STEAM GENERATING UNIT- Is an integrated, ACCORDING TO POSITION OF FURNACE

assembly of several essential components, the - INTERNALLY FIRED BOILER - The furnace
function of which is to produce steam at a of the boiler is inside the drum.
predetermined pressure and temperature. - EXTERNALLY FIRE BOILER – The furnace
- Used for power generation, commercial and is separated from the drum.
industrial application. CLASSIFICATION OF BOILER
BOILER- is a closed vessel in which the water under ACCORDING TO THE POSITION OF PRINCIPLE AXIS
pressure is transferred into steam by the application - VERTICAL BOILER
of heat. - HORIZONTAL BOILER
- INCLINED BOILER
FUNCTION OF BOILER BASIC COMPONENTS OF BOILER
The function of boiler is to transfer the heat to the - Shell - It consists of one or more steel
water in the efficient manner. plates made into cylindrical shape and
welded or riveted together. The ends of the
The steam produced is used for: shell are closed by flat or curved plates
- Producing mechanical work by expanding it called “boiler heads”. Curved or
in steam engine or steam turbine. (Power hemispherical shaped ends are also called
Plants) ‘dished ends.
- Heating the residential and industrial - Foundation and Wall - It is constructed of
buildings. (Commercial/Industrial Plants) bricks. The wall of the boiler and combustion
- Performing certain processes in the sugar chamber may also be made of bricks. This
mills, chemical and textile industries. wall restricts heat to the boiler and forms
(Manufacturing Plants) flue gas passage. Also, walls provide
BOILER PROPERTIES supports to drums and tubes.
- Safety - Tubes - These are narrow pipes that
- Accessibility connect boiler heads. Tubes act as passages
- Capacity for flue gas in FT Boilers and, Water or
steam in WT Boilers where evaporation or
TYPES OF BOILER steam generation takes place in these
- FIRE TUBE BOILER- In this type of boiler, tubes.
the flue gas passes through the tubes and - Baffle plates - These are steel plates that
the water stay inside the shell. blocks off direct exit of flue gases to the
APPLICATIONS: chimney. Baffles make flue gas path longer
o For small capacities (up to 25 and zigzag around heating surfaces and
tons/hr and 17.5 kg/cm2 make boiler more efficient. This also support
ADVANTAGE: tube banks.
o Low capital cost and fuel efficient - Grate - A grate consists of cast iron bars on
(82%) which solid fuel such as coal or wood is
WATER TUBE BOILER - In this type of boiler, the burnt. The air passes through the gaps
water passes through the tubes and the flue gas stay between the bars and sustains combustion
inside the shell. process of fuel. Ashes fall through the grate.
APPLICATIONS: - Steam space - Entire upper space of boiler
o For steam range 5.5 to 130 tons/hr. and tubes which is not occupied by water.
ADVANTAGE:
o Used as high-capacity steam BASIC COMPONENTS OF BOILER
- Heating surface - A surface of boiler tubes
boilers.
or plates, that is exposed to flue gases on
DISAVANTAGE:
one side and water on the other side. Heat
o Efficient control system need.
energy transfer into water takes place
o Capital cost is high.
through the heating surfaces
PACKAGE BOILER - is a boiler that had been - Feed pump - A pump used to
fabricated and available as a complete package. The pump feedwater into a steam boiler
entire pressure parts have been assembled in the - Economizer - This use waste heat pass to
workshop and ready to be sent to the field or site the chimney to pre-heat feed water. This
where power plant is located. also increases efficiency of steam
It comes as a complete package that’s why it is generating system of the boiler.
called package boiler. It is generally shell type with - Super heater - A super heater is a device
fire tube design, used to convert saturated steam or wet
- Large number of small diameter tubes steam into dry steam. Reduction of
leading to good heat transfer. moisture increases internal energy of the
- It has high thermal efficiency compared to steam and then the thermal efficiency.
other types boilers. - Deaerator- A deaerator is a device that is
widely used for the removal of air and other
dissolved gases from the feedwater to
steam generating boilers.
CLASSIFICATION OF BOILER - Furnace or “Fire Box”- is a primary part
ACCORDING TO WHAT FLOW IN THE TUBE
of the boiler where the chemical energy
- FIRE TUBE BOILER
available in the fuel converted into the
- WATER TUBE BOILER
thermal energy by combustion process.
CLASSIFICATION OF BOILER
 o A furnace is designed for efficient certain type of uranium—U-235—as fuel
and complete combustion. because its atoms are easily split apart.
Although uranium is about 100 times more
Major factor of efficient combustion common than silver, U-235 is relatively rare
- Time of fuel inside the furnace, at just over 0.7% of natural uranium.
- Temperature inside the furnace,
- Mixing of coal and air, - Boiler is the heart of the plant/industry. It
Another important feature of the construction of can be useful but also can be dangerous and
furnace is to reduce the air infiltration. deadly.

Types of Furnace WHAT CAUSES A BOILER TO EXPLODE?

- Dry bottom furnace 1. LOW DRUM LEVEL- If the level of water
- Slag type or wet bottom type furnace inside the boiler reached the very low limit
- Oil fired furnace while operating, the heat is now transferred
Boiler Drum- is the secondary part of the boiler to the boiler drum.
where the water absorb the heat and converted into CAUSES OF LOW DRUM
the steam, that steam send to the turbine after • FEED WATER PUMP MALFUNCTION.
reheating by the super-heater. • BLOW-OFF COCK/BLOWDOWN VALVE
MALFUNCTION.
MAIN PARTS OF BOILER • WATER LEVEL INDICATOR/WATER LEVEL
- PRESSURE GAUGE - This indicates the SENSOR MALFUNCTION.
pressure of the steam in the boiler. • FEEDWATER INLET VALVE DIAMETER
- WATER LEVEL INDICATOR- This indicates DECREASES DUE TO SCALES.
the water level in the boiler. • BOILER LEFT UNATTENDED.
- SAFETY VALVE- The function of the safety 2. FAULTY SAFETY DEVICE- If safety device
valve is to prevent the increase of steam like safety valves malfunctioned, the steam
pressure boiler above its design pressure. pressure will increase until it exceed the
- STEAM STOP VALVE - It regulates the flow operating pressure.
of steam supply outside. The steam from CAUSES OF FAULTY SAFETY DEVICE
the boiler first enters into an ant-priming • NO TEST RUN OR WEEKLY CHECKLIST
pipe where most of the water particles • OLD SAFETY VALVE.
associated with steam are removed • SENSOR MALFUNCTION.
- FEED CHECK VALVE - The high-pressure 3. DECREASE IN SHELL AND TUBE
feed water is supplied to the boiler through THICKNESS- Corrosion in the tubes and
this valve. This valve opens towards the shell is making the boiler very fragile.
boiler only and feeds the water to the boiler CAUSES OF CORROSION
- FUSIBLE PLUG - If the water level in the • NOT OPENING THE AIR VENT EVERY
boiler falls below the predetermined level, START UP.
the boiler shell and tubes will be • NO CIRCULATION OF WATER.
overheated. • DEARATOR NOT WORKING.
- BLOW-OFF COCK - The water supplied to 4. NEGLIGENCE OF AUTHORIZED
the boiler always contains impurities like PERSONNEL
mud, sand, and salt due to heating, these o The personnel/operator failed in
are deposited at the bottom of the boiler, monitoring the boiler.
they must be removed using blow-off cock. o The personnel/operator already
notice a problem but did not report
HEAT LOSS IN BOILER to maintenance.
- Heat loss due to un-burnt Carbon - This o The management doesn’t follow
loss can be reduced by using of proper the once-a-week maintenance or
grinded fuel maintenance season for the steam
- Heat loss due to dry flue gases - This generating unit.
heat can be minimized by completely utilize 5. LACK OF TRAINING- The operator is
of heat of flue gases unknowledgeable in the operation and
- Heat loss due to moisture in the fuel- maintenance of the boiler.
For minimizing this loss, we must use of dry
fuel as possible. BOILER RULE BASED ON THE DEPARTMENT OF
- Heat loss due to surface radiation - This LABOR AND EMPLOYMENT RULE 1165
heat loss can be minimized by proper
maintenance of the furnace
-
BOILER FUELS
- Oil Fuels
- GAS FUELS
o NATURAL GAS
o PROPANE GAS
o LIQUID PETROLEUM GAS
- NUCLEAR FUEL- Uranium is the most
widely used fuel by nuclear power plants for
nuclear fission. Nuclear power plants use a
 BOILER WATER TREATMENT

