Mod. 11 PLANT C OMPRESSOR PDF

Kingdom of Saudi Arabia
Saline Water Conversion Corporation

General Directorate Of Training Programs
Training Center – JUBAIL
MAINTENANCE DEPARTMENT
MECHANICAL ENGINEERS COURSE
PLANT COMPRESSOR & O/H
"
Module No. 11:

Version 1.1
Prepared by: Hamed Mahmood
Date:2 0 0 5
SWCC TRAINING CENTER
AL-JUBAIL
COMPRESSOR MAINTENANCE MODULE HOURS
LES SUBJECT/TOPIC THEORY PRACT TOTAL

No HOURS HOURS HOURS
PRINCIPLE AND THEORY
a) Introduction
b) Purpose theory.
1. 10 10
c) Types of compressors.
d) How compressor work.
e) Capacity.
CYLINDER, RELATED PARTS
2. AND CARE 3 2 5
3. CRANKCASE AND CARE OF CRANKCASE PARTS 3 2 5

AUXILIARIES OF COMPRESSOR
4. AND CARE 2 3 5
ROCATING COMPRESSOR TROUBLESHOOTING
5. GUIDE 2 3 5
ROTARY SCREW COMPRESSOR
6. AND MAINTENANCE 5 5 10
7. ROTARY BLOWER AND MAINTENANCE 5 5 10
TOTAL HOURS FOR COMPRESSOR & FAN MAINTENANCE 30 20 50

Plant compressor main & o/h working principle & cla. Of plant comp
LESSON WORKING PRINCIPLE AND

1 CLASSIFICATION OF PLANT
LECTURE COMPRESSORS
Objectives
At the end of the lesson the trainee will be able to:
1. Define the compressor and its uses.

2. Classify air compressor.
1.0 INTRODUCTION
Compressor are required for several plant operation and processes for
example compressors are used in every S.W.C.C plants to provide a
source of compressed air. The plants are use compressed air to
operate machines, tools and some of the instrument that control
processes. Compressor are also used to compress the gases for
liquefied and storage.
1.1 BASIC WORKING PRINCIPLE
Compressors are used to increase the pressure of gas from the initial
condition (air intake) to the discharge condition (air discharge)
discharge of compressor can be used for storage purposes as gas or
liquid forms.
When gas or air to be compressed some work has to be done on it, the
reduced volume of gas have stored or potential energy in the form of
pressure increased.
When that compressed is flow in single direction, some of its potential

energy is convert into the kinetic energy which can make that to do
work.
1.2 USES OF COMPRESSED AIR AROUD THE S.W.C.C PLANTS
Some of the uses of compressed air are listed below:
1. Motive power for grinding and sanding tools, drills, and

wrenches, riveting hammers and chipping hammers.
2. Motive power for air motors which drive hoists and winches.
Lesson 1 Page 1
3. Blast cleaning or sandblasting of surfaces.
4. Spray painting.
5. Engine starting as with diesel engine.
6. Conveyer systems which move powdered and granular

materials by means of compressed air.
7. Control systems where compressed air is used both as a

signaling medium and also to power actuating – devices
such as air cylinders.
8. Atomizing of liquids such as oil for use as a fuel and water

for use in humidifying.
9. Soot blowing for boiler furnaces.
10. Mixing or agitating materials for a process.
2.0 TYPE OF COMPRESSOR
Air compressors are divided into two general categories according to

their basic principal of operation.
1. Positive displacement compressor.

2. Dynamic compressor.
2.1 POSITIVE DISPLACEMENT COMPRESSOR
Positive displacement compressor are work by trapping a mass of air

or gas and squeezing it into a smaller volume. Why they called positive
displacement? Because a definite amount of air is compressed for
every stroke or revolution of compressor. They may be divided in to
two general type.
1. Reciprocating compressor.
2. Rotary compressor.
Each category include several different kinds of compressor which are

explained in next topics.
2.2 RECIPROCATING COMPRESSOR
Lesson 1 Page 2
A reciprocating compressor is one in which the air is compressed by a

piston moving in a reciprocating manner within a cylinder. The cylinder
must be equipped with intake and discharge valves to control the flow
of air entering and leaving. This type of compressor is used in a wide
variety of applications including power plant service and commercial,
industrial and mining installation. It is suitable for all ranges of
pressure. Working principle of a reciprocating compressor is shown in
Fig. 1 – 1. The classification and major pasts of the reciprocating
compressor are defined in lesson number two.
Fig. 1 – 1: A reciprocating compressor
3.0 CLASSIFICATION OF RECIPROCATING COMPRESSOR
Reciprocating compressors are made in variety of designs or

arrangements and may be divided into types according to cylinder
arrangement, method of compression, method of drive and whether
they are single or double acting. Fig. 1 – 2 shows the classification of
reciprocating and 1 – 3 shows the physical arrangement classification.
Reciprocating compressor
According to the According to the

According to the
Cylinder method of
action
arrangement compressor
Single Double vertical V or y L- Single

Horizontal Multistage
Acting Acting type type stage
Fig. 1-2: Classification of reciprocating compressors
Lesson 1 Page 3
Fig. 1-3: Physical arrangement classification.
3.1 ACCORDING TO THE ACTION
As mention before a reciprocating compressor can be either single

acting or double acting.
Double-acting means that the piston is also compressing on the return

stroke shown in Fig. 1-4.
At any given speed the double acting reciprocating compressor has

twice the flow rate as that of a single-stage compressor.
A Single - acting or double-acting compressor usually operates to a

maximum pressure of 10 Bar and can deliver up to 3000 m3h.
Fig. 1-4: A double acting compressor cylinder.
Lesson 1 Page 4
3.1 ACCORDING TO THE CYLINDER ARRANGEMENT
Various cylinder arrangements are used in reciprocating compressor

design. The compressor cylinder may be arranged with its axis vertical
or horizontal, or in some cases, where two cylinders are used, one
cylinder may be vertical and the other horizontal. The latter
arrangement is knows- as an angle compressor. Still another
arrangement is V or -Y type, which has two cylinders with their axis at
an angle of 45°.
Fig. 1 – 5 shows an angle compressor and the Y – type appears in Fig.

1 – 6.
Fig. 1 – 5: Angle or L – Type compressor.
Fig. 1 – 6: Y – Type compressor
Lesson 1 Page 5
3.3 ACCORDING TO THE METHOD OF COMPRESSION
For compressed air pressure up to 850 Kpa or possibly 1000 Kpa, the
air is compressed to the desired pressure in one cylinder which may be
either single-acting or double-acting.
For pressure from 1-000 Kpa to about 6900 Kpa the air is compressed
first in a low-pressure cylinder and then further compressed to the final
pressure in a high-pressure- cylinder. This arrangement is known as
two-stage compression.
For special applications where pressures above 6900 Kpa are

required, the
4.0 ROTARY COMPRESSOR
In a rotary compressor a compressing elements rotates on a shaft. A

volume of air or gas is drawn in the casing, the compressing element
then squeezed the volume, increase pressure and discharge all the
volume. Include rotary screw compressors, sliding vane compressors,
liquid ring compressors, and rotary blowers. See Fig. 1 – 7 for
classification and Fig. 1 – 8 and Fig. 1 – 9 for screw compressors, in
Fig. 1 – 10 shown sliding vane compressor. Fig. 1 – 11 liquid ring
compressor and in Fig. 1 – 12. two lobe rotary compressor.
Rotary Compressor
Screw Vane Liquid ring Lobe

type
Lubricated Non
Dry Wet Double Tripple
Vanes Lubricated
Type Type Lobe Type Lobe Type
type Vanes type
Fig. 1 – 7: Classification chart of rotary compressor
4.1 THE ROTARY SCREW AIR COMPRESSOR
Pressures produced by this type are quite low - 100 Kpa gage for
single stage and 200 Kpa gage for two-stage.
The lobe compressor has the advantages of being compact and

requiring no inlet or discharged valves. In addition it produces an even
flow of oil free air.
As the rotors turns and intermesh, the air is compressed and forced out
the discharge. The screw compressor have two basic type wet type
Lesson 1 Page 6
and dry type in wet type the main rotor drive to other rotor with contact
so lubrication in required and in dry type Fig. 1 – 7 shown a working
principle of a screw compressor. The rotors do not come in contact with
each other, or with the casing thus internal lubrication is not required.
The male rotor is usually the driven one and it in turn drives the female
rotor by means of timing gears.
Fig. 1-8: Single – stage rotary screw compressor.
Fig. 1 –9: Different types of screw compressor
4.2 SLIDING VANE COMPRESSOR
The impellers do not come in contact with each other or with the
casing. Therefore a cylinder lubricant is not required.
The lobe type runs at speeds up to 1750 rev/min and may be direct
driven by a steam turbine.
The sliding vane compressor consists essentially of a cylindrical rotor

having slots into which sliding vanes fit. The rotor is contained within a
water jacketed cylinder or casing and is supported by bearings so that
it is eccentric to the casing. As the rotor turns, the sliding vanes move
out against the casing wall due to centrifugal force. Pockets of air are
trapped between the vanes and the wall. These pockets decrease in
Lesson 1 Page 7
volume, due to eccentricity, as the vanes move around the casing from
the intake to the discharge and in this way the air is compressed.
Fig. 1-10 shows a sectional view of the casing and rotor of a sliding
vane compressor.
Fig. 1 – 10: Sliding vane compressor
4.3 LIQUID RING COMPRESSOR
Fig. 1-11 shown a liquid ring compressor in which an impeller is

fitted a cylinder on its out of center around the rotor a working liquid
which is rotating as rotating rings and form pocket between the blade in
these pocket the air or gas trapped and compressor after that it
discharge from the discharge plate.
Lesson 1 Page 8
Fig. 1 – 11: Liquid ring compressor.
4.4 ROTARY LOBE COMPRESSOR
Fig. 1 – 12: Two lobe type rotary (Blower) compressor.
4.5 THE ROTARY LOBE COMPRESSOR
The general construction of a rotary lobe compressor is shown in Fig.

1-13. This type features two figure - eight shaped impeller revolving in
opposite directions within a casing. The impellers maintain their
relative position with each other by the use of timing gears, the
arrangement being to drive one impeller directly and the other by
means of the timing gears.
Lesson 1 Page 9
As each lobe sweeps past the inlet, a pocket of air is trapped between
the lobe and the casing wall and is carried around to the discharge on
the opposite side of the casing. Fig. 1-14 shows a triple lobe rotary
compressor.
Fig. 1 – 13: Triple lobe type rotary (Blower) compressor.
5.0 DYNAMIC COMPRESSORS
Dynamic compressors work differently. Instead of trapping and

squeezing a mass of air, they accelerate the air, giving it energy that is
converted to pressure when the air stream is slowed down in a
controlled fashion. Fig. 1 – 14 shows one example of the dynamic type
of compressor. The dynamic compressor have two major types.
Fig. 1 – 14: A single stage dynamic compressor and three

Different types of impellers.
Lesson 1 Page 10
5.1 CLASSIFICATION OF DYNAMIC COMPRESSOR
1. Centrifugal
2. Axial flow.
Dynamic compressors
Centrifugal Axial Flow

(Multistage)
Volute Volute
casing With
Diffuser
Single
Multistage
stage
Fig. 1 –15 A different types of dynamic compressor chart.
The terms centrifugal compressor and axial compressor are often

confused the shaft in both compressor rotate in a circular motion but
the design of two types of compressor is different Fig. 1 – 15 shows a
chart for different type of dynamic compressor. The flow of a
centrifugal compressor is from the suction eye, through the impeller
vanes, at right angle to the shaft. Fig. 1-16 shows the volute type and
different type single stage centrifugal compressor.
Fig. 1-16: Volute and Diffuser Arrangement.
Lesson 1 Page 11
Fig. 1-17 shows a multistage stage compressor in which air or gas

compressed five times and then discharge with high pressure.
Fig. 1-18 shows a axial flow compressor which is always multistage

and stationary blades and
Fig. 1 – 17: A multistage centrifugal compressor.
Moving blades rings is called one set or stage. When moving blade
move it create low pressure, the air inlet to the moving blade and flow
over the blade, then it enter to the stationary blade where it velocity
(speed) slow down and some of it’s into pressure and each stage the
pressure increase up to 1:1.2 to 1:1.5 times.
Lesson 1 Page 12
Fig. 1-18
5.2 USES OF DYNAMIC COMPRESSORS
5.3 CENTRIFUGAL COMPRESSOR
1. Use for continuo’s flow in process plants.
2. Use for service air.
3. Use in small gas turbines for continues huge amount of

air.
4. The advanced centrifugal compressors are also used as

air condition compressor to compress the Freon gas.
Lesson 1 Page 13
5.4 AXIAL FLOW COMPRESSORS. (Figure 1-19)
1. Normally it is always multistage because in – between

each stage only pressure increase is 1:1.5 1:2.5 times.
2. Use for continuo’s huge amount of air flow.
3. Use in process plants for continuo’s flow.
4. Use in gas turbine for huge and continuo’s flow.
5. It’s cost is very high, them other compressor so, its

uses are limited.
Fig. 1-19 Axial Compressor
6.0 CAPACITY OF COMPRESSOR
Compressor’s rated capacity is determined by the compressor’s flow

rate and discharge pressure under standard conditions (standard
condition is temperature 68ºF, and pressure 14.7 PSIG and humidity
36%. The rated flow rate is the quantity of air that a compressor is
capable of pumping under standard conditions (immediately before the
suction point of the compressor). It is measured in cubic feet / minute
or cubic meters / minute.
The rated discharge pressure is the effective pressure that a

compressor is capable of developing under standard conditions
(immediately before the suction point) it is expressed PSI or LP.
Lesson 1 Page 14
Plant compressor main & o/h Cylinder, Related Parts And Care
LESSON
CYLINDER, RELATED PARTS
2 AND CARE
LECTURE
Objectives
At the end of the lesson the trainee will be able to demonstrate an
understand the construction of a cylinder and its related parts.
1.0 INTRODUCTION
The compressor cylinder will be either lubricated or non-lubricated

depending on application. The non-lubricated cylinder is used for
applications that prohibit air or gas from being contaminated with
lubricant.
The cylinder end consists of the cylinder with its valves, frame and
outer heads piston, piston rod, piston rings and the stuffing box packing
and control valves. And Fig. 2-1 shown single acting air cooled,
lubricated type cylinder and its related parts list. Fig. 2-2 has shown a
double acting non – lubricated V-type cylinder and related parts and
Fig. 2-3 shown a horizontal double acting cylinder and related parts.
Lesson 2 Page 1
Fig. 2 – 1: A single acting air cooled, compressor’s cylinder
Lesson 2 Page 2
and related parts.
Fig. 2 – 2 shown a double acting non – lubricated v – type – cylinder

and related parts in detailed.
Lesson 2 Page 3
Fig. 2 – 3: A cross section of N.L cylinder mostly

used on vertical or V – shaped compressor
Parts list of Fig. 2 – 3.
Item No. Description
1. Cylinder
2. Cylinder Liner (Special Equipment)
3. Piston
4. Piston guide ring
5. Piston seal ring
6. Piston rod
7. Piston rod nut
8. Separating ring
9. Suction valve without gripper (machine without control
Lesson 2 Page 4
10. Suction valve with gripper

