Aux Mach 1 Air Compressor

AUX MACH 1
AIR COMPRESSORS
AUXILIARY MACHINERIES
AIR COMPRESSOR
 An air compressor is a device that converts
power (using an electric motor, diesel or
gasoline engine, etc.) into potential
energy stored in pressurized air
(i.e., compressed air). By one of several
methods, an air compressor forces more and
more air into a storage tank, increasing the
pressure. When tank pressure reaches its
engineered upper limit, the air compressor shuts
off. The compressed air, then, is held in the tank
until called into use.
AIR COMPRESSOR
 A compressor is a mechanical device that
increases the pressure of a gas by reducing
its volume. An air compressor is a specific type of
gas compressor.
 Compressors are similar to pumps: both increase
the pressure on a fluid and both can transport the
fluid through a pipe. As gases are compressible, the
compressor also reduces the volume of a gas.
Liquids are relatively incompressible; while some
can be compressed, the main action of a pump is to
pressurize and transport liquids.
AIR COMPRESSOR
 The energy contained in the compressed air can
be used for a variety of applications, utilizing the
kinetic energy of the air as it is released and the
tank depressurizes. When tank pressure reaches
its lower limit, the air compressor turns on again
and re-pressurizes the tank. An air compressor
must be differentiated from a pump because it
works for any gas/air, while pumps work on a
liquid.
THE BASICS OF AIR

COMPRESSOR ON A SHIP
 Compressor is one such device which is used
for several purposes on a ship. As the main
aim of the compressor, as the name
suggests, is to compress air or any fluid in
order to reduce its volume. Some of the main
applications of compressors are main air
compressor, deck air compressor, AC
compressor and refrigeration compressor.
THE BASICS OF AIR

 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.
THE BASICS OF AIR

Three Basic Types of Air Compressors
 Reciprocating
 Rotary screw
 Rotary centrifugal
THE BASICS OF AIR

These types are further specified by:
 Number of compression stages
cooling method (air, water, oil)

drive method (motor, engine, steam, other)
lubrication (oil, Oil-Free where Oil Free means
no lubricating oil contacts the compressed air)
packaged or custom-built
THE BASICS OF AIR
Reciprocating Air Compressors
 are positive displacement machines,
meaning that they increase the pressure
of the air by reducing its volume. This
means they are taking in successive
volumes of air which is confined within a
closed space and elevating this air to a
higher pressure. The reciprocating air
compressor accomplishes this by a piston
within a cylinder as the compressing and
displacing element.
 The reciprocating air compressor is single
acting when the compressing is accomplished
using only one side of the piston.
 A compressor using both sides of the piston is
considered double acting.
 Load reduction is achieved by unloading individual
cylinders. Typically this is accomplished by throttling
the suction pressure to the cylinder or bypassing air
either within or outside the compressor. Capacity
control is achieved by varying speed in engine-
driven units through fuel flow control.
TYPES ACCORDING TO STAGES:
 Single-stage compressors are generally used for

pressures in the range of 70 psig to 100 psig.
 Two-stage compressors are generally used for

higher pressures in the range of 100 psig to 250
psig.
ROTARY SCREW COMPRESSORS
- are positive displacement compressors. The
most common rotary air compressor is the single
stage helical or spiral lobe oil flooded screw air
compressor. These compressors consist of two
rotors within a casing where the rotors compress
the air internally. There are no valves. These
units are basically oil cooled (with air cooled or
water cooled oil coolers) where the oil seals the
internal clearances
Since the cooling takes place right inside the

compressor, the working parts never experience
extreme operating temperatures. The rotary
compressor, therefore, is a continuous duty, air
cooled or water cooled compressor package.
Rotary screw air compressors are easy to maintain
and operate. Capacity control for these compressors
is accomplished by variable speed and variable
compressor displacement. For the latter control
technique, a slide valve is positioned in the casing.
As the compressor capacity is reduced, the slide
valve opens, bypassing a portion of the compressed
air back to the suction. Advantages of the rotary
screw compressor include smooth, pulse-free air
output in a compact size with high output volume
over a long life.
CENTRIFUGAL COMPRESSORS
The centrifugal air compressor is

a dynamic compressor which depends on
transfer of energy from a rotating impeller to
the air.
Centrifugal compressors produce high-
pressure discharge by converting angular
momentum imparted by the rotating
impeller (dynamic displacement).
In order to do this efficiently, centrifugal
compressors rotate at higher speeds than the
other types of compressors. These types of
compressors are also designed for higher
capacity because flow through the compressor is
continuous.
Adjusting the inlet guide vanes is the most
common method to control capacity of a
centrifugal compressor. By closing the guide
vanes, volumetric flows and capacity are
reduced.
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.
The oil free rotary screw air compressor utilizes

specially designed air ends to compress air
without oil in the compression chamber yielding
true oil free air. Oil free rotary screw air
compressors are available air cooled and water
cooled and provide the same flexibility as oil
flooded rotaries when oil free air is required.
MAIN PARTS OF A MARINE AIR