- HARD WATER- Is water that has a high

concentration of dissolved minerals, such as
CALCIUM or MAGNESIUM. The minerals in
hard water leave behind deposits called
SCALE, on the interior and exterior of
piping. This can require more frequent
cleaning of surfaces that come into contact
with hard water. Scale build –up inside of
pipes and appliances can reduce efficiency
and could cause a safety issue when it
comes to Boilers and Pressure Vessels.
- SOFT WATER - Contains few or no extra
elements. This can be naturally occurring or
produced with water treatment devices that
work to remove hardness elements.

SCALE FORMATION - Inside tube scales are caused

by impurities being precipitated out of the water
directly on heating surfaces. Common feed water
contamination which may form boiler deposits
include calcium, magnesium, aluminum, iron and
silica.
- Scaling of inside tube boiler causes pressure
drops, restrict circulation and changing in
fluid hydrodynamics conditions and affecting
on heat transfer and fluid flow behavior,
deposit cause decreasing heat transfer rate
to fluid and increasing wall temperature to
lead overheating and tube failure, also scale
may cause hot spots and changes of
temperature distribution.
FOAMING - When the steam space in the boiler is
partially filled with unbroken steam bubbles
CAUSE OF FOAMING - Impurities in the feed water
preventing the free escape of steam as it rises to the
surface or by oily scum on the surface of the water
INDICATION OF FOAMING - Irregular water level at
sight glass. It is practically impossible to tell the true
water level inside the drum
PRIMING - is the carrying over of liquid water from
the boiler by the steam.
INDICATION OF PRIMING - Water hammering when
opening valves on steam lines.
CORROSION - is the wasting-away of the metal
HYDROSTATIC TESTING surfaces of boiler parts internally or externally.
CAUSES OF CORROSION
- externally, water leaks or drips on
the outside surface of the boiler or at places
hidden by insulation
-internally by acids, oxygen (from
air) or other gases in the feed water
CAUSTIC EMBRITTLEMENT - hardening and
crystallizing process sometimes called intercrystalline
corrosion which causes fine cracks in metal due to
the accumulation of caustic substances.
WATER HARDNESS - is expressed in parts of
calcium carbonate per million parts of water (ppm) or
in grains of calcium carbonate per gal.
1 ppm = 0.058 grains per gal.
1 grain per gal. = 17.1 ppm

COMMON IMPURITIES IN BOILER FEED WATER

1. Scale forming substance –carbonates
and sulphates of lime and magnesium.
2. Scum forming substance
 a. Mineral scum-forming or the cement production right from the raw
foaming impurities usually contain soda in grinding to Cement production.
the form of carbonate, chloride or sulphate - STEEL PLANTS - In steel production, fans
b. Organic impurities-water are used in grinding of raw materials, de-
containing sewage. sludge-forming –solid dusting, sintering etc., These fans handle
mineral or organic particles carried in not only very abrasive dusty materials, but
suspension also high temperatures and are lifeline of
3.Corrosive substances the Steel production.
- chemical compounds chloride of - CHEMICAL INDUSTRY - in chemical
magnesium, free acids or gases such as industries must meet the norms that ensure
oxygen and carbon dioxide optimum safety. Heavy duty fans are used in
chemical industries to exhaust corrosive,
PRINCIPLE SCALE-forming impurities in boiler feed high temperature or hazardous gasses from
water the plant.
Sulphates and chlorides of lime and magnesium - PAPER AND PULP APPLICATIONS - Wood
forming a hard scale. Carbonates of lime and and paper industry mostly uses fans to dry
magnesium form a soft scale. Silica also forms a the material before it is sent further into the
dense hard scale and has a hardening influence on process. Fans are used to dry the paper
the soft scale forming substances. which continuously runs on the rolls at
certain speed which usually depends on the
pH VALUE OF BOILER FEED WATER- It is the type of paper to be produced.
degree of acidity or alkalinity of the boiler feed water. - FOOD INDUSTRY- In food industry, fans are
Number 7 on the pH scale is the neutral point. Below required for drying out the moisture content
7, acidity increases, and the lower the number the from the raw food materials. Industrial fans
greater the acidity. Above 7 alkalinity increases and for this industry are usually made up of less
the greater the number, the greater the alkalinity. corrosive material.

CENTRIFUGAL FAN AND ROTARY BLOWER ROTARY BLOWER - A rotary blower, also known as a
- Fans and Blowers use air for ventilation and rotary lobe blower or rotary positive displacement
industrial process requirements. It generates blower, is a type of mechanical device used to move
pressure to move air through ducts, air or gas by generating a continuous flow through a
dampers and other components of the fan system. It belongs to the category of positive
system. displacement machines, which means that it moves a
fixed volume of fluid (in this case, air or gas) with
FANS - is mechanical device is used to create a each revolution.
continuous flow of air through the system.
BLOWERS- is mechanical device that uses higher TYPES OF ROTARY BLOWER
pressure to create continuous flow of air. - ROOTS ROTARY BLOWER- A roots rotary
blower is one of the most known types,
Centrifugal fans- are among the most efficient and especially to automobile enthusiasts.
versatile pieces of air moving equipment. The scroll Featuring twin lobe rotation, this blower is
housing in a centrifugal fan accelerates the air and commonly found in engines to provide more
changes the direction of the airflow twice, a full 90 horsepower. This blower type focuses on
degree, before leaving the housing. Centrifugal fans providing a larger amount of oxygen to the
are quiet and reliable and are made to operate in a engine, thus increasing combustion and
variety of environments and applications. providing an automobile with more power
and speed.
CENTRIFUGAL FAN BLADE TYPES - ROTARY POSITIVE BLOWERS - Rotary
positive blowers are among the most
- RADIAL BLADE CENTRIFUGAL FANS - These delicate types of blower. This stems from
are high-pressure fans with medium airflow. the primary use as a pneumatic transport
Radial-bladed fans are best for industrial for powders and grainy materials. These
applications where there is dust, or in blowers are commonly found in production
environments where there is gas or moisture and manufacturing facilities that deal with
in the air. fine elements that must be kept in a
- FORWARD CURVED CENTRIFUGAL FANS- controlled environment.
These are medium pressure, high airflow - ROTARY LOBE BLOWERS - Rotary lobe
fans that can be used in both clean air, blowers are another commonly used type of
ventilating and exhaust applications. rotary blower, but most people never see
- BACKWARD CURVED CENTRIFUGAL FANS - them in action. One of the biggest uses of
These are high-pressure, high flow, high this type of machine is in water processing
efficiency fans. Power reduces as flow plants. These strong, silent suction devices
increases over the most efficient area of the are used, for example, in transporting a
system. collection of water into a treatment plant for
filtration. These are known to be among the
CENTRIFUGAL FANS APPLICATIONS largest blowers in use.