11. Diaphragm
1 2. Bush
13. Lifting piston
14. Discharge valve
15. Gasket for valve cover
16. Gasket for centering piece
1 7. Belleville spring
18. Lantern for suction valve
19. Lantern for discharge valve
20. Gasket for suction & discharge valve
21. Seal ring for screw plug
22. Pair of seal rings
23. Gasket for stuffing box packing
24. Spacer cup
25. Gasket for valve casing
Fig. 2 – 4 has shown the cross – section of a N.L cylinder that mostly in
horizontal compressors.
Fig. 2 – 4: A horizontal cylinder and related parts.
Lesson 2 Page 5
Air cylinder parts Parts list for Fig. 2 – 4.
No. Description No. Description
1. Cylinder-Bare
2. Gasket-Cylinder for Ext 36. Jack bolt
3. Cover-HH 37. Cap screw-Otr Hd to Cyl
4. Gasket-Cover 38. Cap screw-Ohd to Cyl
5. Cap screw-Cover 39. Cap screw-Fr to Ext
6. Cover-Valve 40. Cap screw-Ext to Cylinder
7. Gasket-valve cover 41. Extension Rate
8. Cap screw-VLV Cover 42. Stud
9. Setscrew-Inlet 43. Nut
10. Nut-Setscrew 44. Gasket-Ext to Fr
11. Gasket-Nut 45. Cover-Ops
12. Setscrew-Dish 46. Cover-Ds
13. Nut-Setscrew 47. Gasket
14. Gasket-Nut 48. Cap screw
1 5. Valve-Inlet 49. Stinger-Half Oil
16. Gasket-VLV Seat 50. Cap screw
17. Un loader-Inlet valve 51. Nut-Flex lock
18. Valve-Disc
19. Gasket-VLV Seat
20. Crab-Disc VLV
21 . Retainer-Disc VLV
22. Packing Rod Complete
23. Case-Packing
24. Gasket-Case
Set-Packing Ring &
25.
Spring Ring
26. Cap screw
27. Piston-Complete
28. Ring-Piston
29. Ring-Rider
30. Rod-Bare
31. Nut-Piston
32. Cotter pin
33. Nut-XHD Lock
34. Head-Outer-Bare
35. Gasket-Head
Lesson 2 Page 6
2.0 CYLINDER
Compressor cylinders are made from cast iron for pressure up to 1000
Kpa (15 psi) or cast steel for pressure up to 6900 Kpa (1000 psi or
more). Above this pressure the material used is usually forged steal.
If water-cooling is used then the cylinder is constructed with a chamber

or water jacket surrounding the cylinder barrel through which cooling
water is circulated.
If air-cooling is used then the cylinder is constructed with integral cast

fins which provide increased radiating area. As shown in Fig. 2-1 Fig. 2
– 5 has shown a water cooled cylinder.
Fig. 2 – 5: A water cooled cylinder.
2.1 PISTON, PISTON ROD AND PISTON RING
They may be constructed of steal, cast iron or Aluminum. Trunk type

(automotive type) piston are used for single-acting compressors while
double-acting pistons may be solid or hollow and are normally fitted on
the piston rod with a taper fit against a machined shoulder on the rod
and are locked in place by means of a nut.
Lesson 2 Page 7
Fig. 2 – 6 illustrates two types of compressor piston, the single-acting

trunk type and the double-acting type.
Fig. 2 – 6: A piston of single acting.
2.2 PISTON RING
Piston rings are used for providing a seal between the cylinder and
piston. They fixed in groove which are made on piston outer surface.
Non lubricated ring:
Non-lubricated (N.L.) rings require the use of TFE (Tetrafluoro -

ethylene) materials. In addition N.L. pistons use a TFE rider ring. See
Fig. 2 - 7 piston rider or guide ring joint and piston compressor ring and
joint.
1. Lubricated ring:
They usually made of cast iron and lubricated piston rings ride in a film
of oil, they maintain a tight seal between the piston and cylinder wall for
long periods of constant service. If, after a relatively long period, a loss
of capacity is suspected, it may be advisable to check the piston rings.
Fig. 2 – 7 shows a set of lubricated cast iron rings.
Lesson 2 Page 8
Fig. 2 – 7: Non lubricated and lubricated ring set
2.3 PISTON ROD
Piston rod is usually used in double acting compressor and it is also

used for non – lubricating single acting compressor.
Piston rod is being made by forged steel and it’s surface hard chrome
plate. It’s one end connect to the piston and other connected to the
crosshead the two different types of attachments as shown in Fig. 2 –
8.
Lesson 2 Page 9
Fig. 2 – 8: Piston rod and their attachment with crosshead.
3.0 REMOVAL OF CYLINDER HEAD, INSPECTION AND MINTENANCE
Some compressor maintenance operation such as inspection or

replacing worn piston rings, piston rod cylinder liner and stuffing box
packing etc., require disassembling the cylinder. For removing the
cylinder head for any requirement it is necessary to follow the
recommend procedure in the particular compressor manual in this
lesson a example procedure for removing the head, inspection of
piston and cylinder is mansion.
3.1 REQUIREMENT FOR REMOVAL OF HEAD
1. Compressor must be completely depressurized

2. Drain the cooling water and isolate that system
3. P.T.W. must be obtained
4. All necessary tools with torque wrench
5. Overhead hoist
6. Chain block and came along (jack chain) and slings
7. Eye bolts for lifting head and piston
8. Lubricant (Molykote and Penetrating oil)
SPARE REQUIRE
9. Head gasket set
Lesson 2 Page 10
3.2 TASK PROCEDURE
REMOVING THE CYLINDER HEAD

The method used for removing the cylinder head from an air
compressor varies from machine to machine. The major cylinder head
removal steps common to most air compressors are to:
METHOD - 1
1. Remove the cooling water piping and drain the cooling jacket
2. Support the cylinder head (use rigging, if required).
3. Remove all nuts.
4. Use jacking studs to push the cylinder head off evenly.
* By using the hoist takes off the head and keeps on

wooden block.
METHOD - 2
1. After loosen all nuts and proper rigging.
2. Remove a valve from the outer end of the cylinder.
3. Move down the piston backward.
4. Insert two pieces of wood equal thickness through the valve

holes.
5. Slowly rotate the compressor by hand so that the piston moves

toward the outer head. (be careful to protect hands and fingers
from being injured between the piston and the outer head.)
6. As the piston slowly presses against the wood, the outer head is
pushed loose from the cylinder. (Do not use power to “bump”
the outer head loose.)
7. Remove the gasket between the outer head and the cylinder. If
this is baked on, it should be loosened by driving a broad, flat
wedge into the joint. Run a knife blade carefully between the
gasket and face. do not use a chisel, as this will injure the face.
8. With the head loose and the gasket free, the nuts can be
removed and the outer head easily pulled. An overhead crane
or lift is desirable for removal of the outer head and piston and
rod assembly.
Lesson 2 Page 11
4.0 CLEANING AND INSPECTION
1. Move flywheel and bring piston on the top position.
2. Cover piston and gaps by cloth of plastic sheet.
3. Remove the gasket and clean the flange surfaces of the

cylinder.
4. Clean the cylinder head.
Do not use hard brush, chisel or scraper for removing the gasket
or deposit.
5. Check the contact surfaces for scoring or crack.
6. Carefully remove the cloth or plastic from piston, do not drop

any particle between the gap of piston and cylinder
4.1 CHECKING PISTON STAND OUT CLEARANCE
Piston stand out clearance is one of the main facts for renewal the
compression rings or piston rings and guide rings or rider rings. Fig. 2-
9 shown the V type compressor cylinder and Fig. 2-10 shown the
vertical type compressor for rider ring wear
Fig. 2-9 Piston Standout.
Lesson 2 Page 12
Fig. 2-10 Checking Rider Ring for Wear
4.2 PROCEDURE FOR CHECKING PISTON STAND OUT
1. According to the Fig. 2-10 place a wooden wedge between the

piston and cylinder. Be careful that the piston ring is not
damaged by the wedge.
2. Measure the clearance between the piston and cylinder at the

bottom with a feeler gauge. Be sure that this is measured at the
main bore not the counter bore.
4.3 REMARKS
The clearance between the bottom of the piston and the cylinder
decrease to 0.005 ~ 0.00635 inches (0.127 ~ 0.25 mm). The wearing
ring or guide ring must be replaced.
If the clearance and overhaul condition of cylinder is satisfactory then

next step is to reassemble the compressor head.
5.0 REASSEMBLY OF CYLINDER-HEAD
Reassembly is reverse procedure of assembly but keep some point in

mind.
1. Use proper rigging for lifting and putting the head back.
2. Lubricate all threaded parts.
3. Use thin graphite or molyckote layer under the gasket.
Lesson 2 Page 13
4. Better to use new gaskets (with recommended gasket

thickness).
5. Tighten nut or bolts in cross pattern and on recommended
torque.
6. All piping connection put in sequence.
7. House keeping and cancelled the P.T.W.
6.0 PISTON REMOVAL FROM CYLINDER
After the decision has made from REMARKS for further check up the
cylinder side, that required to remove the piston from cylinder. In some
compressors piston can remove without piston rod and in some design
that must be pulled out with piston rod.
6.1 REQUIREMENT FOR REMOVAL OF PISTON
1. Compressor must be tagged and cylinder head removed (follow

previous lesson instructions for removing the cylinder head.
2. All necessary tools with micrometer, torque wrench and light.
3. Lead wire or feeler gauge.
4. Over head hoist and slings.
5. Eye bolts.
6.2 TASK PROCEDURE FOR REMOVING PISTON WITHOUT

PISTON ROD
Remove the cylinder head follow section removal of head.
1. Put the clamp bars on piston as mentioned in Fig. 2-11.
2. Unscrew the piston nut.
3. Bump the piston rod with brass rod, carefully not to injure the
threads on the nut.
4. After loosen the piston on the rod remove the piston nut and one
clamp.
5. Insert the eye bolt on the tap hole of piston.
6. Hold with sling and hoist.
7. Remove second clamp and lift the piston from the cylinder
taking care not to damage either the piston rings or the cylinder.
8. Lower the piston on wooden blocks.
Lesson 2 Page 14
Fig. 2- 11 Piston Removal
6.3 TASK PROCEDURE REMOVING THE PISTON WITH PISTON

ROD
Refer to Fig. 2-12 of Fig. 2 – 12 depending on the type of crosshead.
Fig. 2 – 12 Witness marks and measuring the position

Of piston rod before detaching
Lesson 2 Page 15
Fig. 2 – 13 Cross head coupling and oil wiper packing.
1. Put witness marks and measure and record the position of

piston rod.
2. Insert eye bolt in the tap hole on the top of the piston for
removing the piston.
3. Loosen the nut at the crosshead end of the rod.
4. Push the piston rod outward side and make a gap for removing
the wiper rings and piston rod packing.
5. Loosen the wiper ring bolts from crosshead cover and slide out
carefully from piston rod and removed from the gap.
6. Removed the packing holding bolts from the cylinder side and
slide out the packing from the gap.
NOTE: In any case for maintenance or replacement of packing

follow the above steps.
Lesson 2 Page 16
7. Use proper sling and hoist to remove the piston and kept on
wooden block carefully not to damage the rings, better to put
upside down.
TASK PROCEDURE
Refer Fig. 2 – 13
1. Remove the clamp of hood and oil drain pipe.
2. Pull upward the hood and support it.
3. Unlock the tab washers from the coupling bolts.
4. Remove the coupling bolts in cross pattern.
5. Remove coupling flange and clamping bush.
6. Insert a eye bolt on tap hole on the top of the piston for rigging.
7. Pulled out the piston and make a enough gap between cross
head and piston rod end, for removing the packing and hood.
8. Removed the coupling hood and packing from the gap.
9. Carefully remove the piston from cylinder by overhead crane

and put on wooden blocks.
6.4 INSTRUCTIONS FOR CLEANING THE PARTS
1. Do not use any hard scraper or wire brush for cleaning the
polished surface.
2. Use recommended solvent for cleaning.
3. Special care take for N. L. cylinder, do not clean these parts with
oil or do not touch these part with oily hands because it may
break the glazed of the surfaces.
4. For cleaning the piston the rings must be removed from the
piston, and the ring grooves must be cleaned for deposit with
some soft tool (like wood pieces).
6.5 INSPECTION OF PISTON AND ROD
1. Piston must be cleaned and rings should be out from the piston.
Lesson 2 Page 17
2. Outside micrometer as for piston diameter.
3. Visual inspection for sings of scoring, wear or other damage.
4. Check the piston rod for scoring or excessively worn out on

packing area.
5. Measure the oval ties of the piston as mentioned in Fig. 2 – 14.
Fig. 2 – 14 Top and Bottom diameter indicates lopes
6.6 REMARKS
1. If the piston found excessively worn out or scored then change

the piston.
2. Minor worn out piston rod can be polished or other wise change
the piston rod. Because this scored area frequently damaged
the stuffing box packing.
7.0 INSPECTION OF CYLINDER
1. Piston must be out of cylinder.
2. Cylinder surfaces must be cleaned.
3. Visual inspects the cylinder for scoring and deposits.
4. Measured the wear of cylinder by using an inside micrometer as

shown in Fig. 2 – 15 to take readings at several different
points.
Lesson 2 Page 18
Fig. 2 – 15: Using an Inside Micrometer to check

a cylinder for roundness.
7.1 REMARKS
1. If the cylinder is over wear it must be re bored up to oversized

ring.
2. If the oval laity is beyond the over size ring then change the
cylinder sleeve.
3. If cylinder is not oval, but equally worn out up to the limit of over
sized ring then replace the rings by oversized rings.
4. If the surfaces are scored then it must be re bored and polish

and use standard size rings.
8.0 INSPECTION OF PISTON RINGS
1. Visual inspection of rings for scoring, damage, etc.
2. Measure the radial thickness of piston rings as mentioned in Fig.

