SHAKUN SHARMA

MODEL : ASPRO IODM 115-3-19

These are reciprocating
TYPE OFtype compressors.
COMPRESSOR

These are horizontal compressors.

The number of stages in these compressors are three.

 WORKING PRINCIPLE OF COMPRESSOR

Reciprocating compressors are positive displacement compressors.

There are three stages .

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Each stage consists of a cylinder in which there is a piston which

compresses the gas to a certain pressure. The pressure of the gas after
each stage increases while its volume decreases.
After compression in the 1st stage the gas passes through the intercooler
.Here it cools & passes to the next stage where it is again compressed to a
certain pressure.
In the same way the gas passes to the next stage through intercooler where
it gets compressed to the final pressure.
After the final pressure is achieved the gas passes through the after cooler
which reduces its temperature to ambient temperature.
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WORKING PRINCIPLE OF COMPRESSOR

Piston movement PV diagram

 Pt. 1 refers to the inlet pressure &

volume.
 After compression P increases to Pt
2 & volume decreases.
 From 2 to 3 the gas is discharged
through discharge valve. P remains
same but volume decreases.
 Piston moves from TDC to BDC
which reduces volume & increases
the Pressure to Pt 4.
NO. OF STAGES & COMPRESSION RATIOS

NO. OF STAGES THREE

COMPRESSION RATIO

1ST STAGE 3.0

2ND STAGE 2.5

3RD STAGE 1.9

P & I DIAGRAM
LUBRICATION CIRCUIT
VENT LINE
ACTUATION LINE
PRIORITY PANEL
MOTOR RATING & TYPE

 3 Phase Induction Motor

 Squirrel Cage Type
 Flame Proof

1200 SCMH

 Crompton Greaves
 162 KW/217 HP
 1000 RPM
 415 V
 180/230 AMP
 STARTING 624 AMP
COUPLING B/W MOTOR & COMP

 Belt drive

 V-Belt-08 Nos.

 V belt no. - SPC 3150

 PARAMETERS FOR EACH STAGE

STAGE PRESSURE TEMP INLET TEMP OIL

OUTLET DROPS
/MINUTE
Suction 10-18 amb temp 32/43
(16)
1st stage 30-58 60-100 80-160 3
(50) (43) (110)
2nd stage 80-140 60-100 80-160 1
(120) (53) (120)
3rd stage 200-250 60-100 80-160 1
(230) (38) (120)
Storage 200-250 10 > amb temp
(230)
Crank case oil 3-7 bar 35
(5.5-6)
 SAFETY RELIEF VALVES - SETTINGS

BLOW 1ST STAGE GAS 2ND STAGE 3RD STAGE GAS

DOWN OUTLET GAS OUTLET OUTLET
VESSEL
Make Delta Delta Delta Delta
Normal 18 35 110 255
oper range Bar Bar Bar Bar
Valve range 18-36 65-88 115-289 bar 115-289
Bar Bar Bar
Set point 20 60 150 280
Bar Bar Bar Bar
 SRV PRINCIPLE &WORKING

 Spring loaded PRV designed to relieve excess pressure & to reclose &
prevent the further flow of fluid after normal conditions have been
restored.
 Characterized by a rapid opening pop action .

BASIC OPERATION

 As the static pressure rises above the set pressure of the safety valve, the
disc will begin to lift off its seat.
 As soon as the spring starts to compress ,the spring force will increase,
Hence requiring further pressure to lift it.
 Once normal operating conditions are restored the valve is required to
close again. It will close as soon as set pressure is achieved.
SRV PRINCIPLE & WORKING contd….
SRV - CONSTRUCTION
SRV - OPERATION
 GAS DETECTOR

 Make : Det Tronics point watch

Model no. : PIR 9400
Type : Infra Red

 Specifications
 Input voltage : 24v dc
 Output : 4 – 20 ma

 Theory of operation
 IR detection is based on the ability of some gases to absorb IR radiation.
 It follows beer lambart principle which states

T=exp (-A*C*L)
T= transmittance of air , a =absorption coefficient of gas molecule ,
c=conc. Of gas=path length of the beam through the gas.
 GAS DETECTOR : WORKING

