OPERATING MANUAL

FOR

COMMPRESSED AIR SYSTEM

Description of process operation of compressed air system

1 General introduction of the system

This system includes two sections: compressed air station F85B-D33-DC,

F85B-D34-DC, and compressed air network F85B-D92-DC.

2 General description of design

This project has two compressed air stations, one with 5 screw air compressors

(one standby) for Clinker system, the other one with 4 screw air compressors

(one standby) for Cement system. The compressed air station is located in

cement plant independently. They supply the compressed air for the

Consumption of the whole cement plant. The compressed air out of the

compressors overpass the buffer tank、front filter、refrigerated compressed air

dryer and compressed air storage tank to the compressed air pipe net. then will

be supplied to each compressed air storage tank set in each workshop, then to

each consumption.

3 Description of technical parameters of process equipment

3.1 Air compressor

Type Unit Oil Flooded Compressor
Mode SA-120W
3
Capacity m /min 21.1
Discharge pressure MPa(G) 0.75
Motor Nominal power kW 110
Consumption of cooling water t/h 12
Driving mode Direct connection with gear

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 Discharge air Temp. ℃ <40

Max ambient Temp. ℃ 46

Noise level dB(A) 80

Oil Carryover ppm <3
Power requirement && start-up V/Hz/P
380/50/3
mode h
Connection Flange DN80
Outline dimension (L/W/H) mm 2340/1650/1800
Weight kg 3000

3.2 Refrigerating dryer

Type Refrigerating dryer
Air handling capacity 23Nm3/min

Output pressure dew point 3℃

Working pressure 0.6~1.0MPa

Power of refrigeration compressor 4.4kW
Cooling method water cooling
Consumption of cooling water 3.45 t/h
Refrigerant R22
Air connection pipe diameter DN80
Power supply 380V/50Hz
1600/750/1400 (length, width,
Outline dimensions
height)
Net weight of equipment 410kg
Control mode Auto control by instrument
Leveled cement ground, base free
Equipment installation requirement
installation

3.3 Filter
Model
Nominal handling capacity 23Nm3/min
Dust content ≤1μm
Filter ratings
Oil Carryover≤1ppm
Inlet air pressure 0.2~1.0 MPa

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 Model

Inlet air temp. ≤60 ℃

Equipment weight 49 kg
Inlet/outlet pipe dia. DN80

3.4 Buffer tank

Model C-1.0/0.8

Volume 1.0 m3

Working pressure 0.8MPa

3.5 Storage tank

Model C-2.0/0.8

Volume 2.0 m3

Working pressure 0.8 MPa

4 Description of equipment functions

No. Equip. code Equip. name Equip. Qty Remarks
description
01 D31AC01~D31AC05 Air compressor Model: 9 Prepare compressed air for
D32AC01~04 SA120W production of cement plant

02 D31BT01~D31BT05 Model: 9 Stabilize air source

D32BT01~D32BT04 Buffer tank C-1.0/0.8
03 D31FL01~D31FL Model: 9 Coarse filtration of the
05 Filter C-800 compressed air out of the
D32FL01~D32FL compressor
04

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 No. Equip. code Equip. name Equip. Qty Remarks
description
04 D31FD01~D31FD05 Refrigerating Model: 9 Drying compressed air
D32FD01~D31FD04 dryer JYL-250W
05 D31AT01~D31AT05 storage tank Model: 9 Stabilize air source
D32AT01~D31AT04 C-2.0/0.8
06 D31RF01~D31RF04 Roof top FRB Model:WS-85-6 7 building ventilation
D32RF01~D32RF03 axial fan №5.3 system
Capacity:
10800 m3/h

5 Key principles of operation and precautions

5.1 Well prepare before operation

1) Lubricating oil quantity of compressor meets the requirement and the grade

of oil conforms to specification

2) Check whether the valves of air pipelines can be flexibly opened/closed and

whether the instrument and apparatus have been adjusted correctly

3) Check whether the motor and electrical control equipment is normal

5.2 Operate the machine and timely handle the exceptional case

5.3 During operation of the compressed air system, pay attention to the change

of compressed air in the workshop so as to make proper adjustment of the

discharge pressure of compressor or the number of running compressors.

5.4 Perform regular blowdown of the buffer tank, air tank, pre filter and post

filter of the system

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Regularly inspect the joining and fastening conditions of the pipeline and

fittings. Fasten it if necessary.

5.5 Timely start the standby equipment after shutdown of air compressor due to

fault. In the meantime, according to the alarm location of the faulty equipment,

find out the cause and restore.

