However, compressor is a peculiar equipment which tends to get some or the other problem while working.

In
this article, we will go through each and every problem that can arise in an air compressor and also enumerate
ways to troubleshoot that problem.
This is the ultimate guide for troubleshooting air compressors on a ship
1)Lube Oil Pressure Low
The following can be the reasons for lube oil pressure low in the air compressor:

Faulty pressure gauge.

Cock to pressure gauge in closed position.

Low oil level in the sump.

Leakage in supply pipe.

Suction filter is choked.

Oil grade in the crank case is not compatible.

Attached Lube oil gear pump is faulty.

Worn out Bearing, clearance is more.

2) Abnormal noise during operation

If you get any abnormal noise during operation, the following can be the reasons:

Loose foundation bolts.

Worn out bearings, clearance is high.

Imbalance crankshaft resulting in high-end play.

Valve plate broken or faulty.

Relief valve lifting below setting pressure.

Bumping clearance is less.

Piston worn-out, broken piston ring.

3)Vibration in the machinery:

In case of vibrations, the following reasons are to be considered and checked.

Foundation bolts are loose.

Discharge pressure high, faulty discharge valve plates.

Liner and piston worn out.

Small bumping clearance.

4)Cooling water temperature is high

Cooling water temperature can go high because of the following reasons:

Inlet or outlet valve for cooling water is closed.

Inter-cooler is chocked.

Cooling water in the expansion tank is low.

Pipe passage becomes narrow due to scale formation.

Water-pump belt or gear drive broken.

Pump not working.

5)First stage discharge pressure high

In case the first stage discharge pressure is high, it must be because of :

Pressure gauge is faulty.

Inter-cooler air passage is chocked.

Second stage suction valve is not closing properly, allowing air to escape from 2 nd to 1st stage.

Discharge valve of first stage is malfunctioning, and remains in closed position.

Spring of discharge valve is malfunctioning.

6) First stage discharge pressure low

In case the first stage discharge pressure is low, it must be because of :

Pressure gauge is faulty.

Suction filter is choked.

Unloader of first stage is leaking.

First stage suction valve is not closing properly, resulting in compressed air leakage.

First stage suction valve is not opening fully, leading to less intake of air.

Discharge valve is faulty and remains open permanently.

Relief valve after first stage is leaking.

Piston ring of first stage is badly worn out, allowing air to pass.

7)Second stage discharge pressure high:

In case of high discharge pressure in the second stage, the reasons can be:

Faulty pressure gauge.

Discharge valve to air bottle is shut.

Second stage discharge valve plate worn out, and even the spring worn out.

Valve is stuck in closed position.

After cooler air passage choked.

Air bottle is over pressurized.

8 )Second stage discharge pressure low:

When second stage discharge pressure is low, it could be because of:

Pressure gauge is faulty.

Suction valve for second stage is malfunctioning, in open position.

Suction valve for second stage is not opening fully, and thus less intake of air.

Discharge valve is faulty and remains open during operation.

Piston rings of second stage are worn out, leaking out compressed air.

Relief valve of second stage is leaking.

Un-loader of second stage is leaking.

9)Relief valve of first stage lifting

If relief valve of the first stage is lifting, it can be because of

Spring of relief valve is malfunctioning, thus lifting at less pressure.

Discharge valve of first stage is not opening.

Intercooler air passage is blocked.

Suction valve of second stage is in stuck position.

Water inside the compression chamber due to crack in the jacket and water is leaking inside.

10)Relief valve of second stage is lifting

If relief valve of the second stage is lifting, look for the following reasons:

Relief valve is malfunctioning, lifting at lower then setting pressure.

Main discharge valve to the air bottle is closed.

Discharge valve plates and spring are worn out, valve in closed position.

Blockage in the after cooler air passage.

Water inside the compression chamber due to crack jacket.

The above mentioned points are just a brief explanation to the problems of the air compressor tackled on
board. However, they serve as a guiding light for finding the right fault in the compressor.

