ENGINE ROOM LAYOUT (MACHINERY SYSTEM)

DOUBLE DEGREE ON MARINE ENGINEERING

ITS – HOCSCHULE WISMAR

CALCULATION AND SPECIFICATION OF

COMPRESSED AIR SYSTEM
Doc. No. 09 – 42 20 SP035 – CA

Prepared by Approved by
Rev. Date Remark Sutopo Purwono Fitri, S.T., M.Eng.,
Intan Larasati
Ph.D.
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TABLE OF CONTENT

INTRODUCTION .................................................................................................................... 3
OBJECTIVES ......................................................................................................................... 3
REFERENCES ....................................................................................................................... 3
LIST OF ABBREVIATIONS ...................................................................................................... 3
CHAPTER DESCRIPTION ....................................................................................................... 4
DESIGN REQUIREMENTS ..................................................................................................... 4
SUMMARY CALCULATION ..................................................................................................... 8
DETAIL CALCULATION .......................................................................................................... 8
SPECIFICATION OF EQUIPMENTS ......................................................................................... 9
DRAWING OF ARRANGEMENTS ........................................................................................... 9
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I. INTRODUCTION
Ship using diesel engine as main engine need some equipment for starting. For
diesel engine which has small dimension, starting can be easily done by electric motor.
Compressed Air System 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 society. To ensure the functionality of the components in the compressed
air system, the compressed air has to be free from solid particles, water and oil.
For Wartsila 6L26, the starting mechanism is by using direct compressed air
system. Compressed air is pressurized to a certain pressure to be injected to the
combustion chamber to spin the engine until certain speed before fuel can be injected
and then the engine can run by itself. Because of this, compressed air system need to
be installed onboard to support the main engine operation. Pressurized air also used
for automation, blowing for seachest, workshop, hydrophore, and so on.
Compressed Air System is divided into two paths: direct and indirect. Direct system
works by inserting pressurized air directly into the combustion chamber, pressurized
air incorporated during the process, while indirect piston system works by rotating the
flywheel that drives the crankshaft by using electrical motor.

II. OBJECTIVES
The things that we must understand about this document are:
1. To understand the component and equipment of Compressed Air System
2. To understand how to calculate the starting air vessel volume
3. To understand how to calculate the starting air bottle volume
4. To understand how to design Compressed Air demand for engine

III. REFERENCES
1. ClassNK, Part D, Machinery Installation, 2019 Edition
2. Wärtsilä, Marine Solutions. 2018. Product Guide Wärtsilä 26. Vassa: WÄRTSILÄ
FINLAND OY

IV. LIST OF ABBREVIATIONS

Table 9.1 List of Abbreviations
No. Abbreviations Explanation
1. Q Pump Capacity
2. V Volume
3. t Time
4. A Cross-section area
5. v Velocity
6. d Diameter
7. RPM Route per-minute
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V. CHAPTER DESCRIPTION
Compressed air main purpose is to supply starting air for the main engine. The
requirement of pressure and its supporting components are described on the Project
Guide.
The components of Compressed Air system are:
 Compressor
 Filtration Equipment
 Condensate trap
 Pressure Vessel
 Pressure indicator, relief valve for safety equipment
 Reducer, and valves.
Compressor works by compressing the air from ambient into the pressure vessel.
Pressure vessel itself is a spherical/tube container to store the compressed air and
maintain pressure at desired point.
Due to humid ambient air, pressurized air can condensate. Because of that the
system need to be fitted with condensate trap. High amount of water vapor can affect
the initial starting combustion, which may damage the engine.

