operation & maintenance manual for hypercomp cng compressor model 3w815
TRANSCRIPT
OPERATION & MAINTENANCE MANUAL
HYPERCOMP COMPRESSOR MODEL: 3W815
HYPERCOMP (PVT) LTD. HC-OMM-01
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THIS MANUAL IS AN INTEGRAL PART OF
THE COMPRESSOR
IT IS COMPULSORY TO READ IT BEFORE
WORKING ON THE MACHINE
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TABLE OF CONTENTS
1. INTRODUCTION .............................................................................................................................. 7
1.1. GENERAL ................................................................................................................................ 7
1.2. COMPRESSOR DESIGN ........................................................................................................... 7
1.3. COMPRESSOR CONFIGURATION ............................................................................................ 8
1.4. CONTROL PANEL .................................................................................................................... 8
1.5. DRIVE ..................................................................................................................................... 9
1.6. LUBRICATION ......................................................................................................................... 9
1.6.1. OIL QUALITY ....................................................................................................................... 10
1.7. COOLING SYSTEM ................................................................................................................ 10
1.8. COMPRESSOR VALVES ......................................................................................................... 10
1.9. GAUGE PANEL ...................................................................................................................... 11
1.10. CONDENSATE DRAIN AND AUTOMATIC UNLOADING.......................................................... 11
2. SPECIFICATION & TECHNICAL DESCRIPTION................................................................................ 12
3. COMPRESSOR WARRANTY ........................................................................................................... 14
3.1. WARRANTY VOIDANCE .................................................. ERROR! BOOKMARK NOT DEFINED.
3.2. WARRANTY EXCLUSIONS ............................................... ERROR! BOOKMARK NOT DEFINED.
3.3. CAUTION .............................................................................................................................. 14
4. INSTALLATION INSTRUCTIONS ..................................................................................................... 16
4.1. GENERAL SAFETY PRECAUTIONS/ INSTRUCTIONS ............................................................... 16
4.2. INSTALLATION (GENERAL INSTRUCTIONS) .......................................................................... 17
4.3. PLACEMENT ......................................................................................................................... 17
4.4. PIPING .................................................................................................................................. 18
4.5. COOLING SYSTEM ................................................................................................................ 19
4.6. LUBRICATION ....................................................................................................................... 19
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5. COMMISSIONING ......................................................................................................................... 20
5.1. START-UP PROCEDURE ........................................................................................................ 20
5.2. NOTES OF CAUTION ............................................................................................................. 21
6. OPERATING INSTRUCTIONS ......................................................................................................... 22
6.1. SAFETY PRECAUTIONS ......................................................................................................... 22
6.2. START-UP PROCEDURE ........................................................................................................ 23
6.3. RUNNING ON LOAD ............................................................................................................. 23
6.4. SAFETY CIRCUITS .................................................................................................................. 24
6.5. INSTRUMENTS & INDICATORS ............................................................................................. 25
6.6. LUBRICATION ....................................................................................................................... 26
6.7. SAFETY SHUT DOWN ............................................................................................................ 26
6.8. OIL QUALITY ......................................................................................................................... 26
6.8.1. LIST OF SUPPLIERS WITH SUITABLE OIL QUALITIES ........................................................... 27
6.9. COOLING .............................................................................................................................. 27
7. FAULT GUIDE ................................................................................................................................ 30
8. SERVICING/ MAINTENANCE INSTRUCTIONS ............................................................................... 34
8.1. GENERAL .............................................................................................................................. 34
8.2. DAILY INSPECTION AND MAINTENANCE .............................................................................. 34
8.3. 50 HOUR RUN IN MAINTENANCE ......................................................................................... 35
8.4. 3 MONTHLY OR 2000 HOUR INSPECTION AND MAINTENANCE ........................................... 35
8.5. 4500 HOUR INSPECTION AND MAINTENANCE..................................................................... 35
8.6. 9000 HOUR INSPECTION AND MAINTENANCE..................................................................... 36
8.7. GENERAL DAILY INSPECTION ............................................................................................... 36
8.8. DRIVE BELT TENSION AND ALLIGNMENT ............................................................................. 36
8.9. BASIC STEPS FOR V-BELT INTALLATION ................................................................................ 37
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9. REPAIR AND REPLACEMENT ......................................................................................................... 39
9.1. MAINTENANCE AND REPAIR PRECAUTIONS ........................................................................ 39
9.2. 1ST STAGE SUCTION VALVE ................................................................................................. 40
9.2.1. REMOVAL ........................................................................................................................... 40 9.2.2. INSTALLATION .................................................................................................................... 40
9.3. 1ST STAGE DELIVERY VALVE ................................................................................................. 40
9.3.1. REMOVAL ........................................................................................................................... 40 9.3.2. INSTALLATION .................................................................................................................... 40
9.4. 1ST STAGE HEAD .................................................................................................................. 41
9.4.1. REMOVAL ........................................................................................................................... 41 9.4.2. INSTALLATION .................................................................................................................... 41
9.5. 2ND STAGE VALVE AND HEAD.............................................................................................. 41
9.5.1. REMOVAL ........................................................................................................................... 41 9.5.2. INSTALLATION .................................................................................................................... 42
9.6. 3RD STAGE VALVE AND HEAD .............................................................................................. 42
9.6.1. REMOVAL ........................................................................................................................... 42 9.6.2. INSTALLATION .................................................................................................................... 43
9.7. COMPRESSION CYLINDER .................................................................................................... 43
9.7.1. REMOVAL FOR 1ST, 2ND & 3RD STAGE ............................................................................. 43 9.7.2. COMPRESSION CYLINDER INSPECTION .............................................................................. 44 9.7.3. INSTALLATION FOR 1ST, 2ND & 3RD STAGE COMPRESSION CYLINDER ............................. 44
9.8. ROD SEAL CARRIER ............................................................................................................... 45
9.8.1. REMOVAL ........................................................................................................................... 45 9.8.2. INSTALLATION .................................................................................................................... 45
9.9. GUIDE CYLINDER FOR 1
ST, 2
ND & 3
RD STAGE ............................................................................ 46
9.9.1. REMOVAL ........................................................................................................................... 46 9.9.2. INSTALLATION .................................................................................................................... 46
9.10. PISTON / PISTON RINGS FOR 1
ST, 2
ND & 3
RD STAGE ................................................................. 47
9.10.1. REMOVAL ...................................................................................................................... 47 9.10.2. INSTALLATION ............................................................................................................... 47
9.11. PISTON ROD ......................................................................................................................... 47
9.11.1. REMOVAL ...................................................................................................................... 47 9.11.2. INSTALLATION ............................................................................................................... 48
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9.12. GUIDE PISTON ...................................................................................................................... 48
9.12.1. REMOVAL ...................................................................................................................... 48 9.12.2. INSTALLATION ............................................................................................................... 48
9.13. CONNECTING ROD BEARINGS REPLACEMENT / REINSTALLATION ....................................... 49
9.14. OIL PUMP ............................................................................................................................. 50
9.14.1. GENERAL ....................................................................................................................... 50
9.14.2. CAUTION ....................................................................................................................... 50 9.14.3. OIL PUMP REMOVAL ..................................................................................................... 50 9.14.4. OIL PUMP INSTALLATION .............................................................................................. 51
9.15. CRANKSHAFT ....................................................................................................................... 51
9.15.1. GENERAL ....................................................................................................................... 51 9.15.2. CRANKSHAFT REMOVAL & INSTALLATION .................................................................... 52 9.15.3. CHECKING CRANKSHAFT END THRUST .......................................................................... 53
9.16. COMPRESSOR REASSEMBLY ................................................................................................ 54
10. TORQUE WRENCH SETTING ......................................................................................................... 55
11. CLEARANCES/ TOLERANCES CHART ............................................................................................. 56
12. COMPRESSOR EQUIPMENT .......................................................................................................... 57
12.1. EXPLOSION PROOF ELECTRIC MOTOR ................................................................................. 57
12.2. PRESSURE SAFETY VALVES ................................................................................................... 82
12.3. WATER PUMP .................................................................................................................... 116
12.4. WATER FLOW SWTICH ....................................................................................................... 120
12.5. OIL FILTER .......................................................................................................................... 122
12.6. LUBRICATOR ...................................................................................................................... 128
12.7. SOLENOID VALVES ............................................................................................................. 137
12.8. TERMINAL BOX .................................................................................................................. 146
12.9. EXPLOSION PROOF SWITCH GAUGES ................................................................................ 152
13. P & I DIAGRAMS ......................................................................................................................... 186
14. PERIODIC MAINTENANCE CHART .............................................................................................. 187
15. PART LIST .................................................................................................................................... 188
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1. INTRODUCTION
1.1. GENERAL
This manual has been prepared to assist the operators and service
technicians to obtain optimum performance from the Hypercomp
Compressor Model 3W815. It provides information required for the
installation, commissioning, operation, servicing and troubleshooting
faults of the compressor.
Information contained in this manual corresponds to the details as on its
publishing date. Minor differences may be observed on account of
modifications in the compressor made afterwards. Such matters must be
clarified from the compressor manufacturer explicitly so as to ensure safe
and optimum performance of the machine.
Please note that the Model and Serial No. must be quoted in all
communications regarding the compressor.
1.2. COMPRESSOR DESIGN
Hypercomp Compressor Model 3W815 is a W-type three (3) stage heavy
duty machine designed for intermittent or continuous operation with
minimal maintenance. This is apparent from the rugged water cooled
cylinders and crosshead design.
The standard design consists of a packaged unit mounted on a sturdy
steel skid. The unit consists of the compressor, electric motor, flywheel,
vee-belt drive, inter-stage coolers, oil separators / pulsation dampers for
each stage, pressure relive valves, blowdown valves, condensate drains
and automatic unloaders for each stage, optional low oil level safety
switch and Control panel.
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Hypercomp compressor utilizes a strong and robust crankcase frame
design which provides efficient and reliable service under continuous duty
applications.
1.3. COMPRESSOR CONFIGURATION
Hypercomp Compressor is a 3 cylinder 3 stage water-cooled compressor.
The cylinders are mounted in a W type configuration to ensure well
balanced operation. Each cylinder has tangential seals to prevent gas from
pressurizing the crankcase.
The crankshaft is dynamically balanced, counter-weighed and rides on
two tapered roller bearings at each end. The pistons are crosshead
guided.
All connecting rods are forged steel. Connecting rod bearings are steel
backed, Babbitt lined, shell type construction.