 Based on absorption of IR radiation at certain wavelengths as it passes

through a volume of gas.
 Devices using this technology have a light source & a light detector.
 The light detector measures the light intensity at 2 specific wavelengths
one at an absorption (reference) wavelength & one outside of the
absorption (active) wavelength.
 If a volume of gas passes b/w the sources & detector ,the amount of
light in the reference wavelength remains unchanged.
 The gas concentration is determined from the relative difference b/w the
2 signals.
 This signal is converted into required mA signal.
GAS DETECTOR WORKING DIAGRAM
 FLAME DETECTOR

 Make : Pyrotector-Notifier-Honeywell
 Model: 30-2021e-24
 Type : UV flame detectors

Specifications
 Operating voltage :24 v dc
 Current output
 ALARM: 100ma

General
 Responds highly to UV radiations given by all types of flames including
those produced by flammable liquids & gases.
 Does not respond to normal ambient light conditions such as sunlight,
incandescent or fluorescent lighting.
 It is a compact unitized package consisting of a detection tube,
encapsulated solid state electronic circuitry & a dry contact form –c
alarm relay.
 CONTINUED….

 In the event of an alarm ,the relay latches on& an alarm light is

illuminated for easy identification of the unit in alarm state. The relay is
reset by momentarily interrupting power to the unit.
 A 3 sec time delay is built into minimize false alarms caused by the
presence of sparks & lightening.

Theory of operation

 UV flame detectors operate with a Geiger Muller type tube that utilizes
an sensitive photo cathode within a fused silica envelope. When
exposed to UV radiation, the photo cathode emits electrons that ionize
the inert gas inside the tube. This initiates the current flow that
produces an alarm signal
 PRESSURE TRANSMITTER

Inlet gas 18.5 bar Cylinder lube oil 7 bar

1st stage outlet 55 bar Crankcase lue oil 7 bar

2nd stage outlet 120 bar

3rd stage outlet 250 bar

Priority panel inlet 250 bar

pressure
PRESSURE TRANSMITTER -DETAILS

MAKE :WIKA

INPUT : 24V DC

OUTPUT: 4-20 mA

RANGE: 0-400 BAR

 PRESSURE TRANSMITTER -WORKING
CONSISTS OF
 A strain gauge which senses the pressure of the fluid.
 A transmitter which converts this sensed data in a desired
signal as per our requirement.

BASIC OPERATION
 As the pressure increases the gauge in the strain gauge
experiences some deformation in its shape. This deformation
is sensed as strain.
 The strain gauge works on the basis of the relation b/w strain
& resistance.
 Strain is directly proportional to resistance.
 This resistance acts as a variable resistance of the Wheatstone
bridge circuit.
 PRESSURE GAUGES
NORMAL OPERATING INSTRUMENT MAKE
RANGE RANGE

Crankcase lube oil 5 BAR 0-15 BAR ASHER OFT FLUTTER

GAURD
Gas inlet bef reg 10-18 BAR 0-50 BAR DO
valve
Gas inlet bdt 10-18 BAR 0-50 BAR DO

1st stage outlet 55 BAR 0-120 BAR DO

2nd stage outlet 130 BAR 0-250 BAR DO

3rd stage outlet 255 BAR 0-350 BAR DO

Priority panel DO
control
De pressurizing DO
valve
PRESSURE GAUGE DETAILS
 PRESSURE GAUGE WORKING

There is a c shaped bourdon tube linked to a

arrangement which is linked to pointer.

As the pressure increases the tube expands & changes its
shape.

This deformation results in the movement of the whole

link.