What defect during operation:

Effects of sluggish action of valves
At the end of the suction stroke, owing to weak springs or carbon deposits, if the suction valve does not
reset properly and promptly part of the air drawn into the cylinder will be returned through the defective
suction valve. This will reduce the Volumetric Efficiency. Also reduced air delivery and increased running
time. Then reduced air pressure in the suction to the next stage.
Similarly if the delivery valve resets slowly then a part of the air being compressed and delivered will
return back to the cylinder, there by reducing the volumetric efficiency. This effect will reduce delivery and
increase discharge temperature.
Valves leaking
Valves can leak and finally fail. Valves may fail owing to wear and fatigue, insufficient or over-lubrication
presence of foreign particles, oil decomposition and excess valve lift.
The following defect can be occur when operating the compresso r, are:

1. Air inlet strainer for compressor is choke

2. Compressor valve leaking or sticking
3. Sluggish opening and closing of valves (suction and delivery) due to wear spring or deposits
4. Too much Bumping clearance. The larger the bumping clearance caused by incorrect gasket
thickness of valve or cylinder covers and wear down of bearing. This may caused less air discharge
per stroke and reduced the volumetric efficiency
5. Leaky piston rings which are caused by poor maintenance and incorrect lubrication.
6. Leaky cover and gasket, leaky drain or safety valve or pressure gauge fitting
7. Leaking coolers (can be detective by opening water test cock on top, air will blow)
8. Faulty capacity controller
9. Insufficient of cylinder and inter cooler causing high operating temperature that made the cylinder
lubrication is insufficient.
10. High wear rate of piston ring and cylinder liner, fouling of valve and piston seizure to be expected
11. Abnormally high temperature of airs entering the L.P or 1 st stage cycle.
Defects in operation.
The following defects can be occurring when operating the compressor.
1. L.P compressor shows increases in pressure- delivery valve leaky or hung up
2. L.P compressor shows increase in pressure- H.P compressor valve leaky or piston rings leaky.
3. Air compressor pressure falls off. Causes are: (a) Air inlet strainer for compressor checked.
(b) Compressor valves leaking or sticking.
(c) Too much playing top end of L.P compressor cylinder.
(d) Leaky piston rings.
(e) Leaky cover.
(f) Leaky drain or safety valve or pressure gauge fittings.
(g) Leaky cooler (can be detected by opening water test cock on top, air will blow.
What is volumetric efficiency of an air compressor ?

It is the ratio of the actual volume of air drawn in each suction stroke to the stoke volume.

Volumetric efficiency = (Actual volume of air drawn in suction stroke) / (Stroke volume)

What are the factors affecting volumetric efficiency of an air compressor ?

1. The bumping clearance (the larger the bumping clearance the less air is discharged per stroke).

2. Sluggish opening and closing of suction and delivery valves.

3. Leakage past compressor piston rings.
4. L.P inlet air temperature too high.
5. L.P inlet filter dirty and choked.
6. Inlet cooling water temperature too high.
7. Insufficient cooling water owing to fouling of coolers.
What is the difference between inter cooler and after cooler ?
Intercooler
1. Fitted intermediate stages.
2. Saving in power.
3. Increase volumetric efficiency.
4. Reduce temperature for next stage and it can avoid a danger of explosion in compressor cylinder.
5. Can provide good lubrication of the compressor piston.
6. No carbonized material forming of discharge valve.
7. Moisture separation is easier through intercooler drain.
After cooler
1. Fitted at the final stage discharge side.
2. Reduce final discharge air temperature to room temperature.
3. Increase volumetric efficiency.
4. Air bottle size is smaller.
5. Moisture separation is easier through after cooler drain.
Why need bumping clearance in an air compressor ?

This is a clearance must be provided between the piston top and the cylinder head when
the piston is top dead centre.

It must be kept as small as possible for achieving the best compressor efficiency.

To prevent mechanical damage to the compressor.

To provide for thermal expansion

To provide necessary space for valve operation.

How to adjust the bumping clearance ?

It can be adjusted by two ways.

1. By altering the head gaskets (cover joint ) thickness.

2. By adding and subtracting shims between the connecting rod foot and bottom and bearing.
Main air compressor bumping clearance taking procedure ?
1. Stop the compressor and (lock off) take out fuse.
2. Drain the cooling water.
3. Remove the cylinder cover.
4. Clean the cylinder head face and piston crown.
5. Place the lead wire ball on the top face of the piston. That is larger size than expected
by clearance.
6. Cylinder cover is placed on the cylinder with correct joint thickness and tightens the head bolts.
7. Turn the compressor slowly by hand over top centre so that lead wire ball is pressed.
8. Then remove cylinder cover again.
9. Remove the compressed lead wire ball.
10. Take the measurement of lead wire thickness by using micrometer.
At what condition fusible plug is fitted main air bottle ?