The pulsation/filter chamber is placed on the inlet of the compressor with
an adequate sized cartridge type filter positioned inside this tank. The
threads in this tank are B.S.P. on the inlet. The gas passes through a
solenoid valve, into the tank, through the enclosed filter and into the inlet
manifold.
1.4. CONTROL PANEL
The compressor is supplied with an intrinsically safe control panel
monitoring
1. Oil pressure
2. Inlet pressure
3. Inter-stage
4. Final stage pressures
5. Lubricator flow rate (Optional)
6. Final gas temperature and /or water temperature.
Other monitors can be added to system if required.
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1.5. DRIVE
The compressor is designed to be powered either by an electric motor or
gas engine drive. The motor is of explosion proof category (Ex dIIBT4) and
approved for use in hazardous areas.
The electric motor is foot mounted and is driven with anti-static “C”
section Vee belts. Protection for the motor is by thermistors and an over
current device.
1.6. LUBRICATION
Oil is stored in the crankcase sump from which it is drawn by a plunger
type oil pump. This oil pump is located on the front of the compressor
adjacent to the intercooler. The oil pump is driven off an integral cam of
the compressor crankshaft. Normal operating oil pressure is 20 to 60 psi.
The oil is drawn through a screen located in crankcase sump through a
check valve and passes through oil pump plunger to the oil pressure
chamber. From this point the oil is under pressure and is fed through
drilled passages in the crankshaft to the connecting rod and main
bearings. The crosshead pistons and cylinders are splash lubricated by
throw-off from the connecting rod bearings.
The compression cylinders are force-fed lubricated by a single pump
through a divider block or multi pumps depending on the service
conditions. The divider block has a flow sensor to monitor the output.
The oil pump body is bolted and doweled to the compressor from retainer
and carries a non-adjustable pressure relief valve that serves to by-pass
excess oil to the crankshaft sump. The relief valve also serves as a
pulsation eliminator for oil pressure peaks.
Volume of oil contained in sump is 12 liters. Half liter oil is consumed per
50 running hours (depends on conditions).
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1.6.1. OIL QUALITY
i. Oil should be of uniform viscosity, non-detergent and super refined
with rust and oxidation inhibitors. Oil should be of naphthenic base
of a specially compounded type to minimize carbon formation and to
produce carbon residue of a soft and fluffy nature. Oils having animal
fat compounding are not recommended.
ii. Use of following weight oils for the ambient temperature ranges as
indicated below is recommended:
• Above 60 °F : SAE 30
• 32 to 60 °F : SAE 20
• Below 32 °F : SAE 10W
iii. Viscosity according to ISO Classification ISO VG 100 i.e. 90-100 cst
(mm2/s) at 40 °C (Resp. 55-70 cst or 7-9 deg E at 50 °C)
iv. Viscosity index: min. 80
v. Flash point: min. 200 °C
vi. Stock point: max. –12 °C resp. pour point: max –9 °C
vii. To achieve good water separation properties, the oil should not, or
to a light degree only, contain dispersant additives.
1.7. COOLING SYSTEM
The compressor is equipped with Shell & tube type heat exchanger and
jacketed compression cylinders. The cooling can be achieved by either
open or closed circuit. The cooling system should have an adequate
corrosion and scaling inhibitors for maintenance free operation for
extended periods, such as 50% Glycol/water solution or similar
preparation. Water level is maintained by daily “Top up” of the water
tank, located on the top of water circuit.
1.8. COMPRESSOR VALVES
Valves assemblies for all stages are of flat plate, low lift, multiport
concentric type except the 1st stage which are not concentric type but
have individual suction and delivery valves. Easy access is provided to the
valves for their removal and services.
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1.9. GAUGE PANEL
Hypercomp compressor incorporates a gauge panel which can be
mounted either on the skid or on the floor depending on the site
conditions. It is connected to the compressor through flexible hoses. The
gauge panel includes
• Low/High Inlet gas pressure switch gauge
• 1st
stage gas delivery pressure gauge
• 2nd
stage gas delivery pressure gauge
• 3rd
stage gas delivery pressure gauge incorporating stop/start
switch
• Low oil pressure switch gauge
• Water flow switch (fitted on compressor piping)
1.10. CONDENSATE DRAIN AND AUTOMATIC UNLOADING
Each stage of the compressor delivery is piped through a separator which
is connected to a diaphragm drain valve that discharge into a common
chamber from where it is piped back to the blow down recovery vessel.
The drain valves are operated by an EX solenoid valve which is actuated
automatically every time the compressor shuts down and after every 30
minutes of continuous operation. The same system provides for the
unloaded startup of the compressor.
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2. SPECIFICATION & TECHNICAL DESCRIPTION
Make and Model Hypercomp, 3W815
Compressor Configuration W- 60˚
Compressor Design Cross Head design,
Atmospheric crankcase
No. of Cylinders 03
No. of Stages 03
Gas Inlet Pressure (min-max) 08-15 Psig
Gas Discharge Pressure 3625 Psig
Gas Discharge capacity@15 Psig 270 cu.m/hr± 5% (at 30˚C)
Gas Discharge capacity@8 Psig 225 cu.m/hr± 5% (at 30˚C)
Compressor Speed 795-900 RPM
Piston Stroke 127mm
Piston Speed 3.36 m/s @ 795 RPM
3.81 m/s @ 900 RPM
Cylinder Bores
1st Stage 206.375mm
2nd Stage 88.9mm
3rd Stage 38.1mm
Cylinder Jacket Cooling Water
Inter Stage Gas Cooling Water
Cooling System Cooling Tower (70RT Min)
Closed Circuit Optional
Electric Motor Size 75KW (100hp) for
270Cu.m/hr @ 15Psig
75KW (100hp) for
225Cu.m/hr @ 8Psig
Direction of Rotation Clockwise if viewed from
drive end.
Ambient Temp. Range Upto 50˚C
Crankcase Lubrication Big end bearings are pressure
fed. Main bearings, small end
bearings and crosshead
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cylinders are splash
lubricated
Cylinder Lubrication (Optional) Through force feed lubricator
Oil capacity (crankcase) 13 liter
Oil capacity (lubricator) 1.5 liter
Ambient Temp. Range Upto 50˚C
Recommended oil for Above 60˚F: SAE 30
ambient temperature ranges 32 to 60 ˚F : SAE 20
Below 32˚F: SAE 10W
Overall Dimensions (LxWxH) 2135 x 1190 x 1730 (mm)
Weight (without motor) Approx. 1750 Kg
Overall Weight Approx. 2400 Kg
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3. COMPRESSOR WARRANTY
Every Hypercomp Compressor is carefully inspected and test run before
shipment is made from the factory and each new compressor is
warranted to be free from defects in material and workmanship.
If not otherwise specified in the terms of delivery, the compressor is
warranted for a period of 12 months from date of startup or 18 months
from date of dispatch from our works, whichever occurs first.
The warranty covers at the manufacturer’s discretion the replacement or
repair at his cost of any faulty material, parts, or workmanship but does
not cover the financial and other losses to the business and is for the
stated period, subject to full compliance of conditions stipulated in our
O&M manual.
3.1. WARRANTY VOIDANCE
The warranty shall become null and void under following circumstances:-
i. If the compressor has been operated for capacity, medium or
temperatures other than those specified in our offer / quotation.
ii. If the purchaser or a third party undertakes any remedial work or
alteration without our written authorization.
iii. If routine inspection and maintenance as prescribed in this manual
is not strictly followed by the purchaser
iv. If the purchaser does not immediately take steps to notify us of any
defect or malfunction to prevent the fault from becoming more
serious and causing damage.
v. If the piping is not installed by the manufacturer or its recommended
party as per his direction.
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vi. If any damage occurs due to improper handling of compressor and
its parts or use of lubricant other than those listed in this manual.
vii. If the compressor is operated for other RPMs, intake pressures and
capacity as stated in our O&M manual.
viii. If the “Daily Log Sheet “is not maintained properly.
3.2. WARRANTY EXCLUSIONS
This warranty does not cover following:
i. Damage or excessive wear resulting from improper use or impurities
contained in the gas or lubricants outside the normally accepted
standards.
ii. Normal wear and tear of valves, seals, bearings and rings.
iii. Any liability for fires in the machinery or installation.
iv. Physical damage resulting from impact or similar accident including
natural disasters.
v. If any electrical safety setting is altered or by passed for any reason.
Any damage due to high voltages from any source.
3.3. CAUTION
i. Do not compress gas containing corrosive elements (e.g. sulphurous
gases like SO2), which attack carbon steel, cast iron, aluminum alloys
as well as non-ferrous metals.
ii. Do not exceed compressor specifications under any circumstances
without the written approval of the manufacturer.
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4. INSTALLATION INSTRUCTIONS
The following instructions serve for protecting the life and health of
operators and maintenance personnel as well as for maintaining the
operating reliability of the compressor unit.
4.1. GENERAL SAFETY PRECAUTIONS/ INSTRUCTIONS
Most accidents which occur during the operation and maintenance of any
machine result from failure to observe basic rules and precautions. An
accident can often be prevented by recognizing a situation that can lead
to potentially hazardous conditions.
1. Highly compressed gases contain a large amount of energy and
therefore are very dangerous if not handled correctly.
2. Installation, operation, maintenance and repair shall be carried out
only by qualified personnel and in accordance with the corresponding
regulations for operation and safety.
3. Carry out maintenance and repair works on entirely vented areas.
4. Rotating machine parts represent a special danger for accidents.
Covers and guards must not be removed whilst the machine is
operating.
5. Persons staying for long periods in the compressor room should use
hearing protection.
6. Do not store flammable materials near the compressor unit, e.g. oily
rags.
7. Smoking is strictly prohibited near the compressor and other gas
storage system.
8. Supply pipe work and other components which may not include in our
scope of supply must be suitable for the respective working pressure.
9. Never interrupt electrical protective conductors.
10. Electrical cables must be flame proof and must not be linked or get
into contact with rotating parts.
11. Don’t touch blank wires and live (current carrying) parts, when the
electrical system is energized.
12. The switch board may be opened only by qualified and authorized
persons. Even if the main switch is set to the “OFF” position, the poles
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of the switch, the feed cables of the terminal strip are alive. Therefore
do not touch anything on the switch board, and do not carry out work,
when the main current supply is not disconnected. Before starting
work check if the system is entirely free of power.