6 Common faults and maintenance of main equipment

6.1 Table of common faults and troubleshooting solution of compressor

No. Phenomenon Causes of fault Troubleshooting
1.1 Check whether the
cooling air is obstructed or
improve the ventilating
conditions of the compressor
1.1 Insufficient cooling air house and avoid backflow of
or over high temperature of cooling air
cooling air 1.2 Check and replace if
1.2 Over low oil level necessary
Over high exhaust 1.3 Oil cooler blocked 1.3 Wash the cooler
1
temperature
1.4 Bypass valve fault 1.4 Check the valve
1.5 Air cooler blocked 1.5 Wash the cooler
1.6 Compressor head fault
1.6 Ingersoll Rand；
1.7 Temp. sensor fault
Consult Ingersoll Rand
1.7 Check the line and
replace the damaged
elements
2.1 Pressure relief valve 2.1 Repair or replace
fault of the separator tank 2.2 Repair or replace
2.2 Pressure regulator fault 2.3 Repair or replace
Exhaust pressure 2.3 Screw regulating valve 2.4 Check and repair
2
is over high fault 2.5 Check, replace filter
2.4 Control system leakage 2.6 Replace blocking
2.5 Control pipeline elements
blockage 2.7 Repair or replace

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No. Phenomenon Causes of fault Troubleshooting
2.6 Separator blockage
2.7 Minimum pressure
valve fault
3.1
System air consumption 3.1 Increase the number of
exceeds the air discharge of working compressor and
compressor inspect the pipe network
3.2 Air filter element leakage
blockage 3.2 Replace filter element
Exhaust pressure 3.3 Solenoid valve fault 3.3 Replace the valve
3
is over low
3.4 Control hose leakage 3.4 Replace the leaking hose
3.5 Inlet valve is not fully 3.5 Check the valve
opened 3.6 Replace the oil separator
3.6 Oil separator blockage 3.7 Replace the leaking hose
3.7 Air leakage 3.8 Replace the valve
3.8 Safety valve leakage
4.1 Error of pressure
display
4.1 Check the connector or
4.2Pressure relief valve replace pressure sensor
Pressure of damaged 4.2 Repair or replace
4 control pipeline is 4.3 Screw regulating valve
4.3 Repair or replace
over high fault
4.4 Check and repair
4.4 Control system leakage
4.5 Check or replace filter
4.5 Control pipeline filter
blockage
5.1
Oil return pipe filter or
hole blockage 5.1 Clean or replace filter
5.2 Oil-gas separator 5.2 Check or replace
element damaged 5.3 Check and repair
High oil
5 5.3 Lubricating oil system 5.4 Check the oil level,
consumption
leakage discharge the oil to correct
5.4 Excessive lubricating level after pressure relief
oil 5.5 Replace it to correct oil
5.5 Incorrect oil results in
bubble

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 No. Phenomenon Causes of fault Troubleshooting
6.1 System air
consumption exceeds the 6.1 Increase the number of
air supplied working compressor and
6.2 Inlet filter of inspect the pipe network
compressor blocked leakage
Insufficient air 6.3 6.2 Check and replace the
6
supply pressure Inlet valve of compressor filter mesh
cannot be fully opened 6.3 Check lifting valve and
6.4 Pressure sensor or pressure regulator position
connections fault 6.4 Check the connections
6.5 Minimum pressure 6.5 Repair or replace
valve fault
7.1 Pressure sensor fault
7.2 Pressure relief valve 7.1 Check the connections or
replace sensor
7.3 Screw regulating valve
Pressure of 7.2 Check
is out of order
7 control pipeline
7.4 Air signal pipeline 7.3 Check
exceeds the set
leakage 7.4 Check
value
7.5 Air signal pipeline 7.5 Check
blocked

6.2 Table of common faults and troubleshooting solution of dryer

No. Phenomenon Causes of fault Troubleshooting
1.1Pipeline valve is not
fully opened 1.1Fully open the valve
1.2 Pipeline diameter is too 1.2 Enlarge pipe diameter
small 1.3 Redesign the pipe
Too high air 1.3 Too long pipe route and routing system
1
pressure drop too many bends and joints 1.4 Check the bends and
1.4 Too much air leakage at joints
joints of pipelines 1.5 Clean the filter or
1.5 Filter in pipeline replace by the filter element
blocked
2.1 Temp. switch fault
2.1 Replace temp. switch
2 Evaporator iced 2.2Expansion valve
2.2 Replace expansion valve
blocked and not working

