Piston Compressore - Learner Guide
Piston Compressore - Learner Guide
Piston Compressore - Learner Guide
Piston Compressors
Learner Guide
Piston Compressors – Learner Guide
Introduction
This lesson on Piston Compressors, as with your other lessons on Auxiliary Equipment, consists of
two main learning components a self-directed/in-class component and an on-the-job component.
You are expected to complete both components as part of your Certification Program.
Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.
Objectives
Your learning objectives are broken down into two categories learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.
Lesson Outline
The first portion of the lesson, the self-directed/in-class portion, involves reviewing the following
information:
The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on Piston Compressors, including both a running and static inspection. When you
are ready to perform these inspections, inform your Instructor.
If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.
Step One
Your Instructor will ‘walk through’ an inspection procedure with you. At that time you
can ask questions and take down any notes required.
This walkthrough may be completed out in the field or during a meeting with your
Instructor.
Step Two
Your Instructor will demonstrate an inspection procedure in the field.
Step Three
You will conduct an inspection procedure in the field under the supervision of your
Instructor.
Your Instructor will provide you with feedback about your performance during the
inspection.
Step Four
You will complete a full inspection procedure without any assistance from your
Instructor.
This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor and you may only be required to actually complete
Step Four as discussed above.
Reference Material
NA
Pre-requisites
NA
PISTON COMPRESSOR
Components
Belt Wheel Intercooler Manifold
Centrifugal Unloader Intercooler Safety Valve
Crankshaft Oil Seal
Drive motor Outer Bearing
Inlet Filter/Silencer Pilot Valve
Inner Bearing Shaft End Cover
Intercooler Snap Ring
P ISTON C OMPRESSOR
Intercooler Manifold
Belt Wheel
Snap Ring
Oil Seal
Outer Bearing
Bearing
BBearing Pilot Valve
Shaft End Cover
Components (continued)
L.P. Cylinder
Breather Tube
L.P. Cylinder
Air Head
Valve
Connecting Rod
Piston Rings
Rings
Piston
Cylinder
Principles of Operation
The piston compressor can be either a single stage or a two stage operation.
While there are many different types and manufacturers of piston compressors, the principle
operation is the same.
Compressors are equipped with a drive motor or motors and are fitted with belts from the
motor pulley to the belt wheel on the end of the crankshaft of the compressor.
The crankshaft rides in an inner and outer bearing and as the crankshaft turns this causes the
up and down motion of the connecting rod and piston within the cylinder, thus compressing
the air within.
Types of Operation
SINGLE STAGE
Air is compressed once before it is sent to the receiver.
Air enters the cylinder on the suction stroke of the piston through the inlet filter and valve
located in the air head.
On compression stroke of the piston, air is forced out through the valve, passes into a
manifold, and is piped to the receiver tank at a higher pressure.
TWO STAGE
This is type of compressor commonly used here.
.Air enters in same manner as single stage on suction stroke, but on the compression stroke
air is compressed to an intermediate pressure, is discharged through the valve, and is drawn
into the second stage cylinder on its suction stroke.
The compression stroke then compresses the air to the final discharge pressure. Air is then
forced out through the outlet valve into the receiver.
Compressor Cooling
INTERCOOLER TUBES
Two stage compressors are equipped with highly efficient intercooler tubes, used to cool the
air as it passes from the first stage of compression to the second stage cylinder.
Heat is removed by the action of the belt wheel fan passing cool air over the intercooler
tubes.
AFTER COOLERS
After coolers are installed if the cooling of the final (second stage) discharge air is required.
The after coolers can be either water or air cooled, and are installed between the compressor
discharge and the receiver.
Belt Guards
Air Inlet Filters
After
Coolers
Crankcase Heater
& Thermostat
Regulator Types
Auxiliary valve
Air Receiver
Constant Speed
Unloader
Air Head
Cylinder
Valve
Applications
Finish Grind
Raw Grind
Pyroprocessing
Inspection Points
Listen for abnormal noise or vibration in the Compressor and drive system
Troubleshooting
The following troubleshooting information has been prepared to help you resolve common
operating problems associated with the Piston Compressor
T ROUBLESHOOTING
Low Air Pressure Visually inspect the compressor (observe belt tension)
Listen for abnormal operation.
If repairs are required, Shut down and notify mechanical maintenance.
Safety
Always lockout before performing work on Piston Compressors
Be sure all guards are in place.
Make sure to isolate compressor if it is inline with other compressors.
Shutdown the compressor to add oil or check oil level and relieve the pressure inside the oil tank
by slowly removing the cover(cap)
Review Exercise
Complete each of these questions and review your answers with your Instructor.