JOMO KENYATTA UNIVERSITY OF AGRICULTURE AND TECHNOLOGY

COLLEGE OF ENGINEERING AND TECHNOLOGY

SCHOOL OF MECHANICAL, MANUFACTURING AND MATERIALS

ENGINEERING

DEPARTMENT OF MARINE ENGINEERING AND MARITIME OPERATIONS

BSc. MARINE ENGINEERING

EMR 2510: MARINE REFRIGERATION AND AIR CONDITIONING

TERM PAPER

TITLE: COMPRESSORS

GROUP MEMBERS:

1. NINAJOY KIOGORA – ENM241-0099/2018

2. BERNICE MWATHA NZINGA – ENM241-0098/2018

3. OMAR MOHAMED MWAGAO – ENM241-0103/2018

4. KROP NUHU – ENM241-0108/2018

5. OMAR OMAR MOHAMED – ENM241-0209/2018

6. HUSSEIN SHARIFF NOOR – ENM241-0095/2018

INTRODUCTION
Compressors play a vital role in various industries, including marine applications, by converting low-
pressure, low-temperature gas into high-pressure, high-temperature gas. They are essential components
of refrigeration systems, air conditioning units, and other mechanical systems. This report aims to
provide an overview of different types of compressors, their working principles, marine applications,
troubleshooting and maintenance, and the parameters logged during watch-keeping for refrigeration
systems.

WORKING PRINCIPLE OF COMPRESSORS

Figure 1 Compressor Unit

A line diagram of a compressor unit is shown in Figure 1. The compression process requires work input.
Hence a compressor is driven by a prime mover. Generally, an electric motor is used as the prime
mover. Low temperature- low-pressure vapour/air enters into the compressor through the suction valve
and is compressed to high pressure- high-temperature vapour. The high-pressure-high temperature
vapour is then discharged through the discharge valve and is delivered to a reservoir or is directly
conveyed to the desired unit through pipelines.

TYPES OF COMPRESSORS
There are two main compressor categories: positive displacement and dynamic.

1. Positive Displacement Compressors

Positive displacement compressors work by trapping a fixed volume of gas and then reducing its volume
to increase the pressure. *preventing undesired backflow. They are commonly used for applications that
require high pressure and relatively low flow rates. The following are some types of positive
displacement compressors:

a. Reciprocating Compressors
The cylinder block of the reciprocating compressor is designed much like that of an internal combustion
engine found in most automobiles. The similarity ends at the cylinder head which is constructed
specifically for air compression purposes. Air is drawn into the cylinder through a one-way intake valve
as the piston moves down. Once the piston reverses direction and begins upward motion, the intake
valve is forced closed, and the compression of air forces the discharge valve open, passing the air out of
the cylinder and into the air receiver. The most common intake and discharge valves are simple spring-
loaded devices, varying in design and size according to the size of the air compressor.

Advantages of Reciprocating Compressors:

1. High Efficiency: Reciprocating compressors are known for their high efficiency, especially in
low-volume and high-pressure applications. They can deliver high compression ratios, making
them suitable for demanding tasks.

2. Wide Range of Applications: Reciprocating compressors can handle a wide range of gases,
including both dry and wet gases. This versatility makes them useful in industries such as oil and
gas, petrochemical, refrigeration, and manufacturing.

3. Compact Design: Reciprocating compressors have a relatively compact design, which makes
them suitable for installations where space is limited. They can be easily integrated into existing
systems or placed in small enclosures.
 4. Controllable Output: These compressors allow for precise control over output pressure. By
adjusting the stroke length or speed, operators can regulate the compression process and match
the specific requirements of the application.

5. Simple Maintenance: Reciprocating compressors have fewer complex parts compared to other
compressor types. This simplifies maintenance and reduces the overall maintenance costs.
Individual components can be easily inspected, repaired, or replaced, resulting in shorter
downtime.

