How many coolers are there?

What is the capacity of a HP Air Compressor supplying inlet air to the HP O2/N2 producer at 3000 psig?

What is the capacity of a HP Air Compressor supplying inlet air to the HP O2/N2 producer at 5000 psig?

How many passes does air make through the 1st and 2nd stage coolers?

How many passes does air make through the 3rd, 4th, 5th, and 6th stage coolers?

TRUE/FALSE

In the freshwater cooler, seawater goes through the tubes and freshwater goes around around the tubes.

What is the constant speed of the drive motor?

What is this the function of?

-Remove and collect moisture condensed by coolers.

-Delivers dry air to next compression stage.

What is this?

-Condensed moisture from the compressed air is collected in separators that are located after each air cooler.

What is this?

-Converts rotating motion of crankshaft to reciprocating motion of pistons.

What is this?

-Transfers compresses air from stage to stage.

What is the final discharge air temp of the compressor?

What kind of waters is the safety features for a sight flow indicator?

What is the lubrication requirements for 2190 TEP?

What mixture is the cooling fresh water mix of antifreeze and water?

TRUE/FALSE

Fresh water is used to cool the salt water.

What is this model of compressor?

-Rotary drain system (Barksdale) 3000 PSIG

What model of compressor is this?

-Automatic drain system (Tendamatic) 3000 PSIG

What model of compressor is this?

-Automatic drain system (Tendamatic) 5000 PSIG

NAME. THIS. COMPONENT.

Location: Compressor base (between compressor assembly and deck)

Construction Features: Bolted or welded to the ship, contains a cavity for the oil sump.

Function Operation: Supports the frame, frame extension, and the compressor drive motor.

NAME. THIS. COMPONENT.

Location: On the sub-base, bolted to an adjustment track with jacking bolts.

Construction Features: Turns at 1190 RPM, 440V, 60 Hz, 3 phase, 75 hp, constant speed

Function Operation: Provides the driving force for the compressor

How many V-belts ride in the V-slots?

NAME. THIS. COMPONENT.

Location: Bolted to the sub base directly over their sump cavity.

Construction Features: Internally ribbed and braced to support the crankshaft and bearings, contains six access covers for inspection and maintenance, contains an internal oil pipe (frame oil header) to direct oil from the pump to the main and thrust bearings.

Function Operation: Houses and supports the crankshaft, main journal bearing and thrust bearings, supports the frame extension and the rest of the compressor.

NAME. THIS. COMPONENT.

Location: One sheave on the drive motor, one sheave on the compressor crankshaft.

Physical Appearance: Each sheave has eight V-slots, motor sheave is smaller than the compressor sheave.

Construction Features: Each sheave is pressed and keyed to the shaft, 8 V-belts ride in the V-slots.

Function Operation: Drive motor drives the compressor through the 8 v-belts which ride on the drive motor and compressor sheaves.

NAME. THIS. COMPONENT.

Location: Inside the frame (Crank Case)

Physical Appearance: Three throw, 120° offset, inline crankshaft

Construction Features: One piece, steel forged, machined, and balanced crank shaft with 4 split shell main journal bearings and 1 thrust bearing, drilled passages to all bearings, shaft is keyed on sheave end and fitted with a pin on the other end to the oil pump.

Function Operation: Converts rotary motion of the motor to reciprocating motion of the crosshead, drives the oil pump.

NAME. THIS. COMPONENT.

Location: Connected to the crankshaft throws, rides in the frame.

Physical Appearance: Rod with a 2 piece bearing on the crankshaft end and a pressed in bronze bushing in the crosshead end.

Construction Features: Rifle drilled passage through the entire length of the connecting rod to provide an oil passage, lower half of bearing is fitted and pinned to the rod to prevent movement of bearing.

Function Operation: Transforms the rotary motion of the crankshaft to the reciprocating motion of the crosshead.

NAME. THIS. COMPONENT.

Location: Connected to the connecting rods, rides in the frame extension.

Physical Appearance: Looks like a piston with a pin in the center.

Construction Features: Crosshead is made of aluminum, drilled holes in the wrist pins allow oil to flow from connecting rods to the crossheads to lubricate its riding surfaces. The crosshead is head on the connecting rods with wrist pins inserted through the connecting rod bushings.

