MEO Class IV - GEK

Re cipr oca t in g
Air Com pr e ssor s O pe rat ion Exam Guide

This exam guide cont ains m odel quest ions sim ilar t o t he ones you would answer in t he writ t en
exam inat ion. Our aim is t o equip you on im port ant subj ect areas. Answers provided are in t he
form of cues and bullet ed list t o enable easy recollect ion.

Qu e st ion s

1. A main air compressor inter stage air cooler has burst. Put down a logical sequences of event
that could have caused this accident. Put down your analysis, point by point and complete in
technical detail.

2. Give a general description of a three stage air compressor. State the effect on the readings of
the stage discharge pressure gauges if the:
a. LP discharge valves are leaking
b. MP suction valve is leaking
c. HP discharge valve is leaking
 MEO Class IV - GEK
Re cipr oca t in g
Air Com pr e ssor s O pe rat ion Exam Guide

Q 1.
A main air compressor inter stage air cooler has burst. Put down a logical
sequences of event that could have caused this accident. Put down your
analysis, point by point and complete in technical detail.

A The air compressor is provided with safety devices to prevent damage to its components.
Relief valve at each stage delivery will lift to release the excess pressure, if pressure
increases above the limit.

Bursting disc prevent cast iron cooling water spaces getting pressurised if the compressed air
leaks from the tubes of the air cooler.

Why will it burst?

1. Air contains suspended foreign matter, most of which are abrasive. If these abrasive
particles are allowed to enter the compressor, it will combine with the lubricating oil to form
an abrasive paste.

2. These gummy deposits can adhere to valves and can prevent the valve from closing
properly, which can lead to higher discharge temperatures. The oil in the air stream burns
and more deposits are formed.

3. These deposits may find its way out of LP discharge valves and enter the intercooler tubes
with very high velocity.

4. This process takes place repeatedly and copper being a softer metal gives way.

5. The puncture in the copper tube leads to high compressed air into the cooling water spaces
and pressurizes the cooling water in the casing.

6. This should cause the bursting disc to burst and release the pressure and protect the cast
iron casing. But, according to the question, the inter stage cooler had burst. Therefore, the
copper disc thickness would not have been up to the maker’s specification and it was too
thick. Thereby, rather than the bursting disc giving way, the cast iron casing had burst.
 MEO Class IV - GEK
Re cipr oca t in g
Air Com pr e ssor s O pe rat ion Exam Guide

Q 2.
Give a general description of a three stage air compressor. State the effect on
the readings of the stage discharge pressure gauges if the:
a. LP discharge
b. Valves are leaking MP suction valve is leaking
c. HP discharge valve is leaking

A In a three stage air compressor, fresh air from atmosphere is inducted in the LP stage, when
the LP piston moves down. The air is sucked in to the cylinder, against the spring pressure of
the suction valves as the pressure inside the cylinder drops below the atmospheric pressure.
As the piston moves up the air is compressed and pressure increases. The suction valve
remains closed by the springs and the air pressure. The compressed air opens the delivery
valve against the springs and flows to the medium pressure stage through the air
coolers.

HP stage
Aftercooler Intercooler
Air filter

Relief valve

LP stage

MP stage

Crankshaft

Three stage air compressor

The air is further compressed in the MP stage and delivered to the high pressure stage
through the MP stage delivery valve. The air is further compressed in the HP stage and
delivered to the air reservoir through the after cooler.

a. If the LP stage delivery valve leaks then the pressurized air will flow back to the cylinder
during the suction stroke and air will also leak during the compression stroke. The air will
not be compressed to the designed first stage pressure. The delivery pressure at the first
stage will be lesser than normal. Subsequently, the discharge pressure of all the stages will
be lesser than the normal.
 MEO Class IV - GEK
Re cipr oca t in g
Air Com pr e ssor s O pe rat ion Exam Guide

b. If the MP stage suction valve leaks then the air will leak when the air is getting
compressed, to the LP stage delivery side. The compression will not take place properly
in the MP stage. The delivery pressure at the LP stage will be higher than the normal. If
the LP delivery pressure increases above the set limit, the relief valve will lift. The delivery
pressure at the MP and HP stage will be lesser than the normal.

c. When the air is compressed in the HP stage the air will leak through the leaking delivery
valve and pressurised air will return during the downward stroke of the HP piston. This will
delay the opening of the HP stage suction valve. The discharge pressure of the HP stage
will be lesser than the normal.

Powered by TCPDF (www.tcpdf.org)