Air compressors on a ship require special attention and care for their smooth running. It is only through routine maintenance and checkups that you can expect smooth and efficient running of the compressors.
However, compressor is a peculiar equipment which tends to get some or the other problem while working. In this article, we will go through each and every problem that can arise in an air compressor and also enumerate ways to troubleshoot that problem.
This is the ultimate guide for troubleshooting air compressors on a ship
Lube Oil Pressure Low
The following can be the reasons for lube oil pressure low in the air compressor:
- Faulty pressure gauge.
- Cock to pressure gauge in closed position.
- Low oil level in the sump.
- Leakage in supply pipe.
- Suction filter is choked.
- Oil grade in the crank case is not compatible.
- Attached Lube oil gear pump is faulty.
- Worn out Bearing, clearance is more.
2) Abnormal noise during operation
If you get any abnormal noise during operation, the following can be the reasons:
- Loose foundation bolts.
- Worn out bearings, clearance is high.
- Imbalance crankshaft resulting in high-end play.
- Valve plate broken or faulty.
- Relief valve lifting below setting pressure.
- Bumping clearance is less.
- Piston worn-out, broken piston ring.
Vibration in the machinery:
In case of vibrations, the following reasons are to be considered and checked.
- Foundation bolts are loose.
- Discharge pressure high, faulty discharge valve plates.
- Liner and piston worn out.
- Small bumping clearance.
4)Cooling water temperature is high
Cooling water temperature can go high because of the following reasons:
- Inlet or outlet valve for cooling water is closed.
- Inter-cooler is chocked.
- Cooling water in the expansion tank is low.
- Pipe passage becomes narrow due to scale formation.
- Water-pump belt or gear drive broken.
- ump not working.
5)First stage discharge pressure high
In case the first stage discharge pressure is high, it must be because of :
- Pressure gauge is faulty.
- Inter-cooler air passage is chocked.
- Second stage suction valve is not closing properly, allowing air to escape from 2nd to 1st stage.
- Discharge valve of first stage is malfunctioning, and remains in closed position.
- Spring of discharge valve is malfunctioning.
6) First stage discharge pressure low
In case the first stage discharge pressure is low, it must be because of:
- Pressure gauge is faulty.
- Suction filter is choked.
- Unloader of first stage is leaking.
- First stage suction valve is not closing properly, resulting in compressed air leakage.
- First stage suction valve is not opening fully, leading to less intake of air.
- Discharge valve is faulty and remains open permanently.
- Relief valve after first stage is leaking.
- Piston ring of first stage is badly worn out, allowing air to pass.
7) Second stage discharge pressure high:
In the case of high discharge pressure in the second stage, the reasons can be:
- Faulty pressure gauge.
- Discharge valve to air bottle is shut.
- Second stage discharge valve plate worn out, and even the spring worn out.
- Valve is stuck in closed position.
- After cooler air passage choked.
- Air bottle is over pressurized.
8 ) Second stage discharge pressure low:
When second stage discharge pressure is low, it could be because of:
- Pressure gauge is faulty.
- Suction valve for second stage is malfunctioning, in open position.
- Suction valve for second stage is not opening fully, and thus less intake of air.
- Discharge valve is faulty and remains open during operation.
- Piston rings of second stage are worn out, leaking out compressed air.
- Relief valve of second stage is leaking.
- Un-loader of second stage is leaking.
9) Relief valve of first stage lifting
If relief valve of the first stage is lifting, it can be because of
- Spring of relief valve is malfunctioning, thus lifting at less pressure.
- Discharge valve of first stage is not opening.
- Intercooler air passage is blocked.
- Suction valve of second stage is in stuck position.
- Water inside the compression chamber due to crack in the jacket and water is leaking inside
10) Relief valve of second stage is lifting
If relief valve of the second stage is lifting, look for the following reasons:
- Relief valve is malfunctioning, lifting at lower than setting pressure.
- Main discharge valve to the air bottle is closed.
- Discharge valve plates and spring are worn out, valve in closed position.
- Blockage in the after cooler air passage.
- Water inside the compression chamber due to crack jacket.
The above-mentioned points are just a brief explanation to the problems of the air compressor tackled on board. However, they serve as a guiding light for finding the right fault in the compressor.
You may also like to read – What is a Bearing Scraper?
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About Author
An ardent sailor and a techie, Anish Wankhede has voyaged on a number of ships as a marine engineer officer. He loves multitasking, networking, and troubleshooting. He is the one behind the unique creativity and aesthetics at Marine Insight.
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