The deformation in the link gives a deformation in the

pointer which shows the current pressure.
 TEMPERATURE GAUGES/
THERMOMETERS
MAKE NOR IR

1ST STAGE GAS INLET Ashcroft 20-40 0-100

1ST STAGE CYL GAS OUTLET Ashcroft 100-150 0-200

1ST STAGE COOLER GAS Ashcroft 45-55 0-100

OUTLET
2ND STAGE CYL GAS OUTLET Ashcroft 100-150 0-200

2ND STAGE COOLER GAS Ashcroft 45-55 0-100

OUTLET
3RD STAGE CYL GAS OUTLET Ashcroft 100-150 0-200

3RD STAGE COOLER GAS Ashcroft 45-55 0-100

OUTLET
 TEMPERATURE GAUGE
 A device used to indicate the temperature of an item being
monitored.

 The bimetallic element consists of 2 strips of different thermal

expansion coefficients , inseparably joined together.

 This strip is spirally or helically wound with one end fixed to the
body of the thermometer, & the other attached to the axis of a
pointer.

 Measurement of temperature is made with bimetallic strip such as to

rotate the pointer.

 This rotation is indicated on a dial.

 TEMPERATURE TRANSMITTER-SETTING

SR.NO. TEMPERATURE TRANSMITTER MAKE RANGE

1 1st stage cylinder gas inlet Actuatys 100-170

1st stage cylinder gas outlet Actuatys

2 100-170

3 2nd stage cylinder gas outlet Actuatys 100-170

Actuatys
4 3rd stage cylinder gas outlet 100-170

Actuatys
5 Lube oil temperature 50-60
 TEMPERATURE TRANSMITTERS

Temperature transmitter work on the principle of Wheatstone

bridge.

ELEMENTS
 1. Probe
 2. RTD (Resistance Temperature Detector)
 3. Transmitter

 Probe senses the temperature of the fluid.

 Passes this to the resistance wire (platinum) which also heats up.
 This heating increases the resistance of the wire.
 This change in resistance acts as a variable resistance in
Wheatstone bridge which gives output as required in amperes.
WHEATSTONE BRIDGE DIAGRAM

R1
R2

RTD
R3
 What is a Flow meter?

A Micro Motion Coriolis flow meter consists of a

sensor, a transmitter and, in many cases,
peripheral devices.
Sensors detect flow rate, density and
temperature.
Transmitters provide sensor information as
outputs, acting like the brain of the system to
provide a display, basic menu access, and outputs
to interface with other systems.
Peripherals provide monitoring, alarm or
additional functionality, such as batch control and
enhanced density functions. 
OVERVIEW

A Micro Motion Coriolis curved

tube sensor includes:

Flow Tubes
Drive Coil and Magnet
Pickoff Coil and Magnet
RTD
Process Connection
Flow Splitter
Core Processor
Case
Flow Operating Principle:- Signal Generation

Micro Motion magnet and coil assemblies

(called pick-offs) are mounted on the
opposing flow tubes. Pickoff coils are
mounted on the side legs of one flow tube,
and magnets are mounted on the side legs
of the opposing flow tube.
Each coil moves through the uniform
magnetic field of the adjacent magnet.
The voltage generated from each pickoff
coil creates a sine wave. Because the
magnets are mounted on one tube, and
the coils on the opposing tube, the sine
waves generated represent the motion of
one tube relative to the other.
                                 
 
As a result of the twist in the flow tubes, the sine waves generated by the
pickoffs are now out of phase with each other because the inlet legs are
lagging behind the outlet legs.
The time delay between the two sine waves is measured in microseconds,
and is called Delta-T. Delta-T is always directly proportional to the mass
flow rate – the greater the Delta-T created by the Coriolis force, the greater
the mass flow rate.
Delta-T is a function of both the phase difference and the frequency of the
sine wave signals.

 
                                  
Flow Operating Principle:— Flow Calibration Factor

The flow calibration factor format consists of 10 characters, including two

decimal points. An example flow calibration factor for a Micro Motion ELITE
sensor would be: 4.27454.75
The components of the flow calibration factor are:
The first five digits (4.2745) are the proportionality constant.
Each sensor has a unique calibration factor.
This calibration factor, multiplied by a Delta-T measured in micro seconds,
yields mass flow rate in grams/sec. 
This mass flow rate is then converted into the desired units by the transmitter.
Example:
Given 5 microseconds Delta-T
5 X 4.2745 = 21.3725 grams/sec flow rate
The last three digits (4.75) are a temperature coefficient for the sensor
tube material.
This coefficient compensates for the effect of temperature on tube stiffness.
It is expressed in terms of a percent change in the proportionality constant per
100°C.
 
