Safety Devices in Air Compressors on Ships

What is emergency air compressor ?

It is a small compressor independently driven by a prime mover having
power supply from emergency switch board. They are also driven by
diesel engines.

It must be fitted to press up the emergency air bottle and to start

auxiliary engine of a dead ship.

It has no connection between the main air bottle.

What are the safety devices in air compressors on ships ?

1.
Bursting discs are fitted on the cooler shells (At water side).
2.
Relief valves are fitted to discharge side for every stages.
3.
Moisture drain valve (unloader) are fitted at each cooler side.
4.
Cooling water failure alarm.
5.
Low L. O pressure alarm and trip.
6.
Delivery air high temperature alarm on after cooler outlet (Max 93 C)
What are the normal parameters of air compressor ?

Type

LP discharge pressure: 4 bars

HP discharge pressure: 30 bars.
Intercooler inlet air temperature: 130 C
Intercooler outlet air temperature: 35 C
After cooler inlet air temperature: 130 C
After cooler outlet air temperature: 35 C
of intercooler and after cooler ?

Intercooler is single pass type

After cooler is double pass U-tube type

Purpose of unloder valve (moisture drain valve) in air compressor ?
At starting this valve must be opened, this reduced the starting torque
for the machine and clear out any accumulated moisture and oil in the
system.
What would be effect of suction valves of an air compressor having too much
lift ?

The valve will be late in closing and this would reduce the volumetric
efficiency of the machine.

The valve experience greater force and therefore are more liable to
break.
Effects of reduced volumetric efficiency of air compressor ?

1.
Greater bumping clearance.
2.
Sluggish opening and closing of suction and delivery valves.
3.
Insufficient cooling water that effect of high air temperature.
4.
Dirty or partially chocked suction air fitter.
Difference between relief valve, bursting disc and fusible plug ?
Pressure relief valve

Excess pressure is released by opening the valve.

It opens at 10% over working pressure.

Valve lift is proportional to excess pressure build up.

Valve setting pressure can be altered by spring tension.

Bursting disc

Pressure is released by bursting the disc.

It permanently damaged.

It burst at setting pressure.

Setting pressure cannot be altered in place.

Fusible plug

When the air temperature from compressor is high (above 105 C)

pressure is released by melting (fusing) the metal.

It cannot be used next time. ( permanent damage)

Release all content or pressure to empty.

Why multistage compressors are mostly used than single stage
compressor ?
1.
More stages are needed to increase the required final pressure.
2.
Easier to control the air temperature.
3.
Reducing in air compressor size.
4.
Lubrication problem does not exit.
5.
Reduced the thermal stress.
6.
Lower work done to compressing air.
7.
Improve compressor efficiency
Advantages of inter cooling of air compressor ?

To avoid excessive temperature rise associated with higher

compression ratios, and to approach isothermal compression.
Saving in power.
Volumetric efficiency is increased.
Reduced the volume of air delivered and also reduced the compressor
size.
It can reduce the air temperature.
Due to less temperature suction & delivery valves remain cleaner
without being fouled with carbonized oil.
It can avoid a danger of an explosion takes place in compressor
cylinder.

It allows good lubrication of the compressor piston.

Moisture separation is easier through inter cooler drains.
It also enables to deal with a greater weight of air for the same energy
expended.
Why intercooler is fitted in main air compressor on ships ?

1.

Reduced air temperature, volume and increased air density for next
stage
2.
So increased volumetric efficiency and compressor efficiency.
3.
Due to reduced temperature give better lubrication for cylinder and
piston rings
4.
Drain are fitted from which water and excessive oil can be drained out,
to prevent air bottle corrosion and starting air explosion and fouling of
inter coolers and pipe.
5.
Save the work done.
Advantages of after cooler in air compressor ?
To reduce final discharge air temperature thus air bottle size can be
reduced.

To reduce air volume after it has been compressed to the final

pressure.

So greater amount of air could be stored in air bottle.

Increase volumetric efficiency

How to start the air compressor manually on ships ?
1.
Change the switch to manual position on the switch board.
2.
Check the L.O sump level and condition.
3.
Open the moisture drain valve.
4.
Open the compressor discharge valve & charging valve of air bottle.
5.
Open cooling water system valves.
6.
Turn the compressor flywheel by hand (one turn).
7.
Start the motor, after draining the moisture shut the drain valve.
8.
Check the motor ampere consumed.
9.
Check the pressure gauge readings.
10. Frequently drain the moisture.
11. When charging full, open drain valve and stop the compressor
How do you check compressor efficiency during running ?

