KBB

 ARIEL Heavy Duty Balanced Opposed Compressors TECHNICAL MANUAL For Models: KBB and KBV

 ARIEL CORPORATION CORPORATION 35 BLACKJACK ROAD, MOUNT VERNON, OHIO 43050 TELEPHONE: 740-397-0311 FAX: 740-397-3856 MORE INFORMATION AND RESOURCES ARE AVAILABLE ON OUR WEB SITE: www.arielcorp.com REV: 8/07

! CAUTION GAS COMPRESSOR UNITS ARE COMPLICATED AND DANGEROUS PIECES OF EQUIPMENT, IF YOU ARE NOT FULLY TRAINED AND FAMILIAR WITH THEIR OPERATION. BEFORE STARTING THIS UNIT: FAMILIARIZE YOURSELF WITH THE UNIT. UNIT. READ AND STUDY START-UP AND SHUT-DOWN INFORMATION FOR BOTH PACKAGE AND COMPRESSOR CAREFULLY! A GAS/AIR MIXTURE MI XTURE UNDER PRESSURE CAN EXPLODE! YOU CAN BE SEVERELY INJURED OR KILLED. MAKE SURE THE COMPRESSOR IS SUFFICIENTLY PURGED OF ANY EXPLOSIVE MIXTURE BEFORE LOADING. LOADING. AFTER COMPLETING THE ABOVE, BEGIN PROPER STARTING PROCEDURE.

! CAUTION DO NOT ATTEMPT TO START-UP START-UP UNIT WITHOUT W ITHOUT REFERRING TO THIS MANUAL SECTION 1 -“START UP”. UP” . IT IS ALSO ESSENTIAL TO REFER TO THE PACKAGER’S OPERATING MANUAL.

! CAUTION THIS MANUAL EDITION IS BASED ON THE CURRENT DESIGN AND BUILD PRACTICES. THIS MANUAL MAY NOT BE APPLICABLE TO EQUIPMENT BUILT PRIOR TO THE DATE ON FRONT COVER AND IS SUBJECT TO CHANGE WITHOUT NOTICE. CONTACT ARIEL WITH ANY QUESTIONS. REFER TO LAST PAGE OF THIS MANUAL FOR CONTACT INFORMATION. WHEN THIS SYMBOL APPEARS ON THE COMPRESSOR OR CONTROL PANEL, THIS TECHNICAL MANUAL IS TO BE CONSULTED FOR SPECIFIC INFORMATION BEFORE PROCEEDING. IF MORE INFORMATION INFORMATION IS NEEDED CONTACT YOUR PACKAGER AND/OR ARIEL CORPORATION.

! CAUTION GAS COMPRESSOR UNITS ARE COMPLICATED AND DANGEROUS PIECES OF EQUIPMENT, IF YOU ARE NOT FULLY TRAINED AND FAMILIAR WITH THEIR OPERATION. BEFORE STARTING THIS UNIT: FAMILIARIZE YOURSELF WITH THE UNIT. UNIT. READ AND STUDY START-UP AND SHUT-DOWN INFORMATION FOR BOTH PACKAGE AND COMPRESSOR CAREFULLY! A GAS/AIR MIXTURE MI XTURE UNDER PRESSURE CAN EXPLODE! YOU CAN BE SEVERELY INJURED OR KILLED. MAKE SURE THE COMPRESSOR IS SUFFICIENTLY PURGED OF ANY EXPLOSIVE MIXTURE BEFORE LOADING. LOADING. AFTER COMPLETING THE ABOVE, BEGIN PROPER STARTING PROCEDURE.

! CAUTION DO NOT ATTEMPT TO START-UP START-UP UNIT WITHOUT W ITHOUT REFERRING TO THIS MANUAL SECTION 1 -“START UP”. UP” . IT IS ALSO ESSENTIAL TO REFER TO THE PACKAGER’S OPERATING MANUAL.

! CAUTION THIS MANUAL EDITION IS BASED ON THE CURRENT DESIGN AND BUILD PRACTICES. THIS MANUAL MAY NOT BE APPLICABLE TO EQUIPMENT BUILT PRIOR TO THE DATE ON FRONT COVER AND IS SUBJECT TO CHANGE WITHOUT NOTICE. CONTACT ARIEL WITH ANY QUESTIONS. REFER TO LAST PAGE OF THIS MANUAL FOR CONTACT INFORMATION. WHEN THIS SYMBOL APPEARS ON THE COMPRESSOR OR CONTROL PANEL, THIS TECHNICAL MANUAL IS TO BE CONSULTED FOR SPECIFIC INFORMATION BEFORE PROCEEDING. IF MORE INFORMATION INFORMATION IS NEEDED CONTACT YOUR PACKAGER AND/OR ARIEL CORPORATION.

FOR MODELS: KBB AND KBV

TABLE OF CONTENTS  Design Specifications & Data .................................. ..................................................... ............................ ......... 1-1 General ............................. ........................................... ............................ ............................ ............................ ............................ ............................ ................1-1 ..1-1 Compressor Frame Specifications ........................... ......................................... ............................ ............................ ...................1-2 .....1-2 Component Weights ........................... ........................................... .............................. ............................ ............................ .........................1-4 ...........1-4 Opposed Throw - Reciprocating Weight Balancing ........................... ........................................ .....................1-5 ........1-5 Product Information and Safety Plates.............. Plates ........................... ........................... ............................ ........................... ............. 1-6 Important Safety & Data Information ............................ .......................................... ............................ .......................1-7 .........1-7 Clearances .......................... ........................................ ........................... ............................ .............................. ............................. .........................1-10 ...........1-10 Packing Ring, Piston Ring and Wearband Side Clearances ...........................1-11 ...........................1-11 Fastener Tightening Torque .............................. ............................................ ............................ ............................ ........................1-15 ..........1-15 Tightening Torque Procedures ............................ .......................................... ............................ ........................... ................1-18 ...1-18  Ariel Bolting .......................... .......................................... .............................. ............................ ............................ ............................ .......................1-20 .........1-20 Main Bearing Temperature Instrumentation - Alarm & Shutdown .........................1-20 .........................1-20 Thermocouples, Type J (Iron-Constantan) or Type K (Chromel-Alumel) ........1-20 Resistance Temperature Devices (RTDs) ........................... ......................................... ............................1-21 ..............1-21 Main Bearing Temperature Alarm and Shutdown Limits .......................... .................................1-22 .......1-22 Zone 1 Environment .......................... ........................................ ........................... ............................. .............................. .........................1-22 ...........1-22

