eheat er t o t he
ai r - t o- r ef r i ger ant exchanger whi ch cont ai ns t he r ef r i ger at i on coi l s. As t he
ai r passes over t he coi l s, f ur t her cool i ng t akes pl ace and moi st ur e condenses
i nt o dr opl et s. The dr opl et s of oi l or wat er t hen pass t hr ough t he
moi st ur e/ oi l separ at or and ar e col l ect ed and dr ai ned t hr ough a condensat e
t r ap. The cool , dr y ai r i s t hen di r ect ed back t hr ough t he pr ecool er / r eheat er ,
war med by t he i ncomi ng ai r and di schar ged f or r euse by t he syst em.
FI GURE 4- 10. Del i quescent ( Absor pt i on) Dr yer
4- 22
FI GURE 4- 11. Fl ow Di agr am of Ref r i ger at i on Dr yer
3 NORMAL OPERATI ON.
Do not over r un t he uni t . Over r unni ng wi l l r esul t i n t he t ower
becomi ng sat ur at ed and unabl e t o adsor b any mor e moi st ur e. Moi st ur e
l aden ai r wi l l t hen be car r i ed over i nt o t he di st r i but i on syst em.
On syst ems wher e oi l car r yover f r omt he compr essor i s pr esent ,
pr ovi si on shoul d be made t o pr ot ect t he desi ccant bed of t he dr yer
f r om becomi ng oi l sat ur at ed. Oi l deposi t s i n t he desi ccant bed
cause a decr ease i n dr yi ng ef f i ci ency and necessi t at e f r equent
r epl acement of t he desi ccant .
3. 1 Adsor pt i on Type Dr yer . Mai nt ai n nor mal oper at i ng pr essur e and
t emper at ur e i n t he dr yi ng t ower s. Ensur e pr oper oper at i on of condensat e t r aps
on st eamr eact i vat ed dr yer s. React i vat e dr yi ng t ower s at t he i nt er val s
speci f i ed by t he manuf act ur er i f r eact i vat i on i s not under aut omat i c cont r ol .
3. 2 Del i quescent Type Dr yer . Mai nt ai n nor mal oper at i ng t emper at ur es and
pr essur es i n t he dr yer . Mai nt ai n an adequat e l evel of dr yi ng medi um i n t he
dr yer . Ensur e condensat e t r ap i s f unct i oni ng pr oper l y.
4- 23
3. 3 Ref r i ger at i on Type Dr yer . Ensur e condensat e t r ap i s dr ai ni ng pr oper l y
and condensat e i s not al l owed t o bui l d up.
4. 1 Adsor pt i on Type Dr yer .
4. 1. 1 Dai l y I nspect i on. I nspect t he dr yer assembl y f or t he f ol l owi ng
condi t i ons:
( a) Pr oper oper at i on of i nst r ument s and dr ai n t r aps wher e pr ovi ded
( b) Ai r or st eam l eaks
4. 1. 2 Per i odi c I nspect i on. Thor oughl y i nspect t he i nst al l at i on at i nt er val s
pr escr i bed by t he manuf act ur er ' s mai nt enance schedul e. Check t he f ol l owi ng
i t ems:
( a) Saf et y val ves f or pr oper oper at i on
( b) Dr yer t ower s, pi pi ng, and val ves f or cor r osi on, r ust , and peel i ng
pai nt
( c) Desi ccant bed f or oi l , di r t , or ot her f or ei gn mat t er
4. 2 Del i quescent Type Dr yer .
4. 2. 1 Dai l y I nspect i on. I nspect t he dr yer assembl y f or t he f ol l owi ng
condi t i ons:
( a) Pr oper oper at i on of i nst r ument s and dr ai n t r aps wher e pr ovi ded
( b) Ai r or st eam l eaks
4. 2. 2 Per i odi c I nspect i on. Thor oughl y i nspect t he i nst al l at i on at i nt er val s
pr escr i bed by t he manuf act ur er ' s mai nt enance schedul e. Check t he f ol l owi ng
i t ems:
( a) Saf et y val ves f or pr oper oper at i on
pai nt
( b) Dr yer t ower s, pi pi ng, and val ves f or cor r osi on, r ust , and peel i ng
4- 24
( c) Desi ccant l evel
4. 3 Ref r i ger at i on Type Dr yer .
4. 3. 1 Dai l y I nspect i on. I nspect f or t he f ol l owi ng condi ti ons:
( a) Pr oper oper at i on of condensat e dr ai ner
( b) Ai r l eaks
4. 3. 2 Per i odi c I nspect i on. Thor oughl y i nspect t he i nstal l ati on at i nterval s
pr escr i bed by t he manuf act ur er ' s mai nt enance schedul e. Exami ne the f ol l owi ng
i t ems:
( a) Condi t i on of f i l t er car t r i dge
( b) Condensat e col l ect i on chamber and condenser - evapor at or t ubes f or oi l
and di r t accumul at i on
5 MAI NTENANCE.
5. 1 Adsor pt i on Type Dr yer . Pr oceed as f ol l ows:
( a) Cal i br at e i nst r ument s semi annual l y.
( b) Lubr i cat e and r epack l eaki ng val ves.
( c) Repai r al l l eaks.
( d) Repai r or r epl ace def ect i ve cont r ol s and i nst r ument s.
( e) Repai nt dr yer t ower s and pi pi ng wher e pai nt i s damaged.
4- 25
( f ) Repl ace desi ccant. Ref er to desi ccant manuf acturer' s i nstructi ons
f or proper i nterval s and i nstructi ons.
5. 2 Del i quescent Type Dryer. Proceed as f ol l ows:
Do not attempt to repai r or remove any compressor systemparts
wi thout f i rst rel i evi ng pressure f romthe enti re system.
( a) Cal i brate i nstruments semi annual l y.
( b) Lubri cate and repack l eaki ng val ves.
( c) Repai r al l l eaks.
( d) Repai r or repl ace def ecti ve control s and i nstruments.
( e) Repai nt dryer towers and pi pi ng where pai nt i s damaged.
( f ) Repl ace dryi ng medi umas requi red. Ref er to dryi ng medi um
manuf acturer' s i nstructi ons.
5. 3 Ref ri gerati on Type Dryer. Proceed as f ol l ows:
Do not attempt to servi ce the seal ed ref ri gerati on uni t; damage to
the uni t may resul t. Contact the manuf acturer i n the event of any
mal f unct i on.
( a) Cl ean or repl ace f i l ter el ement as requi red.
( b) Cl ean deposi ts f rom condensate col l ecti on chamber and condenser-
evaporator tubes wi th compressed ai r or steam.
( c) Lubri cate and repack l eaki ng val ves.
4- 26
CHAPTER 5. CONTROLS
Sect i on 1. PRI ME MOVER CONTROLS
1 DESCRI PTI ON. Compr essed ai r del i ver y i s r egul at ed by cont r ol of t he
compr essor dr i ve. Thi s i s accompl i shed by var yi ng t he dr i ve speed t o r egul at e
ai r out put i n r esponse t o l oad var i at i ons.
1. 1 St eam Engi ne Cont r ol s. The st eam engi ne i s st i l l used t o a l i mi t ed
ext ent as a pr i me mover at some Navy i nst al l at i ons. When st eam engi nes
r equi r e r epl acement , t hey ar e usual l y r epl aced by el ect r i c mot or s, st eam
t ur bi nes, and i nt er nal combust i on engi nes. Wher e t he st eam engi ne i s used
wi t h r eci pr ocat i ng compr essor s, i t i s gener al l y i nt egr al t o t he compr essor .
Cont r ol i s nor mal l y f ur ni shed wi t h st eam- dr i ven ai r compr essor s by a
combi nat i on of speed and pr essur e gover nor s. These gover nor s ar e of t wo
t ypes, t hr ot t l i ng and aut omat i c cut of f .
