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7.3 Air Compressor

Air compressor is a mechanical device that compresses amount of air to increase

the pressure and reduces its volume in order to use its energy. Air compressors are
just like a pump. Various types of air compressors are available in the market, but the
commonly used onboard is the reciprocating piston type air compressors.

7.3.1 Air Compressor Main Parts

Water safety valve Suction filter

Instrum ent panel Cylinder head

Breather cap Safety valve (1st stage)

(oil port)
Cooling w ater Cooler cover (1st stage)
inlet valve
Drain separator
(1st stage)

(option)

Cooling w ater pum p

Air tem perature sw itch
Magnetic valve
Pressure sw itch
Oil level gauge
Drain valves
Oil screen
Side cover
Oil filter elem ent
Auto drain trap
Oil drain plug
Drain valve
Oil safety valve

Oil release valve

Water checker

Safety valve (2nd stage)

Delivery pipe
Motor
Valve flange (2nd stage)

Cooler cover (2nd stage)

Drain valve

Side cover

Flyw heel cover

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7.3.2. Structure and Principle of Operation

Fig. 7.3.2-1 Cross Section of Air Compressor

(Jonghap-Tanabe Air Compressor, H Series)

1st Stage Suction Filter

Low Press. Valve

Cylinder Head

Piston

Cylinder
Block

After Cooler

2nd Stage
High Press.
Delivery Valve
Inter-Cooler
Piston Rod
2nd Stage
High Press.
Suction Valve

Crankcase Crankshaft

a. Principle of Vertical, Water Cooled Two-Stage Air Compressor

Low pressure air is taken from the atmosphere via suction filter & silencer by the
compressor, passes through the L.P. stage (the L.P. suction/delivery, the L.P.
cooler and drain separator), where air is cooled and moisture is being removed.
After the L.P. stage, air passes through the H.P. stage (H.P. suction/delivery, H.P.
Cooler & Drain separator). Air is further cooled before it is being delivered to an
Air Tank thru a check valve. H.P. & L.P. safety valve is provided on both stages.
Magnetic un-loader is also provided at L.P. & H.P. stages to minimize starting
torque of the compressor motor and to release excess air from the compressor
after stopping.
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Fig. 7.3.2-2 Schematic Diagram

To Starter
AIR HIGH TEMP. SWITCH

H.P. Safety Valve

L.P. Safety Valve Air Outlet Check Valve

L.P. Stage Oil & Water

Drain Separator Separator
H.P.

To Starter To Starter

L.P. H.P.
L.P. Cooler Cooler
Cooler

L.P.
Magnetic Unloader
Magnetic Unloader
Valve(L.P.)
Valve(H.P.)
(Drain Escape)
(Drain Escape)

L.O. Low Pressure Switch L.P. H.P.

Suction Filter

Oil Scraper
Air Inlet

b. Air Valve

The part of air compressor that control or regulate the movement of air and gives
direction from low pressure to high pressure stages. Air valve can be comprised
of:

i. Low Pressure Suction and Delivery Valve (1st Stage)

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This air valve is located on the top of the compressor and imbedded to cylinder
head. Comprise of valve seat, plates and springs.

7.2.3-3 L.P. Suction/Delivery Valve Operation

from Atmosphere
to Air Tank to Air Tank

Delivery Suction Delivery

Fig.7.2.3-4 Details Low Pressure Suction/Delivery Valve

Valve Plate (Delivery)

Valve Spring (Delivery)
Bolt
Nut

Valve Seat Valve Spring (Suction)

Parallel Pin
Valve Plate (Suction)

ii. High Pressure Suction and Delivery Valve (2nd Stage)

Individual assembly and located on the side of the cylinder block.

Valve Plate
Valve Spring Bolt Bolt
Valve Spring
Valve Plate Nut
Nut Valve Seat
Valve Seat

Fig.7.2.3-5 Suction Valve (HP) Fig.7.2.3-6 Delivery Valve (HP)

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c. Cylinder Liner/Block

It is the main frame or body of the air compressor where the liner is cast into the
block. In the sides of the block are the cooling water jackets where the cooler
elements are being inserted.

