Rotary blowers

8/18/2019 Rotary blowers

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CONTENTS

MESSAGE

INTRODUCITON

PAGE NO.

(i)

(ii)

-:::::::n'mmr

1.1 General

1.2 Twin LobeCompressors

1.2.1 Typeof KayTwin Lobe Compressors

1.2.2 Principalsof Operations

1.2.3 CompressorAccessories

1.2.4 Installation

1.2.5 Checklistafter installation of the Compressor

1.2.6 Start upchecklist.

1

1

1

2

3

3

5

5

2.1 Preventivemaintenance 7

3.1 Lubrication 9

4.1 TroubleShooting

4.1.1 AbnormalSound

4.1.2 Overheatingof Compressors

4.1.3 LowVolumeat delivery end

4.1.4 Low Pressureat delivery end

4.1.5 ExcessPowerconsumption

4.1.6 Seizure

4.1.7 OilLeakage

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11

11

11

12

12

12

12

5.1 Crosssectional drawing along with spare parts list for Twin LobeCompressorwith

both sideoil lubrication arrangement.

5.2 Crosssectional drawing along with spare parts list for Twin LobeCompressorwith

one sideoil and other sidegrease lubrication arrangement.

5.3 Crosssectional drawing along with spare parts list for Twin LobeCompressor having

bearing at 5 different location with both side oil lubrication

5.4 Crosssecitonal drawing along with spare parts li'Stfor Twin Lobegas pump

5.5 Formatfor demanding the sparesfrom KayInternational Limited

5.6 Formatfor offer request for annual maintenance contract

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14

15

16

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Dear KayCustomer,

Thanks you for buying a Kay Positive

Displacement Rotary Twin Lobe Compressor

(Roots Blower). We believe that you have

boughtthe best.

Kay International Limited has ISO 9001

certificationfor Marketing&Sales,Development

& Productionof Twin LobeCompressors(Roots

Blowers). Eachcomponent of the Kay blower

undergoesstringent quality control checksto

ensurean international standard end product.

MESSAGE

This installation, Operation & Maintenance Manual contains information about your new equipment & Its

operating & service requirements. Pleasetake a few minutes to read it carefully.

If, for any reason, any of our products do not meet your performance expectations, we would like to hear from

you. At Kay we believe that our sales force is you, our customer, & we want you to be satisfied.

. .Weappreciateyour purchaseof a Kayproduct & look forward to providing you prompt after-sales-service &

cateringto your future equipment needs:

Yours truly,

Sd.xxxxK. L. Arora

Chairman Cum Managing Director

(i)

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INTRODUCTION

KayRotaryTwin Lobe Compressors(Roots Blowers) are designed,

manufactured & provided maintenanceaccordingto ISO 9001. KAY

is dedicated to quality, through excellence of their people and

performance of their production equipment.

Each component that goes into a KAYcompressor undergoes stringent

quality control before being finally fitted. Also, all the rotating parts

are dynamically balanced for smooth running and lower bearing loads.

All manufactured KAY compressors are tested on test benches

according to BS: 1571, Part - II, where the load applied is the same

as in actual service conditions (required by client). Each compressor

duly painted and packed in wooden boxes is ready for shipment to

required destination.

(ii)


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SECTION-l

.1 GENERAL:-

Compressorfitting is a skilled work and should be undertaken only by competant fitters. It is important that the entire

ontents.ofthis manual should be read and understood before carrying out anywork on a compressor.

Maintenancework on a compressoris actually dangerous, and.all reasonablemeasuresshould be taken to safeguard

hose engaged in such work. It is especially important that before any work isstartedstopthe machine.

.2 TWINLOBECOMPRESSOR:-

.2.1 Type of KayTwin LobeCompressors;

. Air CooledCompressor

. Water CooledCompressor

. GasPump

Air Cooled Compressor: The body of this type of compressors cooled by atmospheric air. The CGmpressor body is provided

with fins around it. Heat produced in body is carried to fins and

rom here it is taken away by atmospheric air. These type of

ompressor are suitable for operation up to the pressure of 7000

MMWG.

Water Cooled Compressor: This type of compressor is

providedwith water coolingarrangement. The compressorbodys manufacturedwith water jackets around it. The fresh water is

circulated and the heat produced in body is carried away with

water. These type of compressor are suitable for operation of

above7000MMWGPressure.

Gas Pump: Kay Gas Pump are designed for providing trouble

ree operation with hazardous as well as Non-Hazardous gases.

