User's Manual - Compressor IODM 70-3-19

USER’S MANUAL - ASPRO CNG COMPRESSOR – IODM 70-3-12 / IODM 70-3-19 / IODM 70-3-19 BD

Equipment manufactured under quality assurance system according to ISO 9001:2008

www.aspro.com

ORIGINAL DOCUMENT

USER´S MANUAL IODM 70-3-12/ 70-3-19/ 70-3-19 BD MAN-91540-I

USER’S MANUAL ASPRO IODM 70-3-12 / IODM 70-3-19 / IODM 70-3-19 BD CNG COMPRESSORS (CE & STD) PURPOSE This manual contains important information about the installation, operation and maintenance of the equipment. We suggest: • Read the instructions manual.

IMPORTANT NOTE

This equipment works with high-pressure gas lines (maximum 250 bar) and power voltage (380/440 Vac - 50 Hz/60 Hz) that are risky for the human life.

The installation or eventual repair of the same only shall be performed by Technical Personnel of DELTA COMPRESIÓN S.R.L. or qualified technical personnel duly authorized by the corresponding statutory authorities. The manufacturer reserves its rights to include modifications in the technical or constructive characteristics of the equipment in order to improve its performance, increase its capacity or due to changes in the suppliers or materials used for the fabrication.

The photographs are only for illustrative purpouses. The company reserves the right to modify the content of this document without prior notice. The information contained herein, including the information contained in any attachment hereto, is confidential and may be protected by Industrial and/or Intellectual Property rights, including but not limited to invention patents, usage patterns and industrial designs. This information shall not be disclosed in any way, copied and/or used for commercial purposes, and the recipient shall use it only as per the written authorization issued by Delta Compresión S.R.L. Any violation to the prohibition contained herein may be punished as per the laws of the Argentine Republic and/or international treaties, and shall entitle Delta Compresión S.R.L. to claim for the damages suffered.

DATE REVISION 05-06-06

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INDEX General instruction…………………………………………………………………………………..……………………… 04.About the denomination of the compressor system……………………………………………………………………... 04.Compressor general view……………………………………………………………………………………………..……. 04.General specifications ……………………………………………………………………………………..……………….. 05.Safety system classification …………………..…………………………………………………………………………… 06.Important notes……………………………………………………………………………………………………………… 06.Precautions …………………………………………………………………………………………………………………. 06.Compressor package deliver.…………………………………………………………………………………..………….. 07.Foundation installation……………………………………………………………………………………..………………... 08.Interphase connections……………………………………………………………………………………………………... 08.Start up……………………………….……………………………………………………………………………………...09.Measurement system……….………………………………………………………………………………….…………… 09.Equipment alarms and stop…………………………………………………………………………………….………...… 10.Comments about the alarms...……………………………………………………………………………….…………….. 11.Operative stop system due to storage pressure…………………………………………………………………………… 12.Stop system due to storage overpressure……………………………………………………………………..………….. 13.Equipment safety system.…………..………………………………………………………………………………………. 13.System’s sub-assembly……………………………………………………………………………………………………… 14.Skid sub-assembly…………………………………………………………………………………………………………… 14.Compressor unit sub-assembly……………………………………………………………………………………………… 15.Flame proof. Electric motor….…………………………………………………………………………………….……….. 15.Air-cooler….……………….……………………………………………………………………………………………….… 17.Lubricant system 1. Lubricant………………………………………………………………………………………………………….. 18.2. Gear pump…………………………………………………..…………………………………………….. 19.3. Single piston pump (Cylinders lubrication)……………………..………………………………………. 20.4. Cylinder lubrication (Optional)……………………………………………………………………………….. 23.Gas flow……………. …………..........…………………………………………………………………………………..…24.Cylinders...…………………………………………………………………………………………………………….……… 25.Compressor inlet valve.………………………………………………………………………………………….…..……… 26.Regulator valve…………….……………………………………………………………………………………..……..…… 27.Blow down tank ……………………………………………………………………………………………………..………. 27.Knock down tank …………………………………………………………………………………………………………..... 28.Pulsation dampener…………………………………………………………………………………………………….……. 28.Condenser……………………………………………………………………………………………………………………. 29.Drainage system…………………………………………………………………………………………………………….. 29.Automatic drainage system………………………………………………………………………………………………… 30.Depressurizing procedure…………………………………………………………………………………………………… 31.Safety valve………………………………………………………………………………………………………………….. 32.Vibration sensor……………………………………………………………………………………………………………… 32.Intrinsic safety (only CE)…………………………………………………………………………………………………….. 33.Before starting……………………………………………………………………………………………………………….34.Automatic start procedure………………………………………………………………………………………………….. 35.Manual starting procedure………………………………………………………………………………………………….. 36.-


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INDEX Optional • • • • • •

Acoustic enclosure…………………………………………………………………………………………...37.Temperature transmitters……………………………………………………………………………………38.Gas detector………………………………………………………………………………………………….38.Flame detector……………………………………………………………………………………………….38.39.Mass flow meter and by-pass system………………………………………………………………………. 40.Three ways priority system (outside of compressor)………………………………………………………

Maintenance 42.Troubleshooting……………………………………………………………………………………………………………… 45.Recommended tolls, preventive maintenance ……………………………………………………..……………………… Special characterize of model BD • Main operation……………………………………………………………………………………………….46.47.• Heat exchanger………………………………………………………………………………………………. 48.• Distribution CO2……………………………………………………………………………………………… • Actuators……………………………………………………………………………………………………..49.51.• Inlet coalescent filter & outlet coalescent filter……………………………………………………………..


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GENERAL INTRODUCTION The compressor is built up according to the different world standards. In order to fulfill with these standards our Engineering Dept. performs a permanent and careful material selection for the manufacturing of the different components. The design was developed considering the latest world available technology, having unique characteristics that distinguish it from other compressors offered at present in the market. The compressor has an oil pump, for the crankcase as well as for piston lubrication, and its own associated sensors, such as vibrations detector, low oil level sensor and oil pressure switch. The compressor is driven by an electric motor, having its own pulley-belts-flywheel transmission system. The system control is centralized in a panel called Control Panel, located far from the compressor, it has a touch screen where the operator configures the system, operates the compressor and recognizes the alarms. Included in the panel it is possible to find, among others: • The P.L.C. (Programmable Logic Controller) a last generation device, which works as the system brain. • The Soft Starter, its function is that the main motor starts softly and not at full power, reducing in this way the extra power when starting. • Zenner Barrier, safety device for the sensors and field electric devices. All the system shall be assembled over 4 vibration-dampening chocks supplied with the equipment for this use.

ABOUT THE DENOMINATION OF THE COMPRESSOR’S SYSTEM (IODM 70-3-12 / IODM 70-3-19 / IODM 70-3-19 BD) • • • • •

IODM: (Methane Double Horizontal Compressor), 70: (compression stroke length in millimeters), 3: (number of stages), 12/19: (It indicates the inlet pressure). BD: (Booster Daughter).

COMPRESSOR GENERAL VIEW See the plane associated to the compressor system

GENERAL SAFETY •

The compressor installation, operation, maintenance and repair, shall be done ONLY by Qualified Personnel fulfilling ALWAYS the Safety Standards.

•

The compressor must be maintained in the best working conditions in order to assure a safe operation.

•

Do not loose or tighten valves, flanges or fittings under pressure.


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GENERAL SPECIFICATIONS Brand

ASPRO

Model

IODM 70-3-12 / IODM 70-3-19 / IODM 70-3-19 BD

Compressor Main Motor Maximum Power

3x380 / 3x440Vca (50/60)Hz. (other feedings, to ask) 75 Kw (100HP) / 90 kw (125 HP)

Maximum RPM

1500 maximum (50Hz.) / 1800 maximum (60 Hz).

IODM 70-3-12 Inlet (min. /max.) pressure

07 bar / 13 bar (approx.)

Electric Power feeding

IODM 70-3-19 Inlet (min. /max.) pressure


IODM 70-3-19 BD Inlet (min. /max.) pressure


Stroke

70 mm

Max. outlet pressure 70-3-12 (1st / 2nd / 3rd) stages (Bar) Max. outlet pressure 70-3-19 (1st / 2nd / 3rd) stages (Bar)

( 55 / 150 / 250) bar (approx.) (60 / 150 / 250) bar (approx.) PL-91545-1 for 50Hz PL-91545 for 60Hz PL-91544-1 for 50Hz PL-91544 for 60Hz

See performance curve For IODM 70-3-12 See performance curve For IODM 70-3-19

Maximum flow

See performance curve For IODM 70-3-19 BD 2 x (2.2 kw).

Air cooler motor maximum power ø cooling fan propeller

600 mm

Gas inlet valve STD/BD

ø 1 ½”

Enclosure (acoustic cabin)

Optional

PL-94015

Control operation system

Display touch-screen

System intelligent controller

PLC (in electric control panel)

System filters

Particles filter in the inlet, and coalescent filter in the last compressor’s stage.

Weight (approx.) STD/ BD

2500 Kg./ 4500 Kg (approx.), according to model

External measurements

(See plane according to model)

Safety

For valves, pipelines, tubing, fittings and fastening elements; high safety margins are used. Winding and electronics are assembled according to the rules for equipment working in hazardous areas.

Stop system

One operative, one for safety

Stop pressure switch (pressure range)

215 - 245 bar.

Maximum working pressure

250 bar.

Operation temperature range

-10°C / 50°C

Operation humidity range

5% / 100%

Gas humidity compressor’s operation

0.114 gr. H2O/m3 gas (maximum.) All weather conditions (with acoustic cabin). Snow: ask. See this user`s manual

Weather conditions Optionals


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SAFETY SYSTEM CLASSIFICATION • • •

The system fulfills with safety classification CLASS 1, DIVISION 1, GROUP D according to U.S. NEC 500. The main motor, as well as the air-cooler one are explosion proof, their ducts are made of rigid pipes or of flexible explosion proof ones and the sealers used agree with the standards in force. All the non-safe signals junction boxes are explosion proof, the sensors are either intrinsically safe or they go through the control panel zenner barriers.

IMPORTANT NOTES:

CNG is potentially explosive. Its use requires taking extreme precautions. Before disassembling any component, check that the unit is completely de-pressurized. Never work on the compressor when it is under operation. Watch out NO SMOKING instructions all over the refueling gas station. Control the correct fulfillment of all the Safety Codes. Otherwise there may be mechanical problems or severe injuries caused to human beings or properties. It is prohibited to wash with pressure water the compressor unit system, the junction boxes, the electric motors and all those elements that may affect the operator/s safety. It does emit non-ionizing waves.

PRECAUTIONS It is important to follow the following rules in order to avoid accidents or damages to the personnel as well as to the equipment, in case it is necessary to carry on any task inside the compression equipment. 1. Do not place obstacles around the equipment; keep the working area clean and the floor dry and free of oil or grease stains. 2. Light the equipment and the surrounding area adequately. 3. Do not put tools, parts, etc. on top of the equipment. 4. Keep in perfect conditions, clean: instruments, accessories, stop buttons (emergency push button), etc. 5. Keep the hands far from the mobile or rotating parts during operation. Operate the equipment with caution. 6. Do not alter under any circumstance the equipment’s calibration instruments. 7. When it is necessary to carry on a general cleaning, close the gas inlet and the power supply, de-pressurize the equipment and afterwards clean the affected area. 8. Clean the equipment periodically. Do not allow dust, oil or grease to accumulate. Use dry rags, brooms or similar elements. 9. In case of cleaning air-coolers, use a plastic brush soaked in water, trying not to damage the equipment fins. Repair with pliers the ones that are twisted. Protect previously the motor, the electric valves and the other electric accessories against water and / or humidity inlet. 10. Do not forget to de-energize and de-pressurize the equipment before carrying on any activity inside it. 11. The use of ear protection in the area near the bunker or inside it is recommended.


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COMPRESSOR PACKAGE DELIVER The compressor equipment will have to be located taking in account the effective norms from the place, or in búnker or with enclosure for inclemency. A space will consider in which the operator can maneuver around he himself (not less than 0.9 mts.). In addition, in case the equipment count on cabin is due to be able to open the doors without touching in other equipment, walls, supports, pipes, etc

Also, environment on where the compressor install will have to hold clean and to avoid the direct exhibition to the light to pave and proximity to heat sources because it can affect the capacity of he himself.

COMPRESSOR PACKAGE UNLOADING For unload the compressor package, the crane service shall be provided. The awarded supplier shall inspect the place and the distances in order to plan the unloading taking into account that the weight of the package is abt. 2500 kg (without enclosure and with empty storage) and the height is 2070 mm (reference data). The supplier shall have steel slings according to the weight of the compressor package.- The length shall be 2.1 mts. The compressor package includes structural eye plates suitable for the unloading.

HOISTING EYE PLATE DETAIL

To move the compressor package to the desired position and lift slowly the same, checking for a proper positioning.

ATTENTION!!! It is not the responsibility of DELTA COMPRESIÓN S.R.L. the transportation, hoisting and lifting of the package.


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FOUNDATION INSTALLATION Install the package on vibration dampener chocks (supplied with the package). The positions in which the chocks shall be installed are marked in the compressor skid. The same may differ from the photo shown. According to the place for the installation; the vibration insulator can be an elastomeric compound.

Yellow indication Vibration damper

ATTENTION!!! Please refer to the foundation drawing supplied by Delta Compresión SRL. The compressor foundation shall fulfill the required details on the drawings in order to meet the applicable regulations of the place of installation.

INTERPHASE CONNECTIONS The same shall be done by the supplier in charge of the electro-mechanical installation. The gas outlet shall be connected to the storage. For more details see the information supplied by the installation vendor.

Electrical entrances Vent outlet

CNG outlet

Gas inlet

ATTENTION!!! The installer company will be responsible for the inlet’s and outlet’s connections of the equipment.


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START UP After finishing the electromechanical assembly the compressor start up should be done. DELTA COMPRESION SRL personnel shall carry on this operation, or someone appointed and authorized by the company. In this operation all the compressor’s working parameters are adjusted (pressures, times, compressor’s revolutions, sensors, etc.) In this way the equipment shall be in perfect conditions to start operation.

