Operation & Maintenance Manual for Hypercomp CNG Compressor Model 3W815

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


9.4. 1ST STAGE HEAD .................................................................................................................. 41


9.5. 2ND STAGE VALVE AND HEAD.............................................................................................. 41


9.6. 3RD STAGE VALVE AND HEAD .............................................................................................. 42


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


9.9. GUIDE CYLINDER FOR 1

ST, 2

ND & 3

RD STAGE ............................................................................ 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



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9.12. GUIDE PISTON ...................................................................................................................... 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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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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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.


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.


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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1. Screw rod into crosshead piston.

2. Install seal carrier per 9.8.2.


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.


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.


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

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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

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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”


clearance 2nd

stage

0.002” – 0.004”


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

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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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Operation & Maintenance Manual for Hypercomp CNG Compressor Model 3W815

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Transcript of Operation & Maintenance Manual for Hypercomp CNG Compressor Model 3W815