Air Compressor

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SAHEEM KHAN
Types of air compressors
 Centrifugal
 Rotary vane
 Rotary screw
 Reciprocating
Compressors on ships
 Main air compressors
 Emergency air compressor
 Control air compressor
 Topping up compressor
Uses of compressed air
 Starting of main engine
 Starting of auxiliary engine
 Control air
 General service air
 Cleaning
 Pneumatic tools – grinder/chisel/drill/spanner/pump
 Air horn
 Hydrophore
 Sewage plant
 Quick Closing Valve
 Painting
Regulations
 Two starting compressors must be fitted, of
sufficient total capacity to meet the engine
requirements.
 Each compressor must be able to press up Air
receiver from 15 bars to 25 bars in 30 minutes.
 Two air receivers must to be provided.
 Total air receiver capacity is to be sufficient for
Twelve (12) starts of Reversible engines and six (6)
starts for non- reversible engines.
Reciprocating air compressor
Classification
 By number of stages
 Single stage
 Multi stage
 By stroke
 Single acting
 Double acting
Double Acting
Two stage
Two stage double acting
 Parts of a compressor
Cylinder liner: cast iron with water jacket around it to
absorb heat produced during compression process.
Piston: aluminum alloy / CI piston with piston rings for
sealing and scraping off excess oil.
Piston Rod: alloy steel.
Big end bearing and Main bearing: copper lead alloy.
Crank shaft: forged steel
Frame and crankcase: rigid cast iron
 Parts of a compressor (cont)
 Oil pump:
 Water pump:
 Suction and Discharge valve: Automatic type,
open due to the effect of differential pressure
and close due to pressure of springs + air
pressure.
 Suction Filter:
 Inter-cooler:
 After-cooler:
 Driving Motor:
 Volumetric Efficiency