These pumps have a special sealing arrangement with stuffing

box. As per specific requirements the Kay Gas Pumps can also

be provided with Mechanical Seals in addition to the stuffing box

sealing arrangement.


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1.2.2 Principle of Operation:

'KAY'Rotary TwinLobe Compressorfollows the well establilshedprincipleof the Roots-typemachine.Operation is both

simple and effective. Twin impellers, mounted on paralleled shafts and contained within a casing, rotate in opposite

directions.

The shape of the impellers (Fig. 1.2) is such that a small accurately gauged clearance is maintained at all times between

the impellers and casing (See Fig. 1.3). As they rotate, air is drawn into the space between the impellers and the casing,

where it is trapped as the tip of the impellers passes the edge of the inlet opening (See Gig. 1.1).

Continuing its rotation, the opposite tip of the impeller passes the edge of the outlet opening and the trapped air is

pushed through the outlet into the air line. This action is repeated twice for each revolution of an impeller, or four times

for each revolution of the drive shaft. The volume of air displaced by one revolution of the drive shaft for each size of

compressor has been calculated, and the amount of air moved at any given speed and pressure is known. This makes

it simple to select the speed at which the compressor should operate to supply the required volume of air.

(A) (B)

(C) (D)

Fig 1.1

Air Inlet

.."I:I!....u1;;:5

Centre Clearance

Fig 1.2 Fig 1.3

.."I:I!....u:!'50

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1.2.3 COMPRESSORACCESSORIES:-Refer Fig. 1.4

L Suction Filter :- The filtersafe guards the compressor against dust and foreign particles. The dust ifallowed

to enter inside the compressor willget deposited on casing inner wall and on lobes. This willcause to decrease the

clearances and lead to seizure of the rotating lobes. Alsowhen any foreign object is sucked inside it willdamage the

machine. It is therefore very-very essential to use the filter inthe system.

II. Suction &.Discharge Silencer:- The Silenceris basicallyused to mufflethe noise created by machine. For

this purpose one silenceris fitted at suction end and another is on deliveryend. Bothsilencers are so designed that they

reduce the noise levelcreated insidethe compressor to prescribed limiti.e. measured as 90 db at 1 meter distance from

rear of the compressor.

m Pressure Gauge :- Pressure guage is an instrument to measure the pressure delivered by compressor at

dischargeend.

IV. Safety Valve:- The safety valve is a devicewhichis fitted in down line of the compressor. It isto safe guard

the system from any abnormal rise of the pressure. This happens because of any kindof blockage in the down line. If

there is a blockage in down linethe pressure willrise tremendously because the compressor is positivedisplacement

type. The excessivepressure may cause the pipelineto burst or lead to machine failure. Therefore, the safety valve is

a very criticalitem as it safe guards the system from any undesirable higher pressure.

The valveis adjusted to get operated when the pressure rises beyond the safe limit.The excess pressure is released to

the atmosphereor backto the suctionline.The upperlimitof pressureisset withthe help ofweightplates.

V. Non Return Valve(NRV):- Theequipmentpermitsthe flowoffluidinone directiononly,whenfittedindown

line itwillallow the flow from compressor to discharge point, but isolate the compressor side at the time of shut down.

1.2.4 INSTALLATION

Placethe compressor on a concrete or equallysubstantial levelfoundation with the feet supported evenly on the base

frame. The perfect level can be acquired by inserting the appropriate metallic shim between the base frame and

compressor legs, this willprevent distortion of the casing when tightening down. The foundation bolts should be grouted

in and allowed to set before the compressor is tightened down.

If the compressor is mounted on a base plate together with the motor, ensure that the compressor casing is not

distorted when the foundation bolts are tightened. There should be even tightening (even torque) of all mounting points.

If the Compressor is direct coupled to the prime mover, the flexible coupling must be accurately aligned with an even

gap between the faces. The axis of the coupling must be lined up exactly in both horizontal and vertical directions. When

the drive to compressor is to be given through v-belts then:-

(a) The Compressor and motor must be horizontal and the axis of compressor pulley shaft and electric motor shaft

should be exactly in parallel line.

(b) The belt pulleys are always to be on the shaft in such a way that the belt pull is near to the machine.

(c) V-belts are tightened in such a way that v-belts are able to be pressed by hand at mid of distance between two

pulleys. Too much tightening of belts will be overloading the motor and torque load on the drive shaft of

compressor. Too loose belts will cause the slippage of v-belts over pulleys. This will in-turn burn and damage

the belts.