VI. DESIGN REQUIREMENTS

Table 9.2 Design Requirements
Key
No. Reference Parameter Design
Equipment
1. Internal Product The engine is started with a pneumatic starting
Compressed Guide motor operating at a nominal pressure of 3 MPa (30
Air System Wärtsilä bar). The starting motor drives a pinion that turns
26, the gear mounted on the flywheel. Over 100 rpm the
Section 8: master starter valve closes, and the pinion is drawn
8.1 back by spring force. If the electric system fails, the
pinion will be pushed back by the driving force of the
diesel
engine.
The engine cannot be started when the turning gear
is engaged.
Each HP fuel pump is provided with a pneumatic
stop cylinder which pushes the fuel injection pumps
to zero-delivery when activated. The stop solenoid
valve which admits air to the pneumatic stop
cylinders will be activated by the engine stop and
safety system, also in case of an overspeed or an
emergency stop command.
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Key
No. Reference Parameter Design
Equipment
2. External Product The design of the starting air system is partly
Compressed Guide determined by classification regulations. Most
Air System Wärtsilä classification societies require that the total
26, capacity is divided into two equally sized starting air
Section 8: receivers and starting air compressors. The
8.2 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.
3. Starting Air Product At least two starting air compressors must be
Compressor Guide installed. It is recommended that the compressors
Unit Wärtsilä are capable of filling the starting air vessel from
26, minimum (1.8 MPa) to maximum pressure in 15 to
Section 8: 30 minutes. For exact determination of the
8.2.1 minimum capacity, the rules of the classification
societies must be followed.
4. Starting Air Product The starting air vessels should be dimensioned for
Vessel Guide a nominal pressure of 3 MPa.
Wärtsilä The number and the capacity of the air vessels for
26, propulsion engines depend on the requirements of
Section 8: the classification societies and the type of
8.2.3 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 to 5° towards the drain
valve to ensure efficient draining.
The starting air consumption stated in technical
data is for a successful start. During 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 start can consume two times the
air volume stated in technical data. If the ship has a
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Key
No. Reference Parameter Design
Equipment
class notation for unattended machinery spaces,
then the starts are to be demonstrated.
The required total starting air vessel volume can be
calculated using the formula:

5. Air Filter, Product Condense formation after the water separator

Starting Air Guide (between starting air compressor and starting air
Inlet Wärtsilä vessels) create and loosen abrasive rust from the
26, piping, fittings and receivers. Therefore it is
Section 8: recommended to install a filter before the starting
8.2.4 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 μm. 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.
6. Starting ClassNK 1 The starting air mains are to be protected against
Arrangement Part D, explosion caused by back fire from the cylinders or
Chapter excessive temperature rise in the starting air
2: 2.5.3.1 manifold at the time of starting by the following
arrangements (1) through (5):
(1) An isolating non-return valve or equivalent
thereto is to be provided at the starting air supply
connection to each engine.
(2) An adequate rupture disc device or a flame
arrester is to be fitted at the starting valve on each
cylinder for direct reversing engines having a
starting air manifold. At least one such device is to
be fitted at the supply inlet to the starting air
manifold for each non-reversing engine. However,
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Key
No. Reference Parameter Design
Equipment
the above mentioned device may be omitted for
engines having cylinder bore not exceeding
230mm.
(3) An adequate rupture disc device is to be fitted at
an appropriate position on the starting air manifold
as an emergency means of relieving a pressure
caused by explosion for direct reversing engines
fitted with flame arresters in accordance with (2)
above.
(4) For rupture disc devices of which ruptured discs
cannot be easily replaced, a mechanism of blocking
up the exhaust way is to be provided for the purpose
of quick restart of the engine. This blocking
mechanism is to be fitted with a means of indicating
whether it is blocking or not.
(5) An effective arrangement to prevent the
accumulation of combustibles (fuel oil, lubrication
oil, system oil, etc.) in the starting air manifold or to
prevent the excessive temperature rise in the
starting air manifold is to be provided for direct
reversing engines.
7. Number of ClassNK 2 Where main propulsion engines are arranged for
Start of Part D, starting by compressed air, at least two starting air
Engines Chapter reservoirsare to be provided. These reservoirs are to
2: 2.5.3.2 be connected so that usage can be readily switched
(1), (2) from one to the other. In this case, the total capacity
of the starting air reservoirs is to be sufficient to
provide, without replenishment, the number of
consecutive starts not less than that specified in (1),
(2) and (3) below. Where the arrangements of the
main propulsion engines and shafting systems are
other than shown below, the required number of
starts is to be as deemed appropriate by the Society.
(1) For direct reversible engines
Z = 12C
where
Z : Total number of starts of engine
C : Constant determined by the arrangement of
main propulsion engines and shafting systems,
where the following values are to be referred to as
the standard;
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Key
No. Reference Parameter Design
Equipment
C = 1.0 For single screw ships, where one engine is
either coupled with the shaft directly or through
reduction gears.
C = 1.5 For twin screw ships, where two engines are
either coupled with the shafts directly or through
reduction gear. Or, for single screw ships, where two
engines are coupled with the shaft through
declutchable coupling provided between engine
and reduction gear.
C = 2.0 For single screw ships, where two engines
are coupled with one shaft without any declutchable
coupling between engine and reduction gear.
(2) For non-reversible type engines using a separate
reversing gear or controllable pitch propeller, 1/2 of
the total number of starts specified in (1) above may
be accepted.