Compressor Installation .................................... ........................................................ .................................. .............. 2-1 General ............................. ........................................... ............................ ............................ ............................ ............................ ............................ ................2-1 ..2-1 The Skid Should: ........................... ......................................... ............................ ........................... ........................... ............................ ...................2-1 .....2-1 Lifting the Compressor .......................... ........................................ ............................. ............................. ............................ .......................2-2 .........2-2 Setting the Compressor ........................... ......................................... ........................... ........................... ............................ ......................2-3 ........2-3  Aligning Main Bearing Bores .......................... ........................................ ............................ ............................ .......................2-3 .........2-3 Setting Crosshead Guides ............................ .......................................... ............................ ............................ .........................2-5 ...........2-5 Setting - Miscellaneous ............................ .......................................... ............................ ............................ ............................ ................2-6 ..2-6  Alignment - to Driver ........................... ......................................... ............................ ............................. ............................. .........................2-6 ...........2-6 Cold Alignment ........................... ......................................... ............................ ............................ ............................ ............................ ...............2-6 .2-6 Hot Alignment ............................ .......................................... ............................ ........................... ........................... ............................. .................2-7 ..2-7  Alignment Methods .......................... ......................................... ............................. ............................ ............................ .......................2-7 .........2-7 Electrical Grounding .......................... ........................................ ............................ ............................ ............................ ............................2-8 ..............2-8 Pneumatically Actuated Unloaders & Clearance Devices .......................................2-8 .......................................2-8 Vents and Drains ............................ ........................................... ............................. ............................ ............................ ............................ ................2-8 ..2-8 Distance Piece and Packing Illustrations........................ Illustrations...................................... ............................ .................. .... 2-9 Frame Hold-Down Foot Bolting Tightening Tig htening Tool ........................... .......................................... ........................2-10 .........2-10

 Start Up ................................................... .................................................................... .................................. .............................. ............. 3-1 General ............................. ........................................... ............................ ............................ ............................ ............................ ............................ ................3-1 ..3-1 Start Up Check List ........................... ........................................ ............................ .............................. ............................. ...........................3-2 .............3-2 8/07

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FOR MODELS: KBB AND KBV

TABLE OF CONTENTS

Maximum Allowable Working Pressure ............................ .......................................... ............................ ........................3..........3-7 7 Relief Valve Settings ............................. ........................................... ........................... ........................... ............................. .........................3..........3-8 8 Filling Sump & Priming a Main Oil Lube Oil System - Before Starting .................... ....................3-9 3-9 Filling The Sump .......................... .......................................... .............................. ............................ ............................ ..........................3-9 ............3-9 Priming - Main Lube Oil System .............................. ........................................... ........................... .............................3-9 ...............3-9 Compressor Prelube ............................ .......................................... ............................. ............................. ............................ ...................... ........3-10 3-10 Force Feed Lubricator L ubricator Adjustment ........................................ ...................................................... ............................ .................. ....3-10 3-10 Compressor Re-Application ........................... ......................................... ............................ ............................ ...........................3-10 .............3-10

Lubrication ................................... ................................................... .................................... ..................................... ..................... .... 4-1 General ............................ .......................................... ............................ ........................... ........................... ............................ ............................. .................. ...4-1 4-1 Lubrication Functions ........................... ......................................... ............................. ............................. ............................ ........................4..........4-1 1 Lubricant Characteristics ........................... ......................................... ........................... ........................... ............................ .................... ......4-2 4-2 Viscosity ............................ .......................................... ............................ ........................... ........................... ............................ .........................4...........4-2 2 Viscosity Index ........................... ......................................... ............................ ............................ ............................ ............................ ................ ..4-3 4-3 Pour Point ........................... ......................................... ............................ ............................ ........................... ........................... ........................4..........4-3 3 Flash Point ........................... ........................................ ........................... ............................ ............................ ............................ ....................... .........4-3 4-3 Lubricant Base Stock ........................ ........................................ .............................. ............................ ............................ ..........................4-3 ............4-3 Petroleum-Based Lubricants (also referred to as mineral oils) ..........................4-3 Synthetic Lubricants .......................... ........................................ ............................ ........................... ........................... ....................... .........4-4 4-4 Lubricant Formulations ........................... ......................................... ........................... ........................... ............................ ....................... .........4-5 4-5 Compounded Cylinder Oils ............................ .......................................... ............................ ............................ ........................4..........4-5 5 R&O Oil ........................... ........................................ ........................... ............................ ........................... ............................. ............................4-5 ............4-5 Engine Oil ........................... ......................................... ............................ ........................... ........................... ............................ ........................4..........4-5 5 Used Engine Oil ........................... ......................................... ........................... ........................... ............................ .............................4-6 ...............4-6 Gear Oil ........................... ......................................... ............................ ............................ ............................ ............................ ..........................4-6 ............4-6 FRAME OIL SYSTEM ........................... ......................................... ............................ ............................ ............................ ........................4..........4-7 7 COMPONENTS .......................... ........................................ ............................ ............................ ............................ .............................4-7 ...............4-7 Oil Strainer ........................... ......................................... ............................ ............................ ........................... ........................... ....................... .........4-7 4-7 Oil Pump ............................ .......................................... ............................ ........................... ........................... ............................ .........................4...........4-7 7 Oil Cooler ........................... ......................................... ............................ ............................ ............................ ............................ ........................4..........4-7 7 Oil Temperature Control Valve ........................... ........................................ ........................... ............................ .................... ......4-8 4-8 Oil Filtration .......................... .......................................... .............................. ............................ ........................... ........................... .................... ......4-8 4-8 Compressor Prelube Pump .......................... ......................................... ............................. ............................ ........................4..........4-9 9 Oil Heaters ........................... ......................................... ............................ ............................ ............................ ............................ ...................... ........4-9 4-9 Lube Oil Analysis Sampling Point .................................... .................................................. ............................ .................. ....4-10 4-10 Cold Starting ............................ .......................................... ............................. ............................. ............................ ........................... ............... .. 4-11 Dry Sump ........................... ......................................... ............................ ........................... ........................... ............................ ....................... .........4-12 4-12 FRAME OIL OPERATING CONDITIONS ........................... .......................................... ............................. ................... .....4-13 4-13 Compressor Frame Lubricant ............................ .......................................... ............................ ............................ .................. ....4-13 4-13 Oil Viscosity ............................ ......................................... ........................... ............................ ............................ ............................ .................. ....4-14 4-14 Oil Pressure ............................ ......................................... ........................... ............................ ............................ ............................ .................. ....4-14 4-14 Oil Temperature .......................... ........................................ ............................ ............................ ............................ ...........................4-14 .............4-14 Oil Maintenance ........................... ......................................... ........................... ........................... ............................ ...........................4-15 .............4-15 Oil Sampling ........................... ........................................ ........................... ............................ ............................ ............................ .................. ....4-15 4-15 Oil System Cleanliness ........................... ......................................... ........................... ........................... ............................ ..................... .......4-15 4-15 Cylinder and Packing Lubrication ............................ ......................................... ........................... ............................ .................. ....4-17 4-17 Independent Force Feed Lubricator Systems .......................... ........................................ ....................... .........4-17 4-17 ii

