Slide 1

[Audio] Need to add the control system, pilot valves , and blow down valve. On pilot valve slide tell story about alyeska Go through old presentation to pull out slides Add some fun slides maybe pictures of Alaska Talk a little about my back ground How many of you have seen a machine in operation I would like to have an interactive discussion with questions and answers. Go over slides and go out to the machines and look at location and run a unit At lubrication system add varnished filter and just touch the lubricant..

[Audio] This is the Sullair compressor discharge system. Atmospheric air is drawn to the compressor unit through an air filter. Dust or large particulate matter is stopped at this point before entering the compressor unit. The inlet valve governs the amount of air to the compressor unit. Briefly, the inlet control system regulates the amount of air to the compressor unit according to service air demand. Atmospheric air is captured within the rotor cavities and the volume is reduced toward the discharge end. The air/fluid mixture exits the compressor unit through the discharge of the compressor. Located down line is the discharge temperature probe. The air/fluid mixture then goes through a flexible pipe coupling into the separator/sump tank. Here begins the first stage of fluid separation. The air/fluid mixture hits the far wall or top of the separator tank. Due to the velocity change, heavier droplets of fluid fall to the bottom of the tank. The air and fluid mist continues on to the separator element. Some of the fluid droplets form on the outside of the element and drop to the bottom of the sump tank. The remaining fluid forms on the inside of the element, and drops to the bottom of the element. This fluid is then drawn off the bottom of the element, by the fluid return line, and returned to the compressor unit. The minimum pressure valve located on the top of the sump tank is used to insure a minimum fluid pressure. The dry air in the separator element pushes against the spring-loaded piston in the minimum pressure valve. The spring tension is overcome and air flows to the terminal check valve and on the service line. To have a greater understanding of the components, we will discuss each component individually.

Capacity Control. Air End. Minimum Press./Check Valve.

[Audio] The air filter should be monitored very closely. A dirty or damaged element can pass particulate into the system. This dirt will then mix with the fluid and can plug filters, orifices and separators, as well as cause problems with mechanical valves in the compressor system. A completely plugged air filter will cause loss of capacity and possible filter collapse. All machines are equipped with air filter indicators or differential gauges are located on the instrument panel or the filter itself. These indicators will signal when there is too much restriction through the filter. At this time, the filter will need to be serviced. However, the filter should be checked regularly, regardless of the indicator of gauge reading. In most cases the heavy-duty filter is standard equipment. We do not recommend cleaning this element. It should be replaced on a regular basis, depending on the environment. It is necessary to use a heavy-duty filter in dirty environments. NOTE: Always remember that the quality of air coming into the unit will have a direct effect on the life of the compressor unit, separator, fluid filter and fluid..

[Audio] The Poppet inlet valve governs the amount of air to the compressor unit. Briefly, the inlet control system regulates the amount of air to the compressor unit according to service air demand. From 0- 100 PSI, the compressor will operate with all the control components inactive. The Poppet inlet valve is fully open and the compressor is operating at full rated capacity. The other control components will not come into play until the air demand decreases. As air demand decreases the Poppet inlet will receive a control signal and begin to modulate the inlet valve toward the closed position as indicated above..

Poppet Inlet.

[Audio] With the use of the Poppet style inlet valve several items in the discharge system have been eliminated. These would include the Sullicon Control which controls the position of the inlet valve, the Butterfly inlet valve which would regulate the amount of air being drawn into the compressor unit in conjunction with the Sullicon Control, the Discharge check valve which opens on startup allowing the air/fluid mixture to leave the compressor unit. On shutdown, back pressure will force the piston closed, restricting flow back into the compressor unit. The Oil Stop valve, that opens on startup allowing fluid flow to the injection port of the compressor unit and closes on shutdown stopping all fluid flow to the unit..