4.2. INSTALLATION (GENERAL INSTRUCTIONS)
1. The compressor is supplied on its own base and should be installed in a
vented area allowing adequate room around for suitable access for
maintenance. Every effort should be made to ascertain that ambient
air around the compressor does not exceed 50˚C.
2. Generally the compressor should be mounted on a substantial
concrete base or rigid iron fixture.
3. Anti vibration mountings can be used in situations where minimal
vibration transmission is required. It is an advantage in these
applications to increase the weight of the base by filling the spare
areas with stressed concrete consultation with the factory can
facilitate this at the manufacturing stage.
4. If the compressor is mounted on anti vibration mounts, the inlet,
discharge gas and water piping should be flexible and these pipes
should not be taut.
4.3. PLACEMENT
The compressor can be placed on the foundation and carefully leveled
both crosswise and lengthwise.
1. Under normal circumstances, a special foundation for the compressor
is not necessary but it must be verified first that the support floor is
structurally adequate as well as flat and level.
2. The foundation structure should have o4 foundation bolts of 20mm
diameters buried at least 150mm deep in to the concrete base and
have a hole at the bottom to prevent them from rotating when the nut
is tightened.
3. Alternatively 04 Nos x 20 mm Dyna bolts or equivalent can also be
used.
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4. The compressor can be placed on the foundation bolts and carefully
leveled both crosswise and lengthwise. After the compressor is
leveled, nuts on the foundation bolts should be tightened.
5. The control cabinet containing switch gauges and intrinsically safe
circuits should be mounted “free standing” as close to the compressor
as possible. The cabinet stand should be securely bolted to the floor.
All control hoses and temperature probe cables are marked for
attachment to the appropriate fitting on the compressor. All hoses can
be freely laid across compressor ensuring they are clear of moving
parts.
4.4. PIPING
1. In order to prevent vibrations being transmitted from the compressor
to the fixed distribution piping in the plant room and to facilitate
maintenance removal of pipe work, flexible piping must be fitted at
the following points.
a) Gas inlet
b) Gas Discharge
c) Cooling water in
d) Cooling water out
e) Blow down manifold “OUT”
f) Pressure relief valves manifold out
2. Gas piping to and from the compressor must be entirely cleaned and
free from dirt and scale from the inside (by blowing through with high
pressure air)
3. Piping from the compressor to the storage must be at least ½” (12mm)
in diameter. Never reduce pipe size in the discharge line from a
compressor, minimize bends and fittings in the discharge line.
4. Ensure that all piping to the inlet and from the discharge has been
pressure tested to a minimum of one and half times the working
pressure of each system.
NOTE:
Failure to do this could result in serious injury to nearby personnel.
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5. Before completing pipe work assembly, ensure that all port protection
plugs and blanks have been removed and suction piping is clear of
jointing compound, scale, swarf, dirt, moisture or any other foreign
substance.
4.5. COOLING SYSTEM
The compressor is cooled by a closed circuit system via the cooling tower.
The cooling system should have an adequate corrosion and scaling
inhibitors for maintenance free operation for extended periods, such as
50% Glycol/water solution or similar preparation. Water levels are
maintained by daily “Top up” of the water tank, located on the top of
water circuit.
4.6. LUBRICATION
1. Prior to initial operation, the crankcase of the compressor must be
filled with recommended lubricating oil.
2. It is important to use oil from a known reputable source. Use of
inferior quality oil may create service problems with valves, bearings,
oil pump etc. that will be costly to repair.
3. Check lubricator, flow rate is in accordance with recommended
settings.
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5. COMMISSIONING
Before starting up the compressor for the first time, ensure that one is
familiar with the safety devices and type of controls.
1. Fill the crankcase with oil up to the half way mark on the sight glass.
(Approx. 12 liter)
2. Fill water circuit through cooling tower and bleed air from water
pump as well as the air bleeding points on the compressor.
3. Check for correct voltage and phase sequence; if the phase sequence
is not correct then the phase failure relay will not allow motor to
start.
4. Check V-belts for correct alignment and tension; adjust if necessary.
5. Rotate compressor manually by rotating the fly wheel few full turns
to achieve pre lubrication and to ensure that it is rotating smoothly.
5.1. START-UP PROCEDURE
1. Disconnect the inlet manifold pipe and all inlet pipes to all three
compression cylinders for initial startup
2. By activating the solenoid valve purge the pulsation tank of air until
gas is adequately present. (Caution must be taken during this
procedure to have adequate ventilation and ensure that there are no
ignition sources for at least 10 meters.
3. Disconnect the oil lubricator pipe from all cylinders and pump each
lubricator pump by hand until the oil appears at the discharge end of
each pipe. Reconnect the pipes and continue pumping for another
twenty full strokes.
4. Check that the final discharge valve is open and that the pipe is free
from obstruction.
5. Start/Stop the compressor until discharge gas noise is heard and
check the direction of the rotation. Rotation should be such that the
water pumps are rotating correctly.
6. Replace the inlet pipe to the first stage. Check that all pipe
connections are securely tightened.
7. Check that all pressure switch settings are as recommended in the
manual.
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8. Start the compressor and allow it to run for no longer than 30
seconds during which time oil pressure should be checked to ensure
that it has risen and that gas has flowed through the first stage in
sufficient quantity and to ensure that any foreign matter has been
blown clear.
9. Replace the inlet pipe to the second stage and repeat to clear any
foreign matter. Continue in this manner until all piping is back in
position and securely tightened. The compressor is now ready for
final startup.
10. Having done an initial startup satisfactorily, restart the compressor
and observe the interstage pressures are as recommended in the
operating settings.
11. Check that the receiving vessels to be filled have their valves open.
5.2. NOTES OF CAUTION
1. The discharge pipes from each stage should not be touched during
running as a painful burn can result.
2. Ensure that the cooling system has had sufficient anti-freeze added
to the coolant for the climatic conditions that prevail.
3. A shut-off valve is installed in the high pressure discharge line; the
operator should make certain that this valve is open before starting
the compressor. In addition, a relief valve is also included in the line
between compressor and the shut-off valve.
4. Do not allow the motor to rotate in the wrong direction for more
than a few seconds. If incorrect rewire immediately.
5. For the first start (or after any maintenance repairs have been
performed), make sure adjustments are made if bearing run hot or
if the drive belts do not run true on their respective pulleys.
Observe and obey all safety precautions.
6. The compressor controller gauges should read as indicated in the
table of operation controls and indicators after the discharge
pressure reaches 3600 psi.
7. Safety valves have been set at the factory to relieve at the proper
pressure. Do not change or alter these settings.
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6. OPERATING INSTRUCTIONS
The commissioning procedures described in the previous sections should
be followed for the first time commissioning operation, after a
compressor overhaul or after the compressor has been idle for long
periods (over 4 weeks)
The compressor and its surrounding area should be kept clean at all times.
The exterior of the compressor, especially pipes connections and joints
should be kept clean. If oil film and condensate is wiped clean regularly,
any leaks that occur will be more readily identified.
It is good to monitor and record the interstage gas pressures,
temperatures, currents, hour meter reading, etc. This information is as
per sample Daily log sheet attached. This information gives a good
indication of machine operation and can give advanced warning of
malfunction. The readings vary with ambient temperature and final
discharge pressure but are usually within ±5%. A useful visual indication
can be obtained if the gauge glass is marked at the normal readings.
6.1. SAFETY PRECAUTIONS
1. Read all starting & operating instructions before running
compressor.
2. Do not work over compressor without ensuring that all equipment
is isolated from the electrical supply and will remain isolated
whilst work is in progress.
3. Always open high pressure gas line valves slowly.
4. Never attempt to stop leakage or tighten joints or loose parts
when compressor is running and parts are under pressure
5. Never operate the compressor with a malfunction in the oil or
cooling water system. Should a fault develop in either of these,
the compressor must be stopped immediately and the fault
investigated and remedied.
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6.2. START-UP PROCEDURE
1. Before starting the compressor, the operator should be familiar
with the type of controls and all the safety devices fitted to the
compressor.
2. Check oil level in crankcase and top up if necessary using
recommended oil until level in sight glass is on maximum.
3. Check water level in sight glass and top up if necessary.
4. Check Vee-belts are in good condition and correctly tensioned.
5. Check main isolator switch is ON, the Emergency Stop button is
unlatched and fault circuits are Reset.
6.3. RUNNING ON LOAD
1. Press Start button.
2. If the storage cascade pressure is below the Re start set point of
switch gauge, the compressor motor will start up immediately on
STAR and then change over to DELTA after the time set time delay
of approx. 5-8 seconds (Note: Motor will not start if any of the
overload circuits i.e. compressor motor current overload,
thermistor (for Ex motors), phase failure relay, cooling tower fan
motor overload, water pump motor overload OR temperature fault
circuits are activated).
3. Immediately after the starter contactors change over to DELTA, the
gas inlet solenoid will be activated. However, at this stage the
unload valve is still de-energized and will not allow the compressor
to build up to its full operating pressures.
4. The timer T1 set at approx. 20 seconds (Condensate blowdown)
and timer T4 set at approx. 30 seconds (oil safety By pass) are
activated when the Start button is pushed.
5. The timer3 is set at approx. 20 seconds (Safety bypass) is activated
after the compressor comes on Load.
6. Hence after a lapse of 20 seconds from the time the Start button
was pushed, the compressor goes on Load. The indicator light on
the electric control panel will also show this condition.
7. After a lapse of 40 seconds from the time the Start button was
pushed, the compressor gets into normal on load operation
ensuring that all safety circuits are working correctly.
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8. The compressor is fitted with an automatically fitted unloader to
mechanically remove any oil and condensate from the compressor.
This is controlled by timer T2 set at 30 minutes and timer T1 set at
20 seconds. The operation of the unloader is such that it will
operate whenever the compressor is shut down, during start-up,
and after every 30 minutes of continuous compressor operation for
a period of 20 seconds.
9. The compressor will continue to operate until the final stage gas
pressure reaches the set point for automatic shut down e.g. 250
bars. On reaching this set point, the compressor motor will be de-
energized and the unloader will be energized to bleed gas from all
the cylinders back to the Blow down Recovery vessel. This means
that the compressor is ready and waiting for a signal to restart
automatically as soon as the gas storage pressure falls to the set
point.
10. As gas is used from the storage cascade and the final stage gas
pressure reduces to the set point; e.g. 205 bars, then the
compressor will automatically restart. It will now go through the
same sequence as in steps 2-9 above.
