high pressure air compressor

8/11/2019 High Pressure Air Compressor

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INTERSHIP NAVIGATION TRAINING CENTER, INCMANILA, PHILIPPINES

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Contents

Page

General hints

1. Technical data 3

2. Design 4

3. Commissioning and Operating Instructions/Operation Saet! Instructions "

4. #aintenance 1$

". Operating Trou%les and their &limination 11

'. Starting procedure o air cooled sa(er compressor 12

). *al(e +ssem%l! 13

,. -ongitudinal and Cross Section 14

. Compressor unit ith electric motor 1"

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.

Air compressor

Compressed air has man! uses on %oard ship0 ranging rom diesel engine starting tothe cleaning o machiner! during maintenance. The air pressure o 2" %ar or moreare usuall! pro(ided in multistage machines. ere the air is compressed to a higherpressure in the net stage0 and so on. The to stage cran machine is pro%a%l! themost common0 and one t!pe is shon in 5igure ).1. +ir is dran in on the suction stroe through the irst stage suction (al(e (ia thesilencer/ilter. The suction (al(e closes on the piston upstroe and the air iscompressed. The compressed air0 ha(ing reached its irst stage pressure0 passes

through the deli(er! (al(e to the irst stage cooler. The second stage suction andcompression no tae place in similar manner0 achie(ing a much higher pressure inthe smaller0 second stage c!linder. +ter passing through the second stage deli(er!(al(e0 the air is again cooled and deli(ered to the storage s!stem. The machine has a rigid crancase hich pro(ides support or the therecranshat %earings. The c!linder %loc is located a%o(e and replacea%le liners areitted in the c!linder %loc. The running gear consists o pistons0 connecting rods andthe onepiece0 tothro cranshat. The irst stage c!linder head is located on thec!linder %loc and the second stage c!linder head is mounted on the irst6 each othe head carries its suction and deli(er! (al(es. + chain dri(en rotar!gear pumppro(ides lu%ricating oil to the main %earings and through internall! drilled passages

in the cranshat to %oth connecting rod %earings. Cooling ater is supplied eitherrom an integral pump or the machiner! space s!stem. The ater passes into thec!linder %loc that contains %oth stage coolers and then into the irst and secondstage c!linder heads. + ater 7acet saet! (al(e 85igure ).29 pre(ents a %uildup opressure should a cooler tu%e %urst and compressed air escape. :elie (al(e areitted to the irst and second stage air outlets and are designed to lit at 1$; ecesspressure. + usi%le plug is itted ater the secondstage cooler to limit deli(ered airtemperature and thus protects the compressed air reser(oirs and pipe ors. Cooler drain (al(es are itted to compressors. and does not produce compressed air. + compressor hen startedmust %e inn the unloaded condition. This reduces the starting tor?ue or the machineand clears out an! accumulated moisture in the s!stem. This moisture can aectlu%rication and ma! produce oil/ater emulsions0 hich line the air pipelines andcould lead to ires or eplosions. The compressor motor is started and the machine runs up to speed. Thelu%ricating oil pressure should %e o%ser(ed to %uild up to the correct (alue. The irststage drains and then the second drains are closed and the machine ill %egin tooperate. The pressure gauge cocs should %e ad7usted to gi(e a stead! reading.


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running ill clear the coolers o condensate. The compressor can no %e stoppedand the drains should %e isolated i the machine is to %e stopped or a long period. +utomatic compressor operation is ?uite usual and in(ol(es certain additionale?uipment. +n unloaded must %e itted to ensure the machine starts unloaded0 andonce running at speed ill =load> and %egin to produce compressed air. *arious

methods o unloading can %e used %ut marine designs a(or either depressors0hich hold the suction (al(e plates on their seats0 or a %!pass hich discharges tosuction. +utomatic drains must also %e itted to ensure the remo(al o moisture romthe stage coolers. + nonreturn (al(e is usuall! itted as close as possi%le toessential itting here unloaders are used. The compressed air s!stem or the suppl! o starting air to a diesel engine isdescri%ed in Chapter 2. Control or instrument air supplies ha(e particularre?uirements ith regard to %eing moisture and oil ree and ithout impurities. +special t!pe o oilree compressor ma! %e used to suppl! control air or it ma! %etreated ater deli(er! rom an ordinar! air compressor. This treatment results in theair %eing iltered and dried in order to remo(e (irtuall! all traces o oil0 moisture and