2 – 16.
Lesson 2 Page 19
3. Put guide ring on the piston and measure the projection of guide
ring as mentioned in Fig. 2 – 17.
4. Measure the side clearance as mentioned in Fig. 2 – 18 with

feeler gauge.
5. Place the each ring in the cylinder bore squarely and measure
the end gap of rings by feeler gauge as mentioned in Fig. 9 –
12.
Fig. 2 – 16: Measuring the Radial Thickness
Lesson 2 Page 20
Fig. 2 – 17: Measuring the projection of Guide Ring
Fig. 2 – 18: Ring Side Clearance
Fig. 2 – 19: Measuring the Ring Gap.
Lesson 2 Page 21
8.1 REMARKS
1. If the thickness of the reduced up to 25% to 30% replace the

rings.
2. If the projection of guide ring exceeds more than 0.25 mm

replace the guide ring.
3. If the side clearance is less than the recommendation (for new

rings) use proper rings. If that exceed for used rings it must
change because less clearance bind the ring after expansion
and excessive clearance may cause of knocking.
4. If the end gap exceed of old ring it must be replaced because a

specified amount of ring end gap is required to allow for
expansion and prevent binding as the rings heat during
operation. An excessive gap can allow more escape of gas and
reduced the capacity.
9.0 REASSEMBLE INSTRUCTION
1. Reassemble is the just reverse procedure of disassembly.
2. Follow the witness marks for proper position of parts.
3. Measure the necessary dimensions and clearances for parts

even these are new.
4. Use proper tool for proper work like ring removing and fixing tool
etc., shown in Fig. 2-20 and Fig. 2-21.
5. Use proper lubricant on all threaded parts, but take care on N.L.
cylinder rings, piston and cylinder must be free from oil or
grease
Lesson 2 Page 22
Fig. 2 – 20. Ring expander for removing and fixing the metallic ring
Fig. 2 – 21 Ring Compressor for inserting the piston in cylinder.
6. Check piston end gap or piston and clearance because

whenever the piston rod has been removed or even turned in or
out of the crosshead, it is necessary to check the piston end
clearance and make the necessary adjustment to restore it to
Lesson 2 Page 23
the proper amount. That clearance varies according to the type

and size of compressor. If the piston is not removed from the
rod, the original clearance can easily be maintained by center
punching both the rod and the crosshead and making a suitable
tram before removing the rod from the crosshead.
NOTE: Locate the piston rod tram mark such, that during
operation, it will not enter the oil wiper rings and
destroy the ring to rod seal.
9.1 TO ADJUST PISTON END CLEARANCE
1. Remove a valve from each end of the cylinder.
2. Insert a wax taper or piece of soft lead wire in the valve hole
between the piston and the cylinder head. Have the taper long
enough so that the reading can be taken from a point near the
center of the piston. This is important as some pistons are
considerably narrower in the width at the outside circumference.
3. Rotate the crankshaft by hand so that, when the piston has

moved to the end of its stroke, the taper will flatten to the exact
amount of clearance which exists between the piston and the
head. See Fig. 2 – 22.
NOTE: The rod can be turned by using a socket wrench on

the nut on the face of the piston. Never use a pipe
wrench on the piston rod.
4. Adjust the clearance by screwing the piston rod into or out of the
crosshead as is necessary to provide more clearance at the
outer end than at the frame end.
5. After the proper clearance has been established,

tighten the nut at the crosshead end of the rod and
turn the unit through one complete revolution.
Lesson 2 Page 24
Fig. 2 – 22 (a)Using soft solder to Check Piston End Clearance
10.0 OIL SCRAPER AND PACKING
1. OIL SCRAPER RINGS
As mentioned in Lesson the oil scraper or wiper rings are fixed

in stuffer of crankcase which prevents crankcase oil from being
carried out of the crankcase along the piston rod. Care must be
taken to keep a smooth bearing on the rod, as cracks or dents in
to rings or scores on the rod will not provide a tight seal. When
ever these oil scraper rings are not proper functioning they must
be replaced.
2. PACKING RINGS
The packing rings are the very heart of the packing. They seal
the pressure, take the wear, and must be serviced. When the
rings have worn so that no end clearance exists between the
segments and appear to have further usefulness, the ends may
be dressed off. The rings are the working parts in the packing
and require the most attention. Until the rate of wear is
established, frequent inspection must be maintained.
In removing the packing for cleaning, care should also be taken

to avoid damage to the gasket or any surfaces that make
pressure tight joints. Do not use a chisel or sharp instrument to
Lesson 2 Page 25
open any joint (between packing cups) and do not disturb the
bore of the rings.
11.0 REQUIREMENT OF INSTALLING OIL SCRAPER RINGS
1. All necessary tools.
2. Sets of scraper rings.
3. P.T.W obtain.
Fig. 2 – 23: Oil scraper ring.
11.1 TASK PROCEDURE
1. Follow the Fig. 2-23 and remove the crankcase cover and side
cover.
2. Remove the wiper plate by removing the wiper plate holding
bolts as shown in Fig. 2-23.
3. Hold the wiper plate to wards the cylinder side by some wires
etc.
Lift the scraper ring sits from housing.
4. Remove the ring segments springs as shown in Fig. 2-23 and
then remove the rings segments and repeat that for next.
5. Clean the piston rod and housing.
6. Place the new ring segments sits around the rod.
7. Put the spring on segment groove around the segments and
then lock the spring. Do the same for next set.
8. Lower the rings into the housing care fully.
9. Fix back the wiper plate.
10. Put back the crankcase cover and side cover.
11. Test run and cancel the P.T.W.
Lesson 2 Page 26
12.0 CARE OF PACKING
When ever, if the packing is leak or at the time of compressor

overhauling the packing should be remove for clearing, inspection and
necessary repair.
12.1 REQUIREMENT FOR REMOVAL AND DISASSEMBLE A

PACKING BOX
1. Require P.T.W (compressor tagged out).

2. Gasket.
4. Complete packing ring sets or inspect set.
12.2 TASK PROCEDURE (Follow Fig. 2-24)
1. Remove the crankcase cover and side cover.

2. in same compressor if the packing can not remove unless piston
rod should not be removed, then remove the cylinder head cover.
3. De-attach the piston rod from crosshead by unlocking the grab
lock nut as mansion in piston removing tasks.
4. Remove the packing box holding nut Fig. 2-24.
5. Care fully pull the box from the stuffing box area.
6. Mark the witness marks on the coups.
7. Loosen the cup holding studs and care fully remove the cups only
one.
Lesson 2 Page 27
Fig. 2 – 24: Radial and Tangential Cut Ring
12.3 CLEANING AND INSPECTION
1. Clean the pacing and cups with recommended

solvent.
2. The spring should be washed and inspect for looseness or
damages.
3. Check the clearance (A) as mansion in Fig. 2 – 25.
Lesson 2 Page 28
Fig. 2-25: Clearance between ends of rings of segments
12.4 REMARKS
1. If spring is damaged replaced it.

2. The old and new spring tension should be only for holding the
ring segments not for providing sealing force.
3. If the rings are worn more then recommended replace them.
4. In emergency, the clearance between the ends of the segments
can be adjusted by cutting them off as shown in Fig. 2 – 25.
12.5 INSTALLATION THE PACKING
1. Install packing rings in gland cups as the radial cutting always to

the piston side and then tangential cut ring (4) as shown in Fig. 2
– 24)
2. Assemble all packing cups as witness marks.
3. If packing is lubricated type then it should be lubricated before
installation.
4. Make sure the piston rod and stuffing box area is free and clean.
5. Lift the piston rod and hold it.
6. Placed the new stuffing box gasket on gland.
7. Carefully slide the assembly over the piston rod and insert into
the stuffing box.
8. Equally tighten the gland nuts (11) as in Fig. 2 – 24.
9. Attach the piston rod with crosshead.
10. If piston rod is adjustable type the follow the segment 9 – 1 to
adjust the piston end clearance.
11. Put back the cylinder cover with new gasket and tighten the bolt
with proper torque.
12. Put back the crankcase and side cover.
Lesson 2 Page 29
13. Test runt the compressor without load and allow the packing to
be weared in and self adjusts.
14. Cancels the permit and do the necessary house keeping.
13.0 VALVES
Compressor valve will vary in type and construction depending upon

the gas handled, pressure conditions and valve size.
Normally a typical reciprocating air compressor has valves on one of

three types:
1. Feather
2. Channel valves
3. Plate valves
All of the above mentioned valves operate by the difference in pressure

across the valve and not by mechanical linkage.
13.1 FEATHER VALVE
A feather valve is shown graphically in Fig. 2 – 26. The valve seat has
two ports (inlet and discharge) drilled through it, so this valve is actually
two valves in one. There is a feather attached to each side of the valve
seat. (The feather is simply a strip of metal that is attached to one end
of the valve seat by rivets or similar means). The casing on top of the
seat acts as a guard plate; it contains an inlet port and discharge pipe.
Normally these valves are used in low capacity compressors.
Fig. 2 – 26: A feather Valve
Lesson 2 Page 30
13.2 CHANNEL VALVES
Normally channel valves are used on large capacity reciprocating

compressors. Fig. 2 – 27 shown a reversible valves seat plate and
Fig. 2 – 28 shown the inlet and discharge channel valve construction.
Fig. 2 – 27: Reversible Valve Seat Plate.
Fig. 2 – 28: Inlet and discharge channel valves
13.3 PLATE VALVE
Plate valves are normally use on large capacity reciprocating

compressors. Fig. 2 – 29 shows a simple suction and discharge valve
Lesson 2 Page 31
and Fig. 2 – 30 shown a suction and discharge plate valve with

additional.
Fig. 2 – 29: Assembly layout of Suction Plate Valve.
Lesson 2 Page 32
Fig. 2 – 30: Assembly layout of suction plate valve with additional parts
Lesson 2 Page 33
14.0 COMPRESSOR’S VALVES OVERHAUL
As in earlier lesson mentioned that to obtain the maximum efficiency

from a compressor, the compressor valve must be in good condition. It
is better always to keep spare new valve set or overhaul the valve and
keep as spare for replacing the any defective valve.
14.1 REQUIREMENT
1. Wrenches
2. Allen Keys set
3. Screw driver
4. Soft wire brush
5. Lapping plate
6. Different grade lapping compound
7. Blue
8. Necessary spare parts
9. Solvent for cleaning
14.2 DISASSEMBLY TASK PROCEDURE (CHANNEL VALVE)
Refer Fig. 2 –31 for a Valve disassembly.
1. Lay the valve on a clean flat surface.
2. Take out the two fillister head machine screw with lock-washers
and remove the valve crab.
3. Take out the two flat head machine screw which holds the valve
seat and valve stop plate together.
4. Invert the valve assembly, if necessary, to place the valve set

down.
Lesson 2 Page 34
Fig. 2 - 31. Channel Valve Parts List
Lesson 2 Page 35
5. Rotate the valve stop plate 90o and then lift off the valve stop
plate.
6. On N.L. valves remove the two flow balancers.
7. Remove each valve spring, its corresponding wear

strip (if N.L.) and valve channel separately.
14.3 INSPECTION (CHANNEL VALVE) AND REMARKS
1. Inspect the all parts carefully. During inspection this point kept
in mind that inspection also for finding the possible causes of
defective valves.
For example if valve is oil lubricated and there is a heavy

deposit of carbon means excess of lubrication or if valve too dry
means that lubrication is less than the required rate.
2. Check the valve seat plate, if it is excessively worn or damaged
a. Inverted the valve seat

b. If possible lap the valve seat
c. Replace the valve seat with new
3. In above case valve channels and spring must be changed.
4. Do not exchange the spring of inlet and discharge valve

because the inlet valve spring are softer than discharge valve
springs. You can check the inlet and discharge springs by
difference of their arch.
INLET VALVE SPRING ARCH (Approximately 0.25 inch (6.4 m)
DISCHARGE VALVE SPRING ARCH (Approximately 0.188 inch

(4.8 mm)
15.0 DISASSEMBLY OF PLATE VALVE
Refer Fig. 2-32 for disassembly and assembly of a plate valve.
1. Hold the (damper plate in suction, seat plate in discharge) valve

in vise with soft jaws and loosen and remove the uni-stop safety
nut or hold the valve assembly in hands and loosen the uni-stop
safety nut by striking the spanner with small hammer.
2. After removal of holding nut removed the other parts one by one
and keep them in one container separately.
Lesson 2 Page 36
15.1 CLEANING
1. Brush valve parts carefully with a soft wire brush.
2. Use a bristle brush for all valve seating surfaces.
3. Rinse the metal valve parts thoroughly in safety solvent.
4. Blow away all loose particles with compressed air.
5. The valve guide and wear strips may be wiped using a clean dry
cloth (of channel valve).
(Do not soak valve guides and wear strips in safety solvent)
15.2 INSPECTION (PLATE VALVES) AND REMARKS
1. Check valve parts for hair cracks, chipping wear seat

depressions worn out springs.
2. Check the valve seat
a. If it is slightly worn out or damaged re-lap the seat
b. Excess worn out or damaged, changed the seat
3. Check the valve plates, damper plates and springs, if found

damage any of them replace with new one, but if one out of
several spring is worn out to exchange the entire spring set.
4. Check fixing or locating pin, if possible replace the worn or

damage pin or otherwise change hole plate with pin.
5. Measure the thickness of bottom and top stroke variation shims

of less than the recommended thickness change them.
NORMAL THICKNESS OF VARIATION SHIMS
SUCTION VALVE DISCHARGE VALVE
Bottom 0..6 mm Bottom 0.6 mm

Top 0.8 mm Top 0.6 mm
Lesson 2 Page 37
16.0 INSPECTION (FEATHER VALVE) AND REMARKS
Normally the feather valves cannot be re-build up type and if the

feather or valve plate found worn or damaged the whole valve
assembly must be replace with new one.
17.0 RESURFACING A VALVE SEAT
Resurfacing a valve seat usually involves two procedures: surface

grinding and lapping. Surface grinding, which removes a fraction of the
metal surface, is done on a grinding machine.
After the grinding has been done, the surface is lapped to remove the
tiny scratches that grinding leaves in a metal surface - scratches that
could interfere with efficient valve operation. Lapping makes the
surface of the valve seat as smooth and flat as possible.
The results of the lapping operation are checked by bluing. To check

the valve seating surface for flatness, a thin layer or Prussian blue is
spread on a perfectly flat surface plate. Then, the valve seat is set
(seating surface down) on the layer of Prussian blue and rotated a
quarter of a turn. When the valve seat is lifted from the surface plate,
there should be a thin, even coat of bluing on the seating surface
(Fig. 2-32). If the areas of bluing are uneven (Fig. 2-33), the seating
surface is not perfectly flat. If the seating surface is not perfectly flat,
the bluing is cleaned off the seating surface and the lapping process
continues until a perfectly flat surface is obtained.
Fig. 2-32 Even coat of bluing shows a complete lapped seat.
Lesson 2 Page 38
Fig. 2-33 Uneven Lapping.
17.1 VALVE LIFT
Total valve opening is known as valve lift it varies 0.035 inch (0.9 mm)
for high pressure high speed operation, 0.180 inch (4.6 mm) for low
pressure low speed operation, 0.100 (2.5 mm) for general purpose.
Before the valve is put back in the cylinder the valve lift must be
checked. Excessive lift may cause the valve to fail sooner than it
should, because the increased opening makes the valve slum shut
harder when it closes.
17.2 REASSEMBLE AND VALVE LIFT CHECK
1. Reassembling is the just reverse procedure off valve

disassembly.
2. After reassembling the valve check the free movement of

channel and valve lift for that purpose presses the each channel
of channel valve and damper plate by means of pencil or soft
tools as shown in Fig. 2-34.
Lesson 2 Page 39
Fig. 2-34 Checking valve lift with a Dial Indicator.
18.0 RE – INSTALLATION OF VALVES
Re installation of inspected or overhauled valves follow these additional

instructions.
1. If valves are non– lubricated type so they must be free from oil or
grease.
2. Always use new gaskets.
3. Never forced to valve for installation and make sure that valve is
on this proper seating and position.
4. Valve cover should tighten with proper pattern and torque.
Lesson 2 Page 40
Plant compressor main & o/h Crankcase And Care Of Crankcase Parts
LESSON
CRANKCASE AND CARE OF
3 CRANKCASE PARTS
LECTURE
Objectives
At the end of the lesson the Trainee will be able to demonstrate an
understand the care of crankcase.
1.0 INTRODUCTION
Crankcase is the area of compressor which contain mostly moving

parts like, crankshaft, connecting rod, main bearing, big end bearings,
crosshead and lubricating oil pump and filter oil seals and in some
design also oil cooler located into the crankcase. Fig. 3-1 shows a
vertical compressor crankcase. And Fig. 3-2 has
shown a v – type double acting cylinder crank case with part list.
Fig. 3-1 Crankcase Cross section view of a vertical compressor
Lesson 3 Page 1
Fig. 3-2 Shows a V-type double cylinder compressor crankcase

with parts.
Item Item
Lesson 3 Page 2
No. Description No. Description
1. O-ring 16. Connecting rod bearing