11. During normal operation, the compressor can also, be stopped by
pressing Stop button or the Emergency Stop Button on electric
Control Panel OR the Emergency Stop Button fitted on the side or
front of gauge panel.
6.4. SAFETY CIRCUITS
The compressor operating conditions that are monitored under which the
compressor will be shut down on a Fault are as follows:
1. Low gas inlet pressure
2. High gas inlet pressure
3. Low oil pressure
4. 3rd
stage high gas discharge temperature after cooler
5. Water flow failure
6. Electric motor current overload (overload indication)
7. Electric motor thermistor (Overload indication)
8. Cooling tower fan motor overload (overload indication)
9. Water pump motor overload (overload indication) if fitted
10. Phase failure (overload indication)
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11. Low oil level (optional)
12. High vibration (optional)
13. Gas leak detector (optional)
6.5. INSTRUMENTS & INDICATORS
The electric control panel has the following indicator lights
1. Low/High gas inlet pressure
2. Low oil pressure
3. Discharge gas temperature
4. Overload
5. Ready
6. On load
7. Water flow switch
The Electric control panel has the following switches
1. Reset push button
2. stoop push button
3. Start push button
4. Emergency stop (latch-in-type)
5. Load break isolating switch (with door interlock)
The Electric control panel has the following instruments
1. Voltmeter
2. Ammeter
3. Hours Run
The Gauge panel is fitted with the following
1. Oil pressure switch gauge
2. Low/High gas inlet pressure switch gauge
3. 1st stage gas discharge pressure
4. 2nd
stage gas discharge pressure
5. 3rd
stage gas discharge pressure Stop-Start switch gauge
6. 3rd
stage gas temperature after cooler switch gauge
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The compressor is fitted with the following
1. Oil level sight glass
2. Water level sight glass (only in close circuit system)
6.6. LUBRICATION
The plunger type oil pump with internal by pass relief valve is fitted on
front of the compressor. It draws oil from crankcase through strainer
through a check valve via full flow replaceable filter and passes through
the oil pump plunger to the oil pressure chamber. From this point the oil
is under pressure and is fed through the drilled passages in the crankshaft
to the connecting rods and main bearings. The cross head pistons and
cylinders are splash lubricated by throw-off from the connecting rod
bearings. Non-adjustable pressure relief valve that bypass excess oil to
the crankcase sump. The relief valve also serves as a pulsation eliminator
for oil pressure peaks.
The lubrication circuit is shown on the attached P&I diagram.
An oil pressure switch gauge is fitted as standard which indicates the oil
pressure in the system as well as provides a safety on low oil pressure.
6.7. SAFETY SHUT DOWN
An oil level sight glass allows for easy inspection of oil level in the
crankcase. An option is available to add a low oil level shut down safety
switch to monitor the oil level in the compressor crankcase.
6.8. OIL QUALITY
1. Oil should be of uniform viscosity, non-detergent and super refined
with rust and oxidation inhibitors. Oil should be of naphthenic base
of a specially compounded type to minimize carbon formation and
to produce carbon residue of a soft and fluffy nature. Oils having
animal fat compounding are not recommended.
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2. Use the following weight oils for the ambient temperature ranges
as indicated below is recommended:
a. Above 60 °F : SAE 30
b. 32 to 60 °F : SAE 20
c. Below 32 °F : SAE 10W
3. Viscosity according to ISO Classification ISO VG 100 i.e. 90-100 cst
(mm2/s) at 40 °C (Resp. 55-70 cst or 7-9 deg E at 50 °C)
4. Viscosity index: min. 80
5. Flash point: min. 200 °C
6. Stock point: max. –12 °C resp. pour point: max –9 °C
To achieve good water separation properties, the oil should not, or to
a light degree only, contain dispersant additives.
6.8.1. LIST OF SUPPLIERS WITH SUITABLE OIL QUALITIES
BP Energol RC 100 (ISO) or TH-100 HB (ISO)
CALTEX RPM Compressor Oil 100 or Regal Oil R+0 100
CASTROL Aircol PD 100 or Perfecto T100
ESSO Compressor oil S 100 or Nuto 100
GULF Compressor oil 100 or Harmony 100
Mobil Rarus 429 or DTE 103
Shell Corena H 100 or Turbo oil T100
Texaco Compressor oil VD-L 100 or Regal oil100(R+O)
Valvoline compressor oil 62 or R-506 TOS
6.9. COOLING
Satisfactory compressor operation depends on effective cooling which
requires positive circulation of cool, clean water, free from suspended
particles.
The compressor is water cooled through centrifugal pump which is driven
off compressor crankshaft pulley and cooling tower installed in the safe
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zone. A closed type circuit is also recommended where cooling water
purity and quality is difficult to achieve. However, it should be done with
factory consultation.
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Operational Parameters Parameters Stage 1 Stage 2 Stage 3 *Normal Working 147 705 3625
Pressure (Psig) Maximum Working 184 881 4530 Pressure (Psig) Normal Inlet Working 40 35 35
Temperature (˚C) Maximum Working 50 50 50 Inlet Temperature (˚C) Normal Outlet Working 140 120 160
Temperature (˚C) Maximum Working 200 200 200
Outlet Temperature (˚C) Power Requirement = 68 KW Motor Installed = 75KW
Note: * All Working Pressures and Temperatures are within ±5%
Tolerance.
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7. FAULT GUIDE
S. No. Symptoms Fault Recommendations
1 Oil pressure is
incorrect
Insufficient oil in crankcase Fill crankcase to oil level
Relief valve spring broken Replace spring
Relief valve held open with
dirt Disassemble & clean
Oil pump ball valves held
open with foreign matter Disassemble & clean
Faulty oil pressure gauge Replace gauge
2 Low inlet pressure
Restriction in inlet line Remove restriction
Blocked inlet filter line Replace filter
Insufficient gas supply Contact gas supply
authority
Faulty inlet pressure gauge Replace inlet pressure
gauge
3 High inlet pressure Supply regulator failure Contact gas supply
authority
4 High 1
st stage
pressure
Faulty gasket on 2nd
stage
inlet valve
Check gasket for signs of
leakage and replace
5 High 2
nd stage
pressure
Faulty 2nd
stage inlet valve Repair/ replace valve
Faulty 3rd
stage inlet valve
OR gasket Repair/ replace valve
6
Compressor
capacity down with
low 1st
stage
pressure
1st
stage valves leaking or
faulty
Repair/ replace 1st
stage
valves after checking.
Can be inlet or discharge
valve
1st
stage unloader valve
diaphragm leak
Replace diaphragm
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S. No. Symptoms Fault Recommendations
7
Compressor
capacity down, with
normal inter stage
pressure ( but very
hot blow by on 3rd
stage
Final stage rings worn
excessively Replace final stage rings
8
Capacity down with
low 2nd
stage
pressure ( but very
hot blow by on 2nd
stage
2nd
stage rings worn
excessively Replace 2
nd stage rings
9 Intermediate
pressure too low
Damaged pressure gauges Replace gauge
Damaged discharge valve of
the forgoing stage or 1st
stage
Repair/ replace valve
High leakage rate across the
piston rings back to
forgoing stage and very hot
blow by pipes
Check and replace
piston rings
Low suction pressure Contact gas supply
authority
10 Safety valve blow
off
Closed or clogged shut off
device in discharge piping
of compressor
Locate & repair
Stage pressure too high
Check gaskets and
valves , also for high
inlet pressure
Damaged seat of safety
valve or wrong setting Check & replace
Faulty high pressure switch
gauge
Check electric &
snubbers
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S. No. Symptoms Fault Recommendations
11
Compressor
temperature too
high
Too high ambient
temperature Increase air flow
Insufficient intermediate
cooling (damaged fan,
wrong flow direction of
cooling air, fouled cooler)
Correct or repair
Damaged suction &
discharge valves
Repair/ replace valves
Damaged part inside
compressor (seizure of
piston, corroded cylinder)
12 Oil consumption
too high
Several oil leaks Replace seals
Wiper seals are worn
Oil level too high in
Crankcase Lower oil & gain level
13 Oil leakage from
crankcase
Damaged gaskets or
crankcase seals Replace
Clogged venting device
causing too high pressure in
crankcase
Check crankcase relief
valve
Worn piston rod seals
causing over pressure Check & replace
14
Noisy or hot
crankcase
Damaged bearings Check & replace
Insufficient lubrication Check & replace oil level
Too much axial clearance of
crankshaft
Check clearances as per
chart
Contamination in bearings Check & replace, also
replace oil filter
Loose fly wheel
Check fly wheel and key
retighten 1360 NM (
1000 Ft-lb)
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15 Compressor knocks
( stop immediately)
Too much clearance in the
bearings of crankshaft,
crankpin, piston pin
Investigate & repair
Broken valve parts or
foreign particles in cylinder
Identify foreign particles
and replace clean
affected parts
Piston clearance wrong
Identify which piston
increase clearance as
specified
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8. SERVICING/ MAINTENANCE INSTRUCTIONS
8.1. GENERAL
Regular inspections along with proper corrections of any fault found will
prolong the useful life of your compressor. A regular inspection and
service schedule is outlined in the following paragraph. Please bear in
mind that this schedule is flexible and depending on the type of service,
location, weather condition etc. It may be changed to suit individual
conditions.
8.2. DAILY INSPECTION AND MAINTENANCE
It is useful to record stage pressures, temperatures, oil used in a log
against hour’s run, as this builds up a detailed record of machine
condition. It can also provide a trend and indication of a possible
problem.
1. Before starting OR while machine is idle & unloaded check oil level.
Fill to full mark, if oil level is low. Oil level must be kept between
high and low level marks on sight glass.
2. Drain condensate from blowdown manifold by opening drain cock.
3. Check water levels and refill if necessary.
Warning
Compressed gas is very dangerous. It must be treated with respect and
handled with care. The utmost caution should be observed when opening
any valve after the gas has been compressed. Make certain that no
person or object, that could be moved or damaged, located in the path of
the compressed gas discharge from valve. This gas travels at an extremely
high velocity and should be considered as dangerous as a gun.
Never play with compressed gas!!!! never point a Gas hose at
someone !!!! Never treat compressed Gas lightly.
