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OPERATOR MANUAL
for a
HGP37
HIGH PRESSURE
Natural Gas Compressor
In any correspondence please quote: JOB NUMBER:
MACHINE NUMBERS:
(on nameplate)
PUBLICATION NUMBER:
98407.1293
ISSUE DATE
SEPTEMBER 2002
CUSTOMER ORDER NUMBER:
CompAir UK Ltd. Ranelagh Road, IPSWICH. ENGLAND IP2 0AQ
Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Parts Fax: +44 (0) 1473 601282 Service +44 (0) 1473 556027 www.CompAir.com e-mail: [email protected]
DECLARATION OF CONFORMITY
CERTIFICATE 'B' CATEGORY 298/37/EEC ( Known as the ‘Machinery Directive’ ) BS EN292: ( Safety of Machinery )
BS EN1012-1 ( Compressors - Safety Requirements )
97/23/EC ( Known as the ‘Pressure Equipment Directive’ [PED] )
Language. English. French. German. Spanish. Italian. Dutch. We COMPAIR UK LIMITED
of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
declare that under our sole responsibility for supply / manufacture, the machinery described below,
Machine Type Rotary Compressor Reciprocating Compressor Other Pressure Equipment.
Model No. _________________________ Serial No.________________________________
is in conformity with the essential Health and Safety Requirements identified in the above directives.
This machine/equipment complies with 97/23/EC the Pressure Equipment Directive.
IPSWICH, ENGLAND
Signature and name of responsible person
DATE __________________ ENGINEERING DIRECTOR
Position
Notified Body: Lloyds Register
European Directive Services UK Hiramford
Middlemarch Office Village Coventry.
CV4 4FJ
(Notified Body Reference: 0038)
DECLARATION OF INCORPORATION
CERTIFICATE 'D' CATEGORY 298/37/EEC ( Known as the ‘Machinery Directive’ ) BS EN292: ( Safety of Machinery )
BS EN1012-1 ( Compressors - Safety Requirements )
DECLARATION OF CONFORMITY FOR BELOW
97/23/EC ( Known as the ‘Pressure Equipment Directive’ [PED] )
Language. English. French. German. Spanish. Italian. Dutch. We COMPAIR UK LIMITED
of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
declare that under our sole responsibility for supply / manufacture, the machinery described below, Machine Type Rotary Compressor Reciprocating Compressor
Other Pressure Equipment.
Model No. _________________________ Serial No.________________________________ to which this declaration relates is in conformity with the essential Health and Safety
Requirements identified in the above Directives.
This machine/equipment complies with 97/23/EC the Pressure Equipment Directive.
STATEMENT
This machinery must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the above Directives.
IPSWICH, ENGLAND
Signature and name of responsible person
DATE __________________ ENGINEERING DIRECTOR
Position
Notified Body: Lloyds Register
European Directive Services UK Hiramford
Middlemarch Office Village Coventry.
CV4 4FJ
(Notified Body Reference: 0038)
TYPE: TYPE: CHECK OIL LEVEL
SPEED: B.H.P. CHECK WATER IN/OUT TEMPERATURE
SERIAL NO: DRIVE: DATE INSTALLED: CHECK COOLING FAN BLADES
DATE TIME *HOURS
RUN STAGE TEMP.°C FINAL STAGE TEMP.°C STAGE PRESSURES #(BAR - PSI) FINAL AIR PRESSURE #(BAR - PSI) SERVICE PLAN NUMBER REMARKS SEE OVER FOR MORE
SIGNED #50/100 1 2 3 4 5 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500 12000 12500
*FILL IN HOURS RUN AS DETAILED ON SERVICE PLAN FOR PARTICULAR COMPRESSOR TYPE # DELETE AS NECESSARY - † FILL IN APPROPRIATE STAGE TRIP TEMPERATURE READING SERVICE ENGINEER TO SIGN & FILL IN ANY OTHER COMMENTS IN REMARKS COLUMN SERVICE TELEPHONE +44 (0) 1473 556027 - PARTS +44 (0) 1473 601282
CONTROL PANEL H5437.1.NG - - Y55153.001 - - 9.10.1 102
COMPRESSOR MODULE 55153 - - 5437CNG.55153
H5437 .1.NG Bare Shaft Compressor H5437.1.NG - - 98407.1293.6 - - 6 & 7 51/85
BELT DRIVE COMPONENTS H5437.1.NG - 5437CNG.55153 - 9.2 100
Motor Electric - Main 380V/3PH/50HZ H5437.1.NG - Y55153.002 - APP034C 9.11.1 102
Belt Adjustments Vee Drive H5437.1.NG - - 98407.1293.9 - APP12g 9.2 100
Bush Taper Lock Motor H5437.1.NG - - 98074.1347 - APP12g 9.2.18 100
Pulley Motor H5437.1.NG - - 98080.1360 - APP12g 9.2.16 100
Belt SPC 2800 FRAS Vee Drive H5437.1.NG - - 98080.1491 - APP12g 9.2.17 100
Pulley Flywheel Compressor H5437.1.NG - E61673 - - 9.2.5 100
Guard Belt Drive H5437.1.NG - - E61674 - - 9.2.4 100
CRANKCASE & LUBRICATION SYSTEM H5437.1.NG - - 98407.1293 - - 2.3 17
Valve Isolating Lubricating Oil Drain ISOL101 - - 98650.1971 - APP154
Gauge Oil Level LG101 - - 98281.1002 - - 6.1.22 52
Pump Oil H5437.1.NG - - C85737.2 - - 6.3.16 52
Switch Low Oil Pressure PSLL101 - - 98524.1042 - APP088 6.1.31 52
Gauge Pressure Oil PI101 - - 98288.1019 - APP070 7.18.1 88
Valve Relief crankcase PSV03 - - 98650.2088-2.1- APP167 7.1.6 86
Gauge Pressure crankcase - - - 98288.1086 - APP070 7.1.3 88
COOLING WATER PATH H5437.1.NG - - 5437CNG.55153- - - 81
Bursting disc H5437.1.NG - - C201658.2 - - 6.13 56
GAS SYSTEM H5437.1.NG - - 5437CNG.55153 STAGE 40
Valve Solenoid inlet SOL01 - - Y55153.003 - APP153 9.12.1 100
Valve Purge Gas inlet PGE01 - - 98650.2078 - APP154 9.5.24 100
Gauge Pressure Gas Inlet PI01 - - 98288.1086 APP070 7.16.4 87
Valve Non-Return NRV01 - - 98650.2091 - APP169A 9.5.26 101
Valve Gas recovery ISOL01 - - 98650.2082 - APP154 9.5.22 100
Valve Relief recovery vessel PSV01 - - 98650.2088-2.1- APP167 7.16.14 87
Switch Pressure Low Inlet PSLL01 - - 98524.1128 - APP086 7.16.8 87
Switch Pressure High Inlet PSHH01 - - 98524.1127 - APP086 7.16.11 87
Valve Purge Gas inlet PGE02 - - 98650.2076 - APP154 7.16.13 87
PART DESCRIPTION DESIGNATION SCHEDULE No SHEET No PART NO ANCILLARY PUBLICATION. SECTION No Page No
RELIEF VALVE MANIFOLD H5437.1.NG 5437CNG.55153 STAGE 50 9.6 101
COMPRESSOR ASSEMBLY H5437.1.NG 5437.1.GAS/.1.NG 6 & 7 51 & 85
Running gear Assembly 1st Stage H5437.1.NG - - D101719 - 7.5 86
Liner valve parts 1st Stage H5437.1.NG - - D101728 - 7.14 87
Cylinder Assembly 1st & 2nd Stage H5437.1.GAS - - E61641 - - 6.7 54
Cooler Assembly 1st & 2nd Stage H5437.1.GAS - - D101725 - - 6.8 54
Separator Assembly 1st Stage H5437.1.NG - - E61518 - - 7.8 86
Gauge Pressure 1st Stage PI10 - - 98288.1020 - APP070 7.18.2 88
Valve Safety 1st Stage PSV10 - - 98650.1020-10 APP167 6.19.6 57
Diaphragm Drain Valve 1st Stage DDV10 - - U334.L - APP041 6.24 75
Valve Solenoid DDV SOL10 - - Y55153.004 - APP152 9.13.1 102
Running gear Assembly 2nd Stage H5437.1.GAS - - D101750 - - 6.5.2 53
Liner valve parts 2nd Stage H5437.1.NG - - D101729 - 6.14.2 56
Cylinder Assembly 1st & 2nd Stage H5437.1.GAS - - E61641 - - 6.7 54
Cooler Assembly 1st & 2nd Stage H5437.1.GAS - - D101725 - - 6.8 54
Separator Assembly 2nd Stage H5437.1.NG - - E61519 - - 6.8.1.3 54
Gauge Pressure 2nd Stage PI20 - - 98288.1021 - APP070 7.18.3 88
Valve Safety 2nd Stage PSV20 - - 98650.1021-40 - APP167 6.19.5 57
Diaphragm Drain Valve 2nd Stage DDV20 - - U334.L - APP041 6.24 75
Running gear Assembly 3rd Stage H5437.1.GAS - - D101751 - - 6.5.3 49
Liner valve parts 3rd Stage H5437.1.GAS - - D101730 - 6.14.3 56
Cylinder Assembly 3rd & 4th Stage H5437.1.GAS - - E61642 - - 6.9 55
Cooler Coil Assembly 3rd Stage H5437.1.GAS - - D101609 - - 6.10 55
Temperature Trip 3rd Stage TE/TI/TS30 - - C202556.8 -- APP090 6.18.7 56
Separator Assembly 3rd Stage H5437.1.GAS - - D101726 - - 6.10.3 55
Gauge Pressure 3rd Stage PI30 - - 98288.1022 - APP070 7.18.4 88
Valve Safety 3rd Stage PSV30 - - 98650.1022-150 APP167 6.19.4 57