COMPRESSOR USED IN SHIP
1. CYLINDER LINER
2. PISTON
3. PISTON ROD
4. CONNECTING ROD
5. BIG END BEARING AND MAIN BEARING
6. CRANKSHAFT
7. FRAME AND CRANKCASE

COMPRESSOR USED IN SHIP
8. OIL PUMP
9. WATER PUMP
10. SUCTION AND DISCHARGE VALVE
11. SUCTION FILTER
12. INTER-COOLER
13. DRIVING MOTOR
THE MAIN PARTS OF A MARINE AIR

COMPRESSOR (CONT…)
 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 are 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.

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.

COMPRESSOR
 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.
TYPES OF AIR COMPRESSOR
 There are mainly four types of
compressors:
1. Centrifugal compressor
2. Rotary vane compressor
3. Rotary screw compressor
4. Reciprocating air compressor
*However, on ship reciprocating air
compressor is widely used.
USES OF AIR COMPRESSOR
ON SHIPS
On board a ship, compressed air is used for several
purposes. On the basis of application, different air
compressors are kept for a particular usage. Normally,
air compressors on board ships are:
 Main air compressor

 Topping up compressor
 Deck air compressor
 Emergency air compressor
ON SHIPS
 MAIN AIR COMPRESSOR - is used for
supplying high pressurized air for starting of
main and auxiliary engines. The pressurized
air generated by the air compressor is stored
in air storage bottle. These are high capacity
compressors and the air pressure that is
required from these compressors to start the
main engine is 30 bars.
ON SHIPS (CONT…)
 Control air is also supplied from air bottle
through a pressure reducing valve and a control
air filter. Normally they are twice in number and
can be more than that for redundancy.
 TOPPING UP COMPRESSOR- takes up the
lead to cover up for the leakage in the system.
This means that as soon as the air pressure in
the system goes below a particular level, the
topping up compressor replenished the system
with pressurized air.
ON SHIPS
 DECK AIR COMPRESSOR - is used for
deck use and as service air compressor
and might have a separate service air
bottle for the same. These are lower
capacity pressure compressors as
pressure required for service air is in
between the range of 6 to 8 bar.
ON SHIPS (CONT…)
 EMERGENCY AIR COMPRESSOR - is
used for starting auxiliary engine at the
time of an emergency or when the main
air compressor has failed for filling up the
main air receiver. This type of compressor
can be motor driven or engine driven. If
motor driven, it should be supplied from
emergency source of power.
CLASSIFICATION OF AIR
COMPRESSOR ON SHIPS
 Compressors can be classified according to
the pressure delivered:
 Low-pressure air compressors (LPACs), which
have a discharge pressure of 150 psi or less
 Medium-pressure compressors which have a
discharge pressure of 151 psi to 1,000 psi
 High-pressure air compressors (HPACs), which
have a discharge pressure above 1,000
CLASSIFICATION ACCORDING TO THE
DESIGN & PRICIPLE OF OPERATION
 Single-Stage Reciprocating Compressor

 Two-Stage Reciprocating Compressor
 Compound Compressor
 Rotary-screw compressor
 Rotary Vane Compressor
 Scroll Compressor
 Turbo compressor
 Centrifugal compressor
Difference Between a Single-Stage
Reciprocating Compressor and Two Stage
Compressor
 The main difference between single and two

stage compressors is the number of times that
air gets compressed between the inlet valve and
the tool nozzle.
 In a single stage compressor, the air is
compressed one time.
 In a two stage compressor, the air is
compressed twice for double the pressure.
Compressor
 The air compressor will be often be

confused by the number of cylinders for
the number of stages, when in fact both
single and two stage compressors use two
cylinders.
 In a single stage compressor both
cylinders are the same size.
Compressor
In the two stage compressors, the second

piston is shorter than the first, and the
two are linked by cooling tube, which
brings the temperature of the air down
before the second round of compression.
Produce higher air power which makes the
the better option for large scale operations
Single-Stage Reciprocating
Compressor
 The compressed air is moved onward to a

storage tank.
 In the storage tank, the compressed air
serves as energy for the assortment of
tools that a single stage compressor is
built to accommodate.
Single-Stage Reciprocating
Compressor
 Single stage compressors are also known

as piston compressors. The process that
takes place within a single stage
compressor goes as follows:
 Air is sucked into a cylinder
 The trapped air is compressed in a single
stroke with a piston at roughly 120 psi.
Two-Stage Reciprocating Compressor
The process within a two stage compressor

