WH40H3N (set-04)

OPERATION & MAINTENANCE MANUAL PET COMPRESSOR TYPE WH40H3N

Doc. Ref:WH40H3N Ref:WH40H3N

Important This Instruction Manual covers Installation & Commissioning, Operation and Maintenance of the Gardner Denver Belliss & Morcom ‘PET’ Morcom ‘PET’ range range of compressors. It is ESSENTIAL that ESSENTIAL that this document is read and understood by everyone who will work with this equipment, as f ailure to do so may result in death, deat h, injury or damage to the compressor or its associated equipment.

Disclaimer While every care was taken in the preparation of these instructions, it cannot be guaranteed that every aspect has been covered. Gardner Denver Belliss & Morcom cannot, therefore, accept liability for direct or consequential damage that may arise resulting from nonconformity with this Manual, from repairs carried out improperly, from using other than original spare parts, and from non-observance of good operating and maintenance engineering practices. Should there be any doubt whatsoever, or should any further information or explanation be required, Gardner Denver Belliss & Morcom Morcom must be contacted. This information is given in good faith, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Gardner Denver Belliss & Morcom. Morcom. Gardner Denver Belliss & Morcom reserve Morcom reserve the right to make changes to any information contained within this manual without prior notice.

Warranty Statement The compressor(s) and ancillary equipment supplied by Gardner Denver Belliss & Morcom are covered under Warranty for the period agreed in the Supply Contract. The equipment provided is well designed to afford many years of trouble free service. However, should the need arise to implement a warranty claim then this can be done using Warranty Claim Form Document No.CM4F2 obtainable from Gardner Denver Belliss & Morcom Service Morcom Service Department. A copy of this form is provided in Appendices located at the end of this manual. It should be noted that consumable parts that t hat require replacement during normal compressor operations are not normally covered under Warranty. Similarly, the Warranty does not cover running adjustments. Point of Contact

Gardner Denver Belliss & Morcom Ltd Chequers Bridge, Gloucester, GL1 4LL, England Tel: Fax:

+44 (0) 1452 338198 +44 (0) 1452 338317

Email: Web: Web:

[email protected] www.belliss.com

This document contains confidential information of Gardner Denver Belliss & Morcom Ltd (The Company). The copyright, design right and/or other intellectual property rights in the document belongs to (The Company). All rights conferred by law and by virtue of International Copyright and other conventions are reserved reserved to The Company. Company. This Thi s document and the inf ormation contained therein or any part thereof must not be reproduced, disclosed or used for any other than those for which the prior written consent of The Company has been given. ©

Gardner Denver Belliss & Morcom Ltd

Foreword Gardner Denver Belliss & Morcom Morcom are well known in the market place for the design, manufacture and a nd supply of high-quality air compressor equipment. This Instruction Manual Manual is produced for the ‘PET ‘PET'' range of compressors. These compressors are constructed from the highest quality materials and are designed and built according to the latest manufacturing techniques. The compressor design will give good service providing that it is operated and maintained in accordance with the information contained within this Manual. The information and notes presented in the 'Ancillary Devices’ Instruction Manuals will provide operational and maintenance information for the control and instrumentation system, motor/drive unit and where appropriate, any other device associated with the compressor package.

Targeted Personnel This document is designed to provide competent operatives, who are fully conversant with compressor operating and maintenance techniques, with an understanding of the compressor elements and their operation and subsequent maintenance. It should be noted that the term 'competent' implies that the operative is a compressor engineer suitably trained in the installation, operation and maintenance of the Gardner Denver Belliss & Morcom product. This Instruction manual is not intended to supersede or take the place of the Gardner Denver Belliss & Morcom product-training Morcom product-training course. For further f urther information regarding training courses or to book a place, please contact Gardner Denver Belliss & Morcom Morcom Service Department. The address, telephone/facsimile number is provided at the start of this documentation.

How to Use this Instruction Manual The Instruction Manual is designed to t o enable speedy location of relevant info rmation. To this end the document is divided into six chapters, each of which covers an individual topic. Cross-references between topics and illustrations are identified within the text using bold characters i.e. (Refer to Chap 2 Section 4.1) 4.1) or see Fig 3. 3. At appropriate locations within this document you will see 'Information Boxes' . It is VERY IMPORTANT that IMPORTANT that the information contained within these boxes is adhered to, as failure to do so may result in death, injury or damage to the compressor or its associated equipment. The following outlines the philosophy applied to each of the three levels of boxed notation.

WARNING! This pictogram with the remark "WARNING! " WARNING!"" identifies a potential dangerous hazard. Non-compliance will put the operator or a third party at risk of death or injury.

CAUTION! This pictogram with the remark “CAUTION! “CAUTION!”” identifies the possibility that if noncompliant the compressor and/or its associated equipment can be damaged.

This pictogram marks important Notes, which identifies supplementary information for the competent and economic use/operation of this compressor package.

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Foreword Documentation Storage Always store this th is Instruction Manual near the t he compressor so that it is available for f or reference at all times. If the instruction manual is lost, Gardner Denver Belliss & Morcom can Morcom can supply a new copy for a small fee. When requesting new or additional copies, of this document, please include your compressor details with your order.

Comments and Suggestions We would welcome comments and suggestions for improvements to this Instruction Manual. If you decide to comment, make a copy of the page or pages concerned and add your comments. Then send your response to Gardner Denver Belliss & Morcom. Morcom. Please do not forget to include your name and the name of your company, your company address and your telephone and facsimile numbers.

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COMPRESSOR TYPE WH40H3N

Date:

May 2002

CONTENTS

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Technical Technical Data................. Data................................... .................................... .................................... ................................... .............................. ............. 9 1.1.1 1.1.2 1.1.3 1.1.4

1.2

2.

Operating Operating Data.................................... Data.......................................................................... ................................................................9 ..........................9 Compress Compressor or Data ...................................... ............................................................................ ........................................................10 ..................10 Tightenin Tightening g Torques Torques (Dry Threads Threads)) .................................... .....................................................................13 .................................13 Materials Materials of Constru Construction................................................................ ction...................................................................................14 ...................14

Technical Technical Description Description of the Compress Compressor or .................................... ...................................................... ...................... .... 15 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9

Purpose Purpose of the Equipment Equipment ..................................... ........................................................................... ............................................15 ......15 Compress Compressor or Identificat Identification ion ...................................... ............................................................................ ............................................15 ......15 Compress Compressor or Operation Operation ................................... .......................................................................... ...................................................16 ............16 Crankcas Crankcase e and Lower Motion W ork .................................. ...................................................................16 .................................16 Cylinders, Pistons and Piston Rod Packings......................................................18 Valves...............................................................................................................19 Motor Motor and Couplings Couplings ....................................................................... .........................................................................................19 ..................19 Control Control Panel Panel and Controls............................. Controls.................................................................... ...................................................19 ............19 Safety Safety Equipment Equipment and Systems Systems .................................. .........................................................................20 .......................................20

SAFETY INFORMATION..................................................................................22 2.1

Safety Policy....................... Policy.......................................... ...................................... ...................................... ...................................... ...................... ... 22 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6

Commonp Commonplace lace Hazards Hazards .................................. ........................................................................ ...................................................22 .............22 Proper Proper Use....................................................... Use.............................................................................................. .................................................22 ..........22 Organisa Organisationa tionall Measure Measures s ....................................... ............................................................................. ............................................23 ......23 General Safety Precautions for Compressors Compressors .............. ....... .............. .............. .............. .............. .............. .......... ...23 23 Installation, Commissioning Commissioning and Operation .............. ....... .............. .............. ............... ............... .............. ............. ...... 24 Maintena Maintenance.. nce........................................ ............................................................................. ..............................................................24 .......................24

INSTALLA INSTALLATION TION & COMMISSIO COMMISSIONING NING ...................... .................................. ....................... ...................... ................27 .....27 3.1 3.2

Safety Precauti Precautions ons.................... ........................................ ........................................ ........................................ ................................. ............. 27 Installatio Installation n Require Requirements ments ..................................... ....................................................... ..................................... ........................... ........ 27 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

3.3

3.4

Safety Safety Precaution Precautions s .................................... .......................................................................... ........................................................35 ..................35 Mounting Arrangements Arrangements - Anti-Vibration Mounts ............... ........ .............. .............. .............. .............. ............ ..... 35 Levelling and Alignment - Flange Mounted Motors.............................................36

Preparati Preparation on for Commissi Commissionin oning............................ g................................................. ......................................... ......................... ..... 36 3.5.1 3.5.2 3.5.3 3.5.4

3.6

Stability Stability ................................... .......................................................................... ..........................................................................32 ...................................32 Slinging Slinging Instruction Instructions s ........................................................................ ..........................................................................................33 ..................33 Lifting Lifting Instruction Instructions s ..................................... ........................................................................... ........................................................34 ..................34 Unpackin Unpacking g ..................................... ........................................................................... ....................................................................34 ..............................34

Installatio Installation n Procedur Procedure e .................................... ...................................................... ..................................... .................................. ............... 35 3.4.1 3.4.2 3.4.3

3.5

Location Location .................................. ........................................................................ ..........................................................................27 ....................................27 Ventilatio Ventilation n ..................................... ........................................................................... ....................................................................27 ..............................27 Foundatio Foundations ns .................................. ......................................................................... ....................................................................28 .............................28 Pipework Pipework Installatio Installation.................... n........................................................... ......................................................................28 ...............................28 Cooling Cooling W ater ..................................... ........................................................................... ..............................................................31 ........................31 Electric Electric Cabling Cabling .................................. ......................................................................... ...............................................................32 ........................32

Handling Handling and Unpackin Unpacking............................. g.................................................. .......................................... .................................. ............. 32 3.3.1 3.3.2 3.3.3 3.3.4

Cleaning Cleaning the Compress Compressor or ...................................... ............................................................................ ............................................36 ......36 Preparing Preparing the Compress Compressor........................................................ or.................................................................................36 .........................36 Preparing Preparing the Motor...................................................... Motor...........................................................................................38 .....................................38 Motor Motor Rotation Rotation Check............................................................... Check........................................................................................38 .........................38

Commissio Commissioning ning the Compressor............................. Compressor............................................... .................................... ......................... ....... 38 3.6.1 3.6.2

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OPERATION & MAINTENANCE MANUAL

Trial Run ....................................................................... ...........................................................................................................38 ....................................38 Completio Completion n of Commiss Commissionin ioning g .................................... .......................................................................... .......................................39 .39

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DOC REF: W H40H3N - ISSUE 1, MAY 02

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OPERATING INSTRUCTIONS.........................................................................41 4.1

Controls Controls and Indicat Indicators................................. ors.................................................... ....................................... .................................. .............. 41 4.1.1 4.1.2

4.2

Preparati Preparation on for Starting.................... Starting......................................... ........................................... ........................................... ....................... .. 43 4.2.1

4.3

Starter Starter System......................... System............................................................... ..........................................................................41 ....................................41 Load Load Control Control System System Functions............................................................ Functions.........................................................................42 .............42 Before Operating the Machine (Pre-Start Checks) .............. ....... .............. .............. .............. ............... .......... ..44 44

Starting Starting the Compress Compressor or ...................................... .......................................................... ........................................ .......................... ...... 44 4.3.1 Under Under Normal Normal Conditio Conditions ns ...................................... ............................................................................ ............................................44 ......44 4.3.2 After An Emergency Stop .............. ....... .............. .............. .............. .............. .............. .............. .............. ............... ............... ........... .... 45

4.4

Running Running ....................................... .......................................................... ....................................... ....................................... ............................... ............ 45 4.4.1 Running Running Checks Checks .................................. ........................................................................ ..............................................................45 ........................45 4.4.2 Automatic Operation.... Operation........... .............. .............. .............. .............. ............... ............... .............. .............. .............. .............. .............. ........45 .45 4.4.3 Faults/Haza Faults/Hazards rds .................................... .......................................................................... ..............................................................45 ........................45

4.5

Stopping Stopping the Compress Compressor or ..................................... ......................................................... ........................................ ......................... ..... 46 4.5.1 4.5.2

Normal Normal Stopping Stopping.................................. ........................................................................ ..............................................................46 ........................46 Emergency Emergency Stoppin Stopping g ....................................... ............................................................................. ..................................................46 ............46

4.6. Fault Indicati Indications ons ...................................... .......................................................... ........................................ ...................................... .................. 46 4.6.1

5

Fault Finding Finding ....................................... ............................................................................. ..............................................................47 ........................47

COMPRESSOR MAINTENANCE.....................................................................51 5.1

Preventive Preventive Maintena Maintenance nce ................................... ...................................................... ..................................... .............................. ............ 51 5.1.1

5.2

Maintena Maintenance nce Schedule.................................................................... Schedule......................................................................................51 ..................51

Maintena Maintenance nce Instructi Instructions................................... ons....................................................... ....................................... ............................ ......... 56 JOB No. 001 CRANKCASE OIL CHANGE.....................................................................57 JOB No. 002 FIT PISTON ROD CLAMPS......................................................................59 JOB No. 003 CYLINDER TOP COVERS - REMOVE & REFIT.......................................60 JOB No. No. 004 PISTON RINGS - REMOVE REMOVE & REFIT .............. ....... ............... ............... .............. .............. .............. ............ ..... 62 JOB No. 005 PISTON/CYLINDER END CLEARANCES - INSPECTION........................68 JOB No. 006 PACKING GLAND ASSEMBLY - REMOVE & REFIT................................70 JOB No. No. 007 PACKING GLAND ASSEMBLY - OVERHAUL OVERHAUL ............... ........ .............. .............. .............. ............. ...... 74 JOB No. 008 PISTON ROD OIL SHEDDER - REMOVE & REFIT..................................76 JOB No. 009 OIL SCRAPER GLAND - REMOVE & REFIT............................................78 JOB No. 010 SUCTION & DELIVERY VALVES - REMOVE & REFIT.............................79 JOB No. 011 SUCTION & DELIVERY VALVES - OVERHAUL.......................................81 JOB No. 012 SUCTION VALVE VALVE UNLOADER ACTUATORS - REMOVE REMOVE & REFIT...... .... 83 JOB No. No. 013 PISTON RODS - REMOVE & REFIT REFIT .............. ....... .............. .............. ............... ............... .............. ............. ...... 85 JOB No. 014 OIL FILTER - REMOVE & REFIT..............................................................86 JOB No. No. 015 OIL PRESSURE PRESSURE RELIEF RELIEF VALVE VALVE - ADJUSTMENT ADJUSTMENT .............. ....... .............. .............. .............. ....... 86 JOB No. 016 LUBRICATING LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL .......... ....... ...87 87 JOB No. 017 INTERCOOLER - INSPECT & OVERHAUL..............................................87

5.3

Lists of Tools Tools ................................... ..................................................... ..................................... ..................................... ............................. ........... 88 5.3.1 5.3.2

5.4

Waste Products Products .................................... ....................................................... ...................................... ...................................... ....................... .... 90 5.4.1 5.4.2

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Commercially Available Tools List......................................................................88 Specialis Specialistt Service Service Tools Tools List ....................................................................... ..............................................................................89 .......89 Oil - After After Oil Change Changes........................................................ s.......................................................................................90 ...............................90 Coolant Coolant ................................... ......................................................................... ..........................................................................90 ....................................90


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SPARE SPARE PARTS ....................... ................................... ....................... ....................... ....................... ....................... ....................... ...............92 ....92 6.1 6.2 6.3

