Air Compressor & Receiver

Q) Restriction of air intake is dangerous:

Cause:
1. Compressor will not suction enough air.
2. Low delivery pressure will not be able to open delivery v/v
3. So, same amount of air will compressed & raise the temp.
4. As a result an explosion may induce.
So, restriction of air intake is dangerous.

# Control air compressor:

 Normally single stage.
 Piston ring made by graphite.
 Liner lubrication not necessary.
 Ceramic filter is used.
 Refrigeration unit is used.
Q. Working principal of an air compressor (2 stage)?
Ans:
 Fig: Air compressor (2 stage)
When piston goes down air gets into the cylinder through low pressure inlet v/v. During
the upward stroke of the piston the air being compressed inside the upper chamber of the
cylinder goes to inter cooler through low pressure out let v/v.
Due to the continuous stroke of the piston, from inter cooler air goes to lower chamber of
cylinder through high pressure inlet v/v. Inside the lower chamber, air being compressed,
by the downward stroke of the piston, goes to the after cooler through the high pressure
outlet v/v. From after cooler air goes to air reservoir through the check v/v.
Q. How air compressor unloaded? Why unloaded is necessary?
Ans: Before starting & stopping the air compressor it must be unloaded.
Method of unloading:
1. Throttling the suction.
2. Speed variation.
3. By pass the discharge to suction.
4. Fitting depressor to hold the suction v/v plates on their seats.
5. Opening the first stage & second stage cooler drain.
6. Change in volumetric clearance of the cylinders.
7. Stop unloading of cylinders in a multi cylinder machine.

Purpose:
1. To reduce starting torque on motor.
 2. To clear away accumulate moisture & oil in the system.
Now days a method is commonly used –
The solenoid operated drain v/vs. providing automatic draining of as well as unloading.

Q. Cooling water is necessary for a compressor?

Ans:
1. Cool the heated air & reduce its volume for economy of power.
2. Decrease the thermal expansion.
3. Increase the suction
4. Maintain the quality of lub. Oil.
Q. Why cooler is vertical?
Ans: The cooler is vertical to accumulate and drain the water, moister, oil whatever is
collected.

Lubrication of the compressor: -Gear p/p is used to lubricate air compressor. Its
lubricants main bearing & connecting rod bearing through internally drilled passage in
the crankshaft.
It also lubricates the liner through connecting rod & gudgeon pin if separately cylinder
lubrication is not fitted.
The gear p/p is located with the crankshaft at the fore end of the fly wheel. It is
coupled with the shaft by a chain or ideal gear.

Fittings for automation of air compressor: -

1) Automatic unloading & draining system (solenoid operated unloading v/v are
normally used)
2) Automatic starts & stop under the control of a pressure switch on the air receiver.
3) Low luboil pressure cut out.
4) High air temp cut out.

Capacity of air bottle: -

Must be sufficient to make 12 start of main propulsion machinery.

Q. What is the cause when compressor can’t produce air pressure efficiently?
Ans: Compressor can’t produce air pressure efficiently cause-
 Air filter dirty. Leak in head cover
 Sluggish operation of suction / delivery v/v.
 Wear down cyl. bore & piston ring.
 Leak through the fitting of drain cock, relief v/v pressure gauge connection.
  If the bumping clearance is greater (due to the thicker head clearance).

Q. Materials of air compressor v/v.

Ans: Valve seat: 0.4% carbon steel hardened & polished working surface.
Valve: Nickel steel, chrome vanadium steel or Stainless steel, hardened & ground, then
finally polish to mirror finish.
Spring: Hardened steel (All hardened steel would be tempered).

Q. In case of air compressor explain, why Clearance volume need to be as small as

possible?
Ans: Clearance volume need to be as small as possible because:
 For increasing volumetric efficiency.
 Reduce running hours- Reduce air temp.
 Save work done.

Q. Purpose of compressed air on board-

Ans:
1. For starting main& auxiliary diesel engine.
2. Control system (i.e., pneumatic v/v’s)
3. Operating whistle.
4. For shoot blowing of aux boiler & economizer.
5. Workshop service
6. Hydrophore
7. Testing pipe lines.

Q. Explain Starting & stopping procedure of an air compressor.

Starting procedure of an air compressor: If the compressor has been opened for
cleaning or repair check that all works have been completed & carried out satisfactory.