Disadvantages of Reciprocating Compressors:

1. Vibrations and Noise: Reciprocating compressors produce vibrations and noise during operation
due to the reciprocating motion of pistons. This can lead to discomfort for workers and requires
additional measures, such as vibration isolation and noise reduction, to address these issues.

2. Limited Capacity: Reciprocating compressors are generally limited in terms of their capacity.
While they are efficient in low-volume applications, they may not be suitable for large-scale
industrial processes that require a significant amount of compressed gas.

3. Higher Maintenance Requirements: Although maintenance is relatively simple, reciprocating

compressors typically require more frequent maintenance compared to other compressor types.
This is because they have more moving parts that need regular inspection, lubrication, and
replacement.

4. Reduced Energy Efficiency at Varying Loads: Reciprocating compressors are less energy-
efficient when operated at varying loads. In applications where the demand fluctuates, the
compressor may consume more energy when running at lower loads, resulting in decreased
overall efficiency.

5. Limited Pressure Ratios: While reciprocating compressors can achieve high compression ratios,
they have limitations in terms of the maximum pressure they can deliver. For extremely high-
pressure applications, other types of compressors, such as centrifugal compressors, may be more
suitable.

Applications: Industrial processes, gas pipelines, refrigeration, automotive.

Working of Reciprocating Compressors
The whole compression cycle can be understood with the help of a series of processes on the p-V
diagram in Figure 2.

Process 3-4: Expansion of Clearance Air

At the start of the cycle the piston is at its TDC or ODC position enclosing a small volume of air in the
clearance space. This initial volume of air is called the clearance volume- VC. The clearance volume is
provided to prevent the piston from hitting the cylinder head and the valves. At the TDC/ODC position
both the suction and the delivery valves are closed. The piston now begins its inward or the downward
stroke. Due to the movement of the piston, air in the clearance volume expands and pressure inside the
cylinder reduces. The expansion of clearance air continues till the cylinder pressure reaches the suction
side pressure.

Process 4-1: Suction of Air

With further movement of the piston, cylinder pressure falls below atmospheric. As a result, the air
outside forces the inlet valve to open and make its way into the cylinder; this process is called suction.
As piston continues its stroke, more and more air gets sucked into the cylinder. The suction process
continues till the end of the down-stroke.

Process 1-2: Compression of Air

At the end of suction stroke, when the piston reaches BDC or IDC position, its direction of motion is
reversed because of the slider-crank mechanism. The piston now begins its upward stroke and the
cylinder volume decreases causing an increase of air pressure. After a short while the pressure inside
the cylinder exceeds the atmospheric pressure and as a result, the inlet valve gets closed. The pressure of
the air inside the cylinder continues to increase steadily with the out-stroke of the piston.

Process 2-3: Discharge of Compressed Air

When the air pressure inside the cylinder reaches the desired value, the delivery valve gets opened.
During the remainder of the out-stroke, the delivery valve stays open and the high-pressure air is
delivered to the storage tank. As the piston reaches its top dead center position the delivery valve is
closed. At the end of the stroke, a small volume of compressed air is left in clearance space. The final
state is now the same as the initial state and the cycle gets repeated.

b. Rotary Compressors
There is a present trend toward increased use of the rotary-type compressor due to technological
advances, which have produced stronger materials and better manufacturing processes. They are of two
types;
i. Rotary screw type
ii. Rotary vane type

i. Rotary Vane Type:

The compressor pump consists primarily of a rotor, stator, and 8 blades. The slotted rotor is eccentrically
arranged within the stator providing a crescent-shaped swept area between the intake and exhaust ports.
As the rotor turns a single revolution, compression is achieved as the volume goes from a maximum at
the intake ports to a minimum at the exhaust port. The vanes are forced outward from within the rotor
slots and held against the stator wall by rotational acceleration. Oil is injected into the air intake and
along the stator walls to cool the air, lubricate the bearings and vanes, and provide a seal between the
vanes and the stator wall. After the compression cycle, the oil and air must be separated before the air
can be transferred to the air system.
Advantages:
1. Compact Design: Rotary vane compressors are usually compact in size, making them suitable for
installations where space is limited. Their small footprint allows for easy integration into existing
systems or placement in tight spaces.