Ordering Spares and Spares Spares to to be Held in Stock.... Stock............ ................ ................ ................ ................ ........... ... 92 Spares Spares List.................... List....................................... ...................................... ..................................... ..................................... ............................. .......... 93 Illustrated Parts List List - Main Main Component Component Location View ................. ........ ................. ................ ............. ..... 95 Fig 1 Crankcas Crankcase e Assembly Assembly (2-03-28 (2-03-288)..................................................................... 8)...........................................................................96 ......96 Fig 2 Connecting Rod Assembly (2-76-426)...................................................................97 Fig 3 Crankshaft Assembly (2-06-383)...........................................................................98 Fig 4 Main Guide Assembly (2-07-280)..........................................................................99 Fig 5 Bearing End Cover Assembly (2-25-121) .............. ....... .............. .............. ............... ............... .............. .............. .......... ... 100 Fig 6 Flywhee Flywheell End Cover Assembly Assembly (2-25-123 (2-25-123)) ..........................................................101 ..........................................................101 Fig 7 Second Stage Piston Rod Assembly (2-30-144)..................................................102 Fig 8 Third Stage Piston Rod Assembly (2-30-202)......................................................102 Fig 9 Crosshead Assembly (2-31-066).........................................................................103 Fig 10 Oil Pump and Cooler Assembly (2-34-562) (2-34-562) .............. ....... .............. .............. .............. .............. ............... ............. ..... 105 Fig 11 Piston Piston Rod Scraper Scraper Assembly Assembly (2-63-047 (2-63-047)) ...................................... .........................................................106 ...................106 Fig 12 Crosshead Assembly (2-31-067).......................................................................107 Fig 13 First Stage Piston Rod Assembly (2-30-252).....................................................108 Fig 14 First Stage Cylinder Assembly Assembly (2-01-908) (2-01-908) .............. ....... .............. .............. .............. .............. .............. .............. ......... 110 Fig 15 First Stage Top Cover Assembly (2-04-467)......................................................111 Fig 16 Distance Distance Piece Assembl Assembly y (2-07-414 (2-07-414)) ................................................................112 ................................................................112 Fig 17 First Stage Piston Assembly (2-28-660) .............. ....... .............. .............. ............... ............... .............. .............. .......... ... 113 Fig 18 First Stage Packing Box Assembly (2-64-285)...................................................114 Fig 19 First Stage Suction Valve Assembly (2-70-489).................................................115 Fig 20 First Stage Delivery Valve Assembly (2-70-490)................................................116 Fig 21 Second Stage Cylinder Assembly (2-01-531) (2-01-531) ............... ........ .............. .............. .............. .............. .............. ......... ..118 118 Fig 22 Second Stage Top Cover Assembly (2-04-274).................................................119 Fig 23 Distance Distance Piece Assembl Assembly y (2-07-281 (2-07-281)) ................................................................120 ................................................................120 Fig 24 Second Stage Piston Assembly (2-28-481) .............. ....... .............. .............. .............. .............. ............... ............. ..... 121 Fig 25 Second Stage Packing Box Assembly Assembly (2-64-286) .............. ....... .............. .............. .............. .............. .......... ... 122 Fig 26 Second Stage Suction Valve Assembly (2-70-503)............................................123 Fig 27 Second Stage Delivery Valve Assembly (2-70-504)...........................................124 Fig 28 Third Stage Cylinder Assembly (2-01-481)........................................................126 Fig 29 Third Stage Top Cover Assembly (2-04-305) (2-04-305) ............... ........ .............. .............. .............. .............. .............. ......... ..127 127 Fig 30 Distance Distance Piece Assembl Assembly y (2-07-281 (2-07-281)) ................................................................128 ................................................................128 Fig 31 Third Stage Piston Assembly (2-28-523) (2-28-523) .............. ....... ............... ............... .............. .............. .............. .............. ......... ..129 129 Fig 32 Third stage Packing Box (PSB032-060) (PSB032-060) .............. ....... .............. .............. ............... ............... .............. .............. .......... ... 130 Fig 33 Third Stage Suction Valve Assembly (2-70-236) (2-70-236) .............. ....... ............... ............... .............. .............. ........... .... 131 Fig 34 Third Stage Delivery Valve Assembly (2-70-237) ............... ........ .............. .............. .............. .............. .......... ... 132 Fig 35 First Stage Stage Interstage Interstage Pipework Pipework Assembly Assembly (2-71-780) (2-71-780) .............. ....... .............. .............. .............. ........... .... 134 Fig 36 Second Stage Intercooler Assembly (2-71-781) (2-71-781) .............. ....... .............. .............. ............... ............... ............ ..... 136 Fig 37 Cooling Water Assembly (2-45-2515)................................................................138 Fig 38 Pressure Pressure Gauge Assembly (2-46-1250) (2-46-1250) .............. ....... .............. .............. ............... ............... .............. .............. .......... ... 141 Fig 39 Unloade Unloaderr Assembly Assembly (2-68-642) (2-68-642) ..................................... .........................................................................144 ....................................144 Fig 40 Ancillar Ancillaries ies (2-150-05 (2-150-055)................................................................ 5)......................................................................................145 ......................145

APPENDICES Appendix 1 Appendix 2 Appendix 3

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Safe W orking Limits Warranty Authorisation A uthorisation Claim Form Compressor Log Sheet


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CHAPTER 1 TECHNICAL DATA & COMPRESSOR DESCRIPTION

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CHAPTER 1 - TECHNICAL DATA & COMPRESSOR DESCRIPTION

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TECHNICAL DATA & COMPRESSOR DESCRIPTION DESCRIPTION The information contained in this section is intended for the use of the engineer responsible for the operation and maintenance of the plant. It is essential that any necessary adjustments, servicing or overhaul work should be carried out by competent persons who are familiar with the installation, operation and maintenance of this product and who have the appropriate authorisation. When communicating with the Gardner Denver Belliss & Morcom on Morcom on matters relating to the compressor always quote the compressor type and serial number (e.g.WH40H3N (e.g.WH40H3N Serial No. 8759). 8759 ). This manual is written using SI Units of measurement. The three basic units used herein are: the metre, the kilogram and the second. All measurements in this manual are expressed using these units unless otherwise stated. Standards and Legislation The compressor is manufactured in accordance with the European Economic Community Directive: BS EN 1012-1: 1997 , and is tested in accordance with British Standard: BS 1571 Parts 1 and 2 .

1.1

Technical Data

1.1.1 Operating Data Normal Operating Conditions Instrument Instrument

Pressure Gauge Range

Pressure Range (Normal Operation)

Air Deliv ery - 1st stage

0 - 7 Bar G

2.3 - 2.9 Bar G

Air Deliv ery - 2nd stage

0 - 30 Bar G

11.8 - 13.2 Bar G

Air Deliv ery - 3rd stage

0 - 76 Bar G

45.0 Bar G

Oil Pressure **

0 - 10 Bar G

3 - 4.8 Bar G

**Oil pressure will fluctuate with ambient conditions, compressor loading and with the type and viscosity of the oil being used. Also; oil pressure peaks during start-up before settling back as the oil achieves its operating temperature. This machine is fitted f itted with over-temperature monitoring safety switches for f inal air from both the third stage cylinder and the aftercooler. Details of the settings for these devices are given in Section 1.1.2 Compressor Data. Data.

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Flows and Capacities Cooling Water Flow**

36 m3/h (nominal) 24 m3/h (min)

Pressure

7 Bar G (max) 4 Bar G (min)

Temperature Inlet

** The cooling water flows are design estimates and may need to be adjusted at site to meet the exact cooling requirements. It is recommended that the compressor is monitored during its initial running period and that a record is kept of the flows and temperatures for future reference.

38 ºC. (max) 16 ºC. (min)

Compressed Air Data

Crankcase Data

Gas being compressed compressed

AIR

Oil Sump Capacity

Delivery Pressure

45.0 Bar G

Air Capacity

2220 m3/h

Inlet Temperature

0-45 ºC

Relative Humidity

0 - 100%

91 litres

1.1.2 Compressor Data Installation Data Instrument Air:

Component Weights

Normal Operating Range

7 bar g minimum

Compressor Compressor W eight

9000 kg. (without motor).

Maximum Pressure Pressure

10 bar g

Service/ Maintenance Lift

1000 kg

Vibration: Vibration on the compressor may exceed 2.5 mm/s 2, but there is no bodily contact with the operator. Mechanical Data Cylinder Data

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Bumping Clearance (On All Cylinders)

1st Stage Cylinder Bore

515.00 mm

Piston Top to Top Cover

2.8 - 3.1 mm

2nd Stage Cylinder Bore

287.75 mm

Piston Bottom to Cylinder

1.2 - 1.8 mm

3rd Stage Cylinder Bore

165.10 mm

Piston Stroke

165.10 mm


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Piston/Piston Ring Data: Figures quoted below for new parts. The upper and lower limits arise due to accumulated effect of manufacturing tolerances. All butt gaps are measured with the piston ring in the cylinder. Diametrical Clearance of Piston Body in Cylinder Bore: 1st Stage

4.65 - 4.81mm

2nd Stage

3.37 - 3.55mm

3rd Stage

3.25 - 3.45mm

First Stage Piston Rings Radial Thickness Thick ness Axial Clearance in Groove Gap at Butt Joint

First Stage Bearer Ring

18.67 - 18.92 mm 0.27 - 0.32mm 11.21 - 13.31mm

Radial Thickness Thic kness Axial Clearance in Groove Gap at Joint Diametrical Clearance in Cylinder Standout from Piston Body

Second Stage Piston Rings Radial Thickness Thick ness Axial Clearance in Groove Gap at Butt Joint

0.50 - 0.55mm 15.73 - 18.82mm 1.66 - 2.10mm 1.31 - 1.55mm

Second Stage Bearer Ring

15.21 - 15.39mm 0.27 - 0.32mm 8.00 - 8.50mm

Radial Thickness Thic kness

9.15 - 9.25mm

Axial Clearance in Groove Gap at Joint

0.38 - 0.43mm

Diametrical Clearance in Cylinder Standout from Piston Body

Third Stage Piston Rings

8.00 - 8.50mm 0.55 - 0.80mm 1.31 - 1.41mm

Third Stage Bearer Ring

Radial Thickness Thick ness

9.47 - 9.58mm

Radial Thickness Thic kness

9.27 - 9.37mm

Axial Clearance in Groove Gap at Butt Joint (Each Gap)

0.21 - 0.36mm

Axial Clearance in Groove Gap at Joint

0.71 - 0.91mm

3.86 - 4.88mm

Diametrical Clearance in Cylinder Standout from Piston Body

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11.53 - 11.67mm


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6.35 - 7.11mm

0.57 - 0.89mm 0.21 - 1.42mm



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Crankcase Components Clearances The clearances for new components given are between the limits indicated - the upper and lower limits arise due to accumulated effect of manufacturing tolerances. The corresponding maximum figure is the point where renewal of the component is required. No maximum figure is given against parts which, are not expected to wear to any significant extent in service. Part

New

Max

Crankshaft Bearings (radial clearance)

0.06 - 0.11mm

Connecting Rod Bottom End Bearing

0.10 - 0.15mm

0.20mm

Connecting Rod Top End Bearing

0.10 - 0.07mm

0.15mm

Crosshead to Main Guide Slide

0.22 - 0.30mm

0.38mm

Compressor Compressor Performance Data Speed Direction of Rotation

735 rpm Clockwise: looking on flywheel

Compressor Absorbed Power Drive Type

365 kW Direct drive shaftless motor

Heat radiated (at full load) Cylinder Type Load Control System

365 kW (approx) Double acting non lubricated 3 Step (Full-load or Half-load or No-load).

Safety Device Data Pressure Relief Valve Data: Safety relief valve settings: st 1 Stage nd 2 Stage rd 3 Stage Lubricating oil pump relief valv e setting

3.5 Bar G 15.0 Bar G 47.8 Bar G 5.5 Bar G

Setting of Protection Switches/Devices High air temperature (AST) High air temperature (Separator)

177 ºC (rising) 65 ºC (rising)**

Low lubricating oil pressure pressure Low cooling water flow

1.8 Bar G (falling) 65% of normal flow (falling) (falli ng)

** Switch is factory set to 65 ºC. for temperate (UK type) climates. The switch may be adjusted up to a maximum of 75 ºC. to suit tropical climates during or after installation. However, adjustments MUST only MUST only be performed by a competent, authorised person.

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Normal Settings for the Load Control System (40 Bar G Delivery) Pressure Switch 1 (PS1)

*40.0 Bar G. (unload trip) *38.0 Bar G. (reload trip) *39.0 Bar G. (unload trip) *37.0 Bar G. (reload trip)

Pressure Switch 2 (PS2)

Differential Pressure (between unload and reload trips): = *1.0 Bar G (minimum) The settings quoted above are typical and may be adjusted to suit site requirements during or after installation. However, the switch setting must not exceed the specified design operating pressure. Adjustments MUST only MUST only be performed by competent, authorised persons. Noise Data With compressor running at 735 rpm the following design figures are available: Sound Pressure Level

90 dBA at 1m

Sound Power Level

110 dBA (ref 2 x 10 Pa)

2

1.1.3 Tightening Torques (Dry Threads)

CAUTION! Over-tightening (over-torquing) of the fasteners can lead to damage to the fasteners and/or the components. Component

Thread Size

Torque Nm (Newton metres)

Bearing End Cover Flywheel End Cover

M20 M16

190 - 210 65 - 72

Oil Pump to End Cover Crankcase Access Covers Cover s

M8 M10

15 - 20 25 - 30

Scraper Gland Fasteners Flywheel Retaining Retaini ng

M12 M42

45 - 55 375 - 400

Distance Piece to Crankcase Cylinder to Distance Piece

M20 M24

190 -210 200 - 220

Distance Piece Access Cover

M6

10 - 15

Cylinder/Top Cover Valve Covers

M24 M20

330 - 364 128 - 140

1st Stage Suction/Delivery Valve Nut Inlet/Outlet Flange Packing Gland Fasteners

M20 M24 M24

178 - 215 330 - 364 200 - 220

CRANKCASE COMPONENTS:

DISTANCE PIECE COMPONENTS:

1ST STAGE ST AGE CYLINDER COMPONENTS: COMPONENTS:

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Component

Thread Size

Torque Nm (Newton metres)

Cylinder to Top Cover Valve Covers Inlet/Outlet Flange

M20 M20 M16

190 -210 128 - 140 98 -108

Packing Packi ng Gland Fasteners

M20

128 - 140

Cylinder to Top Cover Valve Covers Inlet/Outlet Flange

M24 M20 M24

330 - 364 128 - 140 330 - 364

Packing Packi ng Gland Fasteners

M20

128 - 140

2ND STAGE CYLINDER COMPONENTS: COMPONENTS:

3RD STAGE CYLINDER COMPONENTS: COMPONENTS:

MOTION WORK COMPONENTS: 5

Crosshead Nut to Crosshead Piston Nut to Piston

1/ /8” BSF 5 1/ /8” BSF

950 - 1050 950 - 1050

1.1.4 Materials of Construction Crankcase & bearing bearing end cover, m ain guides (for crossheads), crossheads), distance pieces, cylinders & cylinder top covers v alve cages and covers, packing gland containers Crankshaft Crankshaft Crankshaft Crankshaft Main Bearings Connecting Rods & Crossheads Connecting Rod End Bearing

Top Bottom

Crosshead Gudgeon Pin Piston Rod

S.G. Iron - Gr 420/12, BS2789 Steel (spherical roller) S.G. Iron - Gr 600/3, BS2789 Lead-Bronze Lead-Copper on Steel Shells Case Hardened Steel

Oil Scraper Gland Rings/Springs Packing Gland Rings/Springs

Carbon Steel - 605M36T, BS970 surface hardness 485 Brinell Stainless Steel PTFE/Stainless Steel

Packing Boxes

Stainless Steel

Piston

st

1 stage nd 2 stage rd 3 stage

Piston Rings: Valve Seats and Guards, Valve Plate, Damper Plates, Lift Washers, Springs and Bolts Fixed tubeplates Intercoolers & aftercoolers

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Cast Iron - Gr 250, BS1452


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Aluminium - LM16TF, BS1490 Cast Iron Gr 250, BS1452 Cast Iron Gr 250, BS1452 PTFE Carbon Steel Zinc Plated Stainless Steel Carbon Steel with copper tubes + bonded inserts


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Technical Description of the Compressor

1.2.1 Purpose of the Equipment The compressor provides a constant supply of compressed air, at a regulated pressure and of a known volume. The compressed air can then be used as part of an industrial process. 1.2.2 Compressor Identification All Gardner Denver Belliss & Morcom Morcom compressors have a rating plate located on the crankcase. The information stamped onto this plate identifies the compressor type, capacity and serial number. The compressor designation indicates the following: W H 40 H3 N

