DEU MARITIME FACULTY

MARINE DIESEL ENGINES I

STARTING AIR SYSTEM
STARTING AIR SYSTEM

 In ship’s main propulsion or in auxiliary engines, considerable torque is

required to overcome the inertia of large reciprocating masses. For this
purpose, the energy stored in the compressed air is used.

 It is in the expansion stroke that the starting air valves are opened to
provide a positive torque to the engine. For 2 Stroke engines, the starting
air valves are opened when the piston just passes the TDC and closed
when the exhaust valves/ports are about to open. In 4 Stroke engines, the
exhaust valves are open for a similar phase when the piston passes the
TDC and closes before the exhaust valve opens in the expansion stroke.

 To minimize the risk of an air start explosion, fuel is not injected into the
cylinder whilst the air is being admitted.
 Different methods are employed for starting the marine diesel
engines on board ships depending on the type and kind of the
engine. There will be a means to start the engine locally as
well as from a remote location (The Bridge or the engine
control room).
STARTING AIR SYSTEM
COMPONENTS
 THE AIR START DISTRIBUTOR

 The air distributor normally consists of a series of pilot valves,

one for each cylinder arranged radially around a cam. Timed to
the engine and driven from the camshaft, the distributor opens the
main air start valves in the correct sequence.
 THE AIR START VALVE
 The air start valve is located in the
cylinder head. When it is opened by the
control air from the starting air
distributor, compressed air at 30 bar
flows into the cylinder, forcing the piston
down.
 THE AIR START VALVE
 The body of the valve could be
of mild steel, the spindle of
high tensile or stainless steel,
and the valve and seat could
have the contact faces stellited
or hardened.
HOW DOES AIR START VALVE WORKS? (MAN B&W)
 Main starting air at about 30 bar from the manifold enters the chamber
above the valve via the circumferential ports in the valve body.
 The air pressure will not open the valve because a spring is holding the
valve shut, and the area of the balance piston is the same as that of the
valve lid so the valve is pneumatically balanced.
 When the valve is required to open, air at 30 bar from
the air start distributor enters the top of the valve body
and acts on a piston. This force overcomes the spring
force holding the valve shut, and the valve opens. When
the air signal from the air start distributor is vented, the
spring closes the valve.
 When the start sequence is finished the main air start
pressure is vented through holes in the main start air
manifold.
HOW DOES AIR START VALVE WORKS? (SULZER)

 The Sulzer air start valve uses air on both sides

of the operating piston to maintain positive
closing.
 Once the valve starts to open then the opening is
accelerated when the larger diameter piston has
the opening air acting on it.
 The stepped piston also means that closing of
the valve is damped as air gets trapped in the
annular space formed when the smaller diameter
piston enters the upper part of the cylinder.
 The air to operate the valve comes from the
main air start supply. The distributor pilot air
operates the pneumatic change over valve.
HOW CAN YOU TELL IF AN AIR START VALVE IS LEAKING?

 When an engine is in operation leakage of starting air valves is

shown by overheating of the branch pipe connecting the starting
air valve to the starting air rail.

 The heating occurs due to the leakage of hot gases from the
engine cylinder into the starting air line connected to the starting
air rail.

 During periods of manoeuvring the temperature of each supply

pipe from the air rail to the starting air valve should be checked by
feeling the pipe as close to the valve as possible.
 THE OVERLAP PERIOD
 Overlap is the simultaneous opening of two starting air valves during the
starting air sequence.
 It is necessary to start the engine in any crank position and thus this ensures
that at least one valve will open when the starting air is inducted in.
 If there is no overlap provided, then the engine could stop in any position
with all the starting air valves closed, when the starting air was given.
 There should be a minimum overlap of 15 degrees provided and the ideal
condition should be between 20 degrees and 90 degrees.
 For a 4 cylinder 2 stroke engine the firing interval is 90 degrees (360/4)
and if the starting air period is 115 degrees then the total overlap period
would be the difference between the two, i.e. 115-90=25 degrees.
 THE AUTOMATIC VALVE
 The automatic valve is only open whilst an air start is taking place.
 It incorporates a non return valve to prevent any explosion in the
air start system getting back to the air receivers.
 A slow turn valve is incorporated in the smaller bore pipework to
the side of the valve.
  The valve itself is a simple ball
valve which is turned through 90°
by pneumatic actuator. The
actuator consists of a central
spindle with gear teeth machined
onto it. This is rotated by two
racks which are driven by pistons.
 Two guide rods which maintain
the alignment of the pistons and
racks are bored to allow air to
either side of the pistons. (only one
guide rod is shown on the
diagram)

 When a start signal is given, the space behind the pistons is pressurized
and they move together, rotating the spindle and opening the ball
valve.
 At the end of the start sequence air is admitted through the second
guide rod (not shown) pressurizing the space between the pistons,
moving them apart and closing the valve.
 SLOW TURNING

