1. The document provides information about an air compressor at Asian Paints Khandala plant, including its specifications, components, electrical and control systems. 2. It describes the oil injected screw compressor as having a capacity of 1500 CFM@7.5Bar powered by a 250KW motor. 3. The key components are the suction air filter, unloading valve, compression unit, oil separator, oil cooler, oil filter and air cooler; and the compressor is controlled through a main control system that monitors sensors for temperature, pressure and alarms.

1. AIR COMPRESSOR
TRAINING
ASIAN PAINTS KHANDALA PLANT

2. WHAT IS AIR COMPRESSOR AND ITS USE
Compressor is used to increase the pressure of air from low
pressure to high pressure by using some external energy.
Types of Compressor
• Positive Displacement
– Reciprocating
– Rotary Screw
• Dynamic
– Centrifugal
– Axial flow
We use the Oil Injected Screw Compressor.

3. SPECIFICATION
• Make : Kaeser Compressor(India) PVT LTD
• Type : Oil Injected Screw Compressor
• Model : ESD-442 SFG/8.5
• Capacity : 1500 CFM@7.5Bar
• Motor Rating : 250 KW

4. Compressor Component
1. Suction air filter
2. Unloading valve
3. Compression unit (Screw elements and comp.
chamber, driver and Bearing Unit).
4. Oil separator
5. Oil Bypass valve (Thermostat principle)
6. Oil cooler
7. Oil filter
8. Air cooler
9. Condensate drain

5. COMPRESSOR SLD
Atmosphere
Suction Filter Inlet Valve
Compressor
Unit
Oil
Separator
Oil Bypass
Valve(Thermostat
Principle)
Oil Cooler
Oil Filter
Air Cooler
To Air Dryer
Air Flow Path
Oil Flow Path
Oil+ Air Flow
Path
If Oil Temp >
Desired value
If Oil Temp <
Desired value

7. OIL COOLER MOTOR
INLET VALVE
SUCTION FILTER
2
3
1
5
4
AIR COOLER MOTOR
1
2
3
4
5 COMPRESSOR UNIT

8. Part Of Oil Cooler Part Of Air Cooler

9. ELECTRICAL COMPONENT
A. Power Switching Frequency Converter
- Compressor Motor (M1 250KW)
- Oil Cooler Motor (M4 5.5KW)
- Air Cooler Motor (M5 2.2KW)
- Frequency Converter (Sinamics G120)
B. Compressor Control
- Main Control System SC2MCS (K20)
- IO Module SC2IOM-1 (K21)
-IO Module SC2IOM-2 (K22)

10. ELECTRICAL DRAWING KEY POINTS
• F4,F5 – Overload Protection Switch Fan Motor
• F7 – Overload Protection Switch Ventilator Fans
• F11 – Overload Protection Switch, Control Transformer
• Q1,Q2 – Main Contactor
• K10 – Condensate Drain Centrifugal Separator
• K20 – Main Control System SC2MCS
• K21 – IO Module SC2IOM-1
• K22 – IO Module SC2IOM-2
• Q4 & Q5 – Contactor ,Fan Motor
• Q7 – Contactor, Ventilator Fan
• T11 – Control Transformer
• T21,T22,T27 – Power Unit 24V DC

11. SENSORS & ACTUATORS
• B1 – Pressure Transducer, Air Main Pressure
• B2 – Direction of Rotation Pressure Switch
• B3 – Oil Filter Differential Pressure Switch
• B4 – Pressure Transducer, Package Internal Pressure
• B5 – Air Filter Vacuum Switch
• B40 – Temp. Probe PT100 Airend Discharge
Temperature
• B41 - Temp. Probe PT100 Oil Separator Tank Air
Discharge Temperature
• B42 – Compressed Air outlet Temp.
• B43 – Inlet Temp.
• B61,B62,B63 – Temp. Probe PT100 Compressor Motor

12. COMPRESSOR INTERLOCKING
• DIGITAL INPUTS
- Emergency Stop F/B
- OLR Switch F/B for air cooler motor
- Condensate drain Separator
- OLR Switch F/B for control cabinet fan
• ANALOG INPUTS
- Compressor motor temperature 1,2 & 3(For
3wdgs)
- Air Main Pressure
- Package Internal Pressure
- Airend Discharge Temp.
- Compressed Air Outlet Temp.
- Inlet Temp (B43)
- Oil Separator (B41)

13. COMPRESSOR INTERLOCKING
• DIGITAL OUTPUTS
- Emergency Stop
- Mains Contactor ON (K50)
- Oil cooler motor contactor start command
- Contactor Start command for cabinet fans
- Start command for Air cooler motor
- Control Valve (DOT)
- Condensate Drain Centrifugal Separator

14. COMMUNICATION
MAIN CONTROL SYSTEM
SC2MCS (K20)
TO SIGMA
CONTROLLER
TO COMRESSOR
MOTOR DRIVE
CU
TO OIL COOLER
MOTOR DRIVE
CU
TO IOM1 (K21)
TO IOM2 (K22)
RS485 IO BUS
COM
MODULE
COM-M502
COM-M503

15. • Please refer Manual and Drawing