-

Denotes cylinder configuration Denotes multi-stage compression Denotes normal capacity Denotes high pressure three stage Denotes oil free cylinder operation

External View of WH40H3N PET Compressor

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1.2.3 Compressor Operation The compressor operates by drawing air from atmosphere via an efficient air filter and silencer system into the 1 st stage cylinder where it is compressed to approximately 3 Bar G. The heat generated by compressing the air is dissipated in the water-cooled intercooler, positioned after the 1 st stage cylinder. The cooled air then flows through the 2nd stage suction separator, which removes any moisture condensed during cooling. The air then passes to the 2 nd stage cylinder where the air is further compressed to approximately 11 Bar G. The heat generated by compressing the air is dissipated in a water-cooled intercooler, positioned after the 2 nd stage cylinder. The cooled air then flows through the 3 rd stage suction separator, which removes any moisture condensed during cooling. The air then passes to the 3 rd stage cylinder where the air is further compressed to its final delivery pressure of 45 Bar G (max). The heat from compression is dissipated in the water-cooled aftercooler positioned after the 3 rd stage cylinder. The cooled air then flows through the final delivery separator, which removes any moisture condensed during cooling. The compressed cool dry air is then discharged into the delivery pipework. 1.2.4 Crankcase and Lower Motion Work Crankcase The crankcase is a heavily-ribbed iron casting with integral mounting feet and cylinder mounting flanges. Also integral within the crankcase are housings for the two crankshaft drive-end bearings. There are machined faces for the flange mounted motor, bearing end cover, crankcase and main guide doors. The bolt-on bearing end cover incorporates the housing for the third crankshaft bearing. The crankcase forms the lubricating oil sump, and is complete with tapped holes for the oil level window nut, the oil pump suction feed pipe, the crankcase drain plug and the oil cooler. Oil retention in the crankcase is made possible by a lip seal fitted at the drive-end of the crankshaft and by scraper rings fitted around the piston rods. Immediately beneath the drive-end crankshaft seal housing is an integral oil return passage. The single throw, cast high-tensile iron, crankshaft has integral design counterbalanced weights. The standard throw is 82.55 mm, giving a piston stroke of 165.10 mm. The crankshaft is supported by three self-aligning, double-race spherical roller bearings, two at the driving end and one at the oil-pump end. Endwise location is by clamping the outer drive-end main bearing (in the oil seal holding cover) against a machined shoulder in the crankcase. The driving end has a tapered shaft which is keyed to accommodate the rotor of a direct mounted motor. The oil pump end of the crankshaft has internal oil passages to the crankpin. Oil Pump The gear type oil pump is mounted on the crankshaft bearing end cover and is driven via a coupling off the non-drive end of the crankshaft. Oil is drawn by the pump from the crankcase sump through a wire mesh strainer and external pipe. The oil is delivered through a full-flow fine-mesh cartridge filter to the oil ways in the crankshaft. Any excess oil output is by-passed back to the sump by a spring-loaded pressure relief valve mounted on the crankcase main bearing housing. All the bearing surfaces surf aces in the crankcase are lubricated by the oil passing through the bore of the crankshaft and connecting rods. The main roller bearings are splash lubed by the oil from the crosshead, and also by the general oil mist in the crankcase.

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Connecting Rods The connecting rods have detachable bottom end caps to facilitate removal of the rods and rods have split-shell bottom end bearings and bush type top end bearings. The bottom end bearing shells are steel backed copper-lead, lead-tin plated. The pressedin top end bushes are lead bronze. An oil passage connects the top and bottom bearings allowing oil under pressure pressure (from the oil pump via passages in the crankshaft) to lubricate both. Oil is sprayed, from an annular groove around the top end bush and through two small holes, onto both slides of the crosshead guide. Crossheads The crossheads run in the main guides which are bolted to the cylinder mounting flanges of the crankcase. The crossheads are attached to the top of the connecting rods by gudgeon pins (which are retained themselves by circlips). The top face of the crosshead is drilled and tapped for reception of the piston rod. The piston rod is retained by a securing pin which passes through the side of the crosshead into the slot in the end of the piston rod. The piston rod is then clamped by a nut, which is tightened down against the top of the crosshead. The securing pin is prevented from coming loose by a retaining plate.

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1.2.5 Cylinders, Pistons and Piston Rod Packings Cylinders The double-jacketed cylinders are cast complete with mounting base, lower valve chambers and housing for piston rod packing assembly. They have machined faces for the top cover; lower mating flange, valve covers, distance rings and valves, and air and water inlets and outlets. The inner jacket of the cylinder is for the cooling water, the outer jacket is divided into suction and delivery air chambers. The cylinder top covers are cast with integral valve chambers, cooling water passages and suction and delivery air chambers. They have machined faces for the cylinder joint, valve covers, distance rings and valves. The cylinders are non-lubricated, the piston rings being made of low friction material, and are spaced off the crankcase by distance pieces containing oil scraper packings. These prevent oil from the crankcase sump getting into the cylinders. Cooling is provided by passing water first through the compressor intercoolers, and then, via a series of pipes, around the compressor cylinder water jackets and cylinder top covers. Pistons and Rings The 1st & 2nd stage pistons are of a two-piece hollow construction with the 3 rd stage piston being of solid construction. Each piston is machined with piston-ring grooves with the centre body of each piston drilled and recessed to take the piston rod. Piston Rods and Packings The piston rods are threaded at both ends. The piston rod bottom end has a cruciform slot to accommodate a securing pin (to prevent rotation of the rod in the crosshead) and is held in the crosshead by a locknut. The top end of the rod is shouldered and waisted inside the piston. A self-locking nut secures the piston to the rod. The piston/cylinder end clearances at the top and bottom are governed by the distance the piston rod is screwed into the crosshead. The oil-free cylinder compressor has separate packing gland assemblies. The packing comprises multiple pairs of PTFE rings, each pair of rings being housed in a container and held against the piston rod by a garter spring. The containers are assembled to a base by long studs and nuts, and the assembly held in its housing in the base of the cylinder by studs and nuts. A soft iron ring is recessed into the top surface of the upper container to prevent air leakage around the packing. The separate scraper assembly is housed in the crosshead-guide loose plate and comprises a number of segmented rings in a split casing, each ring is held in contact with the piston rod by a garter spring. An oil shedder is also fitted to the piston rod between the packing and the scraper assemblies to prevent any oil-creep along the rod.

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1.2.6 Valves Suction and delivery valves are similar in construction but differ in detail. Care must always be taken when servicing the compressor to ensure that the correct valve is fitted into the correct valve chamber. All suction valves are controlled by plate depressors (or (or unloaders), their location being identified by the presence of actuators on the valve covers. The actuators have small bore instrument air pipes connected to them. To unload a working compressor. the suction valves are rendered inoperative by the valve plates being pressed off their seats. This is accomplished by plate depressors (unloaders) being operated by load control actuators. A plate depressor is basically basically an inverted cup-shaped body with fingers protruding from its rim, assembled with a spring-loaded central guide surmounted by a cylindrical cap. The fingers operate through slots in the suction valve seat directly onto the valve plate. In action the plate is depressed, against its spring, by the pneumatically operated actuator. Compressed air fed to the load control actuator, by the load control solenoid valve, acts on a multi-layer diaphragm, which is sandwiched between the two halves of the actuator body. The diaphragm is in contact with the head of the spring loaded plunger immediately under the disk. The plunger, guided in the lower half of the actuator body, has its stem end in contact with the cap of the plate depressors. When the control air is exhausted by the th e solenoid valve, springs return the plunger away from the valve plate. 1.2.7 Motor and Couplings The compressor can be supplied with a flange-mounted motor, or as a bare-shaft machine. The standard motor is a brush-less cage rotor type, with a power output suited to the delivery requirements of the compressor. The motor's rotor is keyed directly onto the crankshaft and the stator casing is bolted to the crankcase. 1.2.8 Control Panel and Controls The compressor can be supplied with or without a starter system. The standard starter system is housed in a two-compartment dust and damp proof wall or floor mounted sheet steel cubicle. The control panel is an integral part of the front of the cubicle and the controls and gauges are divided between the upper and lower compartments. (For full details of the controls their operation and functions refer to the supplementary information provided with your compressor).

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1.2.9 Safety Equipment and Systems There are several safety features fitted to Gardner Denver Belliss & Morcom compressors as standard, with additional features available as options. The following are standard fitments: a.

low lubricating oil pressure indicator and alarm

b.

high delivery air temperature indicator and alarm - compressor

C.

low cooling water flow indicator and alarm

d.

high outlet air temperature indicator and alarm - aftercooler

e.

pressure relief valves after each of the cylinders

f. pressure relief valve after the oil pump Faults 'a' to 'd' (if supplied with a standard control panel) are indicated on the annunciator panel, which is integral with the main control panel. The fault results in the simultaneous alarm signal on the panel and shutdown of the compressor. The fault protection equipment is interlocked with the starter. Fault 'e' results in the release of pressurised air to atmosphere by the relief valve immediately after the over pressured cylinder. During normal operation 'f' bypasses excess oil back to the crankcase sump. For full details of the system and its operation refer to the supplementary information supplied with your compressor.

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CHAPTER 2 SAFETY INFORMATION

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SAFETY INFORMATION Safety Policy The compressor and its associated equipment are to be operated in accordance with current Statutory Health & Safety Policies (and any such regulation applicable in the country of installation). It is the responsibility of the operative to familiarise him/her self with these policies/regulations. Any work practices that may pose a potential health and safety hazard or any faulty/suspect equipment associated with the safe operation or maintenance of the compressor package must be brought to the immediate attention of the supervisor or supervising authority. Always wear appropriate safety equipment when operating or maintaining this equipment. Personnel safety equipment to include but not limited to:    

Ear Defenders Safety Glasses. Industrial Boots. Appropriate Hand Protection (gloves and/or ba rrier cream). Any other safety saf ety item identified under Risk or COSH Assessments.

Loose fitting or frayed/ripped clothing MUST NOT NOT be worn while operating or maintaining this equipment. 2.1.1 Commonplace Hazards If a hazard is identified that is not identified within the Operating Authority 'Standing Safety Instructions' a separate Risk Assessment must must be made. Similarly If a hazard in the form of a Control Of Substances Hazardous to Health (COSHH) is identified, steps must be taken to assess the risk of injury to staff. The compressor and its associated equipment are to be operated in accordance with current statutory Health & Safety at Work policies. It is the responsibility of the operative to familiarise him/herself with these policies. Any work practices that may pose a potential health and safety hazard or any faulty/suspect equipment associated with the safe operation and maintenance of the compressor must be brought to the attention of the supervisor or supervising authority. 2.1.2 Proper Use The compressor is built to stringent manufacturing guidelines to guarantee safe operation. However, using compressed air can be linked to dangerous occurrences if compressed air is not properly handled. Proper use also includes the following: 

  



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Follow the guideline laid down within this instruction manual, observing all pertinent regulations and notes for the compressor. Maintaining the equipment at the mandatory inspection and maintenance intervals. Correct repair of the compressor equipment. The compressor MUST NOT be operated in any other manner than that for which it was originally designed. Operating in accordance with the relevant environmental and operating regulations.


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2.1.3 Organisational Measures It is the customer’s responsibility to ensure that the operating manual is adequately supplemented with internal regulations regarding supervision and notification duties, work organisation, and personnel qualification etc. No modifications may be carried out on the compressor or its peripheral devices without the written consent of Gardner Denver Belliss & Morcom. Morcom. Unauthorised Modification of the equipment will invalidate the WARRANTY. WARRANTY. When renewing compressor components use only original spare parts and accessories supplied by Gardner Denver Belliss & Morcom. Morcom. 2.1.4 General Safety Precautions for Compressors Electrical System - Before performing work on the electrical system the compressor and the peripheral devices must be isolated form the mains and secured against switching on accidentally. Work on the electrical system must only be carried out by qualified staff who are aware of the risk involved with the task. Pressure Relief Valves - These MUST be Full Compressor Capacity Capacity relief valves connected directly to the flow pipework to relieve any excess pressure that may buildup between the cylinder discharge flange and in line equipment (e.g., stop valve, nonreturn valve, cooler, etc).

WARNING! It is forbidden to operate the compressor unless all relief valves are correctly fitted, in fully operational condition and are set at the correct relief pressure for the compressor compressor duty. There must be no restriction of any kind between the relief valve position and the preceding cylinder. Relief valves must be directly mounted with no isolating valves interposed between the relief valve and the pressure sensing point. The exhaust from the relief valves must only discharge into designated safe areas. The setting of relief valves must be checked regularly as required by statutory codes and regulations. Pressure vessels must be fitted with a full capacity pressure relief valve. Vessels must not be operated above their stated operation rating and must be checked regularly as required by codes and regulations. Protection Equipment - All All protection, control switches and circuits must be regularly checked for correct operation. Switches can be tested by checking in calibration rigs, or by carefully controlled simulation of fault conditions at the actual machine. Circuits can be checked by mechanically operating the switches. Frost Protection - Where, due to its location, the compressor could be exposed to frost, then adequate precautions must be taken to prevent freezing of the water system. Guards - All - All guards and covers must be in position and secure be fore start-up.

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Operating Records - It is IMPORTANT IMPORTANT that a regular log sheet be kept for the compressor recording operating pressures, temperatures and oil pressure (a copy of a Log Sheet is provided within the Appendices located at the end of this manual). Variances from normal running performance should be brought to the immediate attention of the Supervisor responsible for consideration and action. Lifting Equipment - Before using any lifting equipment, it is IMPORTANT IMPORTANT that the crane, gantry, hoist or chain block and any slings employed must be certified capable of lifting the weight of the compressor (or motor/compressor assembly). Any such lifting lifting equipment MUST MUST have a current CITB Test Certificate (or an equivalent certificate applicable to the country of installation). 2.1.5 Installation, Commissioning and Operation In all matters of safety regarding the Installation, Commissioning and Operation of the compressor or package, the reader's attention is directed to the full implementation of the requirements of the Health & Safety at Work Act (and any such regulation applicable in the country of installation). Gardner Denver Belliss & Morcom may Morcom may be consulted should any doubt exist regarding matters of safety related to their product. 2.1.6 Maintenance In addition to the General Safety Precautions, the following safety precautions MUST be observed when maintaining your machine. 1)

Before commencing commencing any maintenance work on the compressor or its driving unit or any ancillary, the driving unit must be rendered incapable of being started whilst maintenance and adjustment work is in progress. In the case of an electric motor for example, the machine must be isolated from the main electricity supply, the isolator locked off and/or the fuses withdrawn. This is particularly important with auto start/stop machines where the machine could be started automatically.

2) 3) 4)

5) 6)

7)

8) 9) 10)

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Affix "NOT TO BE USED" boards USED" boards to the compressor and control cabinet. Isolate the compressor from the discharge main and the instrument air. Before opening up the machine, all pressurised pressurised compartments compartments MUST MUST be depressurised down to atmospheric pressure in a safe and controlled manner. Isolate the compressor from the cooling water supply and drain all relevant water containing compartments. If the compressor motion work or rotational parts parts are are to be worked on then piston rod clamps MUST MUST be fitted to prevent accidental movement. Also chocking the crankshaft should be considered where necessary. ALL ALL lifting equipment MUST MUST be correctly rated for the loads being applied and MUST be MUST be certified as being in good working condition. Always ensure that when lifting equipment is used, only specified lifting or slinging points are used. Always refer to the applicable procedure when undertaking maintenance and overhaul procedures. Bolts and nuts must not be under or over tightened, see appropriate torque values in Chapter 1 Section 1.1.3. 1.1.3. Ensure that ALL tools ALL tools and spare parts are accounted for after reassembly, since any items left on or within the compressor may cause serious damage upon restarting.


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DO NOT place the electrical isolating switch to the 'ON' position until your supervisor has inspected and approved the work carried out. Before starting the compressor, bar over the machine by hand where possible to ensure free rotation and that no metallic 'knocking' noise is evident.

CAUTION! Particular care must be taken with compressor valves to ensure that suction valves and associated securing and actuating components are not fitted in delivery valve pockets or vice-versa. Failure to do so could result in severe damage to the compressor.