 A slow turning valve will open instead of the main automatic

valve if the engine has been stopped for more than 30 minutes
during maneuvering.
 It will only supply enough air to turn the engine over very
slowly. This is a precaution in case a cylinder has had oil or
water leak into it which would cause damage to the engine
when starting.
 If the engine completes a full revolution on the slow turn, then
the main automatic valve opens and the engine will start.
 THE TURNING GEAR INTERLOCK
 The turning gear interlock is a control valve which will not
allow starting air to operate the system when the turning gear
is engaged.
 THE AIR RECEIVER

 Two air start receivers are fitted. The total

capacity of the receivers must be
sufficient to start the engine 12 times
alternating between ahead and astern
without recharging the receivers. In the
case of a unidirectional engine, then the
capacity must be sufficient for 6 starts.

 The air receiver will be fitted with a relief

valve to limit the pressure rise to 10% of
design pressure. A pressure gauge and a
drain must also be fitted. A manhole gives
access to the receiver for inspection
purposes.
 THE AIR COMPRESSOR
 Two air start compressors are normally supplied which must be
capable of charging the air receivers from empty to full in one hour.
 They are usually two stage reciprocating with inter and afterstage
cooling. Relief valves will be fitted to each stage which will limit
the pressure rise to 10% of design pressure, and a high temperature
cut out or fusible plug to limit the HP discharge to 121°C.
 Intercoolers are also fitted with relief valves on the water side.
HOW AN ENGINE
STARTS ON AIR?
 The air is admitted into the cylinder when the piston is just past
TDC and continued until just before the exhaust valve opens.

 The opening of the main air start valves is controlled by a set

of pilot valves located in the air start distributor, which in turn
are timed to operate by a drive linked to the main camshaft.

 In the example shown, a small camshaft is used to control the

opening and closing of the air start pilot valves.
HOW AN ENGINE STARTS ON AIR?
 Main Engine Starting Air System.wmv.mp4
 Air supply is provided by opening the main air bottle valve. As
the valve is opened, the air is passed through the pilot valve and
acts on top of the automatic start valve, providing a positive
closing. The other branch supplies air until the turning gear
interlock as the interlock blocks the air to go further.

 To start the main engine, first turning gear has to be disengaged.

This will deactivate the interlock and the air will be supplied to
the automatic start air valve.
 Since there is a spring pressure and additional positive closing
by the air supplied pilot valve, the air will not go further
automatic start valve until the start command is given.

 When the air start lever is operated in the ECR, the pilot valve
shifts and blocks the air on top of automatic valve. It vents the
line and there is no more positive closing.

 Air passed from turning gear interlock pushes the spring,

opens the valve and closes the vent.
 Now the air is available in the cylinder head starting air valve
manifold and in the distributor. The distributor consists of a
negative type cam for positive overlap.
 When the concerned unit number 4 distributor valve comes in
the cam profile, air compresses the spring and the valve is
opened to operate the same unit number 4 cylinder head
starting air valve.
 As the camshaft rotates, unit number 4 line is vented and the
cylinder head starting air valve closes. Now unit number 1
valve will be in contact with the cam profile and the air is
injected in this unit.
 The air injection is done as per the firing order of the engine.
 CONTROL AIR

 Air compressors compress the air to the required high pressure and,
using a Reducing Valve produces the low-pressure air for various
applications. Alternately, low-pressure air for Automation Controls may
be produced by separate air compressors fitted with filter dryers.
 REVERSING MECHANISM

 Reversing of Marine Diesel Engine.mp4

WHAT IS THE PURPOSE OF DRAIN VALVE IN
COMPRESSOR AND AIR BOTTLE ?

 Draining is the process to remove the accumulation of oil water and

sludge from the air bottle, scavenge space, compressor intercooler
and settle and service tank.
 The moisture in the compressed air is not desirable for any
application for prevention of corrosion in the system. Therefore,
drains are provided at various points in the distribution system to
get rid of the moisture. Special filter dryers are provided for
compressed air for automation controls.

 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.
HOW CAN AIR LINE EXPLODE?

 For a fire to happen, it has to complete the three sides of the fire
triangle namely:
Heat, Fuel & Air.
 In an air starting system of main engine, fuel may be present in
the form of lube oil carried over from the air compressor.
Moreover, oxygen is present in the system in abundance.

 The heat source may come from a leaking starting air valve
fitted on the cylinder head and the combination of these three in
proper ratio will lead to an air line explosion.
HOW CAN AIR LINE EXPLODE?
 Air Start explosions occur during a start sequence, when oil, which
can accumulate in the air start receivers or on the surface of the start
air lines, becomes entrained with high pressure air in the air start
manifold and is ignited. The most infamous incident happened
onboard the Capetown Castle in 1960 which killed 7 men.