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Start compressor, and record in your daily log book the following
1. Oil pressure and amount used.
2. Interstage gas pressures.
3. Inlet gas pressure.
4. Water temperature.
5. Gas Company Meter Readings.
6. Any Problem or fault on compressor.
8.3. 50 HOUR RUN IN MAINTENANCE
1. Check interstage pressures.
2. Retighten V-Belts
3. Check for leaks.
4. Check cylinder head bolts and re torque.
5. Check compressor mounting bolts & motor mounting bolts.
6. Check water temperature.
7. Check interstage cooler discharge pipes.
8. Check cooling water level.
9. Change the crankcase oil and oil filter while the compressor is still
warm.
8.4. 3 MONTHLY OR 2000 HOUR INSPECTION AND MAINTENANCE
1. Repeat all DAILY inspection and maintenance procedures as above.
2. While compressor is warm, drain and replace crankcase oil. Remove
side cover from crankcase, inspect and clean the strainer screen.
Remove and replace the oil filter cartridge.
3. Check and make certain that all gas connection are tight and
secure.
4. Check vee belts on drive and water pump for tension and condition.
8.5. 4500 HOUR INSPECTION AND MAINTENANCE
1. Repeat all three monthly inspections and maintenance procedures.
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2. Remove, clean and inspect all compressor intake and discharge
valves. Repair or replace as necessary.
3. Check crankcase venting and distance piece for seal condition.
4. Check discharge capacity.
8.6. 9000 HOUR INSPECTION AND MAINTENANCE
1. Repeat all 4500 hours inspection.
2. Remove and recalibrate all pressure and temperature gauges,
replace if necessary.
3. Check function of safety valves and recalibrate them.
8.7. GENERAL DAILY INSPECTION
What to Inspect What to Inspect for
Surroundings Note dripping water, dust, chips or dirt
On or about the compressor. See if any
boards, canvas, paper or any foreign
objects are left about that might jam
any moving part or may interfere with
proper ventilation.
Technical Conditions Motor or bearing block distress will often
show up in unusual noises caused by
abnormal metal to metal contact or
odors from overheated insulation or
grease.
Bearings Feel bearing housings or pillow blocks
for evidence or excessive heat.
Warning
Shut down compressor prior to checking for heat.
8.8. DRIVE BELT TENSION AND ALLIGNMENT
Checking parallel shaft alignment and axial groove alignment may be done
simultaneously. To obtain accurate alignment, a straight edge should be
used for this measurement, or when a straight edge is not available, a
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taut line may be substituted. Perfect alignment proves to be impossible, a
rough rule of thumb to determine permissible limit of misalignment is
0.4mm (1/54”) out of line for each 300mm (12”) between shaft centers. If
drive belts are too loose, there will be slippage and rapid wear of belts.
Slippage is usually indicated by a squealing or howling noise. Always refer
to belt manufacturer’s catalogue
for proper tension to be applied. Adjust tension by moving motor in
direction necessary to increase or decrease tension. Tighten flywheel nut
to 1356 Nm (1000 lbs ft) torque.
Shaft must be in angular and parallel alignment and sheave grooves
axially aligned to obtain proper performance of V-belt drives. Angular
alignment is obtained by leveling shafts.
8.9. BASIC STEPS FOR V-BELT INTALLATION
1. Reduce centers so belt can be slipped on sheaves 2. Have all belts slack on same side
3. Tighten belts to eliminate slack
4. Start unit and allow belts to seat in grooves
5. Stop the unit then retighten to make sure belts have proper
tension.
6. Recheck tension in 24 to 48 hours.
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9. REPAIR AND REPLACEMENT
9.1. MAINTENANCE AND REPAIR PRECAUTIONS
1. Maintenance and repair may be carried out only on the shutdown and
entirely vented compressor unit. If necessary, empty the receivers and
coolers. First, the main switch in the switchboard of the unit has to be
set to the “OFF” position. Erroneous switching on of the unit should
be prevented by locking the main switch or by providing a
corresponding instruction label.
2. Before starting the work, be sure by opening all manual drain valves,
that the compressor is entirely pressure-less.
3. After modification or repair work on pressure vessels and safety
equipment, all work must be tested and accepted by the inspection
authority concerned.
4. Only use original spare parts and recommended products for
maintenance and repair works on the compressor unit.
5. Never do work connected with heat production like welding near oil or
gas systems. Before working on oil or gas tanks empty them and clean
them carefully, e.g. by a steam jet or purge with nitrogen.
6. During maintenance and repair work observe strict cleanliness. Keep
impurities away, by covering dismounted parts and free opening with a
clean rag, paper or adhesive tape.
7. After having finished the works be sure that no tools, loose parts or
cleaning rags have been left on or in the compressor unit.
8. Do not use easily flammable solving agents for cleaning of parts, until
the unit has cooled thoroughly. After the use of solving agents
carefully rinse the parts and clean them with compressed air.
9. Be very careful, use eye protection, when working with compressed air
for cleaning equipment.
10. The manufacturer takes no responsibility for personal injury or
damage on the unit, caused by the non-observance of the safety
precautions during handling, operation, maintenance or repair of
compressor units.
11. After modification or repair work to compressor and before power is
applied to machine, always manually turn compressor over by hand
using flywheel to ensure compressors running free.
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9.2. 1ST STAGE SUCTION VALVE
9.2.1. REMOVAL
1. Remove 3x bolts on suction valve cover.
2. Lift off valve cover.
3. Remove and discard cover O ring.
4. Remove lantern
5. Remove valve from its seat.
6. Remove metal gasket from seat in head and discard.
9.2.2. INSTALLATION
1. Carefully wipe any loose carbon from valve seat/ pocket ensuring
that no carbon is left in the pocket or on top of the piston.
2. Apply thin smear of grease on valve gasket and place its position.
3. Rotate the valve back & forth to ensure proper seating.
4. Place lantern in valve pocket and rotate to check seating.
5. Place the cover and bolts in right position and gradually apply
torque evenly to final torque value of 48 ft.lb
9.3. 1ST STAGE DELIVERY VALVE
9.3.1. REMOVAL
1 Remove 3x bolts on delivery valve cover.
2 Lift off valve cover.
3 Remove and discard cover O ring.
4 Remove lantern
5 Remove valve from its seat.
6 Remove metal gasket from seat in head and discard.
9.3.2. INSTALLATION
1. Carefully wipe any loose carbon from valve seat/ pocket ensuring
that no carbon is left in the pocket or on top of the piston.
2. Apply thin smear of grease on valve gasket and place its position.
3. Rotate the valve back & forth to ensure proper seating.
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4. Place lantern in valve pocket and rotate to check seating.
5. Place the cover and bolts in right position and gradually apply
torque evenly to final torque value of 48 ft.lb
9.4. 1ST STAGE HEAD
9.4.1. REMOVAL
1. Remove lubricator piping.
2. Remove suction tank discharge tanks and piping.
3. Remove gaskets and discard.
4. Remove 04 bolts (90 degree apart) around head.
5. Lift the head carefully.
6. Remove the head to cylinder gasket and discard.
9.4.2. INSTALLATION
1. Place the new head to cylinder gasket with liberal amount of grease
on both sides.
2. Place the head in right position.
3. Install the 04 bolts & torque them as per torque chart
2.37Nm/175Lb.Ft.
4. Install suction & discharge tanks with new gaskets greased on both
sides.
5. Replace lubricator piping.
9.5. 2ND STAGE VALVE AND HEAD
9.5.1. REMOVAL
1. Remove lubricator piping from head.
2. Remove unloader piping from pulsation damper/ condensate
collector on the suction side of the stage.
3. Remove 1st stage heat exchanger to 2nd stage head piping.
4. Check integrity of O ring at head end and replace as necessary.
5. Remove 2nd stage head to 2nd stage heat exchanger piping.
6. Check integrity of O ring at head end and replace as necessary.
7. Evenly loose head bolts and remove head.
8. Remove head to valve gaskets (Inner & Outer) and discard.
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9. Remove valve.
10. Remove valve to cylinder gasket and discard.
9.5.2. INSTALLATION
1. Ensure all surfaces on cylinder and head are clean and free of
imperfections.
2. Apply a thin smear of grease on the valve/cylinder gasket and place
it in position.
3. Place piston on top dead center.
4. Check head clearance as per clearance chart.
5. Place valve in position and rotate back & forth to ensure correct
seating.
6. Apply a thin smear of gasket cement to the cylinder side of the
inner gasket and place in position on the valve.
7. Apply a thin smear of grease to the valve /head gasket and place in
position in the head.
8. Carefully place head in position on the valve-beware of sudden
movements that may disturb the inner gasket.
9. Apply anti-seize to head bolts, position and hand tighten.
10. Evenly apply gradual torque until the required torque as per torque
chart.
11. Replace 2nd stage head/2nd
stage heat exchanger piping.
12. Replace 1st stage heat exchanger/2nd
stage head piping.
13. Replace suction tank piping.
14. Operate lubricator pump to expel all air from the lubricator piping.
15. Replace lubricator pipe.
16. Re-torque head bolts to original torque after 24 hours running.
9.6. 3RD STAGE VALVE AND HEAD
9.6.1. REMOVAL
1. Remove lubricator piping from head.
2. Remove un-loader piping from pulsation damper/condensate
collector on the suction side of the stage.
3. Remove 2nd stage heat exchanger to 3rd stage head piping.
4. Check the integrity of O ring and replace as necessary.
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5. Remove 3rd
stage head to 3rd
stage heat exchanger piping.
6. Check the O ring condition and replace if required.
7. Evenly loosen head bolts and remove head.
8. Remove head to valve gasket and step ring and discard.
9. Remove valve to cylinder gasket and discard.
9.6.2. INSTALLATION
1. Ensure all surfaces on cylinder and head are clean and free of
imperfections.
2. Apply a thin smear of grease on the valve/cylinder gasket and place
it in position.
3. Place piston on top dead center.
4. Check head clearance as per clearance chart.
5. Place valve in position and rotate back & forth to ensure correct
seating.
6. Apply a thin smear of grease to step ring, place in position, and
rotate to ensure correct seating.
7. Apply a thin smear of grease to the valve /head gasket and place in
position in the head.
8. Carefully place head in position on the valve-beware of sudden
movements that may disturb the inner gasket.
9. Apply antiseize to head bolts, position and hand tighten.
10. Evenly apply gradual torque until the required torque as per torque
chart.
11. Install lubricator piping (bleeding as required).
12. Install 3rd
stage head to 3rd
stage HEAT EXCHANGER piping.
13. Install 3rd
stage head to 2nd
stage HEAT EXCHANGER piping.