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No. Phenomenon Causes of fault Troubleshooting
The local flow for use 3.1 Replace by a larger
Insufficient air exceeds the nominal flow capacity air compressor
3
supply of air compressor, so it 3.2 Reduce air flow
declines naturally
4.1Bypass of air
compressor is not fully
closed
4.1 Close bypass valve
4.2 Air does not pass
4.2 Open all the inlet and
through refrigerating dryer
outlet valves of refrigerating
4.3 High air flow and too dryer
Moisture high pressure drop
4 4.3 Redesign the source
contained at site 4.4 Drainpipe is higher system of air compressor
than auto drainer
4.4 Reinstall the drainpipe
4.5 Whether inlet and
4.5 Recheck
outlet of compressed air
are connected adversely 4.6 Clean or replace
4.6 Drainer does not work
well
5.1 Too high evaporation
5.1 Check air source load of
temp.
air compressor
5.2 Air of surrounding
Refrigerant low environment is polluted 5.2 Select proper location or
pressure switch and it is not well ventilated improve ventilation
5
trips and the light 5.3 Replace expansion valve
5.3 Expansion valve
is lit 5.4 Check and remedy the
blocked and not working
leakage and fill refrigerant
5.4 Refrigerant leakage
5.5 Replace instrument
5.5 Instrument damage
6.1 Service pressure is at
0.15Mpa 6.1 Normal service pressure
6.2 Too high service is at 0.2~1MPa
Auto drain system
pressure 6.2 Use it as per the rated
6 does not work
6.3 Too much water pressure of auto drainer
well
quantity of the system 6.3 Adopt manual drainage
6.4 Filter of the drainer 6.4 Clean the drainer
blocked

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 No. Phenomenon Causes of fault Troubleshooting
7.1 Refrigerant leakage or
insufficient filling of 7.1 Seal leakage or add
cryogen cryogen
7 Low voltage trip 7.2 Cryogen pipeline 7.2 Find out the cause and
chokes the flow repair
7.3 Improper setting of low 7.3 Reset or replace
voltage trip
8.1 Excessive filling of
cryogen 8.1 Discharge the excessive
8.2 Improper setting of cryogen
8 High voltage trip
high voltage switch 8.2 Reset or replace
8.3 Condensing fan burned 8.3 Replace fan
out
9.1 Over current of
9.1 Check the power supply,
compressor
contactor and connections,
9.2
and repair the same
Compressor Insufficient refrigerating
9 9.2 Check the filling of
overload trip leads to over hot of
cryogen (sealing leakage).
compressor
Add cryogen if necessary
9.3 Short circuit of coils of
9.3Replace compressor
compressor
10.1 Contactor does not
work well
10.2 Fan motor burned out 10.1 Replace contactor
10.3 Pressure relay does 10.2 Replace fan
not work well 10.3 Replace pressure relay
Cooler fan does
10 10.4 Fan capacitance does 10.4 Replace capacitance
not work
not work well 10.5 Seal leakage or add
10.5 Cryogen does not cryogen
work well 10.6 Fasten the fixing screw
10.6 Fixing screw of the
fan leaves loosens

6.3 Table of common faults and troubleshooting solution of filter

No. Phenomenon Causes of fault Troubleshooting
1.1 Actual flow exceeds the 1.1 Replace by large flow
Poor filtration inlet volume flow filter
1
effect 1.2 Actual inlet air pressure 1.2 Boost the actual inlet air
is lower than the rated inlet pressure

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No. Phenomenon Causes of fault Troubleshooting
pressure 1.3 Tighten the nut
1.3 Filter element and 1.4 Close bypass valve
fastening nut are not tightly
tightened
1.5 Replace filter element
1.4 Bypass valve is not
1.6 Check the drainage and
closed tightly
find if it is blocked
1.5 Filter element does not
1.7
work
Timely clean the pipeline
1.6 High oil water level in
the filter cylinder that leads
to oil carried air
1.7 Downstream pipeline is
not clean
2.1 Too many impurities in
inlet air
2.1 Improve inlet air quality
Sharp increase of 2.2 Filter element is
2.2 Replace filter element
2 differential heavily blocked
pressure 2.3 Check the drainage and
2.3 Too much water
find if it is blocked
accumulated in filter
cylinder
3.1 Repair
3.1 Air leakage 3.2 Increase inlet air
3.2 Low pressure of inlet pressure
Sharp decrease of air 3.3 Replace the damaged
3 differential 3.3 Sealant damaged part
pressure 3.4Air leakage of pipe 3.4
3.5 Valve is not fully
opened Repair
3.5 Open the valve

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