Diaphragm Drain Valve 3rd Stage DDV30 - - U334.J - APP041 6.24 76
Running Gear Assembly 4th Stage H5437.1.NG - - D101760 - - 6.5.4 54
Liner valve parts 4th Stage H5437.1.GAS - - D101731 - 6.14.4 56
Cylinder Assembly 3rd & 4th Stage H5437.1.GAS - - E61642 - - 6.9 55
Cooler Coil Assembly 4th Stage H5437.1.GAS - - D101610 - - 6.11 56
Valve Safety 4th Stage PSV40 - - 98650.1190-275 APP167 7.19.1 88
Separator Assembly Final Stage H5437.1.NG - - D101619 - - 7.20 88
Valve Isolating Separator Drain ISOL61 - - 98261.1071 - C203998 7.21.4.6 89
Diaphragm Drain Valve 4th Stage DDV30 - - U334.J - APP041 6.24 76
Temperature Trip 4th Stage TE/TI/TS40 - - C202960.1 -- APP090 6.18.8 56
Valve Non-Return Compressor Delivery NRV61 - - 98650.1655 - APP158 6.20.3 57
Valve Pressure Compressor Delivery PCV61 - - U572.B - APP059 9.8.3 101
Switch Pressure Final Delivery PSHH/LL/I61 - - 98524.1004 - APP081 9.8.15 101
Flexible Hose Inlet 5437CNG.55153 - - 98315.1211 - - 9.5.30 101
INLET CONNECTION 600 MM LONG FLEXIBLE HOSE 80 NB FLANGE BS4505 PN16.
Flexible Hose Return R/V Manifold 5437CNG.55153 - - 98315.1212 - - 9.6.17 101
1.1/2" BSPT CONNECTION FLEXIBLE HOSE.
Flexible Hose Return Surge Vessel 5437CNG.55153 - - 98315.1212 - - 9.5.29 101
1.1/2" BSPT CONNECTION FLEXIBLE HOSE.
Flexible Hose Final Delivery 5437CNG.55153 - - 98315.1214 - - 9.8.21 102
AMENDMENTS 5437.1.NG PUBLICATION 98407.1293
ISSUE No. MOD NOTE No. CHANGE - M/C SERIAL No. DATE PAGE No’s
1 NEW JULY 2000 ALL
2 Amend 'air' to 'gas' where appropriate, typing error. SEPT 2002 SECTIONS 1 TO 5 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
OPERATOR MANUAL - 5000 SERIES GAS
COMPRESSORS
CONTENTS
Page Ownership Data --- 2 Foreword --- 3 Safety Precautions --- 5 Dry Gases ---11Typical Gas Purging Instructions ---12
WARNING
The use of replacement parts or lubricating oils not supplied, recommended or approved by CompAir UK Ltd, or the failure to maintain this equipment in accordance with the maintenance instructions, may invalidate the WARRANTY, cause equipment failure, create unsafe or hazardous conditions or result in damage to the equipment.
CompAir UK Ltd cannot accept responsibility for damage, injury or failure caused by these situations.
USE ONLY
CompAir UK Ltd
GENUINE PARTS
AND
OWNERSHIP DATA
TECHNICAL DATA
Model Type: Motor Serial Number:
Serial Number Motor RPM:
Year: Motor kW:
Maximum Pressure: Motor V. Ph. Hz:
Compressor Lubricant: Motor Bearing Grease:
(if applicable)
Capacity M³/hr - CFM Notes:
CompAir UK Ltd CONTACT DETAILS
Contact Name: Sales Telephone: +44 (0) 1473 602222
Address:
CompAir UK Ltd Ranelagh Road Ipswich IP2 0AQ ENGLAND
Notes:
Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704
Contact Names: Parts Telephone: +44 (0) 1473 602222
Parts Fax: +44 (0) 1473 601282
Contact Names: Service: +44 (0) 1473 556027
For any comments or queries about the contents of this MANUAL please write to
CompAir UK Ltd, Ranelagh Road, Ipswich 1P2 0AQ. England marked for the
attention of Mr. Dennis Beeton, Technical Publications Engineer.
FOREWORD
CompAir UK Ltd 5000 Series compressors are designed and manufactured to give optimum performance, with long life and reliability.
This Manual will help you to obtain the best performance from your compressor. It provides the information required to install, commission and operate the compressor and carry out regular maintenance schedules, which will ensure the maximum satisfactory service life.
Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing. Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network of CompAir Companies and CompAir UK Ltd Distributors, backed by the Service and
Parts Departments at CompAir UK Ltd, Ipswich (UK) tel: +44 (0) 1473 602222. fax: +44 (0) 1473 601704. Customer Service +44 (0) 1473 556027 or Parts fax: +44 (0) 1473 601282.
The information in this Manual was correct at the time of printing but modifications to parts and procedures may be made without notice which could affect the servicing requirements of the compressor. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or CompAir UK Ltd Distributor for revised or up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL No. and any CONTRACT Ref.
It is important this Manual is retained with the compressor for reference and should remain with the compressor if it is sold or transferred to another user. Ensure that the new user is made fully aware of the need to study the Safety Section and any Warnings for safe operation given throughout the text.
Protect the environment by using only approved methods of disposal.
Please note: a. Throughout the Manual all pressures quoted are gauge pressures.
b. Whilst recyclable materials are used as far as possible, please ensure when disposing of condensate, spent oil, used filter elements and any discarded parts or waste material of any kind make sure that there is no pollution to any natural water-course, drain system and that no burning waste takes place which could cause pollution of the atmosphere.
CAUTION
Use only CompAir UK Ltd Genuine Parts when carrying out routine maintenance or repair. The use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd can lead to expensive failures, which will not be covered by warranty.
Substitution of parts not manufactured or approved by CompAir UK Ltd can create a potential personnel hazard.
This is a High Pressure Compressor, for safe and reliable operation use only genuine CompAir UK Ltd Parts
To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance with the information given in this manual - refer to the “Maintenance Section”.
Conditions of CompAir UK Ltd warranty are stated in our Conditions of Sale. Details of warranty for a particular unit may be obtained from the local CompAir Company or authorised Distributor.
SAFETY PRECAUTIONS
Page
Warnings General---6
1
Regulations ---7
2
Warnings, Cautions & Notes ---7
3
General Safety Precautions ---7
4
Installation Precautions ---8
5
Operational Precautions---8
6
Maintenance and Repair Precautions---9
WARNINGS GENERAL
• WARRANTYThe Conditions of the CompAir UK Ltd Warranty are set out in the Standard Conditions of Sale. • MAINTENANCE
To ensure continued trouble free operation of the compressor it is important that periodic maintenance and servicing are carried out in accordance with the information given in the "Maintenance" section of this Manual. If any replacement or repair is needed use genuine CompAir UK Ltd parts.
∗
WARNING
The use of replacement parts or lubricating oils not supplied or approved by
CompAir UK Ltd may lead to failures in service which would not be covered by
warranty.
Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance instructions may make it unsafe. The use of replacement parts not supplied by CompAir UK Ltd may
create hazardous conditions over which CompAir UK Ltd has no control.
Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury or result in damage to the equipment. CompAir UK Ltd can bear no responsibility for equipment for
which unapproved replacement parts are included.
SPECIAL NOTE:
THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.
SAFETY PRECAUTIONS
1. REGULATIONSCompAir UK Ltd compressor safety relates to the document BS EN1012-1
Compressors and Vacuum Pumps - Safety requirements and the UK Pressure Systems and Transportable Gas Containers Regulations 1989.