 Check oil level in tank & cyl. oil tank.

 Check the quality of lub. oil and ensure that it has not been impaired by
water or any other foreign matters.
 Check compressor v/v s & lubricate the cyl. with oil.
 Turn over the compressor by hand with suction v/v relieved.
 Check cooling water circulation.
 Check air line v/v’s between the compressor & air bottle are opened.
  Open the manual drain cock.
 Check the load of generator & start the compressor.
 Check lub oil pressure.
If everything operating normally, close the drain cock, set the unloader in the operation
position, Allow the compressor to run for a few minutes before loading it to
maximum working pressure.
Stopping:
 Operate the manual v/v opener to relief the L.P stage suction v/v.
 Open the water trap drain cock.
 Stop the compressor.

Pressure at temp: -
Del. Pressure Air temp
Before, cooler after, cooler
First stage 4 2/3 bar 1300c 350c
Second “ 26 2/3 bar 1300c 350c
Q. Explain the air compressor explosion?
Ans: Air compressor explosion:
If v/v’s damaged & lubrication is increased due to leaky v/v, it will compress same air
again & again, causing the temp. to rise & to vaporize the oil when this oil vapor will
reach to its self ignition point, explosion will take place.
Leaking may occur due to carbon particles getting collected on the v/v seat. Preventing
the v/v closing properly. This Carbon may act as hot spot & will produce flammable
vapor.
Explosion may also take place in compressor discharge pipe; in case of inter cooler &
cooling water circulation failure. High temp. will cause the oil film to produce.
Flammable vapor at certain temp. in presence of air, In this case also explosion may take
place.

Q: What is Emergency air compressor?

Ans:
1) It is a small air compressor independently driven by diesel engine or hand operated.
It must be fitted to press up the emergency air bottle and to start auxiliary engine of a
dead ship.
2) The emergency air compressor presses up the air to the emergency air bottle. It has
no connection between the main air bottles. (It cannot press up air to main air bottle.)
Q: Purpose of unloader valve? (Moisture drain valve)
Ans: At starting, this valve must be opened. This reduces the starting torque for the
machine and clears out any accumulated moisture and oil in the system.
Q: How do you check compressor efficiency at running?
Ans:
1) It can be checked by running time with the previous record also check the first
stage discharge pressure.
2) If compressor efficiency is lower, the compressor will run longer and compressor
temperature will rise.
Q: Where is the fusible plug fitted? Purpose?
Ans:
1. Fusible plug is fitted under side of the pipe between relief valve and air bottle.
2. It is fitted to realize the compressor air from the air bottle in the event of
abnormally high compressed air temperature. Fusible plug melt
 3. at 150ºc
4. It is made by 50% bismuth, 30% tin and 20% lead.

Purpose: A fusible plug is fitted after the second stage cooler to limit the delivered air
temperature and thus protect the compressed air receiver and pipe work.

Q: Can u fit the relief valve at the space of bursting disc and why?
Ans:
1. At the compressor, the relief valve cannot be fitted at the space of bursting disc
because of their different operation.
2. Relief valve releases excess pressure at compressor running and reset at when
pressure reduce or when the compressor is stopped. if the cooler tube burst thus
cooling water enter to compressor air pipe it can cause the water hammer when
the next start of compressor.
3. Bursting disc releases the excess pressure when it burst and permanent damage. It
cannot close after opening. Stop the system operation and can find out the system
fault.

Q: Affect of reduces volumetric efficiency at air compressor?

Ans: 1. greater bumping clearance
2. Sluggish opening and closing of suction and delivery valves.
3. Leakage passes compressor piston rings.
4. In sufficient cooling waters the effects of high temperature.
5. Throttle of air supply to LP suction. (Dirty or partially chocked suction air filter.)
6. Inlet temperature of the air to the L.P. stage is too high.
7. Suction or delivery valves are leaking.
8.Leakage of air from compressor parts and jointings.
Q: Difference between relief valve and bursting device?
Ans: Pressure relief valve:
1. Excess pressure is released by opening the valve.
2. I t opened at 10% above the working pressure.
3. Valve open is proportional to excess pressure build up.
4. Valve setting pressure can be altered by spring pressure.
Bursting disc:
1. Release the entire pressure when it is burst at setting pressure.
2. It permanently damage during operation, cannot close after opening.
3. Setting pressure cannot be altered in place.
4. Stop the system operation can easily find out the system fault.
Fusible plug:
1. When the temperature is high above 105º C pressure is released by melting
(fusing) the meta.
2. It cannot be used next time (permanently damaged)
3. Release all content or pressure to empty.
4. To release entire compressed pressure from air bottle. In case of abnormal high
temperature above 105º C by melting the metal to prevent explosion.
 5. It is permanently damaged and cannot use next time.