1.

Checked by filling time with the previous record and also check
the first stage discharge pressure. If compressor efficiency is lower,
compressor will run longer and compressor temperature will rise.
2.
First stage and second stage pressure gauge must be correct and
stable.
3.
No escape of air from suction filter.

4.
Intercooler and after cooler outlet air temperature should not be high.
5.
If open drain valve nothing can be found.
6.
Low L.O consumption.
7.
Oily air mixture must not blow out from breather pipe.
Safety devices on main air bottle ?
1.
Pressure relief valve.
2.
Fusible plug.(if safety valve is not directly fitted on the bottle)
3.
Pressure gauge.
4.
Low air pressure alarm.
5.
Moisture drains valve.
Where is the fusible plug fitted and its purpose ?
Fusible plug is fitted under side of the pipe between relief valve and air
bottle.

It is fitted to release the compressed air in the event of abnormally

high compressed air temperature.

Fusible plug melt at 105 C and release all content of air.

It is made by 50% bismut, 30% tin, 20% lead.

A fusible plug is fitted after the second stage cooler to limit the
delivered air temperature and thus protect the compressed air reservoirs
and pipe work.
Can you fit the relief valve at the space of bursting disc and why ?

At the compressor, relief valve can not be fitted at the bursting disc,
because of their difference operation.
Bursting disc is fitted for totally release and stop operation circuit.
Release valve opens excess pressure at compressor running and reset
when pressure reduce or when the compressor is stopped. Thus cooling
water can enter to compressed air space; it can cause water hammer
when the next start of compressor.

Effects of leaking valves in Air Compressor:

First Stage Suction:

Reduce air delivery

Reduce 2nd stage suction pressure

Unload the compressor

Increase running time.

First Stage Delivery:

1.

Reduce air delivery

2.

Increase discharge temperature

3.

Less air drawn in, due to high-pressure air leaking back into cylinder.

Second Stage Suction:

1.

Reduce air delivery

2.

High temperature & pressure in 2nd stage suction line

3.

Increase running time

Second Stage Delivery:

1.

Reduce air delivery

2.

Increase suction pressure in 2nd stage

3.

Increase delivery pressure from 1st stage.

4.

Back pressure from air bottle.

How to check Air Compressor Efficiency?

1.

Regular overhauling of valves done or not.

2.

Check Air Bottle filling time.

3.

Compare test results and records.

How to check Air Compressor capacity is sufficient?

Total no. of Air Compressors must be sufficient to fill the empty Air Bottle to
maximum pressure within 1 hour.

Must be sufficient to start at least 12 times for Reversible Engine, and at least
6 times for Non-Reversible Engine.

Bursting Disc:
1.

Fitted on the shell of Intercooler at waterside.

2.

Relieves pressure if the tubes burst.

3.

Rolled Copper Alloy and relief pressure is set while the disc is at softest
condition.

4.

Material tends to harden due to time and surrounding temperature, and set
pressure also increased.

5.

Bursting Disc needed to be annealed, to regain correct relief pressure.

Compound Valves, why used in Air Compressor?

1.

Give large area of opening and small amount of valve lift.

2.

Improve Volumetric Efficiency, as valve open and close in minimum time.

3.

Reduce bumping clearance.

4.

Reduce wear and tear.

LP Relief Valve opening:

Causes:
1.

HP suction valve

2.

Intercooler choked.

3.

Relief valve, jammed by foreign particles, in open position.

HP Relief Valve opening:

Causes:
1.

HP discharge valve, in closed position.

2.

After cooler choked.

3.

Relief valve, jammed by foreign particles, or spring sticking in open position.

(Relief Valves opening pressure are set at 10% above stage pressure.)
Why Intercooler is fitted?
1.

Reduce air temperature and volume, and increase air density for next stage.

2.

Increase Compressor Capacity and Volumetric Efficiency.

3.

Better lubrication for cylinder and rings.

4.

Water and excess oil can be drained out, preventing fouling of Intercooler and
pipes, Air Bottle corrosion, and starting airline explosion.

5.

Work done is saved.

6.

Metal stresses reduced, due to control of temperature.

Volumetric Efficiency:
VE = (Volume of Air drawn into Cylinder) / (Stroke Volume of LP Piston)
and
VE = (Volume of Air discharged as free air) / (Stroke Volume of LP Piston)
Why Multistage Air Compressor is built?
1.

To obtain near to ideal isothermal compression, compressor is to be

constructed of multistage with inter-stage cooling.

2.

Inter-stage cooling reduces air temperature and volume after 1st stage
compression, thus increase mass of air for 2nd

3.