14. Retorque head bolts to original torque after 24 hours running.
9.7. COMPRESSION CYLINDER
9.7.1. REMOVAL FOR 1ST, 2ND & 3RD STAGE
1. Drain water from machine
2. Remove head as per section 9.4.1 for 1st
, 9.5.1 for 2nd
and 9.6.1 for
3rd
stage.
3. Remove water piping from cylinders.
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4. Rotate compressor to bring the piston on top dead center.
5. Unscrew piston locking nut.
6. Unscrew piston from piston rod, keeping rings in order of original
assembly for inspection purpose.
7. Remove piston from cylinder.
8. Rotate compressor to bring piston rod at bottom dead center.
9. Equally loosen and remove cylinder nuts.
10. Carefully remove cylinder by lifting over rod, the threads on the rod
can damage the cylinder bore if contact is made.
11. Remove and check the integrity of the cylinder to seal carrier O
ring.
9.7.2. COMPRESSION CYLINDER INSPECTION
The compressor cylinders are precision honed for standard size pistons
only. Inspect the cylinder bore closely. If a cylinder is out of round, worn,
or deeply scratched, it must be replaced with a new one or the sleeve
pressed out and a new sleeve fitted. The new sleeve should be honed to
.4 microns to the diameter specified. A worn cylinder is indicated by
visible ridging at the end of the ring travel, while an out of round cylinder
can be determined as follows:
Take micrometer reading at various positions along the length of bore of
the cylinder.
9.7.3. INSTALLATION FOR 1ST, 2ND & 3RD STAGE
COMPRESSION CYLINDER
1. Check the O ring on the seal carrier plate.
2. Apply smear of grease to seal carrier and underside of cylinder
base.
3. Place piston rod at bottom dead center.
4. Place cylinder over rod and into position on seal carrier.
5. Place in position and torque to required torque guide
cylinder/cylinder nuts.
6. Place piston rod at top dead center.
7. Apply a liberal amount of crankcase oil to cylinder bore.
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8. Place piston and fittings in position on rod and screw in position,
placing rings in position as piston enters bore. Remember
stamped numbers on rings are placed towards pressure.
9. Install piston washer and nut and torque to required torque-
using special tools as required.
10. Install heads as per 9.4.2 for 1st
stage, 9.5.2 for 2nd
stage and
9.6.2 for 3rd stage.
9.8. ROD SEAL CARRIER
9.8.1. REMOVAL
1. Remove head as per 9.4.1 for 1st
stage, 9.5.1 for 2nd
and 9.6.1 for
3rd
stage.
2. Remove cylinder as per 9.1.1.
3. Remove seal vent piping if present.
4. Place seal protector tool on piston rod threads.
5. Lift seal carrier from guide cylinder top and carefully remove by
lifting seal carrier up the rod and over the seal protector.
6. Check the integrity of seal carrier to guide cylinder O ring seal
and replace as necessary.
7. Remove cap screws from seal block flange.
8. Remove seal pack from seal carrier plate.
9. Remove nuts from seal pack studs.
10. Remove breakdown assembly, then oil rod seals, rod seals, O
rings etc.
11. Note position of seals for inspection purpose.
12. Check the integrity of seals and O rings, replace as necessary.
13. Assemble seal pack.
14. Install seal pack into seal carrier plate.
9.8.2. INSTALLATION
1. Assemble seal pack and install into seal carrier.
2. Place rod thread protector in position and well oil with
crankcase oil.
3. Ensure O ring in position in underside of seal carrier.
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4. Carefully place seal carrier assembly over thread protector on to
the guide cylinder in right position.
5. Install compression cylinder per 9.7.3.
6. Install head per 9.4.2, 9.5.2 and 9.6.2.
9.9. GUIDE CYLINDER FOR 1st
, 2nd
& 3rd
STAGE
9.9.1. REMOVAL
1. Remove head as per 9.4.1 for 1st
, 9.5.1 for 2nd
and 9.6.1 for 3rd
stage.
2. Remove cylinder as per 9.7.1.
3. Remove seal carrier as per 9.8.1.
4. Loosen guide cylinder/crankcase stud nuts, bolts and remove
them.
5. Carefully lift crosshead cylinder from crankcase.
9.9.2. INSTALLATION
1. Place new guide cylinder/crankcase gasket at the lower end of
the guide cylinder or on the crankcase at position where cylinder
is to be installed with smear of grease on both sides.
2. Install the cylinder over the piston and into place. Tighten down
cylinder with cap screws and nuts.
3. Turn the crankshaft slowly until the piston in the reinstalled
cylinder reaches top dead center.
4. Tighten bolts and nuts securing the cylinder to 192Nm.
Note:
During this stage of assembly, adequate lubrication must be provided
to reduce the chance of scuffing the cylinder walls. Use clean
compressor oil and cover the inside walls of the cylinder and dip the
piston in the clean oil so that both components are thoroughly
lubricated.
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9.10. PISTON / PISTON RINGS FOR 1st
, 2nd
& 3rd
STAGE
9.10.1. REMOVAL
1. Remove head as per 9.4.1, 9.5.1 and 9.6.1.
2. Place piston to be removed at top dead center.
3. Unscrew piston locking nut and discard.
4. Unscrew piston carefully from piston rod. Use special tolls as
required.
5. As piston exits the cylinder, remove rings and note order and
position of rings.
6. Remove piston spacer.
9.10.2. INSTALLATION
1. Ensure all surfaces are clean and free of imperfections.
2. Place piston rod at top dead center.
3. Place piston spacer on piston rod.
4. Place piston in cylinder bore and screw in position- position rings
as piston enters bore-note that any characters stamped on ring
face cylinder pressure.
5. Torque piston onto rod.
6. Place piston washer in position, install piston nut and torque nut
to required torque.
7. Place piston to top dead center and check head clearance is
within limits.
8. Install head as per 9.4.2, 9.5.2 and 9.6.2.
9.11. PISTON ROD
9.11.1. REMOVAL
1. Remove head as per 9.4.1, 9.5.1 and 9.6.1.
2. Remove cylinder as per 9.7.1.
3. Remove seal carrier per 9.8.1.
4. Remover guide cylinder cover plates.
5. Loosen cap screws in crosshead piston.
6. Unscrew rod from crosshead piston.
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9.11.2. INSTALLATION
1. Screw rod into crosshead piston.
2. Install seal carrier per 9.8.2.
3. Install compression cylinder per 9.7.3.
4. Adjust head clearance by screwing rod into crosshead piston
thread.
5. Torque up cap screws in crosshead piston.
6. Replace crosshead cylinder cover plates.
7. Replace seal carrier plate as per 9.8.2.
8. Replace cylinder as per 9.7.3.
9. Replace pistons as per 9.10.2.
10. Replace heads as per 9.4.2, 9.5.2 and 9.6.2.
9.12. GUIDE PISTON
9.12.1. REMOVAL
1. Remove head per 9.4.1, 9.5.1 and 9.6.1.
2. Remove cylinder per 9.7.1.
3. Remove seal carrier per 9.8.1.
4. Remove guide cylinder per 9.9.1.
5. Rotate crankshaft until the entire crosshead piston is exposed.
6. Tip piston to expose clamp screw.
7. Straighten lock washer tab.
8. Remove clamp screws and discard.
9. Remove tab washer and discard.
10. Push gudgeon pins out of bearings.
9.12.2. INSTALLATION
1. Check guide cylinder/guide piston clearance by placing piston in
bore and using feeler gauge.
2. Place piston with installed bearings over small end of conrod
and push gudgeon pin in position.
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3. Place tab washer in position on bolt, position bolt rotating
gudgeon pin to align slot in gudgeon as required.
4. Torque bolt to required torque.
5. Bend lock washer tabs over bolt flats to lock in position.
6. Install guide cylinder per 9.9.2.
7. Install seal carrier per 9.8.2.
8. Install compression cylinder per 9.7.3.
9. Install head per 9.4.2, 9.5.2 and 9.6.2.
9.13. CONNECTING ROD BEARINGS REPLACEMENT /
REINSTALLATION
1. Drain the oil from crankcase.
2. Remove piping, tubing, cylinder head and cylinder.
3. Remove the crankcase hand hole cover on side opposite the oil
level indicator by removing the eight cap screws and washers.
4. Remove guide piston per 9.12.1.
5. Remove screws and nuts holding connecting rod to crankshaft.
6. Remove cap and insert type bearings from connecting rod.
7. Install new inserts in connecting rod and reassemble rod.
8. Use a micrometer and take several readings of the bearing and
crankpin diameter bearing at various points to determine the
existing clearance. The use of perfect circle “Plasti gauge” is also
recommended for measuring bearing clearance.
9. Disassemble conrod and lubricate. With proper inserts in place,
reinstall rod onto crankshaft. Connect guide piston to rod,
replace guide cylinder, seal plates, compression cylinder,
cylinder head and piping.
Note:
Each connecting rod and cap is identified with a stamped number. Make
sure the same rod and cap is reassembled on the same side. Under size
bearings in sizes of 0.010” 0.20” and 0.030” are available when the
crankpins are ground to match. Shims are not used and are not available
so that adjustment for wear is obtained only by the use of bearing inserts.
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9.14. OIL PUMP
9.14.1. GENERAL
It is important to understand the operation of the pump and its relation
to the lubrication system of the compressor. Lubricating oil pressure is
provided by a plunger type oil pump driven off the crankshaft. Oil is
drawn through a screen, located in the crankcase sump, through a check
valve and to the pump.
From this point lubrication is under pressure and is carried through drilled
passages in the crankshaft to the connecting rod and main bearings.
Guide cylinders and pistons are splash lubricated by throw-off from the
connecting rod bearings.
9.14.2. CAUTION
Make-up oil may not be added to the crankcase while compressor is
operating. A heavy oil mist will be blown out of the oil filler tube if the
filler cap is opened while the compressor is operating. This is normal and
should not e interpreted as “blow-by”. There is a small flapper type relief
valve assembled in the filler tube cap, which is spring loaded towards the
crankcase caused by the reciprocating motion of the pistons and
crankcase. This valve in the cap allows gas pressure to escape from the
crankcase and prevents air at atmospheric pressure from entering and
maintains a partial vacuum during operation.
9.14.3. OIL PUMP REMOVAL
1. Remove water pump/lube drive pulley.
2. Remove oil connection from oil filter assembly.
3. Screw nuts down on dowel pins and remove tapered dowel pins.
4. Remove pump body attaching bolts/nuts. Remove oil pump
body.
