A Comprehensive Guide to Compressed Air Lines on Ships: Everything You Need to Know

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A Comprehensive Guide to Compressed Air Lines on Ships: Everything You Need to Know

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Ships rely on compressed air for a variety of important functions. One of the most critical uses of high-pressure air on ships is for starting the main engine. Typically, high-pressure air at a pressure of 30 bar is used for this purpose. However, this high-pressure air is usually reduced to lower working pressures through pressure reduction valves. The compressed air at reduced pressures of 7-8 bar is used as service air for many different applications.

There are numerous essential applications that rely on this lower-pressure air. For example, the starting of auxiliary engines and emergency generators, as well as charging freshwater and drinking water hydrophores. The compressed air is also utilized for blowing the fog horn, as spring air for exhaust valves of the main engine, and for dry washing of main engine turbochargers. Furthermore, it is used in sewage treatment plants for aerobic sewage breakdowns, soot blowing of boilers, and pneumatic pumps for oil transfers, amongst many other applications. Additionally, the service air is also used for cleaning, painting operations, chipping, and operating pneumatic tools, such as grinders and chisels.

Another crucial use of the 7-8 bar compressed air is as control air. This is a filtered branch of the service air that is free of any moisture and oil carry-over. The controlled air is used for pneumatic controllers, which are crucial for the operation of machinery onboard ships.

Overall, the air line is a crucial aspect of ship operations, and its importance cannot be overstated. In general, the complete pneumatic air line on a ship includes the main high-pressure airline, the service air line, and the control air line. Each of these lines serves a vital function in ensuring the safe and efficient operation of the ship’s machinery. This article aims to provide insight into the air line of a ship, including its important components and how it works. Understanding the air line is critical for anyone involved in the operation of ships or marine engineering.

Main Air Compressor

The heart of the air-line onboard a vessel is the main air compressor, responsible for compressing air by reducing its volume and increasing its pressure. With various types of air compressors available, including centrifugal compressors, rotary vane compressors, rotary screw compressors, and reciprocating air compressors, vessels can select the best option for their specific needs.

Most modern merchant vessels use multi-stage reciprocating air compressors that come equipped with intercoolers and aftercoolers, complete with automatic draining and unloading arrangements. These compressors have proven to be highly efficient and effective for vessel operations.

To measure the capacity of the main air compressor, the industry uses the term Free Air Delivery (FAD), which is expressed in cubic meters per hour. Free Air Delivery refers to the volume of air discharged by the compressor in one hour, taking into consideration that it would occupy the space if expanded down to atmospheric pressure and cooled to atmospheric temperature.

The pressurized air discharged by the main air compressor is stored in a main air bottle or reservoir, which has a maximum pressure of 30-32 bar. Depending on the capacity of each air compressor, the volume of air needed for starting the main engine, and the overall demand for air on the vessel, a ship may have two or three main air compressors.

In some cases, marine boilers and exhaust gas economizers on certain ships need air to be soot blown, requiring higher capacity air compressors to be employed at the design stage, based on the ship owners’ requirements.

According to SOLAS requirements, a ship’s main air compressors must be able to fill their air reservoirs from zero to maximum pressure (30bar) within one hour. This is a critical aspect of vessel safety, ensuring the air compressors can efficiently deliver the air supply needed for vessel operations in a timely manner.

Main Air Reservoir

On board every ship, there is a crucial component that is responsible for ensuring the proper functioning of the engine. These components are called air reservoirs and each vessel is equipped with a set of two, which can either be of the vertical or horizontal type.

In order to guarantee that these air reservoirs function optimally, they are put through a rigorous hydraulic pressure testing process that ensures they can withstand up to 1.5 times their working pressure. This ensures that they can handle the high pressure demands of the ship’s engine without any issues.

Furthermore, in accordance with Solas regulations, each vessel must have air reservoirs with a total capacity that is sufficient enough to allow for a specific number of consecutive Main Engine starts. For reversible engines, the air reservoirs must be able to support at least 12 consecutive starts without needing to be refilled. Similarly, for non-reversible engines, the air reservoirs must be capable of supporting at least 6 consecutive starts.

To ensure the utmost safety of everyone on board, each vessel must have two identical main air receivers as well as one emergency air bottle. This redundancy ensures that even in the event of a failure in one of the main air receivers, the engine can still be powered by the emergency air bottle, which can provide enough air to start the engine and bring the vessel to safety.