Fusible plug is fitted at main air bottle, when relief valve is fitted indirectly to the air bottle.

It can cause any obstruction by human error.

What is the purpose of bursting disc? Where is it fitted ?

It is fitted on each cooler shell of air compressor, to give ample relief of pressure when
cooler tubes burst.

Why bursting disc need to be annealed ?

Due to heating and time expanded bursting disc is harden so to get back the normal
relief pressure. It must be annealed.

What is first start arrangement on ships ?

1. Firstly start the emergency air compressor to fill up the air to the emergency air bottle up
to desired pressure obtained.
2. Drain out oil and water.
3. Open emergency air bottle outlet valve and pressed up desired pressure.
4. Then start the generator with correct procedure.
5. Close the breaker and switch on the lighting.
6. Start the required machinery ( especially G/E FO booster pump, SW cooling pump, E/ R blower).
7. Start the main air compressor and press up to main air bottle.

8. After that, M/E warming by using generator jacket water and start the L.O pump.
Why provide air compressor on board ships ?

Starting Diesel engines

Instrumentation and control systems,

Various pneumatic tools and cleaning equipments,

Boiler soot blowing and

Ships whistle.

Why need minimum lubrication for air compressors ?

To prevent carbonizing of the valves

To avoid loss of compressor efficiency due to sluggish action of valve

To avoid loss of cooler efficiency due to deposition of oil on the cooling surface

To prevent air line explosion, to prevent air bottle corrosion

Leaky Valves in Air Compressors

Valves can leak and finally fail. Valves may fail owing to wear and fatigue, insufficient of overlubrication, presence of foreign particles, oil decomposition and excess valve lift.
What are the effects of air compressor valve leaking on ships ?
First stage suction valve leaking
1. Reduce air delivery
2. Reduce second stage suction pressure
3. Increase running time
4. Unload the compressor (Motor take less load)
First stage delivery valve leaking
1. Reduce delivery
2. Increase discharge temperature
3. Less air drawn in due to high pressure air leaking back into the cylinder
Second stage suction valve leaking
1. High pressure in suction line of 2nd stage
2. High temperature in suction line of 2nd stage
3. Reduce delivery
4. Increase running time

Second stage delivery valve leaking

1. Increase suction pressure in 2nd stage
2. Reduce delivery in 2nd stage
3. Increase delivery pressure from 1st stage
What are the causes of poor performance of air compressors ?
1. Choked air suction strainer
2. Leaky or sticky valves
3. Too much L.P bumping clearance
4. Leaky piston rings
5. Leaky cylinder head cover and gaskets
6. Leaky drains
7. Leaky relief valves
8. Leaky coolers
9. Worn crankpin bearings
10. Faulty capacity controller
How to maintain air compressor efficiency ?
1. Cleaning of suction air filter.
2. Adjusting bumping clearance.
3. Regular overhaul the suction and delivery valve and checking bearings.
4. Check the piston rings and liner.
5. Clear the cooler drain free from deposits.
6. Clean the cooler regularly.
How air bottle pressure test is carried out in ships ?
1. Gag the relief valve
2. Close all openings
3. Fit test pressure gauge
4. Remove filling valve and fill with fresh water completely
5. Air purge and connect hydraulic pump at filling line.
6. Apply pressure 1.5 times of working pressure and maintain at least 30 min
7. Check leaking points.

What is the purpose of drain valve in compressor and air bottle ?

It is process to remove the accumulation of oil water and sludge from the air bottle,
scavenge space, compressor intercooler and settle and service tank.

To drain the water and surplus oil in the air bottle.

To avoid air bottle corrosion

To prevent staring air line explosion and sluggish & corrosion in the system.

Safety devices are fitted in air compressor?

