AUX MACH – REPORT SCRIPT

What is air compressor?

- A compressor is one such device which is used for several purposes on a ship. The main
aim of the compressor, as the name suggests, is to compress air or any fluid in order to
reduce its volume. A Compressor is a multipurpose device which finds many applications
on a ship. Some of the main forms of compressors used on ships are the main air
compressor, deck air compressor, AC compressor and refrigeration compressor. In this
article, we will learn about air compressors and its types.
- An air compressor is a very useful machine and is not only used extensively in industry
on land but on all types of ships as well. On a ship an air compressor is used to compress
air and store it in tanks for various uses. These use these could range from simple
processes such as cleaning and drying of filters to tasks such as starting the auxiliary
engines and the main engines of the ship.
Applications Of Air Compressors
- Air compressor is a device with vast application in almost all sorts of industries and
household requirements. In the maritime industry as well, air compressors are used in
essential equipment or the feeder equipment to different systems. They can be employed
in a number of processes ranging from small process of cleaning of the filters to the
bigger and crucial tasks such as starting main as well as secondary engines.
- Air Compressor produces pressurized air by decreasing the volume of air and in turn
increasing its pressure. Different types of air compressors are used according to the
usage.
- In a more technical language, an air compressor can be defined as a mechanical device in
which electrical or mechanical energy is transformed into pressure energy in the form of
pressurized air.
How does an air compressor work?
- First of all and let me explain what compression means. It simply refers to the process of
reducing the volume of gas so as to raise its pressure and the compressed gas is stored in
a solid container or tank usually having a pressure gauge and the safety mechanism. Just
notice that I have used the word gas which is obvious since the solids and liquids are
incompressible.
- Air compressor works on the principles of thermodynamics. According to the ideal gas
equation without any temperature difference, with an increase in gaseous pressure, its
volume reduces. The air compressor works on the same principle on which it produces
compressed air, by reducing the volume of air this reduction in volume results in an
increase in air pressure without any temperature difference.
Slide number 6 explanation
- The air is compressed in the first stage, cooled and compressed to higher pressure in the
next stage. Compressors must always be started at the unloaded condition since otherwise
pressures build up rapidly producing very high starting torques.
- Air is drawn in on the suction stroke through the first-stage suction valve via the
silencer/filter. The suction valve closes on the piston upstroke and the air is compressed.
The compressed air, having reached its first-stage pressure, passes through the delivery
valve to the first-stage cooler. The second-stage suction and compression now take place
in a similar manner, achieving a much higher pressure in the smaller, second-stage
cylinder.
- After passing through the second-stage delivery valve, the air is again cooled and
delivered to the storage system. The machine has a rigid crankcase which provides
support for the three crankshaft bearings. The cylinder block is located above and
replaceable liners are fitted in the cylinder block. The running gear consists of pistons,
connecting rods and the one-piece, two-throw crankshaft.
Explanation for slide 8:
What is starting air system of main diesel?
An air-start system is a power source used to provide the initial rotation to start large diesel and
gas turbine engines.
Diesel engines are started by supplying compressed air into the cylinders in the appropriate
sequence for the required direction. The compressed air is then supplied by a large bore pipe to a
remote operating non-return or automatic valve and then to the cylinder air start valve.
What is the function of starting air system?
An air-start system is a power source used to provide the initial rotation to start large diesel and
gas turbine engines.
What is the function of starting system on diesel engine on ships?
Without adequate cooling certain parts of the engine which are exposed to very high
temperatures, as a result of burning fuel, would soon fail. Diesel engines are started by supplying
compressed air into the cylinders in the appropriate sequence for the required direction.
Which air system is used for starting the main engine?
Well, the Starting air system uses compressed air to start the main engine. Compressed air is
inserted into various cylinders in a proper sequence to provide the initial torque; required to
overcome the inertia of reciprocating parts.