8/07

For Models: KBB and KBVSection 1 - Design Specifications & Data

“Hot Surfaces”

“Cold Surfaces”

Where these CAUTION symbols appear on the compressor, the surfaces are hot or cold when compressor is operating and can cause injury if touched without proper insulated protective clothing. If servicing the compressor, allow these surfaces to cool or warm to safe temperatures or wear protective clothing before proceeding. When applied to compressor cylinders, the temperature CAUTION applies to all connected piping and equipment.

FIGURE 1-4 Hot & Cold Surfaces - Caution Symbols

Throw Number 

THROW

Normal (Seconds)

Break In (Sec-

THROW

Distribution Block Part Number 

THROW

Increase Pump Stroke

THROW

P/N A-7162

INCREASE NORMAL BREAK-IN

NORMAL DIST. BLK.

BREAK-IN

NORMAL DIST. BLK.

BREAK-IN

NORMAL DIST. BLK.

BREAK-IN

DIST. BLK. PUMP STROKE

Shown is the data plate for a four (4) pump option. The plate is located on top of the force feed lubricator box at the auxiliary end of compressor. Alternate plate location is on the top cover near the inspection cover. Plate lube values for normal cycle times (seconds) are at maximum rated speeds.

FIGURE 1-5 Force Feed Lubricator Data Plate - Typical

The force feed lubricator provides oil to the piston rod packing and the compressor pistons. The lubricator plate gives directions for adjusting the flow of oil. If this plate is missing, please contact  Ariel Corporation, Mount Vernon, Ohio for a replacement or specific directions. NOTE: THE FORCE FEED LUBRICATOR BOX CONTAINS APPROXIMATELY 3.5 QUARTS (3.3 L) OF LUBRICANT. Lube box oil is for lubricating the internal parts of the box, and not a source of oil for the force feed lube system.

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FOR MODELS: KBB AND KBV

TABLE OF CONTENTS

System Design Considerations and Operating Parameters ............................ 4-50 Force Feed Balance Valves ..................................................................................4-50 Setting and Maintaining Balance Valves ......................................................... 4-50 Checking/Adjusting Balance Valves on Subsequent Start-up .........................4-51 Frame Lubricating System - Description ...............................................................4-52 Lube Oil Strainer, Filter & Filter Installation Instructions .......................................4-52 Lube Oil Strainer ..............................................................................................4-52 Lube Oil Filter .................................................................................................. 4-52 Filter Installation for Spin-On Filters ................................................................4-53 Filter Element Installation Instructions for Cartridge Type Filters ....................4-53 Lube Oil Pump & Lube Oil Pressure .....................................................................4-54 Description & Adjustment ................................................................................4-55 Lube Oil Pressure Regulating Valve ................................................................4-55 Low Oil Pressure Shutdown ..................................................................................4-55

Maintenance ........................................................................................... 5-1 General Introduction ...............................................................................................5-1 Connecting Rod ......................................................................................................5-2 Connecting Rod (Crank Pin) Bearing ................................................................5-2 Connecting Rod - Removal ...............................................................................5-4 Connecting Rod Bushing Removal and Installation ..........................................5-6 Connecting Rod - Installation ............................................................................5-7 Crosshead............................................................................................................... 5-9 Crosshead - Removal ......................................................................................5-10 Crosshead - Installation ................................................................................... 5-13 Crankshaft .............................................................................................................5-18 Main Bearings - Checking Clearances ............................................................5-18 Crankshaft - Removal ......................................................................................5-20 Oil Slinger - Removal .......................................................................................5-23 Oil Slinger - Installation: ................................................................................... 5-23 Chain Sprockets - Removal .............................................................................5-23 Chain Sprockets - Installation: .........................................................................5-23 Main Bearings - Removal and Installation w/Crankshaft Removed ................. 5-24 Main Bearings - Removal and Installation w/Crankshaft In Place ...................5-24 Crankshaft - Installation ................................................................................... 5-27 Torsional Vibration Detuners - Installation on Crankshaft .....................................5-28 Chain Drive System ..............................................................................................5-30 Description .......................................................................................................5-30 Chain Adjustment ............................................................................................5-31 Chain and Sprocket Replacement ...................................................................5-33 Chain Idler Sprockets Replacement - (Eccentric Adjustment Caps) ............... 5-33 Lube Oil Pump Chain Sprocket Replacement .................................................5-34 Force Feed Lubricator Chain Sprocket Replacement .....................................5-35 Piston and Rod .....................................................................................................5-37 Piston and Rod - Removal ...............................................................................5-38 Piston and Rod - Disassembly and Reassembly .............................................5-39 Piston and Rod - Installation ............................................................................5-41 Piston and Rod - Piston Rod Run Out .............................................................5-42 iv