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CHAPTER 3 INSTALLATION & COMMISSIONING

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3

INSTALLATION & COMMISSIONING COMMISSIONING

3.1

Safety Precautions Before carrying out any work related to this Section, it is a requirement that you read and work in accordance with, the Safety Saf ety Precautions given in Chapter 2 of of this manual. For your own protection, be sure to read and obey the WARNING WARNING and CAUTION notices you find in this Section and any associated literature.

WARNING! 1) If the compressor compressor is to be supported on anti-vibration anti-vibration mountings, mountings, air, water and electrical services are to be made with non-rigid (flexible) connections. 2) Due to possible electrical insulation effects of pipe gasket

material and anti-vibration mountings, the machine must be provided with a permanent earth continuity connection of a nonrigid (flexible) type, which should comply with local regulations and safety requirements. requirements.

3.2

Installation Requirements The installation of the compressor, and its associated pipework, should be the subject of careful consideration before undertaking the actual task. This section of the manual provides the necessary information for the installation engineer to locate and to install the compressor to the best advantage.

3.2.1 Location The compressor should be located in a clean, well-lit, well-ventilated area with ample space all around it to facilitate inspection and maintenance. Sufficient room must be allowed for the removal of pistons and cylinders, crankshaft and motor, and as the compressor and many of its components are heavy, there must be headroom sufficient to permit the operation of a crane or hoist, which must be certified capable of lifting safely the weight. Statutory regulations and local by-laws governing the operation of heavy machinery must be complied with, this may have some influence on the choice of location. 3.2.2 Ventilation Approximately 10% of the energy consumed by a compressor is lost as heat. This is the heat generated by the motor, the mechanical losses of the compressor and straight-forward heat radiation from the air manifolds. For example, a 365kW water-cooled compressor would require some 486 m 3/min of ambient air circulation to limit the compressor room temperature rise to 6ºC. Natural convection is normally adequate with the outlet vents at a high level to prevent the temperature building down from the roof.

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3.2.3 Foundations For vibration isolator mounted compressors, all that is required is a floor of sufficient strength to carry the weight of the compressor, motor and ancillaries. For solidly mounted compressors the foundation dimensions must be determined for each installation, consideration being given to the nature of the subsoil and local surroundings.

WARNING! The floor must be level and flat .

Foundation depth must be such that the subsoil reached is, in the opinion of an expert, capable of taking the load of the working compressor and preventing the transmission of vibration. Unless the foundation rests on bed-rock or hard-pan, a sub-footing should be made of such a size and design as to provide a solid bottom. In extreme cases of poor subsoil, piling may be required, and in such circumstances a competent foundation engineer should be consulted. If the compressor is to be mounted on a metal floor, it can be either bolted direct to the floor, or beam or skid mounted. The beams or skids may be bolted or welded to the floor, with due consideration being given to structural vibrations and floor strength. A foundation foundat ion plan (for good subsoil conditions) is furnished in advance of the shipment of the compressor, and the foundation used must not be less than given in the plan. When installing a solidly mounted compressor, it must be ensured that the crankcase feet are ALL ALL flat down and fully supported BEFORE BEFORE tightening the "Holding Down" fasteners. A detailed foundation drawing is available (on request) from Gardner Denver Belliss & Morcom. Morcom. 3.2.4 Pipework Installation These paragraphs give recommendations with regard to both suction and delivery pipework and will help the plant engineer plan the best possible installation. Pipes must not be fixed inflexibly such that heavy thrust can act back onto the compressor otherwise serious damage could result, examine carefully the anchoring point locations and pipework support arrangements.

WARNING! All inlet and outlet connections to compressors mounted on vibration isolators MUST use suitable flexible pipes. All flexible pipes MUST be installed installed in accordance with the manufacturer's instructions. Inlet System An efficient air intake filtration system is essential to ensure that debris is removed from the air flow to the compressor thereby prolonging the life of the machine. Standard Gardner Denver Belliss & Morcom Morcom practice is to fit a machine mounted, combined filter/silencer, however, in hot or dirty locations, or in the presence of difficult combinations (e.g. fumes, alumina or cement dust), filtration may be improved by mounted the intake remotely and ducting the air to the compressor. Special filter/silencer arrangements are available for this type of installation. Only dry type filters must be used with oil-free compressors. Noise regulations should be taken into account when deciding silencer requirements and locations.

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Delivery System The flexible delivery pipe connects the aftercooler to the receiver (where fitted). It must be of the correct specification for the pressure and temperature and nature of the medium being compressed, and not smaller than the size specified below.

'X' and 'Y' dimensions for standard units are usually identical but these can be unequal to suit specific installations.  





Whatever dimensions apply at x and y, this instruction remains totally applicable. For new pipes, x and y are maintained by the presence of "Tie-Bars" to ensure correct installation. Once installed, the Tie-Bars Tie-Bars must be removed before the machine is operated. Hose must be mounted in the position shown above, where one leg is completely horizontal and the other completely vertical and fully supported at its connection: no other position is allowable. When fitted statically, hose must be free of all imposed stresses such as 'torsional', 'distortional', 'compressive', 'tensional' etc. MOVEMENT DURING RUNNING RUNNING (A)

During start-up only:

Frequency up to 12.5 Hz. 20 mm movement in any plane 0.5º about any axis

(B)

During normal running

Frequency up to 25 Hz. < 3 mm movement in any plane < 0.25º about any axis

The pipe must be well supported to avoid strain on the compressor cylinders, and it's configuration be such that any expansion effect, due to the air/gas temperature rise for whatever reason, can adequately be dissipated within the natural elasticity of the pipework leading from the compressor and cannot act back on the cylinder.

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At the junction with the receiver, or pipe main, a shut-off valve should be fitted to isolate the compressor as required. On automatic and multi-machine installations, non-return valves should also be fitted to isolate standby units from system pressure. A safety valve must be fitted, f itted, close to the compressor, in the delivery pipe. The valve must be fitted before any shut-off valve, non-return valve or aftercooler to prevent damage in the event of the compressor being run with the shut-off valve closed. The valve should be a spring-loaded type and of sufficient size to pass safely the maximum compressor output. A small blow-down blow-down valve should be fitted between the compressor and shut-off valve to relieve residual pressure when required for maintenance purposes. Air Receiver An air a ir receiver of ample capacity is required f or use with this equipment. The receiver should have a capacity equal to a one minute supply of compressed air (neglecting temperature rise). The air receivers should, ideally, be located in the coldest place possible, to ensure that as much condensate as possible is precipitated from the air in the receiver. This means that the receiver must be drained frequently, either by fitting an adequate drain or an automatic drain trap. To facilitate servicing of the drain trap whilst the receiver is in commission, a by-pass should also be incorporated. Distribution Piping (air systems) systems) Water Wat er collectors of an automatic discharge type should be fitted at suitable points in the pipe system. They should be fitted with three-way cocks (either in connection with the traps or separately) so that pipes may be blown through to disperse condensation. Delivery pipework must be arranged to prevent condensation running back from the aftercooler or receiver into the compressor cylinders. The pipe system for air distribution should be carefully considered if optimum results are to be obtained. Moisture-laden air can cause rusting in low-lying parts of the pipe system so, ideally, all distribution pipework should be internally galvanized and angled slightly towards the drain points. An effective effect ive way of eliminating possible water damage is to install a refrigerative air dryer or, for dryer air, an adsorption dryer.

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Load Control Piping Connect (with similar size piping) the load control system on the compressor to the control air take-off points on the compressor panel, the connections on the compressor will indicate the size. Connect (with similar size piping) the compressor panel control air inlet point to the compressed air/instrument air main - any isolating valve fitted here must be of the lockable-open type. Drain Valves & Drain Valve Piping It is important that the drain pipes from the water separator drain traps are run individually to open ends (e.g., over OPEN drains). They must NOT be NOT be piped together as there would then be a risk of "blow-back" along adjacent pipes in the event of a trap malfunctioning. Drain valves are fitted to the separators of each compression stage. These valves exhaust the collected moisture at high pressure and must be piped away to a safe area using solid pipework. MOST IMPORTANT - if - if the exhausts of any vent valves are piped away, it is essential that these have direct outlets to atmosphere, they must NOT NOT be connected into any other pipe. It is also recommended that a silencer is fitted to the exhaust in order to reduce noise levels. 3.2.5 Cooling Water An adequate source of clean, cool water for the compressor cylinders, intercoolers and aftercooler should be provided. Cooling water must be as free as possible from scale forming salts, with (if the water is not clean) an efficient filter(s) placed in the intake pipeline. A Duplex type arrangement is recommended as this will allow one filter to be cleaned whilst the other is in service. The temperature of the cooling water supply to the compressor (NOT aftercooler) should not be less than the ambient temperature. The methods of achieving this depend on the cooling system employed: The temperature of the cooling water supply should be in the range 20ºC to 35ºC In situations where the ambient temperature is in excess of 35ºC., advice should be sought from Gardner Denver Belliss & Morcom. Morcom. The pressure in the cooling water pipeline at the compressor must be sufficient to promote the flow required by the size and duty of the machine. This should take into consideration all the friction losses in the overall pipework and valves and across the heat exchanger units (as may be installed) as well as across the compressor. Except for compressors made to special customer requirements, water pressure in the jackets should not exceed 7 Bar B ar g.

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3.2.5 Cooling Water (Cont) It is recommended that thermometer pockets are fitted to the water inlet and outlet pipes to the compressor and, the aftercooler. Temperature differentials between these points will give a good indication of sufficient water flow, 10 to 12ºC being usual.

CAUTION! Failure of water flow is a cause of major damage and must be avoided. Ensure that cooling water pipes to and from the compressor are constructed to avoid the formation of air locks For compressors operating in cold environments, drain points are present on the cylinders to empty the water jackets of the machine (when out of service) to prevent damage in the case of frost. Open air vent cocks at the tops of the cylinders at the time of water drainage. Certain water pipe connections should afterwards be disconnected to completely drain the system.

CAUTION! Exposure to frost conditions will damage your machine unless the proper frost precautions are taken. If advice is required, please contact Gardner Denver Belliss & Morcom. Morcom. 3.2.6 Electric Cabling The electric cabling to the motor must be run such that small amounts of movement at the motor terminals can be safely absorbed within inherent flexibility of the type of cabling used. Check that the motor nameplate details agree with those of the electricity supply on which the motor is to be used. Connect motor in accordance with the instruction supplied. Use cables of adequate size to carry the full load current and also large enough to carry the starting current without excessive voltage drop. Ensure that the motor frame is properly earthed.

3.3

Handling and Unpacking

3.3.1 Stability Due consideration must be given to maintaining the compressor's stability during all lifting procedures. The compressor is only in a stable condition when standing on a suitable, level floor surface with all four crankcase feet firmly down. It MUST be MUST be noted that the Centre of Gravity (C of G) for f or each machine will change depending on whether the compressor is 'bare-shaft' or fitted with a 'drive unit'.

WARNING! The crane, gantry, hoist or chain block or any slings employed must be certified capable of lifting the weight of the compressor (or Motor/Compressor assembly).

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Compressor Slinging Diagram (Typical)

3.3.2 Slinging Instructions On all compressors two cradle slings are positioned, one under each of the two outer cylinder crankcase flanges. A third sling is used to balance the compressor. a. b. c.

In the case of a compressor fitted with with a flange mounted motor, a cradle sling is passed under the motor, taking care to keep it clear of the fan housing. In the case case of a bare shaft compressor, a sling is passed round the intercooler pipework. If the compressor is fitted with with a flywheel, a balancing sling is passed around the shaft.

WARNING! Under no circumstances use the motor lifting hole for balancing the weight (this lifting p oint is for the motor only when detached detached or detaching from the compressor).

Care MUST MUST be taken to ensure that no small bore pipes or other components being trapped by slings.

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3.3.3 Lifting Instructions Because the type of lifting equipment for each installation will be different the following instructions have been written with the intent of being a general guide rather than specific instructions. For compressor maintenance purposes a one tonne block is usually suitable to give good control of the lifting of components. 1.

Whatever What ever your equipment or conditions, good safety procedures must be practiced, i.e.: a) b)

Establish the actual weight of the load. Check whether the lift will will be a straight straight lift, lift, or will an angle rig be needed. These factors will affect the lifting capacity required.

c)

2. 3.

4. 5.

The slings slings must must be free of kinks, knots, broken strands or loose connections etc, and meet the regulation requirements. d) Check the clearance clearance available to make sure the lift can be attempted safely. e) To prevent damage to the machine's finish or the edges of the machine from cutting into the slings, use proper blocking and padding. Know your equipment, and anticipate potential hazards. When involved in the lifting of heavy loads, we suggest you protect yourself by wearing approved protective gear such as: safety helmets, steel toe cap safety shoes, gloves, eye protection, etc. Prepare the installation area before moving the machine. Refer to the machine installation drawings and note the location of the machine support points. Review all machine installation requirements carefully before positioning the machine.

3.3.4 Unpacking No special unpacking instructions can be given here as the compressors may be transported fully boxed, crated, or on open bases, depending on destination and mode of transportation. Boxed compressors have directions for lifting and opening on or with the boxes. Some of the cylinder valves will have been replaced with silica-gel bags. The displaced valves and the accessories are packed in a separate container, which should be located and safeguarded until after the installation of the compressor.

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Installation Procedure

3.4.1 Safety Precautions The following additional safety precautions should be observed before installing the compressor onto its foundation. Personnel must be a safe distance from the compressor during positioning, guide ropes may be used to assist, but not 'hands-on'. The compressor must be lowered slowly, in small stages with no sudden jerks whilst observing for any indications of potential problems. Once in position the compressor must be properly secured with suitable foundation bolts or anti-vibration mounts (AVM's). If the floor is to be drilled for foundation bolts, the compressor must be moved away whilst work proceeds. Each time the compressor is moved check for stability and correct sling placement. DO NOT apply NOT apply load tension to the slings if the compressor is held to the floor. 3.4.2 Mounting Arrangements - Anti-Vibration Mounts A flat and level floor of suf ficient strength to t o support the combined weight of the motor, compressor and ancillaries should be prepared in advance of the compressor delivery. The procedure should then be as follows: 1.

Ensure that the underfaces of the compressor feet are clean.

2. 3.

Bolt the anti-vibration mountings on to the compressor feet. Move the compressor into position and mark on the floor the position of the holding down bolt holes in the anti-vibration mounting plate. Remove the compressor and attached mounts and drill the floor for appropriate size holes for the Raw-bolt shells. Insert shells, reposition compressor and bolt onto floor by means of the mounting holding down bolts.

4. 5. OR:

The anti-vibration mountings may be held down by bolts or anchors of a similar diameter to the holes in the mounting plate. Use of these will eliminate the need to move the compressor to drill the floor holes. The appropriate instructions supplied with the bolts should be followed precisely. 6.

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Finally, check the bolts holding the compressor onto the anti-vibration mountings and use these bolts to finish levelling the compressor (See Levelling and Alignment).


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3.4.3 Levelling and Alignment - Flange Mounted Motors Compressors with flange mounted motors are completely assembled and lined-up before shipping, it is therefore only necessary to set the machine on the foundations and level it in both directions as follows: 1.

Adjust the pressure within the pneumatic AVM's around the machine until the desired level is achieved. Do not inflate AVM's unless the static weight of the compressor is placed on them.

2.

Ensure that the final levelled height of each mount is within the makers limits and that each mount is levelled until it carries its correct proportion of the overall machine weight. If any mount is compressed solid, levelling must be carried out on the free mounts to redistribute the load. Using a spirit level on any horizontal surface, check that the compressor is level in both planes (i.e. parallel to and at right angles to the crankshaft). If NOT, NOT, then adjust again until satisfied.

3. 4. 5.

3.5

Preparation for Commissioning

3.5.1 Cleaning the Compressor The compressor must be thoroughly cleaned before preparing for commissioning. Care should be taken when making connections to see that no grit or impurities of any kind are allowed to enter while the compressor is being piped up and prepared for work. 3.5.2 Preparing the Compressor After works testing, the compressor is prepared for shipment. Before use therefore, the t he compressor will require to be prepared for use as follows: 1. 2. 3. 4. 5. 6.