– alternatively referred to as dual stage
compressor – is similar to that of a single
stage, but with one variation: the
compressed air isn’t sent to storage tank.
It is instead sent to a smaller piston for a
second stroke, this time at roughly 175
psi. From there, the double-pressurized air
is cooled and delivered to a storage tank,
Two-Stage Reciprocating Compressor
Where it serves as energy for vast arsenals

of high-powered equipment.
Both single and two stage compressors use
two cylinders, because it is easier to
balance air that way.
 Fig: Two stage air compressor
 Two stage air compressor
The first-stage cylinder head is located on the
cylinder block and the second-stage cylinder head is
mounted on the first: each of the heads carries its
suction and delivery valves. A chain-driven rotary-
gear pump provides lubricating oil to the main
bearings and through internally drilled passages in
the crankshaft to both connecting rod bearings.
Cooling water is supplied either from an integral
pump or the machinery space system. The water
passes into the cylinder block which contains both
stage coolers and then into the first and second
stage cylinder heads.
A water jacket safety valve prevents a build-up

of pressure should a cooler tube burst and
compressed air escape. Relief valves are fitted
to the first and second-stage air outlets and are
designed to lift at 10% excess pressure. A
fusible plug is fitted after the second-stage
cooler to limit delivered air temperature and thus
protect the compressed-air reservoirs and
pipework.
Cooler drain valves are fitted to compressors.

When these are open the machine is 'unloaded'
and does not produce compressed air. A
compressor when started must always be in the
unloaded condition. This reduces the starting
torque for the machine and clears out any
accumulated moisture in the system. This
moisture can affect lubrication and may produce
oil/water emulsions which line the air pipelines
and could lead to fires or explosions.
The compressor motor is started and the machine
run up to speed. The lubricating oil pressure should
be observed to build up to the correct value. The
first-stage drains and then the second-stage drains
are closed and the machine will begin to operate.
The pressure gauge cocks should be adjusted to
give a steady reading. Where manual drains are
fitted they should be slightly opened to discharge
any moisture which may collect in the coolers. The
cooling water supply should be checked, and also
operating temperatures, after a period of running
loaded.
To stop the compressor, the first and second-

stage cooler drain valves should be opened and
the machine run unloaded for two to three
minutes. This unloaded running will clear the
coolers of condensate. The compressor can now
be stopped and the drains should be left open.
The cooling water should be isolated if the
machine is to be stopped for a long period.
Automatic compressor operation is quite usual and
involves certain additional equipment. An unloader must
be fitted to ensure the machine starts unloaded, and
once running at speed will load' and begin to produce
compressed air. Various methods of unloading can be
used but marine designs favour either depressors which
hold the suction valve plates on their seats or a bypass
which discharges to suction. Automatic drains must also
be fitted to ensure the removal of moisture from the
stage coolers. A non-return valve is usually fitted as
close as possible to the discharge valve on a
compressor to prevent return air flow: it is an essential
fitting where unloaders are used.
Control or instrument air supplies have particular

requirements with regard to being moisture and
oil free and without impurities. A special type of
oil-free compressor may be used to supply
control air or it may be treated after delivery from
an ordinary air compressor. This treatment
results in the air being filtered and dried in order
to remove virtually all traces of oil, moisture and
any atmospheric impurities.
Fig:Air compressor automatic valve

Air compressor arrangement - working
principles and operational guideline
Air compressor – Usually two-stage, two-crank
machine used aboard ship to supply
compressed air. 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 compressor – Usually two-stage, two-crank
machine used aboard ship to supply
compressed air. 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.
AIR COMPRESSOR COOLING
 Due to adiabatic heating, air compressors require
some method of disposing of waste heat. Generally
this is some form of air- or water-cooling, although
some (particularly rotary type) compressors may be
cooled by oil (that is then in turn air- or water-
cooled). The atmospheric changes are also
considered during cooling of compressors. The type
of cooling is determined by considering the factors
such as inlet temperature, ambient temperature,
power of the compressor and area of application.
There is no single type of compressor that could be
used for any application.
 APPLICATIONS
 Most air compressors either are reciprocating piston
type, rotary vane or rotary screw. Centrifugal
compressors are common in very large applications,
while rotary screw, scroll, and reciprocating air
compressors are favored for smaller, portable
applications.
 There are two main types of air-compressor pumps:
oil-injected and oil-less. The oil-less system has
more technical development, but is more expensive,
louder and lasts for less time than oil-lubed pumps.
The oil-less system also delivers air of better quality.
 APPLICATIONS
The power of a compressor is measured in HP
(horsepower) and CFM (cubic feet per minute of
intake air). The gallon size of the tank specifies the
volume of compressed air (in reserve) available.
Gas/diesel powered compressors are widely used in
remote areas with problematic access to electricity.
They are noisy and require ventilation for exhaust
gases. Electric powered compressors are widely
used in production, workshops and garages with
permanent access to electricity.
 APPLICATIONS
 Displacement type
There are numerous methods of air

