MR 1.6.

3 Carry out routine maintenance on the Main air compressor

MR 1.6.4 Check and make good: Control air filters
MR 1.6.5 Check and make good: Control air driers, replacing desiccant
MR 1.8.5 Carry out routine maintenance on Emergency air compressor

1 Introduction - Maintenance of Air compressors

The following is a guide for the maintenance schedule for different items of air compressors.
You need to check up the maintenance schedule given in the operation manual for the
compressor and that suggested in the Planned Maintenance system on your ship. Periods
between maintenance of different items like filters, valves, and coolers can be revised on the
basis of type of compressor, type of lubricating oil in use and the ambient conditions of
operation (temperature of air and water).

Complete overhaul of an air

compressor will normally coincide
with the periodical survey schedule.

2 Safety measures
 Unless it is an emergency or breakdown situation, plan your work to suit the
circumstances, such that the machine will be out of operation without affecting the
operation of other devices.
  Isolate electrical, air, and waterside of the unit before commencing work. Place "Do
Not Start"signs on start panel and switchboards.
 Release pressure from lines before opening up.
 Put warning / danger / caution signs on the machine and adopt measures for
personal protection and precautions.
 Use proper tools and equipment.
 Use genuine spare parts

3 Basic maintenance

The description and diagrams given below are as a guide. These have been taken
from the instruction manual of Tanabe Air Compressor. You must follow the
guidelines and procedures related to the equipment on your ship.

3.1 Air valve

To remove valves you need to remove
cylinder cover sections where the valves
are located.
Remove the combined suction / delivery
valve (1st stage) and suction valve (2nd
stage) and delivery valve (2nd stage)

i) Complete air valve

A Wipe the air valve outside (both 1st and 2nd valves) with a clean cloth, and check for
carbon deposits or any other foreign matter.
B If carbon or foreign matter is stuck, disassemble the valve and carefully clean it with soft
cloth or brush.

ii) Valve plate

A Push the valve plate from the valve seat using a screwdriver or steel bar (3 mm dia.),
and check for abnormality of valve plate face and action of spring.
Push the screwdriver in several places to check the action of the plate. The valve plate
will move equivalent to valve lift.
B If the valve plate shows improper action, disassemble and clean it.
C If the valve plate is worn, replace it with a new one.

iii) Spring
A Disassemble the 1st stage side spring to check for damage
or wear.
B Check the appearance of the 2nd stage side spring for signs
of damage or wear.
C Replace damaged or worn springs with new one. (Compare
the old spring with a new spring from the spares.)

3.2 Cooler
Remove the cooler covers of both 1st and 2nd stages.
A Check the quantity of scale and sludge adhering to the water jacket surfaces.
B Wash out sludge and clean the parts with a brush.

3.3 Oil System

Caution: If oil gets into the eyes during maintenance or inspection, wash it out with
clean fresh water.
3.3.1 Crankcase
A Replacement of oil
B Use ISO.VG100 (SAE N.30) oil as lubricant for compressor.
C Drain the complete oil while the compressor is still warm. Flush the oil screen with clean
oil, followed by filling the compressor with fresh oil. Use only oil recommended for the
purpose.

3.3.2 Oil Screen

A Oil screen blocks coarse dirt.
B Clean oil screen when replacing the oil.
C Cover so that no dirt enters the oil screen, remove stains with
a soft cloth, and wash with clean flushing oil.
D Replace the oil screen if it is broken.

3.3.3 Oil Filter

A Remove oil filter container.
B Drain oil and check the quantity and condition of deposits on
the filter surfaces.
C Clean the filter with compressed air
D Cartridge type filter element to be replaced as per routine after
an oil change.

3.3.4 Oil Pump

A After removing the bolts, remove the connecting piece
suppressor as shown in figure (on left). Release the
pump by shaking mildly and using a (-) screwdriver to
jack the pump out of the housing.
B Make sure that the pump can be rotated smoothly by
hand.
C If it cannot be rotated by hand or resistance is large,
disassemble and clean. Replace the pump if necessary.

