Air Compressors (MOD)

Knowledge about Reciprocating
Air Compressors
AIR COMPRESSORS
Learn More & Save Ourselves
စု-တု-ျပဳ By Wai Yan Tun

1 AIR COMPRESSORS
TABLE OF CONTENTS
TABLE OF CONTENTS ................................................................................................................................................................ 1
AIR COMPRESSORS .................................................................................................................................................................. 3
INTRODUCTION ......................................................................................................................................................................... 3
Use of Compressed Air Onboard Ship ............................................................................................................................. 3
Air Compressors .................................................................................................................................................................. 3
How does an air compressor work? ................................................................................................................................. 3
Use of Air Compressors Onboard Ship............................................................................................................................. 4
Main air compressor ...................................................................................................................................................... 4
Topping up compressor ................................................................................................................................................ 4
Deck air compressor ...................................................................................................................................................... 5
Emergency air compressor ........................................................................................................................................... 5
.................................................................................................................... 5
THEORETICAL POINT OF VIEW .................................................................................................................................................. 6
P-V Diagram of Reciprocating Compressor ................................................................................................................... 8
BUMPING CLEARANCE ........................................................................................................................................................ 9
What is Bumping Clearance ......................................................................................................................................... 9
Bumping Clearance Changes over Time................................................................................................................. 11
Significance of Bumping Clearance ......................................................................................................................... 11
How to Check Bumping Clearance .......................................................................................................................... 12
How to Adjust the Bumping Clearance..................................................................................................................... 12
VOLUMETRIC EFFICIENCY.................................................................................................................................................. 13
Factors Affecting Volumetric Efficiency..................................................................................................................... 13
MULTISTAGE COMPRESSION ............................................................................................................................................. 14
Calculation of required cylinder compression for a multistage reciprocating compressor ............................. 17
AIR COMPRESSOR TYPES ....................................................................................................................................................... 19
Centrifugal Air Compressor ............................................................................................................................................. 20
Rotary Compressor ........................................................................................................................................................... 20
Rotary Vane Compressors ............................................................................................................................................... 20
Rotary Screw Compressors .............................................................................................................................................. 21
Reciprocating Air Compressors ...................................................................................................................................... 22
Rotary + Reciprocating Compressor ............................................................................................................................ 22
Dynamic compressors ..................................................................................................................................................... 22
CONSTRUCTION DESIGN & MATERIALS OF RECIPROCATING COMPRESSOR .................................................................. 23
AIR COMPRESSOR COMPONENTS ....................................................................................................................................... 28
Suction & Delivery Valves ................................................................................................................................................. 28
Why plate type is used? ............................................................................................................................................... 32
Jacket Relief Valve ........................................................................................................................................................... 32
Air Filter................................................................................................................................................................................ 32
GO TO TABLE OF CONTENTS ”စု-တု-ျပဳ” By WAI YAN TUN

2 AIR COMPRESSORS
Piston, Liner & Connecting Rod ...................................................................................................................................... 33

Bearing ............................................................................................................................................................................... 34
Coolers ............................................................................................................................................................................... 35
Air cooled versus Water cooled ................................................................................................................................. 35
Intercooler & Aftercoolers ............................................................................................................................................ 36
Cooler Types .................................................................................................................................................................. 37
 Cooling Problems ................................................................................................................................................. 39
AIR COMPRESSOR SAFETY DEVICES ..................................................................................................................................... 40
Air Cooler Safety Devices ................................................................................................................................................ 40
Safety Valve ....................................................................................................................................................................... 41
Methods of Unloading Compressors ............................................................................................................................. 41
AIR COMPRESSOR PIPING RECOMMENDATIONS................................................................................................................ 42
LUBRICATION........................................................................................................................................................................... 46
AIR COMPRESSOR TROUBLESHOOTING & MAINTENANCE ................................................................................................. 49
TROUBLESHOOTING ........................................................................................................................................................... 49
EFFECTS OF SLUGGISH ACTION OF VALVES ................................................................................................................ 49
EFFECTS OF LEAKING VALVE ......................................................................................................................................... 50
EFFECTS OF AMBIANT AIR TEMPERATURE ..................................................................................................................... 51
EFFECTS OF ATMOSPHERIC HUMIDITY .......................................................................................................................... 52
EFFECTS OF RESTRICTED AIR INLET TO L .P STAGE ....................................................................................................... 53
EFFECTS OF DEPOSITS IN COOLERS & JACKETS ......................................................................................................... 53
EFFECTS OF WORN CRANKSHAFT BEARING ................................................................................................................ 54
EFFECT OF BROKEN OR WORN SCRAPER RING ......................................................................................................... 54
EXCESS LUBRICATION .................................................................................................................................................... 55
POSSIBLE CAUSE OF STARTING AIR LINE EXPLOSION .................................................................................................. 56
TABLE ............................................................................................................................................................................... 57
MAINTENANCE ................................................................................................................................................................... 58
Precaution to be taken before starting ..................................................................................................................... 58
Advantages of Thin Plate (Feather) Valves for Compressors .................................................................................. 59
Maintenance of Air Compressors............................................................................................................................... 60
AIR COMPRESSORS EXPLOSION ........................................................................................................................................... 63
 Introduction ........................................................................................................................................................... 63
 What Causes Explosion?...................................................................................................................................... 63
AIR COMPRESSOR STARTER CIRCUIT .................................................................................................................................... 64
AIR COMPRESSOR QUESTIONS & ANSWERS ........................................................................................................................ 65
QUESTIONS & ANSWERS .................................................................................................................................................... 65
QUESTIONS.......................................................................................................................................................................... 70

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AIR COMPRESSORS
INTRODUCTION
Use of Compressed Air Onboard Ship
The compressed air system are used in marine service

1. For start the diesel engine,
2. Instrumentation and control system,
3. For operating various pneumatic tools such as cleaners, painting chippers,
drill, paint sprayers, grinders and taper,
4. For cleaning machinery, blowing out oil rank and boiler tubes, removing and
cleaning atomizer tubes and fuel oil burner tips,
5. For charging water pressure tank,
6. For pressure test,
7. For high pressure application,
8. For testing pipe line,
9. Whistle for ship,
10. Carbon dioxide fire extinguishing system,
11. For work shop service,
Air Compressors
Air compressors are used everywhere from the smallest workshop on land to
the gigantic ships sailing across the oceans.
An air compressor is a very useful machine and is not only used extensively in
industry on land but on all types of ships as well. On a ship an air compressor is
used to compress air and store it in tanks for various uses. These use these could
range from simple processes such as cleaning and drying of filters to tasks such as
starting the auxiliary engines and the main engines of the ship.
As the main aim of the compressor, as the name suggests, is to compress air
or any fluid in order to reduce its volume. Some of the main applications of
compressors are main air compressor, deck air compressor, AC compressor and
refrigeration compressor.
How does an air compressor work?
It simply refers to the process of reducing the volume of gas so as to raise its
pressure and the compressed gas is stored in a solid container or tank usually

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having a pressure gauge and the safety mechanism. Just notice that I have used
the word gas which is obvious since the solids and liquids are incompressible.
The basic construction of a reciprocating compressor is similar to that of an

internal combustion engine. It consists of the familiar piston and cylinder
arrangement, having inlet and outlet valves for the entry of normal air and the exit
of compressed air respectively. The other component is present in the bigger
engines such as the connecting rod and the crankshaft are also there in the
reciprocating compressor.
The more the power required from the compressor, the greater the number
of cylinders in it. The compressor is driven by an external power source which is
normally an electric motor.
Use of Air Compressors Onboard Ship
On board a ship, compressed air is used for several purposes. On the basis of
application, different air compressors are kept for a particular usage. Normally, air
compressors on board ships are:
 Main Air Compressor,

 Topping Up Compressor
 Deck Air Compressor
 Emergency Air Compressor
Main air compressor
Main air compressor is used for supplying high pressurised air for starting of
main and auxiliary engines. The pressurised air generated by the air compressor is
stored in air storage bottle. These are high capacity compressors and the air
pressure that is required from these compressors to start the main engine is 30 bars.
Control air is also supplied from air bottle through a pressure reducing valve and a
control air filter. Normally they are twice in number and can be more than that for
redundancy.
Topping up compressor
Topping up compressor takes up the lead to cover up for the leakage in the
system. This means that as soon as the air pressure in the system goes below a
particular level, the topping up compressor replenished the system with pressurized
air.

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Deck air compressor
Deck air compressor is used for deck use and as service air compressor and
might have a separate service air bottle for the same. These are lower capacity
pressure compressors as pressure required for service air is in between the range of
6 to 8 bar.
Emergency air compressor
Emergency air compressor is used for starting auxiliary engine at the time of
an emergency or when the main air compressor has failed for filling up the main
air receiver. This type of compressor can be motor driven or engine driven. If motor
driven, it should be supplied from emergency source of power.
There are to be two or more air compressors, at least one of which is to be

driven independently of the propulsion engines and the total capacity of the air
compressors driven independently of the propulsion engines is to be not less than
50% of the total required. The total capacity of air compressors is to be sufficient to
supply within one hour the quantity of air needed to satisfy the starting requirements
by charging the reservoirs from atmospheric pressure.

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THEORETICAL POINT OF VIEW

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For greater efficiency air compression should be isothermal as this requires

the minimum work input. In practice Isothermal compression is not possible, an
ideal Isothermal cycle requires sufficient time to allow all the required heat to be
transferred out of the cylinder, practicality dictates that the piston must have a
relatively high speed to give a reasonable output.
The quantity of air supplied can be controlled in one of two ways:
1. By altering the speed of the compressor, this requires a sophisticated a.c.

controller or a d.c. motor.
2. By the use an unloading valve on the output side of the compressor.

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P-V Diagram of Reciprocating Compressor

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BUMPING CLEARANCE
What is Bumping Clearance
A clearance is required in order to prevent the piston striking the cylinder

cover when starting or stopping off load. This is referred to as the “Bump Clearance”
,and the volume of this clearance is called designed “Clearance Volume” . It is
normally 6 % of swept volume, provided for thermal expansion and necessary
space for valve operation, to prevent mechanical damage to compressor.
The clearance volume for a single stage compressor is defined as the space
created between the piston and head, including the space around the piston to
the top of the upper ring and under the valves, with the piston at TDC.
In new compressors bumping clearance is adjusted by the manufacturers

and the marine engineers are blissfully unaware of its importance. However the ship
does not remain new forever and every machine demands overhauling and that is
where the problems start. Even routine jobs like lifting the cylinder head to change
the low pressure or first stage valves can change the bumping clearance! if the
correct thickness gaskets are not used or if the head is over tightened thus
squeezing out the gaskets. Many engineers miss this vital adjustment during overhaul
of the compressors and efficiency and free air delivery of the compressor suffers.
Clearance volume must be kept as small as possible for achieving the best
compressor efficiency. Excessive bumping clearance gives a large clearance
volume and decrease volumetric efficiency, because high pressure air remaining
in that clearance volume after compression and delivery will expand more than
normal on the return stroke of the piston. This pressure disturb to next suction stroke
and fresh air charge. It may increase the inlet air temperature and reduce

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compressor efficiency. Therefore, designed clearance volume is required to keep

as minimum as possible.
With a large clearance volume the outward travel of the piston will be greater
before the pressure is low enough within the cylinder to allow the suction valves to
open. In consequence a large part of the suction stroke is made ineffective and
the amount of air taken into the cylinder during each suction stroke is reduced. This
lowers the volumetric efficiency. This non-effective part of the suction stroke must
be kept as small as possible as to achieve maximum performance. It is only a
fraction of millimeter in high pressure stage and depends on diameter of piston
speed and discharge pressure.
The effect of excessive bumping clearance gives a large clearance volume

which will be full of air at high pressure when the piston reaches the end of its
stroke, and in double-acting compressors it also reduces the clearance at the
lower part of stroke.
The volumetric clearance not only lowers the possible output of a given
machine but also increases the cylinder charge temperature slightly since the
temperature does not drop to the inlet temperature on expansion.