The line diagram for starting Air System of Marine Diesel Engine (Sulzer / Wartsila
Engine), which comprises of – air bottle to provide 30 starting air, pilot valve to start the
operation, turning gear interlock, automatic air start valve, air distributor, and cylinder head
starting air valve.
Air supply is provided by opening the main air bottle valve. As the valve is opened, the air is
passed through the pilot valve and acts on top of the automatic start valve, providing a positive
closing. The other branch supplies air until the turning gear interlock as the interlock blocks the
air to go further.
To start the main engine, first turning gear has to be disengaged. This will deactivate the
interlock and the air will be supplied to the automatic start air valve.
Since there is a spring pressure and additional positive closing by the air supplied pilot valve, the
air will not go further automatic start valve until the start command is given.
When the air start lever is operated in the ECR, the pilot valve shifts and blocks the air on top of
the automatic valve. It vents the line and there is no more positive closing.
Types of air compressors
 centrifugal compressor
- centrifugal compressors use a rotating disk or impeller in a shaped housing to force the
gas to the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent
duct) section, also called plenum, converts the velocity energy to pressure energy, hence
we get air at high pressure.
- They are primarily used for continuous, stationary service in industries such as oil
refiners, chemical and petrochemical plants and natural gas processing plants, they are
generally single stage machines, but with multiple staging, they can be achieved high
output pressures (>69 MPa)
- The centrifugal air compressor is an oil free compressor by design. The oil lubricated
running gear is separated from the air by shaft seals and atmospheric vents. It’s a
continuous output machine.
- A centrifugal compressor is a type of dynamic compressor, or turbo compressor, with a
radial design. Unlike displacement compressors that work at a constant flow, dynamic
 compressors work at a constant pressure and the performance is affected by external
conditions such as changes in inlet temperatures.
- How does it works?
Air is drawn into the center of a rotating impeller with radial blades and is pushed
toward the center by centrifugal force. This radial movement of air results in a pressure
rise and the generation of kinetic energy. Before the air is led into the center of the
impeller, the kinetic energy is also converted into pressure by passing through a diffuser
and volute. Each stage takes up a part of the overall pressure rise of the compressor unit.
Depending on the pressure required for the application, a number of stages can be
arranged in a series to achieve a higher pressure. This type of multi-stage application is
often used in the oil and gas and process industries. Alternately, in wastewater treatment
plants, low pressure, single-stage applications are used to achieve the desired pressure
ratio. In modern configurations of centrifugal air compressors, ultra-high-speed electric
motors are used to drive the impellers. This results in a compact compressor without a
gearbox and associated oil-lubrication system, thus making it oil-free and appropriate for
applications that require 100 percent oil-free air.

 Rotary vane compressor

- One of the oldest compressor technologies, rotary vane compressors consists of a rotor
with a number of blades inserted in radical slots in the rotor.

- The rotor is mounted offset in a larger housing that is either circular or a more complex
shape. As the rotor turns, blades slide in and out of the slots keeping contact with the
outer wall of the housing. Thus, a series of decreasing volumes is created by the rotating
blades.

- They can be either stationary or portable, can be single or multi-stage, and can be driven
by electric motors or internal combustion engines. They are well suited to electric motor
drive and its significantly quitter in operation that the equivalent piston compressor. They
can have mechanical efficiencies of about 90%

 Rotary screw compressor

- Rotary screw compressors use two meshed rotating positive-displacement helical screw
to force the air into a smaller space

- These are usually used for continuous operation in commercial and industrial applications
and may be either stationary or portable.

- Because of simple design and few wearing parts, rotary screw air compressors are easy
install, operate and maintain.

- Rotary screw compressors are commercially produced in oil flooded and oil free types:

- Oil flooded compressors are nothing but oil cooled compressor where oil seal the internal
cleaners of the compressor. Though filters are needed to separate the oil from the
discharge air, cooling takes place right inside the compressor, and thus the working parts
never experience extreme operating temperature leading to prolonged life.

- The oil free screw air compressors use specially designed air ends to compress air, giving
true oil free air. They are water cooled or air cooled and provide the same flexibility as
oil flooded rotary compressors.

 Reciprocating air compressor

- Reciprocating compressors are the most widely used type of compressors.

 - In these compressors, air compressed by the action of a piston in a cycling with one-way
valves and pumped into an air chamber.

- Reciprocating compressors use cylinders with pistons inside them. Each cylinder has a closed end
next to the cylinder head and is finished at the other end with a movable piston. The valves of the
cylinders are located at the bottom of the compressor’s valve pockets. During the first stage of
compression, air moves into the cylinder via a suction valve, triggered by the movement of the
piston. This creates a vacuum.
- The piston then reverses its motion, fulfilling the “reciprocating” part of the name, and begins
compressing the air in the process. Once the cylinder’s interior pressure exceeds the pressure in
the discharge pipes, valves open and allow air out of the cylinder.
- A reciprocating compressor is a positive-displacement machine that uses a piston to
compress a gas and deliver it at high pressure. They are often some of the most critical
and expensive systems at a production facility, and deserve special attention. Gas
transmission pipelines, petrochemical plants, refineries and many other industries all
depend on this type of equipment.
How does a Reciprocating air compressor?