5. Remove plunger and connecting rod assembly.
6. Remove check valve assembly.
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9.14.4. OIL PUMP INSTALLATION
1. Dip plunger in clean crankcase oil and insert into pump body. Be
sure fulcrum pin does not extend beyond diameter of plunger.
2. Install the oil seal (lip facing inward) into pump body. Seal must
be flush with outside of body so oil return passage will not be
obstructed.
3. Re-install pump body to retainer. Exercise care with connecting
rod and seal.
4. Shellac gasket to chamfered end of sleeve. Slip gasket side
(toward compressor) over crankshaft and through oil seal.
5. Assemble cap screws finger tight.
6. Install dowel pins and tighten cap screws.
7. Install water drive pulley, washer and nut, if so equipped.
Tighten nut securely and bend washer tabs on hex nut. Install
lube pump pulley.
8. Reinstall oil connections to oil filter assembly.
9. Install water pump and lubricator belt and adjust.
9.15. CRANKSHAFT
9.15.1. GENERAL
The compressor crankcase is cast in one piece and is closely machined to
carry the crankshaft and cylinders. Tapered roller bearing outer race are a
tap fit in the crankcase bore at the pulley (drive) end, and a press fit in the
retainer located at the opposite end of the crankcase. Bearing caps at
outer race are installed in the crankcase and retainer with the bearing
surfaces facing the center of the crankcase. Metal shims are placed
behind the bearing retainer to adjust the end thrust of the crankshaft. The
main bearing is shrunk fit on the crankshaft. The one piece, Cast Iron
crankshaft is counter balanced for smooth operation. It is rifle drilled to
provide lubrication to the main and connecting rod bearings.
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9.15.2. CRANKSHAFT REMOVAL & INSTALLATION
To remove and replace the crankshaft, it will be necessary to completely
disassemble the compressor. To do this, proceed as follows:
1. Remove all tubing from cylinder heads and between compressor
and heat exchangers.
2. Remove cylinder heads.
3. Remove all pistons.
4. Remove all compression cylinders.
5. Remove all seal carrier plates.
6. Remove all cross head cylinders.
7. Drain oil from compressor crankcase.
8. Remove drive belts and flywheel from compressor.
9. Remove the oil tubing from the compressor oil pump.
10. Remove side plates on each side of crankcase.
11. Remove pistons and connecting rods.
12. Remove oil pump, oil connections and screen in crankcase of
compressor.
13. Remove crankshaft. Use a bearing puller and remove the
bearings from the crankshaft (only if replacement is needed!).
14. Inspect the condition of the crankshaft and bearings for
indications of excessive wear, galling, pitting etc.
15. Tap out the main bearing outer race or cup from each end of
crankcase.
16. The crankshaft connecting rod journals may be reground to a
maximum removal of .76mm (0.030”) of stock to remove
scratches or other damage.
17. After grinding, polish the shaft with a crocus cloth. Use a
micrometer to check the shaft diameter after grinding and
polishing.
18. Insert new tapered roller bearing outer races into each end of
the crankcase. The race, at pulley end, is a tap fit and a press fit
at the retainer end of the crankcase. Make sure the races are
installed with bearing surface facing the center of the crankcase.
19. The main bearings are tapered roller type and are shrink-fit to
the crankshaft. To install the bearings, heat bearing in oil to 350
deg F (177 deg C), place it over the shaft until it rests on the
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machined cheek of the shaft. Make sure that the large diameter
of the bearing, formed by the cage, is facing toward the center
of the shaft.
NOTE
Never use dry heat on the bearing. Be sure that the crankshaft rifle
drillings has had the pipe plug installed before installing the bearings. Be
sure that pipe plug does not protrude and interfere with assembly of
bearing race. The orifice plug is placed at the crankshaft end opposite the
oil pump. Hands spin the bearings after they cool to make certain they
run free and quietly.
9.15.3. CHECKING CRANKSHAFT END THRUST
Install the crankshaft into the crankcase and proceed as follows to check
the crankshaft end thrust:
1. Position an indicator pointer against oil pump end of the
crankshaft.
2. Push the crankshaft as far forward toward the pointer as
possible. Get the indicator needle of the pointer at zero.
3. Pull the crankshaft rearward as far as possible. Note the
indicator reading. Permissible tolerance is 0.127mm min. to
.75mm max.
4. If the crankshaft end thrust is less than the minimum or more
than the maximum, remove the end cover and add or subtract
shims as necessary to bring end thrust within tolerance.
5. Install the end cover oil seal, pointing the seal lip toward the
inside of the compressor. Coat the outside diameter of the seal
with shellac or any other good sealer before installing it in the
retainer.
To avoid cutting the sealing lip while installing the seal, make certain that
the shaft area over which the seal slides is free from sharp edges and
burrs
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9.16. COMPRESSOR REASSEMBLY
To reassemble the compressor refer to “Crankshaft Removal and
Installation”
Reverse the order of disassembly.
BE SURE TO TIGHTEN THE FLYWHEEL RETAINING NUT TO 339Nm
TORQUE.
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10. TORQUE WRENCH SETTING
S. No Fastening Descriptions Thread Size Newton Meter
(Nm)
Pound Feet
(Lb.Ft)
1
Big end cap lock nut 237 175
2 Gudgeon pin lock nut 107 79
3 Cross head cylinder hold
down bolt
176 130
4 ¾” Piston rod lock nut 163 120
5 1-1/8” Piston rod lock nut 237 175
6 Compression cylinder hold
down bolt/nut
176 130
7 1st
& 2nd
stage compression
piston lock nut
54 40
8 3rd
stage compression
piston lock bolt
27 20
9 1st
stage head 217 160
10 2nd
stage cylinder head 176 130
11 3rd
stage cylinder head 136 100
12 4-Valve head valve cap bolt 65 48
13 Fly wheel lock nut 1356 1000
14 Water pump drive pulley
lock nut
542 400
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11. CLEARANCES/ TOLERANCES CHART
Sr. No. Description Recommended
Clearance
1 Crankshaft end float thrust clearance 0.003” – 0.005”
2 Connecting rod to big end bearing running
clearance 1st
stage
0.002” – 0.004”
3 Connecting rod to big end bearing running
clearance 2nd
stage
0.002” – 0.004”
4 Connecting rod to big end bearing running
clearance 3rd
stage
0.002” – 0.004”
5 Compressor oil pump plunger to body bore
clearance
0.002” – 0.004”
6 Oil pump connecting rod to crank shaft Journal
clearance
0.002” – 0.004”
7 1st
Stage Cross head piston / cross head cylinder 0.006” – 0.10”
8 2nd
Stage Cross head piston / cross head cylinder 0.006” – 0.10”
9 3rd Stage Cross head piston / cross head cylinder 0.006” – 0.10”
10 1st
stage Compression piston to head clearance 0.100” – 0.120”
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12. COMPRESSOR EQUIPMENT
12.1. EXPLOSION PROOF ELECTRIC MOTOR
The literature included for the electric motor used provides its
specifications, dimensions as well as information about its servicing and
maintenance.
Details of Electric Motor are attached.
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12.2. PRESSURE SAFETY VALVES
Pressure Relief Valves and Settings
Pressure relief valves are fitted on the discharge of all 3 stages of the
compressor.
The 3 pressure relief valves on the compressor are piped together to a
common manifold from where they are piped out to vent in to
atmosphere.
Pressure relief valves are safety devices which prevent a high pressure
rise within the cylinder. These are not control devices and should never
be used as such. The safety valves are set on a test bench so that they
blow off when the operating pressure exceeds the set point.
The settings for the pressure relief valves are 20% above the maximum
working pressure for each stage except for the final stage which is set at
10% above the maximum working pressure. The settings are as follows
Compressor Max.Working Pressure Relief
Stage Pressure (Psi) Valve Settings
1st Stage 145 Psi 175 Psi
2nd Stage 700 Psi 870 Psi
3rd Stage 33625 Psi 3990 Psi
The pressure relief valves are used on the Hypercomp 3W815 CNG
Compressor are manufactured by Mercer Valve Co. Inc., USA with the
Model Numbers as follows
The pressure relief valves are to be serviced and certified as being at
correct settings according to the time period stated in the Routine Service
and Maintenance at these time periods, the pressure relief valves are to
be removed from the compressor and inspected for their condition. If
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servicing or repair is required, it should be done according to the
manufacturers specifications which are attached.
After any repairs or servicing the pressure relief valves are to be reset
again on a bench and then sealed to prevent tampering after they have
been replaced back on to the compressor. The date of the resetting has to
be recorded in the Log Book.
Details of Pressure Safety Valves are attached.
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12.3. WATER PUMP
Details of the manufactured water pump follow with extracts from the
manufacturer’s catalogue showing maintenance and operating
instructions spare parts lists.
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GENERAL SPECIFICATIONS
Pump Body:
The standard pumps are of high grade Cast Iron with the suction and
discharge connections, and the base of the pump, being incorporated
with the volute in one casting. This feature permits servicing of all working
parts without disturbing pipe work.
Bearing Housing:
Is Cast Iron fitted with 2 neoprene sealed, fully lubricated, heavy duty ball
rollers which are accurately fitted and retained with the pump shaft as a
sealed unit: which under normal conditions will last the lifetime of pump.
The bearings are suitable for operating up to 50°C rise above ambient
temperature.
Shaft:
Accurately machined steel shafts are standard on all pumps.
NOTE: As none of the liquid being pumped comes into contact with the
shaft, special shaft materials are not normally necessary although
stainless steel shafts are available on request.
Impeller:
Of the closed type of high grade cast iron statically balanced and designed
to reduce dynamic and hydraulic imbalance to a minimum.
Seal Assembly:
Is a mechanical seal assembly which bears axially against a special counter
face? The seal is spring loaded to allow automatic compensation for wear,
thus providing prolonged, trouble free service.
The seal assembly is suitable for service conditions up to 150 Psi and
temperature of 100°C without special cooling.
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A special feature of the seal is that the liquid pumped does not come in
contact with the pump shaft.
NOTE:
Pump must not be run dry or seal damage may occur.
Only in extreme conditions are special seals required.
Specials:
All standard pumps are of cast iron construction. Gun metal pumps or
special treatments are available e.g. Silicon or Teflon etc. to suit unusual
applications.
Gunmetal contains 85% Copper, 5% Tin, 5% Zinc, and 5% Lead.
The M series range is also available with semi open impellers suitable for
handling liquids containing fibrous or solid materials in suspension. These
are “MO” series pumps and are available with discharge sizes from 20mm
to 100mm.