[Audio] The shaft seal, located on the input shaft serves two purposes. First, it retains the fluid within the compressor housing. Secondly, it prevents dirt from being drawn in around the shaft. The shaft seal can be a spring-loaded mechanical seal. The carbon member of the seal rotates against a stationary seat ring, with fluid injected over the seal faces. If the seal fluid orifice becomes restricted, causing a lack of fluid, the faces of the seal will run hot and dry, causing deterioration of the faces and possible seal leakage. Newer style air ends utilize a Teflon lip seal and a wear sleeve on the input shaft. Special tooling is required to remove and install this type of seal. It is important to note that the shaft seal is the only spare part, which may be purchased for the compressor unit. When ordering replacement shaft seals, always supply compressor unit part number and serial number, since we are using various seals for each application..

[Audio] This is what you are protecting by using quality fluid filters that are designed according to manufacturers specifications and adhere to strict performance testing..

[Audio] The air/fluid mixture leaving the compressor unit then overcomes a spring-loaded piston in the discharge check valve, and flows into the separator/sump tank. On shutdown, back pressure will force the piston closed, eliminating flow back into the compressor unit. If the piston does not close off the compressor discharge port on shutdown, back pressure will cause the rotors to turn in the opposite direction of rotation, forcing air and oil out of the compressor inlet. If fluid is observed flowing from the inlet on shutdown of a machine with a butterfly style inlet: Inspect the discharge check valve Inspect fluid stop valve - (will be discussed in the Cooling & Lubrication section).

[Audio] Immediately after passing through the discharge, the air fluid mixture reaches the discharge temperature probe. Presently there are two types of temperature sensing devices used. Standard gauge machines utilize a bi-metallic temperature switch, 24KT machines utilize a thermistor board and thermistor probes. Machines equipped with Supervisors utilize resistive temperature devices. All high temperature shutdown devices will shut the machine down at 235 F discharge..

[Audio] * Talk about the rtd is white sheathed and the thermistor is black sheathed. Each device will warn at 225 F and shutdown at 235 F.

[Audio] Immediately after passing through the discharge, the air fluid mixture reaches the discharge temperature probe. Presently there are two types of temperature sensing devices used. Standard gauge machines utilize a bi-metallic temperature switch, 24KT machines utilize a thermistor board and thermistor probes. Machines equipped with Supervisors utilize resistive temperature devices. All high temperature shutdown devices will shut the machine down at 235 F discharge..

[Audio] A flexmaster coupling is incorporated between the compressor unit and the separator/ sump tank. This allows the compressor unit and separator/sump tank to be separated easily and the flexmaster will also act like an insulator for vibration, and any slight misalignment. *You should not tighten the flex master bolts completely tight. If you do when they start to leak you must change them. Newer design coupling between the compressor unit and sump tank is the Stainless Steel Flexible Expansion Joint..

[Audio] *What is the difference between a vapor and an aerosol? What is coalescing? The separator/ sump houses the coalescing separator element(s). As the air/fluid mixture enters the separator/sump, its direction of travel is changed and the velocity is reduced. This allows the larger droplets of fluid to fall to the bottom of the separator/sump. Up to 90% of the first stage of separation occurs mechanically within the sump tank. However, a small amount of fluid remains suspended in the air in vapor form. **Drain water from sump occasional and always before pulling the oil sample.. When you shut the machine down moisture forms in the sump tank. Water has an sg of 1 and sg of Sullube is .91????.

[Audio] As the air passes through the coalescing element small droplets of fluid collect on the element, then drop to the bottom of the element and is returned to the compressor unit through the fluid return line. Normal restriction through the separator element is 2 to 10 lbs. When the restriction through the element reaches 10lbs., the element will need to be changed. Failure to do so may cause the separator element to collapse. The restriction across the separator can be monitored through the use of the Supervisor Controller. NOTE: A faulty minimum pressure valve can also cause a high differential reading. NOTE: The cleanliness of the fluid will have a direct affect on the life of the separator element. In almost all cases, the separator element fails because of foreign material building up on the element surface. Always check the inlet filter and fluid quality when changing the separator element..

