Compresses Air Installation

COMPRESSED AIR INSTALLATION FOR SPINNING UNIT
Oil and moisture free compressed air is the primary requirement of a spinning
unit. Approximately all the machines require the continuous supply of
compressed air for the proper working of the pneumatics. Winding department
is the biggest consumer of the compressed air therefore in most of the units
the maintenance and overseeing of the installation is done by technical staff of
the winding department. The consumption of compressed air is done at
following positions in a winding head.
1- Optional pneumatic hairiness reduction devices are the largest consumers
of compressed air because they require a continuous supply of compressed
air to create a hairiness-wrapping vortex.
2- Pneumatic or aqua splicers are the second largest consumers of
compressed air. Splicers consume air for untwisting and re-twisting
operations of yarn.
3- Cleaning jets in 3rd generation winders also use air blasts to remove yarn
residuals from the machines.
4- Pneumatic counter-weighting and instant lifting cylinder also consumes
compressed air in lifting the package once each cycle.
5- Compressed air is also consumed in operating pneumatics of the machine
through solenoid valves.
Supply of the compressed air is given to the compressed air regulator and
distributor from where it is supplied to wrest of the machine. Regulator is also
fitted with trip valve, which stops the machine in an event of low pressure or
absence of compressed air. New winders require 6.5 to 7 bars of constant
pressure of compressed air for proper working. Almost all the elements of the
machine are given 6.5-7 bar pressure but counter-weighting cylinder is given
regulated pressure according to the level of package hardness required. For
normal weaving packages it is kept 2 bars.
Compressed air installation consists of following separate units.
1- Compressors
2- Water separators (which remove the condensed water from the air by the
action of gravity).
3- Oil filters
4- Dryers
5- Storage tanks to provide a steady supply of compressed air to the
department.
6- Trip switches or pressure switches.
Page 1 of 3
COMPRESSORS
Compressors are the main parts of the installation. Their function is to
compress the atmospheric air up to a defined pressure (normally 6 - 7.5 bars
are required for a spinning unit and compressors work on this much pressure).
Capacity of a compressor can be determined by the amount of air it produces
in L/min. every compressor consists of following main parts:
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Air end to compress the air with compressor oil

Intake valve
Air filter
Oil separation tank.
Heat exchanger for oil.
By pass valve
Oil filter
Compressed air after cooler
Output pressure switch ( if more than one compressors are present they are
controlled by one pressure switch)
Electrical connection
Intake
valve
Air
filter
Direction of air flow
AIR
END
Oil
separation
Tank
Oil circuit
Compressed
air after
cooler
Pressure
switch
Oil filter
Heat exchanger
By pass valve
SCHEMATIC DIAGRAM OF A COMPRESSOR
Working
Page 2 of 3
1- Air end takes the atmospheric air through intake valve and air filter. Oil is
used for lubrication and to remove the heat of compression from the
compressed air. This air is continuously pumped into the main storage tank
of the installation until a specified unload pressure is reached.
2- Oil is separated for reuse by the gravitational oil separation tanks. If the
temperature of the oil is within limits it is pumped back to air end as it is but
if its temperature rises it is sent to the air end via heat exchanger. Heat
exchangers may be air-cooled or water-cooled.
3- When the specified unload pressure of the air is reached the output
pressure switch closes the intake valves of all the compressors of the
installation bringing them to idle running. The purpose of idle running is to
give some rest to the air end so that heated oil can cycle many times
through the heat exchanger and drop its temperature.
For close monitoring of the compressors following parameters must be
carefully noted time to time.
1- Load time (the time for which the compressors intake valve remains open
for air and compressor pumps air to the main storage tank). Load time is
dependent upon the load pressure setting at the pressure switch.
2- Unload time ( Idle running time)
3- Load Temperature (Temperature of the oil when intake valve just opens)
4- Unload temperature (Temperature of the oil when intake valve just closes
for idle running or oil cooling cycle). It should not exceed 110 0C.
5- Load %age = [Load time / (Load time + Unload Time)] x 100 (must be <
90%).
Page 3 of 3

Compresses Air Installation

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Compresses Air Installation

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COMPRESSED AIR INSTALLATION FOR SPINNING UNIT

Air end to compress the air with compressor oil

Direction of air flow

SCHEMATIC DIAGRAM OF A COMPRESSOR

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