• Most accidents which occur during the operation and maintenance of machinery result of failure to observe basic safety rules or precautions. Recognising a situation that is potentially hazardous can often prevent an accident. • When handling, operating or carrying out
maintenance on the unit, personnel must observe safe engineering practices and all relevant local regulations. The attention of users is drawn to the Health and Safety at Work Act 1974, and the regulations of the Institution of Electrical Engineers.
• CompAir UK Ltd cannot anticipate every possible circumstance, which might represent a potential hazard. The WARNINGS in this manual are therefore not all inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by CompAir UK Ltd then they must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property.
• Failure to observe these precautions given under "Safety Precautions" may be considered
dangerous practice or misuse of the compressor • Read and understand all WARNINGS, CAUTION
AND MANDATORY LABELS on the unit before operating or carrying out maintenance or servicing.
2. WARNINGS, CAUTIONS & NOTES
• The following details for this Safety Section relate
to the ESSENTIAL SAFETY REQUIREMENTS referred to in Directive 89/392/EEC, Amended 91/286/EEC.
• Warnings call for attention to operation
procedures involving specific hazards which could cause injury or death and are identified by the
following:-RISK OF DANGER
RISK OF ELECTRIC SHOCK
RISK OF HIGH PRESSURE
RISK OF HOT SURFACE
RISK OF GAS EXHAUST
CONSULT MANUAL
3. GENERAL SAFETY PRECAUTIONS • When using cleaning solvents, local Health and
Safety Regulations must be complied with. Provide good ventilation and use suitable protection such as a breathing filter mask, safety glass, protective apron and gloves.
• Safety footwear should be compulsory in all workshops. Safety helmets must be worn if there is any risk of falling objects.
• If using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing worn.
• Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing.
• Before releasing compressed air through a hose make sure the free end is held securely so that it cannot whip and cause injury.
• Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in good condition and are of the correct capacity. They must be tested and approved according to local safety regulations.
• Cables, chains or ropes should never be applied to lifting eyes. Always use an appropriate shackle or hook, properly positioned. Arrange lifting cables so that there are no sharp bends. Use a spreader bar to avoid side loads on hooks, eyes and shackles and never leave a heavy load unattended.
• When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting
acceleration and speed within safe limits. 4. INSTALLATION PRECAUTIONS
• Competent personnel under a qualified supervisor must only carry out installation work.
• A fused isolator switch must be fitted between the main power supply and the compressor.
• Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing being sucked into compressor intake. • Ensure that the discharge pipe from the
compressor to the user pipework, receiver or storage is free to expand and that no flammable material is within the vicinity. If any such material is close-by take steps to preclude ignition. • A manual shut-off valve should be fitted in the
discharge line to allow the compressor to be isolated. Non return valves cannot be relied upon for isolating parts from a pressure system. A safety valve must be installed between any compressor unit and the isolating valve.
• A pressure-reliving device must be fitted to every pressure vessel, or equipment containing gas or gas above atmospheric pressure. Never remove or tamper with safety devices, guards or
insulation fitted. In order to limit the risk of Legionnaires Disease, CompAir UK LTD advise caution with the use of cooling towers for water cooling the compressor. Closed circuit or direct mains cooling is preferred.
• Pipework or other parts with a surface temperature above 70°C, which may be
accidentally touched in normal operation, must be guarded or insulated. Other high temperature pipework should be clearly marked and all pipework should be clearly marked. 5. OPERATIONAL PRECAUTIONS
• Competent personnel under a qualified supervisor must only operate the compressor.
• Do not operate compressor with any removable
inspection cover removed e.g. crankcase doors, valve covers etc.
• Never remove or tamper with safety devices, guards or insulation materials.
• The compressor must only be operated at the supply voltage and frequency for which it is designed. Always isolate power before maintenance or servicing.
• When mains power is ON, lethal voltages are present in the electrical circuits and extreme caution is need when essential work is carried out on the electrical system. ALWAYS CONSULT A
QUALIFIED ELECTRICIAN BEFORE ANY SUCH ESSENTIAL WORK.
• Do not open starter compartment to touch electrical components while voltage is applied unless it is necessary for measurement, test or adjustment. Such work should always be carried out by a qualified. Electrician with appropriates tools and protection against an electrical hazard. • If the unit is equipped with a Remote Control
device, attach warning notices stating "THIS
UNIT CAN BE STARTED REMOTELY" in
prominent locations, one on the outside of the unit, the other inside the control compartment. • As a further safeguard, take adequate
precautions that no one is working or checking the unit before attempting to switch on remotely controlled equipment. Attach a "CHECK THAT
ALL PERSONNEL ARE CLEAR OF UNIT BEFORE STARTING" or similar notice.
• Compressed gas and gas piping, together with cooling water piping and other parts, with surface temperature greater than 70°C and may be accidentally touched, should be guarded or insulated.
5. OPERATION PRECAUTIONS (Cont.) • If there is any indication that the compressor is
overheating it must be shutdown. (A high air or gas temperature switch is fitted as standard to guard against operating with excessive
temperature). Beware of burns from hot oil and water when working on a unit recently shutdown. • Do not operate the unit when guards provided for protection for all rotating and reciprocating parts have been removed for essential maintenance. Secure guards following any servicing or repair. • Local noise regulations must be observed. Ear
defenders are suggested by Noise at Work Regulations 1989 when the level is greater than 85 dB A at one meter. Be aware high noise levels can interfere with communication.
6. MAINTENANCE & REPAIR PRECAUTIONS • Competent persons under qualified supervisor
must carry out maintenance repair and modifications.
• The compressor will have a preserving oil applied to interior surfaces (Oil lubricated models). Oil free models will have desiccant bags in valve covers and distance pieces.
• Handling components such as seals, gaskets and diaphragms should not present a personnel hazard. Preservation oils again should not present a personnel hazard if handled under normal handling practices.
• Whilst compressors are asbestos free, treat all damaged gaskets as asbestos - when the Asbestos at work regulations apply.
• Viton 'O' seals under normal operating conditions are safe.
• However, should there be a fire within the compressor or these seals are likely to exceed a temperature of 300°C the material will
decompose.
• Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with the skin an acid formed causes severe burns.
• If Viton seals appear charred or gummy do not touch with unprotected hands: use neoprene or PVC gloves.
• Wash the area with limewater and avoid
breathing any fumes. If contamination of the skin
occurs washes with limewater and seeks medical advice.
Pre-Maintenance Operation
• 1. Isolate the compressor from the main electrical supply. Lock the isolator in the OFF position and remove fuses.
• 2. Attach a label " WORK IN PROGRESS - DO
NOT APPLY VOLTAGE".
• 3. Close the isolating valve between the
compression unit and user's pipework. Close the isolating valve in the cooling water inlet pipe. Attach a label "WORK IN PROGRESS - DO NOT
OPEN".
• 4. Check that all pressurised gas trapped in the system is released to atmosphere or safely to gas storage. Check that all pressure gauges register zero.
• 5. Ensure that the cooling water system has been drained.
• 6. Check that the drain valve on the delivery manifold is clear and gas pressure has been released.
• 7. Check that all interstage drains are open to ensure any gas trapped between stages has been released.
• Stand clear of all valve covers when removing the securing screws.
• When removing valve covers for valve
replacement, ensure a minimum of two threads is left engaged on the valve cover securing screws. Lever the valve cover until the 'O' seal is
disengaged from the port in the cylinder head. Remove the securing screws and take out valve cover.
• Use only lubricating oils and greases
approved by CompAir UK LTD to avoid potential hazards especially the risk of explosion or fire and the possibility of decomposition or generation of hazardous gases.
• Always clean oil spills from the surrounding floor before and after maintenance work.
6. MAINTENANCE & REPAIR (Cont.)
• Make sure all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good order.
• The accuracy of pressure gauges and temperature switches should be regularly checked at least 13 month intervals and thoroughly examined at least every 48 months. They must be renewed or service exchanged when acceptable tolerances are exceeded. • Protection devices should be tested at each
regular service interval and replaced or service exchanged if not functioning correctly. The maximum pressure for safety valves under fault conditions is 1.10 times the set pressure, the set pressure being a minimum of 1.05 times the maximum operating pressure to ensure seat tightness.
• Never use a light source with an open flame for inspection.
• Before dismantling any part of the compressor be sure that all heavy movable parts are secure. • After completion of any maintenance or repair
ensure that no tools, loose items or rags are left on or inside the compressor.
• Do not use any flammable liquid to clean valves, filter elements, cooler passages, pipe bores or any component carrying a flow of air or gas during normal operation. If chlorinated hydrocarbon substances are used for cleaning, safety
precautions must be taken against toxic vapours, which may be released.