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Remove the 'mouldable' wrapping from around the piston rods and clean the rod surfaces. Remove control piping from cylinder valve covers marked with adhesive labels and remove the covers. Extract the silica gel bags from the valve chambers; ensuring that where more than one bag is present, ALL bags ALL bags are removed. Using a plastic or soft metal metal scraper, remove rust resistant paint from the seating in the valve chambers. Remove the valve assemblies from their wrappings. Fit components in their correct order, ensuring that suction and delivery valves are fitted in the correct valve chambers. Where plate lifters are fitted to suction valves, care must be taken to ensure correct assembly.


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7. 8. 9. 10.

11.

12. 13.

14.

15.

16. 17. 18 19. 20.

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Tighten the valve covers and refit the control air pipes Remove and store the adhesive labels and warning plates with the silica gel bags. Check that all gauges and small-bore pipework are undamaged, and are properly connected. Ensure that all external nuts and bolts on the compressor and its ancillary equipment are tight, including all holding down bolts and bolts of all pipework flanges and supports. Remove the crankcase access covers (and (and wooden blocks where fitted), and crosshead access aperture covers, and check to ensure that the interior of the crankcase is clean and free of foreign matter. Ensure free movement of compressor motion by turning the crankshaft round a number of times in the correct direction of rotation. Fill the oil sump (in (in the bottom of the crankcase) with the recommended grade of lubricant to level indicated by the window nut on the front of the crankcase. Initially fill to near the top of the window, the level will fall towards the bottom of the window when the compressor is started, rising to about half-way when the oil has reached its sustained running temperature. Wearing suitable (oil (oil resistant) resistant) protective gloves, liberally liberally coat clean oil onto all the main guide slides - turning the crank to different positions to achieve full face coverage (keep hands out of the crankcase when the shaft is being turned). As the compressor may have been in transit/storage transit/storage for some time, prime the suction side of the lubricating oil pump by disconnecting the suction pipe top fitting. Then using the recommended grade of lubricant pump oil 'in' to 'wet' the gears and fill partially the suction side of the pump body. This promotes a quick pick up of oil pressure on start up of the compressor. Refit the crankcase and crosshead access covers. Ensure that the compressor pressure instrument isolating cocks are open. Ensure that the pipes of the rubber filling plugs are removed to vent the gauge cases and allow correct gauge indication. Ensure that the pressure signal pipelines of the load control system are open (i.e., make certain that any isolating valves are fixed open). Fill slowly and carefully (to avoid trapping air) in the cooling water water spaces of the compressor - do not rush this operation. Open the air vent cocks, at the tops of the cylinder covers to rid the system syst em of trapped air. The operation is carried out in association with any other water-cooled ancillary items in the overall cooling water system of the installation.


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3.5.3 Preparing the Motor Check the driving motor insulation resistance (IR) using a 500 volt megohmeter taking note that the insulation resistance in mega-ohms, measured between any terminal and the frame with the machine cool, is infinity. If the windings have become damp and the insulation resistance is low, then the windings must be thoroughly dried out and re-tested for satisfactory condition before commissioning.

CAUTION! Before using the insulation tester disconnect the supply leads at the motor terminals so that only the motor windings are tested. This will avoid the possibility of the test instrument potential destroying any electronic equipment that may be in ancillary circuits. circuits . 3.5.4 Motor Rotation Check The compressor is designed to rotate in a clockwise direction when viewed from the drive end.

CAUTION! Running the compressor with incorrect rotation will result in serious damage. After checking it is safe to do so, switch on the electricity supply to the compressor control panel. Prepare the compressor for an 'unloaded' start and press the START button, as soon as the compressor starts press the STOP button. Check motor is rotating in the correct direction (indicated on motor end). In the event of wrong direction of rotation, isolate the machine immediately. A qualified electrician must rectify the problem before rechecking.

3.6

Commissioning the Compressor Before commissioning the compressor, read and fully understand Part 3 "Operation" and any associated literature regarding the control panel and any other ancillary equipment.

3.6.1 Trial Run When commissioning, the trial run must include certain vital checks, and these should be carried out as follows: 1. 2. 3. 4. 5.

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Ensure that the factory delivery mains and air using equipment are safe to pressurise - and all delivery isolating valves in the system are open. Ensure that the load control sensing pipework is open to the compressed air main. Ensure that the isolating cocks of all pressure gauges are open. Ensure that the by-pass valves situated at the drain traps are closed. Start compressor in the unloaded condition and allow to run up to full speed, observe oil pressure is quickly established (this will be high with a cold machine) and observe compressor running generally.


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After a 3 minute run, stop and electrically isolate the compressor. Remove the crankcase main doors and check the temperatures of the motion work bearings and guides. This should be done using a thermometer fitted with a suitable surface probe.

WARNING! Take care c are during examination, as some of the parts will have become heated. All should shou ld be cool except e xcept the bottom end bearings, which can be a little warmer than other bearings - also one side (the 'working face' side) of main guides may be slightly warmer than the opposite side. 7. 8. 9.

10.

Refit the crankcase main doors and reconnect the compressor. Run the compressor for a further 10 minutes and repeat checks as in step 6. When satisfied that all is in order, restart the compressor. When the compressor has settled on speed place the load control to the load condition whereupon the compressor will commence compressing. Observe compressor operation and the build up of pressure.

The load control must be set for no higher pressure than that for which the compressor is supplied. (See (See Section 1.1.1 Technical Data). Data). During the first commissioning run on load, make careful observation of the general operation of the compressor. Observe the compressor gauges, until the desired unloading set-point (as set on the load control pressure switches) is reached, at this point the compressor will unload automatically as described in Load Control System. Check that the loading/unloading sequence is in accordance with requirements - adjust the control as necessary. 3.6.2 Completion of Commissioning 1.

2.

3.

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Run the compressor until it attains operational temperature and check that the oil pressure settles at a satisfactory level, approx. 3.5 Bar or above; this will depend upon ambient temperature, oil viscosity at running temperature, and on-load/offload running pattern. After a settled period of running running (approx. 24 hours) check the tightness of all external bolts and nuts - particularly cylinder and valve cover fasteners, also compressor and compressor driver fixings - to complete the commissioning of the machine. During this run (on water-cooled machines) adjust the cooling water flow control valve to achieve the required temperature rise. When on sustained full load, the optimum temperature rise is about 10 o to 12o C.


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CHAPTER 4 OPERATING INSTRUCTIONS

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CHAPTER 4 - OPERATING OPE RATING INSTRUCTIONS

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OPERATING INSTRUCTIONS These instructions are designed to providing experienced operatives, who are fully conversant with compressor operating techniques, with operational information for the Gardner Denver Belliss & Morcom 'PET' range range compressors. Note: The Note: The following operating information assumes that the compressor is fitted with a standard Gardner Denver Belliss & Morcom control Morcom control system. However, if the control equipment is of different manufacture, the compressor MUST MUST be operated in accordance with the supplementary Operating Information supplied Information supplied with the control system. The compressor is designed and built for continuous running and will provide long term reliable operation if regular periodic checks and servicing are carried out in accordance with the information provided within Chapter 5 of of this Instruction Manual.

CAUTION! Prolonged unloaded running of the machine should be avoided not only because of power wastage, but unnecessary component wear can result. It is the customer's responsibility to: 1) 2) 3)

4.1

Maintain the inlet filter system and air blast cooler in a clean condition as dictated by site conditions. Ensure that the specified, clean clean lubricant is added to ensure the correct crankcase oil level is maintained Report promptly to Gardner Denver Belliss & Morcom Service Morcom Service Department any operating abnormalities faults defects or malfunctions of the compressor and/or associated ancillary equipment. Such reports must be forwarded in writing by facsimile transmission. Oral reporting shall be deemed to be acceptable if confirmed in writing in the following 48 hours.

Controls and Indicators

4.1.1 Starter System If supplied with your compressor, the standard Gardner Denver Belliss & Morcom starter control equipment consists of a two compartment panel enclosed in a dust and damp proof wall or floor mounted sheet steel cubicle, and suitable for use on various electrical supplies. The panel incorporates the following features: 1) 2) 3) 4)

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Automatic Star/Delta starter. Pushbutton operated Start and Stop, adjustable timers with overload protection. 'Unload/Manual/Auto' selector switch for operation mode selection. Transformer providing 110 volts a.c. and 24 volts d.c. for control and fault protection equipment.


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Four fault protection units giving alarm and shutdown on: 

Low lubricating oil pressure



High discharge air temperature - compressor

High outlet air temperature - aftercooler Low cooling water flow 'Test' pushbutton to check panel lamps. 'Reset' pushbutton to clear the alarm annunciators and make the compressor available for restarting. This ensures the compressor cannot be restarted except as a deliberate operator action (with selector in Unload or Manual only). Pressure switches and solenoid valves to give 3 step load control with automatic unloaded starting and stopping. A panel mounted mains mains isolator, interlocked with the start start circuit. circuit. 

6) 7) 8)

9) 10) 11) 12) 13)

Ammeter for motor drive current. 'Hours Run' meter. Automatic stop/start to give shutdown after 15 to 30 (adjustable) minutes unloaded running and restart on pressure demand.

Faults are indicated on annunciators with a single fault resulting in simultaneous alarm and shutdown. The fault protection equipment is interlocked with the starter to give automatic override of the oil pressure/low cooling water flow fault conditions during start sequence. The fault circuit is enabled after a short delay in the start cycle. For additional features, see the Operating Philosophy Document provided (where necessary). If a plc panel is supplied - please refer to separate instructions. instructions. 4.1.2 Load Control System Functions All of the suction suct ion valves in the compressor have actuators, which cause the valve plate plate to be held off its seat whenever a pneumatic signal is applied. When the plate is held open then the compression can take place. If all suction valves are held open then the compressor is 'OFF LOAD'. On removal of the pneumatic signal the plate returns to its seat and compression can then recommence. The unloader is pushed back by the valve plate springs and the unloader return spring. If only the upper set of suction valves are held open then the compressor is on 'HALF LOAD'. Three-Step Load Control means that the compressor is either on:FULL LOAD (compression LOAD (compression taking place) - all suction valves being in service or HALF LOAD (compression LOAD (compression taking place in bottom half of cylinder only) - lower set of suction valves only in service. or OFF LOAD (no LOAD (no compression taking place) - all suction valves being held open.

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A complete 'Full Load' to 'Half ' Half Load' to 'Off 'O ff Load' and return to ' Half Load' and 'Full Load' sequence occurs as follows:The Compressor is on FULL LOAD Assuming the compressor is running on Full Load and pressure in t he delivery main is rising (too much air is being supplied by the compressor for the reducing requirements of the end using equipment). When the pressure rises to the upper limit of pressure switch (PS2), PS2 will de-energise solenoid valve (SV2). This will then allow pneumatic signal to pass into the small-bore pipework interconnecting the upper set of suction valve actuators. This causes the upper set of suction valves to be held open and the compressor therefore runs on Half Load. The Compressor is now on HALF LOAD Assuming that pressure in the delivery main is still rising - when the pressure rises to the upper limit of pressure switch (PS1), PS1 will de-energise solenoid valve (SV1). This will then allow pneumatic signal to pass into the small-bore pipework interconnecting the lower set of suction valve actuator. This causes the lower set of suction valves to be held open and the vent valves to vent to atmosphere (blow down), thereby reducing the pressure within the compressor to atmospheric levels. The Compressor is now OFF LOAD Assuming the pressure in the main now begins to fall (as insuff icient air is being supplied to meet the demand), and the low air limit of PS1 is reached, then PS1 will energise SV1. This will then isolate the pneumatic signal to the lower set of suction valve actuators and the vent valves. The lower set of suction valves will re-seat, the vent valves close and the compressor returns to HALF LOAD operation. The Compressor is back on HALF LOAD Assuming the pressure in the main is still falling - when the pressure falls to the lower limit of PS2, then PS2 will energise SV2. This will then isolate the pneumatic signal to the upper set of suction valve actuators. The upper set of suction valves will re-seat and the compressor returns to FULL LOAD operation. The Compressor is back on FULL LOAD If at any point of the sequence the demand increases or decreases randomly, then the pressure switches react to maintain the compressor load function at the required level to meat the change demands. The set points of the pressure switches are given in Chapter 1 - Technical Data. Data.

4.2

Preparation for Starting Note: The Note: The following operating information assumes that the compressor is fitted with a standard Gardner Denver Belliss & Morcom control Morcom control system. However, if the control equipment is of different manufacture, the compressor MUST MUST be operated in accordance with the supplementary Operating Information supplied Information supplied with the control system.

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4.2.1 Before Operating the Machine (Pre-Start Checks) 1) 2)

3)

4) 5) 6) 7) 8) 9)

4.3

Establish that it is safe to discharge high-pressure air into the delivery lines. Ensure that all machine guards are correctly fitted to the machine and auxiliary equipment. It is IMPORTANT IMPORTANT that any loose, missing or damaged guards are correctly fitted before attempting to operating the compressor. Check that access ways around the machine are clear and free from tripping or slipping hazards. Remove any obstacles and neu tralise any fluid spillage such as oils or greases, using an absorbent material. Allow spillage to be absorbed for a short time before thoroughly cleaning the spillage area. Ensure that all of the fault warning, warning, annunciators are extinguished and that the compressor is safe to start. Check oil level in sump. Correct level is halfway up window nut in in front face of crankcase. If the machine has been standing idle for some some time it may be necessary to prime the oil pump. Ensure that the cooling water supply valve is open promoting water circulation through the compressor jackets, intercoolers, aftercooler and oil cooler. Ensure that the air pressure sensing pipeline from the air air main to the pressure switches and solenoid valves in the control panel is locked open. Ensure that the main air-isolating valve is OPEN. OPEN.

Starting the Compressor

4.3.1 Under Normal Conditions Step 1) Turn the main isolator to the 'ON' position position 2) Press the 'CONTROLS ON/RESET' illuminated pushbutton to reset the Safety Relay 3) Press the 'RESET' pushbutton to energise the fault monitoring relays FR1 to FR4. (press the 'RESET' push-button only with the selector in UNLOAD or MANUAL)

Supplementary Information Information The 'SUPPLY ON' lamp will illuminate. The hazard lamps will illuminate to indicate they are all operational. This removes the supply from the hazard lights whilst retaining their respective relays

Ensure that the 'TRIPPED' indicator is extinguished, if illuminated reset thermal overload (OL1) and/or thermistor t hermistor relay (THR1). 4) Select 'MANUAL' on the 'UNLOAD/ MANUAL/AUTO' selector switch 5) Press the 'START' pushbutton. pushbutton.

The Hours Run Meter will be energised as soon as the 'START' pushbutton is pressed.

When the 'START' pushbutton is pressed, the motor starter will energise by pulling in the Star (SC) contactor and the Main (MC) contactor. After a small delay, set by the timing relay (MCT1), (usually between 15 and 20 seconds) the Star contactor will deenergise and the Delta (DC) contactor will energise. When the delta contactor is energised the 'RUNNING' indicator lamp will be illuminated indicating that the motor is now running at full speed and the compressor is ready for use.

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The commissioning timer (CTD) will be energised when the start relay (SR1) is energised. The commissioning timer (CTD) should be set for approximately 15 seconds. After this time period has elapsed the time contacts change state and allow the fault circuit to check for low cooling water flow (LCWF) and low lubrication oil pressure (LLOP). If either eithe r of these items have failed to reach their working working levels during the start-up period, the compressor motor will trip and a fault will be indicated. 4.3.2 After An Emergency Stop Rectify fault condition and proceed from Step 2 of 4.3.1 Starting Compressor Under Normal Conditions.

4.4

Running

4.4.1 Running Checks 1.

4. 5.

Allow the compressor to run up to full speed and then close the small drain cocks. Check the oil pressure. This will fall initially as the oil oil temperature rises, but should steady at between 1.8 to 4.0 Bar G even in a hot environment. Check the cooling water is flowing at the visible outlet or flow indicator. On multicompressor installations balance the flows in the parallel systems of the compressors (including intercooler) to give equal water temperature rise across both - ideally 11ºC. Check all automatic drain traps for unusual discharge. Check all temperatures and pressures periodically.

6.

Check for undue noise, vibration or heat. If present, report immediately.

2. 3.

