G02.

What faults are likely to develop in an air compressor and how are they
remedied.
Most compressor faults can fall into three different categories;

1. Problems with suction and discharge valves.

2. Intercooler and after-cooler problems.

3. Restriction of air supply.

Problems with suction and discharge valves;

By far the greatest item of maintenance concerns are the valve plates. Valve plates are
subject to shock loading and fouling by dirt, dust, oil deposits, and high operating
temperatures. Valve plates must retain their mirror like finish to maintain a good seal and
reduce the “drag” on in-coming air flow, thus improving efficiency and in turn keeping
the temperature of the compressor down.

This problem is remedied by;

a) Regular schedule maintenance on the valves, valve plates and any springs
b) Regular maintenance and monitoring of the intake filter.
c) Use of correct lubricating oil to prevent oil fouling.

Intercooler and after-cooler problems;

Intercoolers and after-coolers need to be cleaned and serviced regularly, especially if

seawater is circulated. For maximum efficiency, compression should follow the
isothermal law as close as possible. Any fouling or decline in efficiency of the cooler
directly affects the efficiency of the entire compressor. In addition if the temperature of
the air is insufficiently cooled, the high temperatures may also affect the lubrication of
the piston and liner resulting in increase wear and damage. If the temperature is allow to
continue to climb it could reach a point where there is a risk of self ignition of any
possible oil vapour in the compressor. During the service of the coolers the following
should also be checked,

a) Condition of any zinc fitted

b) Correct operation/condition of the safety valve or burst disk
c) All coolant pumps and associated drives should also be checked/inspected for
correct operation.

Restriction of air supply;

A restriction of the intake reduces the actual quantity of air that the compressor draws in
and therefore reduces the volumetric efficiency and rate of delivery to the air receivers.
For this reason the intake filter must always be kept clean or replaced. The air compressor
must never be run without an air filter as there is a possibility that abrasive dirt particles
can enter the compressor and damage the piston and liner and possible valves.