- CEMENT PLANTS - in a Cement plant play COMMON APPLICATIONS OF ROTARY

a very important role in different phases of BLOWERS
• Chemical Industry - Vacuum Processing & increased velocity through the outlet. The
Conveying design of the impeller's blades and their
• Dairy - Automated Milking arrangement greatly influences the fan's
• Environmental Services - Sewer Cleaning performance characteristics, such as airflow
& Portable volume, pressure generation, and efficiency.
• Cement & Lime Industry - Fluidization & - The housing of a centrifugal fan, also known
Conveying as the fan casing or enclosure, is a
• Resin & Plastic - Processing & Conveying stationary structure that encloses and
• Process Gas - Gas Boosting supports the internal components of the fan,
• Soil Remediation - Vacuum Extraction & including the impeller. It serves to direct and
Sparging contain the airflow generated by the
• Industrial - Material Vacuuming impeller, guiding it from the inlet to the
outlet. The housing's shape and design are
BASIC PARTS OF crucial in converting the kinetic energy
CENTRIFUGAL FAN AND ROTARY BLOWER imparted by the impeller into pressure
energy, thereby facilitating the movement
- A centrifugal fan's inlet collar is the of air or gas.
component that defines the opening via - The outlet flange of a centrifugal fan is a
which air or gas is sucked into the fan. It's component situated on the discharge side of
commonly a circular or rectangular structure the fan. It typically consists of a flat, circular
on the fan housing's side, next to the plate with bolt holes arranged around its
impeller. The design of the inlet collar has a perimeter. This flange provides a
considerable impact on the fan's standardized connection point where the fan
performance parameters, such as airflow can be securely attached to the ductwork or
efficiency and turbulence resistance. Inlet piping system that carries the pressurized
collars that are properly built help channel air or gas away from the fan.
entering air or gas smoothly into the - Bearings and shafts are integral components
impeller blades, minimizing disruptions and of a centrifugal fan that play essential roles
enhancing the fan's overall performance. in its operation. Bearings are mechanical
- The inlet funnel of a centrifugal fan is a components that support and facilitate the
specialized component that aids in directing rotation of the shaft. The shaft, a rotating
and controlling the flow of air or gas into the rod, connects the fan's impeller to the drive
fan's impeller. This funnel-shaped structure motor. Bearings are strategically placed
is positioned at the entrance of the fan's along the length of the shaft to minimize
inlet, and it serves to streamline the friction, ensuring smooth rotation and
incoming airflow, reducing turbulence and reducing wear on the moving parts. The
enhancing the fan's overall efficiency. The shaft, powered by the motor, transfers
inlet funnel helps ensure a uniform and rotational energy to the impeller, enabling it
directed flow of air or gas, optimizing the to generate airflow.
fan's performance by minimizing energy - A coupling in a centrifugal fan is a
losses and improving the fan's ability to mechanical device used to connect the fan's
generate pressure and airflow. shaft to the shaft of a drive motor or another
- A flanged inlet of a centrifugal fan refers to driven component. It facilitates the
a specific design feature where the fan's transmission of rotational energy from the
inlet is equipped with a flange, a flat, motor to the fan's impeller, allowing the fan
circular plate with bolt holes. This flange to generate airflow. Couplings are designed
provides a standardized connection point to accommodate slight misalignments
where the fan can be securely attached to between the two shafts and to absorb
the ductwork or piping system that supplies shocks and vibrations during operation.
air or gas. The flanged inlet simplifies They come in various types, such as flexible
installation, maintenance, and disassembly couplings that can compensate for
processes, making it a practical choice for misalignment and rigid couplings that
connecting centrifugal fans to ventilation provide a more direct connection.
systems in various industrial and - The motor of a centrifugal fan is a crucial
commercial applications. It ensures a tight component responsible for providing the
and leak-free seal between the fan and the necessary mechanical energy to drive the
ductwork, while also allowing for efficient fan's impeller and generate airflow.
airflow intake. Typically, an electric motor, it converts
- The impeller of a centrifugal fan is a vital electrical energy into rotational motion,
rotating component that drives the which is transmitted through the fan's shaft
movement of air or gas. It consists of a set to the impeller. The motor's power and
of blades or vanes arranged in a circular speed specifications influence the fan's
pattern around a central hub. As the performance in terms of airflow volume and
impeller spins within the fan housing, it pressure generation.
accelerates the air or gas radially outward
due to its curved shape, creating a zone of ROTARY BLOWER
lower pressure at the center. This pressure - In a rotary blower, a gear is a mechanical
difference causes air to be drawn into the component that facilitates the transfer of
fan through the inlet and expelled with rotational motion between different parts of
 the blower's mechanism. Gears consist of • Ensure the fan is correctly installed and
toothed wheels that interlock, allowing the aligned according to manufacturer
rotary motion from one component, such as instructions.
an electric motor or an engine, to be • Calibrate all necessary testing instruments
transmitted to the blower's rotors or other and equipment.
moving parts. Gears help control the speed, 2. Visual Inspection:
torque, and direction of motion, enabling the • Conduct a visual examination of the fan,
blower to efficiently generate the required looking for any visible defects, damages, or
airflow or gas movement. irregularities in components like the
- Bearings in a rotary blower are crucial impeller, housing, and structural elements.
mechanical elements that support and 3. Vibration Analysis:
enable the smooth rotation of moving • Attach vibration sensors to key points on the
components, such as the blower's rotors and fan, including the housing and bearings.
shaft. They reduce friction and wear by • Run the fan at different speeds to measure
providing a stable interface between parts and analyze vibrations.
that move relative to each other. Bearings • Compare vibration levels to acceptable
help maintain accurate alignment and limits to identify any excessive vibration
proper functioning of the blower's internal that could indicate mechanical issues.
components, ensuring efficient and reliable
operation. 4. Noise Testing:
- A cylinder in a rotary blower typically refers • Place sound level meters at specified
to the casing or housing that encloses the distances to measure the noise generated
blower's internal components, including the by the fan during operation.
rotors and other mechanisms. The cylinder • Compare noise levels to applicable
provides a sealed chamber where air or gas regulations and standards to ensure
is compressed and moved. It plays a crucial compliance.
role in maintaining the integrity of the 5. Flow Rate and Pressure Measurements:
compression process, ensuring efficient • Use calibrated instruments to measure the
airflow, and preventing leaks. The cylinder's actual airflow rate and pressure generated
design and materials are important factors by the fan.
in achieving optimal blower performance, as • Compare these measurements to the design
they impact factors such as durability, noise specifications to ensure accuracy.
reduction, and overall efficiency. 6. Efficiency Testing:
- Rotors in a rotary blower are the key • Measure the power input to the fan's motor
rotating components that drive the and the actual airflow and pressure output.
compression and movement of air or gas. • Calculate the fan's efficiency by comparing
They consist of lobes or blades attached to a the power input to the energy transferred to
central shaft. As the rotors rotate within the the airflow.
blower's housing, the lobes intermesh to 7. Static Pressure and Velocity Profiles:
create sealed chambers that draw in and • Use pitot tubes and pressure probes to
compress the fluid. This positive measure static pressure and velocity at
displacement action generates pressure and various points across the fan's inlet and
airflow. The design of the rotors, including outlet.
their shape, size, and arrangement, directly • Create pressure and velocity profiles to
influences the blower's performance evaluate uniformity and efficiency of airflow.
characteristics such as flow rate, pressure 8. Temperature Rise Testing:
capacity, and efficiency. • Place temperature sensors at the inlet and
- The inlet of a rotary blower is the entry outlet to monitor the temperature increase
point through which air or gas is drawn into in the air as it passes through the fan.
the blower's internal mechanism for • Compare the temperature rise to acceptable
compression and movement. It is where the limits to detect any mechanical or
fluid being processed by the blower enters operational issues.
the system. The design of the inlet is 9. Motor Power Measurement:
important for ensuring a smooth and • Measure the power consumption of the fan's
consistent flow of fluid, minimizing drive motor using calibrated power meters.
turbulence and pressure losses. • Compare the measured power to the
motor's rated power and the design
TESTING OF CENTRIFUGAL FAN specifications.
PURPOSE 10. Run-in Tests:
• VOLUME FLOW RATE • Operate the fan continuously for a specified
• POWER INPUT duration to evaluate its performance under
• VIBRATION normal operating conditions.
• TOTAL PRESSURE RISE • Monitor for overheating, vibration changes,
• PROBLEMS/TROUBLES or other irregularities during this period.
1. Preparation and Setup: 11. Vibration Signature Analysis:
• Set up the testing facility in a controlled • Use advanced vibration analysis techniques
environment, including proper to identify specific sources of vibrations and
instrumentation and safety measures. their frequencies.
 • Analyze the results to detect potential • Use a mercury manometer connected to the
mechanical problems or imbalances. discharge piping to see that the pressure
12. Material and Component Testing: rating of the blower in not exceeded. Also
• Perform material testing and durability use good thermometers to determine the
assessments on critical components, such temperature rise through the blower. Both
as impellers and bearings, to ensure they figures should satisfy the conditions listed.
meet specified standards.
13. Control System Testing:
• Test the operation of control systems, safety
interlocks, and automation features if
applicable.
• Ensure that control inputs are accurately TROUBLESHOOTING OF CENTRIFUGAL FAN
reflected in fan performance.
14. Environmental Testing: - CENTRIFUGAL FAN ISN’T PRODUCING
• Test the fan's performance under extreme THE PROPER AIRFLOW.
conditions, such as high temperatures, o When your centrifugal fan is turned
humidity, or corrosive environments, if on, you should notice it moving
required by the application. large amounts of air around at any
15. Factory Acceptance Testing (FAT): given moment. If it’s not, that’s an
• Conduct a final round of comprehensive issue. There are several reasons
testing to confirm that the fan meets all why this might happen. In some
specified requirements before it is approved instances, you might have broken
for delivery to the customer. belts within your centrifugal fan. In
16. Data Analysis and Reporting: others, you might have a pipe leak
• Compile all testing data, including or a broken drive coupling.
measurements, analysis results, and any Whatever the case, it’s a good idea
detected anomalies. to shut your centrifugal fan down
• Prepare a detailed report summarizing the and have it inspected as soon as
testing process, results, and any possible to get it up and running
recommended actions. again.
17. Adjustments and Corrections: - THE BLOWER IN YOUR CENTRIFUGAL
• If any issues or deviations are identified FAN ISN’T ROTATING.
during testing, address them by making o Another common troubleshooting
necessary adjustments, repairs, or issue with your centrifugal fan will
replacements. occur when the blower inside of it
18. Final Approval and Documentation: stops rotating. This can happen if
• Once all tests are successfully completed rust builds up in your blower
and any issues are resolved, provide final impeller chamber. It can also take