DO NOT USE CARBON TETRACHLORIDE.
• Precautions must be taken against using acids, alkalis and chemical detergents for cleaning machined parts. These materials cause irritation and are corrosive to the skin, eyes, nose and throat. Avoid splashes and wear suitable protective clothing and safety glasses. Do not breathe mists. Ensure water and soap is readily available.
• When disposing of condensate, old oil, used filter elements and other parts and waste material of any kind make sure that there is no pollution to any drain or natural water course and that no burning of waste takes place which could cause pollution of the atmosphere.
• Keep the compressor clean at all times. • Protect components and exposed openings by
covering with a clean cloth or tape during repair or maintenance work.
• Protect the motor, intake, electrical and regulation components against the entry of moisture e.g. steam cleaning.
• Precautions must be taken when carrying out welding or any repair operation which generates flames or sparks. The adjacent components must be screened with non-flammable material and if oil present, the system must first be cleansed thoroughly by steam cleaning.
• Condensate (oil and water mixture from
compression process) must be regarded as trade effluent and is therefore not suitable for discharge into a surface water sewer, soakaway or
watercourse.
PROTECT THE ENVIRONMENT USE APPROVED METHODS OF DISPOSAL.
7. PRECAUTIONS IN THE EVENT OF FIRE • Use extreme caution when handling components
that have been subjected to fire or very high temperature. Some components may contain fluoroelastomer materials, which decompose under these conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage.
This is a high pressure Compressor
use only:
GENUINE CompAir UK Ltd
DRY GASES
Lubrication is the introduction and maintenance of a continuous film of oil between two moving surfaces. When this breaks down, wear occurs.
In an gas compressor the agitation, caused by the oil distribution and recovery system, results in the lubricant absorbing some gas whilst it is in the crankcase and cylinders. The oxygen in the entrained gas gradually forms and maintains oxide skins on the moving surfaces. These improve the adhesive strength of the oil film, preventing its breakdown.
When gas is being compressed and there is no oxygen present, even in small amounts, the help from these skins is not normally available. However, it has been established that if moisture is present, film breakdown is prevented. The reason is that gas entrained in the water at source, provides the oxygen for oxide skin formation.
If the gas is dry (we define this as less than 50 ppm by weight) and if no oxygen is present (less than 10 ppm by volume) it is necessary to use a special lubricant capable of maintaining a high film strength to prevent its breakdown.
The properties needed are a stronger than normal adhesion to the metal surfaces and additives which will help oxide film formation. These are provided by an oil which has a HIGH viscosity, a HIGH level of anti-wear additives and a LIMITED amount of anti-oxidant additives.
The lubricant we recommend for this duty is Anderol 1200.
When commissioning or re-commissioning the compressor, it is recommended that the machine is run on air for 10 hours using the recommended oil as this will speed up the formation of oxide skins before changing to gas and Anderol 1200.
TYPICAL GAS PURGING INSTRUCTIONS
Before allowing any Natural Gas to enter the compressor or ancillary piping the whole system must be purged free of air in accordance with the following procedure.If in any doubt as to the efficiency of the purging, ALWAYS REPEAT THE PROCEDURE.
Feeding the purge gas at a pressure equal to the inlet pressure to the compressor, will speed the process.
After any maintenance or repairs have been carried out which involves dismantling and opening up gas containing parts, the system must always be re-purged.
PURGING PRIOR TO INITIAL START-UP Purging with Nitrogen
Connect nitrogen to the inlet purge valve PGE01. Close inlet valve ISOL01, ISOL02, DDV valve ISOL09, filtration isolation valve ISOL68 and purge valve PGE061. Open recovery vessel valve ISOL08 and compressor inlet purge valve PGE02.
Purge nitrogen through until air is displaced. This can be checked with an oxygen meter at the vent stack. Close recovery vessel valve ISOL 08 and open DDV valve ISOL 09 select manual operation on Control Panel and open Solenoid valve SOL01.
Purge nitrogen through until air is displaced. Close compressor inlet purge valve PGE 02 and open delivery purge valve PGE 61.
Purge nitrogen through until air is displaced by checking with an oxygen meter at the delivery purge valve. Most of the compressor system should now be filled with nitrogen. If the downstream equipment needs to be purged with nitrogen then the compressor can be run by feeding nitrogen into the inlet vessel and maintaining the required inlet pressure. The filtration will be pressurised before the pressure-maintaining valve PCV 61 opens. Shut off nitrogen supply when complete.
Purging with Gas
Vent nitrogen from vent system by opening the filtration isolation valve ISOL 62 and venting nitrogen from the recovery vessel ISOL 07 ensuring a small positive pressure is kept in the system. The filtration isolation valve ISOL 62 should then be closed. If the downstream equipment has been purged with nitrogen then it should be vented to a small positive pressure.
Open inlet gas isolating valve ISOL 01 and open inlet gas solenoid valve SOL 01 by switching vent valve inlet switch on starter to Hand. This will allow gas to enter the system. Open recovery vessel drain ISOL 07 until gas is sensed and then vent from delivery purge valve PGE 61. The compressor system should now be filled with gas.
COMPRESSOR MAINTENANCE
Releasing gasTo isolate compressor close DDV and recovery vessel valves ISOL 09 and ISOL 08. Vent gas from compressor purge valve PGE 02.
Repurging with gas
Open compressor purge valve PGE 02 and DDV valve ISOL 09 until gas is present. Close DDV valve ISOL 09 and open recovery vessel valve ISOL 08 and purge gas to PGE 02. Close PGE 02 and open DDV valve ISOL 09.
FINAL COALESCER
Releasing gas
Close filtration isolation valve ISOL 62 & ISOL61, expel gas into the recovery vessel via ISOL63. Close Open compressor purge valve PGE 02 to expel the gas and then open delivery purge valve PGE 61 to vent
CONTENTS
QUICK REFERENCE GUIDE TO PARTS USING P. & I. DIAGRAM D70983
CERTIFICATE OF CONFORMITY
COMPRESSOR PLANNED MAINTENANCE LOG SHEET
WARNINGS & SAFETY SECTION
DRY GAS LUBRICANT RESTRICTIONS
TYPICAL GAS PURGING INSTRUCTIONS
SECTION 1
LEADING PARTICULARS
PAGE 5
1.1 UNIT DESIGNATION --- 7 1.2 TECHNICAL DATA - GENERAL --- 7 1.2.1 TEMPERATURES --- 7 1.2.2 OPERATING SPEEDS --- 7 1.2.3 OPERATING PRESSURES --- 8 1.2.4 LUBRICATION--- 8 1.2.5 COOLING --- 8 1.2.6 INTERNAL DIMENSIONS --- 8 1.2.7 CONNECTIONS --- 8 1.2.8 WATER TEST PRESSURES --- 8 1.2.9 INCLINATION--- 9 1.2.10 RELIEF VALVE SETTINGS --- 9 1.2.11 WEIGHTS--- 9 1.2.12 EXTERNAL DIMENSIONS --- 9 1.3 TORQUE WRENCH SETTINGS --- 10 1.4 RUNNING CLEARANCES AND WEARING DIMENSIONS --- 11