Relief valve:
Fitted after every stage to release excess pressure developed inside it. The setting of the lifting pressure
increases after every ascending stage. Normally fitted between 1st stage and intercooler and 2nd stage
aftercooler.
Bursting disc:

A bursting disc is a copper disc provided at the air cooler of the compressor. It is a safety disc which
bursts when the pressure exceeds over the pre-determined value due to leaky air tubes of the cooler
(intercooler or aftercooler).
Fusible plug:
Generally located on the discharge side of the compressor, it fuses if the air temperature is higher than
the operational temperature. The fusible plug is made up of material which melts at high temperature.
Lube Oil low pressure alarm and trip:
If the lube oil pressure goes lower than the normal, the alarm is sounded followed by a cut out trip signal
to avoid damage to bearings and crank shaft.
Water high temperature trip:
If the intercoolers are choked or the flow of water is less, then the air compressor will get over heated. To
avoid this situation high water temperature trip is activated which cut offs the compressor.
Water no-flow trip:
If the attached pump is not working or the flow of water inside the intercooler is not enough to cool the
compressor then moving part inside the compressor will get seized due to overheating. A no flow trip is
provided which continuously monitor the flow of water and trips the compressor when there is none.
Motor Overload trip:
If the current taken by motor during running or starting is very high then there is a possibility of damage to
the motor. An overload trip is thus fitted to avoid such situation.

What is emergency air compressor ?

It is a small compressor independently driven by a prime mover having power supply

from emergency switch board. They are also driven by diesel engines.

It must be fitted to press up the emergency air bottle and to start auxiliary engine of a
dead ship.

It has no connection between the main air bottle.

What are the safety devices in air compressors on ships ?

1. Bursting discs are fitted on the cooler shells (At water side).
2. Relief valves are fitted to discharge side for every stages.
3. Moisture drain valve (unloader) are fitted at each cooler side.

4. Cooling water failure alarm.

5. Low L. O pressure alarm and trip.
6. Delivery air high temperature alarm on after cooler outlet (Max 93 C)

What are the normal parameters of air compressor ?

LP discharge pressure: 4 bars

HP discharge pressure: 30 bars.

Intercooler inlet air temperature: 130 C

Intercooler outlet air temperature: 35 C

After cooler inlet air temperature: 130 C

After cooler outlet air temperature: 35 C

Type of intercooler and after cooler ?

Intercooler is single pass type

After cooler is double pass U-tube type

Purpose of unloder valve (moisture drain valve) in air compressor ?

At starting this valve must be opened, this reduced the starting torque for the machine
and clear out any accumulated moisture and oil in the system.

What would be effect of suction valves of an air compressor having too much
lift ?

The valve will be late in closing and this would reduce the volumetric efficiency of
the machine.

The valve experience greater force and therefore are more liable to break.

Effects of reduced volumetric efficiency of air compressor ?

1. Greater bumping clearance.
2. Sluggish opening and closing of suction and delivery valves.

3. Insufficient cooling water that effect of high air temperature.

4. Dirty or partially chocked suction air fitter.

Difference between relief valve, bursting disc and fusible plug ?

Pressure relief valve

Excess pressure is released by opening the valve.

It opens at 10% over working pressure.

Valve lift is proportional to excess pressure build up.

Valve setting pressure can be altered by spring tension.

Bursting disc

Pressure is released by bursting the disc.

It permanently damaged.

It burst at setting pressure.

Setting pressure cannot be altered in place.

Fusible plug

When the air temperature from compressor is high (above 105 C) pressure is released
by melting (fusing) the metal.

It cannot be used next time. ( permanent damage)

Release all content or pressure to empty.

Why multistage compressors are mostly used than single stage compressor ?
1. More stages are needed to increase the required final pressure.
2. Easier to control the air temperature.
3. Reducing in air compressor size.
4. Lubrication problem does not exit.

5. Reduced the thermal stress.

6. Lower work done to compressing air.
7. Improve compressor efficiency

Advantages of inter cooling of air compressor ?

To avoid excessive temperature rise associated with higher compression ratios, and
to approach isothermal compression.

Saving in power.

Volumetric efficiency is increased.

Reduced the volume of air delivered and also reduced the compressor size.

It can reduce the air temperature.

Due to less temperature suction & delivery valves remain cleaner without being fouled
with carbonized oil.

It can avoid a danger of an explosion takes place in compressor cylinder.

It allows good lubrication of the compressor piston.

Moisture separation is easier through inter cooler drains.

