JJ618 : PLANT ENGINEERING

TECHNOLOGY
Prepared by:
Engr. Petrus Banati @ Fazzerius,
M. Mfg. Eng. (Mfg. Syst. Eng.), UTeM
B. Eng. (Mech.), (Hons), KUiTTHO
Dip. Edu. (Mech. Eng.), IPTKL
Dip. Mech. Eng. (Automotive), PKB
Cert. Mech. Eng. (Automotive), PKS
TOPIC 3;
(COMPRESSOR AIR PLANT)

SYLLABUS
SYLLABUS
Advantages Of Compressor Air
Plants
Better mechanical balance of the whole unit and
uniform torque.

Increase in volumetric efficiency.

Reduced leakage loss.

Less difficulty in lubrication due to low working
temperature.

Lighter cylinders can be used.

Cheaper materials can be used for construction as
the operating temperature is lower.
Main Components Of An Air
Compressor Plant
Compressed Air System
Components
Intake Air Filters
Inter-stage Coolers
After Coolers
Air-dryers
Moisture Drain Traps
Receivers
INTRODUCTION
Component of an air compresssor plant
used to provide an adequate quantity of compressed air at sufficient
pressure to various points of application

Air compressor
Increase the pressure of air from the initial conditions (air intake) to
the discharge conditions (air discharge). Compressors may be used
as vacuum pumps. A vacuum pump has an intake that is below
atmospheric pressure and usually compresses to no higher than
atmospheric pressure.



Positive Displacement Compressor
Air is compressed as the volume of the enclosed space is reduced. In the other,
a definite quantity of air is trapped and transferred from the suction intake to
the discharge port without reducing its volume.


Dynamic Compressors.
Operate by imparting velocity and pressure to the admitted air, through
the action of a rapidly spinning impeller or rotating vanes
Maximum Pressures and Capacities of Air Compressors
The approximate maximum pressures in pounds-force per square inch gauge
(psig), and the approximate maximum capacities in cubic feet per minute
(cfm) for various types of compressors

Auxiliary equipment
Air Intake Filters. Filters prevent the admission of
atmospheric dust to the air compressor. Refer to chapter 4,
section 1 for details.

Silencers. Silencers reduce objectionable compressor
suction noise.

Intercoolers and After coolers. Intercoolers are used
between consecutive stages of multistage compressors to
remove the heat of compression. After coolers are installed
on the compressor discharge lines to remove the heat of
compression after compression is completed.
Compressor Chart
Compressor Types
Reciprocating Compressor

Screw Compressor

Centrifugal Compressor

OBJECTIVE
Air compressors are used in
a variety of industries to
supply process requirements,
to operate pneumatic tools
and equipment, and to meet
instrumentation needs
Portable Air Compressor
Maintenance
Drain the moisture from the tanks

Clean Intake Vents

Tighten All Fasteners

Check Hoses Regularly

Clean the fuel tank
PROCEDURES
1. Notify all affected employees that servicing or
maintenance is required on a machine or
equipment and that the machine or equipment
must be shut down and locked out to perform
the servicing or maintenance.
2. Review the type and magnitude of the energy
sources involved with this machine or
equipment with affected employees
3. If the machine or equipment is operating, shut it
down by normal stopping procedure.
4. De-activate the energy isolating device(s) so
that the machine or equipment is isolated from
the energy source.
5. Ensure that the equipment is disconnected from the energy source
by first checking that no personnel are exposed, then verify the
isolation of the equipment by operating the push button or other
operating control to make certain the equipment will not operate.

6. Ensure that all belts, motors, pulleys and shafts have come to a
complete stop.

7. Isolate Air Compressor from the system it serves

8. Dissipate any residual hydraulic or pneumatic energy

9. Remove any guards necessary for maintenance or repairs

10.The machine or equipment is now locked out

11.In situations where the lock out or tag out devices must be
temporarily removed from the energy isolating device and the
machine/equipment energized to test or position the machine,
equipment or component
EQUIPMENT
Ultrasonic Leak Detector
Screwdriver
Filter and water trap

Pressure Gauge

Pressure regulator
Lubricator
SAFETY PRECAUTION
1. These explosions are triggered by abnormally high
temperatures, which may be caused by leaky or
dirty valves, excessive pressurization rates, and
faulty cooling systems
2. These oils vaporize easily and will form a highly
explosive mixture with the air under compression
3. 3. Secure a compressor immediately if you observe
that the temperature of the air being discharged
from any stage exceeds the maximum temperature
specified.
4. 4. NEVER leave the compressor station after
starting the compressor unless you are sure that the
control, unloading, and governing devices are
operating properly.




5. If the compressor is to remain idle for any length of time or
is in an exposed position in freezing weather, thoroughly drain
the compressor circulating water system.

6. Before working on a compressor, be sure the compressor is
secured and cannot start automatically or accidentally.
7. When cutting air into the whistle, the siren, or a piece of
machinery, be sure the supply line to the equipment has
been properly drained of moisture.

8. Before disconnecting any part of an air system, be sure the
part is not under pressure.

9. The heat of compression caused by a sudden flow of high
pressure into an empty line or vessel can cause an explosion if
oil or other impurities are present. Slowly crack open the
valves until flow is noted, and keep the valves in this position
until pressure on both sides has equalized. Keep the rate of
pressure rise under 200 psi per second.

Advantages Of Compressor Air
Plants
Better mechanical balance of the whole unit and
uniform torque.

Increase in volumetric efficiency.

Reduced leakage loss.

Less difficulty in lubrication due to low working
temperature.

Lighter cylinders can be used.

Cheaper materials can be used for construction as
the operating temperature is lower.




Discussion


over a period of a month to do the assignment,
students have trouble not knowing the parts.
students are not aware of the process flow
compressor plant water occurs.

in addition, students are faced with the problem of
not knowing how to handle the damaged parts.
students also do not have the skills to do service
in the compressor plant water




over a period of a month to complete the task,
students will learn the parts of the air compressor
plant, compressed and compressed water
process plant conducted.
Besides that, students also can learn how to
handle the problems facing inner-damaged parts.
students can also learn more about how to make
water service at compressor plant
overall student use, the importance of water and
how to handle the plant's compressor and can be
practiced by kind. Students also be able to apply
this knowledge in the future.

Conclusion