approval for the fan's performance. place if there is damage that has
• Document all testing procedures, results, been done to your motor winding.
and any modifications made during the You could even have an electrical
process. wiring issue on your hands. You’ll
usually need to turn your
TESTING OF ROTARY BLOWER centrifugal fan off and take the
• Initial operation should be carried out under blower apart to investigate the
"no load" conditions by opening all valves source of the problem.
and venting the discharge to atmosphere, if - OIL LEAKING FROM YOUR CENTRIFUGAL
possible. Then start motor briefly, listen for FAN.
unusual noises, and check the blower coasts o It’s not out of the ordinary to see a
freely to a stop. centrifugal fan leaking a little bit of
• If no problem appears, repeat this check and oil. Nevertheless, if you notice a lot
let the motor run a little longer. If any of oil leaking onto the floor under
questions exist, investigate before your centrifugal fan, this should be
proceeding further. Now operate the unit for a major cause for concern. Your
about 10 minutes. During this run feel centrifugal fan can lose lubrication
cylinder and headplates for development of due to a worn seal, a blown gasket,
hot spots that indicate rubbing contacts. a loose drain plug, or any number
Also listen for knocking sounds (contact of other things. You should attempt
between impellers and watch for any to see if you can locate the cause
change or increase in vibration. of the leak or call on a professional
• At the end of this run, check the inlet screen for help.
near the blower for collected debris. After
above tests are completed and any TROUBLESHOOTING OF ROTARY BLOWER
necessary corrections made, a final check - BLOWER FAILURE TO ROTATE
run of a least one hour should be performed o This could be from rust in the
under normal operating conditions. Start blower impeller chamber, the
unloaded as above, and apply the system motor winding could be damaged,
pressure load gradually by closing the or there could be improper wiring
discharge atmospheric vent. connections within the motor itself.
 If there’s rust in the blower, then number of things: too much oil in
it’s time for a good cleaning. Turn the gear case, too low operating
off the power, remove it from the speed, dirty air filter, worn
system, and clean the impeller impeller, inlet air flow restricted.
chamber. o If your blower has too much oil in
o Reminder: whenever a blower is the gear case, make sure the unit
disassembled, whether for a deep has come to a complete stop and
clean or an inspection, then drain the oil level to the
manufacturers always recommend specified amount. Side note, if your
that the bearings, seals, and blower is low on oil or has been
gaskets be replaced. This is to running with that batch of oil for
ensure optimum reassembly and longer than the recommended
efficiency. Overhaul kits for each hours, a full oil flush to replace the
size and line of blower are available old oil will aid in lengthening the
(there are exceptions, of course, for lifetime of your blower.
blowers that are obsolete or very - LUBRICATION LOSS
old). o Some leaking is common. But
- NO AIRFLOW excessive loss of lubrication (oil on
o A few probable causes include: the floor/under the blower) or a
 Broken belts or broken consistent drip is not good. Similar
drive coupling, blower to a blower overheating, there
isn’t turning, or a pipe could be too much oil in the blower.
leak. The most obvious There could also be a worn seal,
solution for broken belts or loose oil cover, drain plug or line
a broken drive coupling is loose, a gasket could be worn, or
to simply replace it. But the head plate or gear case/drive
make sure that with belts cover vents could be plugged.
the tensioning is correct. o To check for worn seals, loose
o Belts that are too tightly strung or covers, worn gaskets, etc. this may
too loosely strung can snap or flap require a complete tear down of
around and cause the pulleys to the blower and replacement of
not rotate, hence the lack of air those seals, bearings, and gaskets.
flow. The manual for the blower itself
- BLOWER EXCEEDS MAXIMUM often gives a clear walk through on
VIBRATION how to tear down, clean, and
o Any number of things could cause rebuild a blower. When in doubt,
this issue from a loose mounting, to have your blower inspected by a
bolts failure, loose sheaves in the certified technician. This will ensure
v-belt drive, foundation base is too that your blower is thoroughly
loose, insufficient v-belt tension. inspected. Should your blower be in
The list goes on. good enough condition to be
o When your system is vibrating, turn rebuilt, the technician has the tools
off the power and inspect all of the and parts necessary for proper
bolts, double check the foundation cleaning and rebuilding of the unit.
base, and check the tension on the
v-belt drive. If the sheaves on the SAFETY PROTOCOLS
v-belt drive are loose then make
sure they are installed according to CENTRIFUGAL FANS
your O&M manual and make sure 1. DO NOT attempt to install, connect power to,
your blower is running at the operate or service your new fan without proper
correct speed. If you no longer instruction and until you have been thoroughly
have that manual, call the trained in its use by your employer.
manufacturer of your system and 2. DO NOT attempt to work on, clean or service the
they should be able to provide it. fan, or open or remove any protective cover, guard,
Double check the tensioning of the grate or maintenance panel until the POWER has
v-belts on the v-belt drive. As been turned off and LOCKED OUT, and the fan rotor
noted, before, if they’re too loose has come to a complete stop.
or too tight then they can flap 3. DO NOT Do not manually override or electrically
around aimlessly or snap; not only bypass any protective device.
does this cause vibration but it can 4. DO NOT connect power to or operate the fan
prevent airflow all together. unless all moving parts are covered and all covers,
- EXCESSIVE BLOWER TEMPERATURE guards, grates and maintenance panels are in place
o Each blower has a temperature and securely fastened.
5. DO NOT abuse, overload, mistreat or misuse the
minimum and maximum. If it
fan or attempt to operate the fan if it is in need of
operates outside those restrictions,
service, lubrication, maintenance or repair.
then your efficiency goes down and
6. Never place any part of your body near rotating
you run the risk of ruining the
members or moving parts of the fan.
blower. As with the other common
problems, this one is caused by any
7. If the fan is not equiped with factory supplied drive 19. To prevent human access while the equipment is
and guard, then all rotating members and moving operating, all fan inlet and discharge openings must
parts must be completely enclosed before connecting be completely enclosed and remain enclosed until
power and before operation. POWER IS TURNED
8. Free outlet of the product must be guaranteed at 20. Never allow any kind of metal or other foreign
all times. Otherwise, blockage and severe damage objects to enter a fan while in operation. Examined
may result, or a dangerous situation may occur. raw materials (cleaned air) should be used through
9. If the fan is equipped with a maintenance panel or the machine to ensure proper and consistent
access door incorporating a Protective Interlocking operation.
Limit Switch (PLS), the PLS must be interlocked with 21. To prevent human access while the equipment is
all electrical controls. This is to prevent all motors or operating, all fan inlet and discharge openings must
powered devices on the unit from being energized if be completely enclosed and remain enclosed until
any protective cover, guard, grate or maintenance POWER IS TURNED OFF AND LOCKED OUT. Keep away
panel is open or removed. Never attempt to manually from the moving parts of the fan during operation.
override or electrically bypass a safety device. The 22. Operate safely at all times. Use personal
interlock function of the PLS must be tested and protective equipment when and where appropriate,
logged daily by supervisory personnel. such as hard hats, helmets, gloves, earplugs, dust
10. The fan housing may have an inspection port masks, and eye protection devices. Keep personal
which is fastened with captive hardware. In addition, protective equipment in good repair and convenient
the port has a device that keeps it open as long as it to the operator.
is not fastened down. The port may only be opened
when the fan wheel is motionless, and the repair ROTARY BLOWERS
switch is turned off. 1. Blower casing and associated piping or
11. Many fans are installed and wired to start accessories may become hot enough to
automatically or be controlled from remote locations. cause major skin burns on contact.
Keep clear of all moving parts on industrial Internal and external rotating parts of the
equipment at all times. blower and driving equipment can produce
12. The fan must be equipped with a properly serious physical injuries.
functioning Protective Interlocking Electrical Control 2. Do not reach into any opening in the
Switch (PCS), a Pad lockable Manual Power Lockout blower while it is operating, or while subject
Switch, and with the other basic safety equipment to accidental starting. Cover external
listed above. On-Off, interlock and padlock functions moving parts with adequate guards.
of the PCS must be tested and logged daily by 3. Disconnect power' before doing any work
supervisory personnel. and avoid By-passing or rendering
13. It is the owner’s and the employer’s responsibility inoperative any safety or protective devices.
to adequately train the employee operator in the 4. If blower is operated with piping
proper and safe use of the equipment. Written safety disconnected, place a strong coarse screen
programs and formal instruction are essential. All over the inlet and avoid standing in the
new employees must be made aware of company discharge air stream.
policies and operating rules, especially the 5. Stay clear of the blast from pressure relief
established safety and health procedures. Refresher valves and the suction area of vacuum relief
training of experienced employees in the potential valves.
hazards of the job is important. Up-to-date training 6. Avoid extended exposure in close
records must be maintained at the job site. proximity to machinery with high intensity
14. Special attention must be devoted to outside noise levels.
contractors engaged to enter and perform work on 7. Use proper care and good procedures in
equipment or in the workplace. Special care must be handling, lifting, installing, operating and
exercised to insure all such personnel are fully maintaining the equipment.
informed of the potential hazards and follow plant 4. If blower is operated with piping
rules – with special emphasis on explosion proof disconnected, place a strong coarse screen
electrical tools and cutting or welding in unsafe over the inlet and avoid standing in the
environments. discharge air stream.
15. Keep the workplace cleaned up and free of dirt 5. Stay clear of the blast from pressure relief
and dust at all times. Do not attempt to work on valves and the suction area of vacuum relief
slippery or unsafe ladders or work platforms when valves.
maintenance or repair work is being performed on 6. Avoid extended exposure in close
the fan. proximity to machinery with high intensity
16. The operator must ensure that adequate lighting noise levels.
conditions are provided at the location of equipment 7. Use proper care and good procedures in
operation. handling, lifting, installing, operating and
17. Do not climb on ladders or work on platforms maintaining the equipment.
unless maximum load rating is posted. Do not exceed
maximum load ratings when installing or servicing
the fan.
18. Never allow any kind of metal or other foreign
objects to enter a fan while in operation. Examined
raw materials (cleaned air) should be used through
the machine to ensure proper and consistent
operation.
 AIR COMPRESSOR SYSTEM •Others:
It has High Efficiency and Inexpensive.
Air Compressor System-An air compressor system DISADVANTAGES
is a pneumatic device that uses mechanical power to • Speed Limited
convert atmospheric air into compressed air. • Loud noise
• The backward control system does not meet
WORKING AND FUNCTIONALITY OF AN AIR the needs of chain control and unattended,
COMPRESSION SYSTEM so although the price of piston machine is
very low, it is often not accepted by users.
• The compressed air stores potential energy • There are many moving parts, complex
that can be used to power devices and structure, heavy maintenance work and high
machines, or as a source of kinetic energy. maintenance cost.