Q: Why multi stage compressor is mostly used than single stage compressor?
Ans: More stages are needed to increase the require final pressure.
1. Easier to control the air temperature.
2. Reduction in compressor size can reduce thermal stress.
3. Lubrication system problem not exits.
4. Cooler is fitted to reduce thermal stress and lower work done to compress the air.
5. Improve engine balancing. Robust construction for HP parts.

Q. How many types of compressors are there? Why reciprocating type is most
commonly used?
Ans: Types of compressors:
 Reciprocating
 Rotary- 1. Rotary Vane 2. Rotary Screw 3. Liquid Ring
Reasons for commonly used of reciprocating type:
 In comparison with the isothermal and adiabatic compression, the previous one is
more efficient as extra work done required in later compression.
 Isothermal compression is a constant temperature system where heat to be taken
out as it received heat during compression.
 For this, it is necessary to move the piston slowly in a well cooled small bore
cylinder.
 This assembly is perfectly possible for reciprocating type air compressor. So, it is
most commonly used.
Rotary type normally used to produce large volume of air at relatively low pressure.
Example of rotary compressor:
 T/C blower.
 Auxiliary blower.
 Boiler forced draft fan.
 E/R ventilation fan.
 Condenser’s ejectors.

Q. Sketch a cross-section through a delivery valve of an air compressor, labeling the

principle components.
Ans:

Figure
Q. With respect to reciprocating air compressor define ‘Bumping Clearance’. State
the effect of incorrect bumping clearance on compressor efficiency. How the
bumping clearance can be adjusted.
Ans: Bumping Clearance: Clearance between the piston and cylinder head is known as
bumping clearance when the piston at TDC.
Effect of incorrect bumping clearance:
 If the clearance is high-
1. Volumetric efficiency will reduce.
2. Due to less air, compression pressure will not be sufficient to open the
delivery valve. So same amount of air will be compressed sequence and
temperature will raise which may cause explosion.
 If the clearance is low cylinder head & piston will break.
Adjustment of bumping clearance:
 It can be adjusted by placing additional shims between the cylinder head cover &
cylinder block in case of low clearance or under the connecting rod in case of
high clearance.
 Using the insert under the palm of connecting rod in case of high clearance.
 Using a thicker gasket under the cylinder in case of low clearance.
Q. Define volumetric efficiency of a reciprocating air compressor. Name the factor
contributing to its deterioration & how to avoid them.
Ans: Volumetric Efficiency: It is the ratio of actual volume of air drawn in each suction
stroke volume or swept volume.
Volumetric Efficiency = Suction volume / stroke = Vs/ Vs+ Vc
Factor to deterioration of volumetric efficiency:
 Excessive volumetric clearance.
 Inlet temperature high.
 Faulty valve.
 Chocked filter.
 Sluggish operation of suction & delivery valves.
 Leakage past compressor piston rings.
 Cooling water temperature high.
 Leakages of air from compressor parts & joints.
 Restriction in the intercooler.
Deterioration of volumetric efficiency can be avoided by:
 Adjustments of clearance volume.
 Proper maintenance of compressor valves.
 Cleaning the suction filter.
 Cleaning the cooler.
Q. Briefly describe the necessity to keep the air compressor valve in good condition.
Ans: Necessity to keep the valve in good condition:
If the air compressor valves are faulty they-
 Allow the leakage of air.
 Lead to loss of volumetric efficiency/ Reduce volumetric efficiency.
 Increase the running hours of compressor.
 May cause the rising air temperature which may causes to explosion.
Q. With respect to cylinder lubrication describe the effect of following in case of
reciprocating air compressor- i) Insufficient lubrication ii) Excess lubrication.
Ans: i) Effect of insufficient lubrication:
 Oil distribution will be poor.
 Causes poor sealing between liner & piston ring.
 Increase wear of liner & ring.
 Causes breakdown of piston ring.
 Low compression of air.
 Reduce volumetric efficiency,
ii) Effect of excess lubrication:
 Valve may stuck up due to carbon deposit which cause later compression
explosion.
 Carbon may deposit on the main engine starting air line.
 May causes explosion of starting air line.
 Compressor piston ring may break.
Q. Describe the causes, effects & remedy of the following-
i) First stage delivery valve leaking. ii) Second stage delivery valve leaking.
Ans: i) First stage delivery valve leaking:
Causes:
 Wear down the seat.
 Spring tension loose.
 Carbon deposit due to high temperature or excess lubrication.
 Badly filtration of air.
Effect:
 High pressure air leaking back into the cylinder.
 Less air will be drawn/ reduce delivery.
 Increase discharge temperature.
Remedy:
 If excess wear in seat change the valve plate or valve body.
 Fit the correct tension spring.
 Clean the deposit.
ii) Second stage delivery valve leaking:
Causes:
 Wear down the seat.
 Spring tension loose.
 Carbon deposit due to high temperature & excess lubrication.
Effect:
 Increase suction pressure in second stage.
 Reduce air suction & delivery in second stage.
 Delivery pressure from first stage increased.