SECTION 2
TECHNICAL DESCRIPTION
PAGE 13
2.1 GENERAL DESCRIPTION ---15 2.2 CONSTRUCTIONAL DETAILS ---16 2.3 LUBRICATION DETAILS---17 2.4 CONDENSATE REMOVAL---17 2.5 EXTERNAL COMPONENTS ---18 2.5.1 GAS INLET TRAIN --- 18 2.5.2 PROTECTION --- 18 2.5.2.1 STAGE RELIEF VALVES --- 18 2.5.2.2 BURSTING DISC--- 18 2.5.2.3 PRESSURE GAUGES --- 18 2.5.2.4 PNEUMATIC WATER VALVE --- 18 2.5.2.5 HIGH GAS TEMPERATURE SWITCHES--- 18 2.5.3 DELIVERY --- 18 2.5.3.1 DISCHARGE NON-RETURN VALVE --- 18 2.5.3.2 FINAL FILTRATION --- 18 2.5.3.3 GAS DETECTOR --- 18
SECTION 3
INSTALLATION INFORMATION
PAGE 19
3.1 UNPACKING AND HANDLING--- 21 3.2 LOCATION--- 21 3.3 MOUNTING--- 21 3.4 CONNECTIONS --- 21 3.4.1 GAS CONNECTION--- 21 3.4.2 WATER CONNECTION --- 22 3.4.3 ELECTRICAL CONNECTION --- 22
SECTION 4
OPERATING INFORMATION
PAGE 23
OPERATING INFORMATION WARNING ---25 4.1 SAFETY PRECAUTIONS ---26 4.2 COMMISSIONING ---26 4.3 STARTING AFTER COMMISSIONING ---27 4.4 STARTING DAILY---27 4.5 ROUTINE ATTENTION WHILE RUNNING ---28 4.6 STOPPING PROCEDURE ---29 4.7 PREPARATION FOR SPECIAL ENVIRONMENTS---29 4.8 STARTING AFTER LONG PERIOD OF IDLENESS---29 4.9 INHIBITION FOR STORAGE ---29 4.9.1 UP T0 6 MONTHS---29 4.9.2 LONG TERM---30 4.10 FAULT GUIDE---31 4.10.1 RELIEF/SAFETY VALVE(S) BLOWING ---32 4.10.2 FAILS TO REACH ‘TOP’ PRESSURE ---32 4.10.3 LOW COMPRESSOR OUTPUT ---32 4.10.4 STOPS SUDDENLY ---33 4.10.5 WILL NOT START ---33 4.10.6 OVERHEATING ---33 4.10.7 OVERHEATING RADIATOR STES---33 4.10.8 LOW OIL PRESSURE---34 4.10.9 CUTS OUT ON START-UP ---34 4.10.10 UNUSUAL NOISE RUNNING ON LOAD ---34 4.10.11 UNUSUAL NOISE RUNNING UNLOADED---34 4.10.12 HIGH OIL CONSUMPTION ---34 4.10.13 PREMATURE WEAR OF PARTS ---34 4.10.14 HIGH INLET PRESSURE SWITCH TRIPS ---35 4.10.15 LOW INLET PRESSURE SWITCH TRIPS---35 4.10.16 INLET SAFETY VALVE BLOWING ---35 4.10.17 INTERSTAGE SAFETY VALVES BLOWING ---35 4.10.18 THIRD STAGE TEMPERATURE SWITCH TRIPS---35 4.10.19 FINAL DELIVERY TEMPERATURE SWITCH TRIPS---35 4.10.20 FINAL STAGE TEMPERATURE SWITCH TRIPS ---35 4.10.21 FINAL DELIVERY SAFETY VALVE BLOWING ---35 4.10.22 DISPENSER PRESSURE SWITCH TRIPS---35 4.10.23 MOTOR PROTECTION SWITCH TRIPS---36 4.10.24 INSUFFICIENT COOLING ---36SECTION 5
MAINTENANCE AND REPAIR
PAGE 37
5.1 MAINTENANCE--- 41 5.2 AFTER THE FIRST 100 HOURS OR A MAJOR SERVICE--- 42 5.3 MAINTENANCE PERIODS AND SERVICE HOURS --- 43 5.4 SERVICING STAGE VALVES --- ----44 5.5 COMPRESSOR PROTECTIONS --- 47 5.6 SERVICING COMPRESSOR--- 48
SECTION 6
COMMON PARTS LIST & ILLUSTRATIONS
PAGE 51
6.1 PARTS LISTS R-5437.GAS.COMMON ---52 - 57 6.2 ILLUSTRATIONS R-5437.GAS.COMMON---58 - 84
SECTION 7
BUILD PARTS LIST & ILLUSTRATIONS
PAGE 85
7.1 PARTS LISTS R-5437.1.NG---86 - 90 7.2 ILLUSTRATIONS R-5437.1.NG ---91 - 96
SECTION 8
SERVICE PLANS
PAGE 97
8.1 RECOMMENDED SERVICE PLAN (SYNTHETIC OIL) ---R-5437.1.NG.S 8.2 RECOMMENDED SERVICE PLAN (MINERAL OIL)--- R-5437.1.NG.M427 8.3 RECOMMENDED SERVICE PLAN (MINERAL OIL)--- R-5437.1.NG.MP100SECTION 9
ANCILIARY EQUIPMENT
PAGE 99
BUILD --- 5437CNG.55153 GENERAL ARRANGEMENT --- E46319 P. & I. DIAGRAM --- D70938 SINGLE LINE DIAGRAM --- C89091 WIRING DIAGRAM --- C89092 9.1 NATURAL GAS COMPRESSOR PARTS ---SEE SECTION 7 9.2 VEE DRIVE & ADJUSTMENT PARTS - APP12G --- 100 9.3 WATER PUMP - APP073--- 100 9.4 A.V MOUNTS - APP003 --- 100 9.5 INLET TRAIN --- 100 9.7 SAFETY VALVE MANIFOLD --- 101 9.8 CONTROL BOX SUPPORT --- 101 9.9 PRESSURE CONTROL--- 101 9.10 CONTROL PANEL --- 102 9.11 ELECTRIC MOTOR - APP034C --- 102 9.12 SOLENOID VALVE INLET - APP153--- 102 9.13 SOLENOID VALVE DDV - APP152 --- 102 EXTRA PUBLICATIONS
DRIVE DETAILS --- APP012G ELECTRIC MOTOR DETAILS--- APP034C DIAPHRAGM DRAIN VALVE DETAILS--- APP041 PRESSURE MAINTAINING VALVE DETAILS --- APP059 PRESSURE GAUGES GENERAL --- APP070 WATER PUMP DRIVE DETAILS --- APP073 PRESSURE SWITCH FINAL DELIVERY--- APP081 PRESSURE SWITCHES INLET CONTROL--- APP086 PRESSURE SWITCH LOW OIL --- APP088 THERMOMETER SWITCH 3RD STAGE & FINAL DELIVERY --- APP090 SOLENOID VALVE DIAPHRAGM DRAIN VALVE CONTROL--- APP152 SOLENOID VALVE INLET CONTROL --- APP153 BALL VALVES GENERAL--- APP154 NON RETURN VALVE FINAL --- APP158 SAFETY VALVES GENERAL --- APP167 CHECK VALVE INLET --- APP169A
SECTION 1 CONTENTS
LEADING PARTICULARS
1.1
UNIT DESIGNATION
PAGE 7
1.2
TECHNICAL DATA - GENERAL
PAGE 7
1.2.1 TEMPERATURES---7 1.2.2 OPERATING SPEEDS---7 1.2.3 PRESSURES---8 1.2.4 LUBRICATION ---8 1.2.5 COOLING ---8 1.2.6 INTERNAL DIMENSIONS---8 1.2.7 CONNECTIONS (STANDARD) ---8 1.2.8 WATER TEST PRESSURES---9 1.2.9 RELIEF VALVE SETTINGS ---9 1.2.10 WEIGHTS ---9 1.2.11 EXTERNAL DIMENSIONS---9
1.3
TORQUE WRENCH SETTINGS
PAGE 10
1.3.1 TORQUE WRENCH SETTING --- 10
TYPICAL HGP.37 ILLUSTRATED
RADIATOR COOLED SET
SECTION 1
LEADING PARTICULARS
1.1
UNIT DESIGNATION
Belt drive compressor, electric powered ... R-5437.1.NG
1.2
TECHNICAL DATA - GENERAL
Type... Single acting, four stage, 90° vee Cooling ...Sea or fresh water Direction of rotation, viewed from drive end... Anti-clockwise Number of valves ...Four Type of valve ... Flat plate, low lift
1.2.1
TEMPERATURES - R-5437.1.NG
Examples of 3rd stage temperature controller settings. Running Speed 1800 rpm - 250 bar g delivery
Cooling water inlet temperature - 15°C with a 10°C to 12°C rise across machine.
Inlet Pressure (Bar g) 0 0.3 0.64
3rd Stage Temperature Controller 160°C 165°C 170°C
3rd Stage Temperature Controller Maximum 190°C 195°C 200°C
Maximum gas inlet pressure (subject to a speed restriction)... 1 bar g. Minimum gas intake temperature... 0°C. Maximum gas intake ambient temperature ... 45°C. Maximum gas intake ambient temperature for radiator sets... 30°C. (Higher ambients possible contact CompAir UK Ltd Ipswich Engineering for more information. Maximum cooling water inlet temperature ... 37°C. Temperature rise across machine (Normal requirement) ...10°C - 12°C.
Note: It is important for the life and safety of the machine not to exceed the maximum operating temperatures.
1.2.2
OPERATING SPEEDS
Minimum speed ---750 rev/min Maximum speed --- 1800 rev/min 1st stage piston displacement at maximum speed --- 217.7m³/hr
1.2.3
PRESSURES *
Maximum working pressure --- 350 bar Minimum working pressure (with atmospheric pressure intake) --- 140 bar Minimum working pressure (with 0.55 bar intake) --- 200 bar
Minimum water pressure ...0.6 bar Maximum water pressure ...5.1 bar Oil pressure (New machine) ... 2.0-2.75 bar Minimum oil pressure (Worn machine)...1 bar
1.2.4
LUBRICATION *
Crankcase oil capacity ... 45 litres Recommended silicone grease (for assembly) ...Dow Corning MS33 Recommended oil: Synthetic ...Reavellite, Anderol 555 Recommended oil: Mineral ...Mobil Rarus 427 Recommended oil: Mineral ...Shell Corena P100
* Oil recommendations are based on normal conditions. If difficulty is experienced a change may be advisable - refer to Ipswich Works.