It also enables to deal with a greater weight of air for the same energy expended.

Why intercooler is fitted in main air compressor on ships ?

1. Reduced air temperature, volume and increased air density for next stage
2. So increased volumetric efficiency and compressor efficiency.
3. Due to reduced temperature give better lubrication for cylinder and piston rings
4. Drain are fitted from which water and excessive oil can be drained out, to prevent air
bottle corrosion and starting air explosion and fouling of inter coolers and pipe.
5. Save the work done.

Advantages of after cooler in air compressor ?

To reduce final discharge air temperature thus air bottle size can be reduced.

To reduce air volume after it has been compressed to the final pressure.

So greater amount of air could be stored in air bottle.

Increase volumetric efficiency

How to start the air compressor manually on ships ?

1. Change the switch to manual position on the switch board.
2. Check the L.O sump level and condition.
3. Open the moisture drain valve.
4. Open the compressor discharge valve & charging valve of air bottle.
5. Open cooling water system valves.
6. Turn the compressor flywheel by hand (one turn).
7. Start the motor, after draining the moisture shut the drain valve.
8. Check the motor ampere consumed.
9. Check the pressure gauge readings.
10. Frequently drain the moisture.
11. When charging full, open drain valve and stop the compressor

How do you check compressor efficiency during running ?

1. Checked by filling time with the previous record and also check the first stage discharge
pressure. If compressor efficiency is lower, compressor will run longer and compressor
temperature will rise.
2. First stage and second stage pressure gauge must be correct and stable.
3. No escape of air from suction filter.
4. Intercooler and after cooler outlet air temperature should not be high.
5. If open drain valve nothing can be found.

6. Low L.O consumption.

7. Oily air mixture must not blow out from breather pipe.

Safety devices on main air bottle ?

1. Pressure relief valve.
2. Fusible plug.(if safety valve is not directly fitted on the bottle)
3. Pressure gauge.
4. Low air pressure alarm.
5. Moisture drains valve.

Where is the fusible plug fitted and its purpose ?

Fusible plug is fitted under side of the pipe between relief valve and air bottle.

It is fitted to release the compressed air in the event of abnormally high compressed
air temperature.

Fusible plug melt at 105 C and release all content of air to outside of E/R.

It is made by 50% bismut, 30% tin, 20% lead.

A fusible plug is fitted after the second stage cooler to limit the delivered air temperature
and thus protect the compressed air reservoirs and pipe work.

Can you fit the relief valve at the space of bursting disc and why ?

At the compressor, relief valve can not be fitted at the bursting disc, because of their
difference operation.

Bursting disc is fitted for totally release and stop operation circuit.

Release valve opens excess pressure at compressor running and reset when
pressure reduce or when the compressor is stopped. Thus cooling water can enter to
compressed air space; it can cause water hammer when the next start of compressor.

Purpose of Air Bottle

The high pressure is used for initial starting of the marine I.C engines present onboard vessel.

It also supplies control air to the marine engines.

Service air is supplied from the air bottle.

If the quick closing valves are air operated, safety air is supplied through air bottle.

Spring air for exhaust valve is supplied through air bottle.

Apart from above mentioned ones, there are several other uses as well.

What are the Air Bottle Mountings and Connections?

The general mountings and connection present on air bottle of a ship are:

Filling valve: This is a valve fitted in the supply connection from main air compressor to the air
bottle.

Outlet to Main engine: An outlet valve and pipe is fitted for connection from air bottle to main
engine for supplying air during starting.

Outlet to auxiliary engine: An outlet valve and pipe is fitted for connection from air bottle to
auxiliary engines for supplying air during starting.

Auxiliary connection: Other auxiliary supplies connections such as service air, safety air etc. is
also provided with isolating valve.

Relief valve: A relief valve is fitted on the air bottle to relieve excess pressure inside the bottle.

Drain valve: A drain valve is fitted at the bottom of the bottle to drain accumulated condensate
from the receiver.

Fusible plug: A fusible plug is fitted in the bottle with a separate connection leading out of the
engine room so that in the event of fire, this plug will melt and relieve all the air to the outside
atmosphere.