2. Lantern 17. Centering bush
3. Gasket 18. Connecting rod bolt
4. Gasket 19. Crosshead
5. Oil level sight glass 20. Crosshead pin
6. Radial seal ring 21. Circlip
7. O-ring 22. Distance piece
8. Radial seal ring 23. Flange
9. O-ring 24. Adapter sleeve
10. Crankshaft 25. Hexagon screw
11. Cylindrical roller bearing 26. Tab washer
12. Coupling piece 27. Oil wiper packing
13. Gasket 28. O-ring
14. Connecting rod 29. Gasket
15. Small-end bearing
2.0 CRANKSHAFT
The compressor crank shafts are made of forged steel and for
pressurized lubrication system (normally in large compressors) drilled
to provide oil passages. Crankshaft is used in single stage or
multistage are normally with single crankpin. See Fig. 3-3 and it is
assembled in the bedplate by passing it through the opening on the
bearing housing side of the bedplate. The main crankshaft supporting
bearings may be full floating bushing bearings or antifriction roller/ball
bearings. The outer side housing of the bearings sealed with oil seals.
Whenever it is necessary to check or replace the bearings it is required
to remove the crankshaft from housing.
Lesson 3 Page 3
Fig. 3-3 Crankshaft and Main Bearing Assembly
2.1 Requirement For Removal Of Crankshaft
1. Compressor must be depressurized and isolated.

2. Oil must be drained.
3. Sheaves must be removed (follow section of belt drive care)
4. Connecting rod must be removed (follow section removal of
connecting rod)
5. Require all necessary tools
6. Require overhead hoist; sligs and nylon belts
7. Oil seals; bearing if require
2.2 Task Procedure For Removing Crankshaft And Bearing
1. Remove the connecting rod and cap. (Refer to section

connecting rod removal)
2. Remove the V-belt sheave. (Refer to section V-belt drive care)
3. Remove the crankshaft oil seal. (Refer to section removal of oil
seal)
4. Remove the main bearing housing.
Lesson 3 Page 4
5. Support the crankshaft in a horizontal position and remove from

the frame by pulling it straight out through the main bearing
housing opening.
NOTE:
1. In some design after step (3) necessary to remove
the counter balance weight from the crank web
because the bearing housing opening is not
enough to remove with counter weight.
2. Never use wire slings directly on bearings, better

use the nylon belt for lifting the crankshaft.
3. Keep straight on soft surface.
2.3 Cleaning And Inspection Of Parts
1. Clean the parts by recommended solvent.
2. Visual inspect the crank shaft and bearings.
3. Measure the inner diameter of housing in different places.
4. Measure the outside diameter of main bearing journals.
2.4 Remarks
1. If the clearances of the bearings more than the recommended,

replace them. For replacement see section replacement of
bearings.
2. If found scoring or minor scratches on journals polish it.
2.5 Replacement Of Bearing Or Bushing
1. Normally flywheel side bushings are fixed in bushing housing

from inside the crankcase.
2. In this stage the crankshaft and oil seals are removed from
housing.
3. Use a hollow tube from the flywheel side and push that by
hammer or puller.
4. Clean the housing and fixed a new bus as reverse operation of

removal.
Lesson 3 Page 5
5. Use same procedure for removing and fixing the pump side
bushing.
Notes
1. Be certain that all parts are cleaned before assembly.
2. Use only original bushings
3. It is recommended both bushing must be replaced at the

same time.
4. These bushing must be free to float on the crankshaft and

in the bearing housing. This floating may be from 0.1 mm
to 1 mm and can check fixing the dial indicator on the end
of shaft and moving the shaft axially.
2.6 Removal And Replacement Of Oil Seals
In some design oil seal fixed in main housing casting as shown in Fig.
3-4 and in some design these seals fixed in bearing cover which can
easily removed from housing and seals can replace.
Lesson 3 Page 6
Fig. 3-4 Cross-Section of Oil Seal Assembly
Lesson 3 Page 7
2.7 REPLACEMENT OF SEALS (Fig. 3-4)
1. Work a screwdriver or similar tool along the joint between

the outer surface of the seal and the bearing housing
counter bore. Work the tool around the seal until the seal
is completely removed from the counter bore. The seal
will then slide off the crankshaft.
Notes:
Since it is very probable that the seals will be damaged while
being removed, be certain that new replacements are available.
2. Thoroughly clean the crankshaft and bearing housing

counter bore, and remove any nicks or sharp edges at the
keyway. It is recommended that shim stock or tape be
used over the keyway to protect the lip on the seals
during assembly.
3. The lip section tends to distort if forced abruptly over the

shaft. It is, therefore, recommended that the shaft and
the lip of the seal be well coated with oil and a rotary
screw motion be used while pushing it over the shaft.
4. Slip the oil seal on the shaft and align with seal housing.
5. Use a metal tube over the shaft to force the seal evenly
into its seat.
3.0 CROSSHEAD
The crosshead design in compressor may be adjustable type or non-

adjustable type and the crosshead guide may be closed type like cylinder or
side open.
In cylindrical crosshead guide the crosshead can only removed with

connecting rod and in side open guides, crosshead can remove by detaching
piston, rod and connecting rods crosshead pin. Fig. 3-5 shown a crosshead
with adjustable and change able guide shoes and Fig. 3-6 shows a no adjust
crosshead and its assembly parts.
3.1 REQUIREMENT FOR REMOVAL OF CROSSHEAD
1. Compressor complete shutdown and depressurized.
3. Overhead hoist, sligs, eye bolts etc.
Lesson 3 Page 8
3.2 TASK PROCEDURE (Fig. 3-5)
METHOD 1
The crosshead is of one piece construction. No adjustment is

necessary.
1. On vertical units block the belt wheel to prevent rotation and

block the crosshead prior to removal of the connecting rod.
Remove connecting rod (refer to section to removal of piston
and rod). Lower the crosshead to bottom of the stroke and
relock.
2. Loosen the piston rod crosshead lock nut and star washer.
3. Use a strap wrench to screw the piston rod out of the crosshead.
4. Remove the crosshead blocking and take the crosshead out
through the frame opening.
Fig. 3-5 Crosshead, Crosshead Pin and Retaining Ring
ALTERNATE METHOD 2
1. Block the belt wheel to prevent rotation.
2. Unscrew the piston rod from the crosshead (Refer to step 3
above).
3. Remove the complete cylinder and assembly.
Lesson 3 Page 9
NOTE:
This is accomplished by removing the hex nuts which
secure the frame head and distance piece to the frame.
Because of limited space, an extension wrench must be used to
remove these nuts.
4. Remove one of the crosshead pin retaining rings.
5. Remove the crosshead pin.
6. Remove the crosshead.
NOTE:
During steps 4 and 5 above, be careful not to allow
connecting rod to drop forcibly on the crosshead guide.
Fig. 3-6 has shown a non-adjustable type crosshead assembly with
cylindrical guide.
Fig. 3-6. Cross head Assembly with Cylindrical Guide.
Lesson 3 Page 10
3.3 PROCEDURE (Fig. 3-6)
1. Remove crosshead hood by removing the hood clamps.
2. Hole or support the hood in maximum upward position.
3. Unlocked the tap washer (5).
4. Remove the bolts (4) in cross pattern.
5. Remove (1) flange and clamping bush (2).
6. Push the piston upward (for that the cylinder head must be
removed, for that follow cylinder head removal procedure).
Notes: In this stage crosshead is from piston rod but still

connected with connecting rod.
a. In this stage if require to remove the packing then follow

the packing and scraper ring procedure.
b. Then if require remove the piston from cylinder.
c. For removing the crosshead from guide follow the

connecting rod procedure.
4.0 CONNECTING ROD
Fig. 3-7 shown the connecting rod has a solid eye at the crosshead
end and a split eye at the crank pin end. A drilled oil passage connects
the ends.
The connecting rod cap is held on by two bolts, which are wired
together at assembly.
Two dowels are used at the joint where the rod and cap fit together.
These dowels maintain alignment and must not be removed when
removing the connecting rod cap from the connecting rod. When the
rod is removed, one dowel remains in the cap and one dowel remains
in the rod.
This prevents wrongful assembly when replacing the cap. The crank
pin bushing is full floating and no adjustment is needed.
Lesson 3 Page 11
Fig. 3-7 A Connecting Rod and Cross head Assembly.
Fig. 3-8 A Connecting Rod with parts.
Lesson 3 Page 12
4.1 Task Procedure For Removal Of Connecting Rod (Fig. 3-7)
1. Rotate the crankshaft so that the connecting rod bolts are

accessible through the opening in the frame, and then remove
the cap bolts. (If the compressor is vertical or V-shape then
before removing the cap bolts, put a eye bolt on the tap hole on
crosshead and hold with rope through piston rod hole in cylinder
side)
2. Remove the connecting rod cap through the opening in the

frame.
3. Rotate the crankshaft free of the connecting rod.
4. Remove the connecting rod through the frame opening.
5. In other case release the rope downward with care and remove
the connecting rod with crosshead through the frame opening.
4.2 Care And Inspection Of Crosshead And Connecting Rod
1. Clean all the parts with recommended solvent.
NOTE: Do not use any hard tools or hard brush for cleaning
the parts.
2. Clean the oil passage in the connecting rod by inserting thin

steel wire or by blowing the air through passage.
4.3 Inspect
1. Visual inspect all parts for hair cracks or other damages.
2. Examine the big end journal (crank pin) crankpin bushing or

bearings, crosshead pin and bushing for wear or scoring.
4.4 Wear Checking Procedure
a. Between crosshead pin and bushing by differences of

diameters.
b. Between crank pin and crank pin bushing (big end):
* This can be measured by assembling the connecting rod

cap with bushing and measuring the differences of
diameters or
Lesson 3 Page 13
* Placed the connecting rod on the crank pin and put a lead
wire between the cap and crank pin
* Tighten the cap up to specified torque
* Remove the cap and measure the thickness of lead wire
Notes The above method can also be used while

crankshaft and connecting rod is still in crankcase.
c. Measure the thickness of shoe plates of crosshead which are

replace able type or check the difference between diameters (if
crosshead is single piece type) of crosshead and its guide
cylinder (clearances).
4.5 REMARKS
1. If the clearance between the crank pin and bashing is more

than it’s recommended replace the bushing.
2. If crosshead pin is scored and worn-out also replace it.
3. If the clearance between crank pin and big and bearing is

more than recommended then replace the bearings.
4. If clearance between crosshead and cylinder is more then

replace the crosshead guide lining if it is not like that then
replace the crosshead.
5. If connecting find bent crack during visual inspection, then it

must be replaced.
5.0 REASSEMBLY INSTRUCTION
Reassembly procedure is the just reverse of disassembly procedure

but follow these additional instructions.
1. Always use soft belts for lifting the crank shaft.
2. Use proper lubricants while fixing or sliding the parts in crank case.
3. proper align the parts and do not apply un – necessary force to fix
the parts.
4. Always use new gasket “O” rings and oil seals.
Lesson 3 Page 14
Plant Compressor Main & O/H Auxiliaries Of Compressor & Care
LESSON
AUXILIARIES OF COMPRESSOR
4 AND CARE
LECTURE
Objectives
At the end of the lesson the trainee will be able to demonstrate an
understand the lubrication management.
1. About most of the compressors auxiliaries and auxiliary

systems.
2. Care and maintenance of that.
1.0 INTRODUCTION
As we learn in privies lessons, the compression are used in plant for

many essential use so it is necessary the plant compressors are
operate under satisfactory condition the compressor auxiliary system
are help to operate a compressor my be simple or as completed for
some of the compressor.
A compressor my have these important auxiliaries and system, cooling

system and moisture removal, lubrication system and belt drives.
2.0 COOLING SYSTEM
Compression creates heat as shown in Fig. 4-1. Hot compressed

gases could a compressor overheat. Over heating of a compressor are
causes many major problems in compressed air system.
1. First most of compressors are oil lubricated and excessive heat

can break down the oil.
2. Secondly as gases arc heated, they tend to expand that

tendency to expand creates an addition force and the
compressor must overcome. With more kw consumption.
3. Air always contains some water vapor varying from a small

amount up to the point of saturation at which condensation take
place.
Lesson 4 Page 1
When the air cooled after the compression this moisture condenses
and falls to the bottom of the intercooler and it removed from by
moisture separator.
Fig. 4 – 1: Heat generate by compression
2.1 System Of Cooling
Heat generated during compression is controlled in two ways.
• By limiting the pressure.

