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Why Air Compressor are NOT producing enough

Why Air Compressor are NOT producing enough ?

Almost all compressors in these region ( Tropical ) are not climatised or tropicalised for use here. 

They are standard equipment in country of manufactured.

Tropicalised = suitable for hot and high humidity weather conditions.

Therefore: 

they cannot operate at full load, if load to the rated pressure and flow for a longer period, it will trip due to high operating temperature.

And, it need to off-load or unload. the fan will cool the operating temperature. and not producing any discharge air or pressure.

When compressors go to off-load, it consume energy; varies from 30% to 60% of Full Load Amperes, and no work is done.

        $$$$$     Energy wasted      $$$$$

Air Compressor Sizing 

  3 Simple Ways on How to Select an Air Compressor 

  Two basic scenarios present to decide! 

1. New Plant, and 

2. Old Plant [to upgrade or downgrade] 

  1. New Plant 

Step 1, 

Group all equipment in loading or usage categories. If equipment is in use most or all the time into one group = 1. (100% loading) Example: Production machinery, SMT, Conveyor etc Another group or groups may be .6 [60% loading ], .3 [30% loading] in a day or working shift. 

 Step 2, 

Add up total usage and multiply with the usage factor, to arrive at the capacity usage. 

Step 3,

 add about 10% to 15% of losses, due to leakage and other losses. After listing all the air operated devices and equipment to be supplied by the air compressor, decide using charts, the pressure range and volume of air required by each and every devices and equipment. 

 These air compressor or compressors must maintain a minimum pressure at least equal the highest of these pressure ranges. 

  ----- For Example: 

 If the highest pressure range required by any one device in a given group is 90 psi - 110 psi, a compressor or compressor must be able to supply the required volume, then the cut-in at not less than 90 psi and cut=out at 110 psi should be considered. 

Exceptional: 

Speed Controlled Air Compressor are used! 

 Then You have a rough idea of your plant compressed air requirement! 

  2. Existing Plant 

2a. [Compressor always loading, that is cannot reach the required rated pressure] Formula used: 

P1V1 = P2V2 

 2b. [Compressor can off-load] Formula used: Air Consumption required = Vl/(u+l) 2c. 

 Using Instruments Energy Balance System

Energy Cost:

1.

Total Energy cost in operation of Air Compressors.

2.

Energy cost during Operation.

3.

Energy cost due to maintenance.

4.

Energy cost on operation.

Our Air Compressors & Equipment;

do not used reconditioned or seconded-hand ( pre-loved ) components & parts.

Positive Displacement Compressors-Screw

Rotary Twin Screw Air Compressors

Description: 

Rotary, helical screw, oil-injected, positive-displacement compressors are constant volume, variable pressure machines. They are available in a range from 25 cfm to 3000 cfm at pressure up to 600 psig in single, 2-stage & 3-stage designs. 

USES 

The most common uses of the rotary screw compressors are engine-driven portable compressors for mining, construction, and energy exploration.

  And as electric-motor driven stationary compressors for industrial and mining application. 

 Rotary helical screw compressors of this types are characterized by compact, low vibration, simple foundation, broad pressure and capacity ranges, and long life with minimum maintenance. 

 They are used for pressure or vacuum services.

Design: 

The single-stage design consists of a pair of rotor meshing in a one-piece, dual-bore cylinder. The male rotor, usually 4 helical lobes, spaced 90 degrees apart. The female rotor, usually has six corresponding helical grooves, spaced 60 degrees apart. 

The rotor speed ratio is inversely proportional to the lobe-groove ratio. When the male rotor rotates at 3000 rpm, the female rotor would rotate ...... ....... rpm? The male rotor can be directly driven, belt driven or gear driven by engine or electric motor. 

The female rotor is driven by the male rotor without metal-to-metal contact through the thin oil film developed between the rotors. 

Female rotor drive is possible in some design. The rotors inter-mesh in the dual bores of a one piece cylinder (housing, or case). 

The cylinder provides air passages, oil injection holes, compression chamber, and discharge ports. Each rotor is supported by rolling element bearings located at the ends of the rotor body. 

The bearings at one end, usually the discharge end, take the rotor axial thrust, carry radial loads, and provide for small axial running clearances necessary. 

 Bearings at the opposite end are floating bearings, which allow for uneven thermal expansion of the rotors and cylinder. For 2 and 3 stages, the individual stages are designed to be similar to the single stage as far as the rotor configuration is concerned. 

2 Styles 

 Two styles of multi-stage compressors are in common use; Those axially mounted, in which the second stage is driven directly from the rear of the first stage.