1.2.5
COOLING
Coolant Sea or fresh water
Cooling water flow @ 15°C inlet temp ...75 l/h/kW (12 gals/bhp/hr) Coolant capacity (Approx.) ... 46 litres
Note: Water must not be allowed to freeze in the compressor water jackets, coolers or in a sea water / fresh water heat exchanger.
1.2.6
INTERNAL DIMENSIONS
Piston stroke--- 75 mm First stage cylinder bore --- 185 mm Second stage cylinder bore --- 95 mm Third stage cylinder bore --- 45 mm Fourth stage cylinder bore --- 22 mm Mean piston speed at maximum speed ---4.5 m/s
1.2.7
CONNECTIONS (STANDARD)
Gas inlet connection ... nominal 75 mm Fourth stage delivery ... ½" BSPP Condensate drain... 1½" BSPP Water inlet... 1"BSPT Water outlet...1¼" BSPT
1.2.8
WATER TEST PRESSURES
First stage suction ... 2 bar g First stage delivery ... 21 bar g Second stage ... 81 bar g Third stage ... 300 bar g Fourth stage ... 690 bar g Water jacket ... 100 bar g
1.2.10
RELIEF VALVE SETTINGS
First stage ... 10 bar g Second stage... 40 bar g Third stage ... 150 bar g Fourth stage... Supply pressure +10% Surge vessel Relief valve ... 2.8 bar g Crankcase... 2.1 bar g
1.2.11
WEIGHTS
Machine (bare)... 1090 Kg Cooling water and lubricating oil... 90 Kg Crankshaft ... 45 Kg Flywheel... 51 Kg Cylinder block 1st & 2nd Stage ... 146 Kg Cylinder block 3rd & 4th Stage ... 155 Kg Crankcase... 250 Kg Typical Belt Driven Set (Complete set dry)... 1600 Kg Inertia, rotational compressor and flywheel ... 0.79 kgm²
1.2.12
EXTERNAL DIMENSIONS
Typical Belt Driven Set - Length --- 1700 mm Width --- 1320 mm Height --- 1090 mm
1.3
TORQUE WRENCH SETTINGS
(All figures ±5%)
1.3.1 TORQUE WRENCH SETTINGS FOR NON-LUBRICATED FASTENERS
FASTENING SPANNER SIZE A/F THREAD SIZE NEWTON METRE (Nm) POUND FEET (lb.ft)
Big End Bearing Bolts 24MM M16 203 150
First and Second Stage Cylinder Block to Crankcase 24MM M16 236 175
First Stage Separator 17MM M10 55 40
First and Second Stage Cooler Cover – fixed end 17MM M10 55 40
First and Second Stage Cooler Cover – floating end 17MM M10 55 40
Second Stage Separator Cover 19MM M12 95 70
First Stage Valve Cover * 19MM M12 50 37
Second Stage Valve Cover * 30MM M20 121 90
Third and Fourth Stage Cylinder Block to Crankcase 24MM M16 237 175
Third Stage Cooler Cover 13MM M8 28 20
Third Stage Valve Cover * 24MM M16 118 87
Fourth Stage Valve Cover * 24MM M16 118 87
Fourth Stage Cooler Cover 17MM M10 55 40
Third and Fourth Stage Piston 13MM M8 27 20
Flywheel bolt to Crankshaft 1.1/8" ¾” UNF 162 119
Driving-end Main-end Bearing Housing to Crankcase 19MM M12 95 70
Outer-end Main-end Bearing Housing to Crankcase 19MM M12 95 70
Crankcase Door 13MM M8 28 20
Bursting Disc Cover 17MM M10 55 40
First Stage Valve 17MM M10 39 29
Second Stage Valve 13MM M8 19 14
Third Stage Valve 10MM M6 8 6
Fourth Stage Valve 8MM M5 4.6 3.4
Coupling Ring to Flywheel 17MM M10 55 40
Bell-Housing to Crankcase 19MM M12 95 70
Bell-Housing to Motor 1.1/8" ¾” UNC 237 175
Oil Pump 13MM M8 28 20
Surge Vessel Door 13MM M8 28 20
Diaphragm Drain Valve to Surge Vessel Door 13MM M8 28 20
AV-Shock Mount Bracket to Crankcase 19MM M12 95 70
AV-Shock Mount Bracket to Motor 24MM M16 237 175
Bracket to AV-Shock Mount. 30MM M20 237 175
Under no circumstances are any deviations from the above figures allowable.
1.4 RUNNING CLEARANCES AND WEARING DIMENSIONS
DESCRIPTION STAGE AS FITTED (mm) MAX.
PERMITTED (mm) Piston vertical clearance
(ie. Distance from top of piston to top of liner)
1 2 3 4 0.500 / 1.200 0.250 / 0.950 0.350 / 1.150 0.350 / 1.150 --Piston ring gaps
(Measured in unworn portion of cylinder / liner) 1 2 3 4 Taper Scraper Taper Scraper Plain Plain 0.20 / 0.46 0.20 / 0.46 0.10 / 0.23 0.10 / 0.23 0.05 / 0.18 0.20/0.40 1.63 1.43 1.37 1.27 1.32 1.50 Piston ring axial clearance
(Measured between groove & top face of ring with ring in normal running position)
1 2 3 4 Taper Scraper Taper Scraper Plain Plain 0.04 / 0.09 0.05 / 0.10 0.02 / 0.08 0.05 / 0.10 0.01 / 0.08 0.10/0.06 0.29 0.30 0.28 0.30 0.28 0.30
Piston ring groove width 1
2 3 4 Taper Scraper Taper Scraper Plain Plain 4.80 / 4.83 8.01 / 7.99 3.23 / 7.99 4.83 / 4.80 2.05 / 2.01 2.56/2.53 4.91 8.09 3.31 4.91 2.13 2.64
Piston skirt diameter 1
2 3 4 184.77 / 184.74 94.91 / 94.88 44.92 / 44.89 21.905 / 21.935 184.69 94.83 44.85 21.9
Liner bore diameter 1
2 3 4 185.05 / 185.00 95.04 / 95.00 45.03 / 45.00 22.02 / 22.00 185.11 95.10 45.09 22.08
Crosshead diametral clearance 3,4 0.060 / 0.125 0.19
S/E bearing diametral clearance In connection rod In piston 1 2,3,4 1 2,3,4 0.01 / 0.05 Needle roller -0.003 / 0.013 0.025 / 0.044 0.1 --0.03 0.09
S/E bearing end float 1
2,3,4 0.15 / 0.64 0.15 / 0.55 1.0 1.0 Crankshaft journal
B/E bearing diameter B/E bearing out of round Main bearing diameter Main bearing out of round
84.24 / 84.22 79.95 / 79.93 83.92 0.04 79.90 0.04
B/E bearing diametral clearance 1,2,3,4 0.066 / 0.120 0.24
Main bearing diametral clearance 0.050 / 0.135 0.2
Crankshaft end float 0.23 / 0.66 0.75
Cooler tube nominal bore sizes 1
2 3 4 23 off 8 off 8 off 6 off 1 off 1 off 10 13.4 10 13.4 11.1 6.2
--SECTION 2 CONTENTS
TECHNICAL DESCRIPTION
2.1
GENERAL DESCRIPTION
PAGE 15
2.2
CONSTRUCTIONAL DETAILS
PAGE 16
2.2.1 MATERIAL of CONSTRUCTION--- 16
2.3
LUBRICATION DETAILS
PAGE 17
2.3.1 MAIN LUBRICATION SYSTEM --- 17
2.4
CONDENSATE REMOVAL
PAGE 17
2.4.1 DIAPHRAGM DRAIN VALVES --- 17
2.5
EXTERNAL COMPONENTS
PAGE 18
2.5.1 GAS INLET TRAIN--- 18 2.5.2 PROTECTION --- 18 2.5.2.1 STAGE GAS RELIEF VALVES--- 18 2.5.2.2 BURSTING DISC --- 18 2.5.2.3 PRESSURE GAUGES--- 18 2.5.2.4 PNEUMATIC WATER VALVE (IF FITTED) --- 18 2.5.2.5 HIGH GAS TEMPERATURE SWITCHES --- 18 2.5.3 DELIVERY --- 18 2.5.3.1 DISCHARGE NON-RETURN VALVE--- 18 2.5.3.2 FINAL FILTRATION --- 18 2.5.3.3 GAS DETECTOR --- 18
TECHNICAL DESCRIPTION
2.1
GENERAL DESCRIPTION
TYPICAL ARRANGEMENT
The R-5437.1.NG compressor is a reciprocating 90° vee configuration, 4 stage, single acting, water cooled machine with the 1st and 3rd stage lines on one crank throw, and the 2nd and 4th stage lines on the opposite crank throw of a counterbalanced crankshaft. The running gear consists of the crankshaft, bearings, connecting rods, oil pump, cylinder lubricator and other accessories.