MEASUREMENT SYSTEM The Compressor has an instrument panel, assembled on the compressor skid, so that the operator is able to visualize the system’s main variables. The Compressor has an instrument panel, assembled on the compressor skid, so that the operator is able to visualize the system’s main variables. The instruments on the mentioned panel are: • Compressor inlet pressure gauge. • 1st stage outlet pressure gauge. • 2nd stage outlet pressure gauge. • 3rd stage outlet pressure gauge. • Gas temperature to storage. • 1st stage outlet thermometer. • 2nd stage outlet thermometer. • 3rd or last stage outlet thermometer with electric contact (In compressor for CE, used ATEX electric contact) . Other sensors or equipment instruments are: • Compressor unit crankcase oil pressure gauge. • Compressor unit crankcase oil pressures switch (through zenner barrier). • Compressor unit cam pumps oil level. • High and low inlet pressure switch at the compressor inlet (through zenner barrier). • High-pressure switch at the compressor outlet (through zenner barrier). • Compression unit vibrations detector (through zenner barrier).

Safety Gauge (CE). General instrument panel


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EQUIPMENT ALARMS AND STOP SYSTEM Alarms that activate the immediate or sudden equipment stop: • Safety system (Emergency push button and safety pressure switch on storage). • Crankshaft low oil level. • Compressor main motor Soft Starter failure or alarm. • Gas leakage detector (optional, with flame proof box). • Flame detector (optional, with flame proof box). • Vibration detector (through zenner barrier).

stop

Note: The alarm due to the safety system activation operates without feeding the PLC, thus allowing an emergency even in front of problems in the compressor PLC.

Alarms that activate programmed equipment stop: • Compressor last stage high pressure. • Compressor last stage high temperature. • Compressor high inlet and low inlet pressures. • Cam pumps low oil level. • Main motor or fan motor overload protection failure. • Main motor coil’s PTC and bearings’ PTC (optional).

Note: A the programmed equipment stop means that before stopping the compressor makes a gas sweep in each of the stages towards the storage to discharge it and to remain stand still for a later soft starting.

Emergency push button

Emergency push button

Start and stop push button


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COMMENTS ABOUT THE ALARMS In case any alarm is activated, the compressor shall start the “programmed stop” or the “abrupt stop” process, according to the importance of the alarm. In case of an “abrupt” stop, once the fail is solved, all the compression stages shall be de-pressurized before putting the compressor equipment again in operation. Besides in the switchboard touch screen there is a logo, which indicates if there is an active alarm in the system. If you press over it, you can visualize a list of the active alarms together with the date and time of their activation. In case of a new alarm, the screen shall visualize a text, identifying the alarm together with the “accept” button, which shall be pressed in order to acknowledge the alarm. In order to acknowledge any alarm, you should press over the acknowledging “Ack” key, so that the acoustic signal and the active alarms shall be deactivated. To re-start the compressor after an alarm, the causes that produced the alarms shall be solved, and then the “re-set” button shall be pressed, so that the compressor equipment is started again. From the “See alarms” menu, there is access to a screen showing as are the active alarms, and it allows visualizing an historic record of the alarms produced


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OPERATIVE STOP SYSTEM DUE TO STORAGE PRESSSURE (AUTOMATIC START-STOP) The system has an automatic start-stop pressure switch, which through the reading of the storage pressure starts or stops the compressor. The start-stop pressure switch allows to set, within certain values, the compressor start and stop pressures, this is very useful in the installations with two compressors, achieving in this way their start and stop at regular intervals. The start-stop pressure switch is connected to the system’s PLC, which activates the programmed stop sequence or the recirculation according to its own internal configuration. The outlet signal from the pressure switch to the PLC is of dry contact. As an optional there is a possibility of using a pressure transducer instead of the start-stop pressure switch. In this case the communication between the transducer and the PLC is 4-20mA and the compressor start and stop pressures values are configured in its own PLC. Note: Re-circulation: It is a compressor operation which maintains the compressor working but without compressing. It is used to avoid short compressor stops when the storage is full but a quick pressure drop due to a big quantity of gas sale is assumed. It is achieved closing the gas inlet valve to the compressor and opening the de-pressurizing valve, working in this way in a close cycle

Solenoid inlet valve

Automatic inlet valve

Inlet Valve Only IODM 115-3-19 BD De-pressurizing valve


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STOP SYSTEM DUE TO STORAGE OVERPRESSURE The system has two safety pressure switches as a protection stop for overpressure. These pressure switches, set at 270 bar, automatically stop the compressor in case of an overpressure reading. (265bar only CE) •

The first of them reads the pressure at the last stage outlet and connects to the PLC, which on an alarm signal activates a compressor programmed stop.

•

The second safety pressure switch reads the pressure over the storage battery and in case of an alarm condition; it operates directly over the emergency safety system without passing through the equipment PLC. This second safety pressure switch is not assembled on the machine at the factory; it must be installed during start-up as well as the Bunker’s or dispensers islands’ emergency push buttons.

EQUIPMENT SAFETY SYSTEM The system’s safety is born at the exact moment of design and conception and it goes as far as installation and start up. For total safety during system’s operation, the equipment has the following sensors and safety elements: • Emergency stop push buttons to be installed during commissioning in the bunker as well as in the dispensers’ islands. • Storage high-pressure switch (to be installed in the storage). • Compressor last stage outlet high-pressure switch. • Compressor last stage outlet dry contact thermometer. • Safety valve for each compression stage. • Inlet high-pressure switch. • Inlet low-pressure pressure switch. • Compressor crankcase oil low-pressure switch. • Compressor vibrations detector. • Flame or gas detector (Optional). • Main motor coil’s PTC and bearings’ PTC (optional).


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SYSTEM’S SUB-ASSEMBLIES •

SKID SUB-ASSEMBLY

It corresponds to the structural unit of the compressor equipment, where all the assemblies, sub-assemblies and components are assembled. It is essentially made of bent plate and structural type pipes. The main sub-assemblies assembled over the skid are: • Compressor body or compressor unit assembly. • Main motor and transmission. • Air cooling system. • Oil lubes system. • Cylinders. • Inlet and de-pressurizing valves. • Regulator valve. • Blow down tank. • Knock down tank. • Pulsation dampers • Last stages condenser. • Drain system. • General instrument panel. • Safety valves. • Vibration sensor. • Pipelines. • Electro mechanic equipment. Cooling system

General Instrument panel

Safety valves

Pulsation Dampers

Inlet valve

De-pressurizing valves.

Crankcase system

Knock Tank dank Compressor’s skid

Electric motor


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COMPRESSOR UNIT SUB-ASSEMBLY

In this assembly we can point out the compressor unit that is the skid itself plus all the components included in it (connecting rods, crossheads, pistons, flanges, o’rings, etc.) In general this model is directly driven, by means of an electric motor, which shall provide the necessary useful power so that the machine carries on the compression process. This process shall be performed through the 3 stages that said machine has, what it is achieved is that by means of very low net pressures an excellent performance is obtained, reaching a 250 bar outlet pressure.

•

FLAME PROF. ELECTRIC MOTOR

The motor bearings shall be lubricated according the following: Shaft side bearing (transmission side) each 1500 Hs. Fan side bearing each 3000 Hs. The grease to be according to the manufacturer recommendation (see motor nameplate). For WEG motors use POLYREX EM from Exxon, and for Siemens motors use ALVANIA N°3 from Shell, or YPF 63.

ATTENTION!!! Do not use grease or lubricants not recommended by the manufacturers. The electric motor shall be connected to ground through a javelin with a resistance lower than 5 ohm.


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Ground connection through javelin

Electric motor ground connection

ROTATION DIRECTION The rotation direction is counterclockwise, viewing from the front of the compressor. The connection between the motor and the compressor is mechanic type direct coupling.

Direct coupling

The compressor is moved by the electric motor through a direct coupling, avoiding the use of V Belts. The coupling is of the flexible discs type.


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AIR COOLERS The air-cooling system is divided in the same quantity of stages than the compressor. The air coolers are of the fin tube type, with aluminum fins.- At both ends the tubes are connected to manifold headers.- The gas inlet through one header and flows through the fin tubes to the other header, the quantity of loops depends on the calculation for each cooler. The cooling system includes 2 axial type cooling fans to produce a forced airflow to the outer side of the package. The electric motors are of 2,2 kW - @ 1500 R.P.M. (50 Hz). The fans start a little before the compressor starting and stop after completing the de-pressurizing cycle (controlled from the control panel with pre-determined timing). Optional: By pass in last stage whit ball valve. The compressor equipped with ball valve for last stage air cooler by pass because of low temperature.

Air outlet

Local instrument panel

ATTENTION!!! De-energize the system before carrying on maintenance or cleaning. Do not use any lubricant or grease not indicated by the manufacturer. The electric motor (cooling system) must be connected to a javelin of at least 5 ohm. Verify periodically that the radiator is clean and that the air outlet duct is free of obstructions.

Manual valve of by pass

ATTENTION!!! Switch off the power supply before any maintenance work or cleaning of the system.


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•


LUBRICATION SYSTEM.

The compressor lubrication system has two oil pumps (gear pump and single piston pump) which lubricated the crank system components. 1. Lubricant. The compressor is supplied with oil: LUBRAX COMPSOR 150 GNC. When the oil is replaced, must be used one with type “S” API certification (API Service), which is designed for gasoline motors. The most SM recently oil type include the performance characteristics than previous category (SF, SE, etc). The present and previous API types are showed on next table.

GASOLINE ENGINES Category

Status

Service

SM

Current

For all automotive engines currently in use. Introduced in 2004, SM oils are designed to provide improved oxidation resistance, improved deposit protection, better wear protection, and better low-temperature performance over the life of the oil. Some SM oils may also meet the latest ILSAC specification and/or qualify as Energy Conserving.

SL

Current

For 2004 and older automotive engines.

SJ

Current

For 2001 and older automotive engines.

SH

Obsolete

For 1996 and older engines.

SG

Obsolete


SF

Obsolete


SE

Obsolete

CAUTION: Not suitable for use in gasoline-powered automotive engines built after 1979.

SD

Obsolete

CAUTION: Not suitable for use in gasoline-powered automotive engines built after 1971. Use in more modern engines may cause unsatisfactory performance or equipment harm.

SC

Obsolete


SB

Obsolete


SA

Obsolete

CAUTION: Contains no additives. Not suitable for use in gasoline-powered automotive engines built after 1930. Use in more modern engines may cause unsatisfactory performance or equipment harm.

For more information see http://www.api.org/certifications/engineoil/pubs

Warning: on situations of extreme temperature or even humid climate, could be affected the oil properties. The oil will be replaced according need. In such case consult the Engineering Department.

Note (S*): can be used any oil type included in “S” categories showed on gasoline motors oils table, accomplish with the viscosity before mentioned.


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2.


Gear pump.

The main pump function is to lubricate the assemble crankshaft, connecting rods, piston rods and crossheads that are inside the crank system carter, the pump has two gears, one short and the other long, the long is direct and also has the function to transmit movement to the single piston pump. The system has a pressure transducer. Also with a PLV (pressure limit valve) and a pressure gauge to see easily the pump pressure (see photos). Besides has an oil filter with following characteristics: • PH-20 Fram or equivalent. • External diameter: 96mm. • Length: 139mm. • Connection thread: R 13/16” x 16 threads. • Filtering capacity: particles with diameter higher than 10 µm. The oil released by the PLV is cooled by a radiator, which is located under the compressor coolers. The piping from the pump up to the radiator and the returning up to the carter generally is through flexible hoses. Pump oil pressure: 4 to 7 Kg /cm2 (referent values) 4 to 5.5 Kg/cm2 (compressor running) WARNING!!! In case that the pressure is under 2.5 Kg./ cm2, the pressure switch or the pressure transducer will stop the compressor and will activate a visual alarm on the command board. Filler mouth

Pressure gauge

Pressure transducer

Oil’s radiator (Lubrication’s system)

Oil viewfinder

Maximum level

Minimum level

Oil filter

The oil filling must due through the filler mouth, checking the oil level through the viewfinder. The oil level must verify with the compressor running. Notes: With the compressor running could be verify a carter oil level variation between following admissible values: • Oil level up to 2 Liters for each carter and/or • Oil level up to 1 Liter for each carter. Both values are based over a total of 480 hours per month of compressor running.


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This possible oil level variation is within the normal parameters functioning, therefore the mentioned variations NOT represent functioning problems on those compressors. Pressure limit valve Manual operation press button

Gears pump

Single piston pump

3.

Single piston pumps (cylinders lubrication).

The lubrication pump is a piston type, in this case an only piston that pumps the oil to the cylinders and packing. It´s coupling with the gear pump from which takes it movement and through a worm and ring gear system, there is an rpm reduction of 50:1, over the ring gear shaft there is a cam which pull the pump piston. This mechanism also works through the manual operation press button.

Note: before the first compressor start or compressors that have being stop for more than 48 hs, must be purge the cylinders and packing lubrication system, according with EI-0239. To guarantee the pump good functioning a sintered metal filter is between the oil container and the pump. The pump don´t produce suction at the inlet, for that reason the oil container is located over the pump level (aprox. 500mm). The oil received by the pump from the container is forced to the distributor, where the disification for each cylinder is made, in each distributor outlet there is a check valve. Besides there is a pressure transducer and a release valve, which release oil if the distributor fails. The oil after pass through the distributor goes to the viewfinder and then to the cylinders and packing, previous passage through the air trap and a second check valve per each point to lubricate. Also over the distributor there is a cycle indicator, which send a signal to the PLC per each cycle (oil drop flow); in case of a distributor fail, depending on the failure, the PLC will do a programmed stop or shows on the screen a caution advice. See detail on next photos.

Oil distributor

Check valve and air trap

Viewfinder

Single piston pump DATE REVISION 05-06-06

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The single piston worm and ring gear system lubrication is made through the gears pump. The oil container have a filling mouth, also with a viewfinder and level sensor, this is inside the oil container and through a wire send a signal to the electric board, that shows the container status and when the container have not oil will stop the compressor or not allow to start. The oil reposition must do through the filling mouth, seeing the oil level through the viewfinder. For maintenance, there is a ball valve located between the oil container and the particles filer.

