Air

Compressed air is used for starting main and

auxiliary diesels, operating whistles or typhoons,
testing pipe lines (e.g.CO
2
fire extinguisher) and
for workshop services.
Air is composed of mainly 23% oxygen ,77%
nitrogen by mass and since these are near perfect
gasses a mixture of then will behave as a near
perfect gas, following Boyles and Charles laws

Air compressor
What is isothermal compression?
Compression at constant temperature.

What is adiabatic compression?
Compression under constant enthalpy
condition.




Multi-stage compression
If we had an indefinite number of stages of
compression with coolers in between each stage
returning the air to ambient temperature, then we
would be able to compress over the desired range
under near isothermal condition.
This of course is impracticable so two or three
stage compression with interstage & cylinder
cooling is generally used when relatively high
pressors have to be reached.
Shaded area show saved work during
compression

To prevent damage, cylinders have to
water or air cooled &clearence must be
provided between piston & cylinder
head
Volumetric efficiency
Volumetric efficiency is the measure of
compressor capacity
It is the ratio of actual volume of air drown
in each suction stroke to the stroke volume

Volumetric efficiency =
Actual volume of air drown


Stroke volume
Theoretical method to calculate
clearance volume
Practical method to calculate
volumetric efficiency
Remove suction discharge assembly from the unit
& place a small loose ball of lead wire on the piston
edge, then rotate the flywheel by hand to take the
piston over top dead center. Remove & measure the
thickness of lead wire ball
Put crank on top dead center, slack or remove
bottom half of the bottom half bearing. Rig a clock
gauge with one contact touching some under part of
the piston. Take gauge reading. Then by using
suitable lever bump the piston, i.e. raise it until it
touches the cylinder cover. Take another gauge
reading, the difference between the two readings
gives the mechanical clearance
Three stage compression
Reciprocating air compressors at sea are
generally two or three stage types with
interstage cooling
The pressure & temperature at various
points would be roughly as follows:
Drains
Use to remove the accumulated moisture
from the air storage unit
Filters
Use to remove the suspended foreign
particles from the intake air
Relieving devices
It limits the outlet pressure after each
stage of compression
Lubrication
Certain factors govern the choice of
lubricant for the cylinders of an air
compressor, these are:
Operating temperature
Cylinder pressure
Air condition
Operating temperature
Affects oil viscosity & deposit formation. If
the temperature is high this results in low
oil viscosity, very easy oil distribution, low
film strength, poor sealing & increased
wear. If the temperature is low oil viscosity
would be high, this causes poor distribution,
increased fluid friction & power loss.
Cylinder pressures
If these are high the oil requires to have a
high film strength to ensure the
maintenance of an adequate oil film
between the piston rings & the cylinder
walls.
Air condition
Air contains moisture that can condense out.
Straight mineral oils would be washed off
surfaces by the moisture & this could lead
to excessive wear & possible rusting. To
prevent this a compounded oil with a rust
inhibitor additive would be used.
Two-stage compressor
These compressors are generally of the
reciprocating type, with various possible
arrangements of the cylinders or they could
be a combination of rotary first stage
followed by reciprocating high pressure
stage.
Compressor valves
Modern valves are somewhat more
streamlined & lighter in order to reduce
the friction losses & valve inertia
Material used in the construction are
generally :
Valve seat
0.4% carbon steel hardened & polished
working surfaces
Valve
Nickel steel, chrome vanadium steel or stainless
steel,hardened & ground, then finally polished
to a mirror finish
Spring
Hardened steel (N.B all hardened steel would
be tempered)
Effects of leaking valves
First stage suction
Reduced air delivery, increased running time &
reduced pressure in the suction to the second
stage if the suction valve leaks badly it may
completely unload the compressor
First stage delivery
With high pressure air leaking back in to the
cylinder less air can be drawn in, this means
reduced delivery & increased discharge
temperature

Second stage suction
High pressure & temperature in the second
stage suction line, reduced delivery & increased
running time
Second stage delivery
Increased suction pressure in second stage,
reduced air suction & delivery in second
stage.delivery pressure from first stage
increased.
Regulation of air compressor
Start stop control
A pressure transducer attached to the air
receiver set for the desired max-min
pressures would switch the current to the
electric motor either on or off. It must be
remembered that the starting current for
an electric motor is about double the
normal running current.
Constant running control
The compressor runs continuously at a
constant speed & when the desired air
pressure is reached the air compressor is
unloaded in some way so that no air is
delivered practically no work is done in
the compressor cylinders

Figure shows diagrammatically a
compressor unloading valve fitted to the
compressor suction. When the discharge air
pressure reaches a desired value it will act
on the piston causing the spring loaded
valve close shutting off the supply of air to
the compressor
Automatic drain
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 & air now flows radially outwards
from A across the disc,the air expands increasing
in velocity ramming air in to sea & the space
above the disc, causing the disc to close on the
inlet
In order that this pressure can fall & the trap
reopen, a small groove is cut across the face of the
disc communicating B & C through which the air
slowly leaks to outlet
Starting air compressors
These are required to charged the starting air receivers &
supply compressed air for veriety of uses safety regulations
demand at least two compressors one must have an
independent drive for an emergency use. With the high
pressure demanded & to obtained the best efficiency at full
or part load, reciprocating compressors are invariably used
these are two stage compressors, electrically driven
Piston for each stage may be arranged in line, either as a
trunk piston or cross head alternatively, to reduce size &
weight a tangent arrangement with one piston mounted
above the other & driven from a common cranck may be
used
Second stage piston is smaller than first stage for
corresponding reduction in the volume of air with
a common piston stroke
Each stage has a light, spring loaded non return
suction & delivery valves of low inertia stainless
steel plates
Water-cooled heat exchangers are fitted to act as
an intercooler,which cools the air after first stage
compression & an after cooler to cool it again
after the second stage the maximum air
temperature at a compressor dicharge must not
exceed 93 C & a fusible plug or alarm may be
fitted
Overhauling
Before overhaulthe makers handbook
should be read & special instruction must be
adhered to. Ensure that all receivers are
fully charged & that remaining air
compressors are operational this will
provide for any possible emergency in
which compressed air is required