Function Operation: Connects the piston rods to the connecting rods.

NAME. THIS. COMPONENT.

Location: Opposite end from the compressor sheave, mounted on the frame.

Physical Appearance: Consists of an inner and outer rotor ring.

Construction Features: The inner rotor has one less tooth than the outer ring, positive displacement type pump, driven by the pin on the crankshaft and has a pulley attached to the outside to drive the freshwater pump.

Function Operation: Draws oil from the sump and supplies it the running gear at 40-50 PSIG

What is the lube oil pump adjustable to?

NAME. THIS. COMPONENT.

Location: On the oil pump suction line in the oil sump cavity.

Construction Features: Wire mesh screen.

Function Operation: Prevents large particles from entering the lube oil pump.

NAME. THIS. COMPONENT.

Location: Located in the oil supply line between the pump discharge & the running gear.

Construction Features: Paper and screen filter element.

Function Operation: Prevents small particles from entering the lube oil and damaging the bearings and running gear if the pressure drops across the filter exceeds 10 PSIG, the filter must be replaced.

NAME. THIS. COMPONENT.

Location: Attached to the top of the lube oil pump.

Physical Appearance: Rectangular plate with a threaded adjustment screw sticking out of the top.

Construction Features: Adjustable spring loaded poppet type relief valve.

Function Operation: Prevents damage to the oil system from high pressure by diverting excess oil back to the suction side of the pump through and internal pressure, opens at 50 PSIG.

NAME. THIS. COMPONENT.

Location: Mounted external above the drive belt guard.

Physical Appearance: Pressure switch (Detroit type)

Construction Features: Spring loaded, normally open, pressure closing, bellows actuated.

Function Operation: Senses oil pressure at the most remote bearing, contacts close at 14-18 PSIG and allows the compressor to continue to run, contacts open at 10-14 PSIG.

NAME. THIS. COMPONENT.

Location: Mounted on the top of the frame.

Construction Features: Machined to house the crossheads, oil wipers, and piston rods. Contains 6 hand holes with Plexiglass covers for access to the air rod packing and oil wipers. Contains 4 hand holes for access to the piston rod nuts. Oil breather and filler connection mounted on the side cover.

Function Operation: Provides the riding surface for the crossheads, provides an access to add lube oil, allows access to each piston rid for repairs, mounting area for the oil wipers.

NAME. THIS. COMPONENT.

Location: Mounted on top of the frame extension.

Construction Features: One piece cast construction, has 3 holes for the 1st, 2nd, and 3rd stage cylinder liners. Contains passages for air and fresh water cooling.

Functional Operation: Houses lower stage liners, pistons, and valves. Compression occurs in the liners, fresh water removes the heat of compression by flowing around the liners. Vent holes indicate when an o-ring has failed.

NAME. THIS. COMPONENT.

Location: Mounted in the frame extension.

Construction Features: 3 assemblies per set, 3 parts and 1 spring per assembly. Made of cast iron or a campsite plastic-like material. Oil flinger ring mounted above, directly to piston rod, prevents oil migration into air.

Functional Operation: Scrapes oil from the 1st, 2nd, and 3rd stage piston rods where the piston rod passes through the frame extension.

NAME. THIS. COMPONENT.

Location: Mounted inside the bottom of the cylinder block and accessed through the hand holes in the frame extension.

Construction Features: Full floating mechanical packing rings, contains vent holes to indicate air or water leakage. 1st and 2nd stages have 2 packing rings, the 3rd stage has 3 packing rings. Packing cup is made of solid brass.

Functional Operation: Maintains an effective seal despite any lateral movement of the piston rod due to temperature change or operation, packing is contained in the packing cup, assembly is surrounded by water.

NAME. THIS. COMPONENT.

Location: Mounted on the cylinder block between the 1st stage inlet valves.

Construction Features: Housed in a steel casing, removable, polyester air filter element.

Functional Operation: Prevents dirt and foreign matter from entering the compressor air stream.

NAME. THIS. COMPONENT.

Location: Center of the cylinder block, below the 6th stage.

Construction Features: Made of nodular steel, contains a threaded hole in the center of the piston to attach the piston rod on the bottom and a cup to hold the freedom joint on top 2 compression rings, 1 rider ring made of bronze impregnated Teflon. The rider ring prevents metal to metal contact.