3.3.5 Lubricator
(Works for the lubrication of 1st stage cylinder)
1. Remove the lubricator as illustrated in the given figure.
2. Since quantity of oil supply has been adjusted at installation,
do not change the setting. But when reconditioning becomes
necessary, adjust as per manufacturer's recommendations.

3.4 Other Items

3.4.1 Piping
Check for any leak in the pipes.

3.4.2 Pressure Switch

Check function of pressure switch.

3.4.3 Magnetic Valve

Switch power on / off to check operation.

3.4.4 Suction Filter

Replace the suction filter every 2000 hours of operation.

3.4.5 Pressure Gauge

 Calibrate the pressure gauge periodically.
If abnormality is detected, replace with a new pressure gauge.

3.4.6 Safety Valve

Periodically check operation of the safety valve of 1st stage and 2 nd stage.

3.4.7 Cooling Water Pump

Check if dirt / sludge is present and clean the pump using a brush.

3.4.8 Anchor (foundation) bolts, anti-vibration rubber

Check the anchor bolts and anti-vibration rubber
padding for loosening, breakage and wear.
If the anchor bolts are loosened, retighten them.
Replace broken or worn anti-vibration rubber padding
with new ones.

3.4.9 Major Overhaul

At the time of major overhaul, check anchor bolts and
anti-vibration rubber padding according to the running hours.

3.5.0 Gasket, O-Ring

Replace all copper gaskets with annealed ones. Check the thickness and condition
of the gasket if it is being reused. Clean the landing faces and apply molybedenum
paste / graphite paste (Molykote).
Check condition of 'O' rings and replace when damaged or when hardened.

4 Maintenance of Emergency air compressor

Emergency air compressors on board are generally of two kinds:

 Manual - Reciprocating pump type with a lever to operate it.

 Diesel engine driven - Air cooled type

You may never need to use the emergency air compressor on board. However, it is of
utmost importance that it works when needed. For this reason the emergency compressor is
tried out at regular intervals to ensure it will perform well in pressing up the emergency air
bottle. During maintenance, parts are opened up and cleaned, replaced if necessary and
lubricated where required. Maintenance of the diesel engine will be done during the
maintenance of the air compressor.

Maintenance of the diesel engine would involve general cleaning, renewal of crankcase oil,
periodic inspection of internal parts like crankshaft, bearings, pistons, cylinder head and
valves.

5 Maintenance of air supply for control system

Three basic requirements for control air systems are:

 Correct pressure
 Clean air (free of oil and foreign matter)
 Dry (free of moisture)
On board ships air supply for control systems comes from the main air bottle which is at a
much higher pressure then that required for the control system. Pressure reducing valves
are used to reduce the pressure and it is important that these valves operate within precise
limits. Pressure relief valves are provided for the protection of the low-pressure side in case
of malfunction of the pressure reducing valve.

Instrument Air
This is the air supply for the instrumentation equipment on the ship and thus requiring a high
degree of solid particle filtration, oil and water removal.

The presence of solid particles greater than 5 microns in size, water or oil in air can cause
blockage of orifices, nozzles, damage to diaphragms and '0' rings and clog up dryer
elements.

Moisture can cause corrosion, the products of which may cause blockages, and under low
temperature conditions, such as a sudden pressure drop, or in low ambient temperatures, it
can freeze in pipelines or in actuator mechanisms.

Air Drying
This is usually carried out by 'refrigeration' or by 'adsorption' driers, or by a combination of
both, the former being capable of removing about 96 per cent of the moisture and a
proportion of the lubricating oil carry over, if present.

Adsorption dryers depend upon the condensation of water vapour on the surface of a solid
desiccant such as silica gel, activated alumina and synthetic zealite. The water capacity of
these is low, but rate of adsorption high; however, high air inlet temperatures reduce the
adsorption efficiency of the desiccant, and thus the air must be as cool as possible for
maximum moisture removal.