Fig.7.2.3-7 Cylinder Liner/Block

d. Cooler

When air is compressed, temperature is

considerably increase and affect the
efficiency of the machine. Cooler is
provided to maintain constant temperature
of the air while it is being charged. To
ensure cooler efficiency, carry out periodical
inspection and cleaning as recommended
by the maker. Fig.7.2.3-8 Cooler Elements

e. Piston

Piston is one of the most essential parts of air compressor. Mostly made by
aluminum cast alloys and required periodical inspection and overhauling
maintenance. When overhauling, make sure to consult maker’s maintenance
manual for proper checking and clearance measurements. Carry out the
following:
i. Check for any flaws and oil lubrication if properly supplied. Any abnormalities
observed, corrective measures should be applied without delay.
ii. Check piston pin and bushing dimension. Make sure that all clearances are within
makers recommended measurements.
iii. Reassemble back by confirming correct positioning of parts and following proper
sequence to avoid any damage.
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Fig.7.2.3-9 Piston and Rings

f. Oil System

Suitable lubrication oil properties and proper maintenance is essential to proper

operation of air compressor to maintain its efficiency and to extend the life cycle.

i. Oil Renewal

In deciding when to conduct renewal of the air compressor crankcase oil, it is

imperative to consult the maker’s maintenance manual. Oil renewal time table
can be found and should be followed accordingly. From there on, other
maintenance procedures can be decided according to the judgment on the
condition of the oil.

The table below shows timings when to renew oil during initial start up until the
routine maintenance procedures. When air compressor is newly commissioned, it
is advisable to renew the crankcase oil after running in between 50~100 run-
hours. This procedure is taken to ensure that all lubricating parts are totally run-
up, lubrication has effected and to maintain the cleanliness of the oil. Normal
routine oil renewal is to be conducted every 1000 run-hours as seen on the table.

Fig.7.2.3-10 Oil Renewal Chart

1 5 6 7 8 9 10months

Initial 50 100 200 1000 1100 1200 1400 1600 1800 2000hours
Start

Renew Renew Renew Oil

Oil Oil Replace Filter

Cleanliness of the oil and the air compressor lubricating parts are to be
maintained at all times. It is a fundamental rule, that when renewing the
crankcase oil, the air compressor and filters should be cleaned thoroughly before
replenishing fresh oil.
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ii. Cleaning of Oil Screen and Replacement of L.O. Filter

Cleaning of L.O. system filter strainer is a normal routine maintenance procedure.

In an air compressor, commonly the oil screen is located at the suction of the
pump and being cleaned every oil renewal period. Oil filter are commonly
replaceable or the cartridge type. As a common rule, the oil filter cartridge is
being replaced every two times of oil renewal period.

iii. Oil Pump

Oil pump is of positive displacement type and maintenance is commonly carried

out every 8000 hrs. When assembling the oil pump, always ensure that the pump
shaft is rotating smoothly. If any abnormality observed, overhaul or replace the
pump as necessary. Be careful in handling the oil pump, as any trouble with it will
severely affect the air compressor sliding part and eventual trouble will occur.

Fig.7.2.3-11 Oil System Maintenance

1. Cleaning of oil screen. 2. Replacem ent of oil filter. 3. Inspection of Oil pum p.
R e m o v e t he
c o nne c t ing
pie c e .

O il F ilt e r

O il s c re e n S hif t t he
R emo ve c o nne c t ing pie c e
F lus hing
o il
O il P um p

P re v e nt t he
dirt f ro m e nt e ring
t he o il s c re e n.

Crankcase Drain Plug

g. Lubricator

Some of the air compressors are attached with lubricator pump and others use
the oil pump itself as lubricator. Lubricator pumps maintenance should be carried
out every 8000 hours or as necessary. Normally, lubricator pump are replaceable
by new one. Be careful with handling of this unit as any wrong adjustment will
affect the lubrication quantity of the cylinder. This will promote severe wear on the
piston ring and liner and eventually the air compressor charging efficiency will
decrease. Most of the lubricators are pre-adjusted by maker when shipped to the
vessel therefore it is not required any adjustment unless when necessary. Be
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sure to read the maker’s instruction manual before attempting to adjust the oil
feed rate for cylinder lubrication.

Fig.7.2.3-12 Lubricator Pump

h. Safety Devices

The following devices are essentials to the operation of air compressor.

i. Magnetic Un-loader Valve

A device used to load/unload the

air compressor during starting
and stopping to reduce the
operating torque, controlled by a
solenoid valve and by a timer
relay in the control panel. The
magnetic un-loader valve is in
open position during starting and
will close automatically within 10
seconds maximum setting
(depending on the setting of timer
relay) from the point of starting
and load operation begins. When
stopping the magnetic un-loader
valve will open until to the point
of starting to release the
remaining air pressure in the
compressor system.