In summary, air reservoirs are a crucial component of any ship’s engine system and must be designed and tested to withstand the high-pressure demands of the engine. In order to ensure the safety of everyone on board, it is imperative that each vessel is equipped with the required number of air reservoirs as per Solas regulations.

Air Reservoir Mountings

When it comes to equipping air reservoirs, there are certain mountings that should be present to ensure safe and effective functioning. One of these essential mountings is the Fusible Plug. This plug is composed of Bismuth, Tin, and Lead in the ratio of 50%, 30%, and 20%, respectively, and has a melting point of 220 degrees Fahrenheit (104.4 degrees Celsius). It is typically fitted at the bottom of the reservoir or on the reservoir at the ship’s side when a relief valve is not directly fitted on the reservoir.

The primary function of the Fusible Plug is to release the compressed air in the event of abnormally high compressed air temperature. This is crucial to prevent any potential accidents or hazards that could arise from the overheating of the air reservoir. By melting at a specific temperature, the plug allows for the release of compressed air, which can prevent any damage or explosions.

Another important mounting that should be present in air reservoirs is the Atmospheric Relief Valve. This valve is provided as over-pressure protection and serves as a back-up for the Fusible Plug. In case of an Engine Room fire, when CO2 flooding is required, the valve must be opened before evacuating the engine room. This ensures that the compressed air is released and helps to prevent any damage or explosions that could occur during the CO2 flooding process.

It is worth noting that the air receiver relief valve opening could either open outside the engine room through the ship’s funnel or inside the engine room itself. In case of the latter, CO2 bottle calculations for fighting a fire in the Engine room are done accordingly, and the extra CO2 required is taken into consideration at the ship’s design stage. This demonstrates the importance of proper planning and design to ensure the safety and efficacy of the air reservoirs on board ships.

In summary, equipping air reservoirs with mountings such as the Fusible Plug and Atmospheric Relief Valve is essential for safe and effective functioning. These mountings work together to ensure that any potential hazards or accidents are prevented, and that the air reservoirs are able to operate as intended. Proper planning and design are also crucial to ensure the optimal performance of air reservoirs on ships.

In the world of maritime engineering, ensuring safety onboard is of utmost importance. As such, it’s important to understand the various components that make up a safe and secure vessel. One key component is the spring-loaded safety valve. This valve is responsible for regulating the pressure within the vessel and ensuring that it does not exceed a certain level. Specifically, a setting pressure of 32 bar (for a 30-bar working pressure) is recommended, with equal to or greater than 10% rise in accumulation of pressure that may be fitted directly or with extension. By utilizing a spring-loaded safety valve, the risk of pressure buildup and potential damage to the vessel is greatly reduced.

Another important component is the compensation ring. When a hole is cut or machined into a pressure vessel, the material around the hole is subjected to higher stresses. To reduce this stress and ensure structural integrity, a compensation ring is fitted. This ring acts as a flange on which a valve or fitting is usually mounted, and provides additional support to the vessel, thereby minimizing any potential risks.

In addition to the above, it’s also important to have both manual and automatic drain valves installed. These valves are responsible for draining any accumulated liquids from the vessel, and are an essential component in maintaining optimal conditions onboard.

Pressure gauges are also important, as they allow for easy monitoring and adjustment of the vessel’s pressure. By having access to accurate readings, engineers can quickly respond to any changes in pressure, ensuring the safety of everyone onboard.

Finally, access doors are crucial for providing easy entry and exit points within the vessel. They allow engineers to quickly and easily access important components for maintenance or repairs, and also provide an additional layer of safety in the event of an emergency.

Overall, by understanding and utilizing these components, engineers can ensure the safety and security of everyone onboard a vessel. It’s important to never overlook the importance of proper maintenance and adherence to safety protocols.

When it comes to the operation of air systems on ships, there are various valves and components that play important roles in ensuring the smooth functioning of the system. Among these, the main starting valve, auxiliary starting air valve, fitting valve, and service air or whistle air valve are crucial components that are commonly used on ships.

The main starting valve is a valve that is used to control the flow of compressed air to the main engine starting valve. The auxiliary starting air valve, on the other hand, is used to control the flow of compressed air to the auxiliary engines. Both of these valves are essential for starting the engines and ensuring their smooth operation.