1. 1. 1 Thr ot t l i ng Gover nor s. A change i n st eampr essur e changes i n compr essor
speed. Thi s change var i es t he del i ver y of t he oi l pump whi ch i s chai n- dr i ven
f r om t he compr essor shaf t . Oi l di schar gi ng f r om t he pump passes t hr ough a
var i abl e r est r i ct i on. The back pr essur e r est r i ct i on i s appl i ed t o t he
di aphr agm of t he t hr ot t l e val ve. I ncr eased oi l del i ver y and compr essor speed
r ai ses t he pr essur e on t he di aphr agm causi ng t he t hr ot t l e val ve t o cl ose,
r est or i ng t he speed of t he compr essor . A smal l or i f i ce and r et ur n l i ne i s
pr ovi ded f r omt he t hr ot t l e val ve di aphr agmt o per mi t a smal l amount of oi l t o
be r eci r cul at ed t o pr event any ai r f r om accumul at i ng i n t he di aphr agm. When
r ecei ver pr essur e changes,t he pr essur e cont r ol val ve var i es t he r est r i ct i on
i n t he oi l l i ne f r omt he pump. Thi s changes t he back pr essur e appl i ed t o t he
di aphr agm of t he t hr ot t l e val ve, whi ch changes t he compr essor speed t o r est or e
r ecei ver pr essur e. Thi s cont r ol i s used wi t h st eam engi nes of 150 hp or l ess.
1. 1. 2 Automati c Cutof f Governors. I n t he aut omat i c cut of f gover nor ,
hydr aul i c pr essur e i s suppl i ed by t he oi l pump whi ch i s dr i ven f r omt he
compr essor shaf t . Any var i at i on i n st eam pr essur e, whi ch changes t he speed of
t he compr essor , causes a change i n oi l pr essur e f r omt he pump. Thi s pr essur e
change ei t her r ai ses or l ower s t he pi st on. The r ack on t he pi st on r ot at es t he
spr ocket , whi ch i n t ur n r ot at es t he cut of f val ve r od t o r eset t he cut of f and
adj ust t he speed. Any change i n r ecei ver pr essur e al so af f ect s t he hydr aul i c
pr essur e. The pr essur e cont r ol val ve, whi ch senses r ecei ver pr essur e,
bypasses some of t he oi l f l ow t o i ncr ease or decr ease hydr aul i c pr essur e.
1. 1. 3 Aut omat i c St ar t - St op Gover nor s. Aut omat i c st ar t - st op gover nor s ( f i gur e
5- l ) ar e al so used on st eam- dr i ven compr essor s. Thi s gover nor has a
spr i ng- l oaded di aphr agm, t he under si de of whi ch i s al ways open t o r ecei ver
pr essur e. When r ecei ver pr essur e becomes gr eat er t han t he spr i ng pr essur e
above t he di aphr agm, t he di aphr agmi s r ai sed, unseat i ng t he needl e val ve. Ai r
t hen f l ows t o t he chamber above t he pi st on at t ached t o t he st eamval ve. Ai r
pr essur e on t hi s pi st on f or ces t he st eamval ve t o i t s seat , cut t i ng of f t he
f l ow of st eam t o t he compr essor . Wi t h a decr ease i n st eampr essur e, t he val ve
oper at es i n r ever se t o r eadmi t st eamt o t he cyl i nder .
1. 2 Mot or Cont r ol s. Wher e ai r demand i s i nt er mi t t ent , a st ar t - st op cont r ol
may be pr ovi ded f or t he ai r compr essor . Thi s syst emconsi st s basi cal l y of a
pr essur e oper at ed swi t ch connect ed t o t he mot or st ar t er ci r cui t . When ai r
5- 1
FI GURE 5- 1. Aut omat i c St ar t - St op Gover nor
pr essur e r i ses t o a pr eset l evel , t he pr essur e swi t ch cont act s open,
deener gi zi ng t he st ar t er and shut t i ng down t he mot or . When r ecei ver pr essur e
f al l s t o anot her pr eset val ue, t he pr essur e swi t ch cont act s cl ose, st ar t i ng
t he dr i vi ng mot or . Ther e ar e sever al met hods of obt ai ni ng var i abl e speed
cont r ol of el ect r i c mot or s.
1. 2. 1 Bel t and Pul l ey Ar r angement . The var i abl e speed dr i ve uni t consi st s of
a const ant speed mot or and a bel t and pul l ey ar r angement t o var y t he out put
speed. Speed change i s accompl i shed by var yi ng t he di st ance bet ween t wo di sks
t hat f or meach pul l ey. Tur ni ng t he speed cont r ol di al moves one of t he di sks
on t he mot or shaf t t owar d i t s compani on di sk whi ch f or ms a bel t pul l ey. Thi s
causes t he bel t t o cl i mb up on t he t aper ed di sks t o a l ar ger di amet er .
Si mul t aneousl y, si nce t he bel t i s of f i xed l engt h, t he bel t causes t he t wo
di sks of t he dr i ven pul l ey t o separ at e and per mi t t he bel t t o assume a smal l er
di amet er . Thi s change of pul l ey di amet er s r esul t s i n i ncr eased speed of t he
dr i ven shaf t whi l e t he mot or speed r emai ns const ant . Rever se movement of t he
cont r ol di al r esul t s i n a decr ease i n t he speed of t he dr i ven shaf t . The use
of t hi s ar r angement i s l i mi t ed t o dr i ver s of 30 hp or l ess.
1. 2. 2 Hydr aul i c or Magnet i c Coupl i ngs. Al t hough not dr i ver s, t hese t ypes of
coupl i ngs ar e somet i mes a par t of t he dr i vi ng mechani sm and pr ovi de var i abl e
speed out put f r om a const ant speed dr i ver . Hydr aul i c or magnet i c coupl i ngs
ar e al so used t o var y t he speed of compr essor s dr i ven by squi r r el cage
i nduct i on or synchr onous mot or s.
1. 3 St eam Tur bi ne Dr i ves. Commonl y used wi t h cent r i f ugal or axi al
compr essor s, st eamt ur bi nes can be f i t t ed wi t h var i abl e speed gover nor s whi ch
al l ow t he t ur bi ne speed t o be set at any poi nt wi t hi n i t s oper at i ng speed
5- 2
r ange whi l e t he uni t i s i n oper at i on. An oi l r el ay gover nor ( f i gur e 5- 2) i s
one t ype of var i abl e speed t ur bi ne gover nor . Oi l di schar gi ng f r om a pump
dr i ven by t he t ur bi ne shaf t i s ci r cul at ed back t o a r eser voi r t hr ough an
or i f i ce val ve. The back pr essur e devel oped by t he r est r i ct i on act s on t he
act uat or pi st on. Movement of t he pi st on i s t r ansmi t t ed t hr ough a l i nkage t o
t he pi l ot val ve. The pi l ot val ve admi t s oi l f r oma di f f er ent pump t o ei t her
si de of t he gover nor val ve pi st on, openi ng or cl osi ng t he gover nor val ve. The
l ever whi ch i s at t ached t o t he gover nor val ve pi st on and moves wi t h i t ,
r et ur ns t he pi l ot val ve t o i t s neut r al posi t i on t o st op f ur t her movement of
t he gover nor val ve unt i l t her e i s an oi l pr essur e change bel ow t he act uat or
pi st on. Speed i s changed manual l y by adj ust ment of t he or i f i ce val ve.
FI GURE 5- 2. Var i abl e Speed, Oi l Rel ay Gover nor
5- 3
1. 4 Reci procati ng Engi ne Dri ves. I ndustri al type gas, gasol i ne, and di esel
engi nes are used to dri ve compressors by di rect connecti on or V- bel t dri ves.
Gasol i ne engi nes are avai l abl e i n ei ther 4- or 2- cycl e model s. These
reci procati ng engi nes can be throttl ed and possess a mi ni mumspeed range of
approxi matel y 50 to 60 percent of the rated revol uti ons per mi nute ( rpm) .
2 STARTUP.
2. 1 Prestart I nspecti on. Caref ul l y i nspect the pri me mover control systemto
ensure that the f ol l owi ng prestart requi rements are f ul f i l l ed.
( a) Al l i nstal l ati on or repai r work has been compl eted.
( b) Systemhas been cl eaned and tested f or l eaks.
The operator must have a thorough understandi ng of the control
systemand i ts operati on.
( c) Manuf acturer' s i nstructi ons and di agrams are avai l abl e.
( d) Al l control l ers are l ubri cated.
( e) Al l pi pi ng and tubi ng are cl ean and reservoi rs of hydraul i c
governors or coupl i ngs are f i l l ed.
( f ) Correct el ectri c power suppl y i s avai l abl e f or el ectri c control s.
2. 2 St ar t up Procedure. Proceed as f ol l ows:
( a) Pl ace pri me mover control s i n operati on i n accordance wi th the
manuf acturer' s i nstructi ons.
( b) Make any requi red adj ustments to obtai n desi red compressor del i very
or di scharge pressure.
