Surface Air Supply Systems

The diver's air supply may originate from an air compressor, a bank of high-pressure air flasks, or a combination of both.

8-6.1 Requirements for Air Supply. Regardless of the source, the air must meet certain established standards of purity, must be supplied in an adequate volume for breathing, and must have a rate of flow that properly ventilates the helmet or mask. The air must also be provided at sufficient pressure to overcome the bottom water pressure and the pressure losses due to flow through the diving hose, fittings, and valves. The air supply requirements depend upon specific factors of each dive such as depth, duration, level of work, number of divers being supported, and type of diving system being used.

8-6.1.1 Air Purity Standards. Air taken directly from the atmosphere and pumped to the diver may not meet established purity standards. It may be contaminated by engine exhaust or chemical smog. Initially pure air may become contaminated while passing through a faulty air compressor system. For this reason, all divers' air must be periodically sampled and analyzed to ensure the air meets purity standards. Refer to Table 4-1 for compressed air purity requirements.

To meet these standards, specially designed compressors must be used with the air supplied passed through a highly efficient filtration system. The compressed air found in a shipboard service system usually contains excessive amounts of oil and is not suitable for diving unless filtered. Air taken from any machinery space, or downwind from the exhaust of an engine or boiler, must be considered to be contaminated. For this reason, care must be exercised in the placement and operation of diving air compressors to avoid such conditions. Intake piping or ducting must be provided to bring uncontaminated air to the compressor. The outboard end of this piping must be positioned to eliminate sources of contamination. To ensure that the source of diver's breathing air satisfactorily meets the standards established above, it must be checked at intervals not to exceed 8 months, in accordance with the PMS.

8-6.1.2 Air Supply Flow Requirements. The required flow from an air supply depends upon the type of diving apparatus being used. The open-circuit air supply system must have a flow capacity (in acfm) that provides sufficient ventilation at depth to maintain acceptable carbon dioxide levels in the mask or helmet. Carbon dioxide levels must be kept within safe limits during normal work, heavy work, and emergencies.

If demand breathing equipment is used, such as the MK 21 MOD 1 or the MK 20 MOD 0, the supply system must meet the diver's flow requirements. The flow requirements for respiration in a demand system are based upon the average rate of air flow demanded by the divers under normal working conditions. The maximum instantaneous (peak) rate of flow under severe work conditions is not a continuous requirement, but rather the highest rate of airflow attained during the inhalation part of the breathing cycle. The diver's requirement varies with the respiratory demands of the diver's work level.

8-6.1.3 Supply Pressure Requirements. In order to supply the diver with an adequate flow of air, the air source must deliver air at sufficient pressure to overcome the bottom seawater pressure and the pressure drop that is introduced as the air flows through the hoses and valves of the system. Table 8-1 shows the values for air consumption and minimum over-bottom pressures required for each of the surface-supplied air diving systems.

8-6.1.4 Water Vapor Control. A properly operated air supply system should never permit the air supplied to the diver to reach its dewpoint. Controlling the amount of water vapor (humidity) in the supplied air is normally accomplished by one or both of the following methods:

■ Compression/Expansion. As high-pressure air expands across a pressure reducing valve, the partial pressure of the water vapor in the air is decreased. Since the expansion takes place at essentially a constant temperature (isothermal), the partial pressure of water vapor required to saturate the air remains unchanged. Therefore, the relative humidity of the air is reduced.

Table 8-1. Primary Air System Requirements.

Air Consumption

System

Minimum Manifold Pressure (MMP)

Average Over Period of Dive (acfm)

MK 21 MOD 1

(Depth in fsw x 0.445) + 90 to 165 psi, depending on the depth of the dive

1.4 (Note 1)

MK 20 MOD 0

(Depth in fsw x 0.445) + 90 psi

1.4

Note 1: The manifold supply pressure requirement is 90 psig over-bottom pressure for depths to 60 fsw, and 135 psig over-bottom pressure for depths from 60-129 fsw. For dives from 130-190 fsw, 165 psi over-bottom pressure shall be used.

Cooling. Cooling the air prior to expanding it raises its relative humidity, permitting some of the water to condense. The condensed liquid may then be drained from the system.

8-6.1.5 Standby Diver Air Requirements. Air supply requirements cannot be based solely on the calculated continuing needs of the divers who are initially engaged in the operation. There must be an adequate reserve to support a standby diver should one be needed.