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Bumping Clearance Changes over Time
The bumping clearance in a new machine is set properly by the manufacturers

during construction but over a period of time the clearance changes because of
the following reasons:
1. Wear at the crankpin bearing. The crankpin bearing wears down due to use
and this clearance can travel right up to the piston and an unloaded piston
can hit the cylinder head. This type of wear can be recognized when the
compressor makes impact sounds running unloaded at the starting and
stopping operations. This type of wear would also be accompanied by a slow
decrease in oil pressure over a period of time.
2. Opening up of cylinder heads. In certain types of reciprocating compressors
the cylinder head have to be removed for the changing of the first stage
suction and discharge valves. When the cylinder head is put back the correct
thickness of the cylinder head gaskets should be used otherwise it would
change the bumping clearance.
3. Wear on the main bearings. Over all wear on the main bearings would lower
the crank shaft and would thus lower the piston and increase the bumping
clearances.
Significance of Bumping Clearance
The bumping clearance must be adjusted properly otherwise there is risk of

damage and loss of efficiency. If the bumping clearance is less the volumetric
efficiency would increase but there is risk of the piston hitting the cylinder head,
especially when the compressor is unloaded during start and stopping.
On the other hand to play safe, the engineer gives few millimeters of extra
clearance, the volumetric efficiency of the compressor would decrease, the free
air delivery will fall and there will be a fall in pressure. The extra clearance would
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. This would
endanger the ship during maneuvering by sudden loss of propulsion.

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How to Check Bumping Clearance
The bumping clearance can be checked by the following methods:
1. In case a suitable opening is available the piston can be barred to the top
dead center and then feeler gauges can be put inside and the clearances
checked at two/ three points.
2. The more convenient method is to take lead wire from the engine store and
make a small ball based on the expected clearance and put it between the
piston and the head from the valve opening. Then the piston is slowly turned
to the top dead center with the help of a Tommy bar. After that the piston is
again turned down and the lead wire ball is extracted and the thickness
measured with the help of a micrometer. This measurement would give the
bumping clearance.
3. Alternately, remove the bottom half of the big end bearing and rig a clock
gage with one contact touching the piston and get the first reading, then
push piston upwards until it touches the cylinder cover and take the second
reading. The difference in reading gives the bumping clearance.
4. By use of very accurate depth caliper.
The caution which must be observed in these methods is that the clearances of
the main and the crank pin bearing have not been taken into account. The correct
method is thus that after turning the piston to top dead centre the piston
connecting rod must be jacked up with the help of a crow bar. It is only after this
hidden clearance has been accounted for, will the correct bumping clearance be
found.
How to Adjust the Bumping Clearance
The adjustment of Bumping Clearance is a very critical adjustment of the

clearance volume. If more the volumetric efficiency of the compressor suffers and
if less the unloaded piston may hit the cylinder head and damage both.
The bumping clearance once found to be incorrect would have to be adjusted.

The methods of adjusting the bumping clearances are as follows:
1. The cylinder head gaskets can be changed to a different thickness thus

altering the bumping clearance.
2. The shims between the foot of the connecting rod and the bottom end
bearing can be changed thus changing the bumping clearance.

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However after adjusting the bumping clearance the clearance should be

checked once again to make sure that there is no error and the clearance is within
the range as specified by the manufacturers. It must be stressed that compressors
are unforgiving and incorrectly maintained compressors have claimed many lives.
It is should be checked properly when compressor overhauling. Worn down

bearing can cause the compression noisy, vibration, overheating and excessive
bumping clearance.
VOLUMETRIC EFFICIENCY
The volumetric efficiency of a reciprocating air compressor, is the ratio of

the actual amount of air discharged by the compressor, to the theoretical volume
swept by the movement of the compressor piston.
Volumetric efficiency Vh = Actual suction volume Vx/ Theoretical suction volume Vs
Volumetric efficiency Vh = Vol of Air Discharged as “Free Air” / Swept Volume
Where “Free Air” is air at atmospheric pressure and a temperature of 15’C
Factors Affecting Volumetric Efficiency

1. The bumping clearance ( the larger the bumping clearance the less air is
discharged per stroke )
2. Sluggish opening and closing of suction and delivery valves
3. Piston rings’ leakage
4. L.P inlet air temperature too high
5. L.P inlet air filter dirty and choked
6. Inlet Cooling water temperature too high
7. Insufficient cooling water owing to fouling of coolers
The capacity of a compressor is usually specified in volume of air corrected
to “normal” conditions. This figure called “Free Air Delivery” should be quoted with
reference to the temperature and pressure. There are two different “normal” values.
 One called the “technical normal condition” is defined as standard pressure
0.980665 bar and temperature 20 deg C.
 The other normal condition called “physical normal condition” is specified at
standard pressure 1.01325 bar and temperature 0 deg C.

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MULTISTAGE COMPRESSION
Upon compression the air, the temperature and pressure increases and the
volume decreases. For compression between Isothermal ( temperature remains
unchanged in ideal condition ) and Adiabatic ( temperature rises due to no
intercooling ) , the compression curve on the PV diagram will be Polytropic where
PVn =C , and “n” values being 1.25 < n < 1.35 due to proper intercooling and
cylinder cooling during compression.
In order to approach conditions near to Ideal Isothermal conditions,
Compressors have to be made of the multistage type. The air after being
compressed in the first stage is passed through intercooler thus heat of
compression and volume reduced at constant pressure and also any water
content drained away. The aftercooled-air then passed into the second stage at
nearly its original temperature, and is compressed and intercooled again.
The gain in efficiency can be seen on the PV diagram that Isothermal
compression at constant temperature causes least area of diagram and therefore
least power absorbed.
The main consideration, however, is the reduction in temperature.

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The use of multi stage will give mechanical improvements of compressor

balance a reduction in size and mass robust construction of smaller high pressure
parts and reduction in clearance volume losses. Air discharges from the first stage
of compression passed thru the intercooler where it is cooled at constant pressure
causing as reduction in temperature and volume. The gain in efficiency can be
illustrated on a pressure volume diagram on which it can be seen that isothermal
compression cause least area of diagram and therefore least power absorb.
Returning to compressors line to this curve between stages will reduce power
absorb in second stage by the shaded area shown.

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POINTS DELIVERY PRESSURE AIR TEMPERATURE

( Two Stage ) B/4 cooler After cooler
1st stage 4 bar 130’C 35’C
2nd stage 30 bar 130’C 35’C
( Three Stage )
1st stage 4 bar 110’C 35’C
2nd stage 16 bar 110’C 35’C
3rd stage 40 bar 70’C 25’C
Cylinder cooling on a single stage compressor gives better efficiency but

there is a limitation in the surface area to cylinder volume that can be used for
cooling effect, but multistage compressors with an efficient extended surface
interstage cooler gives cycle improved compression efficiency better
approaching that of the isothermal. In theory the greater the number of stages
the closer the curve will approach the ideal isothermal compression curve,
however there is an increase in cost, complexity, and the law of diminishing
returns limit the number.
Compression in stages has the following advantages;
1. The compression ratio at each stage is lower and so the final temperature is
lower. This reduces problems with lubrication
2. If a final pressure of say 30 bar is sought to be achieved by compression
from 1 bar in a single stage, the air temperature can get close to the auto
ignition temperature of lube oil, resulting in an explosion.
3. The machine is smaller and better balanced
4. Water can be drained off at each stage
5. Compression better approaches the ideal isothermal
None of the stages used is governed by the required final pressure of the
compressed air . As the pressure increased, more stages are required.When the air
is compressed in stages, it is easier to control the temperature of the air and to
hold it at lower temp during its passage through the air compressor . As the air
leaves each stages of the air compressor it is cooled in the inter cooler. The lower
the workdone in compressing the air and prevents a lot of the mechanical
problems which could arise if the air temp was in controlled.,

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Calculation of required cylinder compression for a multistage reciprocating

compressor
For a Two Stage,

r = stage pressure ratio
R = compression pressure ratio for a two stage
r = R1/2
For a three stage
r = R1/3
For example, a 3 stage compressor requiring a final pressure of 64bar would

have the following interstage pressures
1st stage 1bar compressed to 4bar

2nd stage 4bar compressed to 16bar
3rd stage 16bar compressed to 64bar
It would appear that most of the work is being carried out in the final stage,
this is untrue as with the increase in pressure is a complimentary reduction in
volume, if the temperature conditions remain the same then work will be equally
divided between the stages.
By reducing the suction pressure, the cylinder is required to do more work on

the air before the discharge valve opens. This means that the air will be delivered
at a higher pressure. The higher temperature can lead to problems with the
cylinder lubrication as well as a drop in efficiency as well as carbonizing of the oil
and increased deposits on the valves and piston rings and interstage passages. In
the extreme it can lead to seizure and possible diesel detonation of the oil laden
air.
The reduction in pressure at the suction can be due to a partially blocked

suction filter or partially choked suction valve. The lower pressure conditions in the
cylinder at the start of compression can cause oil laden air to be drawn from the
crankcase up the liner. This oil can lead to increased deposits in the compressor as
well as further downstream in the distribution system.

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(P1.V1)/ T1 = (P2. V2)/T2
(P1/P2).(T2/T1) = (V2/V1)
P1.V1g = P2.V2g
and
P1/P2 = V2g/V1g
From these we get;
T2 = T1. (P2/P1) (g -1)/g ,g = 1.4
and if we take for an example

P1 = 0.4 bar
P2 = 1 bar
Pf = 5 bar
T initial = 300 K we end with final temperatures for the two compression's of
T1= 617 K and T2 = 475 K
from the graph it can be clearly seen that losses due to the bump clearance has
increased and the period of constant pressure delivery has been reduced.

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AIR COMPRESSOR TYPES
There are mainly four types of compressors:
1. Centrifugal compressor
2. Rotary vane compressor
3. Rotary screw compressor
4. Reciprocating compressor.
5. Dynamic Compressors
However, on ship reciprocating air compressor is widely used.