• By cooling
The pressure developed in a single stage compressor is usually

restricted to about 120 ≈ psi. In this range the heat of compression is
held below 500ºF. If higher pressure are desired, several stages are
used with intercoolers, placed between every two stages by this it can
also save additional work required to compressed a gas up to required
pressure. Fig. 4 – 2 the advantage of cooling between stages.
Lesson 4 Page 2
Fig 4 – 2 Inter cooling between stages safe addition work.
By cooling system heat removed from the compressor and compressed

air by three ways:
By lubrication some percentage of heat can removed.
By conduction of heat through the cylinder walls.
2.2 Method Of Cooling
Two techniques can be used to remove unwanted heat from

compressor and compressed air.
1. Air Cooling.
2. Water Cooling.
Air cooled compressor have metallic fins on their casing and cylinder.
These fins increase the surface area and that increased surface area
increases the cooling capability of the compressor. There are two
methods of air circulation through these fins.
1. Natural air.
2. Indirect ok forced air.
2.3 Natural Air Cooling
In natural air cooling system air freely circulates through the exterior
cooling fins around the cylinder. The air removed the generated heat of
the compression as shown in Fig. 4 – 3.
Lesson 4 Page 3
2.4 Forced Or Indirect Air Cooling
In forced or induced air cooling a fan create a flow of air over. Under
and around the surface of the compressor this method mostly used in
high pressure compressors and in many cases fan blades are built in to
the fly wheel of the compressor as shown in Fig. 4 – 4.
Fig. 4 – 3: Natural air cooling.
Fig. 4 – 4: Forced air cooling.
2.5 Water Cooling
Water cooling is often used on large compressors. Water is circulated

through special opening in the compressor housing these are often
called. “Water jackets” as shown in Fig. 4 – 5. Compressed air also,
Lesson 4 Page 4
Fig 4 – 5: A water cooled cylinder
Is cool by the heat exchanger these heat exchanger are classified as if

this is equipped between stages that is called intercooler and if that
equipped after Hp cylinder and between air receivers is called after
cooler as shown in Fig. 4 – 6.
Fig. 4 – 6: Inter and after coolers.
Lesson 4 Page 5
3.0 MOISTURE SEPARATOR
Moisture separators are used to remove unwanted moisture. A typical

moisture separator Fig. 4 – 7 works by directing the air stream in a
spiral pattern inside a small vessel the air whirls around the spiral and
exits through an outlet port. Water, which is heavier than air, is thrown
against the sides of the vessel by centrifugal force. It then runs down
to a drain, where it is removed by a float drain valve which is shown in
Fig. 4 – 7.
Fig. 4 – 7: Moisture separator’s drain valve.
4.0 CARE OF COOLING SYSTEM
4.1 Cooling System Pressure Observation
When the compressor is operating, the intercooler pressure should

remain practically constant; wide fluctuations indicate something
wrong. Note the intercooler pressure when the compressor is first
started. Later, is the intercooler pressure goes higher, leakage in the
high pressure cylinder is indicated. An intercooler pressure that is too
low indicates leakage in the tow pressure cylinder. Any marked
deviation from a constant intercooler pressure should be investigated
at once by examining for leaky or broken valve or piston rings.
4.2 Cleaning Of Compressors And Coolers
If system is air cooled, the exterior of the cylinder must be kept as

clean as possible. It can be accomplished by a scheduled routine
maintenance. If the surrounding air is dusty or oily more frequent
cleaning possible with a detergent or steam is required.
If compressor and compressed air system is water cooled external

cleaning is usually not required to improve heat transfer. External
cleaning however is a sign of good house keeping.
Cleaning the internal water passages may be required if the cooling

water contains mineral deposit or sediments. If mineral deposits cause
Lesson 4 Page 6
scale buildup in the water passages and on intercooler tubes, an

annual or semiannual cleaning must be required.
4.3 Care And Cleaning Of Inter And After Cooler
The most common cause of loss of intercooler efficiency is the use of

dirty or hard, scale – forming cooling water. Any coating on the tubes
greatly lowers the heat transfer between the air and water. The
intercooler nest should be inspected at frequent intervals. If a deposit
is found in the tubes, they should be cleaned.
5.0 LUBRICATION SYSTEM
Lubrication of the compressor is the most important system of a

compressor because it is necessary in order to perform the following
functions.
To reduce friction and prevent the moving parts from wear.
To liberate the excessive heat of friction and heat of compression.
Provide sealing between piston rings and cylinder, walls vans, blades
etc. of rotary compressors.
5.1 Sections Of Lubrication
Compressor lubrication may be divided into two main sections.
5.2 External Lubrication
This section refers to the lubrication of moving parts which are external
to the compressor cylinder of reciprocating and casing of many of
rotary compressor.
5.3 Internal Lubrication
It is refers to provide the lubrication in:
Reciprocating for piston rings and valve lubrication.
In rotary compressor between vans and casing.
In screw compressor between rotors and casing lubrication and

sealing.
6.0 METHOD OF LUBRICATION
Both internal and external lubrication are performed by these methods.
Splash lubrication.
Lesson 4 Page 7
Forced or pressurized lubrication.
Control lubrication.
6.1 Splash Lubrication
It is mostly used in reciprocating compressor which is driven by motors

of 5 – HP or less. In single acting compressor this method is
mostly used to lubricate the whole compressor, in double acting
compressor a small amount of lubricant splashing occurs while the
compressor is running and that splash lubricate some of the parts and
also heat is carried away, and reaming parts lubricate by force feed
lubrication. Fig 4 – 8 shown a simple splash lubrication and Fig. 4 – 9
shown a combined, splash and force lubrication.
Fig. 4 – 8: Splash Lubrication.
Lesson 4 Page 8
Fig. 4 – 9. A combine splash and farce lubrication.
6.2 Forced Or Pressurized Lubrication
It is mostly used in large compressor and double acting compressors.

Parts lubricated by that system include the main crank shaft, journal
bearings, crank pin bearing crosshead pin bushing and crosshead. As
shown in Fig. 4 – 10.
Lesson 4 Page 9
Fig. 4 – 10: Forced Lubrication.
6.3 Control Lubrication
Mostly in double acting compressor when the unit is equipped with a

lubricated compressor cylinder, or cylinders, oil is delivered to the
Lesson 4 Page 10
cylinder parts in metered quantities by a mechanical force – feed

lubricator. As shown in Fig. 4 – 11.
Fig. 4 – 11: Control Lubrication.
7.0 LUBRICATION MANAGEMENT
The management of lubrication system in included, maintain the oil

level and feed, inspection of oil, selection of oil and care of lube – oil
pump and lubrication.
7.1 Maintaining Oil Level In Crakcase
Oil can be added to the frame sump while the unit is running by
removing the breather cap and pouring the oil into the breather tube.
Do not fill to a point here the rotating parts will strike the oil surface; this
will cause foaming and loss of oil pressure from the frame oil pump.
Too low oil, level may result in air being entrained in the oil, causing a
Lesson 4 Page 11
fluctuating or total loss of oil pressure to the bearings. It is therefore

important that the operating oil level be maintained at the line on the
gauge glass.
7.2 Rate Of Lubrication Through Lubricator (Only For Control

Lubrication)
Use only enough oil to keep the cylinder walls and valves coated with a
thin film of oil; this will insure a tight piston seal and will prevent pitting
and rusting of the valves.
The best gauge in judging the quantity of the oil to be fed is the
condition of the valves. Occasionally remove the inlet and discharge
valves and observe their condition. The valve surface should have a
greasy appearance – they should not be dry nor carbonized. If they
are coated with carbon, it is a sign that they are receiving too much oil
or the intake is dirty. The feed should be reduced, and the filter
checked. Carbon on the valves will cause leakage and excessive heat
and may cause an explosion.
7.3 Oil Pressure And Temperature
The normal operating oil pressure is from 15 to 40 psi (1.1 to 2.8 Bar).
The compressor can usually be expected to operate satisfactorily with
an oil pressure, as low as the ail pressure shutdown switch setting;
however, the frame and running gear noise level may be higher at oil
pressures below about 15 psi (1.1 Bar),
Refer to the "List _ of possible fault reduced ail pressure and

suggested remedies.
The oil temperature in the frame sump will normally run about 30°C
above the ambient temperature at the compressor site. The local
operating conditions and the viscosity of the lubricating oil can cause
the oil temperature to be varied.
7.4 Frame Oil Recommendations
Use a good grade of highly refined oil as recommended by a reputable

oil supplier or company. The oil selected for use as a frame lubricant
must meet be used as recommended by the compressor
manufactures.
7.5 Oil Change Schedule
Where the compressor is operated in an extremely dirty atmosphere,

installed outdoors, operated intermittently, handling foul gas in the
compressor cylinders, or where the oil reaches high temperatures in a
very hot atmosphere, it may be necessary to change the oil more often.
Lesson 4 Page 12
When changing the lubricating oil, the frame interior should be

thoroughly wiped out to remove puddles of the old oil and any
accumulation of foreign matter on the walls of the frame sump.
Whenever the frame oil is changed, the oil strainer on the end of the
pump suction pipe must be cleaned and a new oil filter cartridge must
also be installed.
Check the oil level in the frame periodically as part of the normal
operating routine and maintain the oil level.
7.6 Frame Breather
The breather is mounted above the oil pump cover. It vents the frame
interior to atmosphere while condensing oil vapors and returning the
condensed oil to the frame sump.
Examine the breather element at regular intervals and service it as

required. Clean the element by washing it thoroughly in a
nonflammable solvent. Allow it to drain dry and then dip it in heavy
motor oil before reinstalling it on its pipe connection.
8.0 FRAME OIL PUMP
The frame oil pump is an internally mounted, gear-type pump with two
rotating gears; it is driven directly off the end of the compressor
crankshaft. See Fig. 4 – 12 internal gear pump and Fig. 4 – 13 for
external gear pump. The function of that pump is to take oil from oil
sump and give pressurized oil and lubricate mostly these main bearing,
big and bearings, small end bearings and cross head of a double
acting reciprocating compressor in rotary compressors that pump also
use to lubricate the external parts of the compressor.
Lesson 4 Page 13
Fig. 4 – 12: Internal gear oil pump.
Fig. 4 – 13: External gear oil pump.
Lesson 4 Page 14
8.1 Care Of Oil Pump
The frame oil pump should not normally be dismantled unless it is

suspected that it has lost capacity. if trouble develops with the pump,
refer to the servicing instructions.
Drive shaft (1) is inserted with about 0.2 mm clearance in the coupling
piece on the crankshaft.
When dismantling the pump, do not separate the casing parts by force
with a wedge, but by means of a light hammer. Blow on the top of the
cover. The adjusting pins and the cover will thus loosen from the
casing without any difficulties.
Part (5) is ground on part (7) so that, as a rule, seals will not be
required.
If, later on any leakages occur liquid seals”curl” or “locktite” may be

used for hydraulic parts.
9.0 FORCE FEED LUBRICATOR
Fig. 4 – 14 shown a force feed lubricator pumping unit Fig. 4 – 15

shown the extension drive shaft for lubricator.
Fig. 4 – 14: Force feed lubricator.
Lesson 4 Page 15
Fig. 4 – 15: Typical lubricator drive.
On the flanged compressor or vacuum pump cylinders the feed line

from the lubricator goes to a fitting on the cylinder flange and then by
means of a tube to the exact top center of the cylinder bore. When
cylinders have tapped inlet and discharge connections, the oil is fed
thru drilled holes in the cylinder. The oil flows on each side of the cyl-
inder wall and midway in the piston travel, thus insuring an even
distribution of the oil.
A check valve is at the end of the force-feed lubrication line at the

cylinder. This prevents air or gas from blowing back into the lubricator.
If these check valves leak they usually get hot. To correct leakage
reseal valve.
9.1 Care Of Lubricator
To adjust lubricator (Fig. 4 – 14) Turn adjusting button to the left to

increase or to the right to decrease the rate of feed.
The force-feed lubricator pumping unit is the ball valve type, and it is
important that these valves be kept clean and only clean oil be used. It
is well to periodically flush out the lubricator reservoir and-at the first
indication of lack of uniformity of oil delivery, to remove the pumping
unit for cleaning. Pumping units may be removed from the reservoir
while the unit is in operation, as the tail piece valve of the pumping unit
will prevent the oil from draining out of the line.
Lesson 4 Page 16
10.0 COMPRESSOR V – BELT DRIVE
Normally the reciprocating compressor is the belt drive type. Small

compressor may have only single belt drive but the large compressor
normally have a set of belts. The motor side pulley or sheave called
drive pulley and the compressor side pulley called driven sheave or
flywheel and that flywheel is heavy enough to supply the necessary
effect. Fig. 4 – 16 shows a v – belt arrangement.
Fig. 4 – 16: Compressor v – belt drive arrangement.
10.1 Method Of Sheave Attachment
The sheaves and flywheel attached on shaft in different way Fig. 4 – 18

shown a flywheel with clamping devices which consist of a set of taper
rings and fitted in reverse like V-packing by tightening the thrust flange
it compressed the rings and these rings expand in both side and grab
the sheave hub and shaft.
In other design normally in small compressors the sheaves may fixed

on shaft with simple parallel keys and grab screws.
Lesson 4 Page 17
Fig.4-18: V – belt pulley with garbing or clamping device.
11.0 CARE OF V – BELT DRIVE
11.1 Inspection While Running (During Routine Maintenance)
A noisy V belt drive is need attention. V drive noise can be caused by

the slapping of belts against the drive guard or other obstruction.
Check for an improperly installed guard, loose belts, or excessive
vibration. Squealing of belts as a drive is started or while it is running is
usually caused by a poorly tensioned drive. But it can also be caused
by oil or grease between the belt and the sheave groove.
If necessary, remove the belt guard and watch the drive while it is run-
ning under load. Each variation in the driven load causes a
corresponding change in the tension of the slack side of the belt.
During across-the-line starts or suddenly applied loads while running,
the sag on the slack side of the drive will increase. If the sag under
these conditions is excessive, tension should be increased.
11.2 Installation Of Belts
Lesson 4 Page 18
When installing a multiple V-belt drive a check should first be made

that the motor and compressor sheaves are properly aligned and that
the shafts are parallel. A shown in Fig. 4 – 19 move the motor toward
the compressor as far as the slide base will permit. Then put the belts
on the sheaves. Fig. 4 – 20 has shown the proper way for bet
installation.
NOTE: Do not pry belts over sheave (pulley) grooves, as this will injure
belts and greatly reduce belt life.
Fig. 4 – 19: Cord touching sheaves at points indicates by

Arrows for sheaves alignment
11.3 Tensioning V – Belt Drives
Without exception, the most important factor in the successful opera-

tion of a V belt drive is proper belt-tensioning. To achieve the Long,
trouble-free service associated with V belt drives, failure. Fig 4 – 20
shows a belt tension diagram.
Fig. 4 – 20: Belt tension diagram.
Lesson 4 Page 19
11.4 Adjustment
After the sheaves are properly installed and aligned and the V – belts
placed in their proper grooves:
1. Adjust the centers until the V-belts are fairly taut and slack is no
longer present.
2. Start the drive and continue to adjust until the belts have only a
slight bow on the slack side of the drive while operating under load
(See Fig. 4 – 20 and 4 – 21). The drive by starting it under load. If
the belts squeal continue to apply tension until the squeal disappears.
3. The belts will properly seat themselves in the sheave grooves

after a few days operation. It may be necessary, at that time, to
readjust the belts as outlined in step 2.
The drive is now properly tensioned and should operate satisfactorily

with only an occasional readjustment to compensate for belt and
groove wear.
Fig. 4 – 21: Measuring the belt tension.
Fig. 4 – 21 shows the dimension for measuring the proper tension of

the belts. The deflection force normally given in the concern
equipment manual the span length can be measure from center of both
sheaves.
Note: After proper adjustment of belt tension, check the sheave
alignment again and if it is misaligned. It can easily align by side
jacking bolts.
Lesson 4 Page 20
Plant compressor main & o/h Reciprocating Comp troubleshooting Guide
LESSON RECIPROCATING
5 COMPRESSOR
LECTURE TROUBLESHOOTING GUIDE
Objectives
At the end of this lesson the Trainee will be able to demonstrate an
understand how to troubleshoot problems on a reciprocating
compressor and its associated equipments.
1.0 INTRODUCTION
An inspection is a routine duty in which all of the components of the

compressor are checked. It determine the condition of the equipment
and the wear they receive over a specific time span.
Troubleshooting is an extension of the inspection and recognized that a

problem exists and finding the correct solution in a minimum time.
Troubleshooting is largely a matter of elimination based on a thorough

knowledge of the inter-related functions of the various parts and the
effects of adverse conditions. A complete list of possible troubles with
their causes and corrections is impractical, but the following list of the
more frequently encountered troubles (with their probable causes and
suggested remedies) is offered as a guide.
2.0 POSSIBLE FAULTS, CAUSES AND SUGGESTED REMEDIES
Suggested remedies for correcting the possible faults are listed in the
next page “List of Possible Faults”.
Lesson 5 Page 1
LIST OF POSSIBLE FAULTS
POSSIBLE FAULT CAUSES REMEDIES
Compressor will not start 1. Power supply failure. 1. Correct voltage or

power supply.
2. Switchgear or starting 2. Check circuitry, inter-

panel malfunction. locks, relays, etc.
3. Low oil pressure shut- 3. Check switch setting.