In addition to these, there is also the fitting valve, which is used to connect the air system to various equipment and machinery on the ship. This valve is crucial for ensuring that the air system can be used to power different equipment and tools as required.

The service air or whistle air valve is yet another important component that is used to provide compressed air to various systems on the ship, including the whistle and other equipment that require compressed air to function properly.

When it comes to the construction of air systems on ships, the air receivers play a critical role. These are large cylindrical bottles that are used to store compressed air. In order to ensure that these receivers are able to withstand the high pressure of the compressed air, they are welded using full penetration welds. The welding details are carefully controlled to ensure that they meet the requirements of classification society regulations and are safe for use.

After the welding process is complete, the receivers are stress relieved or annealed at a high temperature of around 600 degrees Celsius. This helps to ensure that the metal is able to withstand the pressure of the compressed air without deforming or breaking.

To ensure that the air receivers are safe for use, they are subjected to periodic hydraulic testing. This involves testing the receiver at a pressure of 1.5 times the working pressure to ensure that it is able to withstand the pressure without rupturing or failing. For large receivers, this testing is required every 10 years to ensure that they remain safe and reliable for use on the ship.

 

Air Bottle Inspection

Air receivers are a critical component in any compressed air system, and as such, they must be carefully inspected and maintained to ensure optimal performance and longevity. One of the most significant issues that can arise with air receivers is corrosion, which can be caused by moisture accumulating within the vessel. Even with the proper operation of compressor cooler drains, a significant amount of moisture can collect, especially in humid conditions, leading to corrosion.

To prevent corrosion, it is essential to check air reservoir drains regularly to determine the amount of liquid present. In extreme conditions, drains may need to be used multiple times daily to remove accumulated emulsion. It is worth noting that corrosion is typically found near the air receiver drain.

Once a thorough visual inspection has been conducted, it may be necessary to measure the thickness of the air receiver using an ultra-sonic thickness gauge. If the thickness of the air receiver is found to be compromised, it is crucial to reduce the air pressure contained in that particular air bottle. This can be done by changing the cut-in and cut-off settings of the air compressor, as well as adjusting relief valve settings when that particular receiver is in use. Additionally, the air receiver can be isolated entirely and kept on standby, allowing it to be filled manually with caution whenever required.

All internal welds and any small changes in cross-section must be thoroughly inspected to ensure that the air receiver is functioning correctly. If the air bottle is too small to be manually entered, an internal inspection can be carried out using a camera with a probe.

To further protect against corrosion, it is recommended that the internal surface of the air receiver be coated with a suitable material. Graphite suspension in water, Linseed oil, Copal Vanish or Epoxy coating are all excellent choices, providing basic properties such as anti-corrosion, anti-toxic, and anti-oxidation.

In conclusion, regular inspection and maintenance of air receivers is essential to ensure that they continue to operate at optimal performance levels. By identifying and addressing any potential issues early on, it is possible to extend the lifespan of these critical components and avoid costly downtime due to unexpected failures.

Safety Devices On Main Air Bottle

The marine industry has always been subject to constant innovation and development, particularly in terms of safety and reliability. This is particularly true in relation to the control air system of marine vessels. The control air system is an essential component of the vessel that controls the pneumatic equipment on board. The control air system comprises of various components such as fusible plug, pressure relief valve, atmospheric relief valve, low-pressure alarm, and automatic or remote-control moisture drain valve.

The fusible plug is a critical safety device that prevents the pressure inside the vessel from reaching a critical point, which could lead to an explosion. The pressure relief valve is another vital component that is designed to protect the control air system against overpressure. It operates by opening when the pressure inside the control air system exceeds a predetermined level, allowing the excess air to escape.

Similarly, the atmospheric relief valve is another important safety device that is designed to protect the control air system from vacuum conditions. The atmospheric relief valve opens when there is a vacuum condition inside the system, allowing air to enter and equalize the pressure.

To ensure the trouble-free operation of the control-air systems, low-pressure alarms are used to alert the engine crew if the pressure drops below a predetermined level. The automatic or remote-control moisture drain valve is another vital component of the control air system. It is designed to remove moisture from the compressed air and prevent contamination that can cause malfunctioning of the control equipment and valves.

Since control air equipment is sensitive to contaminants, it is essential to ensure that the compressed air supplied is clean and dry. The presence of water, oil, or other contaminants in the compressed air can cause moving parts in control equipment and valves to stick, leading to general deterioration of diaphragms, spools, and other parts made of rubber. Additionally, contaminants in the compressed air can cause rust build-up, metallic wear, and other small particles that can cause damage by abrasion.