an! atmospheric impurities. #aintenance in(ol(es the usual checs and o(erhauls common to reciprocatingmachiner!0 e.g. crancase oil le(el0 cooling ater s!stem0 operating temperaturesand pressures0 etc. The suction and deli(er! air (al(es or each stage ill presentthe most or in an! maintenance schedule. These (al(es are automatic0 re?uiringa small pressure dierential to operate. The constant rapid opening and closing action o the (al(es ma! re?uire theseats to %e reaced. O(erheating0 use o incorrect lu%ricating oil0 or the presence odirt ma! result in sticing or pitting o the suraces. The (arious %uer plates0 springplates0 (al(e plate and seat hich mae up suction or deli(er! (al(e can %e seen in5igure ).3. The (al(es should %e stripped and all parts careull! cleaned andeamined0 an! orn parts replaced and the (al(e seat and plate lightl! lappedseparatel! on a lat surace %eore reassem%l! to ensure a good seal.

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1. Technical a!a

Compressor t!pe


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". esi#n

".1 Per$ormance an% se!&'p

The single acting compressors ith to stages compress atmospheric air in to *lie

arranged c!linders to a inal pressure up to 4$ %ars. Due to the arrangement o the c!lindersand a mostl! %alanced gear it is e(en a high speed pro(ided a smooth running so that anarrangement ithout a %ig machiner! oundation is possi%le.

The recooling o the air compressed in the I. and II. Stage is made in inpipe coolers. Theseare arranged surrounding the l!heel e?uipped as radial (entilator and are placed in the ullairlo o the (entilator.

+ case co(ers the radial (entilator and the coolers and the leads the airlo onto thec!linders.

The three phase emotor model B 3/B." is directl! langed to the coupling cage o the

crancase. The poer transmission is made (ia a lei%le coupling. Diesel engines aremounted (ia special langed. The poer transmission is made serial %! a centriugal clutch.The oil and ater separator is mounted to the coupling case.

"." Cons!r'c!ion %e!ails

Gear The cranshat is tice in roller %earings. The connecting rod %earingsare e?uipped as slide %earings0 the piston pin o the I. stage goes in a%rone %rush0 the piston pin o the II. stage in a needle roller %earing.

-u%rication The hole gear lu%rication is made %! splash lu%rication. Onto the

connection rods there are ri(et lu%rication studs0 hich dip in the oilsump and splash the oil on the lu%rication points.

*al(es Both pressure stages are pro(ided ith lamellar (al(es0 oringithout riction and presenting a (er! long ser(ice lie.

:ecooler The recooler mounted to the radial (entilator o the I. and II. stagesare e?uipped as pot gal(anied pipein cooler made o steel.

Saet! e?uipment +ccording to the regulations the pressure cham%ers o %oth stages aree?uipped ith saet! (al(es. The saet! (al(e o the I. stage isscreed into the c!linder head o the II. stage. The saet! (al(e ostage II is mounted in the separator ater the II. stage.The %lo o pressure is stamped on all the (al(es. 5or control o thecooling a saet! use is installed in the separator. a(ing reached atemperature o 12$oC a %oring is opened and the compressed air issteaming out.

+utomatic 5or automatic operation the unit is e?uipped ith anoperation electromagnetic (al(e or automatic relie and drainage o the

separator. +s a special accessor! the compressorunit ma! %ee?uipped ith a temperature control instead o a saet! use0 as ellas ith an oil le(el control.

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(. Commissionin# an% Opera!ional Re#'la!ions

(.) Opera!ion * Sa$e!+ Ins!r'c!ions

The compressor is %uilt according to the state o art is relia%le. 5rom the plant0 hoe(er0 ma!come dangers in case o that it is used inappropriatel! or not or its destinated application.

5or maintenance ors0 operation and repair onl! authoried personnel ma!%e taen hichdid read the complete instruction manual including the saet! instructions prior to oring onthe plant.

+ll ors on the compressor ma! onl! %e perormed i it is sitchedo and currentlesscondition. +ll compressed air carr!ing parts must %e pressureless.

The user has to care that the compressor is onl! in operation in uno%7ectiona%le condition.The complete plant has to %e clean and ree rom oreign matters. Special care has to %e

taen that no tools lie around.

The compressor ma! onl! %e used or compression o air.

nauthoried reconstructions and alterations hich ma! inluence the sae operation o thecompressor0 are not permitted.

The compressor ma! not %e operated ithout protection de(ice.

The saet! (al(es ma! not %e ad7usted0 onl! sealed (al(es ma! %e used. Damaged saet!(al(es ha(e to %e replaced %! ne ones. Onl! authoried personnel is alloed to read7ust0repair or seal the saet! (al(es.

(.1 Se!!in#&'p A%ices

The compressor unit must %e installed so that the maintenance spaces as indicated in theinstallation draings are ept ree. The erection place should %e easil! accessi%le.