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Centrifugal Air Compressor
The centrifugal air compressor is a dynamic compressor which depends on

transfer of energy from a rotating impeller to the air. The rotor accomplishes this by
changing the momentum and pressure of the air. This momentum is converted to
useful pressure by slowing the air down in a stationary diffuser. The centrifugal air
compressor is an oil free compressor by design. The oil lubricated running gear is
separated from the air by shaft seals and atmospheric vents. The centrifugal is a
continuous duty compressor, with few moving parts, that is particularly suited to
high volume applications--especially where oil free air is required. Centrifugal air
compressors are water cooled and may be packaged; typically the package
includes the aftercooler and all controls. Turbocharger Compressor is an example
of centrifugal air compressor.
Rotary Compressor
Now we will take a very brief look at one more type of compressors namely
rotary compressors. As the name itself suggests, and these compressors have the
rotary motion instead of reciprocating motion of the internal parts responsible for
compressing the air.
Normally rotary compressors consume less energy for motive power but
reciprocating compressors are more powerful and hence used for heavy duty
purposes.
Rotary air compressors are positive displacement compressors. The most

common rotary air compressor is the single stage helical or spiral lobe oil flooded
screw air compressor, but compressors based on the sliding vane principle are also
common. These compressors consist of two rotors within a casing where the rotors
compress the air internally. There are no valves. These units are oil cooled (with air
cooled or water cooled oil coolers) where the oil seals the internal clearances.
Since the cooling takes place right inside the compressor, the working parts never
experience extreme operating temperatures. The rotary compressor, therefore, is a
continuous duty, air cooled or water cooled compressor package. Examples are
sliding vane compressors, screw compressors and roots blowers
Rotary Vane Compressors
Rotary compressors are capable of handling large quantities of low pressure

air much more efficiently than a reciprocating compressor.

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In order to produce increased

pressures it is possible to stage rotary
compressors but leakage problems
increase at higher pressures as well as stress
on the vanes.
The sliding vane compressor consists

of a slotted rotor with its axis offset from that
of the cylindrical casing. Vanes fit in the
slots and have contact with the casing
Rotary Vane Compressor
On the suction side the space
contained between the casing, the rotor and an adjacent pair of vanes is
gradually increasing allowing air to be drawn in.
On the compression side this same space is gradually reduced causing the
pressure increase. When the leading vane uncovers the discharge port air will flow
to outlet. Larger compressors of this type are water-cooled; smaller compressors
tend to be air cooled.
The main problems related with sliding vane compressors concern wear at
the vane tips and sealing of the ends.
Rotary Screw Compressors
Because of the simple design and few wearing parts, rotary screw air
compressors are easy to maintain, operate and provide great installation flexibility.
The two stage oil flooded rotary screw air compressor uses pairs of rotors in a
combined assembly. Compression is shared between the first and second stages
flowing in series. This increases the overall compression efficiency up to fifteen
percent of the total full load kilowatt consumption. The two stage rotary air
compressor combines the simplicity and flexibility of a rotary screw compressor with
the energy efficiency of a two stage double acting reciprocating air compressor.
The oil free rotary screw air compressor utilizes specially designed air ends to
compress air without oil in the compression chamber yielding true oil free air. Oil
free rotary screw air compressors are available air cooled and water cooled and
provides the same flexibility as oil flooded rotaries when oil free air is required.
Rotary oil flooded compressors are designed for continuous running; this suits
their use as control air compressors as control air is required continuously on board.

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Oil free compressors are also used for control systems as these have the
added advantage of not requiring an oil separator and delivering good quality oil
free air.
The rotary compressor may be of the impeller type similar to that used in the
turbocharger, scroll, and twin rotating lobes or of the sliding vane type. In practice
there would be several more vanes than shown.
Reciprocating Air Compressors
These employ either pistons or diaphragms. In case the compression required

is more, the compressors come in more than one stages. Since it is a law of
thermodynamics that when sudden compression takes place, temperature rises.
The graph of pressure against volume for a reciprocating compressor is shown
below.
Hence the air needs to be cooled before being passed on to the next stage
and this is done using intercoolers. Of course there is also an after cooler which is
used to cool the air before it is passed on to the storage tank.
There are several advantages to use multistage compression instead of a

single large compressor including use of smaller sized stages than a single large
stage, low compression ratio for each stage and enhanced lubrication properties.
Rotary + Reciprocating Compressor
Rotary compressors in general do not require internal lubrication but they are
not suitable alone for providing air at a
pressure for starting duties. They can,
however, be linked to reciprocating stages
to produce a hybrid compressor.
The compressor is lighter, more compact

and better balanced than an equivalent all
reciprocating unit. In basic terms the rotary
first stage supplies air to the reciprocating
second and subsequent stages. All stages
being driven by the same shaft
Dynamic compressors
Dynamic Compressors Include Axial Flow and Centrifugal Flow compressors.

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CONSTRUCTION DESIGN & MATERIALS OF RECIPROCATING COMPRESSOR
The compressor casing, cylinder covers and piston rings are generally of
cast iron. Pistons may be of cast iron, steel of aluminum. Aluminum being the
preferred material for use on the LP piston due to its larger diameter. Valves are
usually made so that parts can be interchanged between the suction and
discharge valves. Seats are of mild steel with small diameter air passages to
prevent the fragments of broken valve plate from entering the cylinder. Valve
plates are of vanadium steel heat treated and ground to provide the required
hardness and surface finish. Springs should be arranged such that they lift and
seat squarely. Uneven spring force or deposits on the seat cause valves to bend
resulting in fatigue cracking. Crankshaft is usually made of spheroidal graphitic
cast iron.
Cast iron-Casing, Liners, Pistons (the LP piston is sometimes made from an

aluminum alloy, Cylinder covers
Steel- Crankshaft, Connecting Rods, Pistons, Valve seats
Vanadium Steel- Valve plates

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28 AIR COMPRESSORS
AIR COMPRESSOR COMPONENTS
Suction & Delivery Valves
One of the most important parts of the air compressor, as regards efficiency
is undoubtedly the valves. Any care taken with these parts, during manufacture will
be repaid during the whole life of the valve. Small savings, such as those made by
polishing the ports, reducing the weights of the effective lift of the valve at the
beginning of the suction stroke or to close it at the end of the delivery stroke or by
increasing the time between overhauls are the points to be aimed at during the
design and manufacturing periods.
Air compressor valve needed regular overhaul if they are defective
reducing the volumetric efficiency and also reduce air delivery, increase air
temperature and increase running time.
Valves can leak due to wear and fatigue, insufficient or over lubrication,
present of foreign particles, oil decomposition and excessive lift.

29 AIR COMPRESSORS
At regular interval valve seat, valve plate needed to be properly ground due to
their constant pounding effect. Check the valve seat, valve plate; buffer plate,
damper plate for pitting, overheating and carbon deposit.
Check the spring weak or defective one to be renewed. Absolute

cleanliness of filter and minimum absolute lubrication can longer life of suction and
delivery valve.
It always should be good working order condition, according to running hour.

The air compressor valve are dismantled, cleaned, and refacing thoroughly check
spring plate, etc., and reassemble and test leakage.
If a suction valve does not reseat promptly at the end of the suction stroke
due to a weak spring or to carbon deposit, part of the air drawn into the cylinder will
be returned through the defective suction valve during the first part of the delivery
stroke.

30 AIR COMPRESSORS
If a delivery valve is slow in reseating, for the same reasons, part of the
delivered compressed air will return to the cylinder during the first part of the suction
stroke. So this reduces the compressor performance.
The suction and delivery valves are usually of the same type, the only
differences being in the spring load and the lift. It is therefore necessary ,during
cleaning that the valves be treated as unit,the various parts assembled exactly as
before they were dismentled. The spares also should be clearly marked 'SUCTION'
and 'DELIVERY' and used only for that purpose.
The air suction and discharge valves of concentric types are located in
pockets in the cylinder heads and blocks as shown. These automatic concentric
valves are made up of (1) Valve seat, 0.4% carbon steel (4) Valve plate, Nickel
steel or Chrome vanadium steel or stainless steel (5) Cushion plate, Stainless steel
(6) Spring plates, hardened steel and (2) Buffer plate, stainless steel with (3)Center

31 AIR COMPRESSORS
bolt and (9)locking nut. The combined air filter and silencer is fitted to the
compressor air intake.
The seat is usually made from 0.4 :/. carbon steel ,machined all over from a
solid bank. Owing to the high finish ,minimum losses are secured. The tapered ports
with the inlet edges will rounded off and th passage finely finished, so assisting to
reduced losses are milled from the solid bank. The multiple ports give a large
effective area which allow a low lift being usd. The faces on the seat ,when the
valves bears are narrow and have a mirror finish,by these means air tightness over
a long period is assured.
A pin (8) can be seen in the seat ,this prevents the various parts from rotating,
and must never be left out when assembling. The Guide Washer (7) guides the lift of
the valve plate (4)& Valve Plate is usually made from high gade steel plate,rolled
and cross rolled ,to prevent uni-directional grain flow. The steel used may be nickle
steel,chrome vanadium steel or stainless steel.In order to help the weight down to a
minimum, ports are trepanned or milled thru the plate and the burred edges
carefully removed.Particularly care is taken to leave no nicks or scretchs ,these
might cause a concentration of stresses and lead to to broken valve.
The plate is now heat treated to obtain hardness of between 300 to 400 'C
brunnel.The valve is now ground to a mirror finish on both faces.The sharp edges
are then carefully finished to small,very smooth radic. The cusion plate (5) ,spring
plates (6) and also the buffer plate (2) are all made from steel . The grade and
quality of the steel used for each part is carefully chosened to suit the duties
required from it.
The machining process for each is almost the same ,the ports or apartures
are either trepanned or milled thru the lates, which are then ground to both
faces,all sharp edges carefully removed,leaving a small smooth radius on all
edges. The plates are now heat treated ,if necessary, and in the case of the springs
(6) ,the tongue is set to correct deflection,so giving the exact press. required.
The cushion plate (5) effectively reduced the impact forces from opening &
closing of the valve.Since the Cushion plate has three ribs which are perfectly
matching with the three tongues of Spring Plate, the Valve Plate has therefore three
points of applied press distributed equal distantly. This method being ensures the
valve being seated firmly, promptly and gently without rebound or leakage. When
parts are assembled on the stud, in the correct positions , the valve seat (1) the
washer(10) and the nut (9)&(9a) are put on ,screwed up tight and locked by a split
pin(11).

32 AIR COMPRESSORS
Why plate type is used?
Concentric suction and delivery plate type valve is one of the most important
parts of an air compressor. The suction and delivery valves are usually same type ,
the only difference are spring load , diameter and the lift.
The plate type concentric suction and delivery valves are designed to use
because of the followings
 They separate very low lift
 They have large area of opening with small lift . So , high volumetric
efficiency will obtain.
 They can open and close sharply
 They have low inertia
 They can use in medium or high speed air compressor.
 More length service life to be overhauled.
 Very easy to overhaul , ground in mirror surface.
Jacket Relief Valve
For compressors designed for starting air requirements a water jacket relief
valve is fitted.
Air Filter
If the filter cannot filtrate properly, foreign abrasive particles contain in E.R air
may enter with intake air and leading to damage valve operation. This may affect
high discharge temperature and formation of carbon deposition. These may
become extremely hot on valves, which are not properly closed and lead to
compressor explosion.

