Air compressor used on board is air cooled air compressor and water cooled air compressor from different maker.
A: Air intake filter
B: LP suction valve
C: LP delivery valve
D: LP safety valve
E: LP cooler (intercooler)
F: HP suction valve
G: HP delivery valve
H: HP cooler (aftercooler)
I: HP safety valve
The above sketch is 2 stage water cooled air compressor. The first stage of the compressor is low pressure stage (LP) and the second stage of the compressor is high pressure stage (HP).All bearings are lubricated by a gear pump fitted to the end of the crank shaft.
Tube type coolers are fitted in the compressor cylinder block. The first serve to cool the air after the first stage compression which is called intercooler. The second serve proceed cooling after second stage compression which is called after cooler. The cooling water inlet and outlet are located so that the water circulated through the cylinder block and ensure efficient cooling of the air and compressor cylinder wall.
The compressor fitted with two safety valves, one after the first stage compression and the other after the second stage compression. The cylinder block cooling jacket is fitted with safety plate (bursting disc) which will blow out if the cooling pressure is subjected to excessive pressure, also fitted with thermostat.
The compressor is fitted with unloader valve , manually or automatically with solenoid valve, at starting this valve must be opened, this reduce the starting torque for the machine and clear out any accumulated moisture and oil from the system.
Some compressor is fitted fusible plug at the air out let pipe, when the air temperature is high (above 105 Deg C) pressure is released by melting (fusing) the metal.
Before any work is commenced electric power must be turned off at the starter panel and the main switch board and the switch on the main switch board must be marked with a notice (repair work is in progress)
The discharge valve must be closed and the pressure must be released in all pressurized part of the compressor.
The safety valve, bursting disc (safety plate) and other safety equipment must be fitted and inspected regularly.
The compressor must never be used if the safety equipment is defective.
The usage of the compressed air on board is
Starting air system (both direct air admission and using air motor)
Pneumatic control system
As a power source for machinery and tools
For miscellaneous services such as Ship whistle, boiler soot blowing,
Instrument reading is very important for duty watch man. During watch keeping duty, air pressure must be checked in the control room and near the air bottle and must understand which air bottle is in used and which one is reserved for emergency used.
Watch man should know running compressor and standby compressor
Check starting and stopping pressure of each compressor
When air compressor is starting all unloader valves should be opened. At that moment the motor ampere is low. The motor ampere is coming high, when the unloader valves are closed. The duty watch man must know correct ampere.
When compressor is starting the watch man must check 1st stage (low pressure) side and 2nd stage (high pressure) which can see in the pressure gauge.
Check air temperature before and after intercooler and cooling water in and out temperature
Check air temperature before and after aftercooler and cooling water in and out temperature
Check Sump oil level
Check lube: oil pressure
Check lube: oil drip lubrication
Check air compressor air system leakages
Check air compressor condition during running means, noisy or vibration
Check air compressor running hour
Check safety equipment (safety valve, safety plate (bursting disc), fusible plug if fitted.
If it is found any abnormal, should inform to duty engineer immediately without hesitant.
During air compressor is running, if it is found that suction and discharge valve for low pressure side and high pressure side are not working properly.
Safety valve can be opened
Compressor running time more than normal means, very close to overhauling time.
Compressor is running but air bottle pressure is not coming up or may be air pressure going down
High air temperature can cause explosion.
Low lubrication oil pressure can cause excessive damage