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FOR MODELS: KBB AND KBV

TABLE OF CONTENTS

Piston Rings ......................................................................................................... 5-44 Determining Ring Wear ................................................................................... 5-44 Removal .......................................................................................................... 5-44 Piston Rings - Installation ..................................................................................... 5-44 Wear Bands .......................................................................................................... 5-46 Determining Wear Band Wear ........................................................................ 5-46 Wear Band - Installation .................................................................................. 5-46 Piston Rod Pressure Packing ............................................................................... 5-46 Piston Rod Pressure Packing - Removal ........................................................ 5-46 Piston Rod Packing - Reassembly .................................................................. 5-47 Long Two-Compartment Intermediate Packing ............................................... 5-49 Types of Piston Rod Packing Rings ..................................................................... 5-50 Type “P” Pressure Breaker ............................................................................. 5-50 Type "UP" Pressure Breaker ........................................................................... 5-50 Type “BTR” Single Acting Seal Set ................................................................. 5-50 Type “BD” Double Acting Seal Set .................................................................. 5-51 Type BTUU Single Acting Seal Set ................................................................. 5-51 Type “CUU” Single Acting Seal Set ................................................................ 5-51 Type “WAT” Double Acting Seal Set ............................................................... 5-52 Type “AL” Double Acting Seal Set .................................................................. 5-52 Type “3RWS” Oil Wiper Set ............................................................................ 5-52 Type “RTV” Oil Wiper Set ............................................................................... 5-53  Arrangement of Piston Rod Packing Rings .......................................................... 5-53 Piston Rod Packing Ring Material ................................................................... 5-53 Water-Cooled Piston Rod Packing .................................................................. 5-54 Valves ................................................................................................................... 5-55 Valves - Removal ............................................................................................ 5-56 Valves - Maintenance ...................................................................................... 5-56 Valves - Reassembly ...................................................................................... 5-57 Bolt Tightening for Valve Caps ............................................................................. 5-58 VVCP - Head-End Variable Volume Clearance Pocket ........................................ 5-60 VVCP - Removal ............................................................................................. 5-60 VVCP - Disassembly ....................................................................................... 5-61 VVCP - Maintenance ....................................................................................... 5-61 VVCP - Adjustment ......................................................................................... 5-62 Ethylene Glycol Contamination ............................................................................ 5-62 Cleaning Components & Thread Lube for Non-Lube Compressor Cylinders ....... 5-63

Maintenance Intervals & Trouble Shooting ......................................... 6-1 Recommended Maintenance Intervals ................................................................... 6-1 Daily .................................................................................................................. 6-1 Monthly (in addition to Daily Requirements) ..................................................... 6-2 Every 6 Months or 4000 Hours (plus Daily/Monthly) ......................................... 6-3 Yearly or 8000 Hours (plus Daily/Monthly/6 Months) ........................................ 6-4 Every 2 Years or 16,000 Hours (plus Daily/Monthly/6 Months/Yearly) ............. 6-5 Every 4 Years or 32,000 Hours (plus Daily/Monthly/6 Months/1 & 2 Years) ..... 6-5 Every 6 Years or 48,000 hours (plus Daily/Monthly/6 Months/1, 2 & 4 Years) . 6-5 Trouble Shooting .................................................................................................... 6-5 8/07

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FOR MODELS: KBB AND KBV

TABLE OF CONTENTS

Appendices ............................................................................................ 7-1  Ariel Tools ...............................................................................................................7-1  Ariel Furnished Tools .........................................................................................7-1  Ariel Tools - Purchased Separately From Authorized Dealer ............................7-2 Minimum Hand & Commercial Tools Required .......................................................7-3 Gas Analysis Common Abbreviations .....................................................................7-6 Technical and Service Schools on Ariel Compressors ...........................................7-6  Ariel Customer Technical Bulletins .........................................................................7-7 Vendor Literature ....................................................................................................7-7  Ariel Contact Information: .......................................................................................7-7

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For Models: KBB and KBV

SECTION 1 -DESIGN SPECIFICATIONS & DATA General  Ariel compressors are designed for ease of operation and maintenance. Experience has shown that an Ariel compressor will normally provide years of satisfactory performance with minimal proper maintenance. While Ariel compressors share many similarities, each model has aspects that are unique to the particular type. If you, as an operator, are familiar with Ariel compressors, it is still important to review this manual to determine the differences. If you are new to Ariel compressors, it is critical that you become very familiar with this manual prior to operating the compressor. This manual is designed to provide information on installation, start up, operation and maintenance of a KBB or KBV compressor. If you have any questions please contact your Packager. If they are unable to provide resolution, they will refer your concerns to Ariel Corporation. If you prefer, you may always contact Ariel directly. Contact your Packager or the Ariel Response Center for detailed information. Refer to the last page of this manual for contact information.

Drive/Motor End

See the control panel, specific locations on the compressor and this manual for safety information.