 Free air – air at atmospheric pressure and a temperature of

15o centigrade
 Free Air Delivery (FAD) – indicates delivered air at inlet
conditions. It is measured in Cubic Feet of air per Minute
(c.f.m.).
 Swept volume – The volume through which a piston or
plunger moves as it makes a stroke.
Factors affecting volumetric efficiency
 Volumetric clearance
 Sluggish opening and closing of valves
 Leaking valves
 Leakage past piston rings
 Leakages of air from other parts and jointings – intercooler,
cylinder cover, pipes, mountings.
 Insufficient cooling
 High air inlet temperature to LP stage.
 Suction filter choked.
 Effect of clearance volume (bumping clearance)
 Small amount of HP air is trapped in the clearance volume.
 In the suction stroke, this trapped air must expand below the suction
pressure before the suction valve opens.
 This causes effective loss of suction stroke that results in drop in volumetric
efficiency.
Effect of clearance volume (bumping clearance)
 Bumping clearance
 It is the distance between the cylinder head and the piston at the
top dead center (TDC).
 Usually between 0.5% to 1% of the bore of the cylinder
 Bumping clearance is less
 This may result in piston banging or colliding to the cylinder head,
especially in unloaded condition.
 Bumping clearance is less
 This will result in a small volume of air being re-expanded every
time causing increase in air temperature, fall in efficiency and
overheating of the compressors. Reduces the amount of air
delivered per stroke.
 Why bumping clearance can change…
 Checking Bumping clearance
 The most convenient method is to take lead wire and make a
small ball and put it between the piston and the cylinder head
from the valve opening.
 Then the piston is slowly turned beyond the top dead center so
that the lead ball is compressed by the piston.
 The lead wire ball is extracted and the thickness measured
with the help of a micrometer. This measurement would give
the bumping clearance.
 Can be measured by depth gauge also.
 Adjusting Bumping clearance
 The wear down on the bottom end bearing will be on the top
half, due to the downward load, so adjusting the bottom end
bearing clearance will have no effect of the bumping
clearance.
 This can be adjusted by:
 shims between the connecting rod and the bottom end bearing
 by changing the thickness of the cylinder head gasket.
Limitations of Single stage compression
 Limitations of Single Stage Compression
 P2 < P5 < P8
 The mass of air flowing through the compressor is controlled by the effective
swept volume.
 Delivery pressure – P2
 The compression follows the curve 1234, where 3-4 denotes the re-expansion of
the air in the clearance volume.
 Effective Swept Volume: V1 – V4
 Delivery pressure is increased to – P5
 Effective Swept Volume is reduced to (V1 – V7) as the trapped air in the clearance
volume is at higher pressure and therefore must expand to V7 before suction valve
opens.
 Thus we see that as the delivery pressure increases, effective swept volume
decreases
 In the extreme condition, when delivery pressure is increased to P8, the
compression follows the curve 1-8, where there will be no delivery of
compressed air.
Effect of high temperatures
 As the delivery pressure increases, the delivery air temperature
also increases.
 Lubricating oil may vaporize at high temperatures, resulting in
carbonization and oil breakdown, deposits on valves causing
sluggish valve operation. At extremely high temperatures there is
a risk of fire and explosion.
 Mechanical problems may arise at high temperatures.
 Energy loss.
 Effect of Two stage with Intercooling
 Multi Stage with intercooling -- Approaches the ideal isothermal
compression (constant temperature) to achieve maximum volumetric
efficiency.
 Two stage compression with intercooling:
• Adiabatic process -- occurs without transfer of heat.
• Isothermal process – constant temperature process.
Effect of Two stage with Intercooling
 The intake of air in the first stage gets compressed and then it
is passed over a cooler to achieve a temperature very close to
ambient air. This cooled air is passed to the second stage
where it is again gets compressed and heated.
 Approaches the ideal isothermal compression (constant
temperature) to achieve maximum volumetric efficiency.
3 stage compression
Benefits of multi stage compression
 Improved efficiency: Two-stage compressors perform less work to
compress air to a given pressure, which means reduced power
consumption.
 Lower temperature: The suction and delivery valves remain in cleaner
condition as the temperature and vaporization of lubricating oil is less
 Less moisture buildup: Cooler air has a lower moisture content.
Moisture in compressed air can lead to equipment failure and premature
wear. Using a two- or three-stage compressor can potentially save you
from having to purchase a separate air dryer.
 Smaller size: Multi-stage compressors deliver greater air pressure (PSI) at
higher capacities (CFM) than single-stage machines of a comparable size.
 Higher cost (disadvantage): not necessarily the right choice for every
application
 Air compressor valve
 Thevalves, on most air compressors, are plate type with
concentric rings. The advantages of this type of valve are;
 Fast acting due to being light weight, small distances to travel.
 Efficient seal created.
 Efficient at stopping the delivered air back into the cylinder on
intake stroke.
 No inertia due to the weight.
 Excellent air flow for a small area.
 Valve impact limited due to small movements thus saving the seat
and valve damage.
 Air compressor valve
 Lightweight
 Must impose minimum flow resistance
 Low inertia – for rapid opening and closing.
 Should form an effective seal at the proper time.
 Air compressor valve
 Valve seat with a center bolt and a locating pin
 has numerous concentric circles which form a perfect sealing with
the valve plate.
 Valve
plate
 Damper plate
 Mitigates the adverse effects of flutter as well as constant high
speed impact.
 Spring plates
 Buffer plate
 Situated at the other end.
 Provides support to spring plates which rest against it.
The materials used for the
construction of the valves are;
• Valve body – 0.4% carbon
steel with a hardened seat area,
normally forged.
• Valve plates – alloy steel
(nickel or chrome
molybdenum).
• Plate springs – spring steel.
 Unloader
 Compressor be unloaded by opening the LP and HP stage drains. These
can be operated by solenoid or other means. Other means of unloading are:
 depressors which hold the suction valve plates on their seats
 bypass which discharges to suction.
 Unloaded starting of air compressor reduces the starting torque for the
machine and clears out any accumulated moisture in the system.
 Before stopping the compressor, the machine runs unloaded for two to
three minutes to clear the coolers of condensate. It also blows off the
pressure inside the discharge pipe.
 A non-return valve is usually fitted as close as possible to the discharge
valve on a compressor to prevent return air flow from air receiver: it is an
essential fitting where unloaders are used.
Moisture
 Corrosion
 Damage to next stage
 Damage to control air system
 Can cause emulsion if mixed with oil carried over
from cylinders.
 Regular drain off required – reduce the chance of
getting carried over to air receivers and starting air
line.
 Condensate auto drain

C C
B B
A

Drains coolers continuously while the compressor is running

 Condensate auto drain
 With water under pressure at the inlet, the disc will lift, allowing
the water to flow radially across the disc from A to the outlet B.
 When the water is discharged and air now flows radially outwards
from A across the disc, the air expands, increasing in velocity,
ramming air into C and the space above the disc, causing the disc to
close on the inlet.
 Because of the build up of static pressure in the space above the
disc in this way, and the differential area on which the pressures are
acting, the disc is held firm closed. It will remain so unless the
pressure in the space above the disc falls.
 In order that this pressure can fall, and the trap re-open, a small
grove is cut across the face of the disc communicating B and C
thorough which the air slowly leaks to outlet.
 The whole process is now repeated.
Safety Features
i. Relief Valves
ii. Bursting disc
iii. Fusible plug
iv. LO low pressure alarm and trip
v. CW high temperature trip
vi. Water no-flow trip
vii. Motor overload trip
 Effect of leaky valves
 Suction valve – Compressed air leaks out, reducing the air
flow and thereby volumetric efficiency.
 Discharge valve – Hot air at high pressure is drawn back into
the cylinder for recompression.
 increases the temperature of discharged air.
 Reduces the quantity of air drawn in during the suction stroke.
 Leaky Valves
 First stage suction valve leaking
 Reduced air delivery
 Reduced second stage suction pressure
 Increased running time
 Unload the compressor (Motor take less load)

 First stage delivery valve leaking

 Reduced delivery of air - less air drawn in due to high pressure air leaking back into the cylinder.
 Increased discharge temperature
 Reduced air delivery

 Second stage suction valve leaking

 High pressure and temperature in suction line of 2nd stage
 High pressure in the first stage discharge pipe and intercooler may cause the first stage relief valve to lift.
 Reduces delivery
 Increased running time