3 NORMAL OPERATI ON. Adj ust control s to regul ate compressor output. Check
l i qui d l evel s i n hydraul i c systems at i nterval s prescri bed by the
manuf acturer' s mai ntenance schedul e.
4 SHUTDOWN. When a pri me mover control i s to be taken out of servi ce f or
repai rs, caref ul l y i nspect and observe the operati on of the control and l i st
al l necessary repai r work. Swi tch the compressor to manual control , i f
possi bl e; tag the system; and remove the control f romservi ce i n accordance
wi th the manuf acturer' s i nstructi ons.
5 OPERATI ONAL PREVENTI VE MAI NTENANCE. Report i mmedi atel y to the supervi sor
any mal f uncti oni ng of the pri me mover control system. Where requi red,
mai ntai n correct hydraul i c f l ui d l evel s i n reservoi rs. Keep al l el ectri cal
contact surf aces of components, such as rheostats, cl ean at al l ti mes and
l i ghtl y greased, i f requi red.
5- 4
6. 1 Dai l y I nspect i on. I nspect t he cont r ol syst em dai l y f or pr oper oper at i on.
mai nt enance schedul e, t hor oughl y i nspect t he cont r ol syst em f or cor r osi on,
wear , and di r t . Check al l gover nor l i nkages, mechani sms, spr i ngs, and pi ns
f or mechani cal def ect s and wear . Exami ne gover nor val ves f or er osi on,
cor r osi on, pr oper seat i ng, and condi t i on of packi ng and di aphr agms.
I nspect i on pr ocedur es f or el ect r i cal cont r ol component s ar e cont ai ned i n
NAVFAC MO- 205, Cent r al Heat i ng and St eamEl ect r i c Gener at i ng Pl ant s.
7 MAI NTENANCE.
7. 1 Lubr i cat i on Syst em. Pr epar e a l ubr i cat i on schedul e f or al l pr i me mover
cont r ol s r equi r i ng per i odi c l ubr i cat i on. Consul t t he manuf act ur er ' s
i nst r uct i ons f or f r equency and t ype of l ubr i cant .
7. 2 Cl eani ng. I n accor dance wi t h t he manuf act ur er ' s mai nt enance schedul e,
t hor oughl y cl ean al l cont r ol component s. Cl ean al l sl udge and accumul at i ons
f r om hydr aul i c syst ems wi t h an appr oved sol vent . Thor oughl y f l ush out al l
cont r ol l i nes and r ef i l l syst emwi t h cl ean hydr aul i c f l ui d.
7. 3 Cont r ol Syst em Component s. Repai r or r epl ace def ect i ve cont r ol syst em
component s. Est abl i sh a pr event i ve mai nt enance i nspect i on schedul e f or al l
component s of t he cont r ol syst em. Consul t t he manuf act ur er ' s i nst r uct i ons f or
mai nt enance pr ocedur es. Per f or m t he f ol l owi ng mai nt enance.
( a) Repl ace def ect i ve di aphr agms, bel l ows, and gasket s.
( b) Car ef ul l y i nspect , cl ean, and t est gover nor val ves. Repai r or
r epl ace f aul t y par t s.
( c) Repai r or r epl ace def ect i ve chai ns and spr ocket s.
( d) Repl ace badl y wor n l i nkage pi ns and bushi ngs.
( e) Repai r al l l eaks.
( f ) Repai nt pi pi ng as r equi r ed.
( g) Ref er t o NAVFAC MO- 205, Cent r al Heat i ng and St eam El ect r i c
Gener at i ng Pl ant s f or mai nt enance i nst r uct i ons on el ect r i cal cont r ol
component s.
5- 5
5- 6
Sect i on 2. COMPRESSOR CONTROLS
1 CAPACI TY CONTROL. Capaci t y cont r ol i s usual l y achi eved by one of t hr ee
met hods: aut omat i c st op/ st ar t , const ant speed, and var i abl e speed. Aut omat i c
st ar t / st op i s pr i mar i l y l i mi t ed t o el ect r i c mot or - dr i ven uni t s. Const ant
speed can be appl i ed t o al l t ypes of compr essor s. Aut omat i c st ar t / st op and
const ant speed cont r ol ar e of t en combi ned i n a dual cont r ol t o meet di f f er i ng
demand per i ods. The var i abl e cont r ol i s used wher e t he dr i ver i s capabl e of
f l uct uat i ng wi t h t he demand, such as wi t h gas- and st eam- dr i ven engi nes. The
met hod of cont r ol used i s usual l y associ at ed wi t h t he t ype of compr essor pl ant
bei ng cont r ol l ed.
1. 1 Const ant Speed Cont r ol . Under const ant speed cont r ol , t he l oad on t he
compr essor changes, bei ng f ul l y l oaded f or a cer t ai n per i od of t i me and t hen
var yi ng bet ween par t i al l y and f ul l y l oaded dur i ng anot her per i od of t i me.
Ther e ar e sever al ways used t o achi eve const ant speed cont r ol .
1. 1. 1 Reci pr ocat i ng Compr essor . Thr ee met hods of cont r ol ar e used f or
r eci pr ocat i ng compr essor s: aut omat i c st ar t / st op, const ant speed, and var i abl e
speed. Aut omat i c st ar t / st op i s usual l y l i mi t ed t o el ect r i c mot or - dr i ven
uni t s. Const ant speed i s appl i cabl e t o al l t ypes of compr essor s and dr i ver s.
When var i abl e speed i s used, t he dr i ver can oper at e at speeds commensur at e
wi t h t he demand.
1. 1. 1. 1 I nl et Val ve Unl oader . Ther e ar e sever al met hods of unl oadi ng t he
compr essor . One syst emhol ds t he i nl et val ves open mechani cal l y dur i ng bot h
t he suct i on and compr essi on st r okes, t her eby pr event i ng t he ai r f r ombei ng
compr essed. The unl oader ( f i gur e 5- 3) i s l ocat ed above t he i nl et val ve so
t hat t he yoke f i nger s ar e al most t ouchi ng t he val ve. When t he ai r r ecei ver
pr essur e r i ses t o t he pr eset unl oadi ng pr essur e, a pr essur e swi t ch oper at es a
sol enoi d unl oader val ve whi ch oper at es and sends ai r r ecei ver pr essur e t o t he
i nl et val ve unl oader . The pr essur e f r omt he ai r r ecei ver act i ng on t he
di aphr agmof t he i nl et val ve unl oader f or ces t he yoke f i nger s agai nst t he
i nl et val ve, hol di ng i t open. The i nt ake ai r i s pushed back out of t he i nl et
val ve on t he compr essi on st r oke so t hat no compr essi on t akes pl ace.
( a) Fi ve- St ep Capaci t y Cont r ol .
( 1) Fi gur e 5- 4 shows a t ypi cal ai r f l ow di agr amof a f i ve- st ep
capaci t y cont r ol syst em appl i ed t o a t wo- st age, f our - cyl i nder , doubl e act i on
r eci pr ocat i ng compr essor . Assumi ng t hat t he compr essor i s r equi r ed t o
mai nt ai n a pr essur e of 93 t o 100 psi , t he pr essur e swi t ches woul d be set t o
l oad and unl oad as f ol l ows: ai r pr essur e swi t ch ( APS) No. 1, l oad at 93 psi ,
unl oad at 97 psi ; APS No. 2, l oad at 94 psi , unl oad at 98 psi ; APS No. 3, l oad
at 95 psi , unl oad at 99 psi ; and APS No. 4, l oad at 96 psi , unl oad at 100
psi . As t he r ecei ver pr essur e r eaches t he hi gh set t i ng of each pr essur e
swi t ch, 25 per cent of t he compr essor capaci t y unl oads. As r ecei ver pr essur e
f al l s t o t he l ow set t i ng of each swi t ch, 25 per cent of t he compr essor capaci t y
l oads. APS No. 1 t her ef or e unl oads 25 per cent of t he compr essor capaci t y at
97 psi and l oads 25 per cent at 93 psi . As r ecei ver pr essur e f l uct uat es
bet ween 93 and 100 psi , t he compr essor capaci t y var i es i n f i ve st eps: f ul l ,
75 per cent , 50 per cent , 25 per cent , and zer o capaci t y.