Micro Motion Transmitters: Field Mount
(Model 2700)
SOLENOID VALVE

MAKE : PARKAR

MODEL : 136 SERIES

INPUT :24 VDC

COIL TYPE :ZB 14

 SOLENOID VALVE - GENERAL

 Device for interrupting or diverting the flow of fluids or

gases in pipe work.
 Combination of three basic elements:
 Electromagnet consisting of a solenoid(winding) & a
magnetic yoke (magnetic armature)
 Movable plunger or diaphragm.

 Valve body with an orifice ;opened or closed by plunger

or diaphragm to enable or prevent flow of the medium.
SOLENOID VALVE-OPERATION
A is inlet for fluid.
F is outlet for fluid.
Diaphragm is closed in 1st
fig.
This is no flow condition.
When the coil is
energized :
The diaphragm is
uplifted.
Flow takes place through
A-F.
ACTUATOR

MAKE : PARKAR

MODEL NO.:62AC-3

AC SERIES MEAN

SPRING RETURN
ACTUATORS

ROTATION 90
DEGREES
ACTUATOR - CONSTRUCTION

CONSTRUCTION

 Consists
 Body in which whole system
is enclosed.
 Stem or spindle which is
geared & is coupled to the
pistons & coupling of valve.
 The pistons which move the
stem with a geared
arrangement.
 Springs which move the
pistons back to their original
position.
 ACTUATOR -WORKING

The air enters the inlet port of the actuator.

It falls on the geared arrangement of pistons & stem.
The pistons move outwards thereby compressing the
springs.
The stem rotates due to this pressure & the ball valve
opens. The rotation is 90 degrees.
When the solenoid valve closes, the air supply to
actuator also stops.
The springs which were compressed due to the air
pressure now push the pistons to its original position.
This further rotates the stem by 90 degrees.
Hence the valve again closes.
VIBRATION SWITCH

 MAKE : MURPHY

 MODEL: VS2 SERIES

 BASE MOUNT

 MAGNETIC LATCHING
FEATURE

 LEAF TYPE SPDT,DOUBLE

MAKE CONTACTS USED FOR
SHUTDOWN/ALARM
VIBRATION SWITCH-OPERATION

Gap b/w magnet &

reset push button
As there is shock or
vibration, the magnet
moves towards the
latch.
This closes the circuit &
trips the machine.
Initially it can be NO
or NC.
TYPE OF INTERCOOLER & AFTERCOOLER

Cross flow air cooler

 An axial fan is mounted on the top of compressor.
 Air intake space is provided on both fixed doors of the
compressor.
 As the fan rotates, it sucks air through these doors.
 Due to which the air is thrown upwards.
 This air while moving upwards passes through the gas
tubing.
 Hence the gas is cooled with the help of fan.
TYPE OF INTER COOLER & AFTER COOLER
VENTILATION,COOLING FAN & MOTOR

 Cooling fan  Motor

 Axial type fan  11 KW

 14.7 HP
 960 RPM
PREVENTIVE MAINTENANCE
SCHEDULE
I
 500 HRLY

Crank case oil change.

Oil filter cartridge replacement.
Crankcase cleaning.
To check proper lubrication.
Tightness test-gas leakages.
To check tripping systems.
 2500 HRLY

Cylinder lubrication sight glasses cleaning.

Gas inlet filter cleaning
Cleaning & inspection of electrical panel.
Electric motor bearing greasing
To check drain systems.
To check tripping systems
To check calibration of vibration sensor
 5000 HRLY

Inlet valve diaphragm replacement

De pressurizing valve diaphragm replacement
Coalescent filter cartridge replacement
To check pulley alignment & belt tightening
Inlet/outlet valves replacement
Valve gaskets & o ring replacement
Last stage NRV replacement
Piston rod nuts retightening
If necessary, SRV replacement.
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THANK YOU
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