2. Relatively Quiet Operation: Compared to other types of compressors, rotary vane compressors
tend to operate at lower noise levels. This makes them more suitable for applications where noise
reduction is important, such as in offices or residential areas.

3. Smooth Operation: Rotary vane compressors generally provide smooth and continuous airflow.
The vanes move in a rotary motion, which minimizes pulsations in the compressed air output.
This feature is particularly beneficial for applications that require a consistent and steady air
supply.

4. High Efficiency: Rotary vane compressors can achieve high compression efficiencies, especially
at lower pressure ratios. They are efficient in converting input energy into compressed air output,
resulting in reduced energy consumption and operating costs.

5. Suitable for Continuous Operation: These compressors are designed for continuous operation,
making them ideal for applications that require a constant and uninterrupted supply of
compressed air, such as in manufacturing processes or industrial settings.

Disadvantages:
1. Limited Pressure Range: Rotary vane compressors are typically best suited for low to medium
pressure applications. They may not be suitable for high-pressure tasks as they can experience
limitations in achieving higher pressure ratios.
 2. Sensitivity to Contaminants: Rotary vane compressors are relatively sensitive to certain
contaminants present in the air, such as moisture or particulate matter. These contaminants can
cause wear and tear on the vane surfaces, reducing the compressor's efficiency and lifespan.
Proper filtration and maintenance are essential to mitigate this issue.

3. Thermal Limitations: Rotary vane compressors can experience thermal limitations due to the
heat generated during compression. If the compressor is operated continuously under high
temperatures, it may lead to premature wear of the vanes and other components, affecting overall
performance and reliability.

4. Lower Flow Rates: While rotary vane compressors offer smooth airflow, their flow rates are
generally lower compared to other compressor types, such as screw compressors. If high flow
rates are a primary requirement for a specific application, an alternative compressor type might
be more suitable.

5. Higher Initial Cost: Compared to some other compressor types, rotary vane compressors can
have a higher initial cost. However, this can be offset by their energy efficiency and reliability,
resulting in long-term cost savings through reduced energy consumption and maintenance.

Applications: Air conditioning, pneumatic tools, refrigeration, gas handling.

ii. Rotary Screw Compressors:

This type is very similar to a screw pump. Compression is accomplished by rolling the trapped air into a
progressively smaller volume as the screws rotate. Rotary Screw Compressors work on the principle of
having air fill the void between two helical mated screws and their housing. As the two helical screws
are turned, the volume is reduced, thus increasing air pressure. Most rotary screw compressors inject oil
into the bearing and compression area. The reasons are for cooling, lubrication and creating a seal
between screws and the housing wall to reduce internal leakage. After the compression cycle, the oil and
air must be separated before the air can be used by the air system
Advantages:
1. High Efficiency: Rotary screw compressors are known for their high efficiency and reliability.
They can deliver a continuous supply of compressed air with minimal pulsations or surges,
making them suitable for sensitive applications.

2. Compact and Space-saving: These compressors have a compact design, which allows for easy
installation even in limited space. They typically require a smaller footprint compared to other
types of compressors, making them ideal for industries where space is a constraint.

3. Continuous Operation: Rotary screw compressors can operate continuously without the need for
frequent start-stop cycles. They are designed for continuous duty and can handle high-volume
compressed air requirements, ensuring a steady and uninterrupted supply.

4. High Pressure and Flow Capacity: These compressors are capable of delivering high pressure
and flow rates. They are suitable for applications that demand large volumes of compressed air,
such as manufacturing processes, pneumatic tools, and industrial automation systems.

5. Low Noise Levels: Rotary screw compressors are generally quieter compared to reciprocating
compressors. They incorporate advanced noise reduction features, such as sound-dampening
enclosures and vibration isolation, making them suitable for noise-sensitive environments.