Remedy:
Q. Why inter- stage cooler and multistage compression required in compressor?
Ans: Inter- stage cooler is required for the following:
 To reduce the air temperature.
 To increase volumetric efficiency.
 To save work done.
Multistage compression is required for the following:
 To get high pressure air by small size compressor.
 To reduce temperature.
 High delivery rate.
 Save work done.
Q. What are the safety devices incorporated in a reciprocating air compressor?
State how performance ‘falls off’ in service is indicated. How optimum performance
is restricted.
Ans: Safety device in reciprocating air compressor:
 Low L.O. pressure shut down.
 High delivery temperature shut down.
 High temperature alarm & fusible plug in delivery line.
 Expansion tank low level alarm.
 Relief valve in all stage (delivery).
 Bursting disc for jacket cooler.
 Un-loader.
 Non return discharge valve.
 Suction filter.
 Drain valve.
 Pressure gauge arrangement.
Indications of performance fall off:
 Lengthy running time.
 Low delivery pressure.
 High jacket temperature.
 Oil blow past through the breather.
 Low suction pressure.
Optimum performance is restored by:
 Cleaning the air filter.
 Maintain correct bumping clearance.
 Changing the valves.
 Proper maintenance of running gears.
 Ensure correct lubrication.
 Ensure correct water supply.
 Cleaning the inter-stage & after-stage cooler.
  Ensuring the performance of non-return valve.
 Ensuring the correct operation of drain valve & un-loader.
Q. What are the safety devices incorporated on an air bottle?
Ans: Safety devices on air bottle:
 Safety valve.
 Fusible plug.
 Drain valve.
 Pressure gauge.
 Discharge from safety valve & fusible plug is led to the deck.
Q. Describe the effect of the following faults in the multi-stage reciprocating air
compressor.
Ans:
a) Inter-stage cooler starved of cooling water:

Effect:
 Second stage air temperature will be high.
 Air pressure will be high.
 Loss of volumetric efficiency.
 Work can not be saved.
 If excess lubrication, there is a risk of explosion.
b) Worn crankshaft bearing:

Effect:
 Bumping clearance will be high.
 Loss of volumetric efficiency.
 L.O. pressure will decrease.
 Vibration and noise will occur.
c) Broken or worn scrapper ring:

Effect:
 Ring will not be able to scrap oil to crankcase.
 Crankcase sump level will reduce.
 Causes wear of liner.
 Reduce efficiency.
 Oil blow past through breather.
Q. Explain why air bottle draining is critical.
Ans: Moisture & oil vapor from engine room can be passed to air bottle through the air
compressor after compression.
 In the bottle this is stored as water which is accumulated at the lower part.
 If this water is not drained it may causes corrosion in the bottle & drain pipe or
valve.
 Water oil accumulation gradually may increase & thus may carry over to the air
system which may cause starting air line explosion.
 If water not drained it will reduce the carrying capacity of the bottle.
 Big accumulation may cause shock wave on pipeline.
Q. With reference to reciprocating air compressor state why-
Ans: a) Suction & discharge valve are of plate type:
Causes:
 More streamlined.
 Lighter.
 Reduce friction loss.
 Reduce valve inertia.
Rapid action.