And side or parallel mounted, in which the stages are each mounted directly on a gear housing and are independent of each other. 

 Some designs remove the oil and cool the air between stages in an intercooler, while others discharge the air and oil directly into the next stage. 

Multi-stages 

Multi-stages are used in compressors for either to improved efficiency or for higher pressure. 

  

  Performance 

The overall efficiency of the unit depends almost entirely on the achievement of proper clearance in the rotors during manufacture. The normal manufacturer's warranty allows for plus +- minus of 3% variation in performance. 

 Discharge temperatures are much lower than in other types of compressors. Most manufacturers supply a thermostatic oil control valve to control the minimum discharge air temperature to avoid condensation in the reservoir or oil sump. 

 A 2-stage, 100n psig compressor improves performance by lowering the pressure differential across the leakage paths within the rotors [Blowhole] and end plates. The altitude [sea level vs mountain top] on which the compressor is located also has an effect upon performance. 

 The oi-injected screw machine is capable of operating on vacuum service and produces maximum vacuum equal to that of the 2-stage, double acting reciprocating machine. 

The oil flow are normally reduced because of lower mass flow. The power consumption of the rotary-screw compressor during unloaded operation is normally higher than of reciprocating types. 

Recent developments by some manufacturers have led to systems in with the unloaded horsepower is 15% to 25% of loaded power. This systems are normally used with electric-motor, constant-speed drives rather than engine-drives in which the engine speed can be reduced during unload, for reducing fuel consumption. 

 Application of the unit as a based load compressor is also recommended to avoid any disadvantage due to unloaded power coat. 

source from CAGI handbook edited version

Our Air Compressors do not used reconditioned or pre-loved components & parts!

Air Compressor Classification

Air Compressor Classification 2 types 

Dynamic 

Positive-displacement 

Dynamic 

Ejector 

Centrifugal Positive-displacement 

Reciprocating [Double Acting & Single Acting, Single-stage, Multiple-stage, Piston, Rocking Cam, Diaphragm] Rotary [Single Screw, Twin Screw, Scroll, Lobe, Liquid Ring] *******************************************************

Reciprocating 

Double Acting 

Single Acting 

Double Acting 

Double Acting, Single-stage, Reciprocating Piston Type

Double Acting, 2-stage, Reciprocating Piston Compressors

Single Acting 

Reciprocating Single Acting Piston Type

Rocking cam Diaphragm

Rotary: 

Rotary Single Screw

Rotary Twin Screw Rotary Scroll Rotary Lobe Rotary Water Ring

Rotary Compressor Coolant 

 Lubricant for Oil-Flooded Rotary Screw and Vane Air Compressors

Description: 

The Rotary Compressor Coolant represents a “step-change” advance in lubricating oils specifically developed for oil flooded rotary screw and vane air compressors. They are premier quality products, highly recommended for both static and mobile plant with working temperatures up to 120 degree C. 

The products are based on HVI paraffinic base oils, treated to reduce the polycyclic aromatic content, into which are blended additives to impart anti-oxidant, anti-wear, anti-corrosion, anti-foam and dispersions properties. 

Extended field evaluations have demonstrated a vastly superior performance, to the extent that oil drain periods may be doubled. This effectively means an increase from the current maximum of 2000 hours to 4000 hours at a continuous maximum air discharge temperature of 100 degree C.

Combined with the extended life is a facility to keep the internal surfaces completely free from deposits whilst maintaining a steady differential pressure (dp) across the separator/coalescer. This means that premature blockage of separators/coalescers are eliminated. MKT/JT/ABKD/104 

Benefits: 

Outstanding oxidation and thermal stability, which serves to extend the service life even with bulk oil temperatures up to 120 degree C. Reduced maintenance cost resulting from the doubling of intervals between oil changes. Excellent cleanness properties, eliminating the blockage of separators/coalescers. 

Good protection against corrosion, extending the life of components in service. Limited carry over of oil into the air stream, offering high quality process air. Reduced risk of fire in the separator pack, due to the excellent oxidation and thermal stability of the oil. 

Good anti-foam properties to suppress the tendency to foam excessively in service. Good air release properties to minimize or avoid cavitations effects and increased compressibility.

Application: 

The Rotary Compressor Coolant has been specifically developed to cater for the lubrication requirements of the complete spectrum of rotary screw and vane air compressors. They are applicable to all types and sizes of rotary vane and screw air compressor whether oil flooded or oil injected, male or female drive, single or two stage configurations. 