Functional Operation: Compresses air on the up and down stroke (double acting).

NAME. THIS. COMPONENT.

Location: In the cylinder block on the drive sheave end, below the 5th stage.

Construction Features: Made of stainless steel, contains a threaded hole in the center for piston to attach the piston rod on bottom and a cup to hold the freedom joint on top. 2 compression rings on bottom and 1 rider ring on top.

Functional Operation: Compresses air on the down stroke (single acting).

NAME. THIS. COMPONENT.

Location: In the cylinder block on the oil pump end below the 4th stage.

Construction Features: Made of stainless steel, contains a threaded hole in center for the piston rod to attach on bottom and a cup for the freedom joint on top, 3 compression rings on bottom and 1 rider ring on top.

Functional Operation: Compresses air on the down stroke (single acting).

NAME. THIS. COMPONENT.

Location: Pressed into the cylinder block.

Construction Features: 8" bore, double o-ring seal on both ends of the liner with a telltale groove between the o-rings. Outside o-rings seal against air leakage, inside o-rings seal against cooling water leakage.

Functional Operation: Houses the piston and provides a compression space, provides a smooth sealing and riding surface.

NAME. THIS. COMPONENT.

Location: Pressed into the cylinder block.

Construction Features: 6" bore, double o-ring seal on both ends of the liner with a telltale groove between the o-rings. Outside o-rings seal against air leakage, inside o-rings seal against cooling water leakage.

Functional Operation: Houses the piston and provides a compression space, provides a smooth sealing and riding surface.

NAME. THIS. COMPONENT.

Location: Pressed into the cylinder block.

Construction Features: 4 3/8" bore, double o-ring seal on both ends of the liner with a telltale groove between the o-rings. Outside o-rings seal against air leakage, inside o-rings seal against cooling water leakage.

Functional Operation: Houses the piston and provides a compression space, provides a smooth sealing and riding surface.

NAME. THIS. COMPONENT.

Location: Mounted on top of the 3rd stage piston inside the 4th stage cylinder liner.

Construction Features: Made of stainless steel, 4 compression rings on top and 1 rider ring on bottom. Mounted on top of the 3rd stage with a freedom joint that allows for slight misalignment.

Functional Operation: Compress air on the up stroke.

NAME. THIS. COMPONENT.

Location: Inside the 5th stage cylinder liner, mounted on top of the 2nd stage piston with a freedom joint.

Construction Features: Stainless steel rod of the built-up design, consists of the following pieces: lock nut, piston sleeve, follower, cap screw, piston nut, outer seal, shim, retaining plate, guide, inner seal, o-ring, and piston rod. Uses an energized seal to maintain flare.

Functional Operation: Compresses air on the up stroke.

NAME. THIS. COMPONENT.

Location: Inside the 6th stage cylinder liner, mounted on top of the 1st stage piston with a freedom joint.

Construction Features: Stainless steel rod of the built-up design, consists of the following pieces: lock nut, sleeve, seal, piston rod and socket, piston nut, spring, follower, retaining ring, guide, washer, and teflon o-ring. Uses an energized seal to maintain flare.

Functional Operation: Compresses air on the up stroke.

NAME. THIS. COMPONENT.

Location: Pressed into the upper stage cylinder, mounted above the cylinder block.

Construction Features: 2 1/2" bore, double o-ring seal on bottom of liner with a telltale groove between the o-rings, a copper gasket and a teflon omni seal on top.

Functional Operation: Houses the piston and proves a compression space, provides a smooth sealing and riding surface.

NAME. THIS. COMPONENT.

Location: Pressed into the upper stage cylinder, mounted above the cylinder block.

Construction Features: 1 1/2" bore, double o-ring seal on bottom of liner with a telltale groove between the o-rings, a copper gasket and a teflon omni seal on top.

Functional Operation: Houses the piston and proves a compression space, provides a smooth sealing and riding surface.

NAME. THIS. COMPONENT.

Location: Pressed into the upper stage cylinder, mounted above the cylinder block.

Construction Features: 7/8" bore, double o-ring seal on bottom of liner with a telltale groove between the o-rings, a copper gasket and a teflon omni seal on top.