 Second stage delivery valve leaking

 Increase suction pressure in 2nd stage
 Reduced delivery in 2nd stage
 Increase delivery pressure from 1st stage
 Reciprocating air compressor
 Multi stage models offer  Pulsating flow.
high efficiency  Many moving parts
 Large range of HP  Potential for vibration
 Can achieve extremely problems
high pressures  Heavy Foundation
required
 Many are not designed to
run at full capacity 100%
of the time.
 Rotary screw air compressor

 2 stage designs provide good  Limited screw life

efficiency  High rotational speeds
 Few moving parts  Shorter life expectancy.
 Steady, non-pulsating air  Oil injected designs have oil
flow, with minimum carryover
vibrations and maintenance  2 stage oil free designs have
 High pressure ratio higher initial cost.
 Difficulty in dirty
environment.
 Rotary vane air compressor
 Simple design  Oil injected designs have
 Low to medium cost high oil carryover
 Low maintenance cost  Single stage designs have
 Long life of vanes lower efficiency.
 Low rotational speeds  Difficulty with high
 Fewer moving parts pressures (over 200 psi)
 Can work in dirty  Oil free designs are
environment unavailable.
Centrifugal air compressor
 Can handle large  Not suitable for multi-
volume of air staging
 Lower noise and  Low pressure ratio.
vibration.
 Steady air flow
 Oil free air
 Less maintenance
Two stage air compressor in
tandem
 Troubleshooting
 First stage discharge pressure high
 Inter-cooler air passage is chocked.
 Second stage suction valve is not closing properly, allowing air to escape
from 2nd to 1st stage.
 Discharge valve of first stage is malfunctioning,

 First stage discharge pressure low

 Suction filter is choked.
 Unloader of first stage is leaking.
 First stage suction valve is not closing properly, resulting in compressed
air leakage.
 First stage suction valve is not opening fully, leading to less intake of air.
 Relief valve after first stage is leaking.
 Piston ring of first stage is badly worn out.
 Troubleshooting (cont)
 Second stage discharge pressure high:
 Discharge valve to air bottle is shut.
 Second stage discharge valve malfunctioning.
 After cooler air passage choked.
 Air bottle is over pressurized.

 Second stage discharge pressure low:

 Suction valve for second stage is leaking or malfunctioning.
 Piston rings of second stage are worn out, leaking out compressed
air.
 Relief valve of second stage is leaking.
 Unloader of second stage is leaking.
 Troubleshooting (cont)
 Relief valve of first stage lifting
 Spring of relief valve is malfunctioning, thus lifting at less pressure.
 Discharge valve of first stage is not opening.
 Intercooler air passage is blocked.
 Suction valve of second stage is leaking.
 Water inside the compression chamber due to crack in the jacket and
water is leaking inside.

 Relief valve of second stage is lifting

 Relief valve is malfunctioning, lifting at lower then setting pressure.
 Main discharge valve to the air bottle is closed.
 Discharge valve plates and spring are worn out, valve in closed position.
 Blockage in the after cooler air passage.
 Water inside the compression chamber due to crack jacket.
 Short answer type questions
1. Explain briefly any 3 safety devices installed in air compressors.(3)
2. What are the different uses of compressed air on board the ship?
3. Briefly state the regulations governing the number and capacity of starting air compressors on
board a ship.(3)
4. What is Free Air Delivery and how is it measured (3)?
5. What is bumping clearance? What are the consequences of high and low bumping clearances.(3)
6. How is bumping clearance measured? How can it be adjusted?(3)
7. Name three factors that can affect the volumetric efficiency of a marine reciprocating compressor
(3).
8. Why should an air compressor be started and stopped in unloaded condition? How is it usually
achieved?(3)
9. State the effects of leaky suction and discharge valves in a single stage reciprocating compressor
(3)?
10. Troubleshoot the following (give reasons): (3 x 6)
a. First stage discharge pressure is high
b. First stage discharge pressure low
c. Second stage discharge pressure high:
d. Second stage discharge pressure low:
e. Relief valve of first stage lifting
f. Relief valve of second stage is lifting
 Long answer type questions
1. Explain the necessity of intercoolers and after-coolers in air compressors.
2. Sketch and describe a two stage air compressor suitable with marine use up to 30 bar
pressure. (14)
3. Explain the necessity of intercoolers and after-coolers in air compressors.
4. List the factors affecting volumetric efficiency of a reciprocating air compressor.(7)
5. Explain with a diagram the effect of clearance volume on volumetric efficiency of a
reciprocating air compressor.(7)
6. What are the advantages of multi-stage compression? Why it may not be suitable for all
applications(6+1)
7. State the effect of moisture in compressed air system. With the help of a diagram,
explain the working of a condensate auto drain.(14)
8. Explain with a graph, the effect of clearance volume on volumetric efficiency of a
reciprocating air compressor.(7)
9. What are the limitations of single stage compression? How can it be reduced by
multistage compression? Explain by the help of graphs. (7)
10. What types of valves are used in air compressors and what are their advantages? Name
the parts of an air compressor valve.(7)
11. Sketch and describe a two stage double acting tandem air compressor (14)