Oil level sensor Filling mouth

Viewfinder

The oil container position can change according with each compressor type.

WARNING!!! Over the container lateral sides it´s possible to find identifications for the container oil filling, during the compressor start up and the request that the oil discharge ball valve must remains OPEN.

Ball valve (OPEN POSITION) Oil filter

In operative conditions this valve must be OPEN.


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Release valve Pressure transducer

Cycle indicator Check valve

Proximity sensor

Oil distributor

The oil used for both gears pump and single piston pump lubrication, must have the same technical characteristics, must use only one lubrication oil, read point 1 (“Lubricant”) on LUBRICATION SYSTEM.


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1.


CYLINDER´S LUBRICATION (CHOICE)

A tube comes out from the pump; it gets to a needle valve and then finishes its stroke in a distributor. From it there are three tubes coming out towards the oil sight glasses. The oil sight glasses check that the lubrication is done correctly. The oil path frequency in each sight glass shall be of: 2 drops per minute in the 1st stage, and of 1 drop per minute in each packing. To regulate the quantity of drops unscrew a needle valve, which is located between the gear oil pump and the oil distributor.

Lubrication Pump

Oil sight glasses

Oil Distributor

Needle valve


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GAS FLOW The gas coming from the feeding line gets in towards the blow down tank (by means of the inlet solenoid valve opening and previously passing through the regulating valve). The blow down tank avoids that the fluid gets into the compressor cylinders with “pulsations”. From the blow down tank the gas goes to the 1st compression stage, then it goes to the first air-cooler, that is connected by pipelines to the first stage pulsation damper; the gas then gets into the second compression stage, from there it goes to the second stage air-cooler and after that to the second stage pulsation damper; until it finishes in the last compression stage. At the last compression stage outlet, the cooled gas (last stage air-cooler) goes through the condenser, which has a coalescent filter (in order to filter the liquids) and from there it finishes its passage through the compressor equipment, with an approximate outlet pressure of 250 bar.

Observations: • • • • •

In each air-cooler there is a pressure take-off, with a safety valve, which controls that there are no over-pressures in the circuit, this is the same for the blow down tank. In each compression outlet there are pressure readings, which can be visualized in the compressor general control panel. In this same way temperature values are taken, which are visualized from the same control panel. A vibration detector, located on the topside of the compression unit frame is in charge of sensing all the possible equipment vibrations. The filtered elements are sent to the knock down tank, which will drain through an automatic valve towards a collecting drum.

Air-cooled

Safety valve

Pulsation damper

Compressor De-pressurizing valve

Knock down tank

Main motor


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CYLINDERS: 1st, 2nd, 3rd STAGES.After regulation of the pressure, the gas enters the first compression stage. After compressing, the same flows through the air cooler and the pulsation damper to the second compressing stage.- The process is repeated for the third and fourth stages, ending at a pressure of 250 kg/cm².

1st stage Cylinder

2nd stage Cylinder

3rd stage Cylinder

ATTENTION!!! Check the pressure of each stage in the local instrument panel. (De-pressurize the Blow Down Tank before attempt to perform any maintenance work.- Previously the inlet valve shall be closed with the equipment stopped).


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COMPRESSOR INLET VALVE The gas goes through a pipeline from the gas network up to an inlet valve that allows the fluid passage or blocking. This valve is electrically activated by means a solenoid and it corresponds to the Ø1 ½ ” model. The activation of this valve is done by the system PLC (located in the command electric switchboard), in automatic mode, according to the storage pressure switch status.

Automatic inlet valve

Solenoid inlet valve

Inlet Valve Only IODM 70-3-19 BD


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REGULATOR VALVE It is the one in charge of regulator the inlet pressure to the ranks that the compressor equipment shall handle to be able to start with the compression. It is placed immediately after the gas inlet. The valve has a pilot with an adjustable screw in one of its ends, which can be manually adjusted to modify the inlet pressure regulation of the gas coming from the general feeding line towards the blow down tank, and afterwards to the first compression stage.

Regulator valve regulator screw pilot Regulator valve pilot

Regulator valve

BLOW DOWN TANK The blow down tank used is cylindrical, having used ASTM seamless pipe and semi-elliptical caps to build it. It allows receiving the first gas “pulses”, coming from the general feeding line, in order to accumulate the gas inside and they send it towards the first compression stage in the compression unit.


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KNOCK DOWN TANK The oil separator is a vessel for oil collection from the condenser, blow down tank, solenoid valves vent and sealing packages. The oil is collected in the vessel and the gas is vented. The oil is drained to a plastic tank specially supplied.

Knock Down Tank

Oil collection

PULSATION DAMPENER The pulsation dampeners are cylindrical vessels with a diameter larger than the connecting pipe, located at the inlet of each compression stage and its purpose is to absorb the pulses in the gas entering each stage.

Pulsation dampener


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CONDENSER For each compression stage the package has a pulsation dampener, except for the last stage, in which it has a vessel for pulsation dampening and coalescing filter with a drain valve. The purpose of the filter is to separate the oil from the gas. The oil is retained in the vessel and the gas flows to the storage system.

Condenser

ATTENTION!!! The condenser shall be drained in each shift.

DRAINAGE SYSTEM

It is necessary to drain the condenser in each shift, opening the valve located under the same. Also the Knock down Tank shall be drained through the automatic valve from the control panel Touch screen.

Needle valve Condenser

Knock down Tank

KDT automatic drain valve DATE REVISION 05-06-06

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DRAIN SYSTEM (OPTIONAL) It is necessary to drain DAILY the last condensers; the same will be done automatically as programmed. The working logic is the drain of each condenser to the knock down tank. After the mentioned drains are performed, the automatic valve of the knock down tank shall open. Only oil shall be drained, as any remaining gas is vented. The automatic drain system has one actuated ball valve for 1st blow down tanks´s condenser, one for last stage condenser, plus final coalescent filter, one for the inlet filter and one for the blow down tank. The automatic drain is programmed for 3 drains cycles per day, during adjustable time and with the compressor running.

Actuators

Manual operated ball valves

Solenoid valves for actuators control)


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DE-PRESSURIZING PROCEDURE MANUAL DE-PRESSURIZING There are occasions when the compressor equipment must be stopped abruptly, due to the activation of an emergency stop (push button). In this case the compressor will remain with pressure in all the stages that is why you shall proceed to the manual depressurizing of the whole system. For this all the needle type manual valves located in the blow down tank, in the extra pressure tank and in the condenser with coalescent filter, shall be activated, so that the system manual vent is produced and the equipment starts to be stabilized. After having detected the failure that produced the sudden stop, and having de-pressurized the compressor manually, the equipment will be in conditions of starting up again. In case of any doubt or advice regarding these procedures contact the qualified staff at Delta Compresiòn srl Technical Service Department.

AUTOMATIC DE-PRESSURIZING CYCLE In the exact moment when the compressor equipment programmed stop is carried on, the automatic de-pressurizing cycle starts, which is produced through the de-pressurizing valve that equals the pressure in all the compression stages and sends the gas towards the blow down tank, thus preparing the machine for a new start. In the inlet-outlet status screen of the general switchboard touch screen, it is possible to visualize, in automatic mode, the mentioned valve status.


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SAFETY VALVE The equipment has a safety valve at each compression stage outlet assembled over the radiators’ collector, plus another one on the blow down tank. Each one of them is calibrated according to the working pressure in each stage.

PRECAUTIONS • When the safety valve is under pressure never place any part of your body near the outlet of the valve. • The valve outlet and any separate drains should be piped or vented to a safe location. • Always wear proper safety gear to protect hands, head, eyes, ears, etc. anytime you are near pressurized valves. • Never attempt to remove the safety valve from a system that is pressurized. • Never make adjustments to or perform maintenance on the safety valve while in service unless the valve is isolated from the system pressure. If not properly isolated from the system pressure, the valve may inadvertently open resulting in serious injury. • Remove the safety valve prior to performing any pressure testing of the system. It is recommended that valves with welded inlets be hydrostatic tested using hydrostatic test plugs and caps supplied with the valves. • The safety of lives and property often depends on the proper operation of the safety valve. The valve must be maintained according to appropriate instructions and must be periodically tested and reconditioned to ensure correct function. • For further information including adjustment, maintenance, cleaning lapping and detail illustrations, obtain the appropriate Operation and Maintenance Manual.

VIBRATION SENSOR This device detects possible vibrations of the equipment; if they are in a non-convenient range, the device stops the compressor. USED STANDARD

ONLY CE

ATTENTION!!! In case of excessive vibrations the sensor shall trip the equipment and an alarm sign shall be activated. In this case contact the technical service


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INTRINSIC SAFETY (ONLY CE) The equipments certificated by CE community has an intrinsically terminal box (blue color), which contains an electrical connection terminal. This connection terminal send this signals from the compressor (temperature and pressure transmitters, vibration sensor, etc.) to the electric control panel. These entire signals come through an independent inlet to the box, blue color too.

Box

Blue cable (Analogy signals)


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BEFORE STARTING • •

Gas inlet valve (open). If the package has a valve in the high-pressure gas outlet to the storage the same shall be open.

ATTENTION!!! The ball valves are open when the handle is parallel to the pipeline and closed when the handle is perpendicular to the pipeline. • • •

Check the following valves are closed: Blow down Tank drain. Condenser drain.

Condenser drain valve

•

Check, before starting the compressor the oil level in the crankcase and in the oil reservoir.

Oil level

•

Check inlet gas pressure and voltage.

ATENTION!!! If some of the above points are not fulfilled, the safety systems shall be activated and the starting of the package should not be possible. An alarm indication will show the failure.


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AUTOMATIC START PROCEDURE 1) Check the supply gas pressure (Measuring bridge pressure gauge) and the voltages are within the normal range. (check the safety system is activated). 2) Switch on the main switch.

Main switch (630 A) ON

3) Power the control panel, switching on the control thermo-magnetic switch 220 Vac. If there appears power failure, check if the stabilizer / UPS (if any) are connected. . 4) If on powering the control panel appears some alarm, please see the corresponding part on the Control Panel Manual.

COMPRESSOR STOPPING ALTERNATIVES • Programmed stop: The same is enabled from the control panel, pressing on PROGRAMMED STOP in the touch screen. The machine shall stop following the programmed sequence performing the sweeping and de-pressurizing cycle. After this the machine shall stop and should not start unless the same is reset from the control panel touch screen. • Maintenance stop: The same shall be set for performing disassembly works especially if the same are in the area of moving or risky parts. In this case a programmed stop shall be performed and the power shall be switched off through the main switch. In the control panel is convenient to set the machine in the stand by mode.


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MANUAL STARTING PROCEDURE For enabling this option, the compressor shall be in stand by mode. From this condition and the manual indication set in the touch screen: With the start push button (Green) the compressor starts. With the stop push button (Red) the compressor shall stop suddenly.

Local Instrument Panel

To CE used thermometer whit electrical contact ATEX

Rear connector Protection (only CE)

Emergency shut down

Start push button

Stop push button


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OPTIONALS

ACOUSTIC ENCLOSURE (70DBA):

It is made in galvanized steel plate with epoxy-polyurethane coating or in stainless steel, and in both cases with some auxiliary parts in GRP, being able for atmospheric exposure. A sound level of 70 dba is achieved, through the use of acoustic insulation inner materials, being flame proof. All connection points are located in the pillars, for easy connections. The doors are with weather proof sealing and there is an acoustic / thermal insulation window for the instrument panel. The air inlet ducts in both ends of the enclosure, also air acoustically insulated. Each air inlet duct is composed by three parts, properly matched and bolted, and they are directly bolted to the skid. In the upper part is the inlet louver, with fins to prevent water entry and wire mesh for protection. In case of major maintenance works, the ducts can be disassembled partially if necessary for better access. The enclosure has external emergency push buttons. The air outlet is faced upwards, and the air is ducted through a muffler and a labyrinth passage to avoid rain water entering the enclosure. Rain water is collected by gutters and drained through 3 internal draining hoses. There are installed wire mesh protections to avoid clogging of the draining hoses.

The hoses have to be controlled periodically as well as the protection chests, in order to prevent the clogging of the same. The enclosure has four access doors, and the same can be used in any ASPRO IODM 70 compressors.


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•


TEMPERATURE TRANSMITTERS

To measure temperatures in the different places, temperature transmitters are installed. The signal given is intrinsically safe and is transmitted to the PLC.

•

Transductor de temperatura WIKA

Transductor de temperatura YOKOGAWA

6

6

GAS DETECTOR

There is one, located on top of the air coolers. It can be accessed through a cover sheet at the side of the exhaust trunk. The detection is done in two levels and the same are shown in the touch screen, the first corresponds to 10% of lower explosion limit (with visual warning) and the second corresponds to 20% of lower explosion limit with alarm and tripping of the machine.

Gas detector

•

6 FLAME DETECTOR

Junction box

6 In case there is a fire inside the compressor enclosure; the flame detector transmits a signal for alarm and compressor tripping.

UV Flame Detector X2200

Ultraviolet Flame Detector Model 30-2021

Millennium II

6


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• •


FLOW METER AND BY-PASS SYSTEM INLET FLOW METER

The compressor can be provided, optionally, by one mass flow meter on the gas inlet, with the purpose of measuring gas flow inlet from the compressor. It has a by-pass system in case that is necessary to disassemble the mass flow meter, because maintenance. Normally the valves must be: o Open the ball valves (“A” and “B”). o Close the ball valve (“C”). For mass flow meter maintenance, must be made the procedure following, with the compressor stopped: o Close the ball valves (“A” and “B”). o Open the ball valve (“C”). o To disassemble the mass flow meter.

“B” Valve

Mass flow meter

“C” Valve

“A” Valve


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OUTLET FLOW METER

The mass flow meter is prepared for measuring the gas flow from the compressor. For maintenance purposes, a by pass system is provided. In case it is necessary to disassemble the mass flow meter, the connected tubing has to be vented, with the compressor stopped.