down switch. Install momentary
bypass or on delay for
start-up.
4. Control panel problems. 4. Check connections and
settings of all devices.
Lesson 5 Page 2
Motor will not synchronize 1. Low voltage. 1. Correct voltage supply.

on applicable units
2. Excessive starting 2. Unload compressor
Or torque. during starting.
Trips motor overload or 3. Incorrect power factor. 3. Adjust excitor field

draws excessive current rheostat.
4. Excitation voltage 4. Check field excitation

failure. system.
5. Oil viscosity too high. 5. Use correct lube oil.
6. Constant speed due to 6. Reset it.

steady demand.
7. V belts pulled 7. Check and adjust the

excessively. tension.
8. Pilot valve defective. 8. Repair or replace it.
9. Leaking broken or 9. Repair/replace valve

loose valves. plate.
10. Worn or scored 10. Replace.

connecting rod, piston
pin or crack pin 11. Retighten the
bearings. fan/replace the
bearings.
11. Defective ball bearings
on crankshaft or of 12. Repair/replace the
motor loose motor fan. crosshead or guide.
12. Scuffed crosshead or

crosshead guide.
Lesson 5 Page 3
POSSIBLE CAUSES REMEDIES

FAULT
Low oil pressure 1. Oil pump failure. 1. Repair oil pump.
2. Oil foaming from counter- 2. Heat oil before starting.

weights striking oil surface.
4. Dirty oil filter. 4. Replace filter cartridge.
5. Leaks in suction or disc lines 5. Check oil piping.
6. Worn out bearings. 6. Replace bearings to remedy

excessive running clearance.
7. Improper low oil pressure 7. Reset per switch

switch setting. manufacturer’s instructions.
8. Malfunctioning oil relief valve. 8. Service valve; replace

defective parts.
9. Defective pressure gauge. 9. Replace gauge.
10. Plugged oil sump strainer. 10. Clean strainer.
11. Oil filter clogged 11. Clean the oil filter
12. Oil viscosity too low 12. Adjust the oil

temperature
13. Low oil level
13. Correct the oil level.
Frame knocks or 1. Loose/worn main, crank-pin or 1. Tighten/replace bushings.

rattles crosshead bushings.
2. Low oil pressure. 2. Trouble shoot per above

section.
3. Incorrect oil. 3. Use proper oil per instruction.
4. Knock is actually from cylinder 4. Tighten piston nut.

end.
Lesson 5 Page 4
Contd....
5. Leaking cylinder relief 1. Repair/replace or

valve. adjust
6. Loose belt wheel or

motor pulley or motor 6. Repair the wheel or
with excessive end play pulley.
or shaft.
7. Leaking, broken or
loose valves. 7. Repair/replace the
valve plates.
8. Leaking broken or worn
constant speed 8. Replace the unloader
unloader parts.
9. Defective ball bearing 9. Replace the bearings.

of shaft or motor side.
Machine won’t unload Leaking broken or worn Repair/Replace unloader

constant speed unloader parts
or parts
Auxiliary valve chatters or As above As above

leak
or
Compressor does not Maladjustment of pilot Readjust or replace the O-

unload when stopped valve or O-ring defective. ring.
or
Compressor won’t come As above and abnormal Check the electrical

up to speed motor voltage equipments.
or
Light flicker when As above As above

compressor runs
Crankshaft oil seal leaks 1. Faulty seals or shaft 1. Repair/replace

scored. defective parts.
Lesson 5 Page 5
2. Clogged drain hole. 2. Clear obstruction.
3. Plugged oil separator 3. Clean filter or replace.

filter.
Noise in cylinder 1. Loose piston. 1. Disassemble and

tighten piston on rod.
2. Piston hitting outer 2. Adjust piston rod for

head or frame end of proper end clearance.
cylinder.
3. Tighten nut.
3. Loose crosshead lock
nut.
4. Repair/replace parts.
4. Broken or leaking
valve(s).
5. Replace rings.
5. Worn or broken piston
rings or expanders.
6. Replace gasket and
6. Valve improperly reassemble properly.
seated/ damaged seat
gasket. 7. Replace worn or
broken unloader
7. Free air unloader spring(s).
plunger chattering.
Oil in discharge air 1. Oil viscosity too high 1. Use correct lube oil.
2. Oil level too high. 2. Maintain the level.
3. Oil control ring broken 3. Repair/replace the

or not seated in, stuck rings.
in groove, excessive
side and end gap.
4. Plugged oil separator

filter. 4. Clean or replace the
filter.
Excessive packing 1. Worn packing rings. 1. Replace packing rings.

leakage
2. Improper lube oil 2. Use correct lube oil and
Lesson 5 Page 6
and/or insufficient lube increase lube rate.

rate (blue rings).
3. Dirt in packing. 3. Clean pipings/gas

supply.
4. Excessive rate of 4. Reduce pressure and

pressure increase. increase at more
gradual rate.
5. Packing rings 5. Reassemble as per

assembled instructions.
incorrectly.
6.
Contd....
6. Improper ring side or 6. Establish correct

end gap clearance. clearances.
7. Plugged packing vent 7. Remove blockage and
system. provide low point
8. Scored piston rod. drains.
9. Excessive piston rod 8. Replace rod.
runout. 9. Find and eliminate
cause of misalignment.
Packing overheating 1. Lubrication failure. 1. Replace lubricator

check valve/lubricator
pumping unit.
2. Improper lube oil and/or 2. Use correct lube oil and

insufficient lube rate. increase lube rate.
3. Insufficient cooling 3. Clean coolant

(water cooled packing passages/ install water
cases) filter/ increase supply
pressure. Reduce
coolant inlet
temperature.
Excessive carbon on 1. Broken or leaking 1. Repair/replace parts.

valves valves causing high
temperature.
2. Excessive temperature 2. Clean exchangers,
due to high pressure valves and correct
Lesson 5 Page 7
ratio across cylinders. cause of high pressure.
Insufficient intermediate Check C.W. circuit

High discharge cooling
temperature Damage suction a disc. Dismantle valve, clean,
valve regrind seat.
1. Excessive pressure 1. Repair valve piston
ratio on cylinder due to rings.
leaking inlet valves or
piston rings on next
higher stage.
2. Leaking discharge 2. Repair/replace parts.
valves or piston rings.
3. High inlet temperature. 3. Clean intercooler.
4. Fouled water 4. Clean jackets.
jackets on cylinder.
5. Improper lube oil
and/or lube rate 5. Use correct lube oil
.Damaged part inside and feed rate
compressor (seizure of 6. Dismantle
piston) compressor
Piston rod oil wipers leak 1. Worn wiper rings. 1. Replace rings.
2. Rings incorrectly 2. Assemble and install as

assembled/installed. per instructions.
3. Worn/scored rod. 3. Replace rod.
4. Improper fit of rings to 9. Replace rings.

rod/side clearance.
Safety valve popping 1. Faulty safety valve. 1. Test and reset or

replace valve.
or
2. Leaking inlet valves or 2. Repair/replace
High pressure gauge piston rings. defective parts.
reading
3. Obstruction (foreign 3. Relieve obstruction.
material, rags), blind or
valve closed in
discharge line.
4. Discharge pressure too 4. Plant demand<
high compressor discharge
Lesson 5 Page 8
Air delivery has dropped 1. Clogged intake filter 1. Check/clean.

off
2. Air leak in system. 2. Check systems leak
with soap water.
3. Leaking or 3. Readjust or replace O-

maladjustment of pilot ring of valve.
valve.
5. Repair/replace rings.
5. N.L. piston rings
scratched or broken or
worn.
Water hammer (On units 1. Rate of water flow is 1. Adjust rate of water
equipped with water- not proper flow
cooled aftercoolers)
Water in frame or rusting 1. Detergent type oil 1. Change to non-

in cylinders being used. detergent type with rust
and oxidator inhibitor.
2. Extremely light duty or 2. Adjust the rate of

located in a damp cooling water flow.
humid spot.
Abnormal piston, ring or 1. Inlet muffler and filter 1. Clean them.

cylinder wear. dirty.
2. Scratched, broken or 2. Repair/replace the

worn N.L. piston rings. rings.
Lesson 5 Page 9
Plant compressor & o/h Rotary Screw Compressor & Maintenance
LESSON
ROTARY SCREW COMPRESSOR
6 AND MAINTENANCE
LECTURE
Objectives
understand the function of screw compressor and its associated
equipments.
1.0 INTRODUCTION
Rotary screw compressors are normally compact type units and the
standard compressor is composed of the following.
• Inlet air filtration

• Compressor and motor assembly
• Regulating system
• Pump pressured coolant lubricant.
• Coolant separation system
• Moisture trap and removing system
• Discharge air after cooling system
• Motor starting control system (electrical)
• Instrumentation
• Safety provisions
Fig. 6-1 has shown a typical air oil flow diagram including all above
mansion system and components.
Lesson 6 Page 1
Fig. 6 – 1: A Typical Air/Oil Flow Diagram for Screw Compressor
Lesson 6 Page 2
PARTS LIST
1. AF Air intake filter

2. AR Air receiver
3. AV Air outlet valve
4. BV Thermostatic by-pass valve
5. Ca Air cooler
6. Co Oil cooler
7. CV Check valve
8. Da Outlet automatic drain, moisture trap
9. Dm1 Manual drain valve, moisture trap
10. Dm2 Manual drain valve, air cooler
11. DP1 Drain plug oil tank
1 2. DP2 Drain plug oil stop valve
13. E Compressor element
14. FN Cooling fan
1 5. Gp Discharge air pressure gauge
16. Gt1 Temperature gauge
17. Gt2 Temperature gauge, air outlet
18. K5 Stop delay timer, to stop motor after unloading
19. K23 Delta contact, motor starter
20. M Motor
21. MT Moisture trap
22. OF Oil filter
23. OS Oil separator element
24. OT Oil tank
25. Rf1 Flow restrictor, main oil line
26. Rf2 Flow restrictor, oil scavenge fine
27. S3 Toggle switch, NORMAL UNLOADED
28. S4 Air pressure switch
29. S5 Temperature safety switch, compressor element outlet
30. SV Safety valve
31. TV Throttle valve
32. UA Unloader assembly
33. Vp Minimum pressure valve
34. Vs Oil stop valve
35. W Vent valve
36. Y1 Solenoid valve
A Automatic pressure selector switch
B Calibrated hole, throttle valve
C Control pressure chamber unloader assembly
D Oil scavenge line
Lesson 6 Page 3
2.0 SCREW COMPRESSOR PARTS
Fig. 6 – 2 shown a exploded assembly view of a screw compressor

with oil pump.
Fig. 6 – 2: Exploded Assembly View

PARTS LIST
No. DESCRIPTION No. DESCRIPTION

1. Gasket 21. Retainer Ring
2. Gearcase 22. Bearing
3. Screw 23. Gasket
4. Taper Pin 24. Front Bearing Housing
5. Gasket 25. Bearing
6. Dowel Pin 26. Bearing Spacer
7. Male Piston 27. Retainer Ring
8. Thrust Bearing 28. Bearing Spacer
9. Pump Drive Plate 29. Retaining Ring
10. Screw 30. Gasket
1 1. Coolant Pump 31. Screw
1 2. O ring 32. Inlet Connection
13. Bearing Cover 33. Dowel Pin
14. Bearing Cover 34. Screw
1 5. Clamp Plate 35. Screw
16. Female Piston 36. Washer
17. Rear Bearing Housing 37. Gasket
18. Rotor Housing 38. Screw
19. Rotor Set 39. Gasket
20. Screw
Lesson 6 Page 4
3.0 PREVENTIVE MAINTENANCE GUIDES
Normally the screw compressor's requires a minimum of

maintenance. The major concerns are the air cleanliness, the
quality of the coolant-lubricant and the lubrication of the electric
motors. Over relatively long periods of time, other system
accessories will require replacement. Items such as the coolant/air
separation elements, air filter, oil filter etc. Some preventive
maintenance instructions are summarized in the schedule 6 – 3.
Fig. 6-3: Preventive Maintenance Schedule
ACTION By Operation By Maintenance

Daily Weekly Monthl Yearly
COMPRESSOR
Check oil level (if oil is added, record -*-
Checktitair intake filter vacuum indicator -*-
Check service indicator lamps -*-
Clean air intake filter element -*-
Renew air intake filter element -*-
Check operation of regulating system -*
Check operation of moisture trap -*
Check air discharge temperature -*- -*
Operate safety valve by pulling its lever -*-
Change oil -*-
Replace oil filter element -*-
Have safety valve tested -*-
Have air temperature switch tested -*-
Have pressure difference switches tested -*-
UNIT
Check coolers : clean if necessary -*-