Note: Ifthe pulleyor coupling'isnotof thetaper bushtype, itmustbe pressedonto the shaftto avoiddamageto the

locatingbearing.Under no circumstances should a hammer be used to fit the coupling or pulley.The pulley

should be fitted as close as possible to the drive shaft bearing cover.

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~ .

GENERALARRANGEMENTOF TWIN LOBECOMPRESSOR WITH ACCESSORIES IN THESYSTEM:

2

+/1

+-

ATMOSPHERIC AIR

i

+-

/ 4

~

\ / 7

(Fig.i.4)

4

DESCRIPTIONOF PARTS Q1YWITH EACHBLOWER,

1. SUCTION FILTER iNO.

2. SUCTIONFILTER iNO.

3. TWIN LOBEAIR COMPRESSOR iNO.

4. DISCHARESILENCER iNO.

5. SAFETYVALVE(DEADWEIGHT TYPE) iNO.

6. PRESSUREGAUGE iNO.

7. NON-RETURN VALVE iNO.


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Pipework

It is essential that pipe connection should match up to the compressor flanges without strain and that the pipework is

adequately supported. Otherwise the compressor casing might be distored. This could cause contact between the

impellersand the casing with the result that the compressor willeventually seize. Allpipe lines should be throughly

cleaned internallybefore being connected to the compressor inlet& outlet. Also,the blower must be inspected for any

loose foreignobject insidethe body before givingpipe connections to blower.

Caution: Size reduction of the pipe in suction & delivery line and direction change by putting the sharp bend should be

avoided. Incase of unavoidable circumstances it should be done after proper calculation. This willavoid any back

pressure to the compressor and shall give you the trouble free operation. Do not give immediate bend just after NRV.This may restrict the movement of the NRVfor itsfullrange of operation.

1.2.5. Check list after installation of the Compressor:

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

Checkthe fixationof the Compressor on the base frame.

The Compressor must run freely by hand.

Checkfor allconnection are done;

(a) Connectionto the process.

(b) Water feed pipe (ifthe Compressor iswater cooled). Checkwater circulationas per flowmark on water

pipeline.

(c) Electricalconnectionto electricalboxof the motor.

Checkthe data (RPM,Frequency,Voltage)shown on the name plate of electric motor (before puttingv-belts/

coupling)

Check the motor shaft/motor pulley rotation as marked.

Check the alignment and tension of belts.

Water and electricity supply, available.

Availability of recommended oil on site.

Check the fitment of safety valve, pressure gauge and N.R.Vin the system.

Checkthe N.R.Visfitted in correct direction and has free operation.

Checkthe suppliedweight plates placed on safety valve and small boltfitted on top of safety valvecap.

Checkthe inlet and outlet pipes are wellsupported to avoid any stress on Compressor flanges.

1.2.6 StartupCheckList

The following procedureis recommended whren a compressor is to be started up for the firsttime or when a machine

isputto workagainafter majorerepairswhichhavenecessiateditsremovalfromits foundation.

1. Inspectthe interiorofthe compressorand allpipingleadto andfrom itto ensure that allforeignmatter hasbeen removed.

2. Check for leveland alignment of drive. Check belt tension. Incorrect alignment and/or tension can cause excessive

wear on bearings, V-Belts or coupling bushes.

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-"" "" .."o. --

Checkforcorrect lubrication(Refere Section-3for specifiedlubricant).It is essential that the oillevelin the gear

case should be up to the red dot mark at the center of oilindicatorwhen the compressor is not in operation.

Note : Toomuch oilwillcause over heating excessive noise and oilleakage through breather plug in the gear case.

Too littleoilwillresult inthe rapid failure of the gears/bearings due to their running dry.

3.

4. Pump the recommended grease with grease gun through the grease nipple on both drive and driven shaft

bearings untilfresh grease appears fromthe grease drain plug (Refer the figure at Annexure - II).

s. Rotate the impellersby hand to ensure that there are no tight spots.

6. 'Flilck'the motortwo or three times by putting the starter in and out quicklyto check the directionof rotation,

and also to ensure that the impellersturn freely.

7. Startthe compressorand run for at least fifteenminutesunderno loadconditions.Duringthis periodkeep

checking at various points on the compressor casing and the bearing housing for signs of heating. The compressor

should remain cool throughout this period.

8. Apply the pressure load gradually over a period of say, thirty minutes to one hour. Whilst under full load, keep

the machine under observation.

9. Frequent checking should be carried out for any abnormality during the first day in service.

Note : In the event of suspected faulty operation, shut down the compressor immediately and investigate for possible

causes. If this is not done, serious damage may result in a very short time.

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Rotary blowers