What are Operating Procedures For Industrial Compressors?
Working with compressors can be fun if all the necessary safety procedures can be followed. Compressors play vital roles in industrial operations, especially in the areas of cleaning, drying, pneumatic machines operations, dry cooling systems, etc. Based on the above purposes, its necessity can’t be denied when it comes to industrial operations.
Currently, there are hundreds of compressors designed to play different roles in the industries. The types of compressors that exist can be traced to the size, working principles, operational parts, cooling system, air compression techniques, and volume of pressure it can attain, among other factors.
For instance, there are air-cooled industrial compressors such as the GA-models made by the ATLASCOPCO group of companies.
Another one is the water-cooled industrial compressors made by the GHH company. The actual number of existing compressors may not be possible to ascertain, however; compressors can be carefully selected for industrial applications based on the job they are needed to do.
The clear difference between small compressors and the industrial compressors is the pressure output. While majority of industrial compressors can build pressure ranging from 6 bars to 80 bars based on intended applications, the small compressors built for low pressure cleaning, valve calibration jobs, and small pneumatic machines operations, etc. can have their pressures just within 2bars to 5 bars.
However, no matter the pressure, the operating procedures of all of them seem to be the same except the fact that those with high pressure output pose more danger than others because the mishandling can cause more damage and heavy financial loss to the industry.
Based on the danger associated with the operation of compressors, it is necessary to highlight the basic operational procedures of compressors.
THE OPERATING PROCEDURE FOR WATER-COOLED COMPRESSORS
1. Since water-cooled compressors have various water-heat exchangers along its airflows, ensure that water circulating pump is ON and working properly before moving to the next step in the operation.
2. Check the water pressure gauges along the water-flow/line to ensure it reads up to 5 bars to 6 bars.
3. Open the compressor water inlet and outlet valves.
4. Check the oil level at the base of the machine.
5. Start the oil pump by turning the main switch ON so that oil can start circulating along its flow lines.
6. When the oil pump has operated for about ten minutes, you can then start the compressor by turning its main switch ON.
7. With the compressor ON, turn the oil switch button from automatic to manual.
8. Turn the load switch from unload to load position.
9. Tap the overhead air-inlet valve to open if it hasn’t open properly.
The above procedure is for the water-cooled double stage air compressors especially the GHH model.
Meanwhile, the procedure for the air-cooled single stage air compressors is as follows:
OPERATING PROCEDURE FOR AIR-COOLED SINGLE STAGE COMPRESSOR
• FOR STARTING
1. Check for power supply by looking at the power signals within the power panel or the LED screen display.
2. Check for the power sequence, by opening the power junction unit to check for light signals which indicate the actual direction of rotation of the electric motor used by the compressor.
3. Proceed to the oil gauge to ensure it is at the HIGH gauge and check for any oil drop or leakage on the compressor floor below the oil circulating units.
4. Open the outlet valve beside the cooler and turn the cooler ON, ensure the air-filter vent valve is open for some time when starting the compressor so that any settled water in the air filter can be blown-off before actual comprehension begins.
5. Start the compressor and visually check for the motor direction of rotation to ensure it is in the right direction.
6. Close the vent valve a few seconds after the compressor has started working.
7. Majority of such compressors operate automatically, therefore; it has the ability of determing the LOAD & UNLOAD intervals automatically.
8. When the generated pressure is high and the consumption level is low, open the small vent valve usually attached to the air-flow lines.
9. For water and other liquid evacuation from the air filter, you can be opening the small vent located below the air filter.
10. Go to the LED screen display and take the readings of the pressure, temperature, working hours, and other data that may be needed.
• FOR SHUTDOWN
1. Switch off the compressor
2. Open the air-filter vent valve to evacuate trapped water and oil. Also to help relieve the built pressure in it.
3. Close the cooler check valve to avoid backflow of pressure.
4. Switch off the cooler.
5. Close the small vent valve opened at step 2.
The above procedure is for the air-cooled single-stage compressors.
While working as an operator in the air compressor units, there are safety procedures required to keep the compressor lifespan long and help secure the operator. Below are some of them:
• Open the compressor body casings and coverings after each operation for rapid cooling effects.
• Clean any dirt found within the air suction unit of the compressor and ensure the unit has its guard fixed properly.
• Do not allow any flying objects or waste bin baskets to stay around the compressor. The possibility of drawing flying light objects such as biscuit package, sachet water bags, packaging polyethylene bags, and other similar objects to its self is high.
• Report to the appropriate authority in the event of oil leakage, overheating, and other irregular occurrences.
• Take your reading every one hour of the compressor operating hours.
• Ensure the air-outlet valve is open while the compressor in operation.
• Never leave the compressor environment while it is still in operation.