Dismantle, check and clean float valve of
trap i -*-
Check bolts and nuts for tightness -*-
3.1 Lubrication
Lubrication is the major part of a preventive maintenance, because the

lubricant in a rotary compressor has a triple function to perform in that,
they lubricate the bearing (on wet contacting surfaces of rotors). They
Lesson 6 Page 5
seal internal clearances within the rotor chamber, and they provide for
the cooling of the compression process. The bulk of the fluid is actually
used for cooling, with only small amounts used for lubrication and
sealing.
3.2 Oil Change Condition
The lubricating oil should be changed, and the oil filter renewed after
every 1000 operating hours.
It should be noted that the quality and the temperature of the oil are the
main factors to determine the oil change interval. As a rule of thumb,
the oil lifetime is doubled by each 10°C (18°F) decrease of the oil
temperature. The recommended 1000 hours interval is based on a
maximum outlet temperature of the HP element of 100°C (21 2°F) and
normal service conditions.
Note: Regardless of the operating hours the oil should

be changed once a year.
3.3 Oil Changing Instructions
1. P.T.W. requires.
2. If unit is as stand by then run the unit long enough to
warm up the oil and run 30 to 40 second run with loading.
3. If unit is already running then require complete isolation
and depressurized the oil receiver.
4. If the screw compressor have the same lubrication
system as mentioned in Fig. 10-1 5-4 then follow the
figure.
5. Screw the plug out of the drain hose (11) and place the
later in a screw or container.
6. Screw out the filter plug to speed up draining.
7. Unscrew the plug and drain the oil from oil stop valve.
8. Unscrew and drain the oil of oil cooler.
9. When all oil drained refit all drain plugs (if require use
new gasket or seal washer or O-rings with plugs).
10. Fill new oil through the receiver oil plug up to the level
between normal and high.
11. Refit all cap screw and start the unit in the usual way.
12. Stop unit when normal working temperature are reaches
and wait 5 minutes.
13. Again check oil level the level must be more than
NORMAL and less than HIGH.
14. Top up the oil if necessary.
NOTE: Oil filter must be changed when changing the oil.
Lesson 6 Page 6
3.4 TOPPING UP WITH OIL
1. If the unit runs, put the unit on unload and wait at least 30
seconds.
2. Stop the unit and depressurize the air/oil receiver by

unscrewing the oil filter plug just one turn.
2. When the pressure is released screw out the filter plug and
pours oil through the filler pipe until the gauge registers in the
extremity of the NORMAL range near the HIGH side.
4. Screw home the filler plug. The unit is now ready for
operation.
5. Record the quantity of oil added.
3.5 REMOVAL OF OIL FILTER
Oil filter used on these compressors may be simple cartridge type

which can easily remove by unscrewing the cartridge from mounting or
the filter for large unit may be with out side casing and removable filter
element.
3.6 PROCEDURE (FOR CASTING TYPE) SEE FIG. 6 – 4
1. Confirm all pressure is relieved from the compressor

system and that the main electric disconnect switch is open
and tagged to remain open.
2. Place a suitable container under the filter housing drain

valve which is located near the bottom of the housing.
3. Remove the bolt at the bottom of the housing. This will free
the housing and element from the filter head. Remove the O
ring gasket.
4. Inspect the element and housing for foreign particles which

have been trapped in the element and also for general
overall condition - then discard the element and clean the
housing.
5. Reassemble the filter using a new element and 'O' ring.

Each replacement element is furnished with replacement
gaskets - including one which fits under the bolt head.
Lesson 6 Page 7
Fig. 6 – 4: A casing type oil filter with renewable cartridge
3.7 AIR INTAKE FILTER
Dust contained in the intake air is retained in the filter to prevent

premature wear of the compressor and clogging of the oil separator
element. The dry type filter cartridge is held between adaptor and
casing or cover by a central stud, washer and wing nut. An elbow
connects the adaptor with the unloader assembly. Fig. 6 – 5 has shown
the type of air intake filter.
Fig. 6 – 5: On the top a multi filter and assembly

and in bottom a single filter cartridges
Lesson 6 Page 8
3.8 SERVICING THE FILTER
• In most units the condition of the filter is indicated by the

vacuum indicator equipped on the unit.
• It is also recommended to renew the filter cartridge after

recommended working hours or yearly basis.
3.9 REMOVAL OF AIR FILTER.
1. The compressor unit must be stopped when servicing the

filter. To reduce down-time to a minimum it is recommended
to have a new or cleaned spare cartridge at hand.
2. Unscrew of the wing nut.
3. Lift off the filter casing with hold down bet.
4. Left the filter cartridge off the adaptor.
5. Clean adaptor and casing, inspect the gaskets replace the

cartridge and gasket if required.
6. Position the spare cartridge on the adaptor.
7. If there is bolt then insert the bolt from downward.
8. Or if it a holder like in then put the cover or casing on

cartridge.
9. Position the casing or cover and fit the wing nut with
washer.
3.10 CLEANING THE FILTER CARTRIDGE
1. Gently knock the two end faces of the

cartridge alternately on a flat surface to
remove most of the heavy, dry dirt.
2. Blow dry air with a pressure not exceeding 2.8 bar (40
psi) in reverse direction of normal flow. Blow up and down
the length of the pleats keeping a distance of at least 25
mm (i inch) between hose nozzle and pleats.
3. If the cartridge is greasy, it can be washed in lukewarm

water in which a non-foaming detergent, such as Mann
Lesson 6 Page 9
053, Lissapol N. Hedley's Drymex, etc. is dissolved. Soak

the cartridge for at least 15 minutes in the bath and rinse
it thoroughly with clean water from a hose. Let the
cartridge dry without using any heat to hasten it.
A cartridge can be washed five times, and then it has to

be discarded.
4. Inspect the cartridge by placing a bright light inside it. If

thin spots, pin holes or ruptures show up, discard the
cartridge.
5. Wrap the cartridge in dust-proof packing and store it till

the next air filter service.
NOTE: Never reinstall a washed cartridge on the unit before it

has completely dried out.
3.11 SAFETY VALVE (Fig. 6 – 6)
Have the safety valve, fitted on the air receiver tested at least once a
year. Adjustments of the safety valve are to be done by an authorized
person. At least once every three months pull and release lever (2),
upon which the valve opens and closes, to ascertain that the valve is
operative.
Fig. 6 – 6: Safety valve with parts.
Lesson 6 Page 10
3.12 COOLANT LUBRICATION SEPARATOR ELEMENT
This element separator the maximum oil particles from the air it may be
fitted side wise as shown in Fig. 6 - 7 or from the top of the
receiver/separator.
It must be changed when the differential pressure across the element

reaches 6 to 8 psi at full load or if zero pressure drop is recorded.
Fig. 6 – 7: Coolant lubrication separator complete
3.13 PARTS OF SEPARATOR
1. Tank
1 A. Tank, European
2. Filler Plug
3. Washer
4. Element
5. Adapter
6. Gasket
7. Tee
8. Level Gauge
9. Washer
10. Washer, Lock
11. Screw
12. Elbow, Street
12A. Elbow.
13. Bushing
14. Safety Valve 1 25 # L
Lesson 6 Page 11
1 5. Safety Valve 1 50 # H
1 6. Safety Valve 1 65 # HP
1 7. Safety Valve 1 50 # H
18. Decal
19. Decal
20. Decal
3.14 REMOVAL OF SEPARATOR ELEMENT
1. Shutdown the compressor, close the service air line isolation

valve and open the main electrical disconnect switch.
Confirm all air pressure is relieved from receiver.
2. Remove the small panel on the rear of the enclosure.
3. Disconnect the piping from the receiver cover. Do not

disturb the electrical conduit connections; extra long flexible
conduit has been provided.
4. Remove the cover bolts, leaving the upper two until last.
5. Being mindful of the significant weight of the flange cover

and providing for its support, remove the last two bolts. Se
the cover aside.
6. Withdraw the separator element and replace it with a new

one Gasket is integral with the new element.
Note: The inter stage scavenge hole must be positioned at

the bottom to facilitate drainage.
7. Replace the receiver cover and tighten all bolts evenly.

Replace the removed piping.
8. Close the main electrical disconnect switch and start up the

unit. Check for leaks at the cover and piping connections.
9. Replace the enclosure panel and open the service isolation

valve.
Lesson 6 Page 12
CONDITION POSSIBLE FAULTS SUGGESTED REMEDY
Air consumption
a. a. Check and reduce necessary
exceeds
compressor capacity
b. Choked air intake filter b. Check and correct as
element indicator lamp must necessary if did not light up,
1. Compressor capacity or pressure be live replace lamp or pressure
lower than normal c. Same as 1 b or 7b difference switch as required
d. Oil separator element clogged d. Inspect element; replace if
indicator lamp must be live necessary; if did not light up,
replace lamp or pressure
difference switch as required.
e. Interior leakage of vent valve e. Replace valve
f. A faulty adjustment of f. Re-adjust
regulator
Air consumption too
9. Compressor unloads and loads a. a. Increase consumption
small
too frequently b. Difference between unloading b. Adjust setting
and loading pressures too
10. Excessive oil consumption : a. Oil level too high a. Check and correct as
air outlet valve discharges oil necessary

mist.. b. Restrictor in oil scavenge line b. Disconnect scavenge line on
clogged compressor element dismount
nipple with restrictor, clean
them and reassemble
c. Oil separator element c. Inspect element, replace if
d. Same as condition 9 necessary
1 1. Blow-back of air/oil mist a. Check valve out or order a. Dismount valve, correct or
through air intake filter when replace parts as necessary

unit stops b. Same as 7b; possible
when unit is connected to a
main air line with other
com reasons
12. Blow-back of oil through air a. stop valve out of order and Dismount valves; correct or
minimum pressure valve
intake filter when unit is replace parts as necessary
leaking
stopped
13. Unit shuts down through a. Oil level too low a. Check and correct as
action of the air temperature necessary

switch b. Cooler block dirty b. Clean cooler block externally
c. Insufficient cooling or ambient c. Check and, if necessary,
temp erature too hi h relocate unit
Same as point 12 but
14. Unit overheating; temperature a. a. Correct the cause of over
air
°
indication exceeds 120 C temperature switch is wrongly heating and consult qualified
(248°F) connected to motor start electrician to connect switch
equipment
b. Same as point 1 2 but b. Test switch
temperature switch out
order
Lesson 6 Page 13
4.0 TROUBLESHOOTING GUIDE
Troubleshooting guide for screw compressor can help in ease of

faultier compressor function its parts and system to investigate the
possible reasons of faults and their remedies.
CONDITION POSSIBLE FAULTS SUGGESTED REMEDY
a. Inspect switch; replace if

2. Compressor loads before
Necessary.
toggle switch is changed a. Toggle switch out of order.
over to NORMAL. b. Throttle valve stuck b. Dismount and inspect valve; replace
components as necessary
a. Discharge pressure exceeds a. No action; compressor will load

3. Compressor does not load pre-set working pressure. when discharge pressure reduces.
when toggle switch is b. Same as 1 a. b. Adjust setting or replace switch
changed over to NORMAL c. Pressure switch incorrectly or
out of order. c. Dismount and inspect valve replace
d. Solenoid valve out of order. if out of order
4. Motor stops shortly after

starting i.e. after idling a. Discharge pressure exceeds a. No action; unit restart when
delay; AUTO-OPERAT. pre-set working pressure. discharge pressure reduces
Lamp remains alight. b. Same as 2c
5. Compressor does not stop
Stop delay timer K5 incorrectly set
approx. 6 minutes after Reset or replace switch
or out of order.
unloading
a. Same as 1 b, 2c or 2d.
6. Compressor does not Check and correct as
unload when working b. Air leaks in re gauging system a.
necessary
pressure is exceeded;
safety valve blows
c. Safety valve opens too soon b. Test safety valve
7. Compressor unloads, but

discharge pressure keeps
Vent valve stuck Dismantle and inspect
rising slowly ; safety valve
blows
8. Compressor loads, but does a. Same as 1 b Dismount and inspect valve,

a.
not deliver air. b. Minimum pressure valve stuck replace components as
necessary.
Troubleshooting chart (6-8)
Lesson 6 Page 14
Plant compressor main & o/h Rotary Blower And Maintenance
LESSON
ROTARY BLOWER AND
7 MAINTENANCE
LECTURE
Objectives
understanding the operating principle of rotary blower and function of is
associated equipments.
1.0 INTRODUCTION
Rotary blowers are positive displacement compressors. These

blower’s discharge normally is being use for continous discharge and
not to be stored. These compressor are not aischarge for high pressure
but they aischage with high velouties.
2.0 MATERIAL OF CONSTRUCTION AND PARTS
The shofts of the impeller’s are normally made by steel and rotors,
housing and end plats are made of ductile iron. Timing gears are
normall cascharden. Fig. 7-1 shown a tripple lobe rotary blower and
parts list Fig. 7-2 shows a front vien of that and Fig. 7-3 shows a
double lobe rotary compressor and parts list.
3.0 MAINTENANCE OF BLOWER
For performing a better maintenance programe either it is preventive,

breakdown or a over hauling of the blower it is neeccessor for a
maintenance craft to well known about the nomen clalure of rotary
blower for that follow the Fig. 7-1, 7-2, 7-3 and part lists and preventer
maintenance instructions.
Lesson 7 Page 1
Fig. 7 – 1 Triple Lobe Rotary Blower (Compressor) Front View

.
PARTS LIST
1 Inlet Flange 17 Gasket

2 Oil Seal 18 Bearing cover
3 O-Ring 19 Gauge
4 Flywheel spacer 20 Check valve
5 Shaft 21 Casing bolt
6 Discharge Flange 22 Bearing housing
7 Elbow 23 Drive side bearing cover
8 Casing 24 gasket
9 Driven gear 25 Bearing cover gasket
10 O-Ring for bearing cover 26 Bearing cover
11 Gear lock nut 27 O-Ring for cover
12 Gear lock nut 28 Drive side bearing cover
13 Gear key 29 Grease nipple for bearing
14 Cover 30 Flywheel key
15 Oil sump 31 Flywheel bolt
16 Oil plug 32 Flywheel
Suction filter and silencer
Lesson 7 Page 2
Fig. 7-2 Triple Lobe Rotary Compressor Side View
Fig. 7 – 3: Two Lobe Impellers Rotary Blower
Lesson 7 Page 3
PARTS LIST
1 Casing (body) 26 Gear lock nut