Manhole door: A manhole door is fitted in the bottle to carry out inspection of the same

Give a reason by conformity to each of the following is considered good practice in

air compressor.
(a) The minimum of oil lubrication in cylinder
(b) Absolute cleanliness if intake air filter
(c) The finest safe clearance of top end , bottom end and main bearing
(d) Designed clearance volume

The minimum of oil lubrication in cylinder

The object of cylinder lubrication is to provide an oil film between cylinder
and the piston rings, to furnish an effective seal , there by reducing wear of these
parts and preventing leakage of air.
If the cylinders are getting to much oil , it is harmful in the system and may
cause carbonizing on the valves , loss of compression efficiency due to sluggish
action of the valves and loss of cooler efficiency due to deposition of oil on the
cooling surfaces.
SO air compressor are necessary to have minimum of absolute lubrication in
cylinder.

Absolute cleanliness of intake air filter

If the filter can not filtrate properly , foreign abrasive particles contain in E.R
air may enter with intake air and leading to damage valve operation. This may
effect high discharge temperature and formation of carbon deposition. These may
become extremely hot on valves , which are not properly closed and lead to
compressor explosion.
If any dirt and grease are allowed to accumulate and partly choke the filter ,
the air intake will be restricted and volumetric efficiency will decrease. Therefore
less air will be discharged with high temperature , resulting overheat the valves and
may cause fire and explosion.
The air compressors suction filter should always clean . For the cleaning
maintenance, air filter should be dismantled and wash thoroughly with paraffin oil
and dried. Then dip in high quality L.O and hang for a while before to be fitted back.

Finest & safe bearing clearance

Compressors main bearing , top end bearing and crank pin bearing
clearances must be very finest and safe for the operation.
Excess clearance of bearings may increase clearance volume , mainly
reduced volumetric efficiency , fall compressor performance. Excess clearance of
bearings may cause over loading on corresponding bearing at every upward stroke.
Striking of bearing and tend to bearing failure. L.O pressure will decrease and
insufficient to reach required parts. So ,the finest clearance must be adjusted on top
end , bottom end and main bearing.
Gudgeon pin and piston grooves , piston rings will failure due to top end bearing
excess clearance

Bottom end bearing & connecting rod failure , fracture of connecting bolts are due
to bottom end bearing excess clearance
Main bearing and crankshaft will failure due to main bearing excess clearance .

Designed clearance volume

The clearance provided between the piston top and the cylinder head when the
piston at T.D.C position, is called bumping clearance and the volume of this
clearance is called designed clearance volume . It is normally 6 % of swept
volume , provided for thermal expansion and necessary space for valve operation ,
to prevent mechanical damage to compressor.
Clearance volume must be kept as small as possible for achieving the best
compressor efficiency. Excessive bumping clearance give a large clearance volume
and decrease volumetric efficiency. So , high pressure air remain in the cylinder at
the end of compression and delivery strokes. This pressure disturb to next suction
stroke and fresh air charge. It may increase the inlet air temperature and reduce
compressor efficiency. Therefore , designed clearance volume is required to keep as
minimum as possible.
With reference to the operation of air compressor, discuss: (a) Effect of ambient temperature
(b) Adverse effect of atmospheric humidity
(c) Lubrication and entrained oil in discharge
(d) Scale deposit in cooler and jacket
(e) Effect of valve leakage
(f) Precaution to be taken before starting
(g) Possible causes of explosion in starting air line

Effects of ambient temperature

In a compressor , during compression , applied energy is converted into heat
energy . Therefore any consequence to rising the air temperature may reduce the
volumetric efficiency. If the higher ambient temperature of air drawn into the
cylinder, the greater volume of air will be occupied and the lesser weight of air will
be discharged .
So , ambient temperature for compressor intake should be as low as possible.
If the inlet temperature is decreased by 5 F , 1% of air discharge weight will
increase. Because , the density of air is inversely proportional to its absolute
temperature.
By using of inter cooler and after cooler , the ambient temperature is reduced
and efficiency of air compressor is increased . And better lubrication is also
achieved.

Compressor should be installed away from high ambient temperature area ,

such as , Boiler room , Exhaust manifold and blower air ducts must be closed to
compressor suction.

