Product Guide

8. Compressed Air System

8.

Compressed Air System

Compressed air is used to start engines and to provide actuating energy for safety and control devices.
The use of starting air for other purposes is limited by the classification regulations.
To ensure the functionality of the components in the compressed air system, the compressed air has to
be free from solid particles and oil.

8.1

Instrument air quality

The quality of instrument air, from the ships instrument air system, for safety and control devices must fulfill
the following requirements.
Instrument air specification:

8.2

Design pressure

1 MPa (10 bar)

Nominal pressure

0.7 MPa (7 bar)

Dew point temperature

+3C

Max. oil content

1 mg/m3

Max. particle size

3 m

Internal compressed air system

All engines are started by means of compressed air with a nominal pressure of 3 MPa, the minimum recommended air pressure is 1.8 MPa. The start is performed by direct injection of air into the cylinders through
the starting air valves in the cylinder heads.
All engines have built-on non-return valves and flame arrestors. The engine can not be started when the
turning gear is engaged.
The master starting valve, built on the engine, can be operated both manually and electrically. In addition
to starting system, the compressed air system is also used for operating the following systems:

Electro-pneumatic overspeed trip device

Starting fuel limiter

Slow turning

Fuel actuator booster

Waste gate valve

Turbocharger cleaning

HT charge air cooler by-pass valve

Charge air shut-off valve (optional)

Fuel gas venting valve

Oil mist detector

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8. Compressed Air System
Figure 8.1 Internal compressed air system, in-line engines (3V69E8745-3i)

System components:
01

Starting air master valve

09

Valve for automatic draining

02

Pressure control valve

10

High pressure filter

04

Starting booster for speed governor

11

Air container

05

Flame arrester

12

Stop valve

06

Starting air valve in cylinder head

13

Blocking valve, when turning gear engaged

07

Starting air distributor

14

Oil mist detector

08

Pneumatic stop cylinder at each injection pump

Sensors and indicators:

CV153-1

Stop solenoid

CV321

Starting solenoid

CV153-2

Stop solenoid

CV331

Slow turning solenoid

PT301

Starting air inlet pressure

CV519

I/P converter for wastegate valve

PT311

Control air pressure

CV947

Gas venting solenoid

PT312

Low pressure control air pressure

NS700

Oil mist detector

Pipe connections

88

Size

Pressure class
PN40

Standard

301

Starting air inlet, 3 MPa

DN50

302

Control air inlet, 3 MPa

OD18

DIN 2353

303

Driving air inlet to oil mist detector, 0.2...1.2 MPa OD10

DIN 2353

311

Control air inlet, 0.8 MPa

DIN 2353

OD12

ISO 7005-1

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8. Compressed Air System
Figure 8.2 Internal compressed air system, V-engines (3V69E8746-3h)

System components:
01

Starting air master valve

09

Valve for automatic draining

02

Pressure control valve

10

High pressure filter

03

Slow turning valve

11

Air container

04

Starting booster for speed governor

12

Stop valve

05

Flame arrestor

13

Blocking valve, when turning gear engaged

06

Starting air valve in cylinder head

14

Oil mist detector

07

Starting air distributor

15

Charge air shut-off valve (optional)

08

Pneumatic cylinder at each injection pump

17

Drain valve

Sensors and indicators:

CV153-1

Stop solenoid

CV331

Slow turning solenoid

CV153-2

Stop solenoid

CV519

I/P converter for waste gate valve

PT301

Starting air inlet pressure

CV621

Charge air shut-off valve (optional)