PARTS OF AN AIR COMPRESSION SYSTEM 2. Rotary Screw Air Compressor

AIR COMPRESSOR - An air compressor is a tool that a. Rotary air compressors are a type that makes air
increases air pressure by turning energy (often from denser. The most usual one is the single-stage
an electric motor, diesel, or gasoline engine) into helical or spiral lobe oil-filled screw air
stored energy in compressed air. To put it simply, it's compressor. These have two rotor parts inside a
a machine that compresses air to make it stronger case that squeeze the air. They don't use valves.
and more condensed using electricity or engines. These units get cooled by oil (using air or water)
This type of equipment can be found everywhere, that also keeps the inside parts close together.
from large power plants to small mechanic shops,
and it usually involves rotating parts. TYPES OF ROTARY AIR COMPRESSOR
-Rotary Screw Air Compressor
How an Air Compressor works? - Rotary Vane Air Compressor
- Takes in atmospheric air
- Compresses the air ADVANTAGES
- Deliver the compressed air to the • Easy to maintain and operate
storage tank • Smooth
• Pulse-free air output in a compact size
Air goes into the piston or vane, gets compress to • Long lifespan
increase its pressure, and at the same time, its DISADVANTAGES
volume gets smaller. Once the pressure hits the • Discharge Pressure per stage is low
highest point decided by the operator a switch stops compared to the reciprocating compressor.
more air from going in. The compressed air gets • High Initial Cost.
used, and the pressure goes down. When the • Requires skilled maintenance for rebuilds.
pressure gets to the lowest point set by the user or
maker, the switch lets air back into the compressor. • No flexibility in capacity and compression
This keeps happening as long as the compressor is ratio.
being used.

