Air Compressors: Graph of Pressure Against Volume in A Reciprocating Compressor
Air Compressors: Graph of Pressure Against Volume in A Reciprocating Compressor
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Air Compressors
1. The compression ratio at each stage is lower and so the final temperature is lower.
This reduces problems with lubrication
2. . The machine is smaller and better balanced
3. water can be drained off at each stage
4. Compression better approaches the ideal isothermal
Crankcase lubrication
Lubrication of the crankcase in a compressor does not pose any specific
problems and normally consist of splash lubrication with pressurised oil being
fed to shell bearings. Where drip cylinder lubrication is used, this should be
kept to a minimum conducive with liner wear. A standard mineral oil similar to
that used in the main engine may be used, although due to carbon deposits,
higher quality oils are generally used with the most effective being specifically
designed synthetics which have allow a considerable reduction in maintenance
but are costly.
Temperature can become very high, this may result in oily deposits
at the discharge valves carbonising. Eventually this carbon could glow red and
cause detonation. It is more likely, however, that oily deposits will be carried
over to the air receiver and air start manifold to be ignited by blowpast at the
cylinder air start valve.
The sliding vane compressor consists of a slotted rotor with its axis
offset from that of the cylindrical casing. Vanes fit in the slots and have contact
with the casing
On the suction side the space contained between the casing, the
rotor and an adjacent pair of vanes is gradually increasing allowing air to be
drawn in.
Rotary/reciprocating Compressor
Rotary compressors in general do not require internal lubrication but they are
not suitable alone for providing air at a pressure for starting duties. They can,
however, be linked to reciprocating stages to produce a hybrid compressor.
The compressor is lighter, more compact and better balanced than
an equivalent all reciprocating unit. In basic terms the rotary first stage
supplies air to the reciprocating second and subsequent stages. All stages
being driven by the same shaft
Safety Valve
Materials
Cast iron-Casing, Liners, Pistons( the LP piston is sometimes made from an
aluminium alloy, Cylinder covers Steel- Crankshaft, Conrods, Pistons, Valve
seats Vanadium Steel- Valve plates
It would appear that most of the work is being carried out in the
final stage, this is untrue as with the increase in pressure is a complimentary
reduction in volume, if the temperature conditions remain the same then work
will be equally divided between the stages.
and
(P1/P2).(T2/T1) = (V2/V1)
P1.V1g = P2.V2g
and
Coolers
Plain Tube-
-easy to clean
-very effective due to large surface area of large number small
diameter tubes
-plugging of failed tube allos cooler to continue in service with little
loss in efficiency
-must allow for thermal expansion by having one tube plate floating
'U' tube-
-suitable for higher pressures than plain tube
-self compensating for thermal expansion
-efficent due to large nomber small diameter tubes
-failed tubes may be plugged
-more expensive than plain tube and diificult to clean
Coil tube
-self compensating for expansion
-suitable for high pressures
-difficult to clean
-inefficicent due to large tube diameter
- not easy to plug
-expensive
Air Start Systems
Regulations
1. There must be at least two starting air receivers, the total capacity of which will
give 12 starts for a reversing engine or 6 starts fo a non-reversing engine with
CPP.
2. There must be at least two compressors
3. In addition to these there must be a compressor which can be started by hand i.e.
with a dead ship. Note: this is not necessary if one of the compressors is run off
the emergency switchboard
4.
i. A relief valve must be fitted to the HP discharge and be sufficient size to
ensure that the pressure rise does not exceed 10% of the w.p. when the
compressor is running and the outlet valves on the bottle are shut.
ii. A relief valve or bursting disc on the hp cooler casing in order to protect the
casing from overpressure in the event of cooler tube failure Note: Bursting
discs are generally preferred because they fail and stay failed giving
complete protection. A relief valve will reseat when the compressor is
stopped allowing water to enter the air side.
iii. A drain must be fitted at each stage
Air Receivers
There must be a means of access to allow cleaning and inspection of internals.
The internal surface should be protected by a coating which is flexible enough
to move when the metal distorts. Copal varnish is generally used because it
has these properties and willnot easily oxidise. Usually precautions are taken
the same as for an enclosed space when entering. Ventilation is required to the
solvent fumes in the varnish
Safety devices
The automatic valve (Main air start block valve) prevents connection between
the air receiver and air start manifold unless actually in the process of starting.
Loss
of air can be kept to a minimum by rotating moveable outer hood to blank off
relief ports. The failed cap should be replaced as soon as possible.
An oil film may build up on the start air pipe due to oil dscharge
from the compressor. This oil may come from general lubrication or sticky
scraper ring or from the engine room air,
With a continuous leaking valve hot gasses with unburnt fuel will
enter the pipe and turn the oil film into a hot incandescent carbon. When high
pressure air is put on the pipe line an explosion can occur with resultant high
speed high pressure shock wave.
Two or more air compressors are to be fitted having a total capacity, together
with a topping-up compressor where fitted, capable of charging the air
receivers within 1 hour from atmospheric pressure, to the pressure sufficient
for the number of starts require At least one of the air compressors is to be
independent of the main propulsion unit and the capacity of the main air
compressors is to be approximately equally divided between them. The
capacity of an emergency compressor which may be installed to satisfy the
requirements of first start is to be ignored.
Safety Valves
Where the main engine is arranged for air starting the total air receiver
capacity is to be sufficient to provide without replenishment, not less than 12
consecutive starts of the main engine, alternating between ahead and astern if
of the reversible type and not less than six consecutive starts if of the non-
reversible type. At least two air receivers of approximately equal capacity are
to be provided. For scantlings and fittings of air receivers