What is Compressor ?

• Introduction

        The compressor is a device used to circulate the refrigerant through the system.

• Type of compressors 

      1. Rotary

         Compressor of the rotary type are generally low capacity equipment, used normally in home  refrigerators and freezers and not used for air conditioning.

   

      2. Centrifugal Compressor

          These compressors revolve at high speed, and refrigerant is compressed by the application of centrifugal force. These compressor are normally used with refrigerants possessing higher speed volumes, which need lower compression ratios.

      3. Reciprocating Compressor

          A positive-displacement machine that uses a piston to compress a gas and deliver it at high pressure.

      4. Open Compressor

          One extremity of the crankshaft is drown out of the crankcase, due to which multiple drive can be used with the compressor.

      5. Hermetic Compressor

          These compressors are serviceable hermetic, in which motor and compressor are enclosed in the same housing, while the welded hermetic type has the compressor and motor sealed in a welded steel shell.

• List of application

       1. Rotary : Generally used to supply compressed air for larger industrial applications. They are best applied in applications that have a continuous air demand such as food packaging plants and automated manufacturing systems. In larger facilities, that may have only intermittent applications, the average usage among the many work stations will place a continuous demand on the compressor. 

         2. Centrifugal : used in a wide variety of applications in chemical plants, refineries, onshore and offshore gas lift and gas injection applications, gas gathering, and in the transmission and storage of natural gas. Centrifugal compressors have been used for outlet pressures as high as 70 MPa, thus overlapping with reciprocating compressors over a portion of the flow-rate/pressure domain.

         3. Open type : compressor only with shaft seal and external shaft for coupling connection to belt - or direct-drive using as electric motor or natural gas engine. These are largely used for ammonia refrigeration applications as hermetic designs.

         4. Hermetic : Widely used in refrigeration or air conditioning applications. They are found in household applications such a deep freezers, window air conditioners and kitchen refrigerators.

         5. Reciprocating : Generally used to move gas at increased pressure. The main elements of the compressor are one or more cylinders, and pistons which move within them, rather like in an internal combustion engine.

• Compressor maintenance concept 

Ambient - The surround atmosphere, or ambient, should always be keep free of debris and clean. The area needs to be well ventilated for proper cooling. When the machine cannot ventilate properly it will overheat and strain the compressor system.

Inlet Filter - The inlet filter functions as a silencer and requires regular inspection to make sure it is properly cleaned. If the filter is dirty it can increase the wear on components and lessen operating efficiency. If the intake begins to leak, system contamination can cause extensive damage.

Cooling Water - A proper supply of uncontaminated cooling with regulated temperature and pressure control provides an ideal condition for the operation of water cooled equipment
.
Gauges and Controls - To make sure your equipment is running at highest capacity make sure all gauges and instruments are working and properly calibrated. Moisture and other contaminants can affect the readings the instruments may put out.

Motor and Compressor - These are some of the most important air compressor parts of the machine, and must not go overlooked. If any unusual noises or vibrations are acknowledged immediately locate the cause and fix.

Lubrication - If an air compressor is not thoroughly lubricated parts will begin to break down and these repairs can be costly. Make sure to always use the proper weight and grade of oil specified by the manufacturer. To reduce varnish and sludge build up remember to keep the oil reservoir and component parts clean. This can be done with regular oil changes. When oil breaks down it thins out, lessening lubrication and increasing wear.

Maintenance - Setup a routine inspection checklist that will help everyone remember to check these items. If any issues are discovered take immediate action and replace, repair, or clean if necessary.

Losses - When the air compressor motor is off take the time to check the connections, valves, and lines. Leaks make the system work harder, which increases the electrical output of the machine.

Worn Parts - When parts become worn out they can cause imbalances, vibrations, and noises. Often the friction and loose components may be inaudible, so it is important to do periodic micrometer and seal tests. These test can help prolong the life of the machine.


Safety - Working with large machinery, electricity, and compressed air can be dangerous. When performing maintenance duties always remember to make sure the electrical supply is disconnected and locked out. The air compressor system should be completely relieved of all pressure before any maintenance begins.

https://www.youtube.com/watch?v=U-Zc2cft_ag





What is Valve ?

•  Introduction 

           Valve is a mechanical device, usually use in connection with a pressure-containing vessel to               completely stop or regulate fire.

• Application of valve       

1. Ball Valve  
   

              Flow and pressure control and shut off.
              Steam service.

        2.  Gate Valve

            Used for on-off applications.
            Gate valves are widely used for all types of applications and are suitable for both above-                      ground and underground installation.

       3.  Butterfly Valve

            Corrosive liquids at low temp and pressure.
            These valves are extensively used in large water transmission, distribution, and cooling                      water lines.

       4.  Pinch Valve

            Suited for the handling of slurries, liquids with large amounts.
            Major industries that use pinch valves are:
            Cement industry,
            Waste water industry,
            Chemical industry,
            Food industry,

• Classify type of valve

1. Ball Valve is a kind of valves using the ball as closing part, which mainly consist of valve body, valve seat, valve ball, valve stem and handle (or other actuating device).
2. Gate Valve used in steam systems have flexible wedges. The reason for using a flexible gate is to prevent binding of the gate within the valve when the valve is in the closed position.  
3. Butterfly Valve is a quarter-turn rotary motion valve, that is used to stop, regulate, and start the flow.
4. Pinch Valve are also used for slurries or processes with entrained solids, because the flexible rubber sleeve closes drop tight around solids.