It is good practice to carry out these checks regularly and log the results. 4.4.2 Automatic Operation Before Automatic Operation is selected, the compressor must be prepared for starting as described in 4.2.1 Pre-Start Checks. Checks. Once the compressor is running, 'AUTO' may be selected using the 'UNLOAD/MANUAL/AUTO' selector switch. This will allow the compressor to automatically stop and start on the dictates of the Light Run Timer (LRT) which is usually set at between 15 and 30 minutes. If the compressor has not been on load during the preset period, the compressor will automatically shutdown. During the shutdown period an indicating lamp is illuminated to show that the compressor is on 'AUTO STANDBY'. When air is again required, the compressor will automatically start. 4.4.3 Faults/Hazards Should a fault develop, this will be detected by the appropriate sensing switch and this in turn will de-energise the appropriate fault relay (FR1 to FR4) and illuminate the appropriate fault indicator. This will automatically stop the motor via the motor starter. The compressor will be automatically unloaded via the CTD timer, which will be deenergised by the motor starter.

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Stopping the Compressor

4.5.1 Normal Stopping Step 1) Select the 'UNLOAD' position on the 'UNLOAD/MANUAL/AUTO' selector switch. The 'NO LOAD' indicator lamp will illuminate. 2) Press the 'STOP' pushbutton. 3) Close the main main isolating shut-off valve. 4) Open vent valves. 5) Close the cooling cooling water water supply valve.

Supplementary Information Information This ensures that the compressor is fully unloaded before stopping. This will allow moisture to be purged from the cylinders. The compressor will stop automatically in a controlled manner. To fully de-pressurise system To prevent unwanted circulation of water

The compressor can also be stopped with the 'UNLOAD/MANUAL /AUTO' selector in the 'AUTO or MANUAL' position. However, this leaves the compressor in a pressurised pressurised state and is not recommended. DO NOT attempt NOT attempt to restart the compressor until it has automatically de-pressurised via the automatic blow-down valves. 4.5.2 Emergency Stopping Pressing the 'EMERGENCY STOP' mushroom button stops the machine instantly in whatever mode of operation it is operating.

CAUTION! This is not recommended for routine stopping and stopping and should only be used in the case of an emergency where normal stopping is not possible or is impractical.

4.6. Fault Indications The following is a list of indications of possible faults which could arise in service; periodic surveillance of pressures and temperatures, etc, will establish the normally experienced levels applicable to the site and load conditions. Variation from these t hese due to a f ault arising may be slow to impinge - the early effect effe ct of a fault (with the robust reciprocating type machine) being, usually very gradual. It is IMPORTANT IMPORTANT therefore, to retain a simple daily record sheet of pressures and temperatures. Comparison with previous readings will then warn if there is an untoward trend arising - when reference to the following fault indication's list will indicate the probable cause and remedial action to ta ke. A copy of a t ypical log sheet is provided in the Appendices located at the end of this manual. The running performance of the compressor can also indicate when it is necessary to renew a particular part: Generally, wear or malfunction of valves or piston rings will be indicated by variations (other than those due to suction or delivery conditions) in the interstage or final delivery pressure and temperature. Progressive crankcase bearing wear will slowly give rise to a gradual lowering of the lube oil pressure; if low oil pressure does occur and cannot be traced to any other cause listed, then connecting rod bottom end bearings should be inspected.

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4.6.1 Fault Finding Minor variations in pressure and temperature readings may occur, due to possible small changes in the suction or delivery conditions. These f actors should be considered when checking and assessing instrument readings. Fault Low first stage delivery pressure pressure (normal or low first stage air delivery temperature).

Low first stage delivery pressure pressure (high first f irst stage air delivery temperature).

High first stage delivery pressure pressure (normal or high first stage delivery temperature.

High first stage air delivery temperature after cooler. First stage delivery pressure relief valve blowing.

Low second stage delivery pressure pressure (normal or l ow second second stage delivery temperature).

Possible Cause 1) Leaking or broken suction valv e plate in first stage.

Remedial Action Replace valve plate -examine seat for damage.

2) One or more 1st 1st stage suction valve depressor(s) sticking in "off-load" position. 1) Fouling of inlet filter. filt er.

Remove, clean and refit depressor(s) - examine valve for damage Renew filter filt er elements.

2) Leaking or broken delivery valve plate in first stage. 3) Worn, broken or malfunctioning piston rings in first stage. 1) Leaking or broken suction valv e plate in second stage. 2) Second stage suction valv e depressor depressor sticking in "of f-load" position. 3) Worn, broken or malfunctioning piston rings in third or second stage cylinders. 1) Cooling water flow through first stage intercooler restricted or ceased by blockage. 1) Leaking or broken delivery valv e plate in second stage. stage. 2) Worn, broken or malfunctioning piston rings in third stage. 3) First stage intercooler tubes blocked on air side. 4) Relief valv e defective. 1) Leaking or broken suction valv e plate in second stage.

Replace valve plate - examine seat for damage. Renew rings - clean grooves. Replace valve plate - examine seat for damage Examine, clean, and refit valve plate depressor, depressor, also examine valve for damage Renew rings - clean grooves.

Examine and clean intercooler tubes (both on air and water sides). Replace valve plate -examine seat for damage. Renew rings - clean grooves. Examine and clean air side of intercooler tubes. Repair or fit new valv e. Replace valve plate – examine seat seat for damage.

2) Second stage suction valv e depressor depressor sticking in "of f-load" position.

Remove, clean and refit depressor, depressor, also examine valve for damage.

Low second stage delivery pressure pressure (high second valv e stage delivery temperature).

1) Leaking or broken delivery plate in second stage.

Replace valve plate – examine seat seat for damage.

2) Worn, broken or malfunctioning piston rings in second stage.

Renew rings - clean grooves.

High second stage delivery air pressure and temperature

1) Leaking or broken suction valv e plate in third stage.

Replace valve plate – examine seat seat for damage.

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Fault High second stage air delivery temperature after intercooler Second stage delivery pressure relief valve blowing.

Low third stage delivery pressure. pressure.

High third stage delivery temperature.

High third stage delivery pressure pressure (relief valve blowing).

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Possible Cause 1) Cooling water flow through second stage intercooler restricted or ceased blockage. blockage. 1) Leaking or broken suction valv e or delivery valve plate in third stage. 2) Third stage suction valv e depressor depressor sticking in "of f-load" position. 3) Second stage intercooler interc ooler tubes blocked on air side. 4) Relief valv e defective. 1) Demand of end using equipment has overtaken capacity of compressor.

Remedial Action Examine and clean intercooler cooler tubes (both on air and by water sides) Replace valve valv e plate – examine seat seat for damage Remove, clean and refit depressor, depressor, also examine valve for damage. Examine and clean air side of intercooler tubes. Repair or replace valv e. If none of the previous faults are present, present, i.e. compresso com pressorr running normally, no remedial action possible. When demand reduces, the pressure pressure will rise to normal level (as set by the load controller). Adjust to required pressure. pressure. Repair/replace pressure pressure controller. Replace valve valv e plate – examine seat seat for damage. Replace valve valv e plate – examine seat seat for damage. Remove, clean and refit depressor, depressor, also examine valve for damage.

2) Low setting of load controller. 3) Malfunction of load controller. 1) Leaking or broken delivery valve plate in third stage. 2) Leaking or broken suction valv e plate in third stage. 3) Third stage suction valv e depressor depressor sticking in "of f-load" position 4) Worn, broken or malfunctioning Renew rings and clean piston ring piston rings in third stage. grooves. 1) Isolating valv e, between between Open valve. compressor and delivery delivery main closed or partially closed. 2) Incorrect setting or malfunction Adjust to required pressure pressure or of load controller. repair/replace pressure controller. 3) Restriction or blockage of Remove restriction. control signal to com pressor pressor unloader system. 4) Aftercooler tubes blocked or Examine and clean air side of restricted on air side. aftercooler tubes. 5) Seized closed, or partially Repair Repair v alve. closed non-return valve in delivery main (if f itted). 6) Relief valv e defective. Repair or fit new valv e.


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Fault High final air temperature from aftercooler.

Low lubricating oil pressure.

Loss of oil pressure. pressure.


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Possible Cause 1) Cooling water flow through aftercooler is restricted or ceased by maladjustment of hand valves. 2) Aftercooler tubes partially blocked on airside, or waterside of tubes is fouled. 1) Crankcase oil level is low. 2) Air leakage leakage into suction side of pumping system. 3) Partially blocked oil pump suction strainer in crankcase. 4) Oil relief valv e set too low or valve sticking open. 5) Failure or or wear wear of big end or small end bearings. bearings. 6) Partially blocked oil pump delivery filter element. 1) Compressor Compressor rotation incorrect (first trial run, or after a rebuild). 2) Crankcase oil level very low. 3) Serious air leakage into oil pump section section pipe pipe or or complete disconnection. 4) Complete blockage of oil pump suction strainer. 5) Oil pump drive failure. 6) Oil pump seizure.

No condensate condensate from f rom drain trap of i nterstage moisture separator or aftercooler moisture separator. Large quantity quantity of condensate condensate emitted from drain trap.

1) Drain trap blocked. 2) Separator drain pipe to trap blocked. 3) Dry atmospheric conditions. 1) This suggests that there is an internal leakage from the cooling water spaces into the air spaces of the compressor compressor (low pressure stage).

Remedial Action Check and adjust adjust hand valv e openings.

Examine and clean air and water sides of tubes t ubes.. Check oil level, add oil as required. Check oil level. Check connecting unions on suction pipe to pump. Remove, clean and refit. Remove, check and reset. Renew bearing(s). Check crankshaft for damage. Replace element. Change compressor rotation and recheck Check oil level, add oil as required. Check suction pipe and unions to pump. Check and clean oil sump. Remove, clean and refit strainer. Change oil as necessary. Examine drive coupling, ascertain cause of failure and rectify. Replace pump. Check drive coupling. Dismantle, clean and refit. Dismantle, clean and refit. Applies to 1st stage only. Trace the fault and rectify as necessary.

Note: Note: Water emitted from the traps is usually in the form of a trickle (intermittent or steady) - depending on the humidity of the air taken in by the compressor - or nil in the case of very dry atmospheric conditions.

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CHAPTER 5 COMPRESSOR MAINTENANCE

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CHAPTER 5 - COMPRESSOR MAINTENANCE

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COMPRESSOR MAINTENANCE

WARNING! Before opening up the machine, all pressurised components MUST MUST be depressurised down to atmospheric pressure in a safe and controlled manner.

5.1

Preventive Maintenance This schedule of maintenance, in general terms, is a preventive maintenance guide and running service necessary for our range of reciprocating compressors. However, it does not cover for any eventualities, which could occur from neglect or incorrect operation by the customer or adverse environmental conditions. Before carrying out any preventive maintenance work related to this equipment it is a requirement that you read and work in accordance with the Safety Precautions given in Chapter 2 of this Instruction Manual. Manual. Also, for your own protection, be sure to read read and obey WARNING and WARNING and CAUTION notices CAUTION notices and observe any special notes you find in this Chapter and any associated literature. When working on the compressors rotational parts you MUST fit MUST fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and motion work. Refer to Maintenance Procedure Job No. 002 Fitting Piston Rod Clamps. On plants with two or more compressors the opportunity should be taken during the early weeks of running, following commissioning, to vary the service hours of the compressors so that no two machines reach their maintenance interval at the same time. A gap of about 200 hours between machine running times is recommended. When 'running-in' a new compressor the crankcase oil MUST be MUST be renewed after the first 500 hours of operation and thereafter change in accordance with the intervals laid down in the following maintenance schedule.

5.1.1 Maintenance Schedule The following schedule, lists recommended maintenance tasks which are designed to both prevent unplanned machine breakdowns and to help the maintenance teams to plan maintenance activities. W here a maintenance activity requires greater explanation than that given in the schedule a reference to the relevant associated maintenance instruction is given. All materials used for scheduled maintenance and repair MUST COMPLY COMPLY with Gardner Denver Belliss & Morcom Morcom standards and the standards laid down by associated equipment manufacturers. Only approved spares may be used. When a system component associated with a mechanical or electrical device is changed or renewed, the system must undergo a functional test before the equipment is returned to service. Gardner Denver Belliss & Morcom are Morcom are not responsible for premature failures of parts which are caused by neglect, inappropriate servicing, use of none Gardner Denver Belliss & Morcom Morcom parts, or any other similar conditions over which we have no control.

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EACH DAY A shutdown of the compressor is not normally required for a Shif t inspection. Tasks

Supplementary Information

Check all temperature and pressure gauge readings are normal.

Report immediately any abnormality.

Note: Observe Note: Observe operation of moisture trap drains.

Check for undue noise, oil leakage, vibration or heat.

Report immediately any abnormality.

Note: Ensure Note: Ensure that load control equipment is operating correctly.

Test protection circuits annunciator lamps. All lamps MUST illuminate MUST illuminate

The 'Test' push-button is normally located on the compressor control panel. If a lamp fails, renew the bulb. If the new bulb does not illuminate report failure to the Supervisor.

Check the crankcase oil level. Oil level should be halfway up the window nut.

Use the breather aperture in the top of the crankcase to top-up the oil. Refer to the table of lubricants for oil type.

Note: Where Note: Where vee belts are fitted check tension and adjust if necessary.

Any aspect of the t he Shift inspection requiring further fu rther attention MUST be MUST be reported for action as required.

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MONTHLY - INSPECTION A shutdown of the compressor is not normally required for a monthly inspection. Tasks


Carry out a running examination to ensure satisfactory operation of all compressor and ancillary equipment.

Record all temperatures, pressures and hours run on compressor log sheet.

Note: Check Note: Check air inlet filter element cleanliness - renew if necessary.

Check the cleanliness and ensure correct operation of drain traps on compressor and ancillary equipment where applicable.

Clean drains and renew worn or damaged parts, as required.

Check all external bolts and nuts on the compressor including the holding down nuts for tightness.

Re-tighten or renew any missing nuts and bolts. Tighten nuts to appropriate torque.

Check air pressure supplied to compressor unloaders and note pressure drop.

Pressure should should be 7 bar m inimum at unloader. unloader.

Any aspect of the Monthly inspection requiring further attention MUST be MUST be reported for action as required.

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SIX MONTHLY - SERVICE The compressor is required to be shutdown for two days to perform this service schedule. Tasks


Carry out a running examination to ensure satisfactory operation of all compressor and ancillary equipment.

Record all temperatures, pressures and hours run on compressor log sheet. A copy of this form is provided in Appendices located at the end of this manual. Check cooling water flow rate (If flow recorder is fitted).

Check the cleanliness and ensure correct operation of drain traps on compressor and ancillary equipment where applicable.

Clean drains and renew worn or damaged parts, as required.

Check all external bolts and nuts on the compressor including the holding down nuts for tightness.

Re-tighten or renew any missing nuts and bolts. Tighten nuts to appropriate torque.

Visually examine (through the valve pockets) the general surface condition of cylinder bores for evidence of ring wear or scoring.

Replace worn or damaged parts, as required

Check valv e unloaders & interconnecting interconnecting small bore pipework pipework f or defects.

Clean and service as necessary. Replace worn or damaged parts as required.

Examine piston rods along gland travel to ensure no scoring is present.

Clean and service as necessary. Renew worn or damaged parts as required.

Check that inlet filter filt er is clean

Clean and service as necessary. necessary.

Check that inter and aftercooler moisture drains are operational and that the diffusers on the blowdown blowdown valv es are clear and clean..

Clean and service as necessary

Check one suction and one deliv delivery ery valv e from each stage for cleanliness or f ouling.


Renew third stage piston rod packing, piston rings and rider rings.

Renew worn or damaged parts as required.

Check integrity of all flexible air and water pipes.

Record condition. Renew worn or damaged parts as required.

CRANKCASE INSPECTION Examine crossheads and main guide slipper paths, condition and clearances c learances..


Check connecting rod bottom end bolts are pinned.

Rectify as required.

Check that lubrication oil suction strainer is clean and all pipework to main m ain pump is i n good order and that unions are tight.

Clean and service as necessary. Tighten unions and renew worn or damaged parts as required.