Information Plate (See Fig. 1-3)

www.arielcorp.com

ARI E LC O R P O R A TI RIE  A LFRAMEMO DEL

ON

 F RAM ESERIAL NUMBER

B  E  F P  A   C  T   O  H  N  E A  D  M E   S  V  E  R   O  N  K   G  I  M  O   C  B  L A  E   G  E  R  P  E  R  . C   O   S  P  T  E  L   O  A   C  N  P  E  R  R   O  F   S  N   U  L  F  E  T  N  Y E   S  R   O   S  N   C  N  M  G  I  A  T  L  R  V  A  E  N   G  T A  L   U  I   L  N  A  A  N  I   E  L E  T  D  N   ,  S  P  F  U  I    J   R   U  Y  M AE  T   C    E  A  B  H  D  E   S  R  Y  A  N  T   E  T  I   N   C  N  H  I  R   O  F  V   ,  S  E R   U   S  P  R  D   O  I      A  N  A  M L  O  L  A  V  E E   S  Y  O  P  E N  E   C  . A  N   U  E   S  A   O   C  E  T   S  M Y  T  R  A  L  G  N  I   P   ,  S   S  I   A   6  4   0  -   3 

   E    G  .    M    A    L    V    E    S    I    O    N    0    4    6        N    T    Y    D    C    A    T    E    V    A      A        O    P    A    G    E    R    R    L    O        I        T    P    O    S    R    C    H    O    P    E        U    A    D    N    I   I    R    P    N    A        A    U    R    Y    T    H    E        C    I    C    O    T    N    J    D    I    N    N    S    U    A    L    L    E    E    O    L    R    T    S    I    F    N    S    T    A    E    P    S    U    O    T    I    E    I    V    L    R    R    E    N    S    W    A

STR OKE MAIXMUM RATEDSP EEDRPM MIN IMUM RATEDSP EEDRPM  M AX IMU MR ODLO  ADTE NSION M  AX IMU M RO DL OA DCOM PRE SSION  AR IEL SHIPP INGD AT E ORMALLUBEOILPRESSU N RE MAXIM UM  L B UEOILTE MPER AT RE U UBEOILPRESSU L RE HUT S DOWNSE TTING MAXIM UM UNIT SPEDISMAXIM UM  N A ME LAT P ER AT EDFR AM EORCYLINDERSPEE,D WH ICHEVERIST HEL S ESER. ONSULT AR C IELTEH CNIC A LM AN UAL E BFO OR RPER EPF  AC L O RMING ING UNIT MAINT OPE ENR  AN AE TI. O C N

   K    S  .    L    E    A    S    )    M  .    F    R    O    O    N    )    1    0    N    C    K    T    I    B    A    R    9    (    1      5    C    H    E    U    C    I    0  .    (    1    F    .    T    E    N    T  .    T    R    5    P    S    R  .    L  .    Y    0    L    B    H    V    N    S    R    1    O    V    E    )    M    B    7    0  .  .    E    8      G    U    O    T    I    R    O  .    S    P    C  .    (    N    S    T    S    E    L    A    S    T    O    T    H    R    E    N    0    H    R  .    E    L    Y  .    E    T    O    U    B    E    E    M   V    E    S    A    T    E    N    U    T    S    A    I    R    M    4      0    A    T    U    L    E    T    M    O    V    E    R    T    E    L    O    F    P    L    U    E    P    E    D    C    E    T    H    S    P    E    R    M    D    R    E    R    A    I    N    O    V    T    O    M    R    I    N    G    O    R    Q    R    A    P    P    L    A    O    N    T    E    M    N    O    C    A    N    S    T    R    E    M   B    O    T    L    S    P    T  .    R    S    E    T    E    P    Y    6    M    N    I    G    R    A    I   E    N    T    A    N    D    E  ,    L    Y    T    I    N    T    A    L    O    V    E    L    E    A    R    V    E    R    R    A    T    N    D    P    T    V    B    L    Y    L    E    T  .    S    E    A    E    I    N    S    L    C    L  .    R    E    A    G    G    E    (    S    )    E    O    P    E    /    4    ”    N    S    E    M    O    M    P    S    E    L    V    E    R    D    R    S    T    A    S    E    I    D    E    N    T    M    A    L    I    N    L    U    E    N    3    E    A    S    E    D    C    V    E    S    (    S    )    O    E    A    N  .    G    N    I   L    V    E    T    R    L    E    M    N    O    R    D    R    A    O  ,    P    P    L    A    T    N    I    A    F    O    E    N    T    T    U    B    N    I    R      F    I    L    A    R    R    E    A    T    N    P    T    N    I    G    I    N    G    S    D    R    R    O    I   L    E    M    I    N    E    R    E    R    O    A    N    D    C    F    I    L    T    E    T    3    /    4    ”   R    A    I   S    P    R    I    N    T    E    W    E    T    R    A    C    O    V    A    I    N    A    I    L    L    H    A    E    R    G    E    R    E    N    V    E    N    G    D    V    E    R    I    O    C    T    E    N    T    S    C    T    E    D    R    I    L    T    H    A    N    F    I    E    M    E    O    U    R    I   E    M    O    F    T    E    S    P    E    L    A    C    S    E    R    S    P    E    S    O    L    F    C    D    R    D    R    A    I    N    P    I    N    N    I    )    C    (    1    )    (    2    )   (    3    )   (    4    )   (    )   (    5    6    )   (    7    )   (    8    )   (    )   (    9    1    0

   A      3    5    6    8

      9       5       4       0          A

 Auxiliary End

This manual provides design specifications for standard current production equipment at publication date. Do not exceed information plates ratings for a particular compressor.