compression, divided into either positive-
displacement or roto-dynamic types.
Positive displacement
 Positive-displacement compressors work by
forcing air in a chamber whose volume is decreased
to compress the air. Once the maximum pressure is
reached, a port or valve opens and air is discharged
into the outlet system from the compression
chamber. Common types of positive displacement
compressors are and air is discharged into the
outlet system from the compression chamber
Technical Illustration of a two-stage air

compressor
its up stroke, the charge of air is forced out and
into a storage tank. Piston compressors
generally fall into two basic categories, single-
stage and two-stage. Single stage compressors
usually fall into the fractional through
5 horsepower range. Two-stage compressors
normally fall into the 5 through 30 horsepower
range.
 AIR COMPRESSOR
compressor
Two-stage compressors provide greater
efficiency than their single-stage counterparts.
For this reason, these compressors are the most
common units within the small business
community. The capacities for both single-stage
and two-stage compressors is generally provided
in horsepower (HP), Standard Cubic feet per
Minute (SCFM)*
 AIR COMPRESSOR
compressor
To a lesser extent, some compressors are rated
in Actual Cubic Feet per Minute (ACFM). Still
others are rated in Cubic Feet per Minute(CFM).
Using CFM to rate a compressor is incorrect
because it represents a flow rate that is
independent of a pressure reference. i.e. 20
CFM at 60 PSI.
 AIR COMPRESSOR
 AIR COMPRESSOR
 AIR COMPRESSOR
Technical Illustration of a portable single-stage air compressor
 AIR COMPRESSOR
compressor
Technical Illustration of a portable single-stage air compressor
 AIR COMPRESSOR

Aux Mach 1 Air Compressor

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AUX MACH 1

THE BASICS OF AIR

THE BASICS OF AIR

 Air Compressor produces pressurized air by

THE BASICS OF AIR

Three Basic Types of Air Compressors

THE BASICS OF AIR

cooling method (air, water, oil)

TYPES ACCORDING TO STAGES:

 Single-stage compressors are generally used for

 Two-stage compressors are generally used for

ROTARY SCREW COMPRESSORS

Since the cooling takes place right inside the

The centrifugal air compressor is

The centrifugal air compressor is an oil free

The oil free rotary screw air compressor utilizes

MAIN PARTS OF A MARINE AIR

MAIN PARTS OF A MARINE AIR

THE MAIN PARTS OF A MARINE AIR

It is made of graded cast iron and is

THE MAIN PARTS OF A MARINE AIR

For a non-lubricating type compressor, light

THE MAIN PARTS OF A MARINE AIR

In high capacity compressor which is normally

THE MAIN PARTS OF A MARINE AIR

Connecting rod plays its role to minimize thrust

THE MAIN PARTS OF A MARINE AIR

 5) Big end bearing and Main bearing:

They are constructed to give rigidity to the

THE MAIN PARTS OF A MARINE AIR

THE MAIN PARTS OF A MARINE AIR

 7) Frame and crankcase:

Normally they have rectangular shape and

THE MAIN PARTS OF A MARINE AIR

THE MAIN PARTS OF A MARINE AIR

Some compressor may have attached water

MAIN PARTS OF A MARINE AIR

 10) Suction and Discharge valve:

These are multi-plate valves made up of

MAIN PARTS OF A MARINE AIR

 11) Suction Filter:

It is a air filter made up of copper or soft steel

Inter-coolers are normally fitted in between

THE MAIN PARTS OF A MARINE AIR

 13) Driving Motor:

 Main air compressor

 Single-Stage Reciprocating Compressor

 The main difference between single and two

 The air compressor will be often be

In the two stage compressors, the second

 The compressed air is moved onward to a

 Single stage compressors are also known

The process within a two stage compressor

Where it serves as energy for vast arsenals

A water jacket safety valve prevents a build-up

Cooler drain valves are fitted to compressors.

To stop the compressor, the first and second-

Control or instrument air supplies have particular

Fig:Air compressor automatic valve