2 rotor 27A Bearing lock nut
5A Cover (driving end) 27B Bearing lock nut
5B Cover (driven end) 29 Key
7A Shaft 30 Key
7B Shaft 31 Bearing
7C Shaft 32 Bearing
7D Shaft 33 Bearing
11A Driving gear 35 Bearing cover
11B Driven gear 43 Seal ring
12A Sump 45 Flexible ring
12B Sump 48 Gasket
16A Lubricating disk 49 Gasket
16B Lubricating disk 50 Gasket
19 Gear adjusting hub 68A Centering pin
20 Sealing chamber 68B Centering pin
22 Gear spacer 72 Plug
23A Oil splash disk 76 Oil filling plug
23B Oil splash disk 77 Oil emptying plug
24 Lubricating disk spacer 78 Oil level plug
25 Sealing spacer
3.1 Preventive Maintenance Instructions
1. Check the oil level of oil sump from sight glass.
2. Check the belts (if unit is belt driven)
3. Check FOR unusual noises and vibration.
4. Control the delivery pressure; if it is above the tag pressure, it

means that the blower capacity is too high or the delivery pipe
diameter is not sufficient.
5. Control the depression: if it is excessive reduce the rotation

speed (when possible) or adjust the vacuum by introducing in
the suction chamber air from outside.
6. Check the flow of the cooling water (when used) and its outlet
temperature (not above 45oC).
7. Check the oil level in both sumps and if necessary top it up (see
under lubrication).
8. Check the oil temperature which under normal atmospheric and

pressure conditions, shall not exceed 70oC.
Lesson 7 Page 4
9. Check the temperature of the stuffing boxes (if any).
3.2 Lubrication
In some types of rotary compressors the rotating parts like gear and
bearings are lubricated by oil. The proper disks keyed to main shaft let
the lubricant be parted also to the parts placed above in the sump. In
Fig. 7 - 4 the external parts of the blower which require lubrication are
shown.
Fig. 7 – 4: Parts of the Blower Require Lubricants
3.3 Oil Level
The correct oil level should be checked carefully. Lack of oil

endangers the blower. Too much oil can mean lubricant overheating
and leakage into the rotor housing. Fig. 7 - 5 shows the oil level in
the gauge by height “H” in small blowers it is not less than center line of
gauge and “H” not more than 1 mm from center line of gauge.
Lesson 7 Page 5
Fig. 7 – 5: Correct Oil Level Check
3.3.1 Oil Changing Frequency
Normally the first change of oil is recommended after 300 to 350 hours
and after subsequent oil changes are effected 3000 to 5000 hours of
operation or 1 years.
It is however necessary to check the conditions of the oil regularly. In

unfavorable cases (example contamination by condensate or dust) the
oil must be changed at shorter intervals.
3.3.2 Air Filter Cleaning
A too dirty filter can cause a damaging loss of pressure and loose its
filtering power. Dry filters are cleaned with a blast of blown air; when
necessary change the cartridge.
Wet air filters series DB with cartridge damped with special oil need
regular maintenance. The cartridge must be washed with proper
solvent, dried and then damped with the right type of oil: in this
operation transformers oil may also be used. Before begin used again
the damped cartridge shall allowed to drip for about a day.
It is advisable to keep a spare cartridge at hand in order to avoid

interruptions in the use of the machine.
3.3.3 Silencer Refer Fig. 7 – 1 & 7 – 2
A silencer is used in the suction side of the blower to reduce the

volume of noise caused by the blower and the pipelines. In some
design the inside the silencer a layer of foam material in routine
maintenance that foam must be cleaned.
Lesson 7 Page 6
Notes: Before removing the silencer measure the silencer hood

position. Too low position can increase the suction pressure
and unit can trip due to over load and increase position can
increase the sound level.
3.3.4 Cleaning The Blowers
Air or gases containing dust or condensate can lead to deposits or

foulings in the inner parts of the blower.
Deposits inside the blower may be removed with the aid of a scraper,
solvent or steam, depending on their composition.
Suitable solvent (petrol, fuel oil, kerosene, ammoniacal water, trichloro-

ethylene etc.).
3.4 Corrective Maintenance Of Blower
Reasons for disassembling the unit.
Abnormal noise, vibrations, overheating, fall in delivery, increase in the

amount of absorbed power, are signs of faulty behavior requiring
disassembly, revision and possible replacement of some components.
3.4.1 Disassembly Procedure
1. System completely isolated and P.T.W. obtained.
2. Refer to sectional drawing Fig. 7-2 of Section 18.
3. Place the blower on a smooth horizontal supporting surface;

drain off the lubricating oil.
3. Start the stripping from driving side. Remove key 30

and the sump 12A together with the seal ring 43.
4. Remove the locking nut 27A and 27B, the lubricating disk 16A
and the spacer 24.
5. Remove therefore the cover 5A and the casing 1: everything

else can be left assembled. When necessary the sump 12 B
may be removed for cleaning the gear housing.
6. Before removing and replacing the gaskets 48 and 49 be careful

to mark their exact thickness.
Lesson 7 Page 7
7. Clean the inner surfaces of the blower without scratching or

damaging the sealing surfaces; use, when necessary, a suitable
solvent (refer to paragraph “CLEANING”).
8. Replace the flexible seal rings 45 placed on spacer 25.
3.4.2 Disassembling The Gears And Rolling Bearings
The gears have to be stripped only when it is necessary to replace

them or the rolling-bearings. The wear of the gear’s teeth or the
excessive clearance of the bearings can cause a decrease of the right
clearances between the rotors and therefore to inadmissible rubbings.
After draining of the lubricating oil and cleaning the gears, check the
clearance on the teeth side; for this purpose lock one of the rotors with
a sheet-metal, rotate the other one and measure the clearance with a
thickness gauge or a dial gauge. The maximum clearance on the
original diameter can be required to “Robuschi”. If, after checking, the
clearance between the teeth is over the maximum allowed value, the
gears or the rolling bearings or both must be replaced.
The maximum allowable clearances of the rolling bearings are given by

the bearings manufacturers.
Before disassembling the gears take note of the clearances between

the rotors in 4 positions each at 45o from the others. Fig 18 – 6 shown
the position Fig. 18 – 7 shown the method of measuring the rotor
elcarance with leng feeler gauge or specially supplied from the blower
supplier.
Subtract from measured clearances any possible wear on the sides of

the teeth.
Fig. 7 – 6: Checking inter lobe clearance
Lesson 7 Page 8
In order to strip the gears, loosen the locking nuts 26, remove the
lubricating disk 16B and remove the gears by using the extraction
holes; remove also the adjusting hub 19 together with the gear 11A.
Helical tooth gears are extracted simultaneously. The bearings 31, 32
and 33 are removed only when it is necessary to replace them.
3.4.3 Assembling
Clean all parts carefully; oil the parts that need to slide on each other;
remember not to live any foreign bodies or rags inside the machine
during re-assembly.
Assembling is carried out as per above described steps backwards.

Pay great attention to avoid damaging the sealing surfaces, the rolling
bearings and the gears. Never use force resort to hammer blows.
Assembling shall start from the cover of the driven side placed on a
horizontal surface; support shall include the outer limits of the cover
and allow the rotors to be mounted in a vertical position later; when
reassembling the body and the other cover remember to insert the
gaskets 48 and 49 of the cover before securing them to the casing
definitively. The required operations in securing the covers and those
following shall be carried out with the machine placed on a perfectly
smooth horizontal surface.
3.4.4 Adjustment Of Clearance Synchronization (Refer Fig. 7 – 6

& 7 – 7)
If the gears have been replaced or if the gear 11A has been removed
from the hub 19, it is necessary to check them and to adjust the
clearance between the rotors.
Fit the gears without securing definitively the adjusting hub. Check
that the clearances between the rotors in the 4 main positions are the
same as when they were measured on stripping the machine.
In all cases the clearances should not be below 0.15 mm in the smaller
size and 0.64 mm in the bigger ones. Also between rotors and casing
there should be some clearances which should be checked after the
centering pins are in positions.
If clearance G1-G2-G3-G4 between the rotors are not the same

checked before stripping, it is necessary adjust the gear 11A which
must let to rotate on hub 19; secure the gear on the hub definitively
after required clearances have been measured and lock with the
suitable lock screws.
Lesson 7 Page 9
Fig. 7-7 Gear fitting marks.
If gaskets 48-49, washer 67 for RVT 130-180 and sealing spacers 25

for RVT 30 ÷ 120 of the exact original thickness have been used, the
axial position of the rotors should be correct. Check and make sure
that the clearance between cover and rotor from driving side be
approximately the double of the clearance existing on the opposite
side.
If the blower has been perfectly reassembled, the rotors should rotate
freely by hand. When the machine is re-started, after re-assembling, it
is necessary to keep it under control to be sure the correct and
smoothly running without over heating or vibrations.
If the blower has been perfectly reassembled, the rotors should rotate
freely by hand. When the machine is re-started, after re-assembling, it
is necessary to keep it under control to be sure the correct and
smoothly running without overheatings or vibrations.
4.0 TEST RUN
After completion of re-assembly, the blower must be run for testing by

the following instructions.
Open slide valves, eventually installed in the piping.
Check free rotation of the blower by turning drive shaft by hand.
Check the motor’s correct direction of rotation and the smooth running
of the unit without load.
Check that the pressure is not above pressure indicated on machine

label.
After a short run stop the blower and watch the run down. The blower
has to run down freely and smoothly. Then start up the machine
again.
Lesson 7 Page 10
Control safety instruments.
Control smooth drive, temperature of the blower, oil temperature

(maximum 80oC with uncooled blowers) and oil level.
5.0 TROUBLESHOOTING GUIDE
A list is provided in this section for possible operating trouble causes

and their remedies for time saving troubleshooting of a rotary blower.
5.1 Operating Troubles – Causes – Remedies
1. Excessive discharge pressure.
CAUSES REMEDIES
Reduce the rotation speed of the

Air capacity over the necessary blower, when possible; blow of in the
amount of the plant. open air or by-pass part of the gas
(refer to chapter B).
Obstructions or throttling into the Remove the causes of obstructions or

discharge pipe. throttlings.
2. Safety valve continuous outflow.
CAUSES REMEDIES
Reduce the pressure to the allowed

Excessive discharge pressure.
value.
Valve setting to low in Set again the valve, increasing the

comparison with the plant breathing pressure to the allowable
pressure. value.
Lesson 7 Page 11
3. Air or machine overheating
It is normal the air heating of 10°C degrees, over ambient

temperature for each 1000 mm W.C. (100 mbar) back pressure.
CAUSES REMEDIES
Increase discharge pipe diameter;

remove possible obstructions or
Plants pressure higher than
throttling; reduce when possible
rated pressure
blower rotation speed; release in the
open air part of compressed air.
Clean the filter or replace the

Clogged inlet air filter.
cartridge.
Too viscous lubricant oil or too Replace the oil with another less
high oil level viscous : settle the rig ht level again.
Excessive wear of rotors and
Check the clearances; consult the
consequent increase of
manufacturer.
clearances.
High room temperature due to
scanty Fan the room.
ventilation.
4. Anomalous vibrations and noises (Stop the blower immediately)
CAUSES REMEDIES
Check the rolling bearings; replace-

Excessive wear of rolling
ment is necessary when the clearance
bearings or ball bearings.
is over the value C3.
The rotors meet owing to the Check the back pressure :
phase displacement as disassembly and replace the phase;
consequence of over- loads or before assembling check the rotors be
foreign bodies entry. perfectly aligned.
Rotors mutual sliding or rotor- Clean the blower; check that the
casing sliding due to foreign covers of the casing have not been
materials or dust. damaged.
Lesson 7 Page 12
Verify the air filter; check back

Rotors casing covers sliding
pressure : disassemble and check
due to overheating.
condition of the covers.
Rotors out of balance due to Clean rotors and casing : check the
deposits or foulings. rotors be aligned.
5. Low air capacity.
CAUSES REMEDIES
Clogged inlet air filter. Clean the filter
Settle the stated value of the suction

Excessive suction depression.
pressure again.
Belts drive slip. Stretch the belts.
Wear of the rotors with too Measure the clearances; consult the
high increase of clearances. manufacturer.
Gas leakages from delivery
Check the delivery pipe.
pipe.
6. Motor overloading.
CAUSES REMEDIES
Differential pressure, back

pressure or suction pressure Act on the plant to reduce pressure to
too high in comparison with rated values.
rated values of pressure.
Blowers capacity too high in
Let air surplus leak in the open air or
comparison to requested plants
better reduce rotation speed of the
capacity : consequently
blower.
pressure increase.
Clogged inlet air filter. Clean the filter.
Rotating parts meeting and
internal Stop the blower immediately.
slidings.
7. Oil leakage
Lesson 7 Page 13
CAUSES REMEDIES
Too high oil level in the sumps

Settle oil level as prescribed in fig. 6.
and leaks e from drain holes.
Worn seal ring with leakage at
Replace the rubber seal ring pos. 43.
the shaft end.
Worn out labyrinth flexible
Replace the flexible rings pos. 45.
rings.
Lesson 7 Page 14

Mod. 11 PLANT C OMPRESSOR PDF

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Kingdom of Saudi Arabia

Saline Water Conversion Corporation

PLANT COMPRESSOR & O/H

Module No. 11:

COMPRESSOR MAINTENANCE MODULE HOURS

LES SUBJECT/TOPIC THEORY PRACT TOTAL

3. CRANKCASE AND CARE OF CRANKCASE PARTS 3 2 5

7. ROTARY BLOWER AND MAINTENANCE 5 5 10

TOTAL HOURS FOR COMPRESSOR & FAN MAINTENANCE 30 20 50

LESSON WORKING PRINCIPLE AND

1. Define the compressor and its uses.

1.1 BASIC WORKING PRINCIPLE

When that compressed is flow in single direction, some of its potential

1.2 USES OF COMPRESSED AIR AROUD THE S.W.C.C PLANTS

Some of the uses of compressed air are listed below:

1. Motive power for grinding and sanding tools, drills, and

3. Blast cleaning or sandblasting of surfaces.

5. Engine starting as with diesel engine.

6. Conveyer systems which move powdered and granular

7. Control systems where compressed air is used both as a

8. Atomizing of liquids such as oil for use as a fuel and water

9. Soot blowing for boiler furnaces.

10. Mixing or agitating materials for a process.

2.0 TYPE OF COMPRESSOR

Air compressors are divided into two general categories according to

1. Positive displacement compressor.

2.1 POSITIVE DISPLACEMENT COMPRESSOR

Positive displacement compressor are work by trapping a mass of air

Each category include several different kinds of compressor which are

2.2 RECIPROCATING COMPRESSOR

A reciprocating compressor is one in which the air is compressed by a

Fig. 1 – 1: A reciprocating compressor

3.0 CLASSIFICATION OF RECIPROCATING COMPRESSOR

Reciprocating compressors are made in variety of designs or

According to the According to the

Single Double vertical V or y L- Single

Fig. 1-2: Classification of reciprocating compressors

Fig. 1-3: Physical arrangement classification.

3.1 ACCORDING TO THE ACTION

As mention before a reciprocating compressor can be either single

Double-acting means that the piston is also compressing on the return

At any given speed the double acting reciprocating compressor has

A Single - acting or double-acting compressor usually operates to a

Fig. 1-4: A double acting compressor cylinder.

3.1 ACCORDING TO THE CYLINDER ARRANGEMENT

Various cylinder arrangements are used in reciprocating compressor

Fig. 1 – 5 shows an angle compressor and the Y – type appears in Fig.

Fig. 1 – 5: Angle or L – Type compressor.

Fig. 1 – 6: Y – Type compressor

3.3 ACCORDING TO THE METHOD OF COMPRESSION

For special applications where pressures above 6900 Kpa are

4.0 ROTARY COMPRESSOR

In a rotary compressor a compressing elements rotates on a shaft. A

Screw Vane Liquid ring Lobe

Fig. 1 – 7: Classification chart of rotary compressor

4.1 THE ROTARY SCREW AIR COMPRESSOR

The lobe compressor has the advantages of being compact and

Fig. 1-8: Single – stage rotary screw compressor.

Fig. 1 –9: Different types of screw compressor

4.2 SLIDING VANE COMPRESSOR

The sliding vane compressor consists essentially of a cylindrical rotor

Fig. 1 – 10: Sliding vane compressor

4.3 LIQUID RING COMPRESSOR