air compressor maintenance, case identification and solve

1. Air Compressor ZR Atlas Copco
Prepared by: Bagus Adirianto
Sharing Knowledge Session

2. CONTENT
FUNDAMENTALS
INTRODUCTION OF AIR COMPRESSOR ZR
MAINTENANCE STRATEGY
MAINTENANCE CASE

3. FUNDAMENTALS
COMPRESSOR
MECHANICAL DEVICE (MACHINE) TO COMPRESS COMPRESSIBLE FLUID BY
REDUCING THE VOLUME AND INCREASING THE PRESSURE.
Basic Principle
INTRODUCTION
ATMOSPHERE Storage
Vessel

4. FUNDAMENTALS
APPLICATION
Agriculture Farm equipment, materials handling,
spraying of crops
Mining Pneumatic tools, hoists, controls and
actuators
Wastewater
Treatment
Vacuum filters, conveying
Recreation Underwater exploration – air tanks
scuba
Service Industries Pneumatic tools, hoists, air brake
systems, garment pressing machines,
hospital respiration systems
Transportation Pneumatic tools, hoists, air brake
systems
Power Generation Starting gas turbines, automatic
control valves, cleaning, pneumatic
tools

5. FUNDAMENTALS
CLASSIFICATION

6. INTRODUCTION OF AIR COMPRESSOR ZR
INTRODUCTION
General Views
Main Parts:
• Air Filter
• LP Element
• Intercooler
• HP element
• Aftercooler
• Water Separators
• Electric Motor
• Drive Coupling
• Gear Casing
• Elektronikon device
• Safety Valve

7. TECHNICAL DATA SHEET
MFG : Atlas Copco
Model : ZR 400-10-50
Type : Rotary Screw Oil-Free
Stage : 2
Fluid : Air
Qty : 4 working, 1 standby
Location: Indoor
Coupling: Flexible rubber bolt GGG40
Cap. : 2760 Nm3/h
Oil Cap : 85 liters
Power : 365.5 kW
INTRODUCTION OF AIR COMPRESSOR ZR
Weight : 8,020 kg with motor
LxWxH : 3700 x 2120 x 2400 mm
Pressure: 1,013 bar(g) (inlet)
Temp. : 30/43.2°C (max)
Humid : 80%
Pressure: 10 bar(g) (discharge)
Temp. : 44°C
Motor : Marathon
Type : HCM450-4
Speed : 1485 r/m
Freq. : 50Hz

8. INTRODUCTION OF AIR COMPRESSOR ZR
INTRODUCTION
Oil lubricated VS Oil-free screw compressor

9. INTRODUCTION OF AIR COMPRESSOR ZR
SITE PLAN LAYOUT

10. INTRODUCTION OF AIR COMPRESSOR ZR
General Arrangement (Top View)

11. INTRODUCTION OF AIR COMPRESSOR ZR
General Arrangement (Side View)

12. INTRODUCTION OF AIR COMPRESSOR ZR
Piping & Instrumentation Diagram (1)

13. INTRODUCTION OF AIR COMPRESSOR ZR
Piping & Instrumentation Diagram (2)

14. SYSTEM in AIR COMPRESSOR ZR
INTRODUCTION OF AIR COMPRESSOR ZR
COOLING WATER SYSTEM
OIL SYSTEM
AIR SYSTEM
There are 3 systems in Air Compressor ZR :

15. FLOW DIAGRAM OF AIR COMPRESSOR ZR
INTRODUCTION OF AIR COMPRESSOR ZR
AF = AIR FILTER
OF = OIL FILTER
BV = BYPASS VALVE
Eh = HIGH PRESSURE ELEMENT
El = LOW PRESSURE ELEMENT
OP = OIL PUMP
Co = OIL COOLER
AS = AIR SILENCER
Ci = INTERCOOLER
Ca = AFTERCOOLER
MTi = MOISTURE TRAP IC
MTa = MOISTURE TRAP AC
MTb = MOISTURE TRAP BYPASS
CV = CHECK VALVE
AO = AIR OUTLET