33 AIR COMPRESSORS
If any dirt and grease are allowed to accumulate and partly choke the filter,
the air intake will be restricted and volumetric efficiency will decrease. Therefore
less air will be discharged with high temperature, resulting overheats the valves and
may cause fire and explosion.
The air compressor’s suction filter should always clean. For the cleaning
maintenance, air filter should be dismantled and wash thoroughly with paraffin oil
and dried. Then dip in high quality L.O and hang for a while before to be fitted
back.
Piston, Liner & Connecting Rod
It is made up of Cast Iron casing with cylinder in which run Aluminum alloy
pistons fitted with Cast Iron rings.
The piston is of two differential diameters, the larger acting as the 1st stage
(L.P) and the smaller as 2nd stage (H.P). The pistons are connected to Forged Steel
Con-Rods through fully floating Gudgeon pins running in Phosphor bronze bushes
which have been fitted with Interference Fit. The Con-Rods carry steel backed white
metal lined thin shell bearings which connect on to a S.G Cast Iron Crankshaft. The
bearings are lubricated by Gear pump whilst the cylinder walls by splashing oil mist.
Air compressor Piston rings and cylinder liner are to be regularly over
hauled. The defective piston ring and wear cylinder liner cannot get effective
seal it can reduce the volumetric efficiency, reduce air delivery and increase running
time.
Piston rings and cylinder liner can wear due to lack of lubrication or L.O
contain condensation of water can cause poor lubrication and dirt contain suction
air.At regular interval piston ring to be renewed and check the cylinder liner for
wear and take calibration if necessary renewed.
It should be checked when overhauling the compressor. Remove piston,

clean piston ring groove, piston ring, take the gap clearance of piston ring a
sealing rings and scraper ring should be good working order condition.
If the piston rings are leakage, the compressed air leak into crankcase and
reduces the compressor efficiency and contaminates the L.O.
If the scraper ring is not in good working condition, the lubricating oil can
deposit to valves and it causes the valves to carbonized and sluggish action. L.O is
mixing with compressed air disturb the air starting system. It can cause to airline
explosion and also increase L.O consumptions, deposits at intercooler and reduce
cooler efficiency so piston and cylinder should be good working condition.

34 AIR COMPRESSORS
Bearing
The Con-Rods carry steel backed white metal lined thin shell bearings which
connect on to a S.G Cast Iron Crankshaft. The bearings are lubricated by Gear
pump whilst the cylinder walls by splashing oil mist.
The main bearings of a reciprocating air compressor are sometimes tapered
roller bearings. When mounted, these bearings are given a "cold" end clearance to
allow for longitudinal expansion of the crankshaft as the unit warms up. If a
reciprocating air compressor has a knock occurring in frequency with its operating
RPM, the cause is probably misalignment or worn main bearings. Reciprocating air
compressor bearing failure may result from
 Misaligned crankshaft
 Over tightened drive belts
 Contaminated sump oil
Air compressor main bearing and top end bearing and crank pin bearing
clearance must be check regularly for safe operation.
Excess clearance of bearings may increase clearance volume, mainly

reduced volumetric efficiency, and fall of compressor performance. Excess
clearance of bearing may cause over loading, striking, and insufficient L.O
pressure tends to bearing failure. So the finest clearance must be adjusted on
top end, bottom end and main bearing.
During over haul check the crank pin and holding down surface
Check the bearing surface if it is wear or crack should be replaced. Check
the bearing nut for tightness and locking arrangement and proper lubrication of
bearing. Compressor’s main bearing, top end bearing and crank pin bearing
clearances must be very finest and safe for the operation.
Excess clearance of bearings may increase clearance volume, mainly

reduced volumetric efficiency, fall compressor performance. Excess clearance of
bearings may cause over loading on corresponding bearing at every upward
stroke. Striking of bearing and tend to bearing failure. L.O pressure will decrease
and insufficient to reach required parts. So, the finest clearance must be adjusted
on top end, bottom end and main bearing.
Gudgeon pin and piston grooves, piston rings will failure due to top end
bearing excess clearance .Bottom end bearing & connecting rod failure, fracture
of connecting bolts are due to bottom end bearing excess clearance.
Main bearing and crankshaft will failure due to main bearing excess
clearance.

35 AIR COMPRESSORS
Coolers
Air cooled versus Water cooled
Air cooled Water cooled

01. No corrosion problem Prone to crankcase condensation
02. No Intercooler fouling Fouling of intercooler
03. Hotter running machine Moderate temperature machine
04. Carbonizing problem less carbonizing problem
05. Heavy Noise level Noise level is lower owing to water jackets
on deadening of the machine
The function of intercooler is to reduce the air temperature and volume

reduce at constant pressure as low as possible and volume reduced at constant
pressure and also to drain oil and water vapor. This lowers the work done in
compressing the air and prevents a lot of the mechanical problems which could
arise if the air temperature were uncontrolled.
By keeping the air temperatures low, less difficulty is experienced with the
lubrication of the pistons and cylinders and the suction and delivery valves remain
in a cleaner condition without becoming fouled with carbonized oil.
So that intercooler should be cleaned air side and water side for to get
perfect cooling efficiency.
The effect of operating with fouled inter coolers will be to raise the air
temperature. This will cause lubrication difficulties, the compressor efficiency will
rapidly fall off and there may be the rise of an explosion caused by overheated
parts in the air system.
Air side can be reducing cooler efficiency due to deposition of oil, on

the cooling surface due to over lubrication and suction air contains dirt. It can be
thoroughly cleaned by chemical.
Waterside can be reducing cooler efficiency due to clog of particle and dirt
inside cooling water. It can be thoroughly cleaned. And then cooler is to be tested
by hydraulic pressure to twice the working pressure.

36 AIR COMPRESSORS
Intercooler & Aftercoolers
The Intercoolers are fitted after each stage of compression and arranged as
close to the cylinder to reduce the length of hot delivery pipes. Intercoolers are
fitted so that the temperature of the compressed air could be brought down to
approximately the temperature at which it enters the compressor. This will result in a
lower horse power for the same volume of air delivered and better lubrication can
be achieved due to lower air temperature.
The intercooler is of usually single pass type with copper tubes through which
the air passes. The tubes are expanded into brass tube plates and header, which
allows for expansion. The cast iron casing permits circulation with cooling water.
The aftercooler is of double pass U tube type and operation similar to
intercooler but it has no bearing on the compressor performance since its action
takes place after all work has been done on the air. Its real functions are to bring
the delivery air temperature to a reasonable figure and remove condensate from
the air. Aftercoolers are fitted to reduce the air volume after it has been
compressed to the final pressure, so that a greater amount of air could be stored
in the air bottle.
Two stage compressors are generally more efficient than single stage
compressors. To obtain maximum efficiency, two stage air compressors are usually
fitted with intercoolers. The heat of compression is partially removed from
compressed air by intercoolers, aftercoolers, compressor water jackets The air
charge leaving an intercooler, or after cooler of an air compressor can be
expected to be at or below the dew point.
A dirty intercooler on the ship service air compressor will result in higher than
normal power consumption.

37 AIR COMPRESSORS
Cooler Types
 Plain Tube
o -easy to clean
o -very effective due to large surface area of large number small diameter
tubes
o -plugging of failed tube allos cooler to continue in service with little loss in
efficiency
o -must allow for thermal expansion by having one tube plate floating
 'U' tube
o -suitable for higher pressures than plain tube

o -self compensating for thermal expansion
o -efficent due to large nomber small diameter tubes
o -failed tubes may be plugged
o -more expensive than plain tube and diificult to clean

38 AIR COMPRESSORS
Coil tube
o -self compensating for expansion

o -suitable for high pressures
o -difficult to clean
o -inefficient due to large tube diameter
o - not easy to plug
o -expensive

39 AIR COMPRESSORS
 Cooling Problems
Lack of cooling can also occur when the heat transfer surfaces are covered
with scales or carbon deposits, thus affecting the cooling process. Choked
passages of the heat exchangers can also be a reason. Sometimes the cooling
medium itself is hot due to faulty machinery, thus providing negligible heat transfer.
Non-continuous supply of coolant might also be a reason. This happens

when the cooling pump fails or the valves of the coolant line are stuck or
accidentally closed. An explosion occurs when all the above mentioned factors
come together to make a vicious cycle that ultimately leads to explosion.
Sometimes the oil film in the pipes also turns to deposited carbon, which is
already having a high temperature. The compressed air inside the pipe along with
the oil and deposited carbon becomes a fatal combination for explosion. Thus,
only a rise in temperature above a certain limit or just a generation of a spark or hot
spot can ignite or blow off the whole compressor.

40 AIR COMPRESSORS
AIR COMPRESSOR SAFETY DEVICES
1. WATER JACKET SAFETY VALVE/RELIEF VALVE; spring loaded Relief valves are fitted
on the cylinder jacket to protect the water side against over-pressure in the
event of tube failure.
2. BURSTING DISCS; Also Bursting discs of Brass or Lead are fitted at water side of
each intercooler in the event of tube failure. Bursting disc never should be
renewed with thicker one. If necessary, old spare Brass bursting disc should be
annealed to release stress and can be reused. Over pressurization of an air
compressor intercooler is prevented by the intercooler relief valve or bursting
disc.
3. RELIEF VALVES; these are fitted on the first and second stage air outlets and set
to lift at 10% above normal stage pressure.
4. FUSIBLE PLUG; working at about 121’C are fitted on the aftercooler discharge
head only to meet the Classification requirement for the safety of the system
after the machine’s outlet.
5. MOISTURE/OIL DRAINS/ PURGE POTS; from each intercooler and aftercooler.
6. NON-RETURN DISCHARGE; valve from the compressor to the air system.
7. LOW LUBRICATING OIL PRESSURE ALARM & CUT OUT; for the machine.
8. OIL SYSTEM RELIEF VALVE; is fitted in the Lube oil line to prevent pressure rising
more than 25% above the normal working pressure.
9. HIGH DELIVARY AIR TEMPERATURE ALARM &CUT OUT.
10. COOLING WATER FAILURE ALARM &CUT OUT.
11. CRANKCASE EXPLOSION RELIEF DOOR; must be provided in the case of
crankcase volume of 0.6 m3 or more.
12. COMPRESSOR STARTING FAILURE ALARM.
13. COMPRESSOR ABNORMAL ALARM.
14. MOTOR OVERLOAD TRIP.
15. UNLOADER; The solenoid-operated unloading valves on the 1st and 2nd stage
cooler drains are fitted for automatic and timely draining as well as unloading
when starting and stopping.
Air Cooler Safety Devices
1. Spring Loaded Relief Valves

2. Water Jacket Safety Valve
3. Bursting
4. Purge Pots to Drain Moisture and Oils.
5. The Solenoid Operated Unloading
6. Fusible Plugs

41 AIR COMPRESSORS
Safety Valve
Methods of Unloading Compressors
1. By throttling of suction
2. By speed variation
3. By depressors to hold suction valve plates on their seats
4. By by-passing discharge to suction
5. By changing in volumetric clearance of the cylinders
6. By step unloading of the cylinders in a multi-cylinder machine
7. By opening the interstage air pressure to atmosphere
Compressors must always be started in the unloaded condition; this reduces the
motor current and clears out any moisture in the system. When air compressors are
arranged for automatic operation, the cylinders can be unloaded during starting
and stopping.
Unloading can either be achieved by using the cooler drain valves or by
mechanically holding the suction valves open using unloaders.
The purpose of an air compressor-unloading device is to delay the compression
process until the motor is accelerated to speed. It removes all but the frictional
load and inertial load during starting. Slipping drive belts on a ship service air
compressor is a probable symptom of a failed unloader. If an electric motor driven
air compressor fails to start, it may be due to a tripped overload relay. A first stage
unloader installed in a low pressure air compressor is unable to completely retract.
This will result in an abnormally low intercooler pressure. Compressor tripping on
overload at starting and belts slipping are indications of failed unloaders.