5- 7
FI GURE 5- 3. I nl et Val ve Unl oader
( 2) To under st and t he oper at i on of t hi s f i ve- st ep cont r ol syst em
whi ch combi nes t he component s pr evi ousl y descr i bed, r ef er t o f i gur e 5- 4. When
t he compr essor i s st ar t ed, t he ai r pr essur e swi t ches ar e cl osed and t he
sol enoi ds i n t he unl oader val ves become ener gi zed so t hat r ecei ver pr essur e
cannot ent er t he unl oadi ng l i nes and compr essi on i s al l owed t o t ake pl ace. As
r ecei ver pr essur e bui l ds up and r eaches 97 psi , APS No. 1 br eaks cont act ,
deener gi zi ng t he unl oader and al l owi ng 97 psi r ecei ver ai r t o ent er cont r ol
l i ne No. 1, act uat i ng t he i nl et val ve unl oader . Twent y f i ve per cent of t he
compr essor has become unl oaded and compr essi on has been r educed f r om f ul l t o
75 per cent capaci t y. Cont r ol l i nes Nos. 2, 3, and 4 oper at e i n t he same way
as r ecei ver pr essur e i ncr eases. At 100 psi , al l cyl i nder s ar e unl oaded and
ai r compr essi on ceases, but t he compr essor cont i nues t o r un under no l oad. As
ai r i s dr awn of f f r omt he r ecei ver , t he pr essur e begi ns t o dr op. When t he
pr essur e f al l s t o 96 psi , APS No. 4 makes cont act and ener gi zes t he unl oadi ng
of val ve 4, whi ch cut s of f r ecei ver pr essur e f r omt he i nl et unl oader and vent s
t he unl oader pr essur e t o at mospher e. The i nl et val ve unl oader r el eases t he
i nl et val ve and nor mal compr essi on t akes pl ace, l oadi ng t he compr essor t o 25
per cent capaci t y. I f t he demand f or ai r i ncr eases and r ecei ver pr essur e
cont i nues t o decr ease, cont r ol l i nes Nos. 3, 2, and 1 wi l l l oad i n sequence.
5- 8
5
-
9
( b) Thr ee- Way Sol enoi d Val ve. The unl oader val ve ( f i gur e 5- 5) i s a
t hr ee- way sol enoi d- oper at ed val ve act uat ed by oper at i on of t he pr essur e
swi t ch. Connect i on A of t he val ve i s pi ped t o t he i nl et val ve unl oader ,
connect i on B i s a vent t o at mospher e, and connect i on C i s connect ed t o t he ai r
r ecei ver . When r ecei ver pr essur e has r eached i t s pr eset maxi mum, t he pr essur e
swi t ch cont act s open, deener gi zi ng t he sol enoi d. The cor e of t he sol enoi d
moves t he oper at i ng l ever downwar d t o cl ose connect i on B of t he val ve and open
connect i on C, al l owi ng r ecei ver pr essur e t o act on t he i nl et val ve unl oader .
Connect i on C i s hel d open unt i l r ecei ver pr essur e dr ops t o t he mi ni mumset t i ng
of t he pr essur e swi t ch. The swi t ch t hen cl oses, ener gi zi ng t he sol enoi d.
Connect i on C cl oses, cut t i ng of f pr essur e t o t he i nl et unl oader , and
connect i on B opens, r el easi ng t he pr essur e on t he unl oader t o at mospher e.
1. 1. 1. 2 Cl ear ance Pocket s. Anot her met hod of unl oadi ng a compr essor i s by
t he use of cl ear ance pocket s bui l t i nt o t he cyl i nder . Nor mal cl ear ance i s t he
vol ume at t he end of t he pi st on and under t he val ves when t he pi st on i s at t he
t op of t he compr essi on st r oke. Each end of t he cyl i nder i s f i t t ed wi t h t wo
cl ear ance pocket s whi ch ar e connect ed wi t h, but cut of f f r om, t he cyl i nder by
ai r - oper at ed cl ear ance val ves. Each cl ear ance pocket can hol d one- quar t er of
t he ai r compr essed by t he cyl i nder i n one st r oke. When bot h pocket s at one
end of t he cyl i nder ar e open, no ai r i s t aken i nt o t hat end of t he cyl i nder .
The cl ear ance val ves ar e separ at e f r om, and wor k i ndependent l y of , t he mai n
compr essor val ves. They ar e si mi l ar t o t he r egul ar i nl et val ves but have an
ai r - oper at ed l i f t i ng yoke whi ch oper at es i n t he same manner as t he i nl et val ve
unl oader descr i bed i n par agr aph 1. 1. 1. 1. Fi gur e 5- 6 i l l ust r at es t he oper at i on
of t he cl ear ance pocket s and t he cor r espondi ng i ndi cat or di agr ams of an ai r
compr essor under f i ve- st ep cl ear ance cont r ol .
FI GURE 5- 5. Thr ee- Way Sol enoi d Val ve
5- 10
FI GURE 5- 6. Fi ve- St ep Cl ear ance Cont r ol
1. 1. 2 Cent r i f ugal Compr essor . Fi ve met hods ar e gener al l y used t o cont r ol
cent r i f ugal compr essor s.
1. 1. 2. 1 I nl et Gui de Vanes. Cent r i f ugal compr essor cont r ol may be
accompl i shed by t he use of adj ust abl e i nl et gui de vanes. The pur pose of t he
gui de vanes i s t o di r ect t he ai r f l ow and di st r i but e i t uni f or ml y i nt o t he eye
of t he i mpel l er . The adj ust abl e vanes l ocat ed at t he f i r st - st age i nl et or t he
i nl et t o each st age, ar e used t o modi f y t he pr essur e- vol ume char act er i st i cs of
t he compr essor . Gui de vanes ar e manual l y or aut omat i cal l y adj ust abl e.
1. 1. 2. 2 Bl owof f of Out put . Bl owof f and r eci r cul at i on ar e occasi onal l y used
but do not save any power because t he compr essor i s cont i nual l y oper at i ng at
f ul l l oad pr essur e and i nl et vol ume. Bl owof f r el i eves excess gas t o t he
at mospher e, and r eci r cul at i on put s t hr ot t l ed gas back t hr ough t he compr essor .
1. 1. 2. 3 I nt ake Thr ot t l i ng. I nt ake t hr ot t l i ng i s wi del y used f or cont r ol of
const ant speed machi nes. Ei t her i nl et but t er f l y val ves or i nl et gui de vanes
may be aut omat i cal l y or manual l y cont r ol l ed. Power conser vat i on i s l ess t han
wi t h var i abl e speed, but i s st i l l si gni f i cant .
1. 1. 2. 4 Two- St ep Cont r ol . Two- st ep cont r ol i s mai nl y usef ul dur i ng l oad
oper at i ons bel ow 50 per cent capaci t y. The amount of f l ow i s dependent upon
t wo set poi nt s. Oper at i on i s at f ul l l oad unt i l t he upper set poi nt i s
r eached, t hen t he uni t i s unl oaded and oper at es at 15 per cent f l ow unt i l t he
l ower set poi nt i s r eached and t he syst em r ever t s back t o f ul l l oad. The
act i on i s cycl i c, mai nt ai ni ng an i nt er medi at e pr essur e val ue bet ween t he set
poi nt s. Two- st ep cont r ol i s not r ecommended i f a compl et e l oad- unl oad cycl e
5- 11
occur s mor e of t en t han ever y 3 mi nut es because t hi s wi l l cause excessi ve wear
on t he bear i ngs and val ves.
1. 1. 2. 5 But t er f l y Val ves. Cent r i f ugal compr essor cont r ol may al so be
accompl i shed by t hr ot t l i ng t he suct i on or di schar ge of t he compr essor wi t h a
but t er f l y val ve.
1. 1. 3 Rot ar y Sl i di ng Vane Compr essor . Ther e ar e sever al common met hods f or
mai nt ai ni ng const ant speed cont r ol of r ot ar y sl i di ng vane compr essor s.
1. 1. 3. 1 Aut omat i c St ar t / St op at Pr edet er mi ned Pr essur es. Speed cont r ol i s
mai nt ai ned aut omat i cal l y accor di ng t o pr edet er mi ned pr essur es.
1. 1. 3. 2 Bl ocki ng t he Compr essor I nl et . Bl ocki ng or unbl ocki ng of t he
compr essor i nl et mai nt ai ns speed cont r ol .