FIGURE 1-1 Compressor Throw Numbering and Information Plate Location - Typical

The location of the throws and the data shown on the Information Plates is very important when communicating questions concerning an Ariel compressor. Frame Lifting Lugs

Breather  Chain Tighteners

Frame Oil Filter 

Oil Pump

FIGURE 1-2 Auxiliary End View - Typical

8/07

PAGE 1-1

For Models: KBB and KBVSection 1 - Design Specifications & Data

Compressor Frame Specifications TABLE 1-1 KBB Frame Specificationsa Model

KBB/4

KBB/6

7.25 (184.2)

7.25 (184.2)

900

900

450

450

To 1088 (5.52)

To 1088 (5.52)

Number of Throws

4

6

Horsepower, hp (kW)

To 6667 (4971)

To 10,000 (7457)

Height - Bottom to Crankshaft Centerline, In. (mm)

27.00 (685.8)

27.00 (685.8)

Connecting Rod Centerline to Centerline, In. (mm)

23.000 (584.20)

23.000 (584.20)

Maximum Width with Cylinders, In. (m)

220 (5.59)

220 (5.59)

Maximum Length, In. (m)

128 (3.18)

188 (4.70)

Maximum Height, In. (m)

47 (1.19)

47 (1.19)

78,000 (35 000)

118,000 (54 000)

Oil Pump Flow Rate, GPM (L/s)

121 (7.63)

161 (10.2)

Oil Heat Rejection, BTU/hr (kW)

213,000 (62.4)

320,000 (93.7)

Sump Capacity, US gallons (L)

107 (540)

170 (643)

Piston Rod Diameter, In. (mm)

3.125 (79.38)

3.125 (79.38)

Stroke, In. (mm) Maximum Allowable Speed, RPM

b

c

Minimum Speed, RPM

d

 Average Piston Speed, FPM (m/s)

 Approximate Weight with Cylinders, Lb (kg) e

Internal Rod Load - Double Acting Compression + Tension, Lbf  (kN)

190,000 (845)

190,000 (845)

Tension, Lbf  (kN)

95,000 (423)

95,000 (423)

Compression, Lbf  (kN)

100,000 (445)

100,000 (445)

Internal Rod Load - Single Acting Tension, Lbf  (kN)

95,000 (423)

95,000 (423)

a. For more information, refer to the Electronic Data Book, available in the Ariel Performance Program. b. Maximum allowable speed is the highest (potential) speed at which the compressor frame design will permit continuous operation. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Speed. The lower of the Frame Rated Speed, lowest cylinder rated (RPM) or driver rated speeds is not to be exceeded. c. Minimum Speed is the minimum frame speed to provide adequate oil flow to the compressor bearings. d. Average piston speed as is based on the maximum allowable speed (RPM) of the frame. The cylinder data-plate rated speed (RPM) or frame rated speed may be less, resulting in a lower piston speed rating. e. Flow rate is based on the maximum allowable frame speed rating and 180°F (82°C) oil.

PAGE 1-2

8/07

For Models: KBB and KBVSection 1 - Design Specifications & Data TABLE 1-2 KBV Frame Specificationsa Model

KBV/4

KBV/6

Stroke, In. (mm)

8.50 (215.9)

8.50 (215.9)

Maximum Allowable Speed, RPMb

750

750

Minimum Speed, RPMc

375

375

 Average Piston Speed, FPM (m/s)d

To 1063 (5.40)

To 1063 (5.40)

Number of Throws

4

6

Horsepower, hp (kW)

To 6667 (4971)

To 10,000 (7457)

Height - Bottom to Crankshaft Centerline, In. (mm)

27.00 (685.8)

27.00 (685.8)

Connecting Rod Centerline to Centerline, In. (mm)

23.000 (584.20)

23.000 (584.20)

Maximum Width, In. (m)

220 (5.59)

220 (5.59)

Maximum Length, In. (m)

128 (3.18)

188 (4.70)

Maximum Height, In. (m)

47 (1.19)

47 (1.19)

 Approximate Weight with Cylinders, Lb (kg)

78,000 (35 000)

118,000 (54 000)

Oil Pump Flow Rate, GPM (L/s)e

101 (6.37)

134 (8.45)

Oil Heat Rejection, BTU/hr (kW)

187,000 (54.8)

280,000 (82.1)

Sump Capacity, US gallons (L)

107 (405)

170 (643)

Piston Rod Diameter, In. (mm)

3.125 (79.38)

3.125 (79.38)

Internal Rod Load - Double Acting Compression + Tension, Lbf  (kN)

190,000 (845)

190,000 (845)

Tension, Lbf  (kN)

95,000 (423)

95,000 (423)

Compression, Lbf  (kN)

100,000 (445)

100,000 (445)

Internal Rod Load - Single Acting Tension, Lbf  (kN)

95,000 (423)

95,000 (423)

a. For more information, refer to the Electronic Data Book, available in the Ariel Performance Program. b. Maximum allowable speed is the highest (potential) speed at which the compressor frame design will permit continuous operation. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than Maximum Allowable Speed. The lower of the Frame Rated Speed, lowest cylinder rated (RPM) or driver rated speeds is not to be exceeded. c. Minimum Speed is the minimum frame speed to provide adequate oil flow to the compressor bearings. d. Average piston speed as is based on the maximum allowable speed (RPM) of the frame. The cylinder data-plate rated speed (RPM) or frame rated speed may be less, resulting in a lower piston speed rating. e. Flow rate is based on the maximum allowable frame speed rating and 180°F (82°C) oil.