Workdone is saved and air compressor efficiency increased.

Other advantages are:

1.

Easy to get high final air pressure.

2.

Easy to control air temperature.

3.

Easy to maintain correct lubrication.

4.

Better compressor balancing.

5.

Reduction in size.

6.

reduction in clearance volume loss.

Capacity of air compressor:

1.

Capacity is checked upon how much filling time is lowered.

2.

Compressor should have enough filling capacity so that sufficient stopping

time should be provided between fillings.

12 consecutive starts in reversible engine and

6 consecutive starts in non-reversible engine.

What is Free Air Delivery, FAD?

1.

Capacity of Air Compressor is stated in terms of [ m/ hr ].

2.

Volume of air actually discharged in 1 hour, that would occupy if expanded

down to atmospheric pressure and cooled to atmospheric temperature.

Safety devices on Main Air Compressor:

1.

Bursting Disc on Intercooler: (At water side)

2.

Bursting Disc and Fusible Plug (121C) on Aftercooler

3.

Relief valves on LP and HP stages. (Set to lift at 10% rise above normal stage
pressure.)

4.

Automatic Moisture Drain Valve.

5.

Cooling water supply failure alarm.

6.

Low LO pressure alarm.

7.

Relief valve on crankcase LO pump.

8.

Delivery air HT cut out and alarm on Aftercooler outlet. (Max. 93C)

LP discharge pressure 4 bars and HP discharge pressure 30 bar

Intercooler inlet air 130C and intercooler outlet air 35C

Aftercooler inlet air 130C and Aftercooler outlet air 35C:

Intercooler is single pass type: Aftercooler, double pass U-tube type:}

Uses of Compressed Air:

Engine Starting 20 to 25 bar

Boiler Soot Blowing 20 to 25 bar

General Service (Whistle, Pneumatic Tools, Lifeboat , service air for cleaning
and Pilot ladder) 7 to 10 bar

Instrumentation and Control 5 bar

Air Filter:
1.

Material: Felt, Metal gauze or Nylon strands

2.

Removes contaminants from air. Dirt and dust act as abrasives and increase
wear.

3.

Contaminant deposits on valves can become hot and source of ignition.

Hazard of Dirty Filter:

1.

Very dirty filter or muffling a filter results in large pressure drop.

2.

Air has to be compressed over higher range.

3.

In extreme case, discharge air temperature may exceed flash point, or autoignition temperature resulting in an

4.

As a safety against explosion, air temperature is limited to 93 Fusible

Plug (121C) or a High Temperature cut out(93C) is provided on Compressor.

Pressure Test on Air Compressor:

Cylinders, cylinder cover, Inter & After coolers are hydraulically tested to:

Air Side: 1.5 x max. Working Pressure.

Water Side: 4 bar or 1.5 x max. WP (whichever is greater)

Air receiver:

Total capacity of air receivers must be sufficient to give at least 12 starts for
reversible engine, and at least 6 starts for non-reversible engine, without
refilling the receivers.

There must be two identical main air receivers and one emergency bottle for
every vessel.

Mountings of Air receiver:

1.

Fusible plug:

composition Bismuth 50%, Tin 30%, Lead 20%,

Melting point: 220F (104.4C).

Fitted at the reservoirs bottom or on

reservoir at ship side, when relief valve (safety valve) is not directly fitted on
the reservoir.
2.

Atmospheric relief valve: provided for back-up of fusible plug. In case of

ER fire when CO flooding is required, this valve is opened before evacuating ER.

3.

Spring loaded safety valve: setting pressure: 32 bar (for 30 bar working
pressure), with 10% rise in accumulation of pressure. May be fitted directly or with
extension.

4.

Compensation ring: when a hole is cut or machined in pressure vessel,

higher stresses will subject to the material around the hole, and to reduce this,
compensation rings are fitted. It is a flange on which a valve or fitting is usually
mounted.

5.

Manual Drain valve or Automatic Drain valve.

6.

Pressure gauges.

7.

Access doors.

8.

Main starting air valve, auxiliary starting air valve, filling valve, service air or
whistle air valve.

Internal surface coating:

Graphite suspension in water, Linseed oil, Copal vanish or Epoxy coating having basic
properties of anti-corrosive, anti-toxic or anti-oxidation.
Safety devices on Main Air Bottle:
1.

Fusible plug.

2.

Pressure Relief Valve

3.

Atmospheric Relief Valve.

4.

Low Air Pressure alarm.

5.

Automatic or remote control Moisture Drain Valve.