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dinesh bagal
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Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 5:31 AM

we use reciprocating air compressors in chemical process plant.the compressors are water cool.

air discharge pressure = 5-6 kg/cm2

water pressure = 2.5 kg/cm2

water inlet temp.= 26-29c

water outlet temp.=35-38c

current ,voltage ,belt tension is proper.but in operation suddenly compressors were stop. Please suggest
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kramarat
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#1

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 7:06 AM

Low oil tripping?

Faulty or improperly adjusted pressure regulators?

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kramarat
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#2
In reply to #1

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 7:28 AM

Not only oil level, but oil pressure.

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IdeaSmith
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#3

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 8:35 AM

Does the compressor restart? Was it simply a matter of somebody switching the compressor off? Or is there more to the story that we should know to make an educated guess?

Is the compressor exposed to checmicals?

Has the motor been checked by a proper electrician? Does the motor work when the belt is taken off?

Do you think it is the compressore ceased or the motor stalled?

More input needed?

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lyn
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#4

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 9:05 AM

Have your electrical service checked.
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SolarEagle
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#5

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 9:07 AM

You must first determine the reason it is stopping, is it tripping the breaker, is it cutting off via safety control, if so which one....This is just basic troubleshooting...There is usually operational log kept on equipment like this, I would check the log to see any trends developing....

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Kilowatt0
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#6

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 12:14 PM

PWSlack isn't around at the moment, but I feel sure he would give you this advice:

Well, the simplest thing would be to use one of these

to contact the equipment's manufacturer directly if, indeed, the information were not already actually stated in the user manual that was originally supplied with it.

Edit: Check the troubleshooting section of the manual.

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gsurareddy
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#7

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/08/2013 10:41 PM

Dear Mr Dinesh,

1,Compressor may stop because of Over current Motor.

2.Oil pressure(LOW)

3.Water pressure low.

4.Flow of water may be less.

Please indicate the parametres before it stops.

You please acertain the stoppage is due to mechanica lor electrical

We will give solution.

Regards

G.Surareddy
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dinesh bagal
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#8
In reply to #7

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/09/2013 12:51 AM

thank you sir,

according to compressor manufacturer manual

1 oil presure ,water flow&presure ,current is also ok

2.oil pressure switch is working properly

regards
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PWSlack
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#9

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/09/2013 4:19 AM

Well, no-one can see it from here. Isn't there a Maintenance Technician available - someone with sufficient skills to read the manual, to investigate, and to diagnose and correct the fault locally? Would a phone call to the compressor manufacturer precipitate a site visit by such a person from that organisation, perhaps?

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IdeaSmith
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#13
In reply to #9

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/10/2013 2:32 AM

Not sure where you come from? I can see a leak at the underside-brass-O-ring-connector triggering the low-pressure-OFF-switch!

See it?

Its right there!

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SHOCKHISCAN
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#10

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/09/2013 9:37 AM

Here is a good checklist to start with.

If the motor is stopping:

1. Loose or broken wire in control circuit.

2. Faulty or improperly adjusted control and/or protection device.

3. Mechanical overload.

4. Loss or partial loss of power.

5. Low or high oil pressure.

6. Low or high oil, water, or compressor head temperature.

7. Low or high water flow.

8. Corroded and/or dirty control circuit contact(s).

9. Inadvertent or intentional operation of the stop or E-Stop circuit.

10. If using a synchronous motor; Loss of synchronization.

11. Too much water entrained in the intake air.

12. Water leak(s) in the intercooler, cooling water jacket, cylinder head, and/or into the unloader control.

If the motor stays running but the compressor stops operating:

1. Faulty or improperly adjusted unloader circuit. (Mechanical and/or electrical)

2. Faulty or broken compressor valve(s) and/or bad valve seat(s).

3. Restricted air intake structure.

4. Bad intercooler.

5. Waterlogged compressor assembly from internal cooling water leaks.

If you do not know or understand all of the above, it is time to obtain and read the compressor operation philosophy and get a competent, trained compressor specialist on site from the factory or a reputable compressor service vendor.

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Spinco
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#11

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/09/2013 10:36 AM

What is the method of your control? Is it Start-Stop on low-high pressure or continuously running with valve un-loaders? What KW or HP size are you talking? Is there a continuous demand for the air or intermittent?

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pillay
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#12

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/09/2013 11:57 AM

If an operating compressor stops and resumes as normal than mechanically the compressor is fine.You must tell us what actually happened ,it could be anything the forum members have said but chances are more of electrical control related cause, was there a power dip, control cct interruption, water loss or of operator related flaws.
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Mukesh0861
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#14

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/12/2013 7:36 AM

by this time you might have gone through the check list of SHOCKHISCAN

But you said compressor "stop" not tripped then what type of suggestion are seeking for?

In water cooled compressor, pressure of water is important in term of diffrential because of flow need, but what were compressor parameters before it " stop" and what is the condition there-after.
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Jacob Klepatch
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#15

Re: Troubleshooting in Operation of Reciprocating Air Compressor

10/13/2013 5:53 AM

Dear Sir

Quite interesting !

You must to be "on the spot" when failure occurs

-Do they occur on some time interval?

-It looks that some part in the El. motor / compressor is overheating

(from my own experience in Mech. maintenance)

Good Luck
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Users who posted comments:

dinesh bagal (1); gsurareddy (1); IdeaSmith (2); Jacob Klepatch (1); Kilowatt0 (1); kramarat (2); lyn (1); Mukesh0861 (1); pillay (1); PWSlack (1); SHOCKHISCAN (1); SolarEagle (1); Spinco (1)

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