42 AIR COMPRESSORS
AIR COMPRESSOR PIPING RECOMMENDATIONS

43 AIR COMPRESSORS

44 AIR COMPRESSORS

45 AIR COMPRESSORS

46 AIR COMPRESSORS
LUBRICATION
On a medium pressure, differential piston, reciprocating air compressor,

lubrication of the pistons/cylinders is usually accomplished with metering type
cylinder lubricators. Differential pistons used in some reciprocating air
compressors, serve to provide more than one stage of compression by each
piston.
On small, low pressure, air compressors, the cylinders are usually lubricated by
the splash method
Airline lubricators are used in compressed air systems to lubricate tools and
equipment served by compressed air. Excessive lube oil consumption by a
reciprocating air compressor can be caused by
1. Oil level higher than normal
2. Worn or broken piston rings
Lubrication of the crankcase in a compressor does not pose any specific
problems and normally consist of splash lubrication with pressurized oil being fed to
shell bearings. Where drip cylinder lubrication is used, this should be kept to a
minimum conducive with liner wear. A standard mineral oil similar to that used in
the main engine may be used, although due to carbon deposits, higher quality oils
are generally used with the most effective being specifically designed synthetics
which have allow a considerable reduction in maintenance but are costly.
Mineral oils should only be used since Synthetic Oil can cause damage to
lubricating parts. SAE 30 Oil is Suitable. Mineral oils contain a blend of lighter
elements such as paraffin's, and heavier elements such as asphalt substances.
During compression the lighter elements are vaporized leaving the heavy ends,
these coat the piston rings and discharge valves in combination with oxidized oil
deposits. These deposits also coat passage ways and coolers resulting in higher
interstage air temperatures. Deposits on discharge valves cause them to become
sticky and leak resulting in hot air being drawn back into the cylinder for
recompression. This increases the temperature and hence causes greater
oxidation and deposits, and so the condition deteriorates with increasing rapidity.
Temperature can become very high; this may result in oily deposits at the
discharge valves carbonizing. Eventually this carbon could glow red and cause
detonation. It is more likely, however, that oily deposits will be carried over to the air
receiver and air start manifold to be ignited by blow past at the cylinder air start
valve.
Deposits at piston rings cause leakage allowing oil to enter the cylinder from the
crankcase thus increasing the danger it is essential that crankcase lubrication be

47 AIR COMPRESSORS
kept to a minimum compatible with an acceptable wear rate. Regular

maintenance will minimize oily deposits build up and hence the risk of explosion
The object of cylinder lubrication is to provide an oil film between cylinder and
the piston rings, to furnish an effective seal, thereby reducing wear of these parts
and preventing leakage of air.
If the cylinders are getting to much oil, it is harmful in the system and may
cause carbonizing on the valves, loss of compression efficiency due to sluggish
action of the valves and loss of cooler efficiency due to deposition of oil on the
cooling surfaces.
SO air compressor is necessary to have minimum of absolute lubrication in
cylinder.
Lubrication is needful to get smooth running parts, to carry away heat , to
reduce wear and tear , and failure of cylinder, piston rings and seizure case.
Insufficient lubrication may cause these effects.
Using of unsuitable lubricating oil may cause the above wear & tare effects
due to improper lubrication .Besides, cooler efficiency may loss because oil will
vaporize and carry over with compressed air to cooler and condensed on the
surfaces. If lubrication is excessive, it is harmful to the compressor parts.
Carbonizing on the valve plate and spring, sluggish suction and discharge valves
may cause. Excessive oil also may become emulsify with water vapor from the air,
resulting in the loss of L.O quality. Also excess oil travel along with compressed air
into the cooler impairs heat transfer and reduces cooler efficiency.
Entrained oil in discharge may collected in air reservoir and tend to oxidation.
From this effect, acid formation will cause internal corrosion and pitting on the air
bottle parts. If not properly drain of air reservoirs or extreme case, it may tend to
cause airline explosion consequentially.
To prevent these defects: -

 Use proper grade of L.O
 Avoid excessive L.O level and lubrication pressure. Normally, a relief valve is
fitted in oil system to open25 % above normal working pressure to protect oil
pump and excess lubrication.
 Drain the moisture & oil mixture at the cooler and bottle regularly.
 Periodically cleaned and removed all trace of carbonized oil in the air
passages.

48 AIR COMPRESSORS

49 AIR COMPRESSORS
AIR COMPRESSOR TROUBLESHOOTING & MAINTENANCE
TROUBLESHOOTING
The following defects can occur when operating the compressor.
1. L.P. compressor shows increase in pressure- delivery valve leaky or hung-up.

2. L.P. compressor shows increase in pressure- H.P compressor valves leaky or
piston rings leaky.
3. Air compressor pressure falls off- causes are:-
a. Air inlet strainer for compresor choked.
b. Compressor valves leaking or sticking.
c. Too much play on top of end of L.P. cylinder.
d. Leaky piston rings.
e. Leaky cover
f. Leaky drain or safety valve or pressure guage fitting
g. Leaky cooler ( Can be detected by opening water test cock On top,air will
blow out.)
EFFECTS OF SLUGGISH ACTION OF VALVES
At the end of the suction stroke, owing to weak springs or carbon deposits, if
the suction valve does not reseat properly and promptly part of the air drawn into
the cylinder will be returned through the defective suction valve. This will reduce the
Volumetric Efficiency. Also reduced air delivery and increased running time. Then it
will reduce air pressure in the suction to the next stage.
Similarly if the delivery valve reseat slowly then a part of the air being
compressed and delivered will return back to the cylinder, thereby reducing the
volumetric efficiency. This effect will reduce delivery and increase discharge
temperature.
Cylinder inlet valve failure in a low pressure air compressor can be caused
by sticking valves due to carbon buildup on the seats A knocking sound from one
cylinder of an operating air compressor indicates a loose valve plate. The major
difference between the discharge and suction valves installed in most low pressure,
reciprocating air compressors is that one valve seats upward, while the other seats
downwards. This fact must be kept in mind during assembly so that mistakes are
prevented. Broken valve strips in an operating low pressure, air compressor will
cause a decrease in compressor capacity. A viscous film of oil collected between

50 AIR COMPRESSORS
the valve face and seat of a low-pressure reciprocating air compressor will retard
the opening and closing of the valve. Air blowing from the intake air filter of an
operating air compressor indicates broken inlet valves. Excessively low air pressure
occurring in the intercooler of a reciprocating air compressor is caused by leaky
discharge valves on the LP cylinder. Intake valves installed on most reciprocating
low pressure air compressors are actuated by the pressure differential between the
air in the cylinder and the pressure of the air on the external side of the valve.
Similarly the air pressure further beyond the valve primarily loads discharge valves.
Carbon deposits forming on the discharge valves of an air compressor are caused
by oil deterioration under high pressure. The first step in reducing these deposits
would be to reduce the discharge temperatures. If there is a sudden drop in the
capacity of a reciprocating air compressor, you should check for broken
compressor valves.
EFFECTS OF LEAKING VALVE
A leaking suction valve in the second stage of a two stage, high pressure, air
compressor can cause excessively high first stage discharge pressure and the lifting
of the inter stage relief valve.
Leaking valves in an air compressor can be a result of abrasion, dust, and dirt
Valve leakage do occur in practice and this leads to loss of efficiency and
increase in running time. Fluctuation of stage pressure will occur.
Effects of leaking valves:-
1. 1st. stage suction - reduced air delivery, increase running time and reduced
press. in the suction to the secondary stage. If badly leaking, it may completely
unload the compressor.
2. 1st. stage delivery - with high pressure air leaking back into the cylinder, less air
can be drawn in. This means reduced delivery and increased discharged
temperature. Less air will be drawn by stage due to large volume.
3. 2nd. stage suction - high pressure and temp. in the 2nd. stage suction line
reduced delivery and increased running time.
4. 2nd. stage delivery - Increased sucton press in 2nd: stage delivery press from 1st:
stage increasd. Incapable to charge the air bottle to required pressure .

51 AIR COMPRESSORS
Compressor valves may leak and failure at finally. These are happened by..
- Wear and tear of valve plates
- Malfunctioning and excess valve lift
- Presence of foreign particles
- Oil decomposition and sluggish action.
The compressor pressure gauge jerking is the early sign of the valve leaking.
EFFECTS OF AMBIANT AIR TEMPERATURE
The higher the temperature of air drawn into the L .P cylinder, the lesser will be
the weight of air discharged by the compressor. Because the higher the
temperature of air the greater will be the volume occupied by a given weight of
air.
The intake air should be as cool as posible so that its density is as high as
possible. If the temp. of intake air could be reduced by 5 degree F, then a
delivery increase of 1 % could be achived, because the density of air varies
inversely as its absolute temperature.
It is therefore benificial to fit intercoolers to cool the air to approximately the

temperature at which it enters the Compressor. Great efficiency having been
obtained, less horse power is required for the same volume of air delivered. Better
lubrication can also be assured because the air temperature are lower. The low
pressure suction air should be obtained from the cooler part of the engine room. If
the air is led to the L.P inlet by a duct the area of the duct must be ample and
have as few bends wit as possible. The cooler the air at the L.P inlet, the better the
efficiency will be.
In a compressor, during compression, applied energy is converted into heat

energy. Therefore any consequence to rising the air temperature may reduce the
volumetric efficiency. The higher ambient temperature of air drawn into the
cylinder, the greater volume of air will be occupied and the lesser weight of air will
be discharged.
Compressor should be installed away from high ambient temperature area,
such as, Boiler room, Exhaust manifold and blower air ducts must be closed to
compressor suction.

