Air Compressor

How to Repair an Air Compressor, It’s Uses and Applications

How to repair an air compressor?

If the air compressor starts normally at the beginning of the day but then stops and makes a loud hum on further attempts, the “unloader” valve is defective. If you want to repair your then follow the below-given steps to repair it:

  • Firstly, find the valve position on the compressor. This valve is usually located below the pressure switch. After finding this component, you can determine the type of unloader valve that can be used to replace it.
  • After finding the defective valve and ordering a replacement part, the next step is to repair the compressor.
  • For safety purposes, the device must be switched off completely before starting the repairing process.
  • Next, loosen the drain valve under the compression tank. When the drain valve is released, the air compressor will be depressurized and can easily repair.
  • As soon as the air compressor is switched off and safely decompressed, the replacement process can be carried out. After decompressing, remove all cables connected with the old valve. You can then install a new “unloader” valve. When installing a new valve, then secure it tightly on its position.
  • After the completion of the installation procedure, turn on the equipment to check the repair of your compressor and check the valve’s performance.

Repair Air Compressor leakage:

If your compressors are not delivering air properly and you feel leakage of fittings then follow the below-given steps to repair it:

  • For the confirmation of leakage, make a solution of soap water and pour it on the fittings. If bubbles are coming out from the fitting, it means the fitting is leaked.
  • Turn off the air compressor
  • Depressurized the air tank
  • Emilite the fitting from where bubbles were produced.
  • Get the Teflon’s plumber tape and wrap it around the leaking fitting.
  • After this process, turn on the equipment and check performance.

How to use an Air Compressor?

The operator of the air compressors needs basic skills and training to operate them. First, read the instruction manual and make a maintenance list according to the instructions of the manufacturer. Then, make a chart for the use of your air compressor and operate it according to that.

Following are the basic steps that will be helpful to use an air compressor.

  1. Ensure safe operation
  2. Tight the loose parts
  3. Wear PPE
  4. Check the oil level of the fuel pump
  5. Connect pneumatic tools
  6. Expel the moisture from the air tank
  7. Inspect oil level in the tank
  8. Fill air tank
  9. Regulate the check valve
  10. Ensure more checks
1) Make Sure Safe Operation

It is very important that do not immerse the electrical components of the air compressor in water and keep them away from the water. Doing so could cause an electric shock.

Typically, the operator keeps the electric discharge valve away from wet surfaces. If pneumatic air compressors are activated, then oil changes and refueling can raise safety concerns. And also, use the machine while it cools down.

Also, do not neglect to plug the compressors into an electrical outlet equipped with a lightning rod. The fire extinguisher should also be placed in an important location near the equipment.

The inlet pressure should not exceed 90 PSI unless the internal pressure of the compressors is high. Because this higher pressure of the air may affect the functioning of the air tools. Therefore, it is very important to understand the air needs of air distribution systems, dryers, tools, and other equipment.

2) Tight the losing parts

Check and tighten loose parts in fittings and connectors because they may lose due to vibration of the compression system. Generally, vibration loosens nuts, screws, and bolts. Therefore, take a look at these parts and tighten them if they are loose.

3) Wear PPE (Personal Protective Equipment)

Always wear personal protective equipment (PPE) before operating the air compressor. Before operating the equipment, the operator should boot, goggles, hard hats, and wear gloves.

In the event of an accident at the workplace, PPEs may prevent the worker from any severe injury. Proper PPEs also reduce the risk of environmental damage.

4) Check the oil level of the Air Compressor’s Pump

It is very important to check the oil level of the oil-lubricated compressors before operating them. This will help you in the prevention of equipment damage. In contrast, if you have an oil-free air compressor, you don’t need to perform a regular lubrication inspection. Make sure the power is turned off before eliminating the oil filter plug.

5) Connect Pneumatic Tools

When using the quick-connect accessory, pull and release the spring collar and securely connect it to the compressor. Make sure the pneumatic tools are properly connected to the compressor’s air hose. Ensure that there should be no leakage of air from the pneumatic tool’s inlet valve.

6) Drain the moisture from Air Tanks

As the tank gets moist from the atmosphere, the compression holds the vapors. This situation often occurs with air compressors in humid weather. Therefore, it is essential to drain the moisture from the air tank for the proper working of the equipment.

After completing work, the operator can unlock the drain valve under the air tank to drain the moisturized air. It is necessary to release the air pressure in the tank before releasing the water regularly.

7) Inspect Oil Level

Inspect and replace the lubricating oil of the compressor after each use. Because oil is very important for the piston of your equipment. This oil helps the piston to move forward and backward.

