Question

With reference to reciprocating air compressors explain the cause of the following faults:

(a) Collapse of discharge valve springs.

(b) Breakage of plate valves.

(c) Overheating the discharge air with an unrestricted air intake.

(d) Inoperative piston rings.

Answer 1

Part (a)

Overheating or Insufficient Cooling due to Cooling water supply failure.
Fouling or choking of the intercooler.
Choked suction filters restricting airflow.
Excessive Deposits on the valve due to carryover of oil from the compressor.
Use of improper oil grades.
Worn-out scraper rings leading to oil ingress.
Oxidation of oil causing carbonaceous deposits.
Fatigue Failure caused by repeated stress cycles over time causing material fatigue.
Improper assembly of the valve after maintenance.

Part (b)

Incorrect assembly leads to uneven stress distribution.
Fatigue failure due to repeated high-pressure cycles.
Overheating of the valve leads to structural weakness.
Prolonged use causes the plate to become thin and lose strength.
Exposure to moisture or aggressive contaminants in the air system.
Accumulation of oil or carbon deposits hinders valve movement and causes mechanical failure.

Part (c)

Part (d)

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