3 COMMON TYPES OF AIR COMPRESSORS 3. Centrifugal Air Compressor

1. Reciprocating Air Compressor - The centrifugal air compressor is a type that relies
o Reciprocating air compressors are positive on a rotating part to transfer energy to the air.
displacement machines, meaning that they This spinning part, called an impeller, helps
increase the pressure of the air by reducing its create high-pressure air by using its rotation to
volume. These compressors can be air-cooled or push the air molecules around.
water-cooled, with or without lubrication, and - The parts that require lubrication are kept away
come in various pressure and capacity options. from the air using special seals and openings that
prevent them from mixing. This keeps the
TYPES OF RECIPROCATING AIR compressed air clean and free from oil.
COMPRESSOR ADVANTAGES
- Single Stage Reciprocating Air • High Capacity
Compressor • Faster and Reliable
o generally used for pressures in the • Easy to design and manufacture
range of 70 psig to 100 psig. • Require low maintenance
- Two Stage Reciprocating Air DISADVANTAGES
Compressor • Limited Pressure
o are generally used for higher • High compression
pressures in the range of 100 psig • Sensitive to changes in gas composition
to 250 psig. • Problem of surging, stalling and choking.
ADVANTAGES
• Flexibility PARTS OF AN AIR COMPRESSOR
This type of air compressor comes in both ACTUATOR - is like the mover that takes the
oil-flooded and oil-free varieties. compressed air and makes it either move linearly or
• Produces Higher Pressures rotary. This powerful air is then used to operate tools
Pressures range all the way up to 30,000 or other things. If there's any problem with how the
PSI. However, they are also suitable to climate air flows into the actuator, the force of the air coming
control applications requiring 60-90 PSI. out will become weaker.
BEARINGS - A part that reduces friction so that the level, the pressure switch starts the motor again,
moving parts can work well without getting stuck or which gets the compressor pumping air once more.
wearing out too quickly. Bearings are highly DRAIN VALVE - does what it sounds like: it removes
dependent on the proper lubrication at the right oil, dirt, moisture, and other stuff that can get stuck
viscosity inside the tank. Moisture and oil are often the culprits
BELTS AND PULLEYS - A flexible strap that behind rust forming in the tank if they're not drained
connects two rotating parts. This transfers motion out regularly.
from one part to another. PRESSURE GAUGE -This gauge measures
BUMPERS- Valve bumpers surround the valves for compressed air pressure in the tank of the air
added protection from accidental contact. compressor. It also indicates a problem with the
Note: Replace this small shielding part when needed compressor such as a leak in the tank.
to prevent the more expensive replacement of
valves. TESTING OF AN AIR COMPRESSOR
BUSHING - are components that create a small gap
between moving parts. They're used inside the air PURPOSE OF THE PERFORMANCE TEST IS TO
compressor's internal machinery to prevent major FIND OUT:
breakdowns. Additionally, they minimize unnecessary 1. Actual Free Air Delivery (FAD) of the
movement from side to side, which helps maintain compressor;
proper operation. 2. Isothermal power required.
CONNECTING RODS - It is used to move the piston 3. Volumetric efficiency and
up and down in the crankcase, the connecting rods 4. Specific Power Requirement
take a heavy workload. They are a highly durable
part of your air compressor. TERMS AND DEFINITION
COUPLINGS - It is used on internal components to
prevent leaking from the high-pressure system. COMPRESSION RATIO -It is the Absolute discharge
GASKETS & SEALS are essential components that pressure of last stage divided by the absolute intake
ensure tight connections in machinery. Gaskets are pressure.
placed between parts to prevent leaks, and seals act ISOTHERMAL POWER- It is the least power required
as barriers to contain liquids or gases. They play a to compress the air assuming isothermal conditions.
crucial role in maintaining the proper functioning of VOLUMETRIC EFFICIENCY- The ratio of Isothermal
equipment and preventing any unwanted leaks or power to shaft power.
escapes. ISOTHERMAL EFFICIENCY- The ratio of Isothermal
O- RINGS - It is used for a tight seal; O-rings help power to shaft power.
keep your system running at peak performance SPECIFIC POWER REQUIREMENT- The ratio of
PISTON RINGS AND ROD - are important parts in power consumption (in kW) to the volume delivered
engines. Piston rings help keep the combustion gases at ambient conditions.
inside the engine cylinder and assist in creating
power. Rods, also known as connecting rods, link the MEASUREMENT AND DURATION OF TEST
piston to the crankshaft, converting the piston's up- The compressor begins its operation by releasing air
and-down motion into rotational power that drives from the receiver into the air through a flow nozzle.
the wheels. It's important to make sure that the pressure
SPRINGS - is a flexible, coiled piece of material, decrease caused by the throttle valve is either the
usually metal, that can stretch or compress when a same as or twice the pressure on the other side of
force is applied to it and then return to its original the throttle. Once the system becomes steady, the
shape when the force is removed. It's used to absorb following measurements are taken:
shocks, hold up things, or control movement in 1. Receiver Pressure
machines. 2. Pressure and Temperature before the nozzle.
3. Pressure drops across the nozzle
MAIN PARTS OF AN AIR COMPRESSOR 4. Speed of the Compressor
MOTOR- Air compressor has an electric motor to run 5. kW, kWh and amps drawn by the
the operation od compressing air. The size of the compressor
motor (measured in horsepower, or hp) can vary
depending on the type of compressor. Measuring Instruments required for test:
COMPRESSED PUMP- The pump is an instrument
that compresses and pushes air into a container THERMOMETERS OR THERMOCOUPLE- A
called the receiver. Two-stage air compressors are thermocouple is a temperature sensor that generates
quite common, using two-cylinder pumps to operate. a voltage proportional to the difference in
These compressors can create air pressure of 145- temperature between two different metal conductors.
175 pounds per square inch (PSI) by compressing the PRESSURE GAUGE- also known as manometers, are
air twice. devices used to measure the pressure of gases or
TANK- This is the compressor part that serves as a liquids in a closed system.
storage of the air being compressed. It is the biggest STANDARD NOZZLES- is a precisely engineered
part of the air compressor, and it can range from 1- device used to measure the flow rate of fluids, such
10 gallons or even more for bigger construction as liquids or gases, in a controlled manner.
needs. DIGITAL PSYCHROMETER- A psychrometer is an
PRESSURE SWITCH - automatically shuts down the instrument used to measure relative humidity by
motor when the receiver reaches the factory-set comparing the readings of a dry-bulb thermometer
limit. When the pressure goes down to a specific and a wet-bulb thermometer.
TACHOMETER/ STROBOSCOPE- is a tool used to
measure the rotational speed or frequency of an AIR LEAKS
object, often by reflecting light off moving parts and • Air leaks can result from several factors, but
observing visual patterns. it can usually be fixed using appropriate air
ELECTRICAL DEMAND ANALYZER- An electrical compressor troubleshooting methods. The
demand analyzer is an instrument that monitors and following signs are frequently associated
analyzes the electrical power consumption, helping with air compressor problems related to
to understand energy usage patterns. leaks:
DIFFERENTIAL PRESSURE GAUGE- Differential • COMPRESSOR IS CONSTANTLY LEAKING
pressure gauges or manometers are devices used to • AIR LEAKS FROM OIL TUBE
measure the difference in pressure between two • AIR LEAKS FROM THE HOOD
points in a fluid system, indicating flow or pressure
changes. COMPRESSOR IS CONSTANTLY LEAKING
• A compressor is a machine that
TESTING OF AN AIR COMPRESSOR squeezes or pressurizes air or gas,
Various tests can be done based on the type and use making it more compact.
of the compressor. Below is a simple guide for CAUSES:
conducting a test. Always follow the instructions • Lack of Maintenance
provided by the manufacturer for your compressor • Pressure Overload or High Operating
model. Temperatures
• Chemical Degradation, Corrosion or
VISUAL INSPECTION -Check the compressor for any Rust
visible damage, leaks, or worn-out parts. Make sure • Worn or Cracked Components