If you do not adequately lubricate the piston then it may damage. The manufacturer also recommends that the operator refuel the oil lubrication pump within 500-1000 operating hours.

8) Fill Air Tank

Almost all the compressors have a drain valve for the release of the air or gas. Therefore, make sure the drain valve of your air compressor. If it also has a drain valve, turn it off with a wrench before filling the air tank. After closing, Turn on the power. Instead of using the compressor right away, let the pump run for a few minutes.

Check the air pressure gauge to see if the compressor will automatically shut down when the air pressure reaches 115 PSI. The extreme operating pressure can fluctuate depending on the air compressor’s model. The maximum pressure rating for some DEWALT products is 150 PSI.

9) Regulate the Air Control Valve

You can use the pneumatic power of the air tools to customize the air valve regulator according to your requirements. Typically, turning the air control valve clockwise increases the air pressure. This control valve uses to stop, decrease, or increase the air or gas pressure.

Follow the manufacturer instructions in the product manual to understand the direction in which the control valve will increase air pressure. In addition, though, careful attention to the pressure gauge can provide the correct air pressure for the tool.

10) Ensure More Checks

The separator elements of the compressors can regulate excessive oil consumption. Therefore, the operator should continuously monitor the operation of the air or gas compressor. In addition, the separator element must change after the machine has been running for approximately 1,000 hours.

Applications of  Compressor

  1. It uses in the natural gas plant for gas processing purposes.
  2. Uses in petroleum refineries.
  3. Petroleum plants.
  4. The air compressor uses in the refrigerators to remove heat from refrigerant cycles.
  5. It uses in gas turbines.
  6. The jet engines also have compressors.
  7. They utilize in the diving cylinder to the compressor and provide gas for breathing purposes.
  8. Compressors use in heat pumps and first pistons.
  9. It uses in submarines.
  10. Compressor uses in oil refineries.
  11. They are used in steam turbines.

What is free air delivery in an air compressor?

Free air delivery is a volume of air that a compressor sucks in from the atmospherecompressed, and discharged into the receiver, tanks, pipes, or air house.

The concept of free air delivery is often used to compare the fluids handling capacity of the compressor. 

For example, if you want to calculate the fluid handling capacity of several compressors, you have to compare fluid delivery at the same level (i.e., under the same conditions (pressure and temperature)). Therefore, free air delivery is the amount of air supplied at the outlet but in inlet conditions

To compare multiple compressors, you can use the NPT as an input condition and calculate the free air supply for each compressor under those conditions. These compressors have more free air delivery and, therefore, will have maximum liquid handling capacity.

The V1 is the free air delivery of the compressor.

Why is a compressor used for the refrigeration cycle?

All practical power-consuming or power-producing devices work on a cycle. The refrigeration cycle consists of 4 processes (heat addition, heat rejection, compression, and expansion). After combining these processes, we get continuous work (cooling in this case). Therefore, a compressor is essential equipment for refrigeration and air conditioning units.

A compressor’s principal objective is to surge the temperature and pressure of refrigerants in the refrigeration cycle. A compressor has two objectives in the refrigeration cycle that are given below:

refrigeration

  • The first objective is to increase the pressure and temperature of the refrigerants to allow the flow of refrigerants in the system. Because without pressure difference, the refrigerant can’t flow in the system. It converts the wet or dry saturated vapor to the wet, dry saturated, or superheated vapor.
  • The second objective of the compressor is that it helps in liberating the heat gained in the evaporator to the atmosphere. Because at a lower temperature, the heat can’t be rejected to the atmosphere. Now when the pressure and temperature of the Refrigerant increase to a value greater than atmospheric temperature, the heat transfer takes place from the refrigerant to the atmosphere.

Thus, it liberates heat gained in the evaporator and also the heat gained in the compressor. Therefore, we use a compressor in the refrigeration.

We can also replace the compressor with some other device in some special type of units like in the Vapor Absorption Refrigeration System (VARS). But these types of systems are not very much used practically.

What is the difference between pump and compressor?

Compressor Pump
The compressor has compressible working fluids such as air or gas. The Pump has non-compressible working fluids such as liquids.
It Increases the potential energy by compressing the working fluid. It increases the kinetic energy of the working fluid, which further raises the pressure energy.
There is a change in volume from inlet to outlet. In pumps, there is no change of volume from inlet to outlet.
There must be a pressure change during working. The pressure change is not compulsory.
It has storage capability after compression. It doesn’t have storage capacity after pumping.
Compressors have more cost than pumps. It has a low cost.
It has High ΔP and Low Q. The pump has Low ΔP and High Q.

 

Credits; mechanicalboost.com

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