[Audio] The lubricant which is collected in the bottom of the separator elements must be removed from the elements or it will be discharged into the service line or out the blowdown valve, during the unload mode. Removal of this lubricant is accomplished by the use of a fluid return line. The return line returns the lubricant to the compressor unit. The fluid seeks a lower pressure, thus moving from a high pressure area (in the separator) to a lower pressure area of the compressor unit. A sight glass, strainer and orifice are incorporated in the line. It is important to clean the strainer and orifice periodically. A plugged strainer or orifice will cause high fluid carryover. An improperly positioned return line can also cause a carryover problem. The bottom of the return line is cut at a 45 angle, and should be resting on the bottom of the element, this line is not designed to cool, seal or lubricate the compressor unit. NOTE: If a high lubricant make-up rate is encountered, check for the following: 1. Leakage 2. Return line position 3. Plugged strainer or orifice 4. Defective separator element 5. Foaming lubricant (caused by mixing of lubricants or excessive moisture in the fluid) 6. Compressor overfilled 7. Machine running unloaded for extended periods of time 8. Machine running below 70 PSI 9. Ruptured water cooled oil cooler.

[Audio] The fluid return line of the ES- 6 is located in a downward position below the air/fluid separator. The fluid return orifice is at the tip of the return line and needs to be checked should there be evidence of excessive fluid carryover. The fluid return line is accessible through the opening for the separator once the separator is removed..

[Audio] The minimum pressure valve, located on the dry side of the separator element, is used to insure a minimum fluid pressure in the system. The minimum pressure valve springs are designed to resist pressure under 50 PSI. Pressure build-up beyond 50 PSI flexes the piston spring, raising the piston within the housing, allowing airflow to the service line. If the minimum pressure valve fails to open pressure would build in the sump tank until the high-pressure shutdown switch contacts opened, shutting down the machine. (The high-pressure shutdown switch should be set 5-10 PSI below the relief valve setting.) If the machine is not equipped with this switch, the pressure relief valve would open, relieving the pressure. The majority of the newer machines are equipped with 200 PSI pressure vessel and relief valve. The high discharge pressure switch should be set 10 – 15 PSI above the unload point of the machine, although most all high discharge pressure switches are preset. The one shown above is a combination minimum pressure/ terminal check valve. This valve operates the same as the separate minimum pressure and terminal check valve. *piston can egg shape and stick. Corrosion can also cause problems - should be rebuilt annually.

[Audio] All Sullair Compressors are equipped with a pressure relief valve located on the separator/sump tank. The tank ASME code rating is between 150 and 200 PSI. The pressure relief valve is set at or below the vessels rating. Air and fluid will be exhausted from the tank in the event of a pressure build up in excess of the valves rating. A high discharge pressure switch is incorporated on most machines. If your machine is equipped with this switch it should be set to approximately 10- 15 PSI above the machines unload pressure. The high discharge pressure switch will shut the machine down in the event of a pressure build up in the system rather than discharge out of the pressure relief valve. The pressure relief valve is located on the wet side of the separator on all Sullair compressors. This is to protect the compressor in the event the separator element plugs up, thus providing added safety for the operator. Never plug the outlet of the relief valve. NOTE: If the relief valve opens, check the following: .Check for a faulty pressure relief valve. Is it opening at a lower pressure than set pressure? .Check the operation of the minimum pressure valve. .Check the separator differential .Check the control system components for proper adjustment and operation. ( Pressure switch, Sullicon control diaphragms, blowdown valve, pilot valve) Another common cause is worn bushings or shaft on the butterfly valve..

[Audio] All new machines are equipped with a high discharge pressure shut down switch as standard equipment. Old style machines are equipped with adjustable switches which should be set 10- 15 lbs. above the unload pressure. New style machines are equipped with preset switches, normally set at 135 PSI. In the function menu the Supervisor Controller, through a pressure transducer, will display a High Sump Pressure status should one exist. High Discharge - P1.

