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earning Objectives
Uses of compressed air Installation requirements Air compression theory Multistage compression Volumetric efficiency Constructional details Operation and Maintenance Compressor lubrication Explosion hazard Air receivers
4 7 bar
Service air Whistle air Pneumatic tools Life boat, pilot ladder
1.5 2 bar
Instrumentation & control
Compressors
Minimum 2 or more compressors Sufficient capacity to charge air receivers within 1 hour from atm.
Air Receivers
At least 2 air receivers with sufficient capacity without
Relief v/v to be fitted after each stage of compression Relief v/v to be fitted on the air receiver Relief v/v or bursting disc to be fitted on inter & after coolers
Air Temperature
Limited to 93OC to prevent explosion Fusible plug or high temp cut out provided as safety measure
Pressure Test
Cylinders, cylinder covers, inter & after coolers are tested by hydraulic pressure to twice their working pressure. Casing of intercooler and after cooler is hydraulically tested to 1.5 times the cooling water pressure
Mixture of gases behave as near as perfect gases Follows perfect gas laws Boyles and Charles laws
During compression
TYPES OF COMPRESSION
Isothermal compression (PV = C)
no rise in temp during compression heat is removed during compression least power input & most efficient difficult to achieve in practice
Vc
Vs VI
Clearance vol.
Swept vol (V1 Vc) Induced vol (V1 V4)
induction & del. process Which are modified by v/v action Waviness of the lines 4-1 and 2-3 is due to v/v bounce v/v inertia spring action variation in back pressure
As the pressure increases, more stages are required with intercooling due to following disadvantages of single stage compression:
Low volumetric efficiency
As pressure ratio P2 / P1 is increased, vol efficiency drops
Number of stages is governed by the required final pressure of the compressed air.
press. is high Compression is carried out in stages Ensures equal rise in temp in each stages to prevent v/vs & springs damage Requires minimum work; shaded area indicates the wok saved If stage pressures are P1, P2 & P3, P4 P2 = P1 . P3 & P3 = P2 . P4
Volumetric Efficiency
It is the relationship between the Qty of air discharged and the swept volume. vol of air discharged as free air Vol efficiency = swept vol of L.P. piston
Free air is air at atm. press and at 15 deg C Vol.eff. always refer to low pressure piston
arance Volume
To provide for thermal expansion and prevent the piston from striking cylinder cover, a small clearance, called bumping clearance is maintained between cylinder cover & piston
Bumping clearance must be as small as possible High bumping clearance reduces vol effn. of compressor Reduces compressor capacity & increases disch air temp. Bumping clearance is effected by bearing wear & gasket thickness Low bumping clearance can cause mechanical damage Bumping clearance must be checked after overhauling Clearance volume is about 6% of swept volume
Clearance volume - gaskets , bearing wear down Valves dirty, leaky, spring tension Leakage past piston rings Insufficient cooling water due to dirty coolers High cooling water temp. High air inlet temp. Throttling of air intake due to Dirty intake filter Insufficient suction v/v lift Strong suction v/v spring
Components
Air Filter
Material felt or paper, metal gauze or nylon strands
Remove contaminant to prevent
abrasive wear of piston rings, valves deposit on valves casing source of ignition
omponents
Suction & Delivery Valves
Low inertia automatic valves which operate on low diff
spring load and the valve lift Excessive lift causes impact & v/v breakage Late closing of v/v affects volumetric efficiency Coke deposits make v/vs
leaky & sticky causing overheating reduce vol. efficiency
Piston rings material is alloyed cast iron HP piston rings are made thicker
Bearings
Thin shell type in modern compressor
Crankshaft
Usually forged carbon steel integral with counter
Multi Tubular
Copper tubes expanded in brass
liner and piston ring Corrosion to form iron oxide, assisting degradation of oil
Unloader
Prevents compressor to start on load
Some of many methods to unload compressor cylinder throttling of suction speed variation by-pass discharge to suction
Unloader
Suction Valve Depression
Fitted on each stage
suction valves
Actuated by solenoid or
pilot air
Fabricated from good quality mild steel with UTS 500 MN/m2 with an
elongation of not less than 23% to 25%
having one longitudinal welded seam
Must be cleaned internally & coated with paint or copal varnish Fitted with necessary mountings
Air Receiver
Air Receiver
echanics of Explosion
Oxidation of oil
Temperature Air pressure Presence of catalyst iron oxide Exposure time
press)
Explosion
Fire can initiate in unloaded compressor Burning coke could act as ignition point for air-oil vapour mixture Spontaneous ignition followed by weakening the metal wall can
initiate explosion
Prevention of Explosion
Design of compressor Installation
Air flow rates & exposure time Prevent oil accumulation
Air flow rate of 8m/sec keeps the pipes clean by moving the large oil droplets to cooler areas
change, draining of excess oil Air filtration - contaminants Temperature air flow, leaky valves, CW flow, clean coolers Catalysts Iron oxides (rust) requires regular draining of water
Prevent corrosion
Be suitable for long term use
Type of cooling Number of stages Air flow rate Oil retention time
Ambient condition
Ambient temp Coolant temperature Presence of dust or oil vapour
Operating system
Continuous or intermittent maintenance
deposit
Plain mineral oil is not used as it oxidises easily at high temp. and
pressure
Lube oil must have anti-oxidant additives for good oxidation resistance Low viscosity easy spreading, effective sealing,
If oil has too broad distillation range, the more volatile portion may tend to evaporate leaving behind heavier ends in the hot zone
Product made of chemical synthesis Raw materials or base stock may be mineral oil
derived
The chemical structure is planned and controllable
The molecular structure is variable so that product
Properties
Exceptional low temperature flow Very high viscosity index Exceptional thermal and oxidation resistance Low volatility Exceptional film strength
Choice of Lubricant
Full Synthetic
Semi-Synthetic
Price
Semi-Hydrocracked
Mineral
Performance
Synthetic Oil
Advantages
Superior to mineral oil & excellent protection against corrosion Suitable for severe operation
Good thermal & oxidation stability
Disadvantages
Less compatible with seals & paint Initial cost is high, but overall it may be
Case Study
Intercooler Casing Burst
The vessel was in HK at outside anchorage. One of the electric motor driven main air compressor intercooler casing burst that resulted in the 4th Engr. losing his life and 3rd engineer seriously injured.
Investigation
An immediate investigation revealed following facts: Heavy sludge deposits in intercooler cast iron casing Cooling water inlet valve was jammed in the open position and partially chocked This allowed restricted cooling water into the cooler The casing bursting disc had ruptured HP and LP relief valves were found in following conditions HP relief v/v lifted @ 235 bar! Relief v/v spindle was partially seized LP relief v/v was in proper order; but lifted at 10 bar The compressor was surveyed 14 months before the accident; but record showed no mention of the followings: testing of inter coolers and relief valves
Poor maintenance
thoroughly inspected for their general condition, operation, settings etc at every inspection and survey
Machinery eg air compressors, positive
displacement pumps must not be started with discharge line blocked or shut