all connections are secure and there are no loose • Damaged Valves, Age and Wear
components. MAINTENANCE
POWER AND ELECTRICAL TEST - Check that the 1. Identify where the leak is coming from. If the
power source and electrical connections are in good air only leaks when a hose is connected to
shape. Plug in the compressor and switch it on. the compressor, try disconnecting the hose.
Observe if the motor runs quietly and without If the pressure gauge no longer drops, then
strange sounds. If your compressor has electronic the hose is causing the leak.
controls or displays, confirm they're working as 2. Apply soap to the connections: If you see
expected. bubbles appearing at any spot, that's where
LEAKAGE TEST -Switch off the compressor and shut the leak is located. If you can, try to tighten
the drain valve on the tank. Let the compressor build the coupler where you notice the bubbling.
up pressure once more and then switch it off. Watch 3. Inspect the tank check valve: Air leaks can
the pressure gauge for a little while to see if there's result from faulty tank check valves that
any significant pressure drop, as this could suggest don't close fully. If the pressure gauge drops
potential leaks in the system. when the tank is off, inspect the tank valve.
SAFETY VALVE TEST- The safety valve is made to Clean or replace it if needed.
let out pressure if it gets too high. To test it:
While the compressor is running and the tank is AIR LEAKS FROM OIL TUBE
pressurized, lift the lever on the safety valve slightly OIL TUBE
to release a bit of air. • An oil tube is a hollow pipe that carries oil
Once you let go of the lever, the valve should close from one place to another. It's like a straw
on its own. If it doesn't, it could be broken and might for oil, allowing it to flow smoothly and
need to be changed. efficiently to where it's needed.
EMPTY TANK TEST- Open the drain valve on the air CAUSES:
tank to release any residual air. • Component Wear or Damaged
• Switch on the compressor and wait until it • Excessive Pressure
stops compressing air (cut-out pressure). • Incorrect Installation, Inadequate
• Keep an eye on the pressure gauge and Maintenance
time how long it takes to reach the cut-out • Manufacturer Defects
pressure. • Improper Oil Type or Level
• The compressor should shut off on its own. • Age of Equipment
RECOVERY TIME TEST- When the compressor MAINTENANCE
stops, watch the pressure gauge and record how long 1. VISUAL INSPECTION
it takes for the pressure to fall to the cut-in pressure 2. CONSIDER PROFFESIONAL HELP
(when the compressor starts working again). 3. CHECK SEALS AND GASKETS
• The compressor should start by itself. 4. VERIFY TUBE INTEGRITY
5. TIGHTEN CONNECTIONS
AIR COMPRESSOR TROUBLE SHOOTING AND 6. APPLY SEALANT
MAINTENANCE 7. MONITOR
• Air compressor issues can arise from various If air pressure is escaping through the oil fill tube of
causes, including air or oil leaks, damaged your compressor, examine the piston seals. If they
parts, inadequate pressure or airflow, and are significantly worn, they must be replaced
failures in starting or stopping. However, urgently. This issue requires immediate attention
many of these problems can be resolved because worn pistons can cause friction between
through effective troubleshooting metal parts, potentially leading to internal corrosion.
techniques specific to air compressors.
AIR LEAKS FROM HOOD 5. Replace when necessary.
CAUSES:
• IMPROPER REPAIR OR MAINTENANCE BROKEN AIR COMPRESSOR MANIFOLD
• AGING
• EXTREMES OF USE INTAKE FILTER
• DAMAGED, WOEN RUBBER SEALS, HINGES An air manifold is a tool that manages the flow of
• MANUFACTURING DEFECTS compressed air to different parts in a pneumatic
TROUBLESHOOT system. It's like an air traffic controller for air. If it's
1. Take off the hood. not working properly, it can lead to problems like air
2. Run the compressor for a few minutes. leakage, unreliable operation, and inconsistent
3. Turn off and unplug the compressor. performance.
4. Feel around the motor components for any
air movement. CAUSES:
5. If there's a leak, it's likely from the tank 1. Physical Damage
valve. 2. Corrosion
6. Remove and clean the valve or consider 3. Poor Installation
replacing it. 4. Excessive Pressure
5. Material Fatigue
COMPRESSOR FAILS TO START OR STOP To prevent broken air compressor manifold
When an air compressor fails to start up, shut down 1. Proper Maintenance
or provide any degree of air pressure while active, 2. Regular Inspection
the problem could be down to one of several issues; 3. Monitor Pressure Spikes
CAUSES: 4. Keep records of maintenance activities,
• Faulty Pressure release valve inspections and repair.
• Faulty Pressure Switch 5. Replace when necessary.
• Insufficient air Pressure
COMPRESSOR RUNS BUT FAILS TO GENERATE BROKEN AIR COMPRESSOR FAN
AIR PRESSURE
CAUSES: COMPRESSOR FAN
• Faulty Pump A compressor fan, also called a condenser fan or
• Faulty Gasket outdoor fan, is important in air conditioning and
MAINTENANCE refrigeration systems. Its main job is to release heat
• 1. Seek for Professional Assistance from the system, which keeps the right temperature
• 2. Check power supply, pressure switch, and pressure in the refrigerant cycle.
motor start capacitor, check valves, belt and CAUSES:
pulley if it is working properly or not worn 1. Age and Wear
out. 2. Motor Failure, Power Supply Damage or
• 3. Check for air leaks in the system. Electrical Problems
3. Fan Blade Damage
PARTS AND REPAIR NEEDED 4. Overheating
If an air compressor seems to have stopped working 5. Lack of Lubrication
due to a broken part, you first need to test the part to To prevent broken air compressor fan
verify the root of the problem. A compressor will not 1. Proper Maintenance
work if the following parts are broken. Fortunately, all 2. Regular Inspection of Fan Components,
can be replaced; Electrical and Capacitor connection
• BROKEN INTAKE FILTER 3. Keep the Area Clean
• BROKEN AIR COMPRESSOR MANIFOLD 4. Quality Installation
• BROKEN COMPRESSOR FAN 5. Keep records of maintenance activities,
• BROKEN ON/OFF SWITCH inspections, and any repairs performed on
the compressor fan system.
BROKEN INTAKE FILTER
BROKEN ON/OFF SWITCH
INTAKE FILTER
The intake filter plays a vital role in the air COMPRESSOR FAN
compressor by filtering out dirt and particles from A malfunctioning "on and off" switch, also called a
incoming air. It's prone to damage due to its position. power or toggle switch, can lead to issues in
CAUSES: electronic devices, appliances, or machines. These
1. Lack of Maintenance switches are important as they control the power and
2. Clogging determine whether the equipment works or not.
3. Moisture or Corrosion CAUSES:
4. Chemical Exposure 1. Physical Damage
5. Unbalanced Airflow 2. Mechanical Wear and Tear
3. Corrosion
To prevent broken air filters: 4. Overheating
1. Proper Maintenance 5. Internal Wiring Issues
2. Regular Inspection
3. Monitor Pressure Spikes To prevent broken air compressor on/off switch
4. Keep records of maintenance activities, 1. Proper Usage and Maintenance
inspections and repair. 2. Quality Components
 3. Regular Inspections
4. Use Protective coverings In environments
where moisture, dust, or debris is a concern. SAFETY PROTOCOLS
5. Timely Replacement Safety protocols in air compressors are essential to
6. User Education and Use of Professional ensure the well-being of operators, prevent
Services. accidents, and maintain the efficient operation of the
equipment.
DEPARTMENT OF LABOR AND EMPLOYMENT
RULE TRAINING AND EDUCATION
FOR UNFIRED PRESSURE VESSEL (RULE 1170) • Provide thorough training to all personnel
who will be operating or working around air
RULE 1179: COMPRESSORS compressors.
• Ensure they understand the equipment's
functions, potential hazards, and safe
operating procedures.
READ THE MANUAL
- Read and understand the manufacturer's
manual and guidelines for the specific air
compressor model you're using.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
- Use appropriate PPE, such as safety glasses,
hearing protection, gloves, and steel-toed
boots, to protect against potential hazards.
VENTILATION
- Ensure proper ventilation in areas where air
compressors are operated to prevent the
buildup of harmful fumes or gases.
PROPER MAINTENANCE
- Ensure proper maintenance of the
components of Air compressor, as well as
the proper usage of tools, secure hoses and
connections, monitor the valves and gages.
EMERGENCY STOP BUTTON
- Ensure that an easily accessible emergency
stop button or switch is installed near the
compressor for immediate shutdown in case
of emergencies.
LOCKOUT/TAGOUT PROCEDURES
- Develop and implement lockout/tagout