“A” Valve

“B” Valve

“C” Valve

Normal running: “A” and “B” valves OPEN; “C” valve CLOSE.By pass for mass flow meter maintenance: Programmed stop of compressor. To vent “A-B” valves tubing. “A” and “B” valves CLOSED; “C” valve OPEN. To switched off the power to mass flow meter. Removal of equipment.-

THREE WAYS PRIORITY SYSTEM (OUTSIDE OF COMPRESSOR): In this system the quantity of storage cylinders is divided in three groups: low pressure bank (LPB) middle pressure bank (MPB) and high pressure bank (HPB), plus a direct line to dispensers, making sure that dispensers’ feeding, which want to be fed from it, is a priority. Each filling line has its own priority valve, ball valve, ball valve with actuator. There is a own pressure gauge; an outlet for the regulating valve that commands the actuators.

OPERATION MODE The gas coming from the compressor goes through the manifold where the priority valves and the dispensers’ direct feeding line are located. With the energized system (actuated ball valves from the safety system) it is possible to proceed to the vehicles refilling. The compressor starts unloading; if the direct line needs feeding, this will be the priority, if this is not the case the HPB loading will start; as it is filling up, the pressure will start increasing and the MPB loading will begin and afterwards the LPB. When the pressure reaches the maximum set point, the compressor will stop, leaving all the banks at the same pressure.


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SAFETY SYSTEM All the set has its own actuators (normally closed), plus an ASPRO safety valve with a rooftop venting.

Safety valve (vent)

INLET GAS (FROM COMPRESSOR)

Pressure gauge

Gas outlet (to storage)

Ball valve

Regulator gas inlet valve (For actuators)

Actuator

Outlet gas (to dispenser)

HBP

MBP

LBP

The photographs are only for illustrative purposes.


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MAINTENANCE TROUBLE SHOOTING

FAILURE

Possible causes

How to verify the cause

Dirt in the seat.

With the machine not running, the last stage pressure gauge displays the storage pressure (it should display low pressure)

Last stage pressure gauge is stuck at any pressure.

The pressure gauge on the local panel displays 20 to 30 bar with the machine depressurized.

Seat damaged.

Dirt in the dampening regulator screw.

It should display 210 - 250 Bar, but displays more or less than these values

(according to pressure gauge model)

Corrective action Stop the machine. Close the gas inlet valve (according to the machine model) Close gas outlet valve. Remove non return valve, repair or replace it.

Repair/replace instrument

Stop the machine (programmed stop). Depressurize the stage trough the condenser. The oil sight glass is full of oil. Cylinder or packaging non return valve failure.


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In the sight glass is not shown a drop but is full of oil.


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Dismantle Ø¼” tubing. Remove the non-return valve and dismantle for check conditions; as can have dirt. Install repaired valve or new one. Dismantle the sight glass and empty the same. Check conditions of the internal valves. Fill with new glycerin and reassemble the sight glass.. Re-connect Ø¼” tube to sight glass. Purge the system as described in the manual.

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FAILURE


Possible causes

Fail of phase or power shut down


Corrective action

To check the voltage in the control panel instrument.

De-pressurize the machine and check the voltage in the three phases of the general panel.

Sudden detention of the machine.

(See manual depressurizing procedure).

Emergency shut down.

Check the push buttons.

De-pressurize the machine through the BDT, condenser and KDT, resetting the system 1-If not normal claim to the gas distributor.

To check in the measuring bridge if the supplied pressure is normal

Low inlet pressure Inlet filter failure (clogged) Automatic stop of the machine.


To repair or set the same properly

If the pressure is higher Verify the pressure after the than the regulated pressure-regulating valve. pressure setting, repair or The same shall be below the set the same. set pressure.

High inlet pressure

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Stop the machine, depressurize, remove filter and clean it (or replace).

Pressure regulating valve failure.


2-If the pressure is normal, repair the inlet pressure regulation valve.

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Possible causes

FAILURE


Corrective action Stop the machine (Programmed stop). Disconnect the power supply

Inlet valve failure (any stage).

Spring or plate broken or in bad conditions.

Increase of the temperature of the inlet pipe.

De-pressurize all t5he machine (all stages). Dismantle all the parts required for access to the valve (piping, flanges, bolts, etc.). Replace the valve and copper joints if necessary and reassemble.

Exhaust valve failure (any stage).

Spring or plate broken or in bad conditions

Pressure relief valve blow off

Overpressure in the corresponding stage

Over pressure in Blow Down Tank.

Sealing package blows.


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Seals failure due to dirt or wearing.

MADE BY

Stop the machine. For repair contact Delta Compresión SRL.

Smoke smell

Inlet Pressure regulating valve failure

SANTIAGO SC ALTRITTI

Low performance. Pressure gauge/s displays low pressure.

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Trip due to high-pressure switch. Inlet pressure gauge shows high pressure. Pressure relief valve blows.

“Blow” and gas smell can be noticed.


REVISION 003

Check valve settings. Repair valve. Delta Compresión SRL technical personnel shall do these works.

To stop the machine (programmed mode) and depressurize all stages. Request technical assistance from Delta Compresión SRL.

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FAILURE

Possible causes


Corrective action

Oil pump pressure switch failure

Oil filter clogged

The machine starts with normal oil pressure (4 Kg/cm2) but the same starts to fluctuate between 2,5 and 4 Kg/cm2

To replace filter cartridge.

Pressure switch line with leakages

The oil exiting the crossheads shows foam.

Air entrance to the oil due to loose fitting in the oil inlet line

To dismantle and check all the tubing. -

Low oil level.

Compressor trips due to low oil pressure

Gas leakage through condenser drain

•

To repair leakages

To add recommended oil.

1.Coged filter

To check the filter

Replace filter cartridge

2.Low oil level

To check oil level

To add recommended oil.

3.Air entrance to the system

Oscillation of pressure gauge indication

To tighten properly the tube fittings.

4.Transmission key disconnected

To dismantle, clean and reassembly with new key.

Improper closing of needle valve

To stop machine and set stand by mode. To de-pressurize all stages. To close the gas outlet valve. To de-froze the needle valve (hot water). To close properly the needle valve and open the gas outlet valve. Reset and restart the compressor.

Needle valve frozen.

RECOMMENDED TOOLS

We suggest having the following tools for maintenance works: - 1 set of fixed spanners from 6mm. to 41mm. - 1 set of hexagonal socket spanners. - 1 toolbox for basic electro-mechanical jobs. - Tester.

PREVENTIVE MAINTENANCE If it is noticed any abnormality in the performance of the compressor package, it is convenient to inform the same to Delta Compresión SRL technical service. Authorized personnel shall do the control.

ATTENTION!!! In case of repair jobs, switch off the power supply, and maintain the compressor in the stand by mode.


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Special Features of model “BD” MAIN OPERATION: The compressor has being designed to work with an inlet pressure range between 14 up to 200 bar. In order that the compressor could work in this range a pressure reducer bridge has being add and a gas heater system also. When the inlet pressure is between 61 up to 200 bar, the gas is delivered by the reducer bridge, which reduce the gas pressure through a regulating valve up to 60 bar, then the gas is delivered to the heater and then to the 2º stage inlet. From there, the gas flows in the normal compression route. When the inlet compressor gas pressure is between 25 up to 60 bar the by-pass system avoid that the gas pass through the regulating valve and goes directly to the inlet 2º stage and then to flows in the normal compression route. Finally, when the pressure is between 14 up to 24 bar, the by-pass system make that the gas flows directly to the inlet blow down tank and be normally compressed by the 1º, 2º and 3º stage. The by-pass logic is based on operation’s logical begin, this is interpreted through the signals sent to the PLC located in the electric board, these signals proceed from the inlet pressure sense, which is done through a pressure transducer located at the compressor’s gas inlet. The main differences with respect to an IODM 70-3-19 std. are: a) A reducer bridge and a heater are added. b) The gas´ circuit is modified according with the compressor’s inlet pressure by means of the reducer bridge. c) Under are described the homologize added as optional of the model IODM 70. d) Automatic system of open & closed of valve. e) Automatic drain panel. f) Inter-stages temperature and pressure transducers. g) Crankcase’s oil level sensor. h) Acoustic enclosure. (see drawing Nº 91750) i) Explosive mix detector and flame sensor. j) Explosion proof lighting. k) Optional valve M15 (see drawing Nº 90000)

Heat Exchanger

1st Regulator valve


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2nd Regulator valve

HEAT EXCHANGER: The purpose of the heat exchanger system is increase the 1st regulator valve outlet gas temperature. This system consists of a heat exchanger device which receives cold and hot gas into two independent circuits. The cold gas comes from the first regulating valve and then flow into. A temperature rise due to the interchange of heat among the inlet gas and the last stage's cylinder outlet gas. Next this goes into the last stage air cooler.

BY-PASS INLET TO REGULATOR

FROM 1° STAGE REGULATING VALVE.


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DISTRIBUTION CO2

VENT

(**)INLET CO2

AIR OUTLET

GAS OUTLET

INLET GAS

INSIDE VIEW (**)

OUTSIDE VIEW (**)


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ACTUATORS ACTUATOR BY-PASS

ACTUATOR INLET

This actuator closes the lubrication to the 1st. stage cylinder When this is by-passed


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BLOCKED TO 1° STAGE ACTUATOR

ACTUATOR 1° STAGE BY PASS

ACTUATOR BY PASS REGULATOR


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DOUBLE INLET COALESCENT FILTER The purpose of the coalescent filter is to retain liquids and particles that has the inlet gas (Line gas). The set is shaped by filters, ball valves, differential pressure gauge and needle valves. Normally the gas only must circulate for only one coalescent filter at ones. For example, if the “A” ball valve are opened; the “B” ball valve must be closed or if the “A” ball valve are closed; the “B” ball valve must be opened. The differential pressure gauge must always measure zero, otherwise it must show one different between the inlet pressure and outlet pressure (The coalescent filter must be drained and then replace the filter cartridge). For execute the cartridge’s replace, open the additional coalescent filter’s ball valve and then close the ball valve of the coalescent filter that needs to be replaced. Outlet gas

Ball Valve Inlet gas

Differential pressure gauge

Coalescent filter

Drainage valve

Ball valve “ A”

Ball valve “B”


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MANUAL DE USUARIO ALMACENAJE STORAGE USER´S MANUAL MAN-1740

ALMACENAJES MANUAL DEL USUARIO STORAGE USER’S MANUAL PROPÓSITO Este manual contiene información importante sobre la instalación, operación y mantenimiento de su equipo. El fabricante se reserva el derecho de implementar modificaciones en las características técnicas o constructivas del equipo; en virtud de lograr mejoras en sus prestaciones, ampliación de sus capacidades o por motivos de cambio de marca o proveedor en los materiales usados en su construcción.

PURPOSE The present manual contains important information about installation, operation and maintenance of this equipment. The manufacturer has the right to make modifications in the technical or constructive characteristics of the equipment; in order to achieve a better performance, to increase its capability and due to brand or suppliers changes of the materials used in its manufacture.

NOTA IMPORTANTE Este equipo trabaja con líneas de gas alta presión (250 bar) y tensiones de alimentación que implican riesgos para la vida humana. La instalación o eventual reparación de los mismos sólo debe ser llevada a cabo por personal técnico de DELTA COMPRESIÓN S.R.L. o personal técnico calificado y habilitado por el ente fiscalizador respectivo.

IMPORTANT NOTE This equipment operates with high-pressure gas pipes (250 bar) and electrical power voltage, which means possible risks for human life. Only Delta Compresión S.R.L. technical personnel or certified qualified technicians can perform the installation or eventual repair of the equipment.

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The photographs are only for illustrative purpouses. The company reserves the right to modify the content of this document without prior notice. The information contained herein, including the information contained in any attachment hereto, is confidential and may be protected by Industrial and/or Intellectual Property rights, including but not limited to invention patents, usage patterns and industrial designs. This information shall not be disclosed in any way, copied and/or used for commercial purposes, and the recipient shall use it only as per the written authorization issued by Delta Compresión S.R.L. Any violation to the prohibition contained herein may be punished as per the laws of the Argentine Republic and/or international treaties, and shall entitle Delta Compresión S.R.L. to claim for the damages suffered. DATE REVISION

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INDICE

Propósito……………………………………………………………………………………………………………………………..01.Nota importante……………………………………………………………………………………………………………………... 01.Introducción general………………………………………………………………………………………………………………… 03.Conexionado de acometidas………………………………………………………………………………………………..……… 03.Características……………………………………………………………………………………………………………………….04.Opcionales…………………………………………………………………………………………………………………………… 04.Almacenaje con Adicionales……………………………………………………………………………………………… 06.Almacenaje encabinado…………………………………………………………………………………………………… 08.Almacenaje 3 líneas con panel prioritario………………………………………………………………………………… 09.Modo de operación…………………………………………………………………………………………….. 09.Descripción general…………………………………………………………………………………………….. 10.Conexionado de acometidas…………………………………………………………………………………… 11.-

INDEX Purpose...…………………………………………………………………………………………………………………………….. 01.Important note…………………………………………………………………………………………………………………........01.General introduction………………………………………………………………………………………………………………… 03.Interphase connections…………………………………………………………………………………………………..…………03.Characteristics……………………………………………………………………………………………………………………….04.Optional...……………………………………………………………………………………………………………………………04.Storage with aggregates…………………………………………………………………………………………………06.Storage with cabin………………………………………………………………………………………………………… 08.3 line storage with priority panel…………………………………………………………………………………………. 09.Operation mode………………………………………………………………………………………………… 10.General description…………………………………………………………………………………………….. 10.Interphase connections………………………………………………………………………………………… 11.-

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INTRODUCCION GENERAL El equipo consiste de una batería de cilindros diseñados para ser utilizado como sistema de almacenaje en estaciones de carga de G.N.C. Está compuesto por una estructura metálica contenedora de cilindros, válvulas, sensor de presión y accesorios varios. Los cilindros se encuentran dispuestos en forma vertical, en consecuencia las válvulas de dichos cilindros se encuentran en la parte superior logrando así estar protegidos de golpes. El acceso a estas válvulas se realiza por medio de un escalón dispuesto convenientemente. La estructura metálica presenta uniones soldadas y atornilladas. Posee un recubrimiento de pintura poliuretánica, en color blanco, ó de otro color, según necesidad. En los puntos de contacto de cilindros con la estructura tiene adherida, para evitar posible fricción, corrosión, una banda de goma sintética. Además el cilindro se apoya en un soporte de goma de formato conveniente. Todos los cilindros se vinculan a la estructura mediante unas varillas y cuñas metálicas. Dichos varilla y cuñas disponen de protecciones de goma para evitar el rose entre los cilindros y ellos. Se deberá posicionar la batería de almacenaje sobre un piso nivelado y correctamente alisado que permita un correcto apoyo de todas las patas de la misma.