- Reciprocating compressors usually draw power from a diesel engine. This can be by way of a
direct-drive or a belt drive system, either of which will be in continuous operation as long as the
engine is on. The entire cycle is facilitated by a mechanism for unloading, and some systems have
a governor that is typically mounted directly to the compressor. When a governor is present, it
works to enforce specific intake and cut-out pressure.

- Reciprocating air compressors work on the principle of reciprocation, which means to move
something back and forth. Also known as piston compressors, these machines are positive
displacement equipment, meaning that they increase pressure in air to compress it. Reciprocating
compressors usually draw power from a diesel engine. This can be by way of a direct-drive or a belt
drive system, either of which will be in continuous operation as long as the engine is on. The entire
cycle is facilitated by a mechanism for unloading, and some systems have a governor that is
typically mounted directly to the compressor. When a governor is present, it works to enforce
specific intake and cut-out pressure.

Explanation for slide number 10

A marine air compressor provides compressed air for various purposes on a ship. An air
compressor is one of the most important equipment on a ship which needs special care and
routine maintenance. In this article we will know the basics of the marine air compressor by first
getting familiarized with the different parts of the same.

The main parts of the marine air compressor are:

1) Cylinder liner:

It is made of graded cast iron and is accompanied with water jacket around it to absorb heat
produced during compression process. It is designed so as to give a streamline passage to the
pressurized air resulting in minimum pressure drop.

2) Piston:

For a non-lubricating type compressor, light-weight aluminum alloy piston is used and for
lubricating type graded, cast iron piston are used with piston rings for sealing and scrapping off
excess oil.

3) Piston Rod:

In high capacity compressor which is normally big in size, piston is attached to piston rod made
up of alloy steel. They are fitted with anti-friction packing ring to avoid chances of compressed
air leakage.

4) Connecting rod
Connecting rod plays its role to minimize thrust to the bearing surface. It is made up of forged
alloy steel.

5) Big end bearing and Main bearing:

They are constructed to give rigidity to the running rotational mechanism. They are made up of
copper lead alloy and have a long operational life if proper lube oil and lubrication is provided.

6) Crank shaft:

It is a one piece designed part, using counterweights for dynamic balancing during high speed of
rotation to avoid twisting due to torsion forces. Connecting rod big end bearing and main bearing
are connected to crank shaft at crank pin and journal pin which are polished to ensure long
working life of bearings.

7) Frame and crankcase:

Normally they have rectangular shape and accommodate all the moving parts and that’s why are
made up of rigid cast iron. Main bearing housing is fitted on a bore in crank case and is made
with highest precision to avoid eccentricity or misalignment.

8 ) Oil pump:

A lubricating oil pump is fitted to supply lube oil to all the bearings, which can be chain or gear
driven, through crank shaft. Pressure of oil can be regulated by means of regulating screw
provided in the pump. A filter in the inlet of the pump is also attached to supply clean and
particle free oil to the bearings.

9) Water pump:

Some compressor may have attached water cooling pump driven by crankshaft through chain or
gear. Some system does not use attached pump as they use water supply from main or auxiliary
system for cooling.

10) Suction and Discharge valve:

These are multi-plate valves made up of stainless steel and are used to suck and to discharge air
from one stage to another and to the air bottle. Proper assembling of valves is very important for
efficient operation of the compressor.

11) Suction Filter:

It is a air filter made up of copper or soft steel with a paper material to absorb oil and wire mesh
to avoid any metal or dust particle to go inside compression chamber.

12) Inter-coolers:

Inter-coolers are normally fitted in between two stages to cool down the air temperature and to
increase the volumetric efficiency of compressor. Some compressor have inbuilt attached copper
tubes for cooling and some have outside assembly of copper tube inter-coolers

13) Driving Motor:

An Electrical motor is attached to the compressor for making it operational and is connected to
the compressor through the flywheel.

There are the main parts of a marine air compressor. The parts may vary according to the
requirement of the system or ship.