procedures to safely isolate the compressor

during maintenance or repair work.
EMERGENCY RESPONSE PLAN
- Have a clear emergency response plan in
place in case of accidents, leaks, or other
emergencies. Also, Keep flammable material
away from compressor.

PARTS OF AN AIR COMPRESSION SYSTEM

AIR RECEIVER TANK

- An air receiver, sometimes referred to as a
compressed air tank, is an integral part of
any compressed air system. The main
purpose of this is to act as temporary
storage to accommodate the peaks of
 demand from your system and to optimize
the running efficiency of your plant. COMPRESSED AIR DRYERS
A compressed air dryer is a filter system that removes water
Why do you need an air receiver? vapor and other impurities from compressed air. The air is
Having an air receiver tank can compressed by a compressor, which raises the temperature
and concentrates water vapor and other contaminants. The
• Increase the loading and unloading cycles air is then cooled, causing the water vapor to condense and
on the compressor. collect in tanks, pipes, hoses, and tools. This can be
• Air receivers act as a buffer mechanism damaging and lead to issues like rusting pipes, water coming
between the compressor and the fluctuating from hoses, and water spots on tools. Compressed air dryers
pressure caused by the changing demand. are essential in many applications that are sensitive to
moisture, such as the pharmaceutical industry, where dry
AIR RECEIVER TANK compressed air is required for manufacturing, fermentation,
and drying.
DEPARTMENT OF LABOR AND EMPLOYMENT
RULE
FOR UNFIRED PRESSURE VESSEL (RULE 1170)

RULE 1177: WATER AND AIR PRESSURE TANK