8-6.2 Primary and Secondary Air Supply. All surface-supplied diving systems must include a primary and a secondary air supply in accordance with the U.S. Navy Diving and Manned Hyperbaric Systems Safety Certification Manual, SS521-AA-MAN-010. The primary supply must be able to support the air flow and pressure requirements for the diving equipment designated (Table 8-1). The capacity of the primary supply must meet the consumption rate of the designated number of divers for the full duration of the dive (bottom time plus decompression time). The maximum depth of the dive, the number of divers, and the equipment to be used must be taken into account when sizing the supply. The secondary supply must be sized to be able to support recovery of all divers using the equipment and dive profile of the primary supply if the primary supply sustains a casualty at the worst-case time (for example, immediately prior to completion of planned bottom time of maximum dive depth, when decompression obligation is greatest). Primary and secondary supplies may be either high-pressure (HP) bank-supplied or compressor-supplied.

8-6.2.1 Requirements for Operating Procedures and Emergency Procedures. Operating procedures (OPs) and emergency procedures (EPs) must be available to support operation of the system and recovery from emergency situations. OPs and EPs are required to be NAVSEA or NAVFAC approved in accordance with paragraph 4-2.6.3. Should the surface-supplied diving system be integrated with a recompression chamber, an air supply allowance for chamber requirements (Volume 5) must be made.

All valves and electrical switches that directly influence the air supply shall be labeled:

"DIVER'S AIR SUPPLY - DO NOT TOUCH"

Banks of flasks and groups of valves require only one central label at the main stop valve.

A volume tank must be part of the air supply system and be located between the supply source and the diver's manifold hose connection. This tank maintains the air supply should the primary supply source fail, providing time to actuate the secondary air supply, and to attenuate the peak air flow demand.

8-6.2.2 Air Compressors. Many air supply systems used in Navy diving operations include at least one air compressor as a source of air. To properly select such a compressor, it is essential that the diver have a basic understanding of the principles of gas compression. The NAVSEA/00C ANU list contains guidance for Navy-approved compressors for divers' air systems. See Figure 8-10.

8-6.2.2.1 Reciprocating Air Compressors. Reciprocating air compressors are the only compressors authorized for use in Navy air diving operations. Low-pressure (LP) models can provide rates of flow sufficient to support surface-supplied air diving or recompression chamber operations. High-pressure models can charge high-pressure air banks and scuba cylinders.

8-6.2.2.2 Compressor Capacity Requirements. Air compressors must meet the flow and pressure requirements outlined in paragraph 8-6.1.2 and 8-6.1.3. Normally, reciprocating compressors have their rating (capacity in cubic feet per minute and delivery pressure in psig) stamped on the manufacturer's identification plate. This rating is usually based on inlet conditions of 70°F (21.1°C), 14.7 psia barometric pressure, and 36 percent relative humidity (an air density of 0.075 pound per cubic foot). If inlet conditions vary, the actual capacity either increases or decreases from rated values. If not provided directly, capacity will be provided by conducting a compressor output test. Since the capacity is the volume of air at defined atmospheric conditions, compressed per unit of time, it is affected only by the first stage, as all other stages only increase the pressure and reduce temperature. All industrial compressors are stamped with a code, consisting of at least two, but usually four to five, numbers that specify the bore and stroke.

The actual capacity of the compressor will always be less than the displacement because of the clearance volume of the cylinders. This is the volume above the piston that does not get displaced by the piston during compression. Compressors having a first-stage piston diameter of four inches or larger normally have an actual capacity of about 85 percent of their displacement. The smaller the firststage piston, the lower the percentage capacity, because the clearance volume represents a greater percentage of the cylinder volume.

8-6.2.2.3 Lubrication. Reciprocating piston compressors are either oil lubricated or water lubricated. The majority of the Navy's diving compressors are lubricated by petroleum or synthetic oil. In these compressors, the lubricant:

Prevents wear between friction surfaces

Seals close clearances

Protects against corrosion

Transfers heat away from heat-producing surfaces

Transfers minute particles generated from normal system wear to the oil sump or oil filter if so equipped

8-6.2.2.4 Lubricant Specifications. Unfortunately, the lubricant vaporizes into the air supply and, if not condensed or filtered out, will reach the diver. Lubricants used in air diving compressors must conform to military specifications MIL-L-17331 (2190 TEP) for normal operations, or MIL-H-17672 (2135 TH) for cold weather operations. Where the compressor manufacturer specifically recommends using a synthetic base oil, the recommended oil may be used in lieu of MIL-L-17331 or MIL-H-17672 oil.

8-6.2.2.5 Maintaining an Oil-Lubricated Compressor. Using an oil-lubricated compressor for diving is contingent upon proper maintenance to limit the amount of oil introduced into the diver's air (see Topside Tech Notes, March 1997). When using any lubricated compressor for diving, the air must be checked for oil contamination. Diving operations shall be aborted at the first indication that oil is in the air being delivered to the diver. An immediate air analysis must be conducted to determine whether the amount of oil present exceeds the maximum permissible level in accordance with table Table 4-1.