52 AIR COMPRESSORS
EFFECTS OF ATMOSPHERIC HUMIDITY
Humidity is used to indicate the fact that the air contains some water vapour.
The amount of vapour it contains depends on two factors. The amount of water
available for vapourisation and also the temp.The moisture holding capacity of a
gas varies inversely proportional to its absolute pressure.
Compressed air always contains moisture to some extent, depending on the
condution of the air drawn into the compressor and the system of compression .
The moisture, because of the heated condition of the air as it leaves the
compressor is carried along as a vapour into the intercoolers.
The water or oil vapour, or both, may settle on the cooling surface and
reduce the efficiency. The result will be a loss of efficiency of the whole machine by
allowing the intake air to the next stage to be at a higher temp. than it should be.
Most of the vapour will be condensed in the intercooler and can be withdrawn
from the system by using the drains (e.g. 30 m3 of free air relative humidity 75%
temp.20% being compressed every minute to about 10 bar, 1/2 ltr of vapour
would be obtained/ min.).
Straight mineral oil would be washed off surfaces by the moisture and could
lead to excessive wear and possible rusting. To prevent this a compounded oil with
a rust inhibitor additive would be used. If air drawn into the compressor is more
humid , it will contain more moisture in suspension. The amount depend on the
density and they will deposit as condensate water when air is compressed and
passed through cooler. Unless the condensate is drained off and allowed to pass
the various stages , they wash the cylinder lubrication oil film , cause wear and tear
effect to liner and piston rings.
Corrosion on valve plates and springs due to water vapor may cause also.
Moisture lying on the air passage may effect to corrosion and water hammer. This
moisture effect may also form oil emulsion and settle on cooler surface , effect the
heat transfer coefficient and reduce the cooler efficiency . So , the air to the next
stage will be higher temperature and the efficiency of the whole machinery will
decrease.
Frequent drain of moisture and oily mixture from cooler outlet stages while
running compressor must be done to prevent adverse effect of humid air. In air
bottle also , drain valve is fitted for safety , to drain out moisture and oily mixture
regularly , to prevent the basic problem of air line explosion.

53 AIR COMPRESSORS
EFFECTS OF RESTRICTED AIR INLET TO L .P STAGE
If the inlet passage to the L.P stage is restricted, there will be a partial vacuum
in the cylinder and less air will be discharged during each of the delivery stroke.
Hence it reduces the volumetric efficiency of the compressor.
The reasons for these restrictions could be -
1. Dirty and choked air filter
2. Suction valve springs too stiff and
3. Insufficient suction valve lift.
EFFECTS OF DEPOSITS IN COOLERS & JACKETS
The water jacket must also be examined at intervals especially as sea water is
used for cooling. Scale may form particularly in the H.P jacket and cooler due to
high temperature of compressed air about 270'C . If scale has formed, it must be
cleaned out chemically and It is almost impossible to clean out the whole jacket
system mechanically. For this reason most modern installations use a close-circuit
fresh water cooling system.
Unsuitable compessor L.O or over lubrication may cause oil vapur to pass into
the intercoolers and after coolers, where L.O is condensed on the cooling surfaces
and cover them with a film of oily matter which seriously impairs the cooling
efficiency. Rise of temp difference between inlet and outlet will be noticed. These
deposits can be cleaned chemically.
If sea water is used as coolant , scale may form in a H.P jacket and cooler due
to high temperature of compressed air. Both scaling and depositing effects may
reduce the cooler efficiency . So compressed air will be more heated and reduce
volumetric efficiency.
Running parts will overheat and more work done in compression because of not
approaching isothermal compression. So , cleaning of cooler and jacket must be
done regularly . Air side cleaning can be done by chemical . Also water side have
to be cleaned chemically and manually. But it is almost impossible to clean out
the whole jacket system manually. Therefore , chemical treated F.W cooling system
is used in the most modern compressors.
The following defects will be occurred.
 Reduce volumetric efficiency and rapid fall of discharge pressure.
 Carbonizing to the valves, Sluggish operation and rapid valve deterioration.
 Adversely affect to lubrication
 High temperature running of compressor and lead to explosion in extreme
case.

54 AIR COMPRESSORS
EFFECTS OF WORN CRANKSHAFT BEARING
When crank shaft bearing is worn, the bumping clearance will increase and
larger clearance volume may result.
Therefore high pressure air remains in cylinder after compression and it will
expand more than normal on return stroke of piston.
Normally, the expanded air pressure fall below inlet air before intake . This part
of suction is stroke is non-effective and must keep it as small as possible to achieve
maximum performance.
Due to increase of bumping clearance, this non effective part of suction
stroke is more increase and volumetric efficiency decrease.
Due to crank shaft bearing worn, L.O pressure fall than normal and insufficient
to supply all moving parts. Therefore, vibrated running effect, wear and tear effect
to working parts will occur.
A knocking sound emitted from an unloaded air compressor is probably
caused by a loose piston (excessive bearing clearance).
EFFECT OF BROKEN OR WORN SCRAPER RING
When running the compressor with broken or worn scraper ring, lubricating oil
could not be properly scraped in to sump and carry over with the compressed air ,
sump oil waste & accumulate in stage coolers , reduce cooling efficiency. For this
reason, volumetric efficiency will reduce, work done will be greater, valves will be
carbonized and sluggish action will occur.
In extreme case, L.O may entrain in compressed air discharge line and Oil &
air admixture will reach into the air reservoirs.
This oil and air admixture may cause
 Air reservoir internal corrosion and pitting
 Air system component corrosion , rusting & jam
 Starting airline explosion.

55 AIR COMPRESSORS
EXCESS LUBRICATION
Deposits at piston rings cause leakage-allowing oil to enter the cylinder

from the crankcase thus increasing the danger it is essential that crankcase
lubrication be kept to a minimum compatible with an acceptable wear rate.
Regular maintenance will minimize oily deposits build up and hence the risk of
explosion
Causes and effects of excessive lube oil carryover
Some of the causes can to as follows

 Worn out cylinder liner and piston rings, particularly the bottom oil scraper rings.
 Improperly assembled oil scraper ring will assist in pumping oil into the cylinder
instead of scraping the excess down
 Improperly adjusted cylinder lubrication if such separate facility exists, too much
cylinder lubrication in compressors will be directly carried over with the
discharged
 An engine room atmosphere that is too much oily with oil vapours is another
frequent cause of oily wet air being drawn into the suction of the compressor,
with the result of a carry over.
Also, physically cleaning the interior of all the piping from the automatic air
starting relay valve, to all the cylinder air starting valves (dismantle section by
section, clean chemically if needed and put back) every year is recommended.
Inter stage drains in the compressor are useful not only in draining out the
condensed moisture, but also any appreciable of carry over. Regular draining and
internal cleaning (once a year) of air bottles is very important.
Choice of lubrication oil for compressor depends on -
1. Operating temperature
2. Cylinder pressure
3. Air condition.
The amount of oil in the systems must be checked at intervals and if the
quantity appears to be falling, then steps should be taken to find the cause and
rectify the fault at once. Too much oil in the system is also detrimental and may
cause carbonizing of the valves, loss of compressor efficiency.
Unsuitable oil can also cause the above faults and might also cause scored
cylinder or broken piston rings. The oil may become emulsified with water vapour
from the air, resulting in the loss of the lubricating qualities of oil. The oil may
vapourize and pass with the air into the cooler. The cold tubes will cause the oil to

56 AIR COMPRESSORS
deposit on the cooling surfaces, resulting in a film which will prevent the transfer of
heat from the air to the water.
The following stages will therefore receive hot air and the weight of air taken in
on the suction stroke will be less and the overall efficiency will be reduced. Air line
explosion can be expected if deposited oil in high pressure air pipe and heat
source from leaking air starting valve are affected. The air passage must be
cleaned periodically and all traces of carbonized oil removed. If carbonized oil
accumulated at valve plate and spring, hard carbon will stick the valve plate and
spring due to heat of compression and burning of oil.
POSSIBLE CAUSE OF STARTING AIR LINE EXPLOSION
Due to leaky or jammed starting air valve at partially open position,

combustion hot gas may enter to starting air pipes.
Accumulation of oily mixture in the starting airline due to defective compressor
performance and improper maintenance to air bottle, such as…
 Valve leaking
 Excess cylinder lubrication
 Defective oil scraper rings
 High humidity air
 Oil mist in E.R air
 Improper drain of oil and moisture mixture while compressor running
 Irregular drain of air bottle as routine maintenance
 Irregular drain of air lines.
This accumulation of oil may be burnt and vaporized by the hot gas invasion.
At this condition, concerning starting air valve and its adjacent pipes are very hot
condition, compare to other.
By the weakness of watch keeper or ignorance, when the starting air is
supplied to the system, normally happen at arrival first start, serious air starting line
explosion may occur.
Safety devices fitted on starting airline are spring load relief valve and
bursting safety cap, to avoid serious damage when explosion.

57 AIR COMPRESSORS
TABLE

58 AIR COMPRESSORS
MAINTENANCE
Precaution to be taken before starting
 Lubrication - Check L.O sump, lubricator function and prime manually. In

some compressor, a small quantity of oil can be injected through the valve
port to wet the cylinder wall.
 Cooling - Confirm cooling water supply
 Filter - Ensure clean filter is fitted
 Relief valve - If hand testing lever fitted , manually lift to test each valve,
ensure to freely operate
 Unloading - All cooler drain valves should be opened before starting. This
purpose is to reduce the starting load and confirm cooler leakage
 System - Check correct valve opening to the system
Compressor must always be started in the unloaded condition to prevent very

high starting torque. During running the accumulated moistures in the separators
must regularly be drained out to prevent
1. Rise of lubricating problem
2. Corrosion problem in the starting air line
3. Water hammer in the starting airline and
4. Explosion in the air start line or in the reservoir. A compressor should never be
stopped without first unloading it.
The seats of valve need refacing from time to time due to their constant
pounding effect. Poor selection of lubricating oil, dirt and overheating will result in
valve sticking or seat pitting. Bad valve operation can be observed by the
interstage pressures accompanied by excessive discharge temperature.
Overcooling may cause condensation inside the cylinder and adversely
affecting the lubrication. Poor cooling results rapid valve deterioration and fall-off in
volumetric efficiency. Lloyd’s required that air discharge temperature to reservoir
must not exceed 93’C substantially.
When overhauling, the cylinders, covers, intercoolers and aftercoolers to be
cleaned thoroughly and tested by hydraulic pressure to twice the working pressure.