Inlet and outlet filters should be provided at the drier, the former to prevent oil clogging the
desiccant, the latter to remove desiccant dust which could collect in the pipe lines and
instrumentation.

5.1 Particulate Filter

Primary air filters are designed to separate liquid, water, rust, pipe scale and debris from air
lines. They should be installed upstream of the regulator and / or lubricator to prevent
contamination from reaching other components.

Water is removed mechanically by the deflector which causes the air to move in a swirling
motion. The condensed water droplets are then centrifugally impounded upon the inside of
the bowl, then fall down past the quiet zone baffle to the water sump. The air then passes
through the sintered element utilizing depth filtration and removes debris down to about 5
micron size.

Maintenance:
To maintain maximum efficiency of the filter and to avoid excessive pressure drop the filter
must be kept clean. On standard filters, open the drain (turn counter-clockwise for standard
drain models) periodically to expel contents of bowl before it reaches the level of the lower
baffle.

Cleaning:
Removal from operation is not necessary to clean the filter. Disassembly is simple and can
be performed inline. Before disassembling, shut off air supply and depressurize the filter.
Clean all parts (except the filter element) with soap solution and blow out filter body before
reassembling.
Filter elements should be replaced after a pressure drop of 0.5 bar has been reached or
after 1 year, whichever occurs first.

Particulate Filter with Regulator 

5.2 Coalescing Filter

The coalescing filter is utilized when either clean air is required or longer component life is
desired. This type of filter removes water and oil vapours. It works differently than the
particulate filter; dirty air enters the element from the center and passes through a field of
glass fibers which cause the vapours to form into droplets which are heavier than the
surrounding air. The droplets grow larger as they pass through the element and gravity
causes the oil drops to drain to the sump of the bowl. By removing the harmful oil varnishes
and contaminants that attack seals and gaskets, the valve or cylinder is much less likely to
stick. To maximize the life of a coalescing filter it should always be used downstream of a 5
micron particulate filter or with the optional pre-filter.

Coalescing filter elements come in different grades e.g. a

coarse filter is suited for large amounts of water, rust,
pipe scale and liquid hydrocarbons. A fine filter for
cylinders or valves especially when the circuit is being
run without lubrication ('dry ') or an ultra fine filter for oil-
free instrumentation air, food and drug packaging,
electronics applications and other applications requiring
maximum contamination removal.

5.3 Air
line
lubricator
While dry and clean air is desired for control systems and most other purposes, some
lubrication is required for parts that move in a close fit e.g. valves, cylinders, motors, etc. A
specially designed element supplies a very little quantity of oil to match with the quantity of
air flow.

Also pneumatic devices are likely to be idle for long periods of time and could seize with
improper lubrication.

Lubricator is designed to inject oil droplets into the air stream of a pneumatic circuit. As air
flows from the regulator, some air is diverted from the main orifice and is allowed to flow
through the filter bleed assembly and pressurizes the bowl. This forces oil up the siphon tube
past a flow check and into the integral valve / sight dome. The oil film then drops through the
valve and into the atomization chamber at a rate that is automatically proportional to the air
flow. This virtually eliminates the need for readjustment.

Maintenance:
If both air and oil are kept clean and the oil level
never allowed to fall below the end of the siphon
tube in the bowl, the lubricator should provide long,
unattended service. When oil stops dripping
through the sight dome, irrespective of knob
adjustment, it is indicative of necessary cleaning.

Cleaning:
It is not necessary to remove the lubricator from
the line to clean. First, depressurize and
disassemble the unit. In most cases, cleaning is
only needed in the oil metering area. Pull off the
adjusting knob and unscrew the sight dome
assembly, then remove the inner drip spout and
clean with household soap. Plastic bowls must be
cleaned with house hold soap only.

5.4 Automatic drain for air filter

The liquid level in the bowl, when it reaches a predetermined height, lifts the float and opens
the pivot valve formed by the plate in the float and tube. This admits air above the piston
causing the drain valve to open. When the float drops, the air pilot valve shuts and the air
pressure in the filter acts on the underside of the piston, lifting it to shut the drain valve.