When the solenoid coil is

energized, the L.P. Pilot valve
and H.P. needle valve is forced
by the spring to open the pilot
line to the atmosphere. The air
from the air compressor casing Fig.7.2.3-13 Magnetic Un-loader Valve
1st (L.P.) and 2nd (H.P.) stage is
released to the atmosphere by forcing to open the L.P. valve and H.P. valve.
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When the solenoid coil is de-energized, the control air from L.P and H.P. Control
Air will force to close L.P. and H.P. Valve thus, compressor is in load operation.

ii. Pressure Switch

The pressure switch is connected in the oil system of the air compressor. In the
event that oil pressure in the system is detected lower than the preset pressure,
the contacts in the pressure switch will either close or open to automatically stop
the air compressor. This is to protect the air compressor from running when there
is trouble in the oil system.

Pressure switch should be function tested regularly, ie, every 3 months etc. as
per figure below to ensure its reliability. When carrying out function testing, do the
following;

a.) Connect the pressure test device with calibrated pressure gauge to the test
connection piece after valve (B).
b.) Bleed the line thoroughly by gradual opening of valve (B) and (C), and make
sure that the oil pressure has been stable.
c.) Fully close drain valve (C) and close valve (A).
d.) Gradually open the drain valve (C) until the oil pressure dropped to alarm set
point and record the results.
e.) Compare the results from the set point and adjust if necessary.

Fig.7.2.3-14 Pressure Switch and Test Device

A B C

iii. Temperature Switch

A temperature switch is connected in the air compressor air delivery outlet line
and sometimes in the cooling water line. When the air temperature at the outlet
line of the air compressor during operation increases more than the preset, the
air temperature switch will automatically stopped the operation of the air
compressor. This is to prevent the air compressor to run under overheating
condition.
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How to test a temperature switch;

a.) Remove temperature probe from the device and soak to the test jug together
with a spare thermometer.
b.) Heat up the water a little above the temperature setting of the temperature
switch and check if the switch will be activated.
c.) Record the actual results and compare with the set point. Temperature switch
has no adjustment mode. If the result is not with accordance to maker
guidelines, replace the whole temperature switch unit.

Fig.7.2.3-15 Temperature Switch and Testing Gadgets

TEMPERATURE SWITCH
AND PROBE

TESTING GADGETS

When carrying out maintenance and inspections, be sure to follow the maker’s
recommended maintenance and inspection chart as with the figure below.

Fig.7.2.3-16 Maintenance and Inspection Chart

(Jonghap-Tanabe Air Compressor, H Series)

Operating Time
Check & Adjustments
(hours)
Division 1 2 3 6 8 Remarks
2
Items to be 0 0 0 0 0
Contents of check 5
0 0 0 0 0
checked 0
0 0 0 0 0
Valve as
Disassembling & cleaning X
whole Interval may
Check wear amount or be lightened
Air valve Valve plate X
replace. depending on
the condition
Spring Check for extent of fatigue X
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Inside of
Check extent of wear X
cylinder
Cylinder
Water Jacket Wash off the water dirt X

Cooler Cooler Plate Wash off the water dirt X

Check outside diameter,
Piston
extent of wear of ring X
outside
groove
Piston Check extent of wear or
Piston ring X
replace.
Oil scrapper Check extent of wear or
X
ring replace.
Crank case Replace oil X

Oil screen Clean X

Oil Check oil
Oil filter Replace X
System quantity daily.
Oil pump Check extent of wear X

Lubricator Replace X

Piping Check for leak X

Pressure
Check for function X
switch
Magnetic
Check for function X
valve
Suction Filter Replace X
Pressure
Check & correct More than a year.
gauge
Others Safety valve Check for function Once every year.
Check for extent of wear of
Cooling
mechanical seal and driving X
Water pump
gear. Cleaning
Anchor bolt,
Check for loosening
anti-vibration X
Check for break and fatigue
rubber
Compressor Once three years or
Overhaul
as a whole 9000 hours.
Gasket, O-
Replace At each overhauling
ring

7.3.3. Procedures for Operation

It is understood that any personnel who will operate the air compressor must
thoroughly read and understand the maker’s Operation and Instruction manual
including but not limited to, the Maintenance Manual before operating or maintaining
the unit to prevent personnel injury and damage to the equipment itself.

a. Precautionary Measures
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Various signage, labels & notices are attached to an air compressor. In case the
signage, labels and notices are peeled off or discolored, make sure to renew or
install a new one.

These labels, signage & notices are to be read and understood to prevent injury to
the personnel, damage to the machine and to maintain safety at all times.

Fig. 7.3.3-1 Precautionary Signage

Danger
Picture Meaning
information

Electric Receives electric shock by touching high

shock voltage power supply.
Electric Receives electric shock by touching the object
shock in which power is supplied.

Entangle-
Entangled to the rotating unit to be injured.
ment

Spout Injured by explosion, spout, scattering.

Hot
Surface is hot to cause burn
Surface

No Dis-
Disassembling and remodelling prohibited.
assembling

Fire Ignition causes fire.