GENERAL INTRODUCTION The equipment consists of a battery of cylinders designed to be used as a storage system in CNG refueling stations. It is made of a metallic structure, which contains cylinders, valves, pressure switches and several accessories. Cylinders are assembled vertically, in this way valves will be located at cylinder’s top side, in order to be hit protected. The access to those valves is reached with a suitable located step. The metallic structure shows weld and screwed unions, covered with polyurethane paint, on white color or another one according to requisites. In order to avoid possible friction and/or corrosion were the structure made contact with cylinders, it have a rubber band for both protection. Besides, the bottom cylinder side leans over a suitable rubber support. All cylinders are fixed to the structure by mean of screwed rods and metallic wedges, with plastic and rubber protections who avoid possible friction between. Storage must be located over a smoothed and leveled floor, that allow a suitable structure support.

CONEXIONADO DE ACOMETIDAS INTERPHASE CONNECTIONS Deberá ser conectada a los siguientes puntos: It shall be connected at the following points: •

Entrada de gas: Se conectará a la entrada de gas la tubería proveniente del compresor a través de una brida sw de 1” provista en el conjunto. (U otro según necesidad) Gas Inlet: The pipeline coming from the compressor shall be connected to the gas inlet by means of a 1” sw flange supplied with the kit.

•

Salida de gas: A la misma se conectará la tubería de conexión que alimenta a los surtidores. Gas Outlet: The connection pipeline, which feeds the dispensers, shall be connected to it.

•

Conexión eléctrica del sistema: A la misma se conectarán las señales eléctricas del sensor de presión de arranque / parada del compresor y la alimentación de los actuadores de seguridad que se encuentran en las líneas de salidas del almacenaje. (actuadotes no provistos) System electrical connection: The electrical signals from the compressor electronic start-stop pressure switch and the safety actuators feed, which are placed in the storage outlet lines, shall be connected to it.

•

•

Venteo: Caño de 1” que se conecta a la salida del venteo del almacenaje. Vent: 1” pipe connected to the storage vent outlet.

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CARACTERÍSTICAS a) b) c) d) e) f) g) h) i) j)

Presión de prueba hidráulica : 375 bar.Presión de trabajo : 250 bar.max.Una válvula por cilindro para aislamiento incluye dispositivo sobrepresión y temperatura.Válvula de venteo manual.Manómetro Válvula antiretorno de entrada.Válvula de exceso de flujo.Válvula de seguridad por sobrepresión.Peso estimativo almacenaje según configuración.Pilotaje de actuador de salida por medio del propio gas del almacenaje.

El equipo se encuentra homologado por el Bureau Veritas.-

CHARACTERISTICS a) b) c) d) e) f) g) h) i) j)

Test pressure : 375 bar.Working pressure : 250 bar max.One valve per cylinder for over - pressure and temperature protection.Manual vent valve. Manometer. Inlet Non - return valve.Over - flow valve.Safety valve for over - pressure.Storage approximate weight according to configuration.Outlet actuator pilot by means of the storage ´s own gas.

The equipment is certified by Bureau Veritas.-

OPCIONALES • • • • • • • • • • •

Diseño de cilindros doble ojiva; Sistema de drenaje; Sistema de panel prioritario; Colores; Tratamiento para ambientes corrosivos; Transductor de presión; Encabinado; Tanque de choque para sistema de drenaje; Válvula esférica con actuador; Capacidades adicionales; Otros opcionales a pedido.-

OPTIONAL ● ● ● ● ● ● ● ● ● ● ●

Double neck cylinder design; Drain system; Priority panel system; Colors; Treatment against corrosive environment; Pressure transducer; Cabinet; Knock down tank for drain system; Ball valve with actuator; Additional capacities: Other optional at request.

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Venteo manual y de válvula de seguridad Manual & safety valve vent

Válvula prioritaria Priority valve

Manómetro Pressure gauge

Válvula de seguridad Safety valve

Salida de gas hacia surtidores Gas outlet toward

Cilindro de almacenaje Storage cylinder

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ALMACENAJE CON ADICIONALES (OPCIONAL) STORAGE WITH AGREGATES (OPTIONAL)

Caño de drenaje Drain pipe

Salida de gas hacia tanque de choque Gas outlet toward knock down tank

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Actuador Actuator

válvula solenoide Solenoid valve

Válvula de seguridad (7 Bar) Safety valve (7 bar)

válvula reguladora 67 HR Regulator valve 67 HR

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ALMACENAJE ENCABINADO (OPCIONAL) STORAGE WITH CABIN (OPTIONAL)

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ALMACENAJE 3 LINEAS CON PANEL PRIORITARIO (OPCIONAL) 3 LINE STORAGE WITH PRIORITY PANEL (OPTIONAL) En este sistema los cilindros están divididos en tres grupos, alta, media y baja presión. Cada grupo de cilindros tiene un barral, con sus respectivas válvulas de retención, exceso de fluyo, válvula actuada, etc. In this system the cylinders are divided in three groups, high, middle and low pressure. Each group of cylinders have a manifold, with their respective non return valves, over flow valve, ball valve with actuator, etc.

Baja presión Low pressure

Alta presión High pressure

Media presión Middle pressure

Entrada de gas desde el compresor CNG inlet from the Compressor

Salida de Gas a Surtidores CNG outlet to the Dispenser

MODO DE OPERACION El gas que llega desde el compresor, pasa por un barral o manifould, donde están ubicadas las válvulas prioritarias, y se distribuye a los diferentes grupos de cilindros de almacenaje. Según la presión que se encuentre seteada la válvula prioritaria de cada línea, el gas comienza a circular, cargando el grupo de alta presión, luego el grupo de media presión y finalmente el grupo de baja presión. Cuando las presiones llegan al máximo seteado, el sensor de presión apaga al compresor, dejando a todos los cilindros a la misma presión. La descarga del almacenaje, a los surtidores, se realiza de manera inversa. Primero, los surtidores son alimentados desde la línea de baja presión, luego desde la línea de media presión y finalmente por la línea de alta presión. Cuando las presiones llegan al mínimo seteado, el compresor se pone en funcionamiento llenado las baterías de almacenaje. El objetivo de dicho sistema es cargar desde distintas presiones buscando una ventaja en el consumo eléctrico del sistema.

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OPERATION MODE The gas coming from the compressor goes through the manifold where the priority valves are located and it is distributed to the different cylinder groups. According to the set point pressure of the priority valve of each line, the gas starts to circulate, filling the high pressure group, then the middle pressure group and finally the low pressure group. When the pressure reaches the maximum set point, the pressure switch turns off the compressor, leaving all the cylinders at the same pressure. Unload of the storage to the dispensers is carried out in the opposite way. First the dispensers are feed from the low-pressure line, then from the middle pressure line and finally from the high-pressure line. When the pressure reaches the minimum set point, the compressor is put into operation, filling all the cylinders of storage. The purpose of said system is to load up from distinct pressures looking for an advantage in the electric consumption of system

DESCRIPCION GENERAL GENERAL DESCRIPTION Manómetro 0-400 bar Manometer 0-400 bar

Válvula de cilindro Cylinder valve Estructura metálica Metallic structure

Cilindro de almacenaje Storage cylinder

Válvula prioritaria de media presión Priority valve Middle pressure Válvula exceso de flujo Over flow valve

Suncho Metallic band

Válvula prioritaria de baja presión Priority vale Low pressure

Válvula anti-retorno Non return valve

Panel prioritario Priority panel

Válvula esférica con actuador Ball valve with actuator

Válvula prioritaria de alta presión Priority valve High pressure

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Válvula de seguridad (7 Bar) Safety valve (7 bar)

Actuador Actuator Válvula reguladora 67 HR Regulador valve 67 HR

Válvula solenoide Solenoid valve

CONEXIONADO DE ACOMETIDAS INTERPHASE CONNECTIONS Además de los puntos mencionados en la página 3, se deberá conectar: In addition to the points mentioned in the page 3, he will have to get connected: •

SALIDA DE GAS DE BAJA PRESIÓN: Se conectara a la línea de baja presión del surtidor, a través de un conector ¾ OD. NPT F. LOW PRESSURE GAS OUTLET: it will be connected the low pressure feeding line to dispensers, with a threaded connector ¾ OD. NPT F

•

SALIDA DE GAS DE MEDIA PRESIÓN: Se conectara a la línea de media presión del surtidor, a través de un conector ¾ OD NPT F. MIDDLE PRESSURE GAS OUTLET: it will be connected the middle pressure feeding line to dispensers, with a threaded connector ¾ OD. NPT F.

•

SALIDA DE GAS DE ALTA PRESION: Se conectara a la línea de alta presión del surtidor, a través de un conector ¾ OD. NPT F. HIGH PRESSURE GAS OUTLET: it will be connected the high pressure feeding line to dispensers, with a threaded connector ¾ OD. NPT F.

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Id. Salida de Alta presión Id. High pressure outlet

Id. Salida de baja presión Id. Low pressure outlet

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INFORMACION GENERAL GENERAL INFORMATION

WARRANTY CERTIFICATE 1) This warranty covers normal operation of the equipment (hereinafter referred to as the Product) against any manufacturing and/or workmanship defect and/or vice in materials. The present warranty is limited to the obligation of Delta Compresión SRL to replace or repair at no extra cost any defective Product, only in case it fails in normal operation conditions and under the circumstances detailed herein below: 2) The warranty term is 18 (eighteen) months as from the date of shipment and/or 12 (twelve) months as from the date of start up, whichever occurs earlier. 3) This warranty certificate shall only be valid for Products bought from Delta Compresión S.R.L. in the Argentine Republic, and which are installed and started up in the same geographic territory as agreed in the respective Sale of Goods Agreement. 4) The beneficiary of this warranty is the original buyer, and it shall not be transferred and/or assigned to third parties, without previous written consent of Delta Compresión SRL. 5) This warranty shall be annulled in the following cases: 5.1- Improper use of the Product, or not as per its original design. 5.2- Over or under voltage exceeding the normal conditions. 5.3- Excessive particles and/or hydrates in the feeding gas. 5.4- Installation without following the recommendations of Delta Compresión SRL. 5.5- Repairs and/or any type of works on the Product performed by personnel not authorized by Delta Compresión S.R.L. 5.6- Operation of the Product without following the recommendations of the user manual. 5.7- Lack of maintenance as per the preventive maintenance schedule issued by Delta Compresión SRL. 5.8- Use of oil, grease, and/or lubricants not recommended by the manufacturer. 5.9- Lack of presentation of the commercial invoice and/or delays in payment of the price of the Product and/or delays in payment of the price for the provision of services and/or materials used for the situations described in article 9. 5.10- Removal of the Product from the place where it was initially installed without express consent from Delta Compresión SRL and without observing Delta Compresión SRL’s recommendations. 5.11 – Start up of the Product by personnel not authorized by Delta Compresión SRL. 6) The following services are not covered by the present warranty: 6.1- Cleaning of filters, lubricators, etc. 6.2- Lube Oil and filter cartridge replacement. 6.3- Start up of the Product after tripping due to safety alarm and/or power interruption. 6.4- Replacement of filling hoses, dispenser hoses, filling probe O Rings, other valve O Rings and three way valves. 6.5- Damages or failures caused by deficiency and/or interruptions in the power supply and/or installation defects and/or unauthorized servicing and/or lack of maintenance. 6.6- Damages caused by accidents, vehicles’ collisions, vandalic acts, fires, flooding, atmospheric discharges, or any other natural phenomenon. 6.7- Damages or defects that may be caused to the Product by fault or negligence of personnel involved either in the installation, start up, maintenance and/or operation of the equipment without being properly authorized by Delta Compresión SRL, even in case said personnel has received during start up, basic training on the operation of the Product. 6.8- Damages or defects that may be caused to the Products by fault or negligence of other people that might access the facilities where the Product is located, and who may directly or indirectly damage the Products. 6.9- Loss of profit and/or any other type of damage originated either from non operation and/or defective performance of the Product. 6.10- Damages arising after several consecutive alarms in case this was not promptly and properly informed to Delta Compresión SRL. 7) When requesting the fulfilment of the warranty, the buyer shall contact Delta Compresión SRL or any of the authorized service centres transcribed below according to the territory where the Product is located, either by phone, fax or e-mail, within 30 (thirty) days from discovery of the vice or from the date when the vice should have been discovered by a diligent buyer, or within 15 (fifteen) days

from delivery date in case of patent defects. In this case, the buyer shall take all the rational measures according to circumstances to preserve the Product while the aroused question is settled. 8) In case of failure of the Product, Delta Compresión SRL commits to repair the Product for its normal operation, within a reasonable period of time, depending on the complexity of the reparation, the place where the Product is installed and any other circumstance beyond Delta Compresión SRL’s control. 9) Any intervention of our service network required by the buyer during warranty period, which was not originated by any fault or defect covered by this warranty certificate, and/or any provision of services that may correspond as per the preventive maintenance schedule, shall be paid by the buyer at the rates in force. 10) This certificate cancels any other warranty, either expressed or implied, including the warranty of fitness for a particular purpose and we do not authorize any other person, company or any kind of association to assume on our behalf any other liability regarding our products.