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SIX MONTHLY - SERVICE (Cont) Tasks


Check that crankcase oil is clean and no foreign particles are present. Ensure that oil delivery filter is clean and that oil pressure is satisfactory.

If dirty renew crankcase oil and delivery filter element. If necessary investigate source of any foreign particles. Refer to table of lubricants for oil type and quantity. The crankcase oil and the delivery filter are renewed as a matter of course during the Annual Service.

Any aspect of the t he Six Monthly service requiring further attention MUST be MUST be reported for action as required. On completion of the service, re-commission the compressor and recording all operating pressures and temperatures. Ensure that the working area is left in a clean and tidy condition.

ANNUALLY - SERVICE - (or as stipulated by local regulations) The compressor is required to be shutdown f or five days to perform this service schedule. All Six Monthly tasks are to be undertaken as part of this schedule. Tasks


Remove all air valves and replace with factory refurbished units. Renew crankcase element.

oil

and

delivery

filter

Refer to table of lubricants for oil type and quantity.

Inspect connecting rod bottom end shells, crankpin, top end bearing and gudgeon pin. Check motion work clearances.


Withdraw pistons and piston rods and examine wear. Gauge cylinder bores and piston rods for wear and record readings.

Renew piston rings, piston rod packings, and piston rod scrapers.

Check condition of water jacket spacers for fouling from lime deposits.

Report condition.

Check cleanliness of motor ventilation fan and that air flow paths are clean. Carry out an insulation resistance check on motor windings and record readings.


Check all system protection devices and circuits for correct operation.

Use a calibrated test rig to test the protection devices. Alternatively the devices can be tested by simulation of fault conditions at the machine.

Any aspect of the Annual service requiring further attention MUST be MUST be reported for action as required. On completion of the service close compressor using new jointing and 'O' rings. Re-commission the compressor and recording all operating pressures and temperatures. Ensure that the working area is left in a clean and tidy condition.

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TABLE OF LUBRICANTS Lubricant


Crankcase Oil

Recommended Lubricant Lubricant SAE 30 oil (ISO VG 100) o o (Ambient temperature 0 C to 45 C)

Oil Capacity 91 Litres

Approved Brands:BP Vanellus M30 Mobil Delvac 1330

Esso Essolube HDX 30 Shell Rimula X30

Alternatively:- The oil MUST be MUST be a good quality mineral oil having a flash o point (open test) of not less than 210 C and within a viscosity range o o (Centistokes) of 110 at 40 C to 12.5 at 100 C, the oil should also contain rust and oxidation inhibitors and anti-foam additives. o

If the site is particularly hot (over 45 C) then use an SAE 40 oil (ISO VG 150)

5.2

Maintenance Instructions The following procedures are intended for the use of the technician responsible for the maintenance of the compressor. It is essential that any necessary adjustments, servicing or overhaul work should only be carried out by competent persons who are familiar with the compressor installation and who have the appropriate authority ( Permit to Work ). ). To avoid possible warranty invalidation the following instructions should be read before attempting to maintain the machine.

WARNING! When working on compressor rotational parts you MUST fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and motion work. THIS COULD RESULT IN INJURY OR LOSS OF LIFE.

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JOB No. 001 CRANKCASE OIL CHANGE LIST OF SPECIAL TOOLS Description Thin Spanner (approx. 10 mm thick) LIST OF CONSUMABLES Crankcase Oil SAE 30 oil (ISO VG 100) (Normal Operating Conditions) Industrial cleaning fluid (White Spirit) & lint free cloth

Qty 1 As required As required

WARNING! To avoid scalding by hot oil, allow the compressor to cool down before beginning work. 1)

Isolate mains power and display appropriate warning signs.

2)

Remove the crankcase doors whilst taking care not to damage the oil seals.

3)

Wipe any excess oil off the doors using an industrial cleaning fluid and a lint free cloth. Place the cover in a clean location to avoid oil contamination when refitting.

4)

Empty the oil oil sump using suitable equipment and clean out the crankcase sump (using a lint-free cloth, to avoid fouling of the oil strainer).

5)

To avoid avoid oil oil spillage, never remove the oil suction strainer strainer while oil remains in the crankcase

6)

To remove the oil strainer use a thin spanner, on the strainer body hexagon to unscrew the strainer whilst holding the external hexagon fitting to prevent turning. This fitting is not screwed into the crankcase - it passes through a clear hole.

7)

Refit the oil strainer and check check that all tools and cleaning cloths have been removed from the crankcase sump.

8)

Refill the crankcase sump with the required quantity of clean, new oil.

9)

Refit the crankcase doors after checking the condition of the door seals.

10)

Test run the compressor and check for oil leaks around the strainer seal and crankcase crankcase doors. If all is satisfactory, return the machine to service.

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JOB No. 001 - CRANKCASE OIL CHANGE (Cont)

Crankcase Assembly

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JOB No. 002 FIT PISTON ROD CLAMPS LIST OF SPECIAL TOOLS Description Piston Rod Clamps

Qty 1 Set

LIST OF CONSUMABLES Industrial cleaning fluid (White Spirit) & lint free cloth

As required

1)

Isolate mains power and display appropriate warning signs.

2)

Remove the distance piece access covers from the line of motion motion works NOT NOT being worked on. Wipe any excess oil off the covers using an industrial cleaning fluid and a lint free cloth. Place the cover in a clean location to avoid oil contamination when refitting.

3)

Mark the position of the oil shedder on the piston rod and remove shedder.

4)

Loosely assemble the piston rod clamps onto the piston rod.

5)

Manually 'bar-over' the compressor to the desired position and hold steady.

6)

Whilst one person holds the crankshaft bar in position, the other must tighten the one piston rod clamp firmly against the packing gland box and the other firmly against the scraper gland box.

7)

Only when both clamps clamps are tight in in place can the crankshaft bar be carefully released and safe work or inspection takes place. When working on the third stage of this compressor the following additional checks MUST be MUST be made to ensure that the compressor is safe to work on.

8)

Isolate the non-return valve to prevent possible blow-back pressure.

9)

Isolate the compressor from the receiver at the stop valve.

10)

Vent down the third stage at the anti-surge vessel immediately after the cylinder.

11)

Carefully open the vent valves on the third stage cylinder cylinder to check de-pressurising de-pressurising has been completed successfully.

12)

When removing the valve cover very carefully slacken the fasteners initially in case there is any residual pressure present.

WARNING! When maintenance work has ha s been completed the piston rod clamp MUST MUST be removed.

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JOB No. 003 CYLINDER TOP COVERS - REMOVE & REFIT LIST OF SPECIAL TOOLS Description Lifting Eye-Bolts Slings, Lifting Equipment

Qty 1 Set As required


As required

To Remove 1)

Ensure that the compressor is fully de-pressurised, electrically isolated and isolated from the air supply.

2)

Post signs instructing personnel that the machine MUST NOT be NOT be used.

3)

Isolate and drain the cooling water from the compressor cylinders.

4)

Remove cooling water pipes from the top cover cover and fit blanking blanking plugs to prevent dirt ingress.

5)

Check that there are no supply pipes or hoses fastened to the top cover.

6)

Release and remove the top cover securing nuts from the cylinder fixing studs.

7)

Fit lifting eye-bolts into the relevant lifting holes

8)

Attach a suitable sling to the eye-bolts, and using suitable lifting equipment, take up the slack in the sling.

9)

Slowly lift and guide the top cover from the cylinder studs.

10)

Clean the top cover using an industrial cleaning fluid and a lint lint free cloth.

11)

Lower the top cover onto a suitable, clean work-surface taking care not to damage the machined face.

To Refit If any maintenance has been carried out on the motion work which may affect the piston to cylinder (bumping) clearances, check the clearances are correct before refitting the top cover. Refer to Job No. 004. 1)

Ensure that the cylinder top cover and cylinder top mating faces are clean.

2)

Check the condition of the cylinder top cover gasket. Renew if necessary.

3)

Fit a new gasket over the cylinder studs and onto the cylinder mating face.

4)

Attach a suitable sling to the eye-bolts, and using suitable overhead lifting equipment, raise and position the top cover over the cylinder.

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JOB No. 003 - CYLINDER TOP COVERS - REMOVE & REFIT (Cont) 5)

Slowly lower and guide guide the top cover onto the cylinder, ensuring the correct positioning of the cooling water and gas pockets.

6)

When in position, remove the sling and lightly secure the top cover to the cylinder with the fixing nuts.

7)

Tighten the cylinder cover nuts (centre nuts first), tighten the nuts down evenly and progressively. Nuts to be torque tightened to the appropriate torque figure. Refer to Chapter 1 Section 1.1.3.

8)

Remove the eye-bolts from the top cover and refit the cooling water pipe

9)

Secure the supply lines to the cylinder top cover with their fasteners.

10)

Re-establish water and electrical supplies to the compressor.

11)

Bleed off any trapped air in the cooling system using the plugs in the cylinder water jacket.

12)

Test run the compressor on clean, dry air or nitrogen and check for correct operation and freedom from leaks around any of the disturbed gaskets.

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JOB No. 004 PISTON RINGS - REMOVE & REFIT LIST OF SPECIAL TOOLS Piston rod bullet

1 LIST OF CONSUMABLES

Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

To Remove There are two ways of removing the piston from the compressor: Method 1 1 is as a unit without the piston rod (this ( this procedure) procedure) and Method 2 as as an assembly with the piston rod attached. This method can be used if the maintenance procedure being performed does not call for the piston nut to be removed. If Method 2 is is to be used the piston removal procedure is detailed as part of Job No.013 Piston Rod - Remove/Refit. The '1st stage piston' can piston' can only be removed using Method 2. 2. 1)

Remove the cylinder top cover as described in Job No.003. No.003.

2)

Remove the crosshead access cover and gasket from the crankcase.

3)

Manually 'bar-over' the compressor compressor to ensure that the piston is at its BDC position. Measure and record the TDC and BDC "Bumping Clearances". Refer to Chapter 1 Technical Data. Data.

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JOB No. 004 - PISTON RINGS - REMOVE & REFIT (Cont) 4)

Bend back the tab on the locking plate retaining the piston rod/crosshead securing pin and remove the pin. Ensure that the securing pin is removed before slackening the piston nut. Otherwise, if the piston rod turns in the crosshead while the securing pin is in position, the pin will distort making it extremely difficult to remove.

5)

Slacken the piston nut.

WARNING! It is possible that pressure can have accumulated within the interior of the piston. There is a pressure release hole drilled in the piston top half, which is (on assembly) covered by the underside of the piston nut/washer. It is essential, where the hole is covered by a washer, to ensure that the washer is not stuck in place before the nut is unscrewed by more than one turn. This is to make certain that the pressure relief hole is fully open to atmosphere. 6)

Remove the piston nut.

7)

Remove the piston piston and washer by lifting the piston (which is in halves) very carefully off the rod. If the piston is tight on the rod and cannot be easily lifted, proceed as follows:

8)

Manually 'bar-over' the compressor to turn the piston to TDC and insert diametrically opposite (IMPORTANT (IMPORTANT)) two equal length pieces of hard wood via valve pockets to block the piston. Place the wood chocks about 25mm clear of the piston rod sides NOT at the piston periphery.

9)

Turn the crankshaft to BDC to withdraw the rod.

10)

Carefully turn the compressor back to TDC taking the piston piston upwards. upwards.

11)

Insert longer pieces of hard wood if the piston is still tight on the rod and repeat steps 9 and 10. An observer o bserver MUST be MUST be stationed to control the piston emerging from the cylinder. The two halves being lifted separately from the rod top with care being taken to remove the piston rings safely during the operation.

12)

Remove the wood wood blocks when the piston piston has been lifted out. If the piston halves are stuck together, lift the piston off as an assembly and part the halves carefully on a work-bench taking care not to damage the piston body.

Examination Piston Pressure Rings Rings - For piston pressure ring dimensions refer to Chapter 1 Technical Data. Data. The pressure rings MUST be MUST be replaced with new ones when the radial thickness at any point has worn to 65% or less of the original thickness. Piston Bearer Rings Rings - For piston bearer ring dimensions refer to Chapter 1 Technical Data. Data. The bearer rings MUST be MUST be replaced by new ones, when the standout at any point has worn to 0.5mm or less.

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JOB No. 004 - PISTON RINGS - REMOVE & REFIT (Cont) Piston Rings Renew 13) Remove and discard the old piston rings. 14)

Clean piston ring grooves carefully.

15)

Insert the new piston ring squarely into the cylinder bore and check that the bearing ring standout and axial clearance is correct. Refer to Chapter 1 Technical Data. Data .

Figure Shows Piston Ring Configuration for 1st Stage Piston 16)

Fit the new piston rings by carefully springing them over the piston body (single (single piece rings only).

17)

Ensure that the rings are correctly seated in in the piston piston groove. If the cylinder bore is cored or o r very lightly polished with no signs of ho ning marks it may be necessary to re-hone the bore. (In some cases a flexi-hone can be used!).

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Piston Assembly 1 st Stage

Piston Assembly 2 nd Stage

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JOB No. 004 - PISTON RINGS - REMOVE & REFIT (Cont)

Piston Assembly 3rd Stage To Refit 1) Place the piston rod to TDC and, after checking that the bottom reinforcing reinforcing washer is in order and correctly in place, lower the bot tom half piston body onto the washer and rod and settle it into place. 2)

Fit the top half piston, setting the butt gaps of the pressure rings to opposite sides (i.e. 180o opposed) and carefully lower into place over the rod.

3)

After checking that the pressure relieving hole is clear, fit the top half piston piston to the bottom half piston.

4)

Fit the top reinforcing washer onto the piston top half.

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JOB No. 004 - PISTON RINGS - REMOVE & REFIT (Cont) 5)

Fit and very lightly tighten the piston nut.

6)

Check that the crosshead locknut is tight in in place and, ensuring that the securing pin is removed from the crosshead, fully tighten the piston nut to the appropriate torque figure. Refer to Chapter to Chapter 1 Section 1.1.3.

7)

Measure and record record the end ("bumping") clearances with the piston at the top (TopDead-Centre) and bottom (Bottom-Dead-Centre) of its stroke. Refer to Job No.005. No.005.

8)

Refit the cylinder top cover as described in Job No.003.

9)

Check the piston bumping clearances against the figures earlier recorded to ensure that the piston is properly down.

10)

If adjustment is required, adjust as described in Job No.005.

11)

Recheck the tightness of the crosshead locknut and fit and tighten the securing pin with its locking plate into the crosshead.

12)

Bend over the tab on the locking plate.

13)

Refit the crosshead access cover with gasket and tighten the screws.

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JOB No. 005 PISTON/CYLINDER END CLEARANCES - INSPECTION LIST OF CONSUMABLES Description Sealing Gasket (between 0.8mm - 1.0mm thick)

Qty As required As required

Industrial cleaning fluid (White Spirit) & lint free cloth

There are two ways of measuring the piston Top-Dead-Centre (TDC) clearance: Method 1 is by removing the cylinder top covers and Method 2 is is by removing the valves and checking the clearance through the valve pockets. The Bottom-Dead-Centre (BDC) clearance is checked using Method 2 . Method 1 1)

Remove the cylinder top cover refer to Job No.003. No.003.

2)

Place a sealing gasket of between 0.8mm - 1.0mm on to the cylinder mating face.

3)

Place the machined straight-edge across the top of the gasket on the cylinder.

4)

Bar over the compressor to place the piston exactly at TDC.

5)

Measure the clearance between the straight edge and the piston crown. Ensure that the straight edge is held firmly against the gasket when measuring clearance. record the with a feeler (thickness) gauge. The required clearances are detailed in Chapter 1 Technical Data. Data. If the clearances are out side of the tolerance band the clearance MUST be MUST be adjusted (see later in this procedure).

Method 2 1)

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Remove either a suction or delivery valve from a top cylinder pocket (if measuring TDC clearance) or a bottom cylinder pocket (if measuring BDC clearance).


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JOB No.005 - PISTON/CYLINDER PISTON/CYLINDER END CLEARANCES - INSPECTION (Cont) 2)

With the piston exactly at TDC TDC or BDC, insert a feeler gauge through the valve pocket and measure the clearance. Record the end ("bumping") clearances with the piston at the top (Top-Dead-Centre) and bottom (Bottom-Dead-Centre) of its stroke. The clearances are detailed in Chapter 1 Technical Data. Data . If the clearances are outside of the tolerance band the clearance MUST be MUST be adjusted (see later in this procedure).