[Audio] The discharge air will then travel through some type of aftercooler to cool the air down and drop out the majority of the condensate that has accumulated during the compressed air cycle. The aftercoolers could be either air or water cooled. As much as 65% of the condensate is removed through the aftercooler which requires that the air cooled aftercooler be periodically cleaned if installed in a dirty environment. *The importance of clean coolers is critical to operating the dryer system. * Rule of thumb – per 24 hours, per 100 cfm, @ 70% RH, and 70F there is approximately 17 gallons of water in the air. The cooler will remove 50- 65% of the water. Leaving significantly less water for the filters and dryers to remove..

[Audio] The moisture that has been condensed out of the air through the aftercooler will then have to be collected in some form of moisture separator in order that it can be separated from the air and disposed of from the air traveling into the plant . This is important to service regularly otherwise the condensates will flow down stream to the filters..

[Audio] This is the Sullair compressor discharge system. Atmospheric air is drawn to the compressor unit through an air filter. Dust or large particulate matter is stopped at this point before entering the compressor unit. The inlet valve governs the amount of air to the compressor unit. Briefly, the inlet control system regulates the amount of air to the compressor unit according to service air demand. Atmospheric air is captured within the rotor cavities and the volume is reduced toward the discharge end. The air/fluid mixture exits the compressor unit through the discharge of the compressor. Located down line is the discharge temperature probe. The air/fluid mixture then goes through a flexible pipe coupling into the separator/sump tank. Here begins the first stage of fluid separation. The air/fluid mixture hits the far wall or top of the separator tank. Due to the velocity change, heavier droplets of fluid fall to the bottom of the tank. The air and fluid mist continues on to the separator element. Some of the fluid droplets form on the outside of the element and drop to the bottom of the sump tank. The remaining fluid forms on the inside of the element, and drops to the bottom of the element. This fluid is then drawn off the bottom of the element, by the fluid return line, and returned to the compressor unit. The minimum pressure valve located on the top of the sump tank is used to insure a minimum fluid pressure. The dry air in the separator element pushes against the spring-loaded piston in the minimum pressure valve. The spring tension is overcome and air flows to the terminal check valve and on the service line. To have a greater understanding of the components, we will discuss each component individually.

[Audio] Lubricant analysis is an important part of any maintenance program. It will help to establish the change interval, determine if the inlet air or the lubricant is contaminated, and even monitor machine condition to see if severe wear is occuring..

[Audio] Varnish Free Performance Compatibility Low Carryover Efficient Cooling Long Life Flash Point 505F Biodegradable – Easy condensate disposal approval.

[Audio] Control Temperature Absorb heat of compression Form a Seal Between rotor lobes and stator housing Control Friction Roller and ball bearings Control Wear Bearings and shaft seal areas Control Corrosion Due to condensation development Remove Contaminants Keep particulate in suspension for filter removal.

[Audio] This is what you are protecting by using quality fluid filters that are designed according to manufacturers specifications and adhere to strict performance testing..

[Audio] Petroleum or Hydrocarbon Advantages Low price per gallon Good in contaminated environments Limitations Varnish formation Shorter life Lower flash point Higher carry over into the air system.

[Audio] This is the typical cooling lubrication system. The heat of compression originates in the compressor unit. Heat is carried away from the compressor unit by the fluid and the fluid collects in the separator/ sump. The sump tank siphon line directs fluid to the thermal valve. The thermal valve element senses the fluid temperature and regulates the amount of fluid flow to, and around the cooler. The fluid is cool enough to bypass the cooler at start-up..

[Audio] Located downstream of the main fluid filter is the fluid stop valve. The stop valve is a normally closed valve. On start-up, the stop valve receives an air fluid signal from the discharge check valve area of the compressor unit. This signal enters the bottom of the valve and pushes against the plunger, overcoming spring tension to open the valve. Fluid then flows through the valve to the compressor unit. Should the stop valve fail to open on start-up the absence of fluid to the compressor unit would cause immediate high temperature shutdown. When the compressor is shut down, the air/fluid signal to the stop valve is lost. At that point, the stop valve closes, stopping fluid flow to the compressor unit. If the stop valve fails to close on shutdown, flow would continue to the compressor unit, causing the rotors to turn in reverse and forcing the fluid out the inlet. Machines equipped with Poppet Inlet do not use a fluid stop valve..