DELTA COMPRESIÓN SRL AFTER SALES OFFICE Panamericana Colectora Oeste Km 47,53 Phone Number: (011) 5093-9669 24 hours Mobile: (011)-15-5025-9917 E-mail: [email protected]

AUTHORIZED SERVICE CENTERS

BANGLADESH:

SHOHAGH MOTORS Phone/Fax Numbers: ++88 02 9344477 (EXT 107) Web site: www.shohagh.com/group/

BOLIVIA:

GASCORP SRL Phone/Fax Numbers: ++591 (4) 4485590/ 4488231 Mobile Phone: ++591 7078-9191 E-mail address: [email protected]

BULGARY:

OZONE GROUP Phone/Fax Numbers: ++359 (2) 8548426/27 E-mail address: [email protected]

COLOMBIA:

DELTAGAS S.A. Phone/Fax Numbers: +57 1 6181325/ 6309569/71/72 Mobile Phone: +57 300 5705323 E-mail address: [email protected]

EGYPT:

ARIEGSA ENGINEERING GROUP Phone/Fax Numbers: +201 5 364192/ 5 376500 E-mail address: [email protected]

INDIA:

SOPAN O & M CO. PVT. LTD Phone Number: +91 20 25467841 E-mail address: [email protected] TEAM ASSOCIATES Phone/Fax Numbers: +91 22 55242410/28441499 E-mail address: [email protected]

ITALY:

SAMTECH SRL Phone/Fax Numbers: ++39 049 9903931/9903928 E-mail address: [email protected]

IRAN:

ASIA PETRO GAS SERVICE Phone/Fax Numbers: +98 21 8820 7874/5 Mobile Phone: ++98 (912) 196 6900/243 3362 /717 0824 E-mail address: [email protected]

MEXICO:

INCOGAS S.A. DE C.V. Phone/Fax Numbers: ++01 (55) 5544-1883 E-mail address: [email protected]

PAKISTAN:

AFTEK Engineering (Pvt.) Ltd. Phone/Fax Numbers: ++92 (21) 5050071/5051541/5051542 (ext. 101,103,105) Mobile Phone: ++92 (321) 2429653/ 4224255/200-8605 E-mail address: [email protected]

PERU:

MAQUINAS Y TECNOLOGÍA Phone/Fax Numbers: ++51 (1) 2640250/2640255 E-mail address: [email protected]

PORTUGAL AND SPAIN

ROS ROCA Phone/Fax Numbers: ++34 (973) 500650 E-mail address: [email protected]

TAILAND:

S.SIRISEANG COMPANY LIMITED Phone/Fax Numbers: ++66 2 6919777/ 2778178 Web site: www.siriseang.com

TURKEY:

EMDA INSAAT SANAYI VE MADEN TICARET LTD. STI. Phone/Fax Numbers: +90 312 4474100/4880021 E-mail address: [email protected]

UCRAINE:

I.S. Phone/Fax Numbers: ++38 (067) 7265905 Mobile Phone: ++ 38 (067) 1810006

PROGRAMA DE MANTENIMIENTO PREVENTIVO Mainteinance Preventive Program 0009

N de ISERV

Fecha de emision / Emission date:

14/03/2011

004

Revision

-

Fecha de actualizacion / Updating date:

COMPRESORES IODM 70-3-12 / IODM 70-3-12 COMPRESSOR A LOS ITEMS CON VARIANTES, SEÑALAR LA OPCION CORRECTA Y CANTIDAD QUE POSEE EN LA MAQUINA SHOW THE CORRECT ITEM AND QUANTITY IN MACHINE WHERE OPTIONS ARE AVAILABLE Cant / 4000 hs 8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs Quant.

Tareas / Works

Materiales / Materials

Codigo / Code

Limpieza completa del equipo/ Equipment complete cleaning Lavado de aeroenfriadores/ Aircooler cleaning

Desengrasante y trapos / Degreaser and rags

-

o

o

o

o

o

o

o

o

-

o

o

o

o

o

o

o

o

-

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

-

o

o

o

o

o

o

o

o

-

o

o

o

o

o

o

o

o

-

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

-

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

-

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

-

o

o

o

o

o

o

o

o

Desengrasante y trapos/ Degreaser Limpieza de carter / Crankcase cleaning and rags Aceite multigrado 20 W 50 / 20 W 50 Cambio de aceite / oil change Multigrade oil Filtro FRAM PH 20 / Fram PH 20 Cambio de filtro de aceite / Oil filter change Filter Control de correcta lubricacion de aros / Equipment correct lubrication checking Limpieza de visores de lubricacion / Oil sight Glicerina liquida / Liquid glycerin glasses cleaning Prueba de estanqueidad - Fugas de gas / Watertightness test -Gas leakage Prueba de los sistemas de drenajes / Drain systems test Prueba de los sistemas de detencion del equipo / Equipment stop systems test Calibracion de sensibilidad de sensor de vibracion / Vibration sensor sensitivity calibration

Agua Jabonosa / Soapy water

20679-1 20118

LITROS 8 1

-

1

1

Según documento EI-0012 / As EI0012 document

Control de calibracion de sensores de presion / Pressure sensor calibration control Calibracion de sensor de fuga de gas / Gas leakage sensor calibration Limpieza y revision general de tablero de Desengrasante y trapos / Degreaser instrumentos / Instrument panel cleaning and rags general inspection Limpieza de filtro de entrada de gas / Gas Inlet filter cleaning Cambio de filtro conico de entrada de gas Filtro conico / Conical filter con sus respectivas juntas / Gas inlet conic Junta Klinger / Klinger Joint Cambio de filtro coalescente y sus Filtro coalesente / Coalecent filter respectivas juntas / Coalecent filter and it's O Ring 2-239 N / 2-239 V o-ring Diafragma de valvula Aspro 2" 24 aguj. / Aspro 2" valve diaphragm 24 holes.

55297 23465 23477 20903 27010-1

1 1 2 1 1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C R/C R/C R/C

R/C R/C R/C R/C

R/C R/C R/C R/C

R/C R/C R/C R/C

R/C R/C R/C R/C

R/C R/C R/C R/C

R/C R/C R/C R/C

R/C R/C R/C R/C

Observaciones / Observations

Luego de la reinstalación de componente/s sometido/s a presión / After re-assembly components working under pressure

Revisar contactor, conexiones, ajustar y/o reajustar uniones / Check contactors and connections


N de ISERV


14/03/2011

004

Revision

-


COMPRESORES IODM 70-3-12 / IODM 70-3-12 COMPRESSOR A LOS ITEMS CON VARIANTES, SEÑALAR LA OPCION CORRECTA Y CANTIDAD QUE POSEE EN LA MAQUINA SHOW THE CORRECT ITEM AND QUANTITY IN MACHINE WHERE OPTIONS ARE AVAILABLE

Tareas / Works


Codigo / Code

Diafragma de valvula Aspro 2" 16 Cambio de diafragma de valvula reguladora aguj. / Aspro 2" valve diaphragm 16 27010 de entrada modelo 1098 / Model 1098 inlet holes. regulation valve diaphragm change Diafragma de valvula EPTA 1098 1"/ Epta 1098 1" valve diaphragm Diafragma de valvula EPTA 1098 21215 2"/ Epta 1098 2" valve diaphragm Cambio de filtro sinterizado de valvula Elemento filtrante de filtro sinterizado 286-3 reguladora de entrada / Inlet regulating valve / Sinterized filter filtering element sinterized filter change Limpieza de valvula de entrada / Inlet valve Alcohol cleaning Kit de reparacion de valvula eléctrica Consultar a S.T. / Valpes / Valpes electrical valve consult to authorized repair kit service Kit de reparacion de valvula neumática S. Sarco M40 #300 1 120683-1 + 120245Reparacion de valvula de entrada / Inlet 1/2"/ M40 #300 1 1/2" S. Sarco 1-REP valve repair neumatic valve repair kit Kit de reparacion de valvula Jefferson / Jefferson solenoid valve repair kit Cambio de diafragma de valvula de despresurizado / Depressurizing valve diaphragm change

Diafragma de valvula de Aspro / Aspro valve Diaphragm Diafragma de valvula de Remarco/ Remarco valve Diaphragm

Reparacion de piloto de valvula de Kit de reparacion devalvula EPTA 67 despresurizado / Depressurizing valve pilot HR / EPTA 67 HR Valve repair kit repair Valvula de admision de 1 etapa / Inlet valve 1st stage Valvula de admision de 2 etapa / Inlet valve 2nd stage Valvula de admision de 3 etapa / Inlet valve 3rd stage Valvula de admision de 4 etapa / Recambio de valvulas de admision y escape Inlet valve 4rd stage de todas las etapas / All stages inlet and Valvula de escape de 1 etapa / outlet valve rechange Outlet valve 1st stage Valvula de escape de 2 etapa / Outlet valve 2nd stage

Cant / 4000 hs 8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs Quant. 1

x

x

x

x

x

x

x

x

1

x

x

x

x

x

x

x

x

1

o

o

o

o

o

o

o

o

1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

1

x

x

x

x

x

x

x

x

23640-REP

21258 21258-1 x

20875

x

x

x

1 91136 91136 91159 NA 91139 91139

2 1 1 1 2 1

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x



N de ISERV


14/03/2011

004

Revision

-



Tareas / Works

Materiales / Materials Valvula de escape de 3 etapa / Outlet valve 3rd stage Valvula de escape de 4 etapa / Outlet valve 4rd stage

Juego de O Rings / O-ring joints set Cambio de O Rings y juntas de valvulas / O rings and valves joints change Juego de Arandelas / Valves copper joints set Recambio de valvula antirretorno de ultima etapa / Last stage non-return valve rechange

Valvula antirretrono a platillos / Plates non-return valve

Aros de 1 etapa / 1st Stage rings Aros de 2 etapa / 2nd stage rings Aros de 3 etapa / 3rd Stage rings Aros de 4 etapa / 4th Stage rings Buje guia de 1 et / 1st stage guide bushing Buje guia de 2 et/ 2nd stage guide Cambio de bujes guias de todas las etapas bushing de compresion / All compression stages Buje guia de 3 et / 3rd stage guide guide bushings change bushing Buje guia de 4 et / 4th stage guide bushing Cambio de vastago / piston de 1 Cambio de vastago / piston de 1 etapa/ 1st etapa/ 1st stage piston rod / piston stage piston rod / piston change change Cambio de piston de 2 y ultima etapa Cambio de piston de 2 y ultima etapa / 2nd / 2nd and Last stage piston rod / and Last stage piston rod / piston change piston change Cambio de aros de todas las etapas de compresion / All compression stages rings change

Aros rascaceite / Scraper rings

Cambio de sellos de empaquetaduras / Compressor packing seals change

Sellos radiales para empaquetadura / Packing radial seals Sellos tangenciales para empaquetadura / Packing tangencial seals Rodillo / Roller

Codigo / Code 91162

Cant / 4000 hs 8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs Quant. 1

x

x

x

x

x

x

x

x

NA

1

x

x

x

x

x

x

x

x

91622

1

x

x

x

x

x

x

x

x

91030-70-3-12

1

x

x

x

x

x

x

x

x

1079

1

x

x

x

x

x

x

x

x

91509-J 91506-J 91520-J NA

2 4 5 0

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

91510 91508 NA

1 1 0

NA

0

x

x

x

x

x

x

x

x

85319-1

1

R/C

R/C

R/C

R/C

R/C

x

R/C

R/C

85320-3

1

R/C

R/C

R/C

R/C

R/C

x

R/C

R/C

91105-J

2

91103

14

91104

14

23943

14

Juego de O Rings de empaquetaduras / Packing oring set

91340-3 /91340-4

Aros rompe presion / Down pressure ring

91110

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

1 C/U 2


* Empaquetaduras: Verificar perdidas con: 1- Caudalimetro: revisar valores según EI-0203. 2- Revisando el nivel de aceite con la maquina en funcionamiento. Si verifica perdidas. ** A) Revisar si el vastago esta rayado / gastado a- Si esta rayado / gastado >>> cambiar vastago y empaquetadura. b- Si no esta rayado / gastado >>> cambiar solo empaquetadura.Packing seals: Check leakages: 1 - Flow: check values according to EI-0203.

PROGRAMA DE MANTENIMIENTO PREVENTIVO Mainteinance Preventive Program N de ISERV


14/03/2011

0009

004

Revision

-



Tareas / Works


Codigo / Code

Conjunto porta paquete / Packing seal assembly

85609 / 85610

Conjunto cigüeñal con rodamientos / Cambio de rodamientos de ciqueñal / Crankshaft assembly with bearings. Compressor crankshaft ball bearing change Kit o'ring Cambio de reten de volante / Compressor Reten de ciguenal SAV 6025 / SAV flywheel oil seal change 6025 oil seal Cambio de aro tope de reten Aro tope de reten Cambio de metales de biela / White metal Juego de metales de biela / White bearing change metal bearing change Cambio de crucetas / Cross head Crucetas / Cross Head Cambio de pernos de bielas / Conecting rod Pernos de biela / Conecting rod bolt bolt change Tornillo M8*1,25 L 85 / M8*1,25 L=85 Bolt Cambio de tornillos de perno de bielas/ Tuerca autofrenante M8 / M8 Nut Connecting rod pin stud Arandela separadora / Separative washer Cambio de buje de biela / Bronze bush Buje de biela / Bronze bush change

Cant / 4000 hs 8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs Observaciones / Observations Quant. 1 - Flow: check values according to EI-0203. 2 - Checking the oil level with the machine in x x x x 1 C/U operation.

85084 1 1

3739

x

x

x

x x

23643

1

x

91014-1

1

x

91207

4

91048

2

91051

R/C

2

24721

2 2

23703 91047

4

22094

x

x

2

R/C

x

R/C

x

R/C

x

R/C

x

R/C

x

R/C

x

R/C

x

Valvula antirretorno de lubricacion / Lubrication non return valve

23539

2

Conjunto trampa de aceite / Oil trap assembly

120857

1

Revisión/Cambio bomba a engranajes / Gear pump revised

Kit de reparacion de bomba a engranajes / Gear pump repair kit

91168-4

5

1

R/C

x

Revisión/Cambio bomba a engranajes / Gear pump revised

Kit de reparacion de bomba a engranajes alto caudal / high flow gear pump kit

91322

5

1

R/C

x

Cambio de valvulas antirretorno de lubricacion / Lubrication non return valve

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

065 Revisión y cambio de bomba de lubricacion / Kit de reparacion de bomba de levas Lubrication pump revisedr / Lubrication pump repair kit Cambio de Distribuidor de aceite / Oil Valvula antirretorno (salida) / Check didtributor change valve (outlet) Cambio de Distribuidor de aceite / Oil Valvula antirretorno (entrada) / didtributor change Check valve (inlet)

97300

1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

120864

1

5

R/C

R/C

x

R/C

120865

0.5

1

R/C

R/C

x

R/C

El conjunto trampa de aire se coloca uno en cada etapa de compresion y la valvula antiretorno uno en cada portapaquete / The air traps are installed in each cylinder and the NRV are installed in each packing seal assembly.


