Sunday, November 1, 2009

Energy Saving in Motor Start-up

Energy Saving in Compressor's Motor Start-up

Potential Energy Saving in Speed Controlled Compressor


What is Speed Control?

These Compressors are usually Direct Coupled, Direct Drive, meaning the Main Motor is directly driving the Rotor [usually Male Rotor].

Is a Electronically based control, where the speed [rpm] of Main Drive Motor is varied to adjust the free air delivery [FAD] to change in Plant air usage.

* If Demand Increase!
Motor Speed is increased, and therefore, the speed of the rotors is increased -----> free air delivery increases.

* If Demand Decrease!
Motor Speed is reduced, and therefore, the speed of the rotors is reduced -----> free air delivery decreases.

Monday, October 26, 2009

What If

What if

I can help you earn


the Compressor you buy!

Would YOU be Interested?

Friday, October 16, 2009


Coolant for Rotary Twin Screw Air Compressors


Semi-synthetic Coolant for Rotary Twin Screw Air Compressors

Thursday, October 15, 2009

Turbo Compressors

Centrifugal Turbo Compressors:

We have 2 units of FS-Elliot Turbo compressor install in Prai Industrial Estate.
one unit = 500 horsepower.
one unit = 800 KW
New unit install and ready to start-up!
500 HP, 415V Electric Motor
A view of an 500 HP, 415 V, Electric Motor driving an FS-Elliot Turbo Compressor.

800 KW, 11,000V Electric Motor

A view of 800KW FS-Elliot Turbo Compressor:
Compressor install with an 11,000V, Electric Motor.

Another view of the Turbo Compressor

Another view at the compressor inlet side.

Grey colour is the 800 KW, 11,000KV, Electric motor.
lower blue colour is the base of the compressor, also use as Oil Tank, about 2 drum of 209 litres.

Another side of the same Compressor.
On the left is 3 stage,
On the right is the 2nd stage.

Another View of the same 800 KW Turbo Compressor.

Our neighbour,
A 6500 KW, 11,000KV, Electrical motor driving a Cameron Turbo Compressor.

External Air Filter for Centrifugal 3-stage Air Compressor, install in a Factory in Perai, Penang, Malaysia.

Saturday, September 5, 2009

Air End failure -AC - 03/Sept/2009

A failed Rotary Screw Air Compressor's Air End:=
Atlas Copco GA132, we dismantle on Thursday, 3rd September, 2009 from a factory in Prai Industrial, Penang.

A female rotor of the twin screw rotary screw air compressor.

The male [drive rotor], note; the DE bearing side.

Air End Bearings:=

Types and size of bearings:
QJ 315 = 2 sets
NU 315 ECJ/C3 = 4 sets

There are three types of bearing cage to choose from, there are
NU 315 ECJ = Steel cage
NU 315 ECP = Polymide cage [ a type of plastic material ]
NU 315 ECM = Brass cage

Air End failure -IR - 04/Sept/2009

A failed Rotary Screw Air Compressor's Air End:=
Ingersoll Rand MM75,
[ 75kw = 100 hp ]
We dismantle on Friday, 4th September, 2009 from a factory in Prai Industrial, Penang.

A view of air end after the air end side of the gear box cover remove.

A close-up view of the same air end.

worn out part of the DE side of male rotor.
There is wear on the NU bearing inner cone bearing seat.
Meaning the inner race of the bearing is rotating on the rotor shaft.

The gear box cover that support the rotors.
The bearing support for the male rotor shaft.

Another view of the air end side gear box cover.
The male rotor side.

Air End end cover!

Another view of failed, twin screw rotor.
The male and female rotor.

The male rotor in the housing after the female rotor is been remove from the housing [compression chamber].

The male just coming out of it's housing.

The Male Rotor Before Repair !

The Male Rotor After Repair !

The rotor after repair, rebuilt, and grind to size.

Air End Bearings:
Type and sizes of bearing for this air end are:=
HM 911210 = 4 pcs
HM 911244 = 4 pcs
NU 211 ECM/C3 = 1 set
NU 311 ECM/C3 = 1 set

There are three types of bearing cage to choose from, there are
NU 311 ECJ = Steel cage
NU 311 ECP = Polymide cage [ a type of plastic material ]
NU 311 ECM = Brass cage

A sample of a different air end using ECM bearings.
That is bearing with Brass Cage.

This Air End is for sale, for use on Ingersoll Rand M55 & M75,
55 Kw [75 hp] and/or 75kw [100 hp] air compressors.

C3 = clearance of three thou, clearance between races and roller bearings.
3 thou = 3/1000 inches.

Monday, August 24, 2009

Typical Bearings Failures

Prevent over 60% of Premature Bearing Failures

Poor Fitting [16%]
About 16% of all premature bearing failures are caused by
1. Poor fitting (usually brute force ...)
2. Being unaware of the availability of the correct and proper fitting tools
3. Laziness

Individual installations may require mechanical, hydraulic or heat application methods for proper, correct and efficient dismounting or mounting.

