6/16/2020 December 2002 Question 8

2nd Class Motor Examination Questions

December 2002 Question 8.

With reference to air compressors and starting air systems:

a. state, with reasons, why compressor cylinder lubrication should be kept to a

minimum that is compatible with an acceptable cylinder wear rate; (4)
b. explain the effects of operating an air compressor with a leaking first stage
discharge valve; (4)
c. explain why compressor intercoolers should be kept as clean as possible and with
an adequate circulating water supply; (4)
d. explain why all air pipelines should be kept clear of oil deposits, indicating how this
may be achieved. (4)

a.

If the cylinder lubrication is excessive, oil will be carried over with the compressed air,
depositing on the discharge valves where, especially in the case of mineral oil, due to the
high temperatures it will form carbon deposits preventing the valve from closing properly.
Oil will also be carried over into the air receiver, where it will oxidise and cause corrosion.
excessive oil in the 2nd stage cylinder of an air compressor is dangerous should the
compressor overheat as there is a possibility of the oil vapour being ignited.

b.

The volumetric efficiency of the compressor will be reduced (vol of air drawn in/swept vol of
cylinder); this is because as the piston moves down the cylinder on the induction stroke, air
previously compressed will be drawn back into the cylinder. This will result in increased
running hours and overheating as the recompressed air is raised in temperature each time.

c.

For the compressor to be as efficient as

possible compression of the air should be
as close to isothermal as possible. By
cooling the air between stages the actual
polytropic compression is bought as close
to the ideal isothermal line (see diagram).

Cooling the air between stages will also

prevent the air temperature rising during
compression to a level which would cause
overheating and burning of the cylinder oil,
leading to excessive wear and the danger of
explosion.

The compressor is designed so that equal

work is done by each stage. Inefficient

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6/16/2020 December 2002 Question 8

intercooling would prevent that, leading to

out of balance forces and increased wear.

d.

Oil in pipelines, especially air start pipelines is especially dangerous as an air start explosion
can result. This will happen when starting an engine during manoeuvring, if a cylinder air
start valve has been leaking, if fuel ignites in the cylinder during the start sequence, or, as is
thought, the compressed air rushing down the air start line acts like a piston compressing the
air and oil in the line, raising its temperature and causing ignition. In addition, the oil, as
previously mentioned, will oxidise causing pitting corrosion.

Prevention of oil deposits is achieved by not over lubricating the cylinders of the air
compressors, placing oil separators in the discharge line from the compressor, draining (oil
and water) from the air receivers regularly, and not introducing oil into the air start line
deliberately (lubrication of air start valves clearing of drains using hydraulic pump etc.).

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