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CONTENTS

MESSAGE

(i)

INTRODUCITON

(ii)

PAGE NO.

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1.1

General

1.2 Twin LobeCompressors

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1.2.1
1.2.2
1.2.3
1.2.4

Type of KayTwin Lobe Compressors

Principalsof Operations
CompressorAccessories
Installation

1.2.5

Checklistafter installation of the Compressor

1.2.6

Start up checklist.

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2
3
3
5
5

2.1

Preventivemaintenance

3.1

Lubrication

4.1

TroubleShooting
4.1.1
Abnormal Sound

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4.1.2

Overheating of Compressors

4.1.3
4.1.4
4.1.5
4.1.6

Low Volume at delivery end

Low Pressureat delivery end
ExcessPowerconsumption
Seizure

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4.1.7

Oil Leakage

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5.1
5.2
5.3
5.4
5.5
5.6

Crosssectional drawing along with spare parts list for Twin Lobe Compressorwith
both sideoil lubrication arrangement.
Crosssectional drawing along with spare parts list for Twin Lobe Compressorwith
one side oil and other side grease lubrication arrangement.
Crosssectional drawing along with spare parts list for Twin Lobe Compressor having
bearing at 5 different location with both side oil lubrication
Crosssecitonal drawing along with spare parts li'Stfor Twin Lobe gas pump
Formatfor demanding the spares from Kay International Limited
Format for offer request for annual maintenance contract

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MESSAGE
Dear KayCustomer,

Thanks you for buying a Kay Positive

Displacement Rotary Twin Lobe Compressor

(Roots Blower). We believe that you have

bought the best.

Kay International Limited has ISO 9001

certificationfor Marketing&Sales,Development
& Productionof Twin LobeCompressors(Roots
Blowers). Eachcomponent of the Kay blower
undergoes stringent quality control checks to
ensure an international standard end product.

This installation, Operation & Maintenance Manual contains information about your new equipment & Its
operating & service requirements. Pleasetake a few minutes to read it carefully.

If, for any reason, any of our products do not meet your performance expectations, we would like to hear from
you. At Kay we believe that our sales force is you, our customer, & we want you to be satisfied.

We appreciateyour purchase of a Kay product & look forward to providing you prompt after-sales-service &
catering to your future equipment needs:

Yours truly,

Sd.xxxx
K. L. Arora
Chairman Cum Managing Director

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INTRODUCTION

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KayRotaryTwin Lobe Compressors(Roots Blowers) are designed,

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manufactured & provided maintenanceaccording to ISO 9001. KAY

is dedicated to quality, through excellence of their people and

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performance of their production equipment.

Each component that goes into a KAYcompressor undergoes stringent
quality control before being finally fitted. Also, all the rotating parts

are dynamically balanced for smooth running and lower bearing loads.

All manufactured
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KAY compressors are tested on test benches

according to BS: 1571, Part - II, where the load applied is the same
as in actual service conditions (required by client). Each compressor
duly painted and packed in wooden boxes is ready for shipment to
required destination.

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SECTION-l
1.1

GENERAL :-

Compressorfitting is a skilled work and should be undertaken only by competant fitters. It is important that the entire
contents.of this manual should be read and understood before carrying out any work on a compressor.
Maintenancework on a compressor is actually dangerous, and.all reasonable measures should be taken to safeguard
those engaged in such work. It is especially important that before any work is startedstopthe machine.
1.2

TWINLOBECOMPRESSOR:-

1.2.1 Type of KayTwin Lobe Compressors;

.

Air CooledCompressor

Water CooledCompressor

GasPump

Air Cooled Compressor: The body of this type of compressor

is cooled by atmospheric air. The CGmpressor body is provided
with fins around it. Heat produced in body is carried to fins and
from here it is taken away by atmospheric

air. These type of

compressor are suitable for operation up to the pressure of

MMWG.

Water Cooled Compressor:

7000

This type of compressor is

providedwith water coolingarrangement. The compressorbody

is manufacturedwith water jackets around it. The fresh water is
circulated and the heat produced in body is carried away with
water. These type of compressor are suitable for operation of
above7000MMWGPressure.

Gas Pump: Kay Gas Pump are designed for providing trouble
free operation with hazardous as well as Non-Hazardous gases.
These pumps have a special sealing arrangement with stuffing
box. As per specific requirements the Kay Gas Pumps can also
be provided with Mechanical Seals in addition to the stuffing box
sealing arrangement.