N de ISERV


14/03/2011

004

Revision

-


COMPRESORES IODM 70-3-12 / IODM 70-3-12 COMPRESSOR A LOS ITEMS CON VARIANTES, SEÑALAR LA OPCION CORRECTA Y CANTIDAD QUE POSEE EN LA MAQUINA SHOW THE CORRECT ITEM AND QUANTITY IN MACHINE WHERE OPTIONS ARE AVAILABLE Cant / 4000 hs 8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs Quant.

Tareas / Works


Codigo / Code

Cambio de Distribuidor de aceite / Oil didtributor change Cambio de Distribuidor de aceite / Oil didtributor change Cambio de Distribuidor de aceite / Oil didtributor change

Sensor de proximidad / Proximity switch

120866

0.5

1

R/C

R/C

x

R/C

Indicador de ciclos / Cycle indicator

120867

0.5

1

R/C

R/C

x

R/C

Colector / Manifold

120851-1

1

1

R/C

R/C

x

R/C

Cambio de distribuidor de aceite / Oil distributor change

Modelo discontinuado / Old model

120134-2

Engrase de rodamientos de motor electrico / Electric motor ball bearings greased

Cambio completa de grasa de rodamientos de motor electrico / Electric motor ball bearings grease complete change Cambio de rodamientos de motor principal / Main electric motor ball bearings change Cambio de rodamientos de motor de aero enfriador / Air cooler motor ball bearings change Cambio de valvulas de seguridad (si fuese necesario) / Safety valve change ( Only if necessary)

Revisar valvula solenoide jefferson 1/4" / 1/4" Jefferson solenoid valve revised

Revisar Valvula Drenaje / Drainage valve revised

1

Ver grasa recomentada en chapa motor / See recomended grease to nameplate motor

R/C

R/C

x

R/C

R/C

x

R/C

R/C

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

1

1 1

Ver codigo en chapa motor / See codes on the nameplate motor

-

Juego de valvulas de seguridad / Safety valve set NOCE Juego de valvulas de seguridad / Safety valve set CE Juego de valvulas de seguridad / Safety valve set BD

85416-1

Kit de reparacion de valvula solenoide jefferson 1 1/2" / 1 1/2" Jefferson solenoid valve repair kit

1 C/U

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

21644

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula aguja 1/4" / 1/4" Needle valve

20949

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula de drenaje automatico Aspro / Aspro automatic drain valve

28506

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

22350

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

22860

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

kit paraValvula Spirax Sarco 1/4" 5000PSI kit para Valvula esf. Parker 1/4" 5000PSI

85416

2

85416-2

1 1 1


Una vez al año realizar una limpieza total / One time per year clean deeply.

Verificar en el manual del motor las variaciones de cambio de grasa en funcion de la temperatura de trabajo / Verify in the motor user manual the type of grease according the temperature and working condition


N de ISERV


14/03/2011

004

Revision

-



Tareas / Works

Revisar Actuadores / Actuator revised

Revisar Valvulas antirretorno / Cehck valve revised

Revisar Valvula de alivio / Relief valve revised

Cant / 4000 hs 8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs Quant.


Codigo / Code

kit para Valvula esf. Swagelok 1/4" 5000PSI Kit valvula esf. Oasis 1/4" 5000PSI Kit valvula esf. Valbol 1/4" 5000PSI Kit Air torque AT 101 Kit Rotex ECF 40E Kit Spirax Sarco BVA 315s Kit Spirax Sarco BVA 225s Kit Spirax Sarco BVA 220s Kit Spirax Sarco BVA 230s Kit Spirax Sarco BVA 215D Kit Spirax Sarco BVA 330s Kit Festo doble efec. DAPS-0060090-R-F05

22860-1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

20305-4 22860-2 22860-3 22860-4 22870-3 22870 22870-2 22870-1 22729-2 120245-1-REP

R/C R/C R/C R/C R/C R/C R/C R/C R/C R/C








23285-1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Kit Parker S.E. cod. 62AC

23415

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Kit Parker 1/4"

23389

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Parker 1/4"

23388-1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Sloan 1/4"

120865

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Abac 1/4"

23793

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Swagelok 1/4"

23388-2

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Kit Parker 1/2"

23368

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Kit ABAC 1/2"

23791-1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula 1/8" Aspro

285

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Sloan 1/8"

120864

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Abac 1/4" 18Bar

23787

x

x

x

x

x

x

x

x


23787-1

x

x

x

x

x

x

x

x


23878-2

x

x

x

x

x

x

x

x


24133

x

x

x

x

x

x

x

x


24545

x

x

x

x

x

x

x

x


120627

x

x

x

x

x

x

x

x

Valv Abac 1/4" 100Bar

120019-1

x

x

x

x

x

x

x

x




14/03/2011

0009


004

Revision

-


Tareas / Works


Codigo / Code

Cant / 4000 hs 8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs Quant.

Horas de trabajo / Working hours

Emision: Aprobacion:

Ariel Maiques Pablo Rodriguez

* El mantenimiento debe realizarse cada 2500hs o 6 meses (aquello que suceda primero) /The maintenance must be done every 2500hs or 6 months, whatever comes first

x : Realizar el Cambio / sustitución directa del producto o conjunto, saltear solo si se realizo cambio en una Revisar anterior / To be replaced directly R/C : Revision y/o cambio / Check or replace o : Realizar un control, o accion como calibración, limpieza, engrase, etc / To be checked calibrated - cleaned or greased



N de ISERV


14/03/2011

004

Revision

-


COMPRESORES IODM 70-3-19 / IODM 70-3-19 COMPRESSOR A LOS ITEMS CON VARIANTES, SEÑALAR LA OPCION CORRECTA Y CANTIDAD QUE POSEE EN LA MAQUINA SHOW THE CORRECT ITEM AND QUANTITY IN MACHINE WHERE OPTIONS ARE AVAILABLE Cant / Quant.

Tareas / Works


Codigo / Code

Limpieza completa del equipo/ Equipment complete cleaning Lavado de aeroenfriadores/ Aircooler cleaning


-

o

o

o

o

o

o

o

o

-

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

-

o

o

o

o

o

o

o

o

-

o

o

o

o

o

o

o

o

-

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

-

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

-

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C


-

o

o

o

o

o

o

o

o

R/C

R/C

R/C

R/C

R/C

R/C

R/C

55297 23465

1 1 2

R/C

Filtro conico / Conical filter Junta Klinger / Klinger Joint

R/C R/C

R/C R/C

R/C R/C

R/C R/C

R/C R/C

R/C R/C

R/C R/C

R/C R/C

Filtro coalesente / Coalecent filter

23477

1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

O Ring 2-239 N / 2-239 V o-ring

20903

1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Diafragma de valvula Aspro 2" 24 aguj. / Aspro 2" valve diaphragm 24 holes.

27010-1

Desengrasante y trapos/ Degreaser and rags Aceite multigrado 20 W 50 / 20 W Cambio de aceite / oil change 50 Multigrade oil Filtro FRAM PH 20 / Fram PH 20 Cambio de filtro de aceite / Oil filter change Filter Control de correcta lubricacion de aros / Equipment correct lubrication checking Limpieza de visores de lubricacion / Oil sight Glicerina liquida / Liquid glycerin glasses cleaning Limpieza de carter / Crankcase cleaning

Prueba de estanqueidad - Fugas de gas / Watertightness test -Gas leakage Prueba de los sistemas de drenajes / Drain systems test Prueba de los sistemas de detencion del equipo / Equipment stop systems test Calibracion de sensibilidad de sensor de vibracion / Vibration sensor sensitivity calibration

Agua Jabonosa / Soapy water

Cambio de filtro coalescente y sus respectivas juntas / Coalecent filter and it's respective joints change

20679-1 20118

LITROS 8 1

-

1

-

8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs

1

Según documento EI-0012 / As EI-0012 document

Control de calibracion de sensores de presion / Pressure sensor calibration control Calibracion de sensor de fuga de gas / Gas leakage sensor calibration Limpieza y revision general de tablero de instrumentos / Instrument panel cleaning general inspection Limpieza de filtro de entrada de gas / Gas Inlet filter cleaning Cambio de filtro conico de entrada de gas con sus respectivas juntas / Gas inlet conic

-

4000 hs

-


Luego de la reinstalación de componente/s sometido/s a presión / After re-assembly components working under pressure

Revisar contactor, conexiones, ajustar y/o reajustar uniones / Check contactors and connections


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Revision

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Tareas / Works


Diafragma de valvula Aspro 2" 16 aguj. / Aspro 2" valve diaphragm Cambio de diafragma de valvula reguladora 16 holes. de entrada modelo 1098 / Model 1098 inlet regulation valve diaphragm change Diafragma de valvula EPTA 1098 1"/ Epta 1098 1" valve diaphragm

Cambio de filtro sinterizado de valvula reguladora de entrada / Inlet regulating valve sinterized filter change Limpieza de valvula de entrada / Inlet valve cleaning

Reparacion de valvula de entrada / Inlet valve repair

Cant / Quant.

4000 hs

1

x

x

x

x

x

x

x

x

8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs

27010

-

Diafragma de valvula EPTA 1098 2"/ Epta 1098 2" valve diaphragm

21215

Elemento filtrante de filtro sinterizado / Sinterized filter filtering element

286-3

1

x

x

x

x

x

x

x

x

Alcohol

-

1

o

o

o

o

o

o

o

o

1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

1

x

x

x

x

x

x

x

x

Kit de reparacion de valvula Consultar a S.T. / consult to eléctrica Valpes / Valpes electrical valve repair kit authorized service Kit de reparacion de valvula neumática S. Sarco M40 #300 1 120683-1 + 1202451/2"/ M40 #300 1 1/2" S. Sarco 1-REP neumatic valve repair kit Kit de reparacion de valvula Jefferson / Jefferson solenoid valve repair kit

Diafragma de valvula de Aspro / Aspro valve Diaphragm Diafragma de valvula de Remarco/ Remarco valve Kit de reparacion devalvula EPTA Reparacion de piloto de valvula de despresurizado / Depressurizing valve pilot 67 HR / EPTA 67 HR Valve repair repair kit Valvula de admision de 1 etapa / Inlet valve 1st stage Valvula de admision de 2 etapa / Inlet valve 2nd stage Valvula de admision de 3 etapa / Inlet valve 3rd stage Valvula de admision de 4 etapa / Recambio de valvulas de admision y escape Inlet valve 4rd stage de todas las etapas / All stages inlet and Valvula de escape de 1 etapa / outlet valve rechange Outlet valve 1st stage Cambio de diafragma de valvula de despresurizado / Depressurizing valve diaphragm change

Codigo / Code

23640-REP

21258 21258-1 20875

x

x

x

x

1 91136 91136 91159 NA 91139

2 1 1 1 2

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x



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Tareas / Works


Valvula de escape de 2 etapa / Outlet valve 2nd stage Valvula de escape de 3 etapa / Outlet valve 3rd stage Valvula de escape de 4 etapa / Outlet valve 4rd stage Juego de O Rings / O-ring joints set Cambio de O Rings y juntas de valvulas / O rings and valves joints change Juego de Arandelas / Valves copper joints set Recambio de valvula antirretorno de ultima etapa / Last stage non-return valve rechange

Cambio de aros de todas las etapas de compresion / All compression stages rings change

91139 91162

Cant / Quant. 1 1

4000 hs

8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

NA

1

x

x

x

x

x

x

x

x

91562

1

x

x

x

x

x

x

x

x

91030-70-3-19

1

x

x

x

x

x

x

x

x

Valvula antirretrono a platillos / Plates non-return valve

1079

1

x

x

x

x

x

x

x

x

Aros de 1 etapa / 1st Stage rings

91507-J

1

x

x

x

x

x

x

x

x

Aros de 2 etapa / 2nd stage rings

91506-J

1

x

x

x

x

x

x

x

x

Aros de 3 etapa / 3rd Stage rings

91520-J

1

x

x

x

x

x

x

x

x

Aros de 4 etapa / 4th Stage rings

NA

0

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Buje guia de 1 et / 1st stage guide bushing Buje guia de 2 et/ 2nd stage Cambio de bujes guias de todas las etapas guide bushing de compresion / All compression stages Buje guia de 3 et / 3rd stage guide bushings change guide bushing Buje guia de 4 et / 4th stage guide bushing Cambio de vastago / piston de 1 Cambio de vastago / piston de 1 etapa/ 1st etapa/ 1st stage piston rod / stage piston rod / piston change piston change Cambio de piston de 2 y ultima Cambio de piston de 2 y ultima etapa / 2nd etapa / 2nd and Last stage piston and Last stage piston rod / piston change rod / piston change

Cambio de sellos de empaquetaduras /

Codigo / Code

91505 91508 NA

1 1 0

NA

0

x

x

x

x

x

x

x

x

85391-2

1

R/C

R/C

R/C

R/C

R/C

x

R/C

R/C

85320-3

1

R/C

R/C

R/C

R/C

R/C

x

R/C

R/C

Aros rascaceite / Scraper rings

91105-J

Sellos radiales para empaquetadura / Packing radial seals Sellos tangenciales para empaquetadura / Packing tangencial seals

91103

14

91104

14

2

x

x

x

x

x

x

x

x

x

x

x

x


* Empaquetaduras: Verificar perdidas con: 1- Caudalimetro: revisar valores según EI-0203. 2- Revisando el nivel de aceite con la maquina en funcionamiento. Si verifica perdidas. ** A) Revisar si el vastago esta rayado / gastado a- Si esta rayado / gastado >>> cambiar vastago y empaquetadura.



14/03/2011

0009

004

Revision

-



Tareas / Works


Cambio de sellos de empaquetaduras / Compressor packing seals change

Rodillo / Roller

Cant / Quant.