I the compressor assem%l! is mounted on (i%rations mounts0 no resonance rom re?uenc!o ecitation is permitted to %e transerred in the natural re?uenc! o the (i%ration mounts tothe compressor. The natural re?uenc! o the (i%ration mounts deli(ered as standard iththe compressor is appro. 1$ . I an ecitation re?uenc! o the oundation near thenatural re?uenc! due to other e?uipment installed near%!0 the (i%ration mounts ha(e to %echanged.

Installation o the compressor assem%l! ithout (i%rations mounts is possi%le0 pro(ided thereis a suicientl! rigid oundation.

I a compressor is supplied ithout a dri(e0 the alignment %eteen the compressor and thedri(e has to %e perect.

The drain line o dierent compressors ma! not %e com%ined in one pipeline. The collectedmoisture contains oil and must not drain untreated into the seage ater s!stem. The

moisture should lo through a pipe into a tan and should aterards %e sillull! rec!cled

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or %e disposed o %! a specialied compan!. +s accessories E.P. Sauer F Sohn oermoisture rec!cling units0 hich mae a separation o oil and ater possi%le.

The coolingair has to %e conducted to the coolingairinlet0 not to the c!linders o the compressor8see eample %elo9.

The compressor must not %e installed in a corner so that the cooling air is again induced in a shortcircuit. I more compressors are running at the same time0 an installation in line must %e a(oided sothat the second compressor cannot induce the heated cooling air rom the irst compressor.

I needed0 Sauer supports !ou in the design o the room (entilation.

oselines should not %e installed under tension or turned/tisted around 8see %elo9.


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The electrical connection must %e eecuted %! a silled electrician. It has to %e checed hethercurrent0 (oltage and re?uenc! correspond ith the data gi(en on the t!pe plate. I the compressor isinstalled in an industrial compan!0 the technical connection regulations o the local poer suppl!compan! ha(e to %e o%ser(ed In addition0 the regulations o DI@ *D& $1$$ and DI@ &@ '$2$4 ha(eto %e o%ser(ed.

(." Commissionin#

The compressor is shipped ithout oil charge. +ter unscreing red closing plug0 illcrancase ith 10" l o %randed oil up to upper mar o dipstic in accordance ith the oilrecommendation or Sauer compressors. Prior to initial start0 chec compressor or eas!operation %! rotating cranshat manuall!. During initial start chec direction o rotation8cooling air lo rom an heel to c!linder0 on the right0 hen looing at dri(ing side9.

(.( Opera!ion Ins!r'c!ions

Draining The drainage o the condensate separator is done %! the mounted (al(e. Thiscan either %e manuall! operated or solenoid0 according to order.The solenoid (al(e is closed at direct online start 8DO-9 hen thecompressor is started. +t stop o the compressor it is opened to ena%le arelea(ed runout. +t startdeltastart 8HD9 the (al(e is closed hen sitchinginto deltaphase. The manual (al(e must %e open at the start o thecompressor. It is shut hen the operational speed is achie(ed. +t stop o thecompressor irst the (al(e must %e opened0 the compressor is shut don.

(.- P'! o'! o$ ac!ion

Compressors hich are cuto or short periods0 should perorm a trial o at least 3$ minutese(er! 4 ees.

I operation is interrupted up to 12 ees0 additional corrosion protection is not re?uired.

5or compressors0 here inter(als %eteen operation eceed 12 ees0 anticorrosionprotection is recommended. In such a case compressor oil used must %e replaced %! anticorrosion oil. Since the anticorrosion oil has ade?uate running characteristics0 thecompressors can %e operated at short notice or emergencies. 5or corrosion protection ocompressor a%out to %e made inoperati(e0 proceed as ollos6

- :un compressor or appro. " minutes ithout counterpressure ith pressure lineopen to %lo o condensate0 i an!.

- Drain compressor oil rom crancase.

- 5ill in appro. 10$ l o anticorrosion oil.

- Start compressor and run or appro. " minutes ithout counterpressure ithpressure line open0 then cutout.

- nscre air cleaner and loosen cooler o stage I on c!linder head o stage II.

- Start compressor and slol! spra! 1" cm3o anticorrosion oil into intae connection0and appro. 1$ cm3into open scre connection on c!linder head o stage II 8Caution0an heel ma! not %e co(ered9.

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- Cutout compressor the moment oil og comes out o cooler o stage I and pressureline.

- :einstall air cleaner and cooler.

- Drain anticorrosion oil rom crancase.

5or reneed operation0 reer to item 3.2 Commissioning.