Disadvantages:
1. Higher Initial Cost: Rotary screw compressors tend to have a higher initial cost compared to
reciprocating compressors. The complexity of their design, precision manufacturing, and
advanced control systems contribute to the increased upfront investment.

2. Regular Maintenance: These compressors require regular maintenance to ensure optimal

performance and longevity. Routine tasks include oil changes, filter replacements, and
 inspections. Failure to adhere to maintenance schedules can result in decreased efficiency and
potential breakdowns.

3. Oil Contamination: Many rotary screw compressors rely on oil for lubrication and cooling.
While oil-lubricated compressors offer improved efficiency and durability, there is a risk of oil
contamination in the compressed air system. This can be mitigated by implementing proper
filtration and separation systems.

4. Limited Flexibility: Rotary screw compressors are generally designed for fixed speed operation.
They may not offer the same level of flexibility as variable speed compressors, which can adjust
their output to match varying air demand. This can result in higher energy consumption during
periods of low demand.

5. Complex Maintenance and Repairs: If a rotary screw compressor experiences a major

malfunction or breakdown, repairs can be more complex and costly compared to reciprocating
compressors. Specialized expertise and equipment may be required for certain repairs, which can
increase downtime and associated costs.

Applications: Air conditioning, pneumatic tools, refrigeration, gas handling

c. Scroll Compressor
The scroll compressor is a type of positive displacement compressor that is widely used in various
applications, including air conditioning systems, refrigeration units, and heat pumps. It uses two or more
spiral-shaped scroll pieces for the compression of the working fluid. These scrolls move in a circular
motion instead of upward and downward motion as piston action in a reciprocating compressor. 

Out of two scrolls, one scroll is a rotatory scroll that rotates using a vibratory link while the other scroll
is fixed that remains stationary. When the fluid enters the compressor, the fluid is trapped between the
scrolls, and the compression process occurs when the rotatory scroll rotates. The working and design of
these compressors are very similar to the screw compressors.
Advantages:
1. High Efficiency: Scroll compressors are known for their high efficiency. They have fewer
moving parts compared to traditional reciprocating compressors, resulting in reduced frictional
losses and improved energy efficiency. This leads to lower power consumption and operating
costs.

2. Quiet Operation: Scroll compressors produce significantly less noise and vibration compared to
reciprocating compressors. This makes them suitable for applications where noise reduction is
important, such as residential air conditioning units or environments that require low noise
levels.

3. Compact Size: Scroll compressors have a compact design with a smaller footprint compared to
other compressor types. This makes them ideal for space-constrained installations, such as in
residential and commercial HVAC systems, refrigeration units, and heat pumps.

4. Fewer Wear Parts: Scroll compressors have a simple design with fewer moving parts, resulting
in reduced wear and tear. This leads to improved reliability and reduced maintenance
requirements. Additionally, the absence of valves in scroll compressors eliminates the need for
periodic valve maintenance or replacement.

5. Smooth Operation: The scroll compressor operates with a continuous compression process,
providing smooth and pulsation-free airflow. This ensures stable operation and minimizes
fluctuations in pressure, resulting in improved system performance and reduced stress on
components.

Disadvantages:
1. Cost: Scroll compressors tend to be more expensive upfront compared to reciprocating
compressors. The precision manufacturing required for their intricate scroll design contributes to
 the higher cost. However, the energy savings over the compressor's lifespan can help offset the
initial investment.

2. Limited Capacity Range: Scroll compressors are generally suitable for applications with smaller
to medium capacity requirements. For very high-capacity applications, such as industrial
refrigeration or large-scale air conditioning systems, other compressor types like screw or
centrifugal compressors may be more appropriate.

3. Sensitivity to Liquid Ingestion: Scroll compressors are sensitive to liquid refrigerant entering the
compression chamber, which can cause damage to the compressor and reduce its lifespan. Proper
system design and installation, including adequate liquid refrigerant management, are necessary
to prevent liquid ingestion.

4. Maintenance and Repairs: While scroll compressors generally require less maintenance, repairs
can be more complicated and expensive. If a failure occurs, it is often necessary to replace the
entire compressor unit rather than repairing individual components, which can result in higher
costs.