 In 1999, a large container ship, built in 1981 and fitted with a large
bore two-stroke engine, suffered damage when the starting air
manifold was blown apart by an internal explosion. This occurred
during manoeuvring when berthing. Fortunately there were no
casualties.

 Reference to Lloyds Register database has shown that this was not an
isolated incident – between 1987 and 1999, 11 incidents of explosions
in air start systems have been reported and most have been attributable
to unsatisfactory shipboard practices by ships staff, resulting in the
presence of oil or explosive vapour in the manifold.
HOW CAN AIR LINE EXPLODE?
The source of ignition for these explosions can be attributed to one of
the following three bullets:

 A leaking air start valve. Whilst the engine is running, the hot gases
produced as the fuel burns in the cylinder (at above 1200°C) leak past
a valve which has not re-seated correctly. The branch pipe to the air
start manifold heats up to red heat. If the engine is stopped and
restarted before the pipe has time to cool, any oil vapour in the air can
be ignited and an explosion can result if the mixture of oil/air is
correct.

 Fuel leaking into the cylinder whilst the engine is stopped. When the
engine then undergoes a start sequence, and builds up speed, the fuel
which has leaked into the cylinder vaporises and the heat from the
compression of the air in the cylinder, as the piston rises, ignites the
fuel. When the air start valve opens as the piston comes over TDC, the
pressure in the cylinder is higher than the air start pressure, and the
burning combustion gases pass to the air start manifold, igniting the
oil entrained in the air.
HOW CAN AIR LINE EXPLODE?
The source of ignition for these explosions can be attributed to one of
the following three bullets:

 A recent theory by ClassNK has concluded that the principal cause of

explosions in starting air manifolds of marine engines is probably the
auto ignition of oil deposited on the inner surface of the manifold, not
backfire from cylinders as previously thought. Auto-ignition
conditions occur because of the high temperature generated by the
rapid inflow of high-pressure air, says the research. This incoming air
compresses air downstream of the main starting valve, causing its
temperature to reach as high as 400°C which in some cases causes oil
deposits in the manifold to self-ignite leading to an explosion.
ClassNK has adapted its safety requirements for a starting system to
account for the findings. It now requires the fitting of rupture discs to
the manifold on engines with a flame arrester in each branch pipe
leading to the cylinders. This is beyond IACS unified requirements,
which account for cylinder backfire as the cause of starting air
manifold explosions.
PRECAUTION AND PREVENTION
 For precaution against explosion on
starting air line different safety devices and
arrangements are fitted. They are;
 Relief Valve: It is fitted on the common air
manifold which supplies air to the cylinder
head. Normally fitted at the end of the
manifold and it lifts the valve in the event of
excess pressure inside the manifold. The
advantage of relief valve is it will sit back
after removing the excess pressure and thus
continuous air is available to engine in case of
maneuvering or traffic.
 Non Return Valve: Positioned in between the
Air Manifold and Air Receiver, it will not
allow the explosion and its mixture to reach
the air bottle because of unidirectional
property of N.R. valve.
 PRECAUTION AND PREVENTION
 Bursting Disc: It is fitted in the starting air pipe and consist of a
perforated disc protected by a sheet of material which will burst in
case of excessive pressure caused due to air line explosion. It also
consist of a protective cap such constructed that if the engine is
required to run even after the disc has been ruptured, the cap will
cover the holes when it is turned. This will ensure that in
maneuvering or traffic air is available for engine at all time.
 PRECAUTION AND PREVENTION
 Flame Arrestor (Flame Trap): The flame trap is manufactured
from brass or aluminum alloy which both have a high specific heat
capacity. It is a small unit consisting of several tubes which will
arrest any flame coming out of the cylinder through leaking start air
valve. It is fitted on every cylinder before the start air valve.
 The flame trap will prevent any combustion in the cylinder passing
to the air start line and causing an explosion, whereas a bursting
disk will limit any pressure rise by bursting
 PRECAUTION AND PREVENTION
 For prevention of starting air line explosion following measures to
be performed:

 Ensure that all safety devices fitted are working correctly

 Draining of the air bottle is carried out every watch
 Auto drain to be checked for proper functioning
 Air compressor is well maintained to avoid oil carry over
 The oil separator at discharge of the compressor is working
efficiently
 The starting air manifold pipe to be cleaned and check for paint
deformation which will indicate overheating of the pipe
 Starting air valve to be overhauled regularly to avoid leakage
 Starting air valve seat to be inspected and lapped
EMERGENCY AIR COMPRESSOR

 Emergency air compressor is

used for starting auxiliary
engine at the time of an
emergency or when the main
air compressor has failed for
filling up the main air receiver.
This type of compressor can be
motor driven or engine driven.
If motor driven, it should be
supplied from emergency
source of power.
THANKS FOR YOUR ATTENTION