59 AIR COMPRESSORS
An important point of consideration when replacing a dry type intake filter on

an air compressor is to select the proper size filter so that air flow is not restricted.
The intake filter protects against the damaging effects of airborne solid particles.
Advantages of Thin Plate (Feather) Valves for Compressors
They improve compression efficiency. They operate with a minimum of noise

they are simple and easy to replace. They have low inertia, which is important as
the compressor runs at a high speed. Due to the physical construction of the
valves, a relatively small cylinder clearance space is required.
(a) It is should be checked properly when compressor overhauling. Worn down
bearing can cause the compression noisy, vibration, overheating and excessive
bumping clearance.
The effect of excessive bumping clearance gives a large clearance volume
which will be full of air at high pressure when the piston reaches the end of its
stroke, and in double-acting compressors it also reduces the clearance at the
lower part of stroke.
On the out-ward stroke of the piston the air within the clearance volume
expands until the pressure within the cylinder is low enough to allow the suction
valves to open. With a large clearance volume the outward travel of the piston will
be greater before the pressure is low enough within the cylinder to allow the suction
valves to open.
In consequence a large part of the suction stroke is made ineffective and the
amount of air taken into the cylinder during each suction stroke is reduced. This
lowers the volumetric efficiency.
(b) It always should be good working order condition, according to running hour.
The air compressor valve are dismantled, cleaned, and refacing thoroughly check
spring plate, etc., and reassemble and test leakage.
It a suction valve does not reseat promptly at the end of the suction stroke
due to a weak spring or to carbon deposit, part of the air drawn into the cylinder will
be returned through the defective suction valve during the first part of the delivery
stroke.
It a delivery valve is slow in reseating, for the same reasons, part of the
delivered compressed air will return to the cylinder during the first part of the suction
stroke.
So this is reduced the compressor performance.

60 AIR COMPRESSORS
(c) It should be checked when overhauling the compressor. Remove piston,

clean piston ring groove, piston ring, take the gap clearance of piston ring a
sealing rings and scraper ring should be good working order condition. If the piston
rings are leakage, the compressed air leak into crankcase and reduces the
compressor efficiency and contaminates the L.O.
If the scraper ring is not in good working condition, the lubricating oil can
deposit to valves and it causes the valves to carbonized and sluggish action. L.O is
mixing with compressed air disturb the air starting system. It can cause to air line
explosion and also increase L.O consumptions, deposits at intercooler and reduce
cooler efficiency so piston and cylinder should be good working condition.
(d) The function of intercooler is to reduce the air temperature and volume
reduce at constant pressure as low as possible and volume reduced at constant
pressure and also to drain oil and water vapour. This lowers the work done in
compressing the air and prevents a lot of the mechanical problems which could
arise if the air temperature were uncontrolled.
By keeping the air temperatures low, less difficulty is experienced with the
lubrication of the pistons and cylinders and the suction and delivery valves remain
in a cleaner condition without becoming fouled with carbonized oil.So that
intercooler should be cleaned air side and water side for to get perfect cooling
efficiency.
Maintenance of Air Compressors

The maintenance of air compressors, typical two stage reciprocating type,
should be performed commonly on the following parts:
(a) Air Filter

The most widely used type of filter is the viscous impingement type filter,
usually of cylindrical design and the filtering media usually being woven copper
wire or nylon strands which are, when cleaned, dripped in oil and allowed to drain
before fitting. In this units, first stage failures have been occasionally caused by
some of the copper wire becoming loose and the pulsating air flow bending the
strands backwards and forwards, until a strand has broken free and lodged
awkwardly in either a valve or piston clearance. It is essential that the filter is kept in
a clean condition, so that the air pressure drops across the filter is kept to an
absolute minimum. In some cases, a heavy restriction caused by a dirty or
damaged inlet filter can raise the delivery temperature of the air to a dangerous
level.

61 AIR COMPRESSORS
(b) First Stage Valves

Modern marine compressors use automatic valves which operate on low
pressure differential. This unit operates once every revolution and its movements are
extremely frequent, thus the valve lifts are kept extremely low to reduce impact
forces. The spring assembly design is very critical to ensure correct valve action. It is
extremely important, therefore, that the valve assembly is not altered in anyway.
Valve failure will occur due to wear and fatigue, therefore, if failures occur on a
frequent basis, it is almost certainly due to the wrong machine assembly, or
insufficient oil carry over. Naturally, if the compressor is overheating, wear fatigue
will occur. Failures will also occur due to the presence of foreign particles. Carbon
deposits from the oil also causes valve wear and breakages and it is therefore
important that the compression chambers and oil passages are carefully
examined.
Valves should be removed, dismantled and inspected at frequent intervals,
as recommended by the manufacturer. In the event of a broken valve being
found, all the parts should be located, otherwise the pieces might cause damage
to other parts of the machine. All valve parts should be carefully and thoroughly
cleaned with a cleansing fluid, using a soft brush. Sharp edged tools and wire
brushes should never be used to clean valve seats and plates. Any parts which are
worn, damaged or cracked must be replaced. Valves plates which are worn on
one side should preferably not be turned over and reused, but replaced by a
spare. To ensure good sealing between valve seat and plate, each part should be
lightly lapped, separately on a smooth flat surface. After valves have been
reassembled, check by using a small piece of wood that the plates are free to
move and will fully open. Valves are usually seated in the cylinder either by metal to
metal contact or using a gasket. The former should be lapped together if there are
signs of dents, nicks or scratches, to provide a leak-proof joint. In the case of
gaskets it is best to fit new ones each time valves are inspected. When replacing
the valves in the cylinder, special care should be taken to ensure that the suction
and delivery valves are installed in their respective ports and that the correct
clearance is maintained between the valves and pistons.
(c) First Stage Intercooler

Intercoolers usually cause very little problems, providing the water side of the
tubes is kept free of fouling. On the air side, if the machine is correctly cooled and
there have been no excessive temperatures caused by valve failures, it should be
relatively clean, with only an oil smear present. If excessive temperatures have
been present, it will be found that the cooler inlet is heavily carbonized on its
immediate entrance. This carbon will sometimes also affect the relief valve, so
carbonizing in this area is a defect that must be treated very seriously and the
cooling of the machine investigated. It is extremely important that the condensate,
which is collected at the outlet end of the cooler, is drained from the machine,
preferably by an automatic drain valve.

62 AIR COMPRESSORS
(d) Second Stage Valves

The configuration of these valves is identical to the first stage valves, except
they are usually smaller since the air is reduced in volume, and also the scantlings
are usually heavier since the stage pressure to be withstood is higher. Maintenance
should be carried out in a similar manner and at the same intervals as the first
stage valves.
(e) Aftercooler
This is the same as the intercooler, but as the pressures and usually the inlet
temperatures are also higher, the cleanliness of this cooler is more critical from a
safety point of view. However this cooler has absolutely no bearing on the
compressor performance as its action takes place after all works have been done
on the air. Its function is just to bring the delivery temperature to a reasonable figure
and remove condensate from the air.
(f) Fusible Plug

This unit, which melts at 121⁰C, fitted immediately on the outlet of the
aftercooler to meet Classification Society Regulations. It must also be noted that
the metals which are found at these low temperatures are usually fairly soft and the
pulsating nature of the pressure does sometimes extrude the metal, even though
the temperatures are not excessive.
(g) Oil System Relief Valve

This valve should be sufficient to ensure that the system pressure rise is not
more than 25% above the normal working pressure when the oil is cold on start up.
This pressure limitation prevents a transmission strain on the oil pump. As the running
clearances increase, the relief valve should be adjusted to maintain this figure.
(h) Bearings
The modern approach on bearings is to eliminate all hand fitting; however it
does not eliminate the responsibility of checking the correct running clearances. It
is important that the journals are in good condition and any marks caused by
foreign bodies should be carefully stoned smooth; the tolerances of thin shelled
bearings to rough journals are far less than the older thick shell white metal
bearings, although when correctly fitted and run, the life tends to become greater.
(i) Crankshaft End Float and Bending

It is important that a crankshaft has an end float to allow expansion for a
minimum of 0.025mm per 25mm of allocation length. If misalignment of the
crankshaft is suspected, distance between the balance weight throws should be
taken at as large a radius as possible with its feet unbolted. Any discrepancy
between the two sets of readings will show a misalignment caused by incorrect
chocking on the mountings.

63 AIR COMPRESSORS
AIR COMPRESSORS EXPLOSION
Can an air compressor burst on board a ship? You must have heard about
crankcase explosions or boiler explosions, but now find out what leads to an air
compressor burst.
 Introduction
Incidents of boiler and crankcase explosions are quite heard of on board a

ship. But can an air compressor burst? Technically, an air compressor is also equally
potent to explode because of all the extreme parameters it deals with as we have
seen in the article - "How marine air compressors work?" Air compressors have to
withstand high pressures along with equally high temperatures. Although
compressors have necessary precautions such as relief valves to prevent
incidences of over pressuring, a situation involving fire is a totally different matter.
 What Causes Explosion?
It is very important to keep in mind that an air compressor has all the things
that are required for a perfect explosion. A fire propagates at a very fast rate when
three things are easily available – fuel, oxygen and heat source. This is also known
as the deadly fire triangle which needs to be avoided in all cases where there is a
possibility of explosion or fire. A compressor is a rich source of highly compressed air
and when it gets in contact with other two sources, an explosion is bound to take
place.
Probably the next question that might arise is to how does an air compressor
get fuel for explosion? It is to note that most of the ships use oil lubricated
compressors and it is the lubrication system of these compressors that provide the
necessary fuel for a probable explosion. One more potent source of fuel is the
carbon deposits that are created when the oil heats up at high temperatures.
The last and the most easily producible factor - the heat source, can be
generated due to variety of reasons.
The most common source of heat source is heat generated due to friction
between two surfaces. Lack of proper lubrication is the most common cause for
heat generated in this way. However, lack of lubrication can also be due to
degradation of lubricating oil, faulty lubricating oil pump, chocked oil filter, worn
out parts etc. These are the prime reasons for the developments of hot spots.
The lack of lubrication will increase the wear and tear of the moving parts of
the compressor, deteriorating the quality and operation of the compressor. As the
components continue to operate poorly, carryover of the oil to the air passages

64 AIR COMPRESSORS
takes place, increasing the temperature of that area. Also, it is very important to
remove this heat generated. If proper steps are not taken to remove the heat, heat
buildup will take place increasing the temperature substantially. Inter-coolers play
an important role in this heat removal and thus need to be properly working.
AIR COMPRESSOR STARTER CIRCUIT
Starting and stopping sequence is adjustable, the magnetic valves are open
when the compressor is stopped so any residual pressure is blown off. On starting
the magnetic valve are sometimes delayed to close so as to allow the compressor
motor to reach full speed before the compressor is loaded up.
The non-return valves prevent HP air leaking back from the receiver on which
the filling is also of the non-return type.
See More on Air Compressor No.1 & No.2 Starter Diagrams!

