AIR COMPRESSORS

• Theory
• Construction
• Operation
• Lubrication
• Cooling
• Safety Fittings
• Problems and Maintenance
• Rules and Regulations
• Inspection of bottles
• Safety Fittings
• Problems and Maintenance of Air Bottles
Pressure against volume in a
reciprocating compressor
 Introduction

• Uses of compressed air: starting main and auxiliary

diesel engines, operating ship’s whistle, control
equipment, instrumentation and pneumatic tools such
as lifting gear, impact and torque wrenches, drilling
machines, grinders etc.
• For general use - 5 to10 kg/cm2,
• for diesel engine starting - 25 to 30 kg/cm2

• When work is done on air (that is by compressing it)

temperature and pressure increase and the volume
decreases. Air is compressed in a compressor, which is
run by electric motor or a diesel engine or any other
prime mover.

• The compressed air is stored in air bottles.

 Theory
• Isothermal compression is compression at constant
temperature. If air was to be compressed in a cylinder,
all the heat generated should be absorbed by the piston,
cylinder cooling water to maintain constant temperature
– PV=constant
• Adiabatic compression (isentropic) is compression in
which all the heat due to compression is retained. If air
was to be compressed in a cylinder, all the heat
generated is retained in the air, no heat is lost to the
piston or cylinder cooling water
• Compression without any heat loss – PV = constant
where n= CP/CV, for air = 1.408
• Where P – absolute pressure, V- volume, CP – specific
heat at constant pressure, CV - specific heat at constant
volume
 Theory

• In actual practice air compression in a compressor is

polytropic, neither isothermal nor adiabatic and is
between the two –PVn = constant (mean n= 1.3 and
varies for each compressor)
• Isothermal compression is ideal, as the work done is
minimum. If isothermal compression could be achieved
in a single stage compressor, it would be ideal from
thermodynamic point of view, but this is not practically
possible. During compression stroke, as the volume
becomes less the heat becomes more and the area of
the cylinder wall which cools the air becomes less and
hence the ideal cannot be obtained.
Pressure - Volume
Effects of multi stages with inter-cooling

• If the air is compressed in

stages with cooling after each
stage to the initial
temperature, the compression
will be nearer to the
isothermal compression.
• This results in lower power
requirement; better
lubrication and less thermal
distortion because of lower
air temperatures.
• Pressure ratio in each stage
is kept equal so as not to
overheat the valves in one
stage and thereby damage
the springs and valves.
 Effect of volumetric clearance

• Clearance is maintained between the cylinder head and

the piston top when the piston is in top dead centre to
prevent mechanical damage. The clearance volume
should be kept as small as possible to achieve best
efficiency. Volumetric efficiency is the ratio of actual
volume of air drawn to the stroke volume.
• Volumetric efficiency reduces by - increase in clearance
volume. Cylinder charge air temperature increases as
temperature of air in clearance volume does not drop to
inlet temperature during expansion.
- leakage past piston rings
- sluggish opening and closing of suction and
delivery valves.
- insufficient or high temperature cooling water
- air inlet temperature high
- air suction filter blocked
Two stage Air Compressor
 Construction

• It consists of cast iron casing with L.P. and H.P. cylinder

liners in which run aluminium pistons fitted with cast
iron piston and scraper rings.
• Pistons are connected to forged steel connecting rods
through fully floating gudgeon pins running in phosphor
bronze bushes.
• The connecting rods carry steel backed white metal
lined thin shell bearings, which connect on to forged
steel, crank shaft.
• Air filter- Felted cloth or paper, woven copper wire or
nylon strands. Pressure drop should be minimum else
delivery temp will be very high.
 Suction and delivery valves Construction

• The valves are automatic, operate on low press

differential, lift is low to reduce impact forces,-Failure
occurs due to fatigue and wear, overheating, foreign
solid particles or liquid oil from crankcase, carbon
deposits from oil.
• Second stage valves are smaller, scantlings are heavier.
• The seat is made of carbon steel, seat faces are narrow
and have a mirror finish. The distance piece sets the lift
of the valve. The valve plate is made of high grade steel
(nickel steel or chrome vanadium steel or stainless
steel) The cushion plate, spring plates, and the cover
are made of steel. The cushion plate effectively reduces
the impact forces of opening and the spring plates
ensure the valve plate is seated firmly, promptly and
gently without leakage.
 Cooling

• Inter cooler:
• Cools air below its dew point; condensate is separated
and drained.