5. Operating Conditions: Scroll compressors may experience reduced performance in extremely

high or low ambient temperatures. Proper system design and considering the compressor's
performance specifications within the desired operating conditions are crucial to ensure optimal
performance and reliability.

Applications: Air conditioning, heat pumps, refrigeration.

d. Diaphragm Compressor
A diaphragm compressor is a type of positive displacement compressor that uses a flexible diaphragm to
compress gases or fluids. It operates on the principle of reciprocating motion, where the diaphragm
moves back and forth to create a pressure differential and compress the gas or fluid.
Working Principle
1. Suction Stroke: During the suction stroke, the diaphragm moves away from the compression
chamber, creating a vacuum. This allows the gas or fluid to enter the chamber through the inlet
valve.

2. Compression Stroke: In the compression stroke, the diaphragm moves towards the compression
chamber, reducing its volume. This action increases the pressure inside the chamber,
compressing the gas or fluid.

3. Discharge Stroke: Once the compression stroke is complete, the diaphragm moves away from the
compression chamber again, causing the pressure inside the chamber to drop. This allows the
compressed gas or fluid to exit through the outlet valve.

Advantages:
1. Contamination-Free Compression: Diaphragm compressors provide contamination-free
compression since the gas or fluid being compressed does not come into contact with lubricants
or other compressor components. This makes them suitable for handling sensitive or reactive
gases.

2. Leak-Free Operation: The diaphragm acts as a barrier, preventing leakage of the gas or fluid
being compressed. This makes diaphragm compressors suitable for applications requiring high
purity or where leakage is undesirable.
 3. Wide Range of Applications: Diaphragm compressors can handle a wide range of gases and
fluids, including corrosive, toxic, or explosive substances. They find applications in industries
such as pharmaceuticals, petrochemicals, chemical processing, and food processing.

Disadvantages:
1. Lower Efficiency: Diaphragm compressors have lower efficiency compared to some other
compressor types, such as reciprocating or rotary compressors. This is because the diaphragm's
reciprocating motion results in energy losses due to friction and heat generation.

2. Limited Pressure Range: Diaphragm compressors are generally limited in the pressure range they
can achieve. They are typically used for low to medium pressure applications, and high-pressure
applications may require a different type of compressor.

3. Lower Flow Rates: Diaphragm compressors are not suitable for high-flow-rate applications due
to the limitations imposed by the reciprocating motion of the diaphragm.

Applications: Chemical industry, oil and gas, hydrogen fuel cells.

2. Dynamic Compressors
Dynamic compressors use high-speed rotating impellers to continuously impart velocity to the gas,
converting kinetic energy into pressure energy. These compressors are suitable for applications that
require a large volume of gas at relatively lower pressures. Some types of dynamic compressors include:

a. Centrifugal Compressors
Centrifugal compressors use a high-speed rotating impeller to accelerate the gas and convert kinetic
energy into pressure energy. The gas enters the impeller axially and is accelerated radially outward. The
high-speed gas is then directed to a diffuser where the kinetic energy is converted into pressure.
Advantages:
1. Wide Range of Applications: Centrifugal compressors are suitable for a variety of applications,
including oil and gas, petrochemical, refrigeration, and air compression. They can handle high
flow rates and are commonly used in large-scale industrial processes.

2. Compact Size: Centrifugal compressors are known for their compact design, which makes them
ideal for installations where space is limited.

3. Low Vibration and Noise: They generally produce less vibration and noise compared to other
compressor types, making them suitable for applications where noise reduction is important.

4. High Efficiency: Centrifugal compressors can achieve high levels of efficiency, especially in
applications with a large volume flow rate.

Disadvantages:
1. Limited Pressure Ratio: Centrifugal compressors are not well-suited for applications that require
high-pressure ratios. Their pressure ratio capability is typically lower compared to axial
compressors.