1. 1. 3. 3 I nt ake Unl oader s. I nt ake unl oadi ng consi st s of an aut omat i c val ve
l ocat ed at t he compr essor suct i on. Thi s val ve cl oses of f t he compr essor
i nt ake, t her eby pr event i ng t he compr essor f r om t aki ng i n ai r . The i nt ake
unl oader ( f i gur e 5- 7) i ncor por at es t wo val ves i n one body, an ai r
pi st on- oper at ed i nl et val ve and a pr essur e r el ease val ve. When t he compr essor
i s del i ver i ng ai r , t he i nl et val ve i s i n i t s nor mal open posi t i on and t he
r el ease val ve i s cl osed. When r ecei ver pr essur e bui l ds up t o t he unl oadi ng
pr essur e, a pr essur e swi t ch deener gi zes a t hr ee- way sol enoi d pi l ot val ve whi ch
admi t s r ecei ver pr essur e t o t he pi st on of t he i nl et val ve. The pi st on r i ses,
cl osi ng t he i nl et val ve and openi ng t he pr essur e r el ease val ve. The pr essur e
r el ease val ve r el i eves ai r pr essur e f r omt he por t i on of t he compr essor
di schar ge l i ne bet ween t he compr essor and t he di schar ge check val ve. Thi s
per mi t s unl oaded oper at i on of t he compr essor at at mospher i c pr essur e. When
r ecei ver pr essur e dr ops t o t he l ower set t i ng of t he pr essur e swi t ch, t he
cont act s cl ose, ener gi zi ng t he sol enoi d pi l ot val ve. Thi s cut s of f r ecei ver
pr essur e and vent s t he pr essur e i n t he unl oader t o at mospher e. The i nl et
val ve i s opened, per mi t t i ng t he compr essor t o l oad.
1. 1. 4 Rot ar y Twi n- Lobe Compr essor . Cont r ol met hods f or t he r ot ar y t wi n- l obe
ar e t he same as f or t he r ot ar y sl i di ng vane compr essor .
1. 1. 5 Rot ar y Li qui d Pi st on Compr essor . Cont r ol met hods f or t he r ot ar y l i qui d
pi st on compr essor ar e t he same as f or t he r ot ar y sl i di ng vane compr essor .
1. 1. 6 Axi al Fl ow Compr essor . Cont r ol met hods f or t he axi al f l ow compr essor
ar e t he same as f or t he cent r i f ugal compr essor .
1. 2 Var i abl e Speed Cont r ol . Ther e ar e many met hods avai l abl e t o var y t he
speed of t he compr essor t o pr oduce a mor e ef f i ci ent syst em. Those l i st ed
bel ow may not appl y t o al l t ypes of compr essor s, but gener al l y, mor e t han one
met hod deser ves consi der at i on dur i ng a syst em desi gn or r et r of i t . The
f ol l owi ng met hods var y i n appl i cabi l i t y dependi ng on ener gy sour ce,
hor sepower , wei ght , r evol ut i ons per mi nut e, and cost r equi r ement s.
1. 2. 1 Gasol i ne, St eam, and Di esel Engi nes. These engi nes can be manual l y
cont r ol l ed or l oad cont r ol l ed by t he use of a gover nor .
5- 12
FI GURE 5- 7. I nt ake Unl oader f or Rot ar y Sl i di ng Vane Compr essor
5- 13
1. 2. 2 Mul t i pl e Wi ndi ng Mot or s. The advant ages of t he mul t i pl e wi ndi ng met hod
ar e t hat i t i s r el at i vel y si mpl e and i nexpensi ve. The di sadvant age i s t hat
t he number of di f f er ent avai l abl e speeds i s l i mi t ed. The mul t i pl e wi ndi ng
met hod i s t her ef or e unsui t abl e f or appl i cat i ons t hat r equi r e a cont i nuousl y
var yi ng speed of r ot at i on.
1. 2. 3 Var i abl e Di amet er Pul l eys. A t ypi cal var i abl e di amet er pul l ey has
coni cal f aces t hat can be adj ust ed so t hat t he di st ance bet ween t he f aces i s
var i abl e. I f t he dr i ve bel t f or t he pul l ey has edges t hat ar e t aper ed t o
mat ch t he shape of t he pul l ey f aces, t he bel t can be made t o cont act t he
pul l ey anywher e al ong t he pul l ey f aces, dependi ng on t he di st ance bet ween t he
pul l ey f aces. Thi s ef f ect i vel y changes t he pul l ey di amet er . At l ar ger pul l ey
di amet er s, t he shaf t dr i ven by t he pul l ey r ot at es mor e sl owl y. At smal l er
pul l ey di amet er s, t he shaf t dr i ven by t he pul l ey r ot at es mor e qui ckl y. The
advant ages of t he var i abl e di amet er met hod ar e t hat i t i s r el at i vel y si mpl e
and i t i s compar at i vel y i nexpensi ve. The di sadvant ages ar e t hat i t s use i s
l i mi t ed t o appl i cat i ons r equi r i ng appr oxi mat el y 30 hp or l ess; t he pul l eys
r equi r e car ef ul al i gnment ; and t he bel t s ar e sensi t i ve t o smal l mi sal i gnment s
and can be damaged easi l y.
1. 2. 4 Gear ed Tr ansmi ssi ons. A gear ed t r ansmi ssi on can be used t o var y t he
speed of r ot at i on of t he dr i ve shaf t i n di scr et e st eps. The advant ages of
gear ed t r ansmi ssi ons ar e t hat t hey ar e r el at i vel y r el i abl e and can be used f or
hi gher power appl i cat i ons. The di sadvant ages ar e t hat t hey ar e expensi ve,
r el at i vel y i nef f i ci ent , and di f f i cul t t o i nst al l .
1. 2. 5 Fl ui d Coupl i ngs. Fl ui d coupl i ngs, or t or que conver t er s, can be used t o
pr ovi de a cont i nuousl y var i abl e out put t o t he shaf t of a cent r i f ugal pump.
The advant ages of t hi s t ype of pump ar e t hat f l ui d coupl i ngs ar e si mpl er t han
gear ed t r ansmi ssi ons, ar e easi er t o i nst al l , and ar e cont i nuousl y var i abl e.
The pr i nci pal di sadvant age of t hese pumps i s t hat t hey ar e compar at i vel y
i nef f i ci ent .
1. 2. 6 Eddy Cur r ent Coupl er s. Eddy cur r ent coupl er s ar e magnet i c cl ut ches i n
whi ch t he i nt ensi t y of t he magnet i c f i el d, whi ch coupl es t he t wo maj or
r ot at i ng par t s of t he cl ut ch, can be var i ed. An i ncr ease i n f i el d i nt ensi t y
i ncr eases t he amount of magnet i c coupl i ng, wi t h a consequent i ncr ease i n
t or que. The advant ages of t he eddy cur r ent coupl er ar e t hat i t i s r el at i vel y
si mpl e and r el i abl e. I t s pr i nci pal di sadvant age i s t hat i t i s i nef f i ci ent .
The sl i ppage devel oped i n t he cl ut ch causes a l oss of ener gy t hat i s
di ssi pat ed i n t he f or m of heat . Eddy cur r ent coupl er s and ot her devi ces t hat
al l ow t he mot or t o r un at f ul l speed but at r educed t or que, have an adver se
ef f ect on t he power f act or of t he mot or .
1. 2. 7 Synchr onous I nver t er s. Synchr onous i nver t er s ar e el ect r oni c devi ces
t hat var y t he i nput power f r equency t o t he mot or . Advant ages of t he
synchr onous i nver t er as a means t o change mot or r pmar e numer ous. Typi cal
out put f r equenci es of a synchr onous i nver t er r ange f r om0 t o 90 her t z, whi ch
pr oduces a wi de and cont i nuous r ange of mot or speeds. The synchr onous
i nver t er may be mount ed i n a r emot e l ocat i on not r equi r i ng mechani cal r et r of i t
changes. Because t he synchr onous i nver t er i s not a mechani cal devi ce,
mai nt enance i s mi ni mal .
5- 14
2 STARTUP.
2. 1 Prestart I nspecti on. Caref ul l y i nspect the control systemi nstal l ati on
to ensure that the f ol l owi ng prestart requi rements are f ul f i l l ed.
( a) Al l i nstal l ati on or repai r work has been compl eted.
( b) Systemhas been cl eaned and tested f or l eaks.
The operator must have a thorough understandi ng of the control
systemand i ts operati on.
( c) Manuf acturer' s i nstructi ons and control pi pi ng and wi ri ng di agrams
are avai l abl e.
( d) Correct el ectri c power i s avai l abl e f or operati on of el ectri cal
components.
( e) Al l pi pi ng and tubi ng are bl own out cl ean.
