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Tool Talk Discussion Forum

Air Compressor; What Happened?

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Johnski

02-27-2004 23:33:45




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I have a tow behind air compressor at work that shattered the fan blade taking out the oil cooler and radiator. It has a JD (it's brown) 4 cyl diesel and a screw type compressor. This happened about a year ago and I just found out the whole story. It seems that one of my guys decided to blow out the air filter on the compressor inlet while it was running then he stuck the air hose into the inlet, that was followed immediatly by the fan blade exploding. Lucky no one hurt. Any theories about why this happened?

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Wayne

02-28-2004 22:55:33




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 Re: Air Compressor; What Happened? in reply to Johnski, 02-27-2004 23:33:45  
I've worked on a good many of the Atlas-Copco, IR, Gardner Denver, and Compair rotary screw and sliding vane type compressors and I just can't see where putting excess air into the intake on any of them would create any problems by itself. The way all of those compressors are designed they basically unload at a set output pressure, not input pressure. Each mfg. has their own design on the idea but all do it by starving off the intake air flow to the minimum required to maintain the called for output load (psi and flow) as well as maintaining just enough psi and flow for pressure lubing the compressor. This is always dependent on the pressure inside the compressor housing which will remain constant, or nearly so unless the load is large enough to drag it below the normal parameters. Even then most designs it will never drop below a set minimum pressure due to a minimum pressure valve in the system that insures the lube pressure is always there no matter what the output load. Also the control system will always have a built in "timer" to balance it and keep the unit from hunting and prevent overspeeding or bogging when the load is stopped or started "instantly". Basically if the controls are working correctly it should make no difference wether he force fed it or not. The one obvious thing that everybody overlooked is that you have a fan moving at high speed behind a grill that nothing but air can reach. Now think about blowing on a pinwheel and making it move one way and then blowing on it and try to make it reverse...it takes alot of force to reverse it. What I figure happened is when the guy got the air hose near the intake he inadvertently directed the air stream coming from the hose at the fan. That many CFM at the rated psi of most compressors would have given any fan, especially the plastic bladed ones they use nowdays, a huge shock load. If it happened to be rotating against the force of the blast instead of with it that would have made the shock even greater. It would have in effect been like the fan slapping against a wall which would almost certainly have made it shatter. Like most of the posts said it's just a wonder nobody got hurt. Just my .02

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rhudson

02-28-2004 04:27:13




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 Re: Air Compressor; What Happened? in reply to Johnski, 02-27-2004 23:33:45  
are you trying to say that compressed air was blown down the intake to the engine? supercharger effect maybe? if so, i would be supprised if the damage you see is the only damage there is. off hand i'd say maybe someone let the air blow the filter out of their hand into the spinning fan blade? did you see the old filter or housing?



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Mark

02-28-2004 05:34:08




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 Re: Re: Air Compressor; What Happened? in reply to rhudson, 02-28-2004 04:27:13  
Took the words right out of mouth..... .give em back sir. (Grin)

Probably the fan was subjected to an instantaneous step function in HP which torqued the engine and the fan was just trying to hang on for the ride.....what a deal. Did it blow the head gasket too?

Mark



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Johnski

02-28-2004 05:15:52




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 Re: Re: Air Compressor; What Happened? in reply to rhudson, 02-28-2004 04:27:13  
No, compressed air was blown directly into the screw compressor inlet pipe. The fan is completly shrouded so it wasn't hit by anything. HTH



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Britt Misker

02-28-2004 06:56:15




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 Re: Re: Re: Air Compressor; What Happened? in reply to Johnski, 02-28-2004 05:15:52  
I think that there are two posibilities.

1. A brown JD engine usually means an exchange engine. It is possible that the fan blades wer bent and then straightened when the engine was changed. This can cause a stress riser (weak area) to form in the blade. Then at some time in the future, BAM it comes apart with the results you described. You are lucky that no one was "in the line of fire". It is always good policy to replace the fan blades once they have been damaged in any way. They are under a lot of stress and can fail with little or no warning. And as you found out, as a suction fan (as in all cars trucks and most tractors) fails it's blades will pull themselves forward into the radiator or oil cooler.

2. When air was blown directly into the compressor air intake, it probably slammed the butterfly shut instantly which caused the engine to overspeed which resulted in the fan comming apart. In this instance you will be fortunate if there was no other damage to the engine and the compressor.

It could be a combination of these two that resulted in the fan comming apart.

What was your help thinking? If the airfilter was dirty enough to need cleaning, it shouldn't be cleaned with the compressor running!! A very poor practice. Not only did the fan come apart, but alot of the dirt that was in the filter most likely went right into the compressor.

I would have had to tell that guy, "It was nice knowing you".

Good Luck

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Johnski

02-28-2004 07:29:17




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 Re: Re: Re: Re: Air Compressor; What Happened? in reply to Britt Misker, 02-28-2004 06:56:15  
1. This unit only has 200 hrs on it. I think the engine is brown 'cause it's an industrial application. 2. I had similar thoughts, the rapid unloading of the comp must have caused the engine to overspeed the gov. I don't have the auth to hire/fire I'm just the mechanic, but he's a good guy and I guarantee that it wont' happen again



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Roger

02-28-2004 21:46:26




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 Re: Re: Re: Re: Re: Air Compressor; What Happened? in reply to Johnski, 02-28-2004 07:29:17  
While blowing air down the screw isn't an approved method for accomlishing anything, there is absolutely no correlation between doing that and the fan blades letting go. If the compressor was unloaded at the time, the air simply would feed back through the intake to atmosphere. If the compressor was pumping, it would simply take in the air and compress it, as it can pump a whole lot more air than a hose can deliver. Was this a MultiWing fan? If the bolts holding the hub together were loose, I am not surprised the blades let go. With only 200 hrs on the compressor, it sounds like an assembly error from the factory. Most compressor fans are pushers, since it helps to scavenge hot air from inside the cabinet, This is also why you run portable compressors with the doors shut. Using compressed air to clean filters is also a good way to tear them. We had one unit pack it in after a few months because frequent blowing out of the filters with compressed air caused them to tear. You could not see it by looking, but when we took the filters to a filter supply shop, they put it in a special black booth that had a light in the middle, When the filter was placed over the light, and a small amount of air was blown up through it, the tears became immediately visible as vertical beams of light along the walls. Removing a filter why the compressor is running is also a bad idea, for obvious reasons. If this is a LeRoi compressor, I am not surprised the engine is brown, as the whole unit is brown. This JD engine is widely used in compressors, so it might have been pulled from a LeRoi also. It is a nice engine. Much smoother than Perkins or Detroits.

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