2. Sensitivity to Operating Conditions: They can be sensitive to changes in operating conditions,

such as fluctuations in inlet flow rates or changes in temperature. This can affect their
performance and efficiency.

3. Higher Maintenance Costs: Centrifugal compressors often require more maintenance compared
to other types, particularly in terms of the bearings and seals.

Applications: Gas pipelines, refineries, petrochemical plants.

 b. Axial Compressors
Axial compressors use a series of rotating and stationary blades to compress the gas. The gas flows
parallel to the axis of rotation, and the blades impart velocity and pressure to the gas as it passes through
each stage. Axial compressors are commonly used in aircraft engines and gas turbines.

Advantages:
1. High Pressure Ratios: Axial compressors excel at achieving high-pressure ratios, making them
suitable for applications requiring substantial compression.

2. Efficiency: Axial compressors are known for their high efficiency, especially at large flow rates.
They can efficiently handle a significant volume of air or gas.

3. Continuous Flow: They provide a continuous flow of compressed air or gas, making them
suitable for applications where a steady supply is required.

4. Relatively Lower Maintenance: Axial compressors generally have a simpler design with fewer
moving parts, leading to lower maintenance requirements compared to centrifugal compressors.

Disadvantages:
1. Large Size: Axial compressors tend to be larger and longer in size compared to centrifugal
compressors, which can limit their application in space-restricted environments.

2. Increased Noise and Vibration: Axial compressors typically produce more noise and vibration
compared to centrifugal compressors, which can be a disadvantage in certain settings.

3. Sensitivity to Changes in Operating Conditions: They can be more sensitive to changes in

operating conditions, such as variations in inlet flow or temperature, which may affect their
performance.
Applications: Jet engines, gas turbines, power plants.

c. Mixed Flow Compressors

Mixed flow compressors combine elements of both centrifugal and axial compressors. The gas enters
the impeller axially but then exits the impeller at an angle between axial and radial directions. Mixed-
flow compressors are suitable for applications that require a combination of high pressure and high flow
rates.

Advantages:
1. Good Balance of Pressure Ratio and Flow Rate: Mixed flow compressors combine features of
both centrifugal and axial compressors, offering a balance between pressure ratio and flow rate
capabilities. They can handle moderate to high pressure ratios while maintaining a relatively high
flow rate.

2. Compact Design: Mixed flow compressors are often more compact compared to axial
compressors, making them suitable for applications where space is limited.

3. Improved Efficiency: These compressors can achieve higher efficiency compared to centrifugal
compressors, especially at moderate to high flow rates.

Disadvantages:
1. Complexity: The design of mixed flow compressors is more complex than either centrifugal or
axial compressors, leading to potential challenges in terms of manufacturing, maintenance, and
troubleshooting.
 2. Limited Application Range: While mixed flow compressors offer a good balance between
centrifugal and axial designs, they may not be the most suitable choice for applications requiring
extreme pressure ratios or exceptionally high flow rates.

3. Potential Noise and Vibration: Mixed flow compressors may produce more noise and vibration
compared to centrifugal compressors, although typically less than axial compressors.

Applications: Turbochargers, HVAC systems, aerospace industry.

d. Turbochargers
A turbocharger is an exhaust-driven device that is used to increase the power output of an internal
combustion engine. It does this by forcing more air into the engine, allowing it to burn more fuel and
create more power.

The main components of a turbocharger are the compressor, turbine, wastegate, and air intake. The
compressor is powered by the exhaust gases from the engine and is used to draw in and compress air
before it enters the engine. The turbine is located on the other side of the compressor and is used to
convert the exhaust energy into the rotational energy needed to turn the compressor. The wastegate is
used to regulate the amount of exhaust gases entering the turbine, and the air intake is the final
component, which is used to draw in the air needed for combustion.
 Table: Comparison of various compressor types

TYPES USED IN MARINE APPLICATIONS

In marine applications, compressors play a crucial role in various systems and processes. They are
responsible for compressing air or gas, which is then utilized for different purposes onboard ships and
vessels. There are several types of compressors used in marine applications, each with its own
advantages and specific areas of application. Let's discuss some commonly used types of compressors
and the reasons for their use:

Reciprocating Compressors: Reciprocating compressors are widely used in marine applications due to
their compact size, high efficiency, and versatility. They operate by using a piston within a cylinder to
compress the air or gas.
These compressors are suitable for low-to-medium capacity requirements and can provide high-pressure
ratios. They are commonly used for starting and controlling the main engine, as well as for various
pneumatic systems onboard.