The gas end consists of two cylinder blocks - combined 3rd & 4th stage – combined 1st & 2nd stage. Each block is complete with individual cylinder liners, pistons, valves, valve covers, inter-stage coolers for the 1st, 2nd, 3rd and 4th stages and condensate separators for 1st, 2nd and 3rd stages. The 1st & 2nd stage cylinder blocks contains renewable wet cylinder liners and are jacketed for water-cooling. The 3rd and 4th stage cylinder blocks contains renewable dry cylinder liners again jacketed for water-cooling. Water flow is arranged within the cylinder jackets and coolers in series to provide even and effective cooling for either sea or fresh water.
First and second stage pistons are conventional trunk type, whilst the third and fourth are an integral piston and crosshead assemblies. All are fitted with split piston rings.
A single combined suction and discharge (concentric) valve is fitted at the head of each cylinder. Water-cooled inter-stage coolers are provided after each stage of compression, with condensate separators after each inter-stage cooler. The water flows over the tubes and the gas through for all stage coolers. All stage coolers are withdrawable to ease maintenance. The fourth or final stage cooler cools the hot gas delivered from the fourth stage cylinder to within 5°C of the cooling water inlet temperature.
The oil pump is directly driven from the crankshaft to provide a forced-feed lubrication system via a suction strainer through a filter element to the running gear. The cylinders, pistons and valves are splash/spray lubricated. A low oil pressure switch is provided to protect the running gear against lubrication failure, an oil level sight gauge is provided in the crankcase for maintaining oil to the correct level.
An automatic drainage system drains each stage condensate separator at approximately 10 to 20 1st Stg Safety Valve
1st Stage cylinder 2nd Stage cylinder
Diaphragm Drain valves
2nd stage Safety valve. Pressure gauge panel.
minute intervals for a period of 5-10 seconds into a discharge surge vessel, in-built in crankcase. This interval and period is dependent upon the ambient temperature and humidity and for high ambient high humidity conditions the interval must be reduced and the period increased. The drainage system whilst removing oil/moisture also acts as an unloading device to prevent the compressor starting under load, by bleeding off automatically all the gas in the compressor through the condensate separators whenever the compressor stops.
Pressure gauges to indicate all gas stage pressures and oil pressure are located in a gauge board mounted between each cylinder block.
Gas relief valves for each stage are fitted to prevent over-pressure in cylinders and coolers, and bursting diaphragms are fitted to protect the water jackets from accidental application of gas pressure to the cooling system. A pneumatic water inlet valve (if fitted) will not allow the cooling water to flow when the compressor stops this helps to prevent over-cooling.
High gas temperature switches are fitted to the 3rd stage cylinder discharge, inlet (or exit from the third stage cooler) and exit from the 4th stage delivery after cooling to stop the compressor on over-temperature in the gas stream. These switches combine both a visual dial display of the temperature and again an indication of the switch setting.
The compressor gas intake should be fitted with a filter to prevent solid particles entering the compressor cylinders.
A non-return valve is located at the final discharge connection to prevent system pressure returning to the cylinders when the compressor is shut down.
2.2
CONSTRUCTION DETAILS
2.2.1 MATERIALS of CONSTRUCTION
Component
Material
Crankcase Cast Iron
Crankshaft Spheriodal Graphite Iron
Main-End Bearings White-metal lined Gun Metal
Connecting Rods Spheriodal Graphite Iron
Big-End Bearings Steel backed aluminium-tin with overlay
Small-end Bearing – 1st stage Phosphor Bronze
Small-end Bearings – 2nd, 3rd & 4th stage Steel – needle roller
Flywheel Cast Iron
First Stage Piston Aluminium alloy
Second Stage Piston Cast Iron
Third Stage Piston Cast Iron
Fourth Stage Piston Cast Iron
First & Second Stage Cylinder Block Speriodal Graphite Iron Third & Fourth Stage Cylinder Block Speriodal Graphite Iron 1st, 2nd & 3rd Stage Cylinder Liners Grey Cast Iron
4th Stage Cylinder Liner Nitrided steel
1st & 2nd Stage Cooler Tubes Copper
3rd & 4th Stage Cooler Tubes Stainless Steel
Cooler covers & separators Spheriodal Graphite Iron
Gudgeon Pins Steel
Tube plates Cast Iron
2.3
LUBRICATION
2.3.1 MAIN LUBRICATION SYSTEM
A forced feed oil pump pressurises the lubrication system conveying oil from the crankcase to the main, big end and small end bearings via a replaceable filter element . Oil thrown off the moving parts ensures adequate lubrication to all stage pistons, crossheads and cylinders. Oil returns to the
crankcase and is drawn up to the pump suction through a strainer.
An oil pressure gauge indicates if over-pressure and is relieved through a safety valve within the oil pump. A protective Low Oil Pressure Switch or LOP s installed to shut-down the compressor if the pressure falls below 1 bar ( 15 psig). On starting if the oil pressure has not built up within about 10 seconds the LOP, connected to a delay timer in the motor starter control, will shut down the compressor.
THE GUARANTEE MAY BE INVALIDATED SHOULD A FAILURE BE ATTRIBUTED TO THE USE OF A LUBRICANT NOT RECOMMENDED BY COMPAIR IPSWICH
2.4
CONDENSATE REMOVAL
2.4.1 DIAPHRAGM DRAIN VALVES
Diaphragm Drain Valves or DDV’s are installed after each compression stage to automatically drain oil/moisture collected in each inter-stage separator and to act as unloader valves to remove any gas load on starting. All these valves are similar in design and operation – only the valve orifice and seat vary to suit each stage.
Each valve to operated from first stage pressure via a three-way solenoid valve. With no gas pressure all valves are open to the blowdown vessel. In operation, gas pressure from the 1st stage acts on the diaphragm to close the valves. A timed signal every 10 - 20 minutes actuates the three-way solenoid valve for 5-10 seconds to release the gas pressure and allow the valves to open and drain the collected condensate in each separator to drain. The sudden release of gas and condensate is passed via an integral surge vessel, to attenuate the noise, for connection to drain trap to drainage vessel, ready for safe disposal.
Oil Pump Oil filter
Oil filter By-pass
Main Bearing O/E Main Bearing D/E
Conn Rods Low Oil
Pressure Switch
2.5 GAS INLET TRAIN
2.5.1 GAS INLET TRAINAttached to the first stage gas intake flange and to provide maximum sound attenuation with minimum gas resistance together with a replaceable filter to prevent particle ingress. Gas should be drawn from a clean, dry, cool source.
2.5.2 COMPRESSOR PROTECTION
2.5.2.1 STAGE GAS RELIEF VALVES. Gas Safety valves are fitted to all four stages. 2.5.2.2 BURSTING DISC
Thin plastic membrane and PTFE/metal discs protect the cooling water system against a possible cooler gas leak, ruptured cooler tube etc. It is not intended as a protection against water over-pressure and therefore the burst pressure (17 bar or 250 psig) has no particular relationship to the cooling water system operating pressure.
2.5.2.3 PRESSURE GAUGES
Glycerine filled pressure gauges are supplied for each compression stage and for monitoring the main lubrication oil system pressures.
2.5.2.4 PNEUMATIC WATER VALVE ( IF FITTED )
This valve is a normally closed diaphragm operated shut off valve to prevent cooling water flow whenever the compressor is not operating. This function is automatic since the valve is actuated by the first stage gas pressure.
2.5.2.5 HIGH GAS TEMPERATURE SWITCHES
Temperature sensors are fitted into the 3rd stage delivery port, exit from 3rd stage separator at inlet to 4th stage inlet and at the final delivery after cooling. Each connected to a temperature switch.
2.5.3 DELIVERY
2.5.3.1 FINAL DISCHARGE NON-RETURN VALVE
Fitted at the compressor exit to prevent gas under pressure in the downstream piping or reservoir from flowing back through the machine when the compressor is unloaded and stationary.