65 AIR COMPRESSORS
AIR COMPRESSOR QUESTIONS & ANSWERS
QUESTIONS & ANSWERS
Question and answer for main air compressor

Why is it dangerous to operate an air compressor without the proper inlet air filter?
Every effort must be made to have only clean, dry air at the compressor
intake because dust leaden intake air may cause an explosion within the air
compressor, discharge line, or receiver.
Why is it dangerous to operate an air compressor without the proper inlet filter?
In the event of compressor was operating in a combustible atmosphere and
oil, paint fumes, dust and so on. There is the possibility of dieselization.
What cause of air compressor to shut off automatically?
A pressure switch opens the primary motor circuit when a predetermined
pressure is reached.
What is the principle cause of valve trouble in air compressor?
Oil works up from crankcase or in from excess lubrication or through faulty
parts. This oil forms carbon which mixes with metal dust from wear parts, and with
dust drawn in with the intake air. The resulting mixture is hard, abrasive products
which accumulate around the valves. This has an erosive effect, to which may be
added a corrosive effect if the oil is acid or the in drawn dust or fumes contain
acids or acid forming element.
Other than waste of power if there is any probable bad effect of running an air
compressor unloaded for a long period of time?
Yes. There is an increased tendency to get excess lubricant into the cylinders
and other members, leading to possible formation of carbon about the valves,
increased need for cleaning, and even to explosion hazards.
What causes of air compressor explosion?
1.Excess oil feed resulting in carbon deposit on discharge valve, piping and
Intercooler. Under excessive temperatures these deposits become incandescent
and give off vapors which combine the excess oil vapor and ignition results.
2.Excessive accumulation of emulsions.
3.Oil vapors in compressor.

66 AIR COMPRESSORS
How would you remove scale from cylinder jacket of the compressor?
Drain compressor thoroughly. Fill cooling jacket with solution of hydrochloric
acid and heated water. Leave until effervescence stops. It may about at least 10
hours to almost 12 hours. Add more acid. If effervescence start again, wait until it
stops and add more acid. Continue until addition of acid causes no further action.
Drain jacket and flush thoroughly with a soda water solution.
If an air compressor beings to lose capacity, what is your first step in locating its
trouble?
Lock at the pressure and temperature gage on the various stages. Any
variations from the normal ratio of pressure of normal relations of pressure to
temperatures will indicate the probable trouble or will at least suggest the further
investigations to be made.
What would be the result of having too cold water flowing through the jacket of
the high pressure cylinder?
Condensation in the inlet passage from the intercooler to the high pressure
cylinder, probable loss of lubrication, excessive metal stresses set up.
What are some causes of compressor overheating?
1. Broken valve strips.

2. Wrong direction of rotation.
3. Filter clogged internal leakage.
4. Discharge pressure higher than rated.
5. Insufficient lubricating oil.
What are some causes of failure to deliver air?
1. Suction valve blocked.

2. Dirty filter.
3. Valves improperly installed.
4. Suction valve unloader stuck in unloaded position.
5. Strips missing from valves.

67 AIR COMPRESSORS
1. Sketch and describe a two stages air compressor.

Give reasons for fitting the following; suction filter, bursting disc, drains.
What would be effect of excessive clearance volume in the two stages?
2. An air compressor has to have a new bottom end bearing fitted.
Describe the procedure for the fitting and the precaution to be taken before
and after starting compressor.
3. Sketch and describe a suction and delivery valve fir an air compressor.
Show clearly how they are fitted in the cylinder head and cylinder liner.
Describe the overhauled of one of the valves.
4. Sketch and describe a two stage reciprocating air compressor insert on your
diagram pressures and temperature at the salient points.
Describe the effects of leaking second stage discharge valves and alteration
in clearance volume.
5. Sketch and describe three stage reciprocating air compressor giving
temperature and pressures at the salient point in the cycle.
Why is air cooling necessary?
Explain how clearances may be obtained and adjusted.
Describe any safety features which guard against excess pressures.
6. What effect is obtained for intercooler and after cooler?
How would the following effect the running of the compressor?
1.excessive cylinder clearance

2.choke air inlet filter
3.leaking high pressure stage suciotn valve
4.leaking low pressure suction valve
5.water precipitation
Question: 1
What are causes of an air compressor explosion?
Explosion in air compressor and related equipment are caused by
accumulations of oil or by operating in a contaminated atmosphere, dust,
inflammable fumes, etc. When air compressors run without adequate filters on the
suction, the air is contaminated, the heat of compression or glowing carbon will be
combustion to take place. Leaky oil or compression rings can cause crankcase
explosions and if the explosion occurs in piping or air receiver, it is evidence of
faulty intercoolers which have not removed the heat of compression, resulting in
pocket of oil or vapors igniting.

68 AIR COMPRESSORS
Question: 2
What is the purpose of an unloading valve on an air compressor?
The purpose of an unloading valve on an air compressor is to automatically
vent the cylinder each time it stops to eliminate compression. By relieving the
compression, it reduces greatly the required starting torque on the driving unit each
starting.
Question: 3
What are major trouble’s encounters with valves of an air compressor?
Valves are subject to distortion due to heat and pounding, erosion from wire
drawing, corrosion from moisture and chemical breakdown of lubricating oil.
Deposit of metal dust and carbonized oil cakes on the valve, causing overheating
and poor seating. Where feather strips valves are used, the strops break from
overheat if allowed to run when carbonized and may pass over to other parts to
the system.
Question: 4
Why is an air compressor beginning to lose their Capacity?
Look at the pressure and temperature gage on the various stages. Any
variation from the normal relations of pressure to temperatures will indicate the
portable trouble or will at least suggest the further investigations to be made.
Question: 5
What effect cans excessive air temperatures have upon valves and what
examination of a valve should be made it the temperature has been too high?
Excessive temperature can draw the temper of parts. After excessive
temperatures have occurred examine the valve spring to see it temper drawing
has made them sluggish or warped.

69 AIR COMPRESSORS
Question: 6
Why the pressures rise abnormally in the high pressure stage?
1. Pipe obstructed beyond the compressor.
2. Faulty high pressure delivery valve.
Question: 7
What would be results of having too cold water flow through the jacket of the high
pressure cylinder?
1. Condensation in the inlet passage from the intercooler to the high pressure
cylinder
2. Probable loss of lubrication
3. Excessive metal stresses set up.
Question: 8
What are the principals’ causes of valve and seat erosion?
1. Wire drawing of damp air
2. Carbon formation.
3. Metallic dust from wear of parts.
4. Intake dusts.
Question: 9
Where does the water come from which is found in an air compressor cylinder?
Air carries water in suspension. The amount depends on the temperature and
pressure. When the air is compressed and cooled some of this moisture is
deposited out as water.
Question: 10
What are some causes of failure to deliver air?
1. Suction line blocked.
2. Dirty filter.
3. Valve improperly installed.
4. Suction valve unloaders stuck in unloaded position.
5. Strips missing from valves.

70 AIR COMPRESSORS
Question: 11
What are causes of compressor overheating?
1. Broken valve strings
2. Wrong direction of rotation
3. Filter clogged; internal leakage
4. Discharge higher than rated
5. Insufficient lubricating oil.
Question: 14
What causes an air compressor to shut off automatically?
A pressure switch is opened to the primary motor circuit when predetermined
pressure is reached
Question: 12
Why groaning noises from an air compressor cylinder are and what trouble would
you look for?
This may cause by excessive pressure against which the compressor is
working. Other causes may be a closed discharged valve and obstruction in a line,
lack of lubricating, misalignment and broken piston ring.
Question: 13
Describe in detail how you would remove scale from cylinder jacket.
Question: 14
How would you clean the internal parts of the compressor?
QUESTIONS
01. Sketch and describe two stage air compressor.

02. Describe how to take and adjust Bumping Clearance.
03. Compare multistage and single stage air compressor.

71 AIR COMPRESSORS
04. Describe effect of bumping clearance.

05. Describe Bursting Disc and annealing of it.
06. Effect of cleaning air suction filter.
07. Restriction of cylinder lubrication to absolute minimum.
1. Why is the multi-stage compressor used?
(a) Explain it in theoretically and practically
(b) Why is the P-V diagram important?
(c) What are the defects experienced during operation?
2. Explain theoretical and practical benefits: -

(a) Why are multi stages compression designed and constructed at modern air
compressor?
(b) What are defects to be found while operation?
(c) Sketch two stages air compressor.
3. (a) Defines the terms "volumetric efficiency" as related to air compressor. [4]
(b) Describe the effect of the following faults in multi stage reciprocating air
compressor.
(1) Stage cooler [4]
(2) Worm crank shaft bearing [4]
(3) Broken or worm scrapper ring. [4]
4. Explain the operation of an air compressor, with the following references:

(a) Effect of ambient temperature.
(b) Atmospheric humidity.
(c) Valve leaking.
(d) Scale deposits in cooler and jacket.
What are possible causes of explosion in starting airline?
5. Air Compressor:-
(a) Lack of lub. Oil supply.
(b) Cleanliness of suction air filter.
(c) Bearing clearance and main bearing clearance.
(d) Bumping clearance.
FINISHED AT 8th SEPTEMBER 2014

Air Compressors (MOD)

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Air Compressors (MOD)

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Knowledge about Reciprocating

စု-တု-ျပဳ By Wai Yan Tun

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Piston, Liner & Connecting Rod ...................................................................................................................................... 33

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Use of Compressed Air Onboard Ship

The compressed air system are used in marine service

How does an air compressor work?

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The basic construction of a reciprocating compressor is similar to that of an

Use of Air Compressors Onboard Ship

 Main Air Compressor,

Main air compressor

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Deck air compressor

Emergency air compressor

There are to be two or more air compressors, at least one of which is to be

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THEORETICAL POINT OF VIEW

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For greater efficiency air compression should be isothermal as this requires

1. By altering the speed of the compressor, this requires a sophisticated a.c.

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P-V Diagram of Reciprocating Compressor

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What is Bumping Clearance

A clearance is required in order to prevent the piston striking the cylinder

In new compressors bumping clearance is adjusted by the manufacturers

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compressor efficiency. Therefore, designed clearance volume is required to keep

The effect of excessive bumping clearance gives a large clearance volume

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Bumping Clearance Changes over Time

The bumping clearance in a new machine is set properly by the manufacturers

Significance of Bumping Clearance

The bumping clearance must be adjusted properly otherwise there is risk of

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How to Check Bumping Clearance

The bumping clearance can be checked by the following methods:

How to Adjust the Bumping Clearance

The adjustment of Bumping Clearance is a very critical adjustment of the

The bumping clearance once found to be incorrect would have to be adjusted.

1. The cylinder head gaskets can be changed to a different thickness thus

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However after adjusting the bumping clearance the clearance should be

It is should be checked properly when compressor overhauling. Worn down

The volumetric efficiency of a reciprocating air compressor, is the ratio of

Volumetric efficiency Vh = Actual suction volume Vx/ Theoretical suction volume Vs

Volumetric efficiency Vh = Vol of Air Discharged as “Free Air” / Swept Volume

Where “Free Air” is air at atmospheric pressure and a temperature of 15’C

Factors Affecting Volumetric Efficiency

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The use of multi stage will give mechanical improvements of compressor

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POINTS DELIVERY PRESSURE AIR TEMPERATURE

Cylinder cooling on a single stage compressor gives better efficiency but

Compression in stages has the following advantages;

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Calculation of required cylinder compression for a multistage reciprocating

For a Two Stage,

For a three stage

For example, a 3 stage compressor requiring a final pressure of 64bar would

1st stage 1bar compressed to 4bar