Note:
Pumps are supplied without pulleys or couplings unless specified.
Models having flanged suction and discharge connections are supplied
with companion flanged and gaskets.
Accessibility:
Pump is readily disassembled for inspection or service without disturbing
suction and discharge pipes. All working parts are removed as a complete
unit except MH2 and M5 pumps.
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12.4. WATER FLOW SWTICH
The water flow switch is mounted on the outlet of water pump and is
connected to the compressor controller which will close down the
compressor should the flow rate vary from the settings. This flow switch
has been set at the factory to the correct water flow rates.
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12.5. OIL FILTER
Specifications of oil filter used are illustrated below
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12.6. LUBRICATOR
The compression cylinders and valves are automatically lubricated by a
lubricator driven off the compressor drive shaft.
The oil is pumped to the cylinders via stainless steel tube; back flow is
prevented by the fitting of non-returns adjacent to the heads.
The oil is presented to the cylinders in turn, automatically controlled by
the divider valves.
On initializing the system, fill lubricator reservoir with Rarus 429 oil or
authorized equivalent, see reference to full mark on sight glass.
Details are attached.
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12.7. SOLENOID VALVES
There is a 2-way solenoid valve for activating the Gas Inlet Valve whereas
another 3-way solenoid valve is incorporated for Automatic Condensate
Drain Valve Assembly.
Details of these valves are attached.
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CE-E Explosion Proof Solenoid Valves
The valve is inspected to be qualified by the state instrument explosion-
proof safety testing bureau, is in accordance with the standard of
GB3836.1-2000 “general requirements for explosion-proof electric device
in explosion environment” and GB3836.2-2000 “electric device in
explosion environment explosion-proof electric device safety regulation”.
Explosion-proof number is GYB99309.
1. General Description
The valve is suitable for explosive environment which are a kind of
automatic control device used in various industrial processes, they open
and close automatically according to electric-controlled signals in the
control of liquid media, air and gas.
2. Features
These solenoid valves feature:
Wide applications, suitable for various kinds of gas and liquid.
State-of Arts design and compact construction.
(3) Reliable service and high sensitivity. The solenoid valves can work
normally even when the working differential pressure is close to zero.
3. Construction
CE series solenoid valves work on the principle of kick-directed step
action. Each valve is composed of a valve body, a valve cover, a valve core
and a coil. When the coil is charged, the electro-magnetic force thus
produced will attract the armature, causing the pilot valve to open. Then,
the pressure built in the back cavity of the valve core will be released via
the pilot valve, thus building a differential pressure between the main
cavity and the back cavity of the valve core, causing the valve to open.
When the power source of the coil is turned off, the armature will cause
the pilot valve to close under the force of the restoration spring. Then the
differential pressure between the main cavity and the back cavity of the
core will reach balance and the valve will thus be closed under the force
of the spring. A highly sensitive device, the solenoid valves can work with
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a differential pressure that is close to zero and they can therefore be used
to replace the direct operation solenoid valves.
CE-E series is added explosion-proof device on the CE series. The coil shell
can endure the gas explosion pressure for the interval at the explosion
isolating position can prevent the explosion energy transferring. So even if
the inner explosive mixed material occurs scintilla and will explode, it can
still prevent the explosive mixed material in outer space from exploding.
4. Technical specification
Pipe size NPT
1/4
NPT
3/8
NPT
1/2
NPT
3/4
NPT
1
NPT
1¼
NPT
1½
NP
T 2
Flow coefficient (KV) 0.54 1.4 2.8 5 10 16 20 32
Medium
Pressure
(PSi)
CE (F) 0.3~200 3~200 3~100
CE 0~57 0~100
0~57
Medium Temp. (℃) -10~100
Suitable medium Oil, gas, air, water
Power voltage (V) AC220 AC120 (+10% -15%) DC24V DC12V (±10%)
Power consumption AC6.7VA DC11W
Leakage Rate
(ml/min)
0.09 0.15 0.3 0.4
5
Grade of insulation
Grade of protection IP54
Explosion marking ExmIIBT4
Seal material VITON
Body material Brass Stainless steel
5. Installation & Maintenance
1. The pipeline must be clear completely before installation and a
filter is needed at the front of the valve.
2. The arrow marked on the body of a solenoid valve indicates the
flow direction of the working medium.
3. Make sure that the coil of the solenoid valve is always in the
upright position & upwards in order to make the explosion
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marking easy to see and there must remain over 110mm
radiating space.
4. Make sure that the pipe has enough effective threads for a tight
fit with the threads of the solenoid valves. Sealing tapes are
needed for a tight seal.
5. For easy maintenance and routine inspections, the solenoid
valves must be installed in areas that are easily accessible.
6. There is ground screw on the shell and in the junction box of the
solenoid valve and the ground marking is “ 〨”.
7. Change-over cable must be three core fire-preventing cables
with outer diameter φ6, and the rubber sealing gasket of outlet
must be compressed tightly by the compressing nut.
8. During installation, the solenoid valves should not be energized.
Spark not permitted while operating. The maintenance and
testing instrument must be explosion-proof construction.
9. There is explosion-proof junction box with the same explosion
proof level between the outlet cable and out parts.
10. There should be overflow protective device on the power
position to prevent the overflow or over-voltage.
11. After installation, the solenoid valves should have test runs
before being put into normal operation.
12. Wash the valve core and cavities periodically to keep them
clean. During cleaning, pay attention to not damage the seal
faces of the solenoid valves.
13. Among the import cable, the black cable is earthing wire; the
other two are electrical source wires.
6. Sizes and Dimensions
Pipe size NPT
1/4
NPT
3/8
NPT
1/2
NPT
3/4
NPT
1
NPT
1¼
NPT
1½
NPT
2
Orifice size (mm) 6 15 15 20 25 40 40 50
H1 12 14 14 16.5 22.5 30 30 37
H 78 85/100 85/100 88/100 111 145 145 153
W 40 56 56 56 72 128 128 140
L 50 70 70 70 105 140 140 160
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7. Outline drawing
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Explosion Proof Solenoid
Valve
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12.8. TERMINAL BOX
A 4-way terminal box is used for activation of Gas Inlet Solenoid valve,
Blowdown Solenoid Valve and Water Flow Switch.
Details of Terminal Box are attached.
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1. This enclosure has been designed as an electrical enclosure suitable
for installation within an explosive atmosphere as described in BS
EN 50014.
Installation must be in accordance with BS EN 60079 and current
wiring regulations of the country where the enclosure will be
installed.
2. Installation
The enclosure must be fixed into position using the external fixing
lugs provided for this purpose. Under no circumstances must the
enclosure be supported by way of any cable entry device.
The gasket must be secured between the body and the cover.
It is important that the cover is securely fitted to the body of the
enclosure. All cover fixing screws must be tightened down to 3.5Nm
3. Cable entry devices
These must be selected in accordance with the marking on the
cover of the enclosure.
4. “T” Ratings
The enclosure may be approved for installation in various ambient
temperatures. The marking on the label on the cover must comply
with the ambient temperature into which the enclosure is being
installed.
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5. Conductor Installation
All conductors must be fully tightened down within the terminals.
Conductor tightening screws may be below the surface of the
terminal, it is important that the correct sized screwdriver is used.
An oversized screwdriver will break the insulation around the
terminal.
6. Earthing
The enclosure is fitted with a brass M6 hexagon headed internal
and external earth connection; a suitable ring type terminal lug
must be used to secure the earth conductor.
7. Maintenance
Periodic inspection of this enclosure is necessary; refer to EN
60079-17 Clause 4.3 for guidance.
Particular attention should be paid to; gaskets cover fixing screws
and earth assemblies, if any are lost or require replacement,
contact FEEL for the appropriate part. Failure to use approved
replacement parts will very likely invalidate certification.
8. Surrounding Area Conditions
The Junction box has been manufactured from cast iron and is
fitted with stainless steel cover fixing screws. Neoprene or silicone
gasket and brass earth screws.
The performance of these materials should be considered with
respect to contact with aggressive substances with which the
enclosure may come into contact.
The enclosure is intended for use under normal industrial
conditions and must not be installed in an area where extreme
vibration may occur.
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9. Ingress Protection
The enclosure has been tested to IP66 and with the cover fully
tightened down and the use of suitable cable entry devices will
maintain this protection under normal working conditions, however
a minimum protection of IP64 must be achieved.
10. Conditions for safe use
Please refer to the product certificate, a copy of which is available
upon request.
11. Misuse
The enclosure must be used as an electrical enclosure only. It is not
intended for any other function.
12. Tools
Allen Key, 5mm across flats for cover fixing screws.
Box spanner 10mm across flats, for and internal and external earth.
13. CAUTION
The installation of this product must be carried out by suitable
trained and qualified personnel only
Flameproof Electrical Enclosures Ltd., Will not accept any
responsibility for any damage, injury or any form of loss due to
products not being installed or used in strict accordance with
these instructions. If in doubt, please contact us.
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12.9. EXPLOSION PROOF SWITCH GAUGES
The switch gauges used on the gauge panel are all EX rating and are
manufactured by WIKA, Germany.
List of Switch gauges is as follows.
1. Oil Pressure Switch Gauge
2. Low/High Gas Inlet Pressure Switch Gauge
3. 3rd Stage Gas Discharge pressure Switch Gauge
4. Final Gas Discharge Temperature Switch Gauge
Literature is attached.
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13. P & I DIAGRAMS
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14. PERIODIC MAINTENANCE CHART
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15. PART LIST
Following Part Lists are given in the Manual.
1. Crankcase Assembly
2. Crankshaft Assembly
3. Connecting Rod Assembly
4. Oil Pump Assembly
5. 1st stage Cross Head Cylinder Assembly
6. 1st stage Seal Carrier Plate & Stuffing Box Assembly
7. 1st Stage Live Cylinder Assembly
8. 1st stage Suction & Discharge Valve Assembly
9. 1st Stage Internal Assembly
10. 2nd & 3rd stage Cross Head Cylinder Assembly
11. 2nd & 3rd stage Seal Carrier Plate & Stuffing Box Assembly
12. 2nd stage Live Cylinder Assembly
13. 2nd stage Valve Assembly
14. 2nd stage Internal Assembly
15. 3rd stage live cylinder Assembly
16. 3rd stage Valve Assembly
17. 3rd stage Internal Assembly
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18. Internal Assembly
19. External Assembly
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