• After cooler:
• Pressures and temp are higher and cleanliness is critical.
Compressed air is cooled in the after cooler to reduce
the temperature and volume and hence more quantity
can be stored in air receiver.
• Fusible plug is fitted immediately after the cooler. If
high temp cut out is provided fusible plug is not
required.
 Lubrication

• Main, crankpin and gudgeon pin bearings are lubricated

by attached luboil pump or splash lubrication.
• Cylinder Liner is lubricated by splash of oil and by oil
feed to the liner by a separate pump or drip with suction
air.
 Safety features
• Compressor L.P. & H.P. relief valves
• Bursting disc in the cooling water space. Under sudden rise
of pressure, relief valve has not proved to be efficient. Disc
type is more suitable
• Crank case relief doors if crank case volume is 0.6 m3 or
more
• High air temperature, low oil pressure alarms and auto
stops.
• Oil relief valve: 25% more than normal pressure Min 2 bar.
• Crankshaft end float to allow for expansion 1in 1000.
• Non-return valve in the pipeline after the after cooler so
that air vessel pressure is not acted upon the delivery
valves during compressor starting.
• Condensate pot after the compressor. The delivery line
from compressor turns vertically downwards after the non-
return valve and into the condensate pot, fitted with an
auto drain.
 Problems

• Low output – gaskets leaking, intake filter fouled, piston

ring problem, piston/cylinder worn or damaged,
restricted discharge line, un-loader system wrong,
valves fouled, valves not seated correctly, valves
worn/broken.
• Crank case emulsification- condensate carry over, inter
cooler not drained, piston ring problem, piston/cylinder
worn or damaged,
• Excessive carbon – excessive oil, gaskets leaking, intake
filter fouled, piston ring problem, piston/cylinder worn
or damaged, poor piston drain holes, valves fouled,
valves worn/broken, ventilation poor, water quantity
too low, wrong oil.
 Problems

• High air discharge temp – discharge pr high, intake filter

fouled, piston ring problem, piston/cylinder worn or
damaged, valves fouled, valves not seated correctly,
valves worn/broken, ventilation poor, water quantity
too low,
• Inter cooler press high - restricted discharge line, valves
not seated correctly, valves worn/broken.
• Inter cooler pressure low – intake filter fouled, piston
ring problem, piston/cylinder worn or damaged, valves
fouled, valves not seated correctly, valves worn/broken.
 Maintenance

• For economy, air compressor should be kept free from

leakage. Leaky valves often result from the wear and
pounding of valves against their seats. Dust and dirt
from unfiltered air are an obvious cause of wear.
• Overheating of the air cylinders should be avoided. It
results in loss of lubrication - oil being carried into the
discharge lines – and reduced efficiency
• Valves:
• All valves are taken out, properly tagged and overhauled.
• Lapping of the valve seats valve plates should be carried
out using faceplate and with brasso as the lapping media
and not grinding paste.
• Locating pins if taken out, should be fitted back into
place securely
 Maintenance

• Assembly of the valve should be done correctly.

• The nuts should be tightened to the correct torque and
provided with locking.
• Operation of valve should be checked by hand before
fitting back n place.
• Valve housing should be cleaned before fitting the valves.
• Piston and cylinders:
• Piston should be taken out carefully ensuring that the liner
is not scratched.
• Piston and rings calibrated and changed if required.
• Liners checked for ridges at the upper part.
• Liners are calibrated.
• Pistons fitted back properly with the rings properly placed.
 Maintenance

• Bearings:
• Bearings are checked for wear
• In case of excessive wear, the bearings are changed.
• The clearance checked.
• Lubricating oil bores are checked and cleared.
• Bearing bolts are torque tightened and locking done.
• Grease bearings

• Crankcase:
• Luboil drained,
• Crankcase checked for any metal particles
• Luboil pump inspected and cleaned.
• Luboil pump strainer cleaned.
 Maintenance

• All running gear checked for tightness, alignment and

security.
• New oil filled.
• Pump should be activated and lubrication checked.
• Compressor turned by hand to ensure free running.

• Air suction filter

• Taken out and cleaned.

• Coolers
• Coolers water side cleaned and bursting discs
replaced/inspected
• Air side cleaned by soaking in chemical
 Maintenance

• Safety features:
• Relief valves overhauled and opening pressure checked
and set.
• Auto start and stop pressures checked.
• Alarms and trips tested
 Rules & Regulations

• Two starting air compressors must be fitted of sufficient

capacity so as to fill an air bottle in one hour.
• One emergency compressor with a driving unit not
requiring air for starting is to be fitted for initial charging
of air vessel.
• Each compressor must have a relief valve, so that the
accumulated pressure with the main outlet valve of the air
compressor closed will not exceed 10% of maximum
working pressure.
• Bursting discs are to be provided on the coolers water side,
• Cylinders, covers, inter-coolers, after coolers are to be
tested to twice working pressure.
• Inter cooler and after cooler casings to be tested to 2 bar
 Rules & Regulations

• A water separator or drain should be fitted on the air

side of each cooler and should be used at regular
intervals during operation and before starting and
stopping the compressor.