M02 –Compressors - Theory, Practice and Maintenance

• 3 golden rules of Compressed Air usage

• Compressed air system – Supply side and Demand side

• Compressed air – One of the most expensive utilities on the shop floor

• Inappropriate use of compressed air

  • Open blowing

  • Sparging, Aspirating, Atomizing

  • Padding

  • Vacuum generation

  • Hand blowing

  • Unregulated End use

  • Abandoned equipment

• Potential for energy saving
  
  
• Overview of sub-systems and sub-components of a compressor system
  
  
  • Intake Air Filters
  • Compressed Air Filters
  • Why compressor cooling is required
    • Inter stage coolers
    • After coolers
  • Separators

  • Why air drying is essential

    • Air Dryers

    • Deliquescent air dryers

    • Refrigerated Air Dryers

    • Moisture drain traps

  • Air receiver
  • Lubrication
  • Heat recovery
  • Air distribution system
    
    
• Types of compressors
  
  
• Choice of compressors
  
  
• Reciprocating compressor
  
  
  • Single acting air cooled
  • Double acting water cooled
    
    
• Rotary compressor
  
  
  • Single stage
  • 2 stage
  • Screw Compressors
    
    
    • Lubricant injected
    • Oil free
      
      
• Centrifugal air compressors
  
  
• Compressor Prime Movers
  
  
• Comparison of compressors
  
  
• Capacity of a compressor
  
  
• Calculating compressor efficiency

  • Isothermal efficiency

  • Volumetric efficiency

• Leaks
  
  
  • Defining and Quantifying leakage
  • how to calculate leakage
  • Cost of leakage
  • Leak detection
    
    
    • Ultrasonic leak detection
  • How to stop leaks
    
    
• Compressed air system performance opportunity roadmap
• Air quality
• Air quantity
• Load profile
• System pressure
  
  
  • Pressure drop and controlling system pressure
  • What causes pressure drop ?
  • Minimizing pressure drop
  • Measurements necessary for pressure profiling a compressed air system
  • Stabilizing system pressure
    
    
    • Importance of Primary and Secondary Storage
    • Dedicated compressors
      
      
• Control strategy
  
  
  • Matching Demand and Supply
  • System controls
  • Multiple compressor controls
  • Pressure/Flow controllers
  • Variable loads
    
    
• Ensuring efficiency of compressed air end-use applications
  
  
• Heat recovery and compressed air systems
  • Air cooled, rotary screw compressors
    
  • Water cooled compressors
    
    
• Calculating cost of compressed power
  
  
• The 7 step action plan to analyse and improve compressed air system
  
  
• Tools needed for monitoring and base-lining compressed air system
  
  
• Using Power, Pressure, and Flow to base-line System Performance and Energy Consumption
  
  
• Maintaining air compressors
  
  
  • Lubrication
  • Cleaning
  • Belts
  • Air treatment equipment
  • Automatic traps
  • Point-of-use filters, regulators, lubricators
  • Shutting down for maintenance
  • Routine maintenance practices for various periodic frequency
    
    
• Energy saving ideas for compressor air system
  
  
  • Energy saving concept – Usage of VFD

Reading nomenclature of compressors

• Types of valves

  • Plate type

  • Finger type

• Loading and Unloading characteristics of compressors
  
  
• Types of unloading devices
  
  
• Types of Drainage systems

• Mounting

• Horizontal

• Vertical

• Type of lubrication

• Soft

• Outside

• Non lubricated compressor

• Foundation

• Condition monitoring

• Temp analysis

• Vibration analysis

• Alignment analysis – axial and radial (laser based)

• Preventive / Predictive maintenance

• Breakdown maintenance

• Trouble shooting

• Checklist