2.5.3.2 FINAL FILTRATION
SECTION 3 CONTENTS
INSTALLATION INFORMATION
3.1
UNPACKING AND HANDLING
PAGE 21
3.2
LOCATION
PAGE 21
3.3
MOUNTING
PAGE 21
3.4
CONNECTIONS
PAGE 21
3.4.1 GAS CONNECTIONS --- 21 3.4.2 WATER CONNECTIONS--- 22 3.4.3 ELECTRICAL CONNECTIONS --- 22TYPICAL HGP.37
LIFTING EYES
VIEW FROM TOP
SECTION 3
INSTALLATION INFORMATION
3.1 UNPACKING AND HANDLING
The compressor unit is delivered in a packing case. All openings will have been sealed with plastic plugs or adhesive tape. The packing case should be carefully disassembled to avoid damage to gauges, pipework, and valves etc. and loose components packed separately.
• The unit should be lifted by the eyebolts on the motor and compressor.
3.2 LOCATION
It is desirable that the compressor unit is installed in as clean, cool and dry environment within the parameters stated in the ‘Leading Particulars’ section.
The surface, on which the unit is to stand, must be flat and capable of bearing the total weight of the unit without distortion.
In selecting the location it is essential to consider accessibility. Allow sufficient space around the installation for safe maintenance work. Sufficient clearance must be allowed to ensure that the set will not touch any obstruction or any flexibly mounted equipment, with an added allowance for maximum movement from the mounting system.
3.3 MOUNTING
The compressor unit is mounted on anti-vibration mounts. These mounts should be inspected for any tear of the rubber to metal plate bond or ageing before use. Ensure the mount is not impregnated with oil or grease, and that any protective lacquer is intact. Reject any mount that is not in good condition. Lower the compressor unit onto the mounts and screw on the mount holding down nuts. Rock unit to ensure mounts is free and not distorted, and that the set will not touch any obstructions or other flexibly mounted equipment.
3.4 CONNECTIONS
Note: As the compressor unit is flexibly mounted, all connections must also be flexible. Short flexible sections must be incorporated, should be suitable for the pressures and
temperatures involved and capable of easy removal to facilitate maintenance.
3.4.1 GAS CONNECTIONS Suction
The intake gas pressure can vary, typically between 0.02 and 1bar g from a local gas utility and must be as clean and dry as possible.
Final Delivery
The final delivery connection ½ ” BSPP is situated at the end of the non-return valve. The flexible connection must be suitable for the set working pressure.
Unloading / Condensate Drain
The unloading / condensate drain connection at the crankcase, for the surge vessel, is screwed 1½” BSPT female to accept the discharge pipe. This pipe must be led away with a minimum of bends, and must have a minimum internal diameter of 38mm (1½”). There must be no obstruction in the line as any restriction during operation may cause the safety valve at the crankcase for the surge vessel to open.
3.4.2 WATER CONNECTIONS Cooling Water
The quality, quantity and temperature of the water used can materially affect maintenance. A positive circulation of cool but not cold, clean water, free from suspended particles is required for satisfactory continuous operation.
Note: It is vital a suitable inhibitor is used especially in HARD WATER areas. Therefore it is recommended that a suitable water softener unit be fitted to the inlet water line.
It is recommended that temperature indication or gauges are fitted to water inlet (1 ¼” BSPT) and outlet (1 ¼” BSPT) pipes to monitor water temperature rise across the compressor to approximately 10-12 °C. If this rise is too high the average water temperature is high and can cause overheating and accelerate formation of scale in the coolers and water passages. Too low a rise reduces the average temperature and may improve the cooler efficiency but can cause condensation in the cylinders.
A lockable throttle valve is recommended at the inlet, installed before the pneumatic water inlet valve (if fitted), to allow adjustment the water flow to achieve the correct temperature rise then locked for security,
The inlet connection is to the pneumatic water control valve (if fitted) inlet only. This valve is operated by the first stage compressor gas pressure to only allow water in when the compressor operates.
Note: Continued water circulation when stationary can cause condensation within the cylinders and breakdown of oil lubrication creating premature wear. (I.e. over-cooling)
Pneumatic Water Inlet Valve
A compatible CompAir UK Ltd Ipswich automatic pneumatic water inlet valve can be fitted to control water supply and prevent overcooling. Water flow arrangements should be fail-safe to ensure that compressor can not run on full load without water flow.
3.4.3 ELECTRICAL CONNECTIONS
Electric Motor for Hazardous Area Zone 1
Main leads from the motor controller / starter should be brought through a suitable Zone 1 flexible armoured cable sheath to the terminal box on the side of the motor. The size of the cable shall be suitable for the supply voltage and current involved, and the terminal connections shall be as shown in the terminal box.
A suitable overload device should always be fitted.
An hours-run meter fitted to the motor starter is recommended for maintenance scheduling. A timer should be incorporated in the starter to de-energise the solenoid valve for between 5-10 seconds every 10 - 30 minutes to periodically, dependent upon ambient temperature and humidity. Contact CompAir UK Ltd Ipswich for more information on humidity if required. This will allow the diaphragm drain valves to operate and discharge any accumulated condensate.
Adequate flexibility shall be ensured to allow for movement of the set on the anti-vibration mounts. Solenoid Valve for Hazardous Area Zone 1
The cable should be run through a suitable Zone 1 flexible armoured cable sheath from the motor controller.
High Gas Temperature Switches for Hazardous Area Zone 1 The cable entry is through a conduit entry hole.
Details of the terminal connections are on the switch.
Cable should run through a suitable Zone 1 flexible armoured sheath. Low Oil Pressure Switch for Hazardous Area Zone 1
See High Gas Temperature Switches above.
Note: When the compressor set is on flexible mounting it can become electrically insulated. A flexible braided earth strap of suitable length to ensure it will not fail under maximum movement of the set must be fitted between the set and the its seating.
SECTION 4 CONTENTS
OPERATING INFORMATION
4.1
SAFETY PRECAUTIONS
PAGE 26
4.2
COMMISSIONING ON AIR
PAGE 26
4.3
RUNNING ON AIR AFTER COMMISSIONING
PAGE 27
4.4
PURGING THE COMPRESSOR READY FOR GAS
PAGE 27
4.5
ROUTINE ATTENTION WHILE RUNNING
PAGE 28
4.6
STOPPING PROCEDURE
PAGE 29
4.7
PREPARATION FOR SPECIAL ENVIRONMENT
PAGE 29
4.8
STARTING AFTER LONG PERIOD OF IDLENESS
PAGE 29
4.9
INHIBITION FOR STORAGE RUNNING ON AIR
PAGE 29
4.9.1 INHIBITION FOR UP TO SIX MONTHS ---29 4.9.2 LONG TERM STORAGE ---30
4.10
FAULT GUIDE
PAGE 31
4.10.1 RELIEF/SAFETY VALVE(S) BLOWING ---32 4.10.2 FAILS TO REACH ‘TOP’ PRESSURE ---32 4.10.3 LOW COMPRESSOR OUTPUT ---32 4.10.4 STOPS SUDDENLY ---33 4.10.5 WILL NOT START---33 4.10.6 OVERHEATING---33 4.10.7 OVERHEATING RADIATOR STES ---33 4.10.8 LOW OIL PRESSURE---34 4.10.9 CUTS OUT ON START-UP ---34 4.10.10 UNUSUAL NOISE RUNNING ON LOAD ---34 4.10.11 UNUSUAL NOISE RUNNING UNLOADED ---34 4.10.12 HIGH OIL CONSUMPTION ---34 4.10.13 PREMATURE WEAR OF PARTS ---34 4.10.14 HIGH INLET PRESSURE SWITCH TRIPS ---35 4.10.15 LOW INLET PRESSURE SWITCH TRIPS ---35 4.10.16 INLET SAFETY VALVE BLOWING ---35 4.10.17 INTERSTAGE SAFETY VALVES BLOWING---35 4.10.18 THIRD STAGE TEMPERATURE SWITCH TRIPS ---35 4.10.19 FINAL DELIVERY TEMPERATURE SWITCH TRIPS ---35 4.10.20 FINAL STAGE TEMPERATURE SWITCH TRIPS---35 4.10.21 FINAL DELIVERY SAFETY VALVE BLOWING---35 4.10.22 DISPENSER PRESSURE SWITCH TRIPS ---35 4.10.23 MOTOR PROTECTION SWITCH TRIPS---36 4.10.24 INSUFFICIENT COOLING ---36
TYPICAL HGP.37
STAGE PRESSURE GAUGES STAGE TEMPERATURE GAUGES
SAFETY VALVE MANIFOLD
SAFETY VALVES
3RD STAGE CYLINDER 4TH STAGE CYLINDER 2ND STAGE CYLINDER