Grounding Be sure to ground the machine.

Use Ear
Noises may cause disorder in the ear.
plugs

Instruction Follow instruction manual

manual
General
Call attention to content of cautions.
caution

Some of the labels, signage & notices are attached below and may change from time
to time. It is better to be always precautious when considering operating and carrying
out maintenance to any air compressor unit.

b. Checks Before and During Start-up Operation

i. Quantity of Oil

Make sure that the oil level is between H and L of oil level gauge. Refill the oil
when oil level comes near level L.
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ii. Oil Pressure and Adjustment

Make sure that oil pressure rise up to the desired pressure based on
recommended setting of maker’s instruction manual by checking on the pressure
gauge. If the oil pressure does not rise to the desired setting, stop the
compressor and investigate the cause. Adjust oil pump relief valve if equipped
and set to the preset pressure. Never run air compressor continuously with oil
pressure is lower than the preset pressure as this will promote wear on moving
parts and eventually troubles will occurs.

iii. Quantity of Water

Adjust quantity of water so that maximum temperature at the cooling water outlet
is 50oC or below, and the difference between the inlet and outlet temperature is
10oC or below.

Fig. 7.3.3-2 Adjustment of Cooling Water

Adjust difference of
temperatuture at outlet &
inlet to 10OC or below
50OC or below
OUTLET

Adjust quantity
of water
INLET

iv. Safety Devices

Most of the air compressor unit onboard is equipped with cooling water flow
switch, oil pressure switch and discharge air temperature switch. These switches
are safety devices, that when activated the compressor will automatically stop.
When any of these safety devices activated while the air compressor is in
service, check the causes and take remedy/countermeasures before attempting
to restart the unit again.

Be sure to carry out periodical function testing of all safety devices to ensure its
reliability.

v. Instruments, Piping’s, Drains and Other Related Parts

Check with the instruments if oil pressure (at each stage), current, temperature at
cooling water outlet and discharge air are not abnormal. All the gauges should be
periodically calibrated and function tested, to ensure proper indication at all times.
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Check any leakage of air in the discharge piping’s, unloader and other areas.
These leakages can increase air compressor operating time and will promote
wear and tear to each sliding parts.

Make sure that discharge drains are open and functioning properly, (if equipped
with automatic discharge drains) and done from time to time (if manual valve is
provided).

Check all bolts and other related parts are properly connected and well tightened.

vi. Operation Time

Record the operation time everyday. This is helpful for proper upkeep/
maintenance and detecting trouble.

vii. Control of Trouble

If any abnormality observed, stop the air compressor, turn off the electrical power
supply, investigate the cause of trouble and carry out corrective action.

Fig.7.3.3-3 Checkpoints for Air Compressor

When air compressor or the motor is newly overhauled, the following checks
should be done before attempting to running in and put on service operation.

a.) Check that the motor and compressor shafting are correctly aligned.
b.) Check that the flywheel is free to move by turning using the manual bar. It
should be observe that the flywheel can be move easily by hand.
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c.) Check the direction of rotation of the motor is correct. Operate the air
compressor motor by pushing the start switch in an instant to inch the
flywheel, visually check the rotation and compare with the stamped mark.
When the direction of rotation is not coinciding with the markings, check the
motor connection and interchange the two lead wires in the connection box.
Re-check the direction of rotation and confirm correctly.
d.) Check oil level in the crankcase and confirm correct oil level.
e.) Check that cooling water is properly supplied by confirming in the water
checker.
f.) Make sure that all drain valves are open.

c. Start/Stop Operation Procedure

i. Automatic Start/Stop Operation

a.) Turn on the main power supply, the operating power supply and select a
button at the control panel to “auto” mode control. Air compressor enters the
automatic operation mode.
b.) Perform automatic start/stop operation by using the pressure switch. When
preset pressure reached the set point for starting, air compressor will
automatically start the motor and the magnetic un-loader valve is in open
position for about 5~10 seconds (no-load operation) then after the preset time,
the magnetic un-loader valve will automatically close (load operation).When
preset pressure reached the set point for stopping, the motor will
automatically stopped and magnetic un-loader valve will open to released the
excess air in the compressor.

ii. Manual Start/Stop

a.) Turn on the main power supply and the operating power supply. Select button
at the control panel to manual mode. Air compressor is in manual operation
mode.
b.) By selecting manual start/stop push button, air compressor can be operated.

Notes:

During manual operation of air compressor, make sure to check the air tank pressure
that it does not to exceed the maximum working pressure at all times. Never leave
the air compressor running when control mode is in “manual” operation. Start/stop
pressure switch may not activate during this mode. To confirm, check the maker’s
operation manual as this process may vary depending on the design.