[Audio] * Why do we need a thermal valve? To prevent the water vapor from condensing out and mixing with the oil. Keep water in a vapor form so it passes through the compressor..

[Audio] The filter on the left is a washable strainer that can be removed from the housing, cleaned and reused. On older machines this was used as the main strainer for the injection fluid for the unit. On newer machines the washable main strainer is replaced by the spin on fluid filter that services both the main unit injection and unit bearings. When changing out this filter or cleaning the main strainer always check for the bypass valve being in place. The exception is on the 250028- 032 element which has the bypass built into it..

[Audio] New Generation Coreless Filter with stainless steel center support tube available as standard equipment on the larger LS, TS20 and TS32 series machines and replaces the Micro-Glass media filter..

[Audio] As the temperature rises, the thermal element begins to direct flow to the cooler. From the cooler, the fluid then passes through the main filter element. The fluid then continues down line to the fluid stop valve. Upon start-up the piston, in the fluid stop valve, receives an air/fluid signal from the discharge check valve area. The valve then opens, allowing the fluid flow to the compressor unit. As the discharge temperature rises above 170 F, the thermal valve begins to close and a portion of the fluid then flows through the cooler mixing with the fluid that is bypassing the cooler..

[Audio] When the fluid temperature reaches 200°F and above, the thermal valve is completely closed off to the bypass port and all fluid at that time should be flowing through the cooler and back to the unit..

[Audio] Unload Mode When line pressure reaches 110 PSI, the pressure switch contacts open which de-energizes the pilot valve, unloading the compressor. With the pilot valve de-energized Port 3 now opens to Port 1 allowing the pressure signal to go to the Inlet control thus keeping the inlet valve closed. The signal also opens the blowdown valve, venting pressure from the receiver tank to atmosphere..

Shuttle Valve. Pneumatic Signal. Pneumatic Signal.

[Audio] * Should add control system slide, and pilot valve, blow down valve.

[Audio] Compressed air volume is varied by rotating the spiral valve, which opens and closes by-pass ports in the stator, and returns air to suction rather than compressing it. By matching compressor displacement with output need, this energy-saving system uses up to 17% less power..

[Audio] Compressed air volume is varied by rotating the spiral valve, which opens and closes by-pass ports in the stator, and returns air to suction rather than compressing it. By matching compressor displacement with output need, this energy-saving system uses up to 17% less power..

[Audio] As the air demand continues to decrease the spiral valve will move toward full modulation At full modulation or minimum position the tandem airend is at 50% of full load capacity. At this point the motor is using 62% BHP vs straight line modulation at 82% BHP. Once the spiral valve is at full modulation the inlet butterfly valve will begin to throttle toward the closed position..

[Audio] Spiral Valve Actuator with the rack indicator in the maximum position Cutaway of the actuator indicating the inflatable diaphragm that could require maintenance.

Spiral Valve Unit.

[Audio] The purpose of the compressor control system is to regulate the compressor air intake to match the amount of compressed air being used. For explanation purposes we use a machine with an operating pressure range of 100 – 110 PSI. For the proper pressures for your machine, refer to the machine serial number plate. NOTE: Check for plant air pressure requirements before setting controls. If high pressure machines are in use ( 115 – 125 PSI) and the plant air pressure only needs to be 90 – 100 PSI, set the controls for a low pressure machine. Setting the controls for a low pressure machine will save energy and deliver more capacity ( CFM). One half percent of motor horsepower is wasted for every pound of pressure over what the plant requires, i.e. 10 PSI over what is needed equals 5% of motor horsepower..