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3. At stopping the same is done so as to drain all the moisture inside and in
preparation for the next starting.
4. Intermittently the compressor is unloaded to remove the condensed
water inside which could go outside with the air.
For the purpose of unloading there are different types of unloaders
some of them are pneumatic and some are solenoid operated. They all
have a timer in the circuit which energizes the solenoid at the starting,
stopping, and intermittently.
7. Air line piping: check that all the valves in the discharge piping are open
and correctly lined up.
8. Final check: the compressor can be turned a few revolutions with a
turning bar to check for the free movement.
After the above checks have been made a compressor may be started
with the unloaders open.
plate must be replaced with new ones. The valve plate must never be
turned over and used as it can lead to fatigue failure.
5. The valve plate and the valve seat must be separately lapped on a
surface plate using fine and extra fine grinding paste.
6. Thereafter all the parts must be washed with diesel and cleaned with
compressed air.
7. The valve should then be assembled, with the lapped surface of the
valve plate and the valve seat facing each other.
8. After the assembly of the valve the operation of the valve should be
checked by a soft wooden stick.
After the overhaul the valves have to be checked for leakage. The
space above the valve plate should be filled up with water or light oil like
kerosene. If after a few minutes no drop in level or leakage is there then
the valve is satisfactory for the use. While installing care should be taken
to avoid the interchange of the suction and the discharge valves, as it could
lead to an explosion due to over pressurization of the compression
chamber.
piston rings worn, liner worn out causing piston slap, valves not properly
seated, and valves broken or faulty.
4. First stage discharge pressure low: causes can be that the first stage
suction valve is not closing fully and allowing the air to leak during the
compression or it is not opening fully allowing less air to come in the
chamber or the discharge valve is faulty and opening prematurely or
incorrect springs have been fitted which are compressing on little pressure,
intake filter fouled, leakage from piston rings.
5. First stage discharge pressure high: causes can be that the second stage
suction valve is not holding and while compression high pressure air is
coming to the inter-cooler and showing an increase in the pressure, intercooler tubes choked.
6. Second stage discharge pressure low: causes can be leakage from the
piston rings, second stage suction valve faulty and allowing the air to
escape, second stage discharge valve leaking or opening prematurely due
to wrong springs fitted.
7. Second stage discharge pressure high: causes can be obstruction in the
after cooler, obstruction in the discharge valve, air bottle pressure high,
second stage discharge valve springs very stiff.
The above is just a brief exposure to the problems encountered onboard
and how it must be investigated. An experienced marine engineer keeps an
eye on the parameters and knows when maintenance is expected.
Conclusion
A compressed air system used onboard is very important to the
marine engineer and without any air the ship would soon become a dead
ship. The various parts of the compressed air system, be it the
compressors, the pipe lines, or the air bottles have to be maintained in
good condition. In this article a brief guideline has been given about the
compressors used onboard, use of compressed air onboard, the safety
devices fitted, the importance of unloading during starting, the operating
procedure, the basic maintenance, the valves overhaul procedure and the
trouble shooting have all been discussed.
It is hoped it would guide junior engineers and marine engineers about the
various facets of marine compressors.