The use of specialised tools, equipments and techniques will make the above job easier, faster and more cost effective.

These is one positive step towards long bearing life, thurs achieving maximum compressor uptime.

Poor Lubrication [36%]
About 36% of premature bearing failures are caused by incorrect specification and inadequate application of the lubrication.

Any bearings deprived of proper lubrication will long before its normal service lifespan. Bearings are usually the least accessible components of the compressors, therefore, neglected lubrication compounds the problem.

Effective lubrication, using recommended lubrication [grease, oil, coolant], Special tools, equipments, and techniques, really helps to greatly reduce downtime.

Contamination [14%]

Bearings are precision components that will not operate efficiently, unless both the bearings and its lubricants are isolated from contamination. At least 14% of all premature bearing failures are attributed to contamination.

Fatigue [34%]
Whenever compressors are overloaded, incorrectly serviced or neglected, bearings will suffer, resulting in 34% of all premature bearing failures.

Sudden or unexpected failure can be avoided, because neglected or overstressed bearings emit "early warning" signals, which can be detected and interpreted using Condition Monitoring Equipment.

Condition Monitoring Equipment
CME includes hand-held instruments, hard-wired systems and data management software for periodic or continuous monitoring of key parameters.

edited from

A failed QJ bearing, behind is the Controller for Screw Air Compressors.

Sunday, August 23, 2009

High Oil Consumption

Increased Oil [Coolant] Consumption

1. Blocked drainage [scavenging] line

2. Type of Oil [Coolant]
[ oil vapour content]

3. Over filled sump

4. Air Release
[Oil foam build-up]

Rotary Compressor Coolant
One of the best for Rotary Screw & Vane Air Compressors
Mineral based, Long change intervals

Packing := 5 us gal.

Economic Service Life Of Oil Separators

Economic Service Life

1. Oil Care
2. Selection of Oil / Coolant
3. Operating Conditions

1. Oil Care
Oil Change Interval!
Oil Filter Change Interval!
Air Filter Change Interval!
Oil Compatibility
Oil Contamination!

2. Selection of Oil / [Coolant]
Aging Resistance
Insensitivity with Water
Compressor Suitability
Air Separation Efficiency

3. Operating Conditions
Ambient Temperature
System Cooling Oil Temperature
Foreign Harmful Bodies in Air

Thursday, July 2, 2009

Oil Separators

Rotary Screw Air Compressors parts

Oil Separator Factory in Shanghai, China.

Basic Operation Principles of Oil Separation
1. Direct Interception
2. Inertial impaction
3. Diffusion

What will the effect?

Meaning, a 3 ppm rated Oil Separator Element, do not need to have a 3 micron rating, it is usually more than that, and it will get a 3 ppm performance on its' Oil Separator element.
Cool 0r Cool

Oil Separator Element Support!
The direction of Air Flow!

Oil Separator Tank with Vertically installed Oil Separator

Oil Separator Tank with Horizontally installed Oil Separator

Many newer comes with Spin-On Oil Separators, especially on smaller capacity, so far it is use on compressors up to 150 hp Rotary Screw Air Compressors.

These type are usually found installed in German Made Rotary Screw Air Compressor.
Example: Alup SCK 125, SCK 151, using 3 numbers on Spin-On Oil Separators --- [Parallel Flow]

A typical Oil Separation & Oil Lubrication combination unit.
On the left, the white colour is an Spin-On Oil separator, on the right, is an oil filter mounted on a combination unit, include MPV and Themo valve.

Commonly found on small unit, Italian made compressors,
Example:= Fiac, Fini, etc.

Saturday, June 20, 2009

Trainer Profile

Trainer Profile

Wong Chong Sen a.k.a. Handsome Wong

The biggest screw air compressor in the Northern Region.
Located in Penang Seagate, Bayan Lepas Industrial Estate. Penang.
The 350 kW is water cooled, and use Auto-transformer to start.

Take two day to start it up.

Industrial Robotics & Automation.

Champion Service Training

Champion Air Compressor
Sales & Service Training

City and Guild of London Institute
Electrical Engineering
Part II

City and Guild of London Institute
Electrical Engineering
Part III

City and Guild of London Institute
Electrical Engineering
Full Technological Certificate

Skilled Certificate
General Mechanic

Member Singapore Institute of Engineering Technologists

Ultra Filters
Cleaned Compressed Air Treatment
Line filtration

" Traditional & Brick Mortar Business "

Certificate from Almig of Germany.
The number air compressor company in Germany.
The hot bed of air compressors manufacturing and air end productions.

Good news for those who have vast working experiences to obtain Government approved skill certificate without having to go back to school.


For adult only, with working experiences only