Reciprocating compressors are also used for refrigeration and air conditioning systems in marine
environments.

Screw Compressors: Screw compressors are known for their high capacity and reliability.

They consist of two interlocking rotors that compress the gas or air as it passes through the compression
chamber. Screw compressors are well-suited for continuous operation and can handle large volumes of
gas or air. These compressors are commonly used in marine applications for cargo handling systems,
pneumatic tools, and HVAC systems.

They are also employed in refrigeration and air conditioning systems on ships.

Centrifugal Compressors: Centrifugal compressors are utilized in marine applications where high flow
rates and large capacity are required. They use an impeller to accelerate the gas or air, which is then
converted into pressure energy. These compressors are highly efficient and are capable of handling large
volumes of gas or air at high pressures.

Centrifugal compressors find applications in marine propulsion systems, gas turbine power plants, and
large-scale pneumatic systems. They are also employed for compressed air supply to the ship's control
systems and various utility systems.

Vane Compressors: Vane compressors are known for their simplicity, compact size, and low
maintenance requirements. They consist of a rotor with radial slots that hold vanes, which slide in and
out as the rotor rotates. Vane compressors are commonly used for smaller capacity requirements, such as
air conditioning systems and small-scale pneumatic tools. In marine applications, they can be found in
smaller vessels, yachts, and pleasure crafts.

Axial Compressors: Axial compressors are another type of dynamic compressor commonly used in
marine applications. They use a series of rotating air foils or blades to compress the air. They are often
employed in gas turbine engines for power generation on ships.

Scroll Compressors: Scroll compressors are compact and efficient compressors that use two interleaved
spiral-shaped scrolls to compress the refrigerant or air. They are commonly used in smaller air
conditioning systems on ships and cruise ships to compress the refrigerants for small scale refrigeration
like food refrigeration.

Diaphragm Compressors: Diaphragm compressors use a flexible diaphragm to compress gases. They
are often utilized in specific applications where oil-free, leak-tight compression is required, such as in
gas systems on ships.

Piston Compressors: Piston compressors are similar to reciprocating compressors but are typically
smaller in size. They are used in various marine applications, including clamping, lifting, and cargo
handling systems.

Horn Air Compressors: For ship horns or pneumatic signalling devices, specific air compressors
designed for horn applications are used. These compressors are typically smaller and provide sufficient
air pressure and volume to produce the desired sound.

The reasons for using different types of compressors in marine applications depend on various factors,
including capacity requirements, pressure ratios, space limitations, reliability, and energy efficiency. By
employing different types of compressors, marine systems can be designed to meet specific operational
needs and optimize performance. Additionally, compressors contribute to the safe and efficient
operation of onboard equipment, such as main engines, propulsion systems, cargo handling systems, and
utility systems like air conditioning and refrigeration.

TROUBLESHOOTING AND MAINTENANCE

A compressor requires proper planned routine maintenance for safe and efficient operation and for
avoiding a breakdown. Routine maintenance depends on the manufacturer’s advice given in the manual.

The following are the maintenance checks that should be carried out after the mentioned running hours.

250 hrs:
 Clean air filter
 Check the un-loader operation
 If a belt is provided for driving the cooling water pump, check its tightness
500 hrs:
 Change lube oil and clean the sump
 Clean lube oil filter
 Check and renew suction and discharge valves with a new one
4000 hrs:
 Piston and big end bearing overhauling, piston ring renewal
 Intercooler cleaning
 Motor overhauling
Running hours may differ from maker to maker. The above description is a rough idea for the general
maintenance of the marine air compressor.