To prevent the presence of contaminants in the compressed air, special provisions must be made to ensure that the air quality is high. This is particularly important when the source of control and instrument air is the main air compressors and the main air reservoir itself. The pressure reducing valve, which reduces the main air pressure to the 7 or 8 bar required by the control air system, can be affected by emulsion carry-over and may require frequent cleaning to prevent air contamination.

Although automatic drain traps can be fitted in the control air system, many traps require daily draining by the engine crew. Therefore, it is crucial to ensure that the engine crew is adequately trained to identify and rectify any issues with the control air system to ensure the safe and efficient operation of the vessel. In conclusion, the control air system is a vital component of marine vessels that must be maintained to ensure safe and reliable operation.

Controlling air quality on a vessel is a crucial part of ensuring efficient and safe operation. Large amounts of free moisture and oil emulsion carry-over in the air can cause a number of issues including decreased efficiency of machinery and corrosion of equipment. Fortunately, these issues can be addressed with the use of special control-air membrane filters installed in the control air line.

A typical control air filter arrangement includes an oil and moisture collecting filter followed by a membrane air dryer filter. This treatment of air through these membrane filters results in the air being filtered and dried to remove virtually all traces of oil, moisture, and air impurities. A simple line air filter is provided with a small plastic float and auto-drain arrangement, and it can also be drained manually if the vessel enters a highly humid environment and frequent draining is required.

The filter dryer unit is made up of a primary filter, secondary filter, and membrane hollow fiber elements. The control air enters the dryer chamber through the line filter located in the lower part of the dryer unit. In the dryer unit, the primary filter removes the coarse rust particles, dust, and other larger impurities, while the secondary filter acts like a coalescer, separating water droplets and oil mists up to 0.3 microns. A differential pressure gauge indicates the condition of the primary and secondary filters, and a higher differential pressure indicates a dirty membrane filter. The membrane elements are to be renewed as per the ship’s PMS.

It is also important to consider the high-pressure air piping from the air compressor to the receiver. The piping should be as smooth as possible without any bends in the pipeline so as to allow air to flow freely to the receiver without restrictions. Bends in the piping can create backpressure in the line in case of accumulated moisture or oil emulsion in the line.

Overall, proper control air filtration is essential to maintain equipment efficiency and avoid costly repairs. By utilizing these special control-air membrane filters and ensuring smooth high-pressure air piping, vessels can operate at their maximum potential while also maintaining safe and efficient operations.

Emergency Air Compressor And Emergency Air Bottle

The importance of having a reliable emergency air compressor on board cannot be overstated. This compact and versatile piece of equipment can be powered by an independent prime mover, such as an engine, or draw power from the emergency switchboard. Its primary function is to fill up the emergency air bottle with a sufficient volume of air, which can then be used to start the auxiliary engine of a dead ship.

The emergency air compressor also plays a critical role in the operation of the Emergency Shut-Off Valve system, where control air is necessary. Moreover, an emergency QCV air bottle with 7 bar air pressure is used to operate all Quick Closing valves, fire and funnel dampers on board. This arrangement typically comprises a 7 bar Emergency QCV air bottle with QCV- shut off valves that are always ready to be used in the event of an emergency.

In case of an uncontrollable fire in the engine room, the Quick Closing valves are activated, which supplies control air to SHUT specific outlet valves of all Fuel Oil and Lube Oil tanks and ER funnel and Blower dampers, thereby cutting off all fuel and air supply. This effectively helps to prevent the spread of fire and contain the damage.

It is worth noting that control air supply is also essential in Emergency Shut Down Systems (ESDS) on Gas Tankers. In such scenarios, a reliable and efficient emergency air compressor is indispensable.

In conclusion, the importance of having an emergency air compressor on board cannot be overemphasized. It is a crucial piece of equipment that plays a vital role in ensuring the safety of the ship and crew. However, it is essential to ensure that the emergency air compressor is regularly maintained and checked to ensure its optimal performance. Finally, it is important to note that the author’s views expressed in this article do not necessarily reflect the views of Marine Insight, and all data and charts used have been sourced from available information and have not been authenticated by any statutory authority.

 

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A Comprehensive Guide to Compressed Air Lines on Ships: Everything You Need to Know

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