( f ) Al l control components are i nstal l ed, tested, and adj usted i n
accordance wi th the manuf acturer' s i nstructi ons.
2. 2 Startup Procedure. Proceed as f ol l ows:
( a) Set unl oadi ng devi ce to unl oad posi ti on bef ore pl aci ng the
compressor i n operati on.
( b) Pl ace the compressor i n servi ce per manuf acturer' s i nstructi ons or
as gi ven i n chapters 2 and 3.
( c) Pl ace the control systemi n servi ce f ol l owi ng the procedures
outl i ned i n the manuf acturer' s i nstructi on manual .
3 NORMAL OPERATI ON. Adj ust the control systemto obtai n systempressure or
compressor capaci ty. Drai n condensate f rommoi sture separators and strai ners
once each shi f t.
4 SHUTDOWN. I f the compressor control systemi s to be taken out of servi ce
f or repai rs, caref ul l y i nspect the i nstal l ati on, observe the operati on, tag
the system, and l i st al l necessary repai rs. Transf er the compressor to manual
control , i f possi bl e, and remove the control l er f romservi ce.
5 OPERATI ONAL PREVENTI VE MAI NTENANCE. Report i mmedi atel y to the supervi sor
any mal f uncti on i n the control system or components. Thoroughl y drai n al l
moi sture f rompneumati c control l i ne separators at l east once each shi f t.
6. 1 Dai l y. I nspect the compressor control systemf or operati on of al l
control components.
5- 15
mai nt enance schedul e, t hor oughl y i nspect al l cont r ol syst em component s f or
wear , cor r osi on, di r t , or def ect s.
7 MAI NTENANCE. Pr epar e a l ubr i cat i on schedul e f or al l compr essor cont r ol
syst em component s. Consul t t he manuf act ur er ' s i nst r uct i ons f or f r equency and
t ype of l ubr i cant t o be used. Obt ai n det ai l ed i nst r uct i ons f r om t he
manuf act ur er and use t hese i nst r uct i ons when maki ng adj ust ment s t o, and
cal i br at i ons of , t he cont r ol syst em component s. Onl y one per son shoul d be
r esponsi bl e f or t he adj ust ment s and cal i br at i ons of t he cont r ol syst em
component s.
7. 1 Cont r ol Syst em Component s. Pr epar e a per i odi c mai nt enance pr ogr amf or
al l compr essor cont r ol syst em component s. Ref er t o t he manuf act ur er ' s manual s
f or mai nt enance i nst r uct i ons f or each par t i cul ar cont r ol component . Per f or m
t he f ol l owi ng mai nt enance wor k as r equi r ed.
( a) Car ef ul l y cl ean, i nspect , and t est t he oper at i on of unl oader s,
cl ear ance cont r ol , and pi l ot val ves. Regr i nd or r epl ace wor n val ve seat s and
di sks. Repl ace badl y wor n val ve st ems and def ect i ve di aphr agms. Check spr i ng
t ensi on adj ust ment s.
( b) Thor oughl y cl ean moi st ur e separ at or s and st r ai ner s. Remove al l oi l
deposi t s. Repl ace def ect i ve st r ai ner el ement s.
( c) Ref er t o NAVFAC MO- 205, Cent r al Heat i ng and St eam El ect r i c
Gener at i ng Pl ant s, f or mai nt enance i nst r uct i ons f or el ect r i cal cont r ol
component s.
7. 2 Pi pi ng. Thor oughl y cl ean al l cont r ol syst em pi pi ng and t est f or l eaks.
Li nes shoul d be t hor oughl y bl own out wi t h compr essed ai r unt i l al l oi l and
di r t have been r emoved. Repai r al l l eaks and r epai nt pi pi ng as r equi r ed.
5- 16
APPENDIX A
ABBREVIATIONS AND ACRONYMS
A-1
APS
CFM
CPR
F
HP
LTS
PM
PSI
PSIG
RPM
SCFM
VPI
APPENDIX A
ABBREVIATIONS AND ACRONYMS
Air pressure switch
Cubic feet per minute
Cardiopulmonary resuscitation
Fahrenheit
Horsepower
Long-term storage
Preventive maintenance
Pounds per square inch
Pounds per square inch gauge
Revolutions per minute
Standard cubic feet per minute
Vapor phase inhibitor
A- 2
APPENDIX B
EVALUATION OF LOSSES IN COMPRESSED AIR SYSTEMS
B-1
APPENDI X B
EVALUATI ON OF LOSSES I N COMPRESSED AI R SYSTEMS
1 COMPRESSED AI R SYSTEM LEAKS. Leakage of compr essed ai r i s a pr obl em at
i ndust r i al i nst al l at i ons and, i f uncor r ect ed, wi l l r esul t i n si gni f i cant
monet ar y l osses ( t abl e B- l ) . Leakage can r esul t f r om cor r osi on i n under gr ound
pi pi ng, damaged j oi nt s, and def ect i ve f i t t i ngs and val ves. A r el at i vel y
si mpl e t est has been devi sed whi ch r api dl y and economi cal l y det er mi nes whet her
a di st r i but i on l i ne i s l eaki ng and i f so, t he magni t ude of t he l osses.
2 TEST METHOD. Thi s t est r equi r es t hat a segment of a compr essed ai r
di st r i but i on l i ne be pr essur i zed, seal ed, and checked by use of a pr essur e
gauge t o det er mi ne i f t he l i ne i s l eaki ng. I f t her e i s no pr essur e decr ease,
t her e i s no l eakage. I f t he pr essur e does decr ease, a l eak i s i ndi cat ed. The
amount of l eakage can be det er mi ned and a gr aph pr epar ed t hat det er mi nes t he
l oss at oper at i ng pr essur e.
3 TEST EQUI PMENT. The f ol l owi ng t est equi pment i s si mpl e and i nexpensi ve:
Pr essur e gauge
St opwat ch
4 TEST PRECAUTI ONS. Thi s t est pr oduces val i d r esul t s as l ong as t he
r el at i onshi p bet ween pr essur e and f l ow r at e i s l i near . Assumi ng a soni c exi t
vel oci t y, t he r el at i onshi p wi l l be l i near as l ong as t he r at i o of t he
at mospher i c pr essur e t o t he l i ne pr essur e exceeds t he cr i t i cal pr essur e r at i o
of 0. 53 f or gases. Thus, t o ensur e maxi mum accur acy, t est dat a shoul d not be
used i f t he pr essur e gauge r egi st er s l ess t han 20 psi g.
5 TEST PROCEDURES. The f ol l owi ng st eps must be per f or med t o compl et e a
pr essur e decay t est .
( a) Obt ai n scal e dr awi ngs of t he sect i on t o be t est ed. Ver i f y dr awi ngs
i n t he f i el d and cal cul at e t he vol ume of t he sect i on t o be t est ed.
( b) I nst al l a pr essur e gauge at a conveni ent l ocat i on.
( c) Secur e al l l oads t he l i ne suppl i es.
( d) I sol at e t he l i ne f r omt he compr essed ai r syst em.
( e) I mmedi at el y begi n t aki ng r eadi ngs at t he pr essur e gauge but do not
t r y t o st ar t t he moment t he val ve i s cl osed. Obser ve t he pr essur e gauge and
begi n t i mi ng when t he poi nt er passes a conveni ent mar k. Exampl e: On a
l OO- psi g syst em, wai t f or t he pr essur e gauge t o r each 95 psi g bef or e st ar t i ng
t he st opwat ch.
( f ) Not e t he t i me at conveni ent pr essur e i nt er val s ( 5 or 10 psi
i ncr ement s) . Cont i nue dat a r ecor di ng unt i l 20 psi g i s r eached. A suggest ed
f or mat f or col l ect i ng t hi s dat a i n t he f i el d i s shown i n t abl e B- 2.
B-2
TABLE B- l . Amount and Cost of Ai r Leaks
1
Ai r f l ow i s based on nozzl e coef f i ci ent of 0. 64. Cost s of ai r l osses based on a syst em
cont i nuousl y pr essur i zed wi t h compr essed ai r cost s of $0. 50 per 1, 000 cubi c f eet .
B-3
( g) Usi ng t he f i el d dat a, const r uct a char t as shown i n t abl e B- 3. The
LOSS col umn val ues ( Q) ar e cal cul at ed by usi ng t he f i el d dat a i n f or mul a
5. 1( a) .
( h) On gr aph paper , pl ot Q on t he Y axi s and P on t he X axi s.