(. A%ice $or opera!ion o$ !he compressor /i!h %iesel en#ine %rie

The compressorunit is e?uipped ith a centriugal clutch to guarantee an unloaded start othe diesel engine.The clutch is engaged at appro. 1$$$ 1/min. a deinite poer transmission is made rom14$$ 1/min on.Due to this act the speed regulating de(ice o the dieselengine is not to %e changed.

Se!!in# !o /or0

1. Control oil le(el ith dipstic.

2. Open condensate outlet coc on separator.

3. Start motor.

4. Close condensate outlet coc.

P'!!in# o'! o$ opera!ion

1. Open condensate outlet coc

2. Sitch o dri(ing motor.

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(.2 A%ice $or a'!oma!ic opera!ion

The %ottle pressure sitch does the control o the compressorunit in automatic operation. Itis mounted on the compressed air reser(oir or in the compressed air pipe.


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-. Main!enance

Scre connections "$ operating hours ater initial operation chec %olts and nuts incrancase0 c!linders0 pipelines and holders or tight seat. +ter "$hours o operation also chec scre connections released duringmaintenance 7o%s or tight seat.

-u%ricating oil During initial operation0 change oil ater "$ hours o operation0additional oil changes ater each 1$$$ hours or operation0 %ut at leastonce a !ear. se a t!pe o lu%e oil in accordance ith our oilrecommendation. Chec the oil le(el dail!.

+ir cleaner


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. Opera!in# Tro'3les an% !heir elimina!ionSaet! (al(e I. stage is %loing o6

- The com%ined suction and deli(er!(al(e o II.stage is not tight. Dismantle the (al(eand chec it.

- Gaset damaged %eteen c!linderhead stage II and compressor(al(e.

- Cooler got choed.

Saet! (al(e II.stage is %loing o6

- The loc (al(e in the %ottle illing leads is closed.

- Bottle pressure sitch is damaged or ad7usted incorrectl!. :eplace pressure sitchor read7ust0 respecting the instruction gi(en.

- @onreturn (al(e does not open at all or onl! partiall!. :eplace nonreturn (al(e. +damaged nonreturn (al(e can also %e the possi%le reason or pressure loss in theair %ottle at compressors standstill.

A!!en!ion- Dont ad7ust saet! (al(es to higher pressure. :eplace deecti(e (al(es.

-oss o capacit!6

- The concentric (al(e o I.stage is not tight. Dismantle the (al(e and chec.

- -eaages in the compressor tu%ing or in the %ottle illing leads0 repair leaages.

- Drainage (al(e not tight resp. not closed0 repair damaged drainage (al(e or replaceit. Dont close the drainage pipeline

- Dirt! air ilter0 clean air ilter.

- :ecooler or air pipes got choed.

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2. S!ar!in# proce%'re o$ air&coole% saer compressor

4RIE5 INSTR6CTION 5OR THE INITIAL START O5 OPERATION

1. The unit must not %e installed in the direct air stream o a (entilation s!stem.

2. 5ill the compressor ith oil according to our oil recommendation up to theupper mar on the dipstic.

3. Chec the correct installation o connections to the surrounding plant. Checespeciall!the pressuried air connection.

4. Chec i the lo through the nonreturn is in the right direction 8direction oarro9.

". In the drainage line o the stopped compressor no pressure must %e %uild up%! other

units %loing into the same drainage line.'. Start the compressor o some seconds to chec the sense o rotation. It must%e identicalith the arro glued to the cran case

). The compressor must start %! open drainage (al(e. +ter a e seconds the(al(es closeand the compressor runs up against the pressure. The pressure gauges o the

stages shall sho the (alues gi(en in the operation manual.,. +ter "$ operation hours all scre connection at the crancase0 c!linders0

pipes and

5asteners must %e checed or tightness. +n oil change must %e eecuted.

4RIE5 OPERATION INSTR6CTION

1. Chec dail! the oil le(el. Beore loer the dipstic mar is reached the oilmust %e reilledup to the upper mar ith oil according to our oil recommendation.

2. The compressor must start %! open drainage (al(e. +ter a e seconds the(al(es closeand the compressor runs up against the pressure.

3. Three and our stage air compressors need an intermediate drainage. Thisshould %e

set that the compressor is drained e(er! 1" minutes or 1" seconds.4 Chec the operation noise o the nonreturn (al(e. During normal operation

the (al(e must not rattle.". Chec i at increasing operation hours the pressure gauge indication de(iates rom the normal (alues.". O%ser(e the maintenance inter(als or Sauercompressors. + shortening o

The maintenance inter(als does not impro(e the operation %eha(ior or thelietime o the Compressor.

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high pressure air compressor

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