Effect of atmospheric humidity

If air drawn into the compressor is more humid , it will contain more moisture in
suspension. The amount depend on the density and they will deposit as condensate
water when air is compressed and passed through cooler.
Unless the condensate is drained off and allowed to pass the various stages , they
wash the cylinder lubrication oil film , cause wear and tear effect to liner and piston
rings.
Corrosion on valve plates and springs due to water vapor may cause also.
Moisture lying on the air passage may effect to corrosion and water hammer.
This moisture effect may also form oil emulsion and settle on cooler surface , effect
the heat transfer coefficient and reduce the cooler efficiency . So , the air to the
next stage will be higher temperature and the efficiency of the whole machinery will
decrease.
Frequent drain of moisture and oily mixture from cooler outlet stages while running
compressor must be done to prevent adverse effect of humid air. In air bottle also ,
drain valve is fitted for safety , to drain out moisture and oily mixture regularly , to
prevent the basic problem of air line explosion.

Lubrication and entrained oil in discharge

Lubrication is needful to get smooth running parts , to carry away heat , to
reduce wear and tare , and failure of cylinder, piston rings and seizure case.
Insufficient lubrication may cause these effects.
Using of unsuitable lubricating oil may cause the above wear & tare effects
due to improper lubrication .Besides , cooler efficiency may loss because oil will
vapourise and carry over with compressed air to cooler and condensed on the
surfaces..If lubrication is excessive , it is harmful to the compressor parts.
Carbonizing on the valve plate and spring , sluggish suction and discharge valves
may cause. Excessive oil also may become emulsify with water vapour from the air ,
resulting the loss of L.O quality. Also excess oil travel along with compressed air into
the cooler , impairs heat transfer and reduces cooler efficiency.
Entrained oil in discharge may collected in air reservoir and tend to
oxidation . From this effect , acid formation will cause internal corrosion and pitting

on the air bottle parts . If not properly drain of air reservoirs or extreme case , it
may tend to cause air line explosion consequentially.
To prevent these defects: -

Use proper grade of L.O

Avoid excessive L.O level and lubrication pressure. Normally , a relief valve is
fitted in oil system to open
25 % above normal working pressure to protect oil pump and excess lubrication.
-

Drain the moisture & oil mixture at the cooler and bottle regularly.
Periodically cleaned and removed all trace of carbonized oil in the air
passages.

Deposit in cooler and jacket

If sea water is used as a coolant , scale may form in a H.P jacket and cooler due to high temperature of
compressed air , having about 270 C. Besides , by using unsuitable L.O or excess lubrication , it may
cause oil vapour , passing through the cooler , condensed and cover as oil film deposit on the cooler
surface. Both scaling and depositing effects may reduce the cooler efficiency . So compressed air will be
more heated and reduce volumetric efficiency. Running parts will overheat and more work done in
compression because not approaching isothermal compression.
So , cleaning of cooler and jacket must be done regularly . Air side cleaning can be done by chemical .
But water side have to be done by chemically and manually. But it is almost impossible to clean out the
whole jacket system manually. Therefore , chemical treated F.W cooling system is used in the most
modern compressor.
Effect of valve leakage
Compressor valves may leak and failure at finally. These are happened by..
- Wear and tear of valve plates
- Malfunctioning and excess valve lift
- Presence of foreign particles
- Oil decomposition and sluggish action.
The compressor pressure gauge jerking is the early sign of the valve leaking.
Leaking at first stage suction
- Reduce air delivery to second stage , So insufficient suction pressure for second stage
- Increase running time
- Unload the compressor
Leaking at first stage delivery
- Reduce compressed air delivery to second stage suction
- Leaking back to the cylinder
- Increase discharge temperature
- Loss air drawn by stage due to large volume
Leaking at 2nd stage suction
- High pressure and temperature in 2nd stage suction
- Reduce delivery
- Increase running time
Leaking at 2nd stage discharge
- Increase 2nd stage suction pressure

Counter act to 1st stage delivery

Incapable to charge the air bottle to required pressure.

Precaution to be taken before starting

Lubrication

Check L.O sump , lubricator function and prime manually.