1.2.2 Principle of Operation:

'KAY'Rotary Twin LobeCompressorfollows the well establilshedprinciple of the Roots-type machine. Operation is both
simple and effective. Twin impellers, mounted on paralleled shafts and contained within a casing, rotate in opposite
directions.
The shape of the impellers (Fig. 1.2) is such that a small accurately gauged clearance is maintained at all times between
the impellers and casing (See Fig. 1.3). As they rotate, air is drawn into the space between the impellers and the casing,

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where it is trapped as the tip of the impellers passes the edge of the inlet opening (See Gig. 1.1).
Continuing its rotation, the opposite tip of the impeller passes the edge of the outlet opening and the trapped air is

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pushed through the outlet into the air line. This action is repeated twice for each revolution of an impeller, or four times
for each revolution of the drive shaft. The volume of air displaced by one revolution of the drive shaft for each size of
compressor has been calculated, and the amount of air moved at any given speed and pressure is known. This makes
it simple to select the speed at which the compressor should operate to supply the required volume of air.

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(A)

(B)

(C)

(D)

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Fig 1.1

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Air Inlet

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Centre Clearance

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Fig 1.3

Fig 1.2

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1.2.3 COMPRESSORACCESSORIES:-Refer Fig. 1.4

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Suction Filter :- The filter safe guards the compressor against dust and foreign particles. The dust ifallowed
to enter inside the compressor willget deposited on casing inner wall and on lobes. This willcause to decrease the
clearances and lead to seizure of the rotating lobes. Alsowhen any foreign object is sucked inside it willdamage the
machine. It is therefore very-very essential to use the filter inthe system.
II.
Suction &.Discharge Silencer:- The Silencer is basicallyused to mufflethe noise created by machine. For
this purpose one silenceris fitted at suction end and another is on deliveryend. Bothsilencers are so designed that they
reduce the noise levelcreated insidethe compressor to prescribed limiti.e. measured as 90 db at 1 meter distance from
rear of the compressor.
m
Pressure Gauge :- Pressure guage is an instrument to measure the pressure delivered by compressor at
discharge end.
IV.
Safety Valve:- The safety valve is a device which is fitted in down line of the compressor. It is to safe guard
the system from any abnormal rise of the pressure. This happens because of any kindof blockage in the down line. If
there is a blockage in down line the pressure willrise tremendously because the compressor is positive displacement
type. The excessive pressure may cause the pipelineto burst or lead to machine failure. Therefore, the safety valve is
a very criticalitem as it safe guards the system from any undesirable higher pressure.
The valve is adjusted to get operated when the pressure rises beyond the safe limit.The excess pressure is released to

the atmosphereor backto the suctionline.The upperlimitof pressureisset withthe help ofweightplates.
V.

Non Return Valve(NRV):- Theequipmentpermitsthe flowoffluidinone directiononly,whenfittedindown

line it willallow the flow from compressor to discharge point, but isolate the compressor side at the time of shut down.

1.2.4 INSTALLATION
Place the compressor on a concrete or equally substantial levelfoundation with the feet supported evenly on the base
frame. The perfect level can be acquired by inserting the appropriate metallic shim between the base frame and
compressor legs, this willprevent distortion of the casing when tightening down. The foundation bolts should be grouted
in and allowed to set before the compressor is tightened down.
If the compressor is mounted on a base plate together with the motor, ensure that the compressor casing is not
distorted when the foundation bolts are tightened. There should be even tightening (even torque) of all mounting points.

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If the Compressor is direct coupled to the prime mover, the flexible coupling must be accurately aligned with an even
gap between the faces. The axis of the coupling must be lined up exactly in both horizontal and vertical directions. When
the drive to compressor is to be given through v-belts then:(a) The Compressor and motor must be horizontal and the axis of compressor pulley shaft and electric motor shaft
should be exactly in parallel line.
(b) The belt pulleys are always to be on the shaft in such a way that the belt pull is near to the machine.
(c) V-belts are tightened in such a way that v-belts are able to be pressed by hand at mid of distance between two
pulleys. Too much tightening of belts will be overloading the motor and torque load on the drive shaft of
compressor. Too loose belts will cause the slippage of v-belts over pulleys. This will in-turn burn and damage
the belts.

Note: Ifthe pulleyor coupling'isnotofthe taper bushtype, itmustbe pressedonto the shaftto avoiddamageto the
locatingbearing.Under no circumstances should a hammer be used to fit the coupling or pulley. The pulley
should be fitted as close as possible to the drive shaft bearing cover.