It should be noted that air in the higher stages of a compressor has a greater amount of lubricant injected into it than in the lower stages. It is recommended that the compressor selected for a diving operation provide as close to the required pressure for that operation as possible. A system that provides excessive pressure contributes to the buildup of lubricant in the air supply..

8-6.2.2.6 Intercoolers. Intercoolers are heat exchangers that are placed between the stages of a compressor to control the air temperature. Water, flowing through the heat exchanger counter to the air flow, serves both to remove heat from the air and to cool the cylinder walls. Intercoolers are frequently air cooled. During the cooling process, water vapor is condensed out of the air into condensate collectors. The condensate must be drained periodically during operation of the compressor, either manually or automatically.

8-6.2.2.7 Filters. As the air is discharged from the compressor, it passes through a moisture separator and an approved filter to remove lubricant, aerosols, and particulate contamination before it enters the system. Approved filters are listed in the NAVSEA/00C ANU list.

8-6.2.2.8 Pressure Regulators. A back-pressure regulator will be installed downstream of the compressor discharge. A compressor only compresses air to meet the supply pressure demand. If no demand exists, air is simply pumped through the compressor at atmospheric pressure. Systems within the compressor, such as the

MP Compressor Assembly

Figure 8-10. HP Compressor Assembly (top); MP Compressor Assembly (bottom).

intercoolers, are designed to perform with maximum efficiency at the rated pressure of the compressor. Operating at any pressure below this rating reduces the efficiency of the unit. Additionally, compression reduces water vapor from the air. Reducing the amount of compression increases the amount of water vapor in the air supplied to the diver.

The air supplied from the compressor expands across the pressure regulator and enters the air banks or volume tank. As the pressure builds up in the air banks or volume tank, it eventually reaches the relief pressure of the compressor, at which time the excess air is simply discharged to the atmosphere. Some electrically-driven compressors are controlled by pressure switches installed in the volume tank or HP flask. When the pressure reaches the upper limit, the electric motor is shut off. When sufficient air has been drawn from the volume tank or HP flask to lower its pressure to some lower limit, the electric motor is restarted.

All piping in the system must be designed to minimize pressure drops. Intake ducting, especially, must be of sufficient diameter so that the rated capacity of the compressor can be fully utilized. All joints and fittings must be checked for leaks using soapy water. Leaks must be repaired. All filters, strainers, and separators must be kept clean. Lubricant, fuel, and coolant levels must be periodically checked.

Any diving air compressor, if not permanently installed, must be firmly secured in place. Most portable compressors are provided with lashing rings for this purpose.

8-6.2.3 High-Pressure Air Cylinders and Flasks. HP air cylinders and flasks are vessels designed to hold air at pressures over 600 psi. Convenient and satisfactory diving air supply systems can be provided by using a number of these HP air cylinders or flasks. Any HP vessel to be used as a diving air supply unit must bear appropriate Department of Transportation (DOT) or military symbols certifying that the cylinders or flasks meet high-pressure requirements.

A complete air supply system includes the necessary piping and manifolds, HP filter, pressure reducing valve, and a volume tank. An HP gauge must be located ahead of the reducing valve and an LP gauge must be connected to the volume tank.

In using this type of system, one section must be kept in reserve. The divers take air from the volume tank in which the pressure is regulated to conform to the air supply requirements of the dive. The duration of the dive is limited to the length of time the banks can provide air before being depleted to 200 psi over minimum manifold pressure. This minimum pressure of 200 psi must remain in each flask or cylinder.

As in scuba operations, the quantity of air that can be supplied by a system using cylinders or flasks is determined by the initial capacity of the cylinders or flasks and the depth of the dive. The duration of the air supply must be calculated in advance and must include a provision for decompression.

Sample calculations for dive duration, based on bank air supply, are presented in Sample Problem 1 in paragraph 8-2.2.3 for the MK 21 MOD 1. The sample problems in this chapter do not take the secondary air system requirements into account. The secondary air system must be able to provide air in the event of failure of the primary system per U.S. Navy Diving and Manned Hyperbaric Systems Safety Certification Manual, SS521-AA-MAN-010. In the MK 21 sample problem (Sample Problem 2), this would mean decompressing three divers with a 30-minute bottom time using 1.4 acfm per diver. An additional requirement must be considered if the same air system is to support a recompression chamber. Refer to Chapter 22 for information on the additional capacity required to support a recompression chamber.

8-6.2.4 Shipboard Air Systems. Many Navy ships have permanently installed shipboard air supply systems that provide either LP or HP air. These systems are used in support of diving operations provided they meet the fundamental requirements of purity, capacity, and pressure.

In operation, a volume source (such as a diesel or electrically driven compressor) pumps air into a volume tank. The compressor automatically keeps the tank full as long as the amount of air being used by the diver does not exceed the capacity of the compressor. The ability of a given unit to support a diving operation may be determined from the capacity of the system.

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