TRAINING REPORT

OBJECTIVE
Authorization for inspection of Air Compressors.
DEFENITIONS:
Compressors:
By definition, compressors are intended to compress a substance in gaseous state.
There are two basic types of compressor types: positive displacement and dynamic
In positive displacement type, a given quantity of air is trapped in a compression chamber
and the volume it occupies is mechanically reduced, causing a corresponding rise in pressure
prior to discharge. At constant speed, the air flow remains essentially constant with
variations in discharge pressure.
Dynamic compressors impart velocity energy to continuously flowing air or gas by means of
impellers rotating at very high speeds. The velocity energy is changed to pressure energy
both by the impellers and the discharge volutes or diffusers. In the centrifugal type dynamic
compressors, the shape of the impeller blades determine the relationship between the air
flow and the pressure or head generated.

Reciprocating
Positive
displacement
Rotary
Types of
compressors
Centrifugal
Dynamic
Axial

Reciprocating compressors:
These are the most widely used type in industries. The compressor capacity is directly
proportional to the speed and the output is a pulsating one

The reciprocating compressor is considered single acting when the compressing is

accomplished by using only one side of the piston. A compressor using both side of the
piston is considered double acting.
Rotary compressors:
A rotary compressor has rotors in place of pistons and gives a continuous pulsation free
discharge. They operate at high speeds and generally provide higher outputs than
reciprocating compressors. Their capital costs are low, compact in size, have low weight and
are easy to maintain compared to reciprocating compressors.
Types of rotary compressors include Screw compressors, Lobe compressors, Rotary
vane/sliding vane compressors etc.

Screw compressors employ two rotating inter linked helical screws which capture air in a
pocket between them, the space in which the air is trapped becomes smaller as it moves
down the axis of the screw. The compressed air is discharged from the opposite end of the
intake.
Centrifugal Compressors:
The centrifugal air compressor is a dynamic compressor, which depends on transfer of
energy from a rotating impeller to the air. The rotor accomplishes this by changing the
momentum and pressure of the air. This momentum is converted to useful pressure by
slowing the air down in a stationary diffuser. Centrifugal machines are better suited for
applications requiring very high capacities.

Axial Compressors:
Axial compressors are used for very high flow and low-pressure applications It is a
rotating, airfoil-based compressor in which the working fluid principally flows parallel to the
axis of rotation.
Compressed air systems consist of following major components:

Intake Air Filters that prevent dust from entering a compressor. Dust causes sticking
valves, scoured cylinders, excessive wear etc.

Inter-stage Coolers that reduce the temperature of the air before it enters the next
stage to reduce the work of compression and increase efficiency. They are normally
water-cooled.

After-Coolers with the objective is to remove the moisture in the air by reducing the
temperature in a water-cooled heat exchanger.

Air-dryers that remove the remaining traces of moisture after after-cooler as

equipment has to be relatively free of any moisture.

Moisture drain traps that are used for removal of moisture in the compressed air.
These traps resemble steam traps. Various types of traps used are manual drain
cocks, timer based / automatic drain valves etc.

Receivers that are provided as storage and smoothening pulsating air output reducing pressure variations from the compressor

Among air compressors there are multiple control schemes, each with differing advantages
and disadvantages.
Start/Stop: In a start/stop control scheme, relays actuate to apply and remove power to the
compressor air end according to compressed air needs.
Load/Unload: In a load/unload control scheme, the compressor air end remains
continuously powered. However, when the demand for the compressed air is satisfied,
instead of disconnecting power to the compressor air end, the inlet valve is closed,
unloading the compressor. This reduces the number of start/stop cycles for the electric
motors over a start/stop control scheme in electrically driven compressors, improving
equipment service life with minimal change in operation cost. This scheme is utilized by
nearly all industrial air compressor manufacturers.
Modulation: Instead of starting and stopping the compressor or actuating the inlet valve
between two distinct positions, a modulation control scheme proportionally adjusts the
inlet valve open and closed, altering the compressor discharge according to the demand.
Power consumption in this scheme is significantly higher than the load/unload scheme.
Variable speed: While an air compressor powered by a variable speed drive can offer the
lowest operating energy cost without any appreciable reduction in service life over a
properly maintained load/unload compressor, the variable frequency power inverter of a
variable speed drive typically adds significant cost to the design of such a compressor,
negating its economic benefits if there are limited variations in demand.
Inspection of Air Compressors:
LR Standard scope of inspection for Castings includes:
COMPRESSORS