Functional Operation: Houses the piston and proves a compression space, provides a smooth sealing and riding surface.

NAME. THIS. COMPONENT.

Location: Suction valves are bolted into the cylinder block on the outboard side and discharge valves are bolted into the cylinder block on the inboard side.

Construction Features: Channel type valves, consists of the following pieces: valve seat, guides, springs, stop plate, channels, guide holder, wear strips. Discharge valves have stuffer springs, suction valves have threaded holes for mounting the first stage adjustable assembly.

Functional Operation: First stage suction valves are adjustable and can vary the compressor capacity up to 10% by changing the clearance between the valve and the cylinder. Air pressure overcomes spring tensioning the valves open to draw air in/out of the cylinder.

NAME. THIS. COMPONENT.

Location: In the cylinder block adjacent to the 2nd stage.

Construction Features: Channel type valves, consist of the following pieces: valve seat, guides, springs, stop plate, channels, guide holder, wear strips. Discharge valves have stiffer springs.

Functional Operation: Air pressure overcomes spring tension and the valves open to draw air in/out of the cylinder.

NAME. THIS. COMPONENT.

Location: Bolted into the cylinder block on the outboard side and discharge valves are on the inboard side.

Construction Features: PLATE TYPE VALVES, consists of the following pieces: cotter pin, roll pin, valve plate, nut, bushing, valve seat, stop plate, spring set. Discharge valve springs are stiffer.

Functional Operation: Air pressure overcomes spring tension and the valves open to draw air in/out of the cylinder.

NAME. THIS. COMPONENT.

Location: Bolted into the 4th stage head.

Construction Features: PLATE TYPE VALVES, consists of the following pieces: cotter pin, roll pin, valve plate, nut, bushing, valve seat, stop plate, spring set. Discharge valve springs are stiffer.

Functional Operation: Air pressure overcomes spring tension and the valves open to draw air in/out of the cylinder.

NAME. THIS. COMPONENT.

Location: Pressed into the 5th stage head.

Construction Features: PLATE TYPE VALVES, consists of the following pieces: back-up ring, spring set, stud, o-ring, valve plate, valve seat, stop plate, bushing. Discharge valves have stiffer springs and are not interchangeable with suction valves.

Functional Operation: Air pressure overcomes spring tension and the valve opens to draw air in/out of the cylinder o-ring and back-up ring seal valve in head.

NAME. THIS. COMPONENT.

Location: Pressed into the 6th stage head.

Construction Features: PLATE TYPE VALVES, consists of the following pieces: back-up ring, spring set, stud, o-ring, valve plate, valve seat, stop plate, bushing. Discharge valves have stiffer springs and are not interchangeable with suction valves.

Functional Operation: Air pressure overcomes spring tension and the valve opens to draw air in/out of the cylinder o-ring and back-up ring seal valve in head.

How many stages do the relief valves in the air flow components have?

What is the 1st stage relief valve setting?

What is the 2nd stage relief valve setting?

What is the 3rd stage relief valve setting?

What is the 4th stage relief valve setting?

What is the 5th stage relief valve setting?

What is the 6th stage relief valve setting?

NAME. THIS. COMPONENT.

Location: In the air piping after each compression stage.

Construction Features: Spring loaded disc type.

Functional Operation: Protect compressor from over pressurization.

NAME. THIS. COMPONENT.

Location: After the 6th stage separator, before the discharge check valve.

Construction Features: Spring loaded, adjustable valve.

Functional Operation: Allows the compressor 5th and 6th stage seals to seal by maintaining a minimum discharge pressure set at 2500 PSIG.

NAME. THIS. COMPONENT.

Location: After the back pressure regulator.

Construction Features: Poppet type check valve.

Functional Operation: Prevents a back flow of air into the compressor.

NAME. THIS. COMPONENT.

Location: In the discharge air piping between the sixth stage cylinder and air cooler.

Construction Features: Cylindrical vessel with a top inlet and side outlet.

Functional Operation: Reduces pulsation and provides a steady, uniform airflow form the 6th stage. PREVENTS FLUCTUATION OF AIRFLOW.

NAME. THIS. COMPONENT.