• Characteristic of valve

1. Ball Valve
The most common design that is utilized features a ball that rotates between two circular seats which are usually made of some type of PTFE, co-polymer, or other resilient plastic material.
When this type of ball valve is in the open position, media flows through the opening in the ball, and when closed the flow is completely blocked. Ball valves are often used for On/Off service (isolation) and are suitable for Bi-Directional Flow.

 

2. Gate Valve
 Gate valve is the opening and closing body (valve plate) driven by the valve stem sealing surface for lifting movements of the valve can be connected or cut off the fluid channel. When the valve part of the open, the back of the gate vortex, easy to cause erosion and vibration of the gate, but also easy to damage the valve seat sealing surface, repair difficulties. Gate valve is usually applied to do not always open and close, but also to maintain the gate open or fully closed operating conditions. Not suitable for use as throttling or throttling. 

3. Butterfly Valve
 Has a disk that rotates about a central shaft or stem. When the valve is closed, the disk face is across the pipe and blocks the flow. Butterfly valve seat consist of a bonded resilient liner, a mechanically fastened resilient liner, an insert type of reinforced resilient liner, or an integral metal seat with an O-ring inserted around the edge of the disk. Both the full open and the throttled positions permit almost unrestricted flow.

4. Pinch Valve
Pinch valves are suitable for handling slurries and solids in suspension, avoiding contact with the valve mechanism and any contamination towards or from the environment. Generally, the pinch valve is limited to work at low pressures.

• Determine valve maintenance concept

1. Control Valve Selection

• Pressure drop during normal flowing conditions
• Pressure drop at shutoff
• Maximum permissible noise level
• Degrees of super heat or existence of flashing
• Inlet and outlet pipeline size and schedule
• Special tagging information required

 2. Control Valve Installation

• Always inspect your valve to make sure no damage occurred during shipping.
• Clean both the valve and the pipeline.
• Install the valve in the appropriate orientation. Many control valves can be installed either vertically or horizontally depending on the flow direction.
• Ensure piping has ample support and is properly aligned with the valve.
• Provide the valve with enough headroom to accommodate normal operation as well as be accessible for maintenance.

  https://www.youtube.com/watch?v=ocZD63hQIkY

What is Pump ?  

• Introduction 

         Irrigation pump lift water from an existing source such as surface or groundwater to high level

• Application of pumps

           Pumps are used through society for a variety of purposes. Early application include the use of the windmill or watermill to pump water. Today, the pump is used for irrigation, water supply, gasoline supply, air conditioning systems, refrigerator ,chemical movement ,sewage movement ,ect.

• Type of pumps

          # Gear Pump 

              

https://www.youtube.com/watch?v=c6gwU7IHtlo

        # Vane Pump
           

https://www.youtube.com/watch?v=L30JpM8Lv_A&list=RDQM1KNOb5Yotwk&index=1

                                         
        # Dual Vane Pump
           

        # Variable displacement vane pumps

            

• Pump maintenance concept

Poor maintenance can cause undue wear and tear of fast moving parts and premature failure of equipment. Such as premature failure or breakdown causes immense hardship to the consumers and staff and avoidable increase in repair cost. The shortcomings in maintenance can also result in increase I hydraulic and power losses and low efficiency. Inefficiency running of the pump increase burden of power cost. Important of preventive maintenance, therefore, need not be overstressed.

• Pump maintenance procedures

      Daily maintenance

l  Clean the pump , motor and other accessories

l  Check coupling bushes / rubber spider

l  Check stuffing box, gland etc

      Monthly maintenance

l  Check alignment of the pump and the drive. The pump and motor shall be decoupled while correcting alignment and both pump and motor shaft shall be pushed to either side to eliminate effect of end play in bearings

l  Clean oil lubricated bearing and replenish with fresh oil. If bearing are replaced/replenished to the correct quantity. An anti friction bearing should have its housing so packed with grease the void space in bearing housing should be between on third of half. A fully packed housing will overheat the bearing and will result in reduction of life of bearing.

l  Tighten the foundation bolts and holding down bolts of pump and motor mounting on base plate or frame

l  Clean vibration level with instrument if available, otherwise by observation

l  Clean indicator, other instrument and appurtenances in the pump house.

Conclusion

Pump:

i. centrifugal pump is a kind of machinery used for pumping water through the centrifugal movement.

ii. Positive displacement pumps will always be more efficient than centrifugal pimps due.

iii. As a conclusion, we had obtained a performance curve at 3 different speed of pump by available characteristic. The efficiency of pump have related to the losses mean energy during the process. This efficiency will be increase if less loss occur.

Valve:

i. The control valve is used in plant processes to regulate the rate of fluid flow as the position of the valve plug or disk is changed by force from different types or actuators available.

Compressor:

ii. The machine which takes in air or any other gas at low pressure and compresses it to high pressure are called compressors.