PT311

Control air pressure

CV947

Gas venting solenoid

PT312

Low pressure control air pressure

NS700

Oil mist detector

CV321

Starting solenoid

PI

Manometer

Pipe connections

Size

Pressure class

Standard

301

Starting air inlet, 3 MPa

DN50

PN40

ISO 7005-1

302

Control air inlet, 3 MPa

OD18

DIN 2353

303

Driving air inlet to oil mist detector, 0.2...1.2 MPa OD10

DIN 2353

311

Control air inlet, 0.8 MPa

DIN 2353

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OD12

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8. Compressed Air System

8.3

External compressed air system

The design of the starting air system is partly determined by classification regulations. Most classification
societies require that the total capacity is divided into two equally sized starting air receivers and starting
air compressors. The requirements concerning multiple engine installations can be subject to special consideration by the classification society.
The starting air pipes should always be slightly inclined and equipped with manual or automatic draining
at the lowest points.
Instrument air to safety and control devices must be treated in an air dryer.
Figure 8.3 Example of external compressed air system (3V76H4173D)

System components

Pipe connections

3F02

Air filter (starting air inlet)

301

Starting air inlet, 3 MPa

3N02

Starting air compressor unit

302

Control air inlet, 3 MPa

3T01

Starting air receiver

303

Driving air to oil mist detector, 0.8 MPa

311

Control air to bypass / wastegate valve, 0.8 MPa

314

Air supply to turbine and compressor cleaning unit (ABB TC)

8.3.1 Starting air compressor unit (3N02)

At least two starting air compressors must be installed. It is recommended that the compressors are capable
of filling the starting air vessel from minimum (1.8 MPa) to maximum pressure in 15...30 minutes. For exact
determination of the minimum capacity, the rules of the classification societies must be followed.

8.3.2 Oil and water separator (3S01)

An oil and water separator should always be installed in the pipe between the compressor and the air vessel.
Depending on the operation conditions of the installation, an oil and water separator may be needed in the
pipe between the air vessel and the engine.

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8. Compressed Air System

8.3.3 Starting air vessel (3T01)

The starting air vessels should be dimensioned for a nominal pressure of 3 MPa.
The number and the capacity of the air vessels for propulsion engines depend on the requirements of the
classification societies and the type of installation.
It is recommended to use a minimum air pressure of 1.8 MPa, when calculating the required volume of the
vessels.
The starting air vessels are to be equipped with at least a manual valve for condensate drain. If the air
vessels are mounted horizontally, there must be an inclination of 3...5 towards the drain valve to ensure
efficient draining.
Figure 8.4 Starting air vessel

1)

Size
[Litres]

L1

Dimensions [mm]
L2 1)

L3 1)

Weight
[kg]

500

3204

243

133

480

450

1000

3560

255

133

650

810

1250

2930

255

133

800

980

1500

3460

255

133

800

1150

1750

4000

255

133

800

1310

2000

4610

255

133

800

1490

Dimensions are approximate.

The starting air consumption stated in technical data is for a successful start. During a remote start the
main starting valve is kept open until the engine starts, or until the max. time for the starting attempt has
elapsed. A failed remote start can consume two times the air volume stated in technical data. If the ship
has a class notation for unattended machinery spaces, then the starts are to be demonstrated as remote
starts, usually so that only the last starting attempt is successful.
The required total starting air vessel volume can be calculated using the formula:

where:
VR = total starting air vessel volume [m3]
pE = normal barometric pressure (NTP condition) = 0.1 MPa
VE = air consumption per start [Nm3] See Technical data
n = required number of starts according to the classification society
pRmax = maximum starting air pressure = 3 MPa
pRmin = minimum starting air pressure = 1.8 MPa

NOTE!

The total vessel volume shall be divided into at least two equally sized starting air vessels.

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8.3.4 Starting air filter (3F02)

Condense formation after the water separator (between starting air compressor and starting air vessels)
create and loosen abrasive rust from the piping, fittings and receivers. Therefore it is recommended to install
a filter before the starting air inlet on the engine to prevent particles to enter the starting air equipment.
An Y-type strainer can be used with a stainless steel screen and mesh size 400 m. The pressure drop
should not exceed 20 kPa (0.2 bar) for the engine specific starting air consumption under a time span of 4
seconds.

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