In some compressor , a small quantity of oil can be injected through the valve port to wet

the
Cooling

cylinder wall.
Confirm cooling water supply

Filter

Ensure clean filter is fitted

Relief valve

If hand testing lever fitted , manually lift to test each valve, ensure to freely operate

Unloading
starting

All cooler drain valves should be opened before starting . This purpose is to reduce the
load and confirm cooler leakage

System

Check correct valve opening to the system

Possible cause of starting air line explosion

Due to leaky or jammed starting air valve at partially open position , combustion hot gas may enter to
starting air pipes.
Accumulation of oily mixture in the starting air line due to defective compressor performance and
improper maintenance to air bottle , such as
- Valve leaking
- Excess cylinder lubrication
- Defective oil scraper rings
- High humidity air
- Oil mist in E.R air
- Improper drain of oil and moisture mixture while compressor running
- Irregular drain of air bottle as routine maintenance
- Irregular drain of air lines.
This accumulation of oil may be burnt and vapourized by the hot gas invasion.
At this condition , concerning starting air valve and its adjacent pipes are very hot condition , compare to
other.
By the weakness of watch keeper or ignorance , when the starting air is supplied to the system ,
Normally happen at arrival first start , serious air starting line explosion may occur.
Safety devices fitted on starting air line are
serious
damage when explosion.

spring load relief valve and bursting safety cap , to avoid

(a) Describe the term Volumetric Efficiency as related to air compressor

(b) Describe the effects of the following faults in multi stage reciprocating air
compressor.
1. Inter stage cooler starve cooling water
2. Worn crankshaft bearing
3. Broken or worn scraper ring

Volumetric Efficiency
It is an efficiency measure of a compressor.
Volumetric efficiency is the relationship between the volume quantity of air
discharge when brought to standard atmospheric condition and the swept volume of
air by L.P piston.
Volumetric Efficiency

= Volume of air discharged as free atmosphere

Swept volume of air by L.P piston

Free air is assumed as air in atmosphere at 15 C temperature.

The factors govern to Volumetric Efficiency are
1.
2.
3.
4.
5.
6.
7.

Bumping clearance
Sluggish action of the valves
Piston ring leakage
Dirty air suction filter or choke
Inlet air temperature ( ambient temperature ) too high
Cooling water temperature too high
Insufficient cooling water to inter cooler

Effect on inter cooler starvation of water

shaded area represents
w ork saved due to m ultistage com pressio n w ith
in te rstage cooling
3 rd. stage

intersta ge cooling
reduces air volum e and
tem p.
Adiabatic com pressio n

in te rstage cooling

2 nd. sta ge

is otherm al com pression

Actu al com pression

1 st.stage

Above P.V diagram shows , shaded area represents work save due to using the
efficient inter cooler in multistage compressor.
If inter stage cooler starve cooling water or cooler efficiency is drop due to
depositing
-

The slope of curve will increase and far away from Isothermal compression curve
Area under the curve will increase and more work done to be applied
Work save will not exist due to temperature increase.

The following defects will be occurred.

-

Reduce volumetric efficiency and rapid fall of discharge pressure.

Carbonizing to the valves , Sluggish operation and rapid valve deterioration.
Adversely effect to lubrication
High temperature running of compressor and lead to explosion in extreme case.

Worn crank shaft bearing

When crank shaft bearing is worn , the bumping clearance will increase and larger
clearance volume may result.
Therefore high pressure air remain in cylinder after compression and it will expand
more than normal on return stroke of piston.
Normally , the expanded air pressure fall below inlet air before intake . This part of
suction is stroke is non effective and must keep it as small as possible to achieve
maximum performance.
Due to increase of bumping clearance , this non effective part of suction stroke is
more increase and volumetric efficiency decrease.
Due to crank shaft bearing worn , L.O pressure fall than normal and insufficient to
supply all moving parts. Therefore , vibrated running effect , wear and tare effect to
working parts will occur .
Broken or worn Scrapper Ring

When running the compressor with broken or worn scraper ring , lubricating oil
could not be properly scraped in to sump and carry over with the compressed air ,
sump oil waste & accumulate in stage coolers , reduce cooling efficiency. For this
reason , volumetric efficiency will reduce , work done will be greater , valves will be
carbonized and sluggish action will occur.
In extreme case , L.O may entrained in compressed air discharge line and Oil & air
admixture will reach into the air reservoirs.

This oil and air admixture may cause

- Air reservoir internal corrosion and pitting

- Air system component corrosion , rusting & jam

- Starting air line explosion.