Location: Between the gauge board and the uniblock, piped from the 3rd stage discharge.

Construction Features: Adjustable diaphragm valve

Functional Operation: Air is supplied from the 3rd stage discharge and is regulated at 145 to 155 psig for unloading systemm.

NAME. THIS. COMPONENT.

Location: After each compression stage (6 total), located in a rack over the drive motor.

Construction Features: Shell and tube, u-bend heat exchangers. 1st and 2nd stage are 2 pass, 3rd through 6th are 3 pass. ZINC ANODES INSTALLED IN EACH COOLER TO REDUCE CORROSION.

Functional Operation: Removes the heat of compression, air flows through the tubes, sea water around the tubes, all coolers are protected by a common relief valve is Machalt 255 has been installed or individually by a burst disk.

NAME. THIS. COMPONENT.

Location: Bottom of cooler rack above the drive motor.

Construction Features: Shell and tube, 2 pass heat exchanger.

Functional Operation: Removes the heat from the freshwater, freshwater flows around the tubes, sea water through the tubes.

NAME. THIS. COMPONENT.

Location: Mounted above the oil pump.

Construction Features: Centrifugal type pump, belt driven by the lube oil pump.

Functional Operation: Circulates a 50/50 mixture of freshwater and ethylene glycol through the closed loop system at 6.5 GPM.

NAME. THIS. COMPONENT.

Location: Mounted on top of the cooler rack, next to the temperature monitor.

Construction Features: Contains a sight glass and vented fill plug.

Functional Operation: Stores and allows for the expansion of the freshwater due to the temperature changes in the fresh water system, vents air form the fresh water system, allows for monitoring of the fresh water level, should be 3/4 full at all times.

NAME. THIS. COMPONENT.

Location: In the fresh water return line, built into the back of the surge tank.

Construction Features: Factory set to open at 120°F, not adjustable.

Functional Operation: Temperature actuated valve, which maintains the fresh water temperature at 120°F to 130°F at the freshwater pump inlet. By bypassing the fresh water cooler as needed, prevents condensation from forming in the cylinder liners.

NAME. THIS. COMPONENT.

Location: Int he return line prior to the surge tank.

Construction Features: IMPELLER TYPE SIGHT FLOW INDICATOR.

Functional Operation: Indicates fresh water flow through the compressor.

NAME. THIS. COMPONENT.

Location: In the seawater outlet piping.

Construction Features: IMPELLER TYPE SIGHT FLOW INDICATOR.

Functional Operation: Indicates the flow of sea water through the compressor.

NAME. THIS. COMPONENT.

Location: In the air piping after each air cooler.

Construction Features: Air inlet and internal swirl chamber on top, air outlet through internal stand pipe on bottom, connections for drain line and monitor probe, each separator is a different size, but they all have the same function.

Functional Operation: Removes moisture from the air stream and prevents carry over.

NAME. THIS. COMPONENT.

Location: On the back of the drain block manifold, one in-line after 1st through 5th stages.

Construction Features: Spring and ball type check valve.

Functional Operation: Pressure on the outlet side of the check valve closes the valve and prevents condensate and pressure from higher stages from entering lower stages.

NAME. THIS. COMPONENT.

Location: Mounted above the motor to the right of the gauge board.

Construction Features: CPV manual drain block manifold.

Functional Operation: Allows for manual draining of the 1st through 6th stages.

NAME. THIS. COMPONENT.

Location: Mounted to the right of the gauge board.

Construction Features: Impingement type sight flow indicator.

Functional Operation: Condensate and air impinge against the glass so the operator can visually check the drainage. The condensate then flows out through the drain line.

NAME. THIS. COMPONENT.

Location: To the left of the condensate drain monitor, about waist level.

Construction Features: Direct acting solenoid.

Functional Operation: Automatically drain the 1st and 2nd stages, when the compressor starts, the solenoid valves are energized and they close. They are de-energized when a drain sequence is initiated or when the compressor is stopped. This allows compressor to unload and to drain.

NAME. THIS. COMPONENT.

Location: On compressor base below the condensate drain monitor.

Construction Features: Pilot operated.