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GENERALARRANGEMENTOF TWIN LOBECOMPRESSOR WITH ACCESSORIES IN THESYSTEM:

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+ATMOSPHERIC AIR

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DESCRIPTIONOFPARTS

1.

SUCTION FILTER

iNO.

2.

SUCTIONFILTER

iNO.

3.

TWIN LOBEAIR COMPRESSOR

iNO.

4.

DISCHARESILENCER

iNO.

5.

SAFETYVALVE(DEADWEIGHTTYPE)

iNO.

6.

PRESSUREGAUGE

iNO.

7.

NON-RETURN VALVE

iNO.

(Fig.i.4)

Q1YWITH EACHBLOWER

Pipework

It is essential that pipe connection should match up to the compressor flanges without strain and that the pipework is
adequately supported. Otherwise the compressor casing might be distored. This could cause contact between the
impellers and the casing with the result that the compressor willeventually seize. Allpipe lines should be throughly
cleaned internallybefore being connected to the compressor inlet&outlet. Also,the blower must be inspected for any
loose foreignobject insidethe body before givingpipe connections to blower.

Caution: Size reduction of the pipe in suction & delivery line and direction change by putting the sharp bend should be

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avoided. Incase of unavoidable circumstances it should be done after proper calculation. This will avoid any back
pressure to the compressor and shall give you the trouble free operation. Donot give immediate bend just after NRV.
This may restrict the movement of the NRVfor its fullrange of operation.
1.2.5. Check list after installation of the Compressor:

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(1)

Checkthe fixationof the Compressor on the base frame.

(2)

The Compressor must run freely by hand.

(3)

Checkfor allconnection are done;

(a) Connectionto the process.

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(b) Water feed pipe (if the Compressor is water cooled). Checkwater circulationas per flowmark on water

pipeline.
(c)

Electricalconnection to electrical box of the motor.

(4)

Checkthe data (RPM,Frequency,Voltage)shown on the name plate of electric motor (before putting v-belts/
coupling)

(5)

Check the motor shaft/motor pulley rotation as marked.

(6)

Check the alignment and tension of belts.

(7)

Water and electricity supply, available.

(8)

Availability of recommended oil on site.

(9)

Check the fitment of safety valve, pressure gauge and N.R.V in the system.

(10)

Checkthe N.R.Vis fitted in correct direction and has free operation.

(11)

Checkthe supplied weight plates placed on safety valve and small bolt fitted on top of safety valve cap.

(12)

Checkthe inlet and outlet pipes are wellsupported to avoid any stress on Compressor flanges.

1.2.6 Start upCheckList

The following procedure is recommended whren a compressor is to be started up for the first time or when a machine

isputto workagainafter majorerepairswhichhavenecessiateditsremovalfromitsfoundation.

1.

Inspectthe interiorofthe compressorand allpipingleadto and fromitto ensure that allforeignmatter has
been removed.

2.

Check for level and alignment of drive. Check belt tension. Incorrect alignment and/or tension can cause excessive
wear on bearings, V-Belts or coupling bushes.

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3.

Checkforcorrect lubrication(Refere Section-3for specifiedlubricant).It is essential that the oillevelinthe gear

case should be up to the red dot mark at the center of oil indicator when the compressor is not in operation.

Note : Toomuch oilwillcause over heating excessive noise and oilleakage through breather plug in the gear case.
Too littleoilwillresult in the rapid failure of the gears/bearings due to their running dry.
4.

Pump the recommended grease with grease gun through the grease nipple on both drive and driven shaft
bearings untilfresh grease appears from the grease drain plug (Refer the figure at Annexure - II).

s.

Rotate the impellersby hand to ensure that there are no tight spots.

6.

'Flilck'the motor two or three times by putting the starter in and out quicklyto check the direction of rotation,
and also to ensure that the impellers turn freely.

7.

Start the compressorand run for at least fifteenminutesunder no loadconditions.Duringthis periodkeep

checking at various points on the compressor casing and the bearing housing for signs of heating. The compressor
should remain cool throughout this period.

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8.

Apply the pressure load gradually over a period of say, thirty minutes to one hour. Whilst under full load, keep
the machine under observation.

9.

Frequent checking should be carried out for any abnormality during the first day in service.

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Note : In the event of suspected faulty operation, shut down the compressor immediately and investigate for possible
causes. If this is not done, serious damage may result in a very short time.

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