The cooling system of the main air compressor should include the following maintenance procedures:

• Regular inspection of the intercoolers and after-coolers

• Leakage testing of the intercoolers and if any tube is found leaking, same to be plugged
• Removal of oil or deposits from the intercooler tube nests using suitable chemicals
• Regular inspection of the cylinder water jacket to check for any cracks or deposits
• Overhauling of water line valves
There are some common problems that can arise in air compressors that need to be checked out as soon
as possible and fixed:

Low Lube Oil Pressure

This can be due to:

• Faulty pressure gauge

• Cock to pressure gauge in the closed position
• Low oil level in the sump
• Leakage in the supply pipe
• The suction filter is choked
• Oil grade in the crankcase is not compatible
Abnormal noise during operation:
If you get any unusual noise during operation, it can be due to the following reasons:

 Loose foundation bolts

 Worn out bearings, clearance is high
 Imbalance crankshaft resulting in high-end play
 Valve plate broken or faulty
 Relief valve lifting below setting pressure
 Bumping clearance is less
 Piston worn-out, broken piston ring

Vibration in the machinery:

In the case of vibrations, the following reasons are to be considered and checked:

 Foundation bolts are loose

 Discharge pressure high, faulty discharge valve plates
 Liner and piston are worn out
 Small bumping clearance

Cooling water temperature is high

Cooling water temperature can go high because of the following reasons:

 Inlet or outlet valve for cooling water is closed

 Inter-cooler is chocked
 Cooling water in the expansion tank is low
 Pipe passage becomes narrow due to scale formation
 Water-pump belt or gear drive broken
 Pump not working

PARAMETERS LOGGED DURING WATCHKEEPING

Watch-keeping is an integral part of the marine engineer’s duties on board the ship. A lot of
maintenance work can be reduced by following an efficient watch-keeping routine in the ship’s engine
room. Additionally, it can help to avoid serious accidents from taking place.

During watch-keeping, several parameters of various machinery and equipment are typically logged to
ensure proper operation and performance. For the refrigeration system in particular, the following
parameters are of importance:

Temperature: The temperature at various points in the system is crucial for monitoring and control. This
includes the temperature of the refrigerant at different stages (condenser, evaporator, suction line, and
discharge line), as well as the temperature of the cooled space or product being refrigerated.

Pressure: The system's refrigerant pressures are significant indicators of its operating conditions.
Pressure readings are typically taken at the compressor inlet and outlet and other critical locations. High
or low pressures can indicate issues such as blockages, leaks, or inefficient operation.

Refrigerant level: Monitoring the refrigerant level within the system, especially in critical components
like the evaporator or receiver, helps ensure proper operation and avoids issues like low refrigerant
charge or refrigerant migration.

Oil levels in the compressor: The compressor oil is crucial for lubrication and cooling, and maintaining
the proper oil level is essential for the compressor's smooth operation and longevity.
CONCLUSION
Compressors are integral to various industries, including marine applications, where they play a crucial
role in refrigeration systems. Understanding the working principles, types, and suitable applications of
compressors allows for informed decision-making and effective troubleshooting. Regular maintenance
and monitoring of critical parameters during watch-keeping contribute to the reliable and efficient
operation of compressors. By implementing best practices and adhering to manufacturer guidelines,
organizations can maximize the lifespan and performance of compressors in marine applications.

REFERENCES
(“A Guide to Marine Air Compressors on Ships” NOTICE OF LIABILITY, 2019; Air Conditioning
Engineering 5th Edition By W P Jones, n.d.)

Team, M. (2021, December 20). Complete engine room watch keeping. mfame.guru.
https://mfame.guru/complete-engine-room-watch-keeping/

Raunek. (2021, June 28). 8 most common problems found in ship’s refrigeration system. Marine Insight.
https://www.marineinsight.com/refrigeration-air-conditioning/8-most-common-problems-found-in-
ships-refrigeration-system/

Jones, W. P. (1973). Air Conditioning Engineering.