VII. SUMMARY CALCULATION

Table 9.3 Summary of Calculation
Measurement
No Object Value
Unit
Requirement Air Receiver
1. Volume Required 500 L
2. Quantity 2
3. Manufacturer Atlas Copco
4. Type Starting air Receiver 500L Model
5. Volume 500 L
6. Pressure Bar 33 bar
7. Length 3050 m
8. Weight 360 kg
Requirement Main Compressor
1. Capacity Required 23.69 m3/h
2. Quantity 2
3. Pressure Required 30 bar
4. Manufacturer Atlas Copco
5. Type LT 7-30 KE
6. Capacity 26.5 m3/h
7. Pressure 30 bar
8. Power Required 5.5 kW
9. Speed 1500 RPM
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Air Pipe Specification

1. Type 40A
2. Outside Diameter 48.6 mm
3. Inside Diameter 41.6 mm
4. Wall Thickness 3.5 mm
5. Material Carbon Steel
6. Standard JIS G3452

VIII. DETAIL CALCULATION

See attachment of Doc. No. 09 – 42 20 SP035 – CA

IX. SPECIFICATION OF EQUIPMENTS

See attachment of Doc. No. 09 – 42 20 SP035 – CA

X. DRAWING OF ARRANGEMENTS
See attachment of Dwg, No. 07 – 42 20 SP035 – CA
 ENGINE ROOM LAYOUT (MACHINERY SYSTEM)
DOUBLE DEGREE ON MARINE ENGINEERING
ITS – HOCSCHULE WISMAR

ATTACHMENT OF COMPRESSED AIR

SYSTEM
Attachment of Doc. No. 09 – 42 20 SP035 – CA

Prepared by Approved by
Rev. Date Remark Sutopo Purwono Fitri, S.T., M.Eng.,
Intan Larasati
Ph.D.
 ATTACHMENT OF Doc. No 08- 42 20 SP035 – CA
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SYSTEM Page 2 of 11

1. Internal Compressed Air System

2. External Compressed Air System

2.1 Starting Air Vessel
Based on Wartsila W26 Project Guide, 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, which is following ClassNK Part D Section 2.5.3. Project Guide of
Wartsila W26 recommends to use a minimum air pressure of 1.8 MPa, when
calculating the required volume of the vessels. Technical Data from Wartsila 6L26:

The required total starting air vessel volume can be calculated using the formula:
𝑃𝐸 × 𝑉𝐸 × 𝑛
𝑉𝑅 =
𝑃𝑅𝑚𝑎𝑥 −𝑃𝑅𝑚𝑖𝑛
Where:
VR = total starting air vessel volume (m3)
PE = normal barometric pressure (NTP condition), which is 0.1 MPa
VE = air consumption per start (Nm3), according to Wartsila 6L26 Technical
data, which is 1.4 Nm3
PRmax = maximum starting air pressure, which is 3 MPa
PRmin = minimum starting air pressure, according to Wartsila 6L26 Technical
data, which is 1.4 MPa
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n = required number of starts according to the classification society, which

is 6 for single main engine configuration.

12 × 1
𝑧=
2
𝒛 =𝟔
𝒕𝒉𝒆 𝒄𝒂𝒍𝒄𝒖𝒍𝒂𝒕𝒊𝒐𝒏 𝒇𝒐𝒓 𝑉𝑅 :

0.1 × 1.4 𝑁𝑚 3 × 6
𝑉𝑅 =
3 𝑀𝑃𝑎 − 1.4 𝑀𝑃𝑎
𝑽𝑹 = 𝟎. 𝟓𝟐𝟓 𝒎𝟑
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The total air volume above shall be divided into two equally sized of starting air vessels. So:
Wartsila 26 Project Guide, Starting Air Vessel, Page 75
The total volume of each air receiver is :
VAR = VR /2
= 0.525 / 2 = 0.2625 m3
= 262.5 liter
Air Vessel selection
Based on the calculation above, choosen an air reciever with spesification:
Merk : Atlas Copco
Capacity : 500 liter
Pressure : 33 bar