Although primarily designed for static industrial application, the coolant is equally applicable to the lubrication of air end in mobile plant configurations. 

 Oxidation Stability: 

 

Oxidation can be considered the most important single property of oil for rotary compressors, since it is this, which primarily determines the useful life of the oil and its resistance to thickening and to the formation of carbonaceous deposits. 

The excellent oxidation stability of the Rotary Compressor Coolant makes it possible to operate compressors continuously for long periods between oil changes, and at higher temperatures without the need to resort to highly price synthetic lubricants. 

The IP 280 and IP 306 test results confirm the outstanding oxidation stability of the Rotary Compressor Coolant, in particular the very low ratios of sludge to TOP (total oxidation products) of 2.54% and 2.15% respectively against a permissible maximum of 40%. 

Anti-foaming: 

The ability of compressor oil to resist foaming is important, since malfunctioning of the compressor can occur if excessive amount of foam is allowed to form in the separator. Tests have proved that the special additive combination in the Rotary Compressor Coolant reduces the tendency of the oil to foam in the separator. 

Typical results in terms of IP 146 – the Foaming Characteristics of Lubricating Oil: Sequence 1 10/NIL (Foaming Tendency/Foam Stability) Sequence 2 Nil/NIL (Foaming Tendency/Foam Stability) Sequence 3 20/NIL (Foaming Tendency/Foam Stability) 

Protection Against Corrosion: 

The occasional presence of water in oil-flooded compressor systems is possible, so it is important that the oil gives protection against corrosion. In addition to the associated mechanical problems, fine particles of rust dispersed in the oil will reduce the oxidation stability of the oil considerably and will also adversely affect its air release properties. 

The Rotary Compressor Coolant have excellent corrosion inhibition properties and give a ‘no-rust’ result against IP 135 B – Rust Preventing Characteristics of Steam Turbine Oil in the presence of synthetic salt water. 

  Oil Drain Periods: 

For many years, 2000 hours has been generally accepted as an extended oil drain period for rotary vane and screw air compressor maintenance schedules and service requirements. It is recognised that operating temperature has a fundamental effect upon the rate of oil degradation through oxidation. 

With our Rotary Compressor Coolant incorporating the most up to date oil technology, 4000 hours oil change may now be accepted as the norm, even when operating at a continuous maximum discharge air temperature of 100 degree C. 

  Internal Cleanliness: 

Coupled with the long life capability is the ability to maintain excellent internal surface cleanliness in service. This is particularly relevant to the function and operation of the separator/coalescer. Design varies according to the manufacturer; nominal filtration of ½ micron is typical for this application. 

Blockage of these elements with what was thought to be polymerised products of oxidation has been endemic, in some cases after only 100/200 hours of operation. 

In a test using Rotary Compressor Coolant, the separator element from a Compair - Broomwade Ltd trial machine was removed and inspected after 8400 hours of intermittent operation, simulating typical in-service conditions.

The metal and fibreglass element were in ‘as new’ condition, and the dp (differential pressure) across the separator was recorded at a constant 2.5 psi over the whole evaluation. The screw element from the trail assembly was also inspected and was found to be in excellent condition. 

  Sealing: 

 The Rotary Compressor Coolant is suitable for use in conjunction with all commonly used sealing materials. 

  Change-over Procedure: 

 Changeover is relatively straightforward: 

1. 

 The original charge should be fully drained and disposed of. 

2. 

 If the oil system has shown evidence of contamination or is otherwise less than satisfactory, a flushing charge may be appropriate. 

3. 

 Assuming item (2) not to apply, the system may be filled to the correct level and run in the normal way. 

4. 

 Assuming item (2) to be necessary, the flushing charge should be introduced and run up to normal working temperature for, say, 4 hours. It should then be fully drained, preferably at 50 degree C or above and then disposed of. 

5. 

The working charge should then be introduced to the normal working level and the machine restarted. 

  Health And Safety: 

The Rotary Compressor coolant is unlikely to present any significant health or safety hazard when properly used in the recommended application and good standards of industrial and personal hygiene are maintained. See separate Safety Data Sheet. 

MKT/JT/ABKD/104

Air Filters maintenance

Air Filters 

 The 1st place that dirt get into the compressor is via the intake. To prevent dirt from getting inside is to install a appropriate size air filters. Some typical use air compressor filter elements.

They are made of filter grade filter paper.

 

Filter maintenance 

1 Visual inspection

 

Remove of filter dust trapped at cover through centrifugal flow of air inside the filter housing.

 

Low air pressure jet to clean air filter

 

Choke up air filter

  

Air filter need to replace.