Component Weights  Approximate component weights are given in Table 1-3 to provide data for determining proper lifting facilities when servicing the compressor and prevent personal injury. Note that weights given are for the bare part and that attached parts weights may need to be accounted when determining lifting facilities. TABLE 1-3 Approximate Component Weights Component

Frame Assembly w/o Cylinders

8/07

Lbs

(Kg)

Refer to Ariel Electronic Data Booka

Main/Connecting Rod Bearing

11

(5.0)

Thrust Plate

29

(13)

PAGE 1-3

For Models: KBB and KBVSection 1 - Design Specifications & Data TABLE 1-3 Approximate Component Weights Component

Lbs

(Kg)

Spacer Bar

145

(66)

Top Cover, Drive End, 4-throw/6-throw

100/80

(45/36)

Top Cover, Center Section (each)

180

(82)

Top Cover, Auxiliary End, 4-throw/6-throw

120/105

(55/48)

Top Cover Cross Bar

125

(57)

End Cover Drive End

225

(102)

Dust Seal Cover

50

(23)

End Cover Auxiliary End

375

(170)

Lube Oil Pump

130

(59)

Crankshaft, 4-Throwb

2900

(1315)

Crankshaft, 6-Throwb

6000

(2722)

Main Journal Caps

100

(45)

Connecting Rodc

325

(147)

Crosshead Guide

3120

(1415)

Crosshead Guide Gland

50

(23) d

Crosshead

Refer to Balancing Record

Crosshead Pin

90

(41)

Crosshead Guide Side Cover, Large

30

(14)

Crosshead Guide Side Cover, Small

25

(12)

Piston Rod

150

(68)

VVCP Cylinder Assembly

Refer to Ariel Electronic Data Booka

Piston and Rod Assembly

a. b. c. d.

Valve Retainer

35

(16)

Valve Cap

90

(41)

Piston Rod Packing

85

(39)

Nut Ring (Around Flywheel)

40

(18)

The Electronic Data Book is available in the Ariel Performance Program. Crankshaft weight is without flywheel, vibration detuner donuts, or damper. See Balancing Record and footnote D. for an exact weight of a given connecting rod assembly. Provided by Ariel in the Parts Book for each compressor.

Opposed Throw - Reciprocating Weight Balancing  Ariel recommends that the reciprocating weight differential between opposing throws be 5.0 pounds (2.27 kg) or less for KBB and KBV compressors. If replacing any major reciprocating component, that is; a connecting rod assembly, piston, piston & rod assembly, crosshead-balance nuts or crosshead, weigh component parts on a calibrated scale to 0.1 pounds (0.05 kg) and compare to the Compressor Balancing Record sheet that comes in the parts manual with each compressor. If there are weight changes, recalculate opposing throw reciprocating weight differentials. If not within the recommended limit, new balance nuts and/or crossheads are to be selected to provide the least possible differential.

PAGE 1-4

8/07

For Models: KBB and KBVSection 1 - Design Specifications & Data

If it is desirable to exchange opposing throw compressor cylinder locations, all reciprocating components must be exchanged to the opposite throw, except the connecting rod assemblies. Check the Balancing Record sheet and recalculate reciprocating weight differential, with the connecting rod weights included. If not within the recommended limit, new crosshead-balance nuts are to be selected to provide the least possible differential. If opposing throws can not be balanced within the recommended reciprocating weight differential limit, contact your packager and/or Ariel. When applying or re-applying a different cylinder to a throw, the opposing throw reciprocating weight differential must be re-calculated and new balance nuts or crossheads may be required. The force feed oil distribution system may also need to be resized. Contact your Packager or the Ariel Response Center for detailed information, if reciprocating weights change and exceed the recommended reciprocating weight differential between opposing throws, when exchanging opposing throw compressor cylinder locations or when applying or re-applying a different cylinder to a throw. Refer to the last page of this manual for contact information

8/07

PAGE 1-5

For Models: KBB and KBVSection 1 - Design Specifications & Data

Product Information and Safety Plates Direction of Rotation Plate, Located At The Drive End Standard Rotation Shown

 A-719

Top Cover Drive End

 A-719

ROTATION

ROTATION

Manual Lifting Handles Compressor Frame Name Plate: Tapped Holes For Top Cover Lifting Eyebolts

Ariel Frame Model Number 

ARIEL CORPORATION

Frame Serial Number 

 ARIEL FRAME MODEL

Stroke of Piston

FRAME SERIAL NUMBER

Maximum Rated Speed, RPM

STROKE

Minimum Rated Speed, RPM

MAXIMUM RATED SPEED RPM

Top Cover(s) Center 

MINIMUM RATED SPEED RPM

Max. Rod Load Tension Max. Rod Load Compression

MAXIMUM ROD LOAD TENSION MAXIMUM ROD LOAD COMPRESSION

Ariel Shipping Date, Month Year 

 ARIEL SHIPPING DATE NORMAL LUBE OIL PRESSURE

Breather(s)

Normal Lube Oil Pressure Max. Lube Oil Temperature

MAXIMUM LUBE OIL TEMPERATURE LUBE OIL PRESSURE SHUTDOWN SETTING

Lube Oil Pressure S/D Setting

MAXIMUM UNIT SPEED IS MAXIMUM NAME PLATE RATED FRAME OR CYLINDER SPEED, WHICHEVER IS THE LESSER. CONSULT ARIEL TECHNICAL MANUAL BEFORE PLACING UNIT IN OPERATION OR PERFORMING MAINTENANCE.

Ariel Logo, Name, And Address Plate

      9       5       4       0          A

Max. Unit Speed is Max. Name Plate Rated Frame or Cylinder Speed, Whichever is the Lesser. Consult Ariel Technical Manual Before Placing Unit in Operation or Performing Maintenance

Top Cover Auxiliary End

CAUTION! Severe Personal Injury and Property Damage will Result if Suction and Discharge Valves are not Installed in their Proper Location.