Functional Operation: Automatically drains 3rd through 6th stages. Pilot air is applied to the drain valve when the solenoid is energized. The pilot air pushes against a piston which seats a needle valve, preventing drainage of the separator. When a drain signal is received, the drain valve solenoid vents off pilot air pressure and opens the pilot operated drain valve to allow condensate drainage. These valves are open when the compressor is not running to allow the 3rd-6th stages to drain and unload.

NAME. THIS. COMPONENT.

Location: Below the compressor gage board.

Physical Appearance: Metal box with lights and buttons.

Construction Features: Demand based, microprocessor controlled. Monitored mode shuts the compressor down on high condensate level. Automatic mode drains sat timed intervals or if a high condensate level is sensed.

Functional Operation: Monitors and controls compressor drain system functions. Secures the compressor, in the event of high condensate levels or system component failure. The system automatically drains condensate at timed intervals unless it senses a buildup of condensate before this time, and it will drain on demand. The drain module opens the appropriate solenoid valve to drain the separator. If placed in manual mode, the compressor must be drained every 7 minutes.

NAME. THIS. COMPONENT.

Location: Mounted remotely near the compressor.

Position: Manual or automatic.

Function: In automatic mode, pressure switches PS-1 and PS-2 is energized, which will allow the compressor to start and stop automatically. In manual mode, PS-2 is bypassed, which will allow the compressor to stop automatically, but must be restarted manually.

NAME. THIS. COMPONENT.

Location: Next to the monitor controller.

Position: Open (stop) or closed (start/run).

Function: Starts and stops the compressor drive motor.

NAME. THIS. COMPONENT.

Location: Inside the motor controller with external reset button.

Position: Protects the drive motor form damage caused by excessive current. The reset button is for resetting the relay if tripped.

Function:

NAME. THIS. COMPONENT.

Location: Mounted remotely near the compressor.

Position: Opens at 3000 PSIG. Closed below 3000 PSIG.

Function: Stops the compressor when system pressure reaches 3000 psig.

NAME. THIS. COMPONENT.

Location: Mounted remotely near the compressor.

Position: Open when the compressor is stopped. Closed below 2700 PSIG (compressor restarts).

Function: In automatic this restarts the compressor when the system pressure drops below 2700 PSIG. In manual this is bypassed.

NAME. THIS. COMPONENT.

Location: Backside of the compressor above the drive belt guard. Senses from the most remote bearing.

Position: Open when oil pressure is below 10-14 PSIG. Closed when oil pressure is above 10-14 PSIG.

Function: Shuts down the compressor in the event there is a loss of lube oil pressure. Opens at 10-14 psig stopping the compressor, closes at 14-18 psig, allowing the compressor to run.

NAME. THIS. COMPONENT.

Location: Inside the motor controller

Position: Opened or closed

Function: Allows the compressor 12 SECONDS to build sufficient oil pressure. If pressure is not reached pithing 12 SECONDS the relay will allow the oil pressure switch to shutdown the compressor.

NAME. THIS. COMPONENT.

Location: Mounted on top of the compressor above the gauge board.

Position: Reads 16 temperatures from points throughout the compressor.

Function: Provides a means to monitor temperatures throughout the compressor and will secure the compressor if temperatures reach a predetermined trip point. Function test button and calibration buttons allow for testing and monitor the accuracy of the circuits. Temperature is sensed by resistance temperature detectors; heat is transmitted to the internal windings of the probe and changed into an electrical resistance which is read on this.

What is the set point of the 1st stage discharge?

What is the set point of the 2nd-6th stage discharges?

What is the set point of fresh water?

What is the set point of high oil temp?

What is the set point of sea water?

What is the set point of final air?

NAME. THIS. COMPONENT.

Location: Mounted on the front of the compressor above the condensate drain monitor.

Position: All gauge cutout valves are normally open.

Construction Features: Bourdon tube type gauges.

Function: Displays system pressure during operation.

NAME. THIS. COMPONENT.

Location: Seawater outlet piping, fresh water return line to surge tank.

Position: N/A

Function: Indicates water flow

NAME. THIS. COMPONENT.

Location: Inside the motor controller

Position: Open or closed

Function: Allows the air compressor 12 SECONDS to build sufficient oil pressure. If pressure is not reached within 12 SECONDS the relay will allow the oil pressure switch to shut down the compressor.