1. Pre-inspection meeting

TYPE RECIPROCATING
BELOW 100 100 KW &
KW
ABOVE
X
X

CENTRIFUGAL
ALL SIZES
X

2. Identify basic materials against test data

3. Review basic material test data
4. Review weld procedures
5. Review welder qualifications
6. Review NDT procedures
7. Review NDT operators qualifications
8. Audit equipment
9. Inspect principal forgings and castings
dependent on delivery to:
Scope 02 for Principal Forgings
Scope 03 for Principal Castings
10. Visually inspect weld fabrication at:
Preparation
Tack Assembly
Back Gouge
Completed Welds
11. Review heat treatment charts
12. Review NDT reports
13. Witness/ Monitor:
Ultrasonic Exam
Electro Magnetic Exam
Liquid Penetrant Exam
Magnetic Exam
Radiographic Exam
14. Examine radiographs
15. Countersign NDT reports for tests witnessed
16. Witness pressure tests
17. Inspect sub-assemblies of rotor shafts
18. Witness static balance tests of rotors
19. Witness dynamic balance test of rotors
20. Inspect alignment of rotor shafts
21. Witness dimensional check after the overspeed
stretch of fabricated rotor, if applicable
22. Witness performance test and audit direction
of rotation, with driver
23. Witness overspeed, governor, vibration tests
and safety functions
24. Witness static seal oil tests
25. Witness strip down examination
26. Review manufacturers test data
27. Stamp for identification
28. Issue visit reports
29. Issue certification

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The scope of inspection for the inspection carried out at M/s KPCL for ISGEC includes
-

Review of raw material TCs of Crank Case, Cylinders, End Covers, Crank Shaft,
Connecting rods, piston rods, pistons and cross heads, big end bolts, main bearings for
their chemical and mechanical properties.
Review of in process inspection reports
Witnessing pressure test of cylinder with end covers and leak test of crank case with
cutting oil.
Witnessing UT on crank shafts, piston rods and big end bolts for detecting surface
defects.
Witnessing MPI on crank shafts, big end bolts, piston rods and connecting rods.
Witnessing DP test on pistons, cylinder and liner.
Witnessing final dimensional check on the overall assembly.
Witnessing Mechanical Run Test and Performance test with job motor & shop starter
for 4 hours
Witnessing post performance partial strip test and internal inspection.
Review of TCs for instruments as per approved data sheets.
Review of painting, packing and despatch.
Issue of IRN.

Free Air Delivery (FAD) : This indicates the amount of air sucked by the compressor at
specified suction and discharge conditions
For FAD Measurement, the following parameters are to be recorded while testing:
-

Ambient temperature
1st/ 2nd stage delivery pressure Kg/cm 2
1st/ 2nd stage air inlet temperature
1st/ 2nd stage air outlet temperature
After cooler air inlet/outlet temperature
Inter cooler air inlet/outlet temperature
After cooler water inlet/outlet temperature
Compressor water inlet/outlet temperature
Oil cooler water inlet/outlet temperature
Compressor speed in RPM
Air temperature before nozzle
Differential pressure of nozzle in mm of water
Upstream pressure of nozzle in mm of water
Suction pressure drop in mm of water

Calculations:
1

3(34)

F.A.D = K . 1

where K = 3600 . 4 2 2
= coefficient of expansion of air = 1
= Expansion Factor
. = 1 (For routine test as per IS 10431)
Ra = Gas Constant = 287.1
D = Diameter of Nozzle in meters
T1 = Air inlet temperature in oK
P1 = Air inlet pressure in mm of H2O
= (Barometric pressure x 13.52 Pressure drop across the filter)
P3 = Pressure upstream of nozzle in mm of H2O
= (Barometric pressure x 13.52 + upstream pressure in mm of H2O)
P3 P4 = Differential pressure at the nozzle(pressure difference across the nozzle
in mm of H2O
Power Measurement:
The following parameters to be recorded for the calculations of power consumptions, such
as current voltage, wattmeter readings etc.
Input Power =

(1+2)
1000

Output Power = Input power x Motor Efficiency

Motor Output corrected at rpm & considering belt losses is calculated from this.

Submitted by

Yathiraj Sudharnnan.
Assistant Surveyor,
LRA, Pune.