Full Flow Lubricator Information Plate, Alternate Location

www.arielcorp.com

ARIELCORPORAT ION  ARIELFRAME MODEL FRAME SERIALNUMBER

T  I    ,V  R  R  P  E  C  E  E  R  N A  A   O  A  L  L  L   S  P  N M V  O  Y  E   C  A  E  O  S  R  E  N  C  S  T  T  .  U  A  E  E  Y  P  N  M A   S  L  I   N  I    ,  G  S  A   0  -   6  4   3 

   E    G    A    S .    E    N   4    4    6    M    V      A    O   0    I    L    D    A    T   A    A    Y    V    C

STROKE

B  N  D  E  P  A  T  H   O  A   S  E  F  C  T  M V   O  K  E  B  C  A  E  R I    O  G  R  E  N  O  E  L  P  G  . T  M E  P  E  C   S  P   C  E   O  O L  R  E  A  N  S  R  N  F  S  N T   O  E  R  O  R   U  F  L  E  N  L  Y   S  A  M L  T  A   U  L  I   N A  N V  E  L  I    G R  G N  T  N  E  T  I    J   A  I   E   S  N  E  F   U  Y  L   ,H D  P  R  T  E  B  E  R  Y  E  M C  A  E   S  A  N  A  D F   S  D  I   N  H  S  N   O  U 

MAXIMUMRATEDSPEEDRPM

 C  A   U  T   I       O  N 

   T    E    O        N   E    R    G    L    R    P    R    A    E        O   R    O    H    P        I    C    P    O    S    I    R        T   N    D    D    P    A    D    R    I        U   R    Y    N    E    A    H    U    N    T        A   N    J    O    I    N    I    I   C    T    D        C   A    L    U    E    L

MINIMUMRATEDSPEEDRPM MAXIMUMRODLOADTENSION MAXIMUM ROD LOAD COMPRESSION  ARIELSHIPPING ATE D NORMALLUBE OILPRESSURE

   N    S    L    O    F    I   A    S    T    R    T    S    L    E    N    U    I    P    S    T    E    E    O    R    R    N    E    L    V    L    E    I    E    R    S    W    A

MAXIMUM LUBE OILTEMPERATURE LUBE OILPRESSURE SHUTDOWN SETTING MAXIMUMUNITSPEEDISMAXIMUMNAME PLATERATEDFRAMEORCYLINDERSPEED, WHICHEVER IS THE LESSER. CONSULTARIELTECHNIC ALMANUAL BEFORE PLACING UNITIN OPERATION OR PERFORMING MAINTENANCE.

   9    5    4    0      A

   S    N    )    O    R    A    I    B    T  .    C    0    1    (    U    S    I    R    P  .    5    R    T    1    E    V    S    R  .    O    )    N    O    C    S    I  .    (    S    P  .    T    R    N    T    H    O   E    E  .    Y  .    T    B    M    N    0    E   L    E    U    R    E    0   U   E    V    T    L    E    0

   T    O   R    E    T   E    M    4   -   A    M   E    E    L    E    R   P    N    V    E    S   E    I    R    A    H    M   D    C    T    P   O    R    O    N    M   C    N    T    M    A    O    E   N    A    S    E    L    M    T    T    D    R  ,    Y    P    6   G   I    A    N    N    L    N   D    R    V    E    A    E    E    Y   I    Y    T    R    T    R    L    E    E    A   D    P    T    B    R    L

 .    S    K    A    E    L  .    R    )    M   O    F    N    K    0    1    C    1   -    E    5    H    9    (    C  .  .    T    T    F   -    N    B    E    V  .    L    H    Y    L    0    G    B    8   -    U    M   0  .    E    7    O    L    S    R    O   H    E    T    S    S    A    S    T    S    E    T    I    R    E    T    V    U    A    A    N    F    L    E    D    O   P    U    E    P    G   Q   P    M   N    O   I    R    A    T    R    T    O   T    R    T    P    O   S  .    E    B    L    E    R    S    N    A    L    V    A    I    E    T    T    O   L    A    S    C    E    E    N    S    I    L    R  .

   8    5    6    3      A

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CAUTION! Severe Personal Injury and Property Damage can Result if Pressure System is not Completely Vented Before Loosening Bolts on Flanges, Heads, Valve Caps. Consult Ariel Technical Manual Before Performing any Maintenance.

Duplex Filter Cartridge Replacement Instructions: 1. Change Filter Elements(s) every 6 Months - 4000 Hours or 15 psid (1.0 bar d) at Normal Operating Temperature. 2. Inspect Unused filter for Oil. Release Trapped Air if Necessary. 3. Equalize Pressure between the Filters. 4. Turn Handle of Transfer Valve Towards Unused Filter until it Stops. 5. Shut Off Equalizing Line. 6. Remove 3/4” NPT Drain Plug and Drain Completely. 7. During Draining, open 3/4” NPT Vent and Remove Top Cover. 8. Remove Spring Plate Assembly and Strainer Tube. 9. After Oil Has Drained Completely, Remove Elements(s). 10. Inspect Interior of Vessel. 11. Place new element(s) Over Seat in Bottom of Vessel. 12. Insert Strainer Tube and reinstall Spring Assembly. 13. Inspect Cover O-Ring. Install cover. Torque Nuts to 70-80 LB-FT (95-110 N·m). 14. Close Drain and fill Vessel. Release Trapped Air through Vent. Check for Leaks.

FIGURE 1-3 Top Covers - Typical

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8/07

For Models: KBB and KBVSection 1 - Design Specifications & Data

Important Safety & Data Information CAUTION: Severe personal injury and property damage can result if pressure system is not completely vented before loosening the bolts on flanges, heads, valve caps, or packing. Consult Ariel technical manual before performing any maintenance. CAUTION: Severe personal injury and property damage will result if suction and discharge valves are not installed in their proper location. CAUTION: Noise generated by reciprocating machinery can be a source for hearing injury. See packager’s information for any specific recommendations. Wear hearing protection when unit is running. CAUTION: Hot (or cold) gas temperatures especially the cylinder discharge areas, 190°F (88°C) oil and high friction areas can be a source for burns or fost bite. Wear proper insulation when working around these areas. Shut down unit and allow to cool (or warm) before doing maintenance in these areas.

8/07

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