The total vessel volume shall be divided into at least two equally sized starting air
vessels. So, the selected Air Bottle will have capacity of 0.525 m3 or equal to 500L.
2.2 Starting Air Compressor
ClassNK Part D Section 2.5.3 requires a minimum of 2 compressor to be installed
Based on Wartsila W26 Project Guide, the starting air compressor should be capable
of filling the starting air vessel from minimum (1.8 MPa) to maximum pressure (3 MPa)
in 15 to 30 minutes.
Because the engine maker doesn’t specify the required capacity, so the capacity of
the compressor will be calculated with General Gas Equation, as follows.
𝑃. 𝑉 = 𝑛. 𝑅. 𝑇
𝑉 = 𝑃 / (𝑛. 𝑅. 𝑇)
Where:
P = total pressure to be filled (Pa)
V = specific air volume (to be found)
n = number of air molecules
R = Boltzmann Constant (8.314 J/K.mol)
T = working temperature in Kelvins (assume ambient air of 25°C, or 298K)

a. Pressure to be filled (P)

∆𝑃 = 𝑆𝑡𝑎𝑟𝑡𝑖𝑛𝑔 𝑎𝑖𝑟 𝑀𝑎𝑥. 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 − 𝑆𝑡𝑎𝑟𝑡𝑖𝑛𝑔 𝑎𝑖𝑟 𝑀𝑖𝑛. 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒
= 3 𝑀𝑃𝑎 − 1.8 𝑀𝑃𝑎
= 1.2 𝑀𝑃𝑎
= 1200000 𝑃𝑎
b. Number of Molecules (n)
𝑛 = 𝑚/𝑀𝑟
Where:
m = mass of air (g)
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Mr = Molar number of ambient air, which is average of 28.9647 g/mol

Mass of air = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡𝑖𝑛𝑔 𝑎𝑖𝑟 𝑣𝑒𝑠𝑠𝑒𝑙 × 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑎𝑖𝑟
Mass of air = 0.5 𝑚 3 × 2 × 1.1897 𝑘𝑔/𝑚 3
Mass of air = 1.1897 𝑘𝑔
Mass of air = 1189.7 𝑔
So, the number of molecules of air
𝑛 = 𝑚/𝑀𝑟
𝑛 = 1189.7 (𝑔) / 28.9647 (𝑔/𝑚𝑜𝑙)
𝑛 = 40.87389132 𝑚𝑜𝑙
After knowing all the variables, then we can calculate the required Volume to
increase the pressure from 1.8 MPa to 3 MPa.
𝑉 = 1200000 𝑃𝑎 / (40.87389132 𝑚𝑜𝑙 × 8.314 𝐽/𝐾. 𝑚𝑜𝑙 × 298𝐾)

𝑽 = 𝟏𝟏. 𝟖𝟒𝟗𝟕𝟒𝟒𝟐𝟐 𝒎𝟑
Assume the volume above is to be filled within 30 minutes, so the capacity required
for the compressor is as follows.
𝑄 = 𝑉/𝑇

𝑄 = 11.8497 𝑚 3 / 0.5 ℎ𝑜𝑢𝑟

𝑸 = 𝟐𝟑. 𝟔𝟗𝟗 𝒎𝟑 /𝒉

3. Air Pipe
Based on Wartsila W26 Project Guide, the air pipe used is DN40. So, based on the
requirement, then the pipe selected with following specification:
Air Pipe Specification
Outside diameter : 48.6 mm
Wall thickness : 3.5 mm
Inside diameter : 41.6 mm
Nominal pipe size : 40A
Standard : JIS G3452
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Table 3.1 Air Pipe Specification

4. Equipment Specification
4.1 Starting Air Vessel
Requirement:
Volume = 0.525 m3
= 262.5 L
Pressure = 3 MPa
= 30 bar
Selected:
Brand = Atlas Copco
Type = Starting air Receiver 500L Model
Amount = 2 units
Volume = 500 L
Max. pressure = 33 bar
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4.2 Starting Air Compressor

Requirement:
Capacity = 23.699 m3/h
Pressure = 3 MPa
= 30 bar
Selected:
Brand = Atlas Copco
Type = LT 7-30 KE
Amount = 2 units
Capacity = 26.5 m3/h
Max. pressure = 30 bar
Power = 5.5 kW
Speed = 1500 RPM
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Electric Motor Used

Type : Y132S-4
Power : 5.5 kW
Speed : 1440 RPM
Efficiency : 85.5 %
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5. External Compressed Air System