16. INTRODUCTION OF AIR COMPRESSOR ZR
COOLING & CONDENSATE DRAIN SYSTEM
AF = AIR FILTER
OF = OIL FILTER
BV = BYPASS VALVE
Eh = HIGH PRESSURE ELEMENT
El = LOW PRESSURE ELEMENT
OP = OIL PUMP
Co = OIL COOLER
AS = AIR SILENCER
Ci = INTERCOOLER
Ca = AFTERCOOLER
MTi = MOISTURE TRAP IC
MTa = MOISTURE TRAP AC
MTb = MOISTURE TRAP BYPASS
CV = CHECK VALVE
AO = AIR OUTLET

17. INTRODUCTION OF AIR COMPRESSOR ZR
OIL SYSTEM
AF = AIR FILTER
OF = OIL FILTER
BV = BYPASS VALVE
Eh = HIGH PRESSURE ELEMENT
El = LOW PRESSURE ELEMENT
OP = OIL PUMP
Co = OIL COOLER
AS = AIR SILENCER
Ci = INTERCOOLER
Ca = AFTERCOOLER
MTi = MOISTURE TRAP IC
MTa = MOISTURE TRAP AC
MTb = MOISTURE TRAP BYPASS
CV = CHECK VALVE
AO = AIR OUTLET

18. INTRODUCTION OF AIR COMPRESSOR ZR
AIR SYSTEM
AF = AIR FILTER
OF = OIL FILTER
BV = BYPASS VALVE
Eh = HIGH PRESSURE ELEMENT
El = LOW PRESSURE ELEMENT
OP = OIL PUMP
Co = OIL COOLER
AS = AIR SILENCER
Ci = INTERCOOLER
Ca = AFTERCOOLER
MTi = MOISTURE TRAP IC
MTa = MOISTURE TRAP AC
MTb = MOISTURE TRAP BYPASS
CV = CHECK VALVE
AO = AIR OUTLET

19. INTRODUCTION OF AIR COMPRESSOR ZR
REGULATING SYSTEM
UNLOADING PROCESS
UA = UNLOADER
UV = UNLOADING VALVE
TV = THROTTLE VALVE
US = UNLOADING SILENCER
AS = AIR SILENCER
CV = CHECK VALVE
EL = LP ELEMENT
EH = HP ELEMENT
Ci = INTERCOOLER
Ca = AFTERCOOLER
Y1 = SOLENOID VALVE
AF = AIR FILTER
1 = CHAMBER
3 = CHAMBER
2 = PLUNGER
4 = DIAPHRAGM

20. INTRODUCTION OF AIR COMPRESSOR ZR
AIR SYSTEM
LOADING PROCESS
UA = UNLOADER
UV = UNLOADING VALVE
TV = THROTTLE VALVE
US = UNLOADING SILENCER
AS = AIR SILENCER
CV = CHECK VALVE
EL = LP ELEMENT
EH = HP ELEMENT
Ci = INTERCOOLER
Ca = AFTERCOOLER
Y1 = SOLENOID VALVE
AF = AIR FILTER
1 = CHAMBER
3 = CHAMBER
2 = PLUNGER
4 = DIAPHRAGM

21. MAINTENANCE STRATEGY
SAFETY PRECAUTION!!
• Always use the correct safety equipment (helm, shoes, glass)
• Use only the correct tools for maintenance work
• Use only genuine spare parts for maintenance work
• Maintenance work allowed when the machine has cooled down
• Stop the compressor before starting any maintenance/repair
• Close the compressor air outlet and depressurized
• Open the isolating switch (CB) to switch off the voltage (LOTO)
• Never weld or perform any involving heat near the oil system
• Never use a light source with an open flame for inspecting
• Make sure that no tools, loose parts, or rags are left in machine
• Never use caustic solvent which can damage materials
• Never use flammable solvents for cleaning parts.

22. MAINTENANCE STRATEGY
MAINTENANCE SCHEDULE (OEM)
OEM use meter-based maintenance for maintaining the Air
Compressor (based on running hours)
RUNNING INSPECTION
4000 HOURS INSPECTION (Lv. A)
8000 HOURS INSPECTION (Lv. B)
16000 HOURS INSPECTION (Lv. C)
40000 HOURS INSPECTION (Lv. D)
Service Plan as OEM recommendation:

23. MAINTENANCE STRATEGY
 Check the Elektronikon Display for warnings
 Check that condensate is discharged during loading
 Drain the aftercooler and intercooler Moisture Traps
 Check possibilities for leakage from hoses, connectors, etc.
 Check the oil level
 Take records and measure several parameters
RUNNING INSPECTION