( i ) Usi ng l i near r egr essi on, cal cul at e t he equat i on f or t he best f i t t i ng
st r ai ght l i ne and sol ve f or Qnomi nal . ( Qnomi nal i s def i ned as nor mal
oper at i ng pr essur e. )
TABLE B- 2. Pr essur e Test Dat a
Pr essur e Ti me
( psi g)
( mi n: sec)
90 0: 00
80 10: 42
70 23: 17
60 38: 34
50 58: 56
40 87: 28
30 135: 01
TABLE B- 3. Cal cul at i on of Losses
Aver age
Pr essur e Pr essur e Ti me Ti me Loss
( psi g) ( psi g) ( mi n: sec) ( mi n) ( scf m)
90- 80
80- 70
70- 60
60- 50
50- 40
40- 30
30- 20
85 10: 42 10. 70 40
75
65
23: 17 23. 28 34
38: 34
55 58: 56
38. 57 28
58. 93 21
45 87: 28 87: 47 15
35 135: 01 135. 02 9
25 277: 40 277. 67 3
B- 4
d
2
V =
1
1

(
10. 75 i n
x 1, 000 f t
4
=
4
x
12 i n/ f t
)
5. 1 Test For mul a. I n det er mi ni ng t he ai r l osses, use t he f ol l owi ng mass l oss
f or mul a.
( a)
Q = 35. 852 V
( T+460) ( t F- t I )
( PI - PF)
Wher e: Q = vol umet r i c ai r f l ow ( scf m)
V = vol ume of t ank, f t
3
T = t emper at ur e, F
P = pr essur e, psi g
t = t i me, mi nut es
F
I = i ni t i al
= f i nal
( b) Al t hough t he r egr essi on equat i on can be cal cul at ed by hand, t he
cal cul at i ons ar e qui t e l abor i ous. I t i s st r ongl y r ecommended t hat an
i nexpensi ve hand- hel d cal cul at or wi t h st at i st i cs capabi l i t y or an i n- house
comput er pr ogr ambe used as t he i nf or mat i on can t hen be r api dl y and accur at el y
cal cul at ed.
5. 2 Exampl e. The f ol l owi ng exampl e i l l ust r at es t he pr essur e decay t est
pr ocedur e.
( a) A sect i on of l 0- i nch compr essed ai r l i ne i s suspect ed of l eakage.
The l i ne i s l ocat ed on dr awi ngs and ver i f i ed by a f i el d i nspect i on. Usi ng an
engi neer i ng scal e and t he dr awi ng, t he l engt h of l i ne i s f ound t o be 1, 000
f eet . Cal cul at i ng t he vol ume of t he l i ne:
V = 630. 3 f t
3
( b) A pr essur e gauge i s i nst al l ed on t he l i ne at an out l et val ve, and
al l l oads on t he l i ne ar e secur ed. Wi t h a per son wat chi ng t he gauge, t he l i ne
i s i sol at ed f r omt he cent r al ai r di st r i but i on syst em.
( c) The pr essur e gauge, whi ch had i ndi cat ed 96 psi g, begi ns t o f al l
i mmedi at el y. When t he gauge r eaches 90 psi g, t he st opwat ch i s st ar t ed. Ti me
i s r ecor ded at l 0- psi i nt er val s as shown i n t abl e B- 2. ( A st opwat ch wi t h a
l ap count er makes t hi s easi er . )
( d) Assumi ng an ambi ent t emper at ur e of 68F, t he l osses can be
cal cul at ed f or each pr essur e i nt er val , usi ng equat i on 5. 1( a) . Resul t s ar e
shown i n t abl e B- 3.
( e) The dat a can be pl ot t ed as shown i n f i gur e B- l t o det er mi ne how wel l
t he t est dat a f i t s a st r ai ght l i ne. Al t hough t est dat a f r om an act ual t est
wi l l nor mal l y be of f set f r oma st r ai ght l i ne t o some degr ee, sever e devi at i ons
wi l l r equi r e t hat t he t est be r epeat ed.
B- 5
AVERAGE PRESSURE ( PSI G)
FI GURE B- l . Loss ( cf m) vs Pressure ( psi g)
( f ) Cal cul ati ng the l i near regressi on f ormul a f romthe avai l abl e data
and maki ng the f ol l owi ng substi tuti ons:
X = avg press. ( P)
Y = l oss ( Q)
Y = mX+b
yi el ds the equati on: Q = 0. 62 P - 12. 75.
Losses at operati ng or nomi nal pressure ( 96 psi g) are cal cul ated:
Q
9 6
= 0. 62 ( 96) - 12. 75 Q
9 6
= 47 scf m
At a cost of 50 cents f or 1, 000 cubi c f eet of compressed ai r,
thi s represents: $12, 35O/ year ( dol l ar f i gure wi l l vary based on
f aci l i ty costs f or compressed ai r) .
6 CORRECTI VE MEASURES. Qnomi nal represents the l oss i n the compressed ai r
systemat operati ng condi ti ons, assumi ng a constant pressure over the l ength
of pi pe i n questi on. Thi s val ue, taken wi th the acti vi ty' s cost to produce
compressed ai r, can be used, as j usti f i cati on, to devel op proj ects to repai r
or repl ace secti ons of compressed ai r l i ne.
B- 6
REFERENCES
1. NAVFAC DM- 3. 5, Compr essed Ai r and Vacuum Syst ems.
2. NAVFAC MO- 205, Cent r al Heat i ng and St eam El ect r i c Gener at i ng Pl ant s.
3. NAVFAC MO- 209, Mai nt enance of St eam, Hot Wat er . and Compr essed Ai r
Di st r i but i on Syst ems.
4. NAVFAC MO- 225, I ndust r i al Wat er Tr eat ment .
5. NAVFAC MO- 322, I nspect i on of Shor e Faci l i t i es.
6. NAVFAC MO- 324, I nspect i on and Cer t i f i cat i on of Boi l er s and Unf i r ed
Pr essur e Vessel s.
Ref er ence- l
I NDEX*
A
Abbrevi ati ons and Acronyms . . . . . . . . . . . . . . . . . . . .
Ai r Compressor Pl ant
Breakdown Mai ntenance . . . . . . . . . . . . . . . . . . . . . . .
Compressed Ai r Leaks . . . . . . . . . . . . . . . . . . . . . . .
Engi neeri ng Responsi bi l i ti es . . . . . . . . . . . . . . . .
Mai ntenance Responsi bi l i ti es . . . . . . . . . . . . . . . .
Operati on, Mai ntenance, and Supervi si on . . . . .
Operator Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . .
Operator Responsi bi l i ti es . . . . . . . . . . . . . . . . . . . .
Preventi ve Mai ntenance . . . . . . . . . . . . . . . . . . . . . .
Supervi sory Responsi bi l i ti es . . . . . . . . . . . . . . . .
Troubl eshooti ng . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ai r Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operati ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ai r Fi l ters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I nspecti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ai r Recei vers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operati ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxi l i ary Equi pment . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ai r Recei vers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ai r Dryers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ai r Fi l ters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I ntercool ers and Af tercool ers . . . . . . . . . . . . . . .
Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Si l encers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C
Compressed Ai r System Losses . . . . . . . . . . . . . . . . . . B- 1
Compressor
Control s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6, 3- 7, 3- 9, 3- 10, 5- 7 t hr u
5- 16
Constant Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 7 thru 5- 12
Control System Mai ntenance . . . . . . . . . . . . . . . 5- 16
Pi pi ng Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . 5- 16
*( T) = Tabl e ( F) = Fi gur e
I ndex- 1
A- 1
1- 7
1- 7, B- 1
1- 5
1- 5
1- 5 thru 1- 7
1- 6
1- 5
1- 7
1- 5
1- B thru 1- 12 ( T)
4- 21 thru 4- 26
4- 25
4- 23
4- 24
4- 21
4- 1 thru 4- 4
4- 1
4- 2
4- 19
4- 20
4- 19, 5- 1, 5- 7, 5- B, 5- 10,
5- 12
4- 19
4- 1 thru 4- 26
1- 3, 4- 19, 4- 20, 5- 1, 5- 7,
5- B, 5- 10, 5- 12
1- 3, 4- 21 thru 4- 26
1- 1, 4- 1 thru 4- 4
1- 11, 2- 6, 2- 16, 3- 6, 4- 7
thru 4- 12, 4- 15
1- 3, 2- 23, 4- 10, 4- 13, 4- 14
1- 1, 4- 5, 4- 6
1- 3, 3- 6, 3- 7, 4- 9, 4- 15 thru
4- 17, 4- 23, 4- 24
Compressor ( Conti nued)
Control s ( Conti nued)
Normal Operati on . . . . . . . . . . . . . . . . . . . . . . . . .
