DESIGN IV MACHINERY

DEPARTMENT OF MARINE
ENGINEERING

CALCULATION AND
SPESIFICATION OF
COMPRESSED AIR SYSTEM
Doc.No. 09 - 42 19 MA029- CA

Prepared by Approved by
Rev. Date Remark Muzami Thahir Dr. I Made Ariana S.T.,
M.T.
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AIR SYSTEM
I. INTRODUCTION
Compressed air is used to start engines and to provide actuating energy
for safety and control devices. The use of starting air for other purposes is limited
by the classification regulations. To ensure the functionality of the components in
the compressed air system, the compressed air has to be free from solid particles
and oil.

II. OBJECTIVES
1. Understand the compressed air system for the engine.
2. Calculate and determine compressor specification for compressed air system
at ship.
3. Drawing the compressed air system.

III. REFERENCES
1. NK Class
2. Project Guide MAN B&W L27 38
3. Japanese Industrial Standards (JIS) G3455 2004 Carbon Steel Pipes for
Ordinary Piping.

IV. LIST OF ABBREVATIONS

N Symbo
Definition
o l
1 Lpp Length between perpendiculars
2 B Breadht of ship
3 H Height of ship
4 T Draught of ship
5 Q Minimum capacity of pump
6 A Pipe Area
7 V Velocity of water in pipe
8 hs Head static of bilge pump
9 hp Head of pressure difference
10 hv Head of velocity difference
11 Rn Reynould number
12 u kinematic viscocity
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AIR SYSTEM
13 λ Friction loss coefficient
14 L Length of pipe
15 D Diameter of pipe
16 HTOTAL Total head

V. SYSTEM DESCRIPTION
The compressed air system on the engine consists of a starting system, starting
control system and safety system. Further, the system supplies air to the jet system and the
stop cylinders on each fuel injection pump.
The compressed air is supplied from the starting air receivers (30 bar) through a reduction
station, where from compressed air at max. 10 bar is supplied to the engine. The reduction
station should be located as near the starting air receiver as possible. To avoid dirt
particles in the internal system, a strainer equipped with a drain valve is mounted in the
inlet line to the engine.
Starting System
The engine is started by means of a built-on air starter, which is a turbine
motor with gear box, safety clutch and drive shaft with pinion. Further, there is a
main starting valve.
Control System
The air starter is activated electrically with a pneumatic 3/2-way solenoid
valve. The valve can be activated manually from the starting box on the engine,
and it can be arranged for remote control, manual or automatic.
For remote activation the starting coil is connected so that every starting
signal to the starting coil goes through the safe start function which is connected
to the safety system mounted on the engine. Further, the starting valve also acts as
an emergency starting valve which makes it possible to activate the air starter
manually in case of power failure.
Safety System
As standard the engine is equipped with an emergency stop. It consists of
one on-off valve, see diagram, which activates one stop cylinder on each fuel
injection pump. Air supply must not be interrupted when the engine is running.
Pneumatic Start Sequence
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AIR SYSTEM
When the starting valve is opened, air will be sup plied to the drive shaft
housing of the air starter. The air supply will - by activating a piston - bring the
drive pinion into engagement with the gear rim on the engine flywheel.
When the pinion is fully engaged, the pilot air will flow to, and open the
main starting valve, whereby air will be led to the air starter, which will start to
turn the engine.
When the RPM exceeds approx. 158, at which firing has taken place, the
starting valve is closed whereby the air starter is disengaged.

VI. DESIGN REQUIREMENTS

No
Key Equipment Reference Parameter Design
.
1 P = 30 * V (m3/h) 1000
P = Total capacity of the compressors
Project Guide
Compressor (m3/h)
MAN B&W
Capacity V = Total volume of the starting air
L27/38
reciever (dm3) at service pressure of 30
bar)
2 As standard the engines are fitted with a
Project Guide
Pressure Reducing 10 bar air starter. Therefore the air
MAN B&W
Valve supply needs to be reduced from 30 bar
L27/38
to 10 bar before inlet engine.
3 Project Guide The receiver may be minimum 5° off
Starting Air Receiver MAN B&W the horizontal, with the drain valve at
L27/38 the lowest position.
4 Pressure and Time Project Guide All of the starting air receivers, items 3
for Starting Air MAN B&W and 3A, should be pressurized to 30 bar
receivers L27/38 for approx 60 minutes

Table 1.1. Design Requirements

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VII. SUMMARY OF CALCULATION

SYMBO RESUL
NO CALCULATION   L T  
Capacity Starting Air
1 Receiver Q 750 m3/h
2 Capacity Compressor Q 45 m3/h

VIII. DETAIL OF CALCULATION

VIII.1 Calculation Starting Air Vessel
Based on the Project Guide of MAN B&W L27/38, the starting air must conform to
the following :

Purity with respect to solid pa rticles Qua lity cla ss 6

Pa rticle size >4 0 μm ma x. concentra tion <5 mg/ m³
Purity with respect to humidy Qua lity cla ss 7
Residua l wa ter content <5 mg/ m³
Purity with respect to oil Qua lity cla ss 5

The compressed air system on the engine consist of a starting system, starting
control system, and safety system. The compressed air is supplied from the starting air
receivers (30 bar) through reduction station, where from compressed air at max. 10 bar is
supplied to the engine. The reduction station should be located as near the starting air
receiver as possible. To avoid the dirt particles in the internal system, a strainer equipped
with a drain valve is mounted in the inlet line to the engine. According to the Project
Guide, the volume of starting air system required is :

Engine Type Single Engine Arrang. Twin Engine Arrang.

L27/38 8-9 Cylinders 2x750 ltr 3 x 750 ltr
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VIII.2 Starting Air Receiver Choosen
Compressed Air Vessels Specification:
Brand = Mellcon
Volume = 750 Litres
Max. Pressure = 30 bar
Height = 1450 mm
Diameter = 750 mm

VIII.3 Calculation of Compressor

According to the project guide of MAN B&W L27/38, all of the starting air
receivers should be pressurized to 30 bar for approximately 60 minutes. In artic condition,
it shall be 30 minutes. Compressors are to be installed with total capacity sufficient for
charging air receivers of capacities specified from atmospheric to full pressure in the
course of one hour. Two or more compressors of total capacity as specified are to be
installed. So, here’s the calculation :

Q =( V x 30 ) / 1000
P = Total capacity of the compressors (m3/h)
V = Total volume of the starting air reciever (dm3) at service pressure of 30 bar)
Q = ( 1500 x 30 ) / 1000
Q = 45 m3/h

So after we know the total capacity of the compressor, now we can chose the
compressor. Here’s the compressor specification that choosen.

VIII.4 Compressor Chosen

The compressors Specification:
Brand = HATLAPA
Type = L190
Capacity = 46,6 5 m3/h
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AIR SYSTEM
Rotation = 1750 rpm
Power = 46.5 kW

IX. SPECIFICATION OF EQUIPMENTS

See attachment of Doc. No. 08 - 42 19 MA029 – CO

X. DRAWING OF SYSTEM
See attachment of Dwg. No. 08 - 42 19 MA029 – CO