24. MAINTENANCE STRATEGY
4000 HOURS INSPECTION (Lv. A)
 Take service readings (air, oil, water temperature, pressure)
 Check cooler functions (approach temperature)
 Change intercooler condensate check valve
 Check for air, oil, and water leakage
 Check for the presence of water in lube oil
 Cleaning / replace air filter element
 Replace filter element of gear case breather
 Check cycle of air intake throttle valve
 Check / cleaning condensate drain
 Clean fan cowl of electric motor
 Check rubber insert of drive coupling
 Take and record all S.P.M readings

25. MAINTENANCE STRATEGY
8000 HOURS INSPECTION (Lv. B)
Carried out 4000 Hours Inspection task (Lv. A)
Check operation of safety valves
Change compressor oil filter
Replace the diaphragm of air throttle valve
Replace bearing block (air intake valve)
Check function of check valve
Check balance piston diaphragm
Inspect electrical contactor (electric portion)
Check all electrical connections (electric portion)

26. MAINTENANCE STRATEGY
16000 HOURS INSPECTION (Lv. C)
 Carried out 4000 Hours Inspection task (Lv. A)
 Carried out 8000 Hours Inspection task (Lv. B)
 Service intercooler blowdown valve
 Replace oil lubrication (Roto-Z)
 Overhaul air intake valve
 Replace insert of drive coupling

27. MAINTENANCE STRATEGY
40000 HOURS INSPECTION (Lv. D)
 Carried out 4000 Hours Inspection task (Lv. A)
 Carried out 8000 Hours Inspection task (Lv. B)
 Carried out 16000 Hours Inspection task (Lv. C)
 Overhaul oil pump
 Replace HP and LP Element

28. MAINTENANCE CASE
The maintenance case is based on experience handling Atlas
Copco Air Compressor type ZR 355 in Tanjung Jati 1&2

29. MAINTENANCE CASE
RUNNING INSPECTION

30. MAINTENANCE CASE
Check Air Filter

31. MAINTENANCE CASE
Check Air Filter
Clean the air filter
Check rubber seal
Cleaning surface from dirt
Cleaning / replacing the Air Filter is carried out in routine PM or Different Pressure increase (>
0.045 bar)

32. MAINTENANCE CASE
Checking the Drain Valve

33. MAINTENANCE CASE
Checking the Drain Valve
Check the float
Check the membrane
Check the O-ring seal
Check the strainer
Cleaning deposit / sludge
Check the valve base and casing

34. MAINTENANCE CASE
Checking the Drain Line
Replace the pipe coupling
Replace connector pipe

35. MAINTENANCE CASE
Replace the Water Separator

36. MAINTENANCE CASE
Replace the Water Separator
Found air leakage from the bowl of Water Separator. Caused by a loose connection between
the tie rod (9035) thread and head (9040), the tie rod detached and then hit the bowl
Replace water separator

37. MAINTENANCE CASE
Replace the LP Element

38. MAINTENANCE CASE
Replace the LP Element
LP element stuck due to bearing broken (bearing lifetime)
The ball bearing is totally broken
Two screw element touch and stuck
Replace the LP Element

39. MAINTENANCE CASE
Replace the Muffler

40. MAINTENANCE CASE
Replace the Muffler
Air Compressor trip due to high temperature at the HP element outlet. Caused during
unloading, pressurized air cannot be released to the atm due to the muffler being blocked.
After replacing the muffler, the HP outlet element decreased and back to normal operation

41. MAINTENANCE CASE
Checking Air Intake (loading / unloading system)

42. MAINTENANCE CASE
Checking Air Intake (loading / unloading system)
Check the diaphragm condition
Check the spring and piston condition

43. MAINTENANCE CASE
Overhaul Air Compressor Unit (15 days)
Overhaul Air Inlet Valve
Checking disc condition
Replace bearing block part
Replace O-ring and seal
Replace membrane
Replace Diaphragm
Check piston and spring

44. MAINTENANCE CASE
Overhaul Air Compressor Unit
Replace rubber coupling
Replace oil filter
Replace HP and LP element
Cleaning intercooler and aftercooler

45. MAINTENANCE CASE
Overhaul Air Compressor Unit
Check the oil pump Replace gear case breather
Check air silencer
Check and cleaning other parts

46. MAINTENANCE CASE
Overhaul Air Compressor Unit
Inspection & maintenance report

47. Thank You