Preventi ve Mai ntenance . . . . . . . . . . . . . . . . . . .
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vari abl e Speed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dynami c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Al i gnment Mai ntenance . . . . . . . . . . . . . . . . . . . .
Axi al Fl ow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Beari ngs Mai ntenance . . . . . . . . . . . . . . . . . . . . .
Centri f ugal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Col d Cl i mate Shutdown . . . . . . . . . . . . . . . . . . . .
Long- Term Shutdown . . . . . . . . . . . . . . . . . . . . . . .
Lubri cati on Mai ntenance . . . . . . . . . . . . . . . . . .
Preventi ve Mai ntenance . . . . . . . . . . . . . . . . . . .
Short- Term Shutdown . . . . . . . . . . . . . . . . . . . . . .
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maxi mum Capaci ty . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maxi mum Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . .
Posi ti ve Di spl acement . . . . . . . . . . . . . . . . . . . . . . .
Li qui d Pi ston, Rotary . . . . . . . . . . . . . . . . . . . .
Reci procati ng . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sl i di ng Vane, Rotary . . . . . . . . . . . . . . . . . . . . .
Twi n- Lobe, Rotary . . . . . . . . . . . . . . . . . . . . . . . .
Control s, Pri me Mover . . . . . . . . . . . . . . . . . . . . . . . . .
Cool i ng Water Treatment . . . . . . . . . . . . . . . . . . . . . . .
E
5- 15
5- 15
5- 15
5- 15
5- 12 thru 5- 14
1- 1, 3- 1 thru 3- 12
3- 10, 3- 11 ( F) , 3- 12 ( F)
3- 1, 3- 3 ( F)
3- 11
3- 1, 3- 2 ( F)
3- 7
3- 6
3- 9
3- 7
3- 5
1- 1, 1- 3 ( T)
1- 1, 1- 3 ( T)
1- 1, 1- 3, 2- 1 thru 2- 26
2- 20
2- 1, 2- 2 ( F) , 5- 1, 5- 7
2- 13
2- 19
5- l thru 5- 16
1- 4
Engi neeri ng Responsi bi l i ti es . . . . . . . . . . . . 1- 5
H
Hi gh- Pressure Compressed Ai r Systems . . . . . . . . . . 2- 1
I
I ntercool ers and Af tercool ers . . . . . . . . . . . . . . . . . 4- 7 thru 4- 12
Cl eani ng Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . 4- 11
Preventi ve Mai ntenance . . . . . . . . . . . . . . . . . . . . . . 4- 9
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 9
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
Tubes Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 11
L
Leaks, Compressed Ai r . . . . . . . . . . . . . . . . . . . . . . . . . B- 1
I ndex- 2
M
Mai ntenance Responsi bi l i ti es . . . . . . . . . . . . . . . . . . 1- 5
0
Operator Responsi bi l i ti es . . . . . . . . . . . . . . . . . . . . . 1- 5
P
Pl ant, Ai r Compressor ( See Ai r Compressor Pl ant)
Pri me Mover Control s . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1, 1- 3, 1- 4, 5- 1 thru 5- 16
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
Cl eani ng Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
Lubri cati on Mai ntenance . . . . . . . . . . . . . . . . . . . . . 5- 5
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
Normal Operati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
Preventi ve Mai ntenance . . . . . . . . . . . . . . . . . . . . . . 5- 4
Reci procati ng Engi ne . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
Steam Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
Steam Turbi ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 2
R
Reci procati ng Compressor . . . . . . . . . . . . . . . . . . . . . .
Beari ngs Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . .
Bel t Dri ves Mai ntenance . . . . . . . . . . . . . . . . . . . . .
Cl eani ng Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . .
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hi gh Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubri cati on Mai ntenance . . . . . . . . . . . . . . . . . . . . .
Motor Dri ven Startup . . . . . . . . . . . . . . . . . . . . . . . .
New/ Overhaul ed Startup . . . . . . . . . . . . . . . . . . . . . .
Normal Operati on . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packi ng Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . .
Pi ston Ri ngs Mai ntenance . . . . . . . . . . . . . . . . . . . .
Saf ety Precauti ons . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam- Dri ven Startup . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Li qui d Pi ston . . . . . . . . . . . . . . . . . . . . . . . . . .
Beari ngs Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . .
Lubri cati on Mai ntenance . . . . . . . . . . . . . . . . . . . . .
Normal Operati on . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packi ng Mai ntenance . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I ndex- 3
1- 1, 2- 1 thru 2- 12
2- 10
2- 10
2- 8
2- 5
2- 1
2- 8
2- 4
2- 4
2- 5
2- 8
2- 9
2- 6, 2- 7
2- 1
2- 5
2- 3
1- 1, 2- 23, 2- 24 ( F) ,
2- 25 ( F) , 5- 12
2- 26
2- 26
2- 23
2- 26
2- 25, 2- 26
2- 23
2- 23
Rot ar y Sl i di ng Vane . . . . . . . . . . . . . . . . . . .
Bear i ngs Mai nt enance. . . . . . . . . . . . . . . . . . . . . . . .
Cl ear ances Mai nt enance. . . . . . . . . . . . . . . . . . . . . .
Cyl i nder s Mai nt enance. . . . . . . . . . . . . . . . . . . . . . .
Ext ended Shut down. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubr i cat i on Mai nt enance. . . . . . . . . . . . . . . . . . . . .
Nor mal Oper at i on. . . . . . . . . . .. . . . . . . . . . . . . . . . .
Pr event i ve Mai nt enance. . . . . . . . . . . . . . . . . . . . . .
Rot or Bl ades Mai nt enance. . . . . . . . . . . . . . . . . . . .
Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
St ar t up . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . .
Rot ar y Twi n- Lobe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bear i ngs Mai nt enance. . . . . . . . . . . . . . . . . . . . . . . .
Lubr i cat i on Mai nt enance. . . . . . . . . . . . . . . . . . . . .
Nor mal Oper at i on
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pr event i ve Mai nt enance. . . . . . . . . . . . . . . . . . . . . .
Seal s Mai nt enance. . . . . . . . . . . . . . . . . . . . . . . . . . .
Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
St ar t up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ti mi ng Gear s Mai nt enance. . . . . . . . . . . . . . . . . . . .
S
Saf et y Pr ocedur es, Hi gh- Pr essur e Syst ems . . . . . .
Separ at or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mai nt enance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oper at i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pr event i ve Mai nt enance . . . . . . . . . . . . . . . . . . . . . .
Si l encer s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I nspect i on and Mai nt enance . . . . . . . . . . . . . . . . . .
Super vi sor y Responsi bi l i t i es . . . . . . . . . . . . . . . . . .
T
Tr aps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bucket s and Fl oat s Mai nt enance . . . . . . . . . . . . . .
Cl eani ng Mai nt enance . . . . . . . . . . . . . . . . . . . . . . . .
Lever s Mai nt enance . . . . . . . . . . . . . . . . . . . . . . . . . .
Pr event i ve Mai nt enance . . . . . . . . . . . . . . . . . . . . . .
Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
St ar t up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Val ves Mai nt enance . . . . . . . . . . . . . . . . . . . . . . . . . .
Tr oubl eshoot i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1- 1, 2- 13 t hr u 2- 18,
2- 14 ( F) , 5- 12, 5- 13 ( F)
2- 18
2- 18
2- 17
2- 15
2- 18
2- 15
2- 16, 2- 17
2- 17
2- 15
2- 13
1- 1, 2- 19 t hr u 2- 22,
2- 20 ( F) , 5- 12
2- 22
2- 22
2- 21
2- 21
2- 22
2- 21
2- 19
2- 22
2- 1
4- 13, 4- 14
4- 14
4- 13
4- 13
4- 5, 4- 6
4- 5
1- 5
4- 15 t hr u 4- 17
4- 17
4- 15
4- 17
4- 15
4- 15
4- 15
4- 17
1- B ( T) t hr u 1- 12 ( T)
I ndex- 4

Operation and Maint of Air Compressor

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Operation and Maint of Air Compressor

Diunggah oleh

Hak Cipta:

Format Tersedia

T H E B E S T D E S E R V E S T H E B E S T

Anda mungkin juga menyukai