23943

14

Juego de O Rings de empaquetaduras / Packing oring set

91340-3 /91340-4

Aros rompe presion / Down pressure ring

91110

Conjunto porta paquete / Packing seal assembly

85608 / 85610

Conjunto cigüeñal con rodamientos / Crankshaft assembly with bearings. Kit o'ring Reten de ciguenal SAV 6025 / Cambio de reten de volante / Compressor flywheel oil seal change SAV 6025 oil seal Cambio de aro tope de reten Aro tope de reten Cambio de metales de biela / White metal Juego de metales de biela / White bearing change metal bearing change Cambio de crucetas / Cross head Crucetas / Cross Head Cambio de pernos de bielas / Conecting rod Pernos de biela / Conecting rod bolt change bolt Tornillo M8*1,25 L 85 / M8*1,25 L=85 Bolt Cambio de tornillos de perno de bielas/ Tuerca autofrenante M8 / M8 Nut Connecting rod pin stud Arandela separadora / Separative washer Cambio de buje de biela / Bronze bush Buje de biela / Bronze bush change Cambio de rodamientos de ciqueñal / Compressor crankshaft ball bearing change

Cambio de valvulas antirretorno de lubricacion / Lubrication non return valve

Codigo / Code

Valvula antirretorno de lubricacion / Lubrication non return valve

Revisión/Cambio bomba a engranajes / Gear Kit de reparacion de bomba a pump revised engranajes / Gear pump repair kit

8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

1 C/U 2 1 C/U 85084

x

x

3739

1 1

x

x

23643

1

x

x

91014-1

1

x

x

91207

4

91048

2

91051 24721

x

2

23703

2

91047

4

22094

2

23539

R/C

R/C

R/C

R/C

R/C

x

R/C

x

R/C

x

R/C

x

R/C

x

R/C

x

R/C

R/C

R/C

R/C

R/C

1

5

1

R/C

Observaciones / Observations empaquetadura. b- Si no esta rayado / gastado >>> cambiar solo empaquetadura.Packing seals: Check leakages: 1 - Flow: check values according to EI-0203. 2 - Checking the oil level with the machine in operation. If you check losses. ** A) Check if the rod is scratched / worn a-If it's scratched / worn>>> change rod and packing. b-If it is not scratched / worn>>> change just packing. "

x

2

120857

91168-4

R/C

2

2 Conjunto trampa de aceite / Oil trap assembly

4000 hs

x

El conjunto trampa de aire se coloca uno en cada etapa de compresion y la valvula antiretorno uno en cada portapaquete / The air traps are installed in each cylinder and the NRV are installed in each packing seal assembly.


N de ISERV


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Revision

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Tareas / Works


Kit de reparacion de bomba a Revisión/Cambio bomba a engranajes / Gear engranajes alto caudal / high flow pump revised gear pump kit 065 Revisión y cambio de bomba de lubricacion / Kit de reparacion de bomba de Lubrication pump revisedr levas / Lubrication pump repair kit Cambio de Distribuidor de aceite didtributor change Cambio de Distribuidor de aceite didtributor change Cambio de Distribuidor de aceite didtributor change Cambio de Distribuidor de aceite didtributor change Cambio de Distribuidor de aceite didtributor change

/ Oil / Oil / Oil / Oil / Oil

Cambio de distribuidor de aceite / Oil distributor change

Engrase de rodamientos de motor electrico / Electric motor ball bearings greased

Cambio completa de grasa de rodamientos de motor electrico / Electric motor ball bearings grease complete change

Valvula antirretorno (salida) / Check valve (outlet) Valvula antirretorno (entrada) / Check valve (inlet) Sensor de proximidad / Proximity switch Indicador de ciclos / Cycle indicator

Cant / Quant.

Codigo / Code

91322

5

4000 hs

8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs

1

97300

R/C

R/C

R/C

R/C

R/C

x

R/C

R/C

R/C

R/C

1 120864

1

5

R/C

R/C

x

R/C

120865

0.5

1

R/C

R/C

x

R/C

120866

0.5

1

R/C

R/C

x

R/C

120867

0.5

1

R/C

R/C

x

R/C

Colector / Manifold

120851-1

1

1

R/C

R/C

x

R/C

Modelo discontinuado / Old model

120134-2 1

R/C

R/C

x

R/C

R/C

x

R/C

R/C

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

1

Ver grasa recomentada en chapa motor / See recomended grease to nameplate motor

Cambio de rodamientos de motor principal / Main electric motor ball bearings change Ver codigo en chapa motor / See Cambio de rodamientos de motor de aero codes on the nameplate motor enfriador / Air cooler motor ball bearings change Juego de valvulas de seguridad / Safety valve set NOCE Cambio de valvulas de seguridad (si fuese Juego de valvulas de seguridad / necesario) / Safety valve change ( Only if Safety valve set CE necessary) Juego de valvulas de seguridad / Safety valve set BD


1 1 85416 85416-1

2 1 C/U 1 1

85416-2 1

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Una vez al año realizar una limpieza total / One time per year clean deeply.

Verificar en el manual del motor las variaciones de cambio de grasa en funcion de la temperatura de trabajo / Verify in the motor user manual the type of grease according the temperature and working condition


N de ISERV


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Revision

-



Tareas / Works Revisar valvula solenoide jefferson 1/4" / 1/4" Jefferson solenoid valve revised

Revisar Valvula Drenaje / Drainage valve revised

Revisar Actuadores / Actuator revised

Revisar Valvulas antirretorno / Cehck valve revised

Materiales / Materials Kit de reparacion de valvula solenoide jefferson 1 1/2" / 1 1/2" Jefferson solenoid valve repair kit Valvula aguja 1/4" / 1/4" Needle valve Valvula de drenaje automatico Aspro / Aspro automatic drain valve kit paraValvula Spirax Sarco 1/4" 5000PSI kit para Valvula esf. Parker 1/4" 5000PSI kit para Valvula esf. Swagelok 1/4" 5000PSI Kit valvula esf. Oasis 1/4" 5000PSI Kit valvula esf. Valbol 1/4" 5000PSI Kit Air torque AT 101 Kit Rotex ECF 40E Kit Spirax Sarco BVA 315s Kit Spirax Sarco BVA 225s Kit Spirax Sarco BVA 220s Kit Spirax Sarco BVA 230s Kit Spirax Sarco BVA 215D Kit Spirax Sarco BVA 330s Kit Festo doble efec. DAPS-0060090-R-F05 Kit Parker S.E. cod. 62AC

Codigo / Code

Cant / Quant.

4000 hs

8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs

21644

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

20949

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

28506

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

22350

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

22860

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

22860-1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

20305-4

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

22860-2

22860-3 22860-4 22870-3 22870 22870-2 22870-1 22729-2 120245-1-REP 23285-1









23415

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Kit Parker 1/4"

23389

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Parker 1/4"

23388-1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Sloan 1/4"

120865

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Abac 1/4"

23793

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Swagelok 1/4"

23388-2

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Kit Parker 1/2"

23368

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Kit ABAC 1/2"

23791-1

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula 1/8" Aspro

285

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C

Valvula Sloan 1/8"

120864

R/C

R/C

R/C

R/C

R/C

R/C

R/C

R/C


23787

x

x

x

x

x

x

x

x


23787-1

x

x

x

x

x

x

x

x



N de ISERV


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004

Revision

-



Tareas / Works

Revisar Valvula de alivio / Relief valve revised

Cant / Quant.


Codigo / Code

4000 hs

8000 hs 12000 hs 16000 hs 20000 hs 24000 hs 28000 hs 32000 hs


23878-2

x

x

x

x

x

x

x

x


24133

x

x

x

x

x

x

x

x


24545

x

x

x

x

x

x

x

x


120627

x

x

x

x

x

x

x

x

Valv Abac 1/4" 100Bar

120019-1

x

x

x

x

x

x

x

x

Horas de trabajo / Working hours

Emision: Aprobacion:

Ariel Maiques Pablo Rodriguez

* El mantenimiento debe realizarse cada 2500hs o 6 meses (aquello que suceda primero) /The maintenance must be done every 2500hs or 6 months, whatever comes first

x : Realizar el Cambio / sustitución directa del producto o conjunto, saltear solo si se realizo cambio en una Revisar anterior / To be replaced directly R/C : Revision y/o cambio / Check or replace o : Realizar un control, o accion como calibración, limpieza, engrase, etc / To be checked - calibrated cleaned or greased


HERRAMIENTAS ESPECIALES SPECIAL TOOLS LIST

COMPRESSORS & DISPENSERS CNG STATIONS

ANEXO Nº 1. ANNEX

LISTADO DE HERRAMIENTAS ESPECIALES. LIST OF SPECIAL TOOLS.

A ) Armado del Manovelismo IODM 70 : A) IODM 70 COMPRESSOR UNIT ASSEMBLING:

1 - HE -0075

1- Alargue de torquimetro 400Nm. 400 Nm. torquimeter extension

2 - HE -0181

2- Alargue de torquimetro 500Nm. 500 Nm. torquimeter extension

3 - HE -0007

3- Alargue de torquimetro 700Nm. 700 Nm torquimeter extension

1

COMPRESSORS & DISPENSERS CNG STATIONS Application: Coupling tightening

4 - HE -0001

Aplicación : Apriete de acople

4- Llave ajuste acople de cigueñal. Spanner to adjust crankshaft coupling.

5 - HE -1599

Application: Crankshaft placement.

Aplicación : Colocación del cigüeñal.

5- Medialuna de apoyo del cigueñal. Crankshaft support.

2


6 - HE -0510

Application : Nut blocking

Aplicación : Apriete de tuerca.

6- Llave apriete tuerca vástago/cruceta. Nut blocking spanner (piston rod / crosshead).

7 - HE -0523

Application: 1st stage piston rod threading

Aplicación : Roscado de vástago de 1º etapa.

7- Llave para ajustar el vástago de 1º etapa de compresión. Spanner to adjust 1st stage compression piston rod.

3


8 - HE -0520

Application: Torque Clearance Pocket Regulator (C.P.R.) piston

Aplicación : Torquear pistón R.E.N.

8- Llave para torquear válvula de 4º etapa de compresión. 4th compression stage valve torquimeter wrench.

9 - HE -0526

Application: Crankshaft complete turn

Aplicación : Giro completo del cigüeñal.

9-Llave/manija para movimiento giratorio del cigueñal. Device for crankshaft turning movement.

4


10 - D-0344

Application: Device to control coupling distances

Aplicación : Distanciador de acoples.

10- Dispositivo distanciador de acoples. Device to control coupling distances.

11 - HE –00--

Application: Piston rod thread protection

Aplicación : Protección de rosca vástago.

11- Capuchón para protección de roscas de vástagos. Cover to protect piston rods threads.

5


12 – D- 0820

Application:. Crankshaft assembling

Aplicación : Montaje del cigüeñal.

12- Dispositivo de izaje para montaje del cigueñal. Hoisting device for crankshaft assembling.

13 - HE -0516

Application: To bar the crankshaft

Aplicación : Palanquear el cigüeñal.

13- Apoyo para desplazamiento del juego axia del cigueñal. Support to move crankshaft axial clearance.

6


14 - HE -0500

14-Llave para ajustar pistón de 4º etapa de compresión. Spanner to adjust 4th stage compression piston

15 - HE -0525

15- Llave para ajuste de vástago-pistón 3º en cruceta. Spanner to adjust 3rd stage compression crosshead in piston rod.

7

COMPRESSORS & DISPENSERS CNG REFUELING STATIONS

ANEXO N º 1. ANNEX No. 1.

LISTADO DE HERRAMIENTAS ESPECIALES. LIST OF SPECIAL TOOLS.

A ) Armado del Almacenaje : A) Storage Assembly:

1 - D -1493

1- Prensa caño para cañería de Ø1/2``. 1- Pipe clamp for Ø 1/2`` pipeline.

2 – D- 1494

2- Prensa caño para cañería de Ø 3/8``. 2- Pipe clamp for Ø 3/8`` pipeline.

3 – D- 1495

3- Prensa caño para cañería de Ø 5/8``.. 3- Pipe clamp for Ø 5/8`` pipeline. Manual del usuario - Almacenaje

User’s Manual - Storage

1


4 – HE- 0511

Application: Neck Plug tightening.

Aplicación : Apriete de tapón ojiva.

4- Llave ajuste de tapón ojiva. 4- Spanner to adjust neck plug.

5 – HE- 0512

Application: Thread reducer tightening.

Aplicación : Apriete de reductor de roscas.

5- Apriete de reductor de roscas entre válvula y cilindro. 5- Thread reducer between valve and cylinder tightening.

Manual del usuario - Almacenaje


2


6 - HE -0503

Aplicación : Apriete de válvula de seguridad..

Application: Safety Valve tightening.

6- Llave apriete de válvula de seguridad sobre barral. 6- Spanner to tighten safety valve over manifold.

Application: Cylinder Hoisting.

Aplicación :Elevación del cilindro .

7- Dispositivo para elevación de cilindros . 7- Device to hoist cylinders.



3


8 - HE -1117

Application: Flange placement and fastening.

Aplicación : Colocación y fijación de brida..

8- Centrador de espárragos de sujeción de brida. 8- Centering device for flange fastening pins. Application: Inlet flange adjustment.

Aplicación : Ajuste de brida de entrada..

9-Grinfa para ajuste de brida entrada. 9- Special spanner to adjust inlet flange.



4


Application: Over flow valve adjustment.

Aplicación : Ajuste de válvula de exceso de flujo..

10- Llave de apriete de válvula de exceso de flujo. 10- Spanner to tighten over flow valve. Application: Cylinder valve adjustment.

Aplicación : Ajuste de válvula de cilindro.

11- Apriete de válvula shopping en cilindro. 11- Cylinder valve tightening.



5

COMPRESSORS & DISPENSERS CNG REFUELING STATIONS Application: Ø 5/8`` Pipeline bending.

12 – D- 1496

Aplicación : Curvado de cañería de Ø 5/8``.

12- Dispositivo para curvado (90º) de cañería de Ø 5/8``. 12- Device to bend (90º) Ø 5/8`` pipeline. Application: Cylinder pipeline bending.

Aplicación :Curvado de cañería de cilindros.

13- Dispositivo para curvado 360º de cañería de Inter-conexionado de cilindros. 13- Device to bend 360º the cylinders inter-connecting pipeline. Manual del usuario - Almacenaje


6

PLANOS DRAWINGS

User's Manual - Compressor IODM 70-3-19

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