CAUTION Feeler gauges MUST NOT NOT be inserted into the valve pocket whilst turning the machine over because if trapped, the machine components could be strained or damaged. Piston/Cylinder End Clearances - Adjustment The end ("bumping") clearance is adjusted by screwing the piston rod into, or out of, the crosshead. To adjust the piston to cylinder end clearances proceed as follows: 1)

Remove the crosshead access cover and gasket from the crankcase.

2)

Bar over the crankshaft to reveal the crosshead locknut and the piston rod securing pin.

3)

Bend back the locking plate tab retaining the securing pin and remove the pin. Ensure that the securing pin is removed before slackening the crosshead nut. Otherwise, if the piston rod turns in the crosshead while the securing pin is in position, the pin will distort making it extremely difficult to remove

4)

Slacken the crosshead locknut. The piston rod has a slotted end at the crosshead (through which the securing pin fits) it can only be turned in 90 o steps, one step represents a linear movement of 0.8mm, (the screwed end of the rod having 8 threads per inch).

5)

To adjust the top end clearance, screw the piston piston rod rod into or out of the crosshead. Ensure that the top and bottom clearances are as close to equal as is possible. If equal clearances are not obtainable then always, on final setting, make the TOP clearance the larger of the two (by an amount equal to no more than one quarter turn only of the piston rod in the crosshead i.e., by no more than 0.8mm).

6)

Fully tighten the crosshead locknut.

7)

Recheck that the piston rod slots are correctly aligned for clearance clearance of the piston rod securing pin.

8)

Fit a new locking plate to the securing pin before fitting and fully tighten the pin.

9)

Bend over the locking plate tab to prevent the securing pin from rotating.

10)

Inspect the crosshead access cover gasket. Renew Renew if necessary.

11)

Refit the access cover.

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JOB No. 006 PACKING GLAND ASSEMBLY - REMOVE & REFIT LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

Due to their construction, these packing glands can only be satisfactorily examined and repaired when they are removed from the compressor and disassembled on a suitable workbench. To Remove First & Second Stage Packing Assemblies Only 1)

Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and motion works. Refer to Job No.002. No.002.

2)

Mark the position position of the oil shedder on the rod surface and remove shedder with with its two clamping screws.

3)

Remove the nuts from the small diameter gland assembly tie studs.

4)

Remove the securing securing nuts from the gland cover and lower the cover down the piston rod until it is resting on the oil scraper gland assembly.

5)

Slide each container assembly down the piston rod until it is clear of the gland.

6)

Slide the container a little way back up the piston piston rod rod to expose the packing packing rings and in turn, unhook the garter springs and remove the packing ring segments.

1st Stage Gland Packing

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JOB No. 006 - PACKING GLAND ASSEMBLY - REMOVE & REFIT (Cont)

2 nd Stage Gland Packing 7)

Reassemble and carefully store each ring of segments and garter spring, immediately on removal. Repeat Step 7 until all of the packing rings have been removed. Observe that each ring is marked with matching numbers and letters for use in reassemble. Also the lowermost ring has a peg which locates locates into a hole in the uppermost ring to form a container pair. pair. The rings can can be reused depending upon condition after inspection.

To Refit 1st & 2 nd Stage Packing Assemblies Only

CAUTION! The rings and glands refitted completely without oil (the compressor being an oilfree cylinder machine) - on NO ACCOUNT introduce oil or grease into the gland. If refitting "used" rings first ensure that there is no dirt or grit embedded - examine also the piston rod surface If the piston rod is out of the compressor, the gland can be assembled on the work-bench, then fitted into place as a finished unit. If the rod is in place, the rings and their springs are assembled around the rod by working through the distance piece apertures. 1)

Assemble each ring onto the piston rod with its garter spring.

2)

Fit the rings as pairs into their respective containers (ensure peg is pointing upwards).

3)

Slide each container assembly up the piston rod in turn, finally clamping the completed gland assembly with the tie rod nuts.

4)

Refit and tighten the packing nuts and secure the gland assembly to the cylinder bottom.

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JOB No. 006 - PACKING GLAND ASSEMBLY - REMOVE & REFIT (Cont) 5)

Refit the oil shedder to the piston rod in the position position marked during removal and secure with its clamping screws.

6)

Remove piston rod clamps.

7)

Inspect the crosshead access cover gasket. Renew if necessary.

8)

Refit the access cover.

To Remove Third Stage Packing Assembly Only 1) Drain the cooling water system. 2)

Remove the cylinder cylinder top cover, distance piece access doors and the piston and piston rod assembly. Refer to Job No.004. No.004.

3rd Stage Gland Packing 3)

Remove the inlet and outlet cooling water pipes from the packing gland cover.

4)

Whilst supporting supporting the gland assembly, carefully slacken and remove the nuts securing the gland to the underside of the cylinder.

5)

Slowly lower the gland gland assembly assembly from its its studs into into the distance piece, turn the unit and withdraw it sideways from the machine.

6)

Place the gland assembly onto a clean workbench for disassembly.

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JOB No. 006 - PACKING GLAND ASSEMBLY - REMOVE & REFIT (Cont) To Refit Third Stage Packing Assembly Only If refitting 'used' rings first ensure that there is no dirt or grit embedded - examine also the piston rod surface. 1)

Refit the gland assembly into the pocket on the underside of the cylinder.

2)

Secure in position with nuts and fully tighten.

3)

Refit the inlet and outlet cooling water pipes to the packing gland.

4)

Bar over the compressor a couple of turns to seat the packing rings and ensure freedom of movement of the line of motion work.

5)

Refit the cylinder top cover, distance piece access doors and the piston and piston rod.

6)

Refill the cooling water system.

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JOB No. 007 PACKING GLAND ASSEMBLY - OVERHAUL LIST OF SPECIAL TOOLS Description Wear Wea r Check Tool Thread Guard Cap

Qty 1 1


As required

Due to their construction, these packing glands can only be satisfactorily examined and repaired when they are removed from the compressor and disassembled on a suitable workbench To Disassemble Disassemble 1)

Remove the nuts from the small diameter gland gland tie studs and separate and disassemble the containers. As each container ring is lifted off the assembly, take meticulous care of the precision ground and lapped faces between the containers and the plates.

2)

Observe carefully that the ring containers and the plates between them are staggered sequentially, with number 1 being the top container ring.

3)

Observe that the tie studs are unequally spaced to ensure the correct orientation of the internal water passageways is maintained.

4)

Observe and carefully record the construction and sequence of assembly for the rings, noting that each ring of segments is marked marked with matching numbers and letters. In addition note that there is a peg and hole location in the segmented ring pairs in the containers with the peg pointing upwards.

5)

As each container is lifted off the assembly, remove and store the packing rings and carefully retain the various 'O' rings as they become free (it is recommended that 'O' rings are renewed, if not guard the displaced rings against loss and damage). There is an 'O' ring on each tie stud as well as around the cooling water spaces (third stage only)

6)

Observe the condition of the soft metal sealing ring in the top face of the uppermost gland ring ensure that it is not damaged during handling and storage.

7)

Unscrew the small diameter tie studs from the uppermost container ring.

To Inspect 1) The packing rings are checked for wear by re-assembling, with garter spring, squarely around the piston rod, or on the Wear Check Tool and and examining the butt clearances. 2)

When parts are new the butts are each approx. 3mm wide; discard the ring when the butts reduce to 0.5mm.

3)

Examine the soft metal sealing ring on the top-most container of the gland ring to ensure this is in good condition.

4)

Examine the 'O' rings to ascertain their condition - renew if required. (3 rd stage only).

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JOB No. 007 - PACKING GLAND ASSEMBLY - OVERHAUL OVERHAUL (Cont) To Reassemble Scrupulous cleanliness of all parts is required on assembly, particularly of the lapped faces between the containers and plates. 1)

Identify and layout the gland components in sequential order in preparation for reassembly.

2)

Place piston rod/piston assembly onto a clean work-bench resting on the piston crown with the piston rod pointing upwards so that the rod can be used as an assembly tool.

3)

Thoroughly clean the rod surface and fit the thread guard cap to the rod end.

4)

Thread the packing gland cover plate over the piston piston rod to rest on the piston.

5)

Locate the lowest ring pair of the packing assembly onto the flange cover recess, first the ring with the peg pointing upwards, then the ring with the hole located over the peg.

6)

Locate the tie studs (temporarily (temporarily removed from the top container) in the holes in the cover to align subsequent containers.

7)

Fit the 'O' rings into the grooves around the cooling cooling water spaces in the cover and around each tie stud. Great care must be taken not to knock or disturb these during later stages of assembly (Third stage only)

8)

Progressively build up the gland assembly in the correct numbered sequence of the plates and containers refitting packing rings and O rings in their correct positions as noted during dismantling.

9)

When the top container ring is reached, very carefully withdraw the tie studs taking great care not to shake the assembly.

10)

Firmly screw the tie studs back into their original positions in the top gland ring. ring.

11)

Carefully thread the tie rods back through the gland assembly assembly until the top gland ring ring rests squarely onto the top container.

12)

Whilst clamping the assembly firmly to prevent, separation, displacement displacement of 'O' rings or misalignment, lift the assembly sufficiently to fit the nuts to the tie studs.

13)

Progressively tighten the nuts evenly to clamp the assembly.

14)

Refit the gland assembly as described in Job No.006. No.006.

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JOB No. 008 PISTON ROD OIL SHEDDER - REMOVE & REFIT LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

The piston rod oil shedder is clamped in halves to the piston rod by socket head screws. The shedder is fitted so as to run clear of the packing gland and the scraper gland covers. If the shedder becomes damaged renew as follows: The oil shedder should only be fitted onto the piston rod when both the oil scraper gland and packing gland are fully fitted in place. To Remove 1) Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and motion works. Refer to Job No.002. No.002. 2)

Mark the position position of the oil shedder on the rod surface and remove shedder with with its two clamping screws.

To Refit 1) Place the piston in BDC position and assemble the shedder onto the piston rod with the hollowed side placed downwards. 2)

Position the shedder 2.5mm above the top face of the scraper gland and lightly but firmly tighten the two screws.

3)

Turn over the compressor compressor to ensure that the oil shedder does not foul either the upper packing gland or the lower scraper gland.

4)

When adjustment is satisfactory, fully tighten the shedder clamping screws.

5)

Refit the access cover to the cylinder distance piece.

6)

Two small diameter washers of the required thickness placed either side on top of the scraper gland are helpful in setting the shedder position - remove the washers immediately afterwards

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JOB No. 008 PISTON ROD OIL SHEDDER - REMOVE & REFIT (Cont)

Oil Shedder & Scraper Housing

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JOB No. 009 OIL SCRAPER GLAND - REMOVE & REFIT LIST OF SPECIAL TOOLS Description Wear Wea r Check Tool

Qty 1


As required

The support housings of the scraper glands fit directly on to the top of the guide for the crossheads To Remove 1)

Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and motion works. Refer to Job No.002. No.002.

2)

Lift the plate and slide the upper pair of scrapers up the rod.

3)

Unhook the garter springs and remove the scraper ring segments.

4)

Re-assemble and carefully store each ring of segments immediately upon removal. The segments are marked relative to each other, the lower ring pair having a peg and locating hole arrangement for correct re-assembly. re-assembly. The rings can be re-used depending upon condition.

5)

Lift the container and slide the lower pair of scrapers up the rod.

6)

Re-assemble and carefully store each ring of segments immediately upon removal.

Oil Scraper Gland - Inspection 7) The oil scraper rings are checked for wear wear by re-assembly, with garter spring, squarely around the piston rod, or on the wear check tool and examining the butt clearances in the case of ring W1 and W2. 8)

When parts are new the butts of W1 and W2 are each 0.8mm (0.032") wide.

9)

Discard the rings and their sealing rings when the butts reduce to 0.12mm (0.005") each or a total of 0.36mm (0.015") or less, and replace with a new pair. The segments of the sealing ring have angle cut contact faces - there are no butt clearances.

To Refit 1)

Ensure that the correct relationship is maintained between the rings. There are oil drain slots cast in the bottom of the housing. Should the housing need to be removed it must be refitted with these slots (in the case of the inclined cylinders) positioned lowermost. "TOP" is is staggered on the housing.

2)

Remove piston rod clamps.

3)

Bar over the compressor a couple of turns to check for correct operation.

4)

Refit the access covers to the cylinder distance piece.

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JOB No. 010 SUCTION & DELIVERY VALVES - REMOVE & REFIT LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth Grinding Paste

Qty As required As required

Each valve is installed in an individual pocket. They are fitted with metal-to-metal contact (i.e. no jointing material) to the seat face in the cylinders. To Remove

CAUTION! Serious damage could result from suction valves and their associated components, being fitted in delivery valve pockets or vice-versa. Therefore, ensure valves are correctly identified with their pockets. 1)

Remove the securing bolts from the valve cover.

2)

Remove the valve cover/cage complete with 'O' ring.

3)

Remove the valve from its pocket (using a valve extraction tool where necessary).

To Refit 1)

Ensure that there are are no bruises or burrs on the valve seat or pocket seat. A light grinding-in operation may be needed, it is important to ensure that no grinding paste enters the cylinder and that all is clean after completion. The diametric clearance between the valve se at and the seating in the cylinder is small, small, therefore the valve has to be fitted very carefully to ensure that it fits squarely on to its seat. It is essential that the valve is squarely fitted on its seat and metal to metal contact established.

2)

Check that 'O' rings are in good condition and that their associate grooves are clean before final assembly of valve cover/cage. Renew if necessary.

3)

Refit the valve cage and the valve cover.

4)

Refit the cover securing bolts and tighten evenly and squarely to the correct torque.

CAUTION! It is important after fitting valves (or after work of any kind which has been done inside the cylinders) to ensure that all is clear in the cylinders by barring over the crankshaft a few revolutions.

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JOB No. 010 SUCTION & DELIVERY VALVES - REMOVE & REFIT (Cont)

1st Stage Delivery Valve (Typical)

1st Stage Suction Valve (Typical)

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JOB No. 011 SUCTION & DELIVERY VALVES - OVERHAUL LIST OF SPECIAL TOOLS Description Valve Holding Tool

Qty 1


As required

To Remove 1)

Remove the suction delivery valve in accordance with Job No.010. No.010.

To Inspect

CAUTION! The correct holding tool must be used when dismantling and assembling valves. The valves themselves must never be gripped in a vice. 2)

Inspect the 'O' ring for each valve cover/cage. Renew if necessary.

3)

Disassemble the valves. There are locating pegs in all valve seats; these ensure correct relationship between various components, except the valve coil springs.

4)

Thoroughly clean all parts and examine for signs of fatigue or wear.

5)

Check for distortion or damage to the sealing faces of valve seats, examine also the guards.

6)

Check for distortion, wear, cracks or breakage of valve plates.

7)

Compare the height of displaced springs, with new spares, to determine determine any deterioration in spring loading.

8)

Replace any part, which is found to be defective.

To Overhaul

CAUTION! Care must be taken when reassembling overhauled valve components. The components must be assembled correctly. An incorrectly assembled valve will quickly deteriorate in service and consequently may damage other parts or affect the compressor performance. Particular care must be taken when assembling valves to ensure that the springs remain correctly in their locations.

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JOB No. 011 - SUCTION & DELIVERY DELIVERY VALVES - OVERHAUL (Cont) 1)

The valves have locating pins, which ensure that the various components are correctly related radially. The pins are of differing diameters which ensures that the valve seat, valve plate, valve damper plates, and valve guard are correctly fitted, one to the other. If new locating pins are fitted to an old seat it is essential that they are of the correct sizes and positioned exactly as on original valve seats, with correct standout height above the valve seat top surface.

2)

Lift Washers - when not of identical thickness - should be fitted with the thinner one next to the valve seat (this thinner one is referred to as the lower lift washer).

3)

Conical type springs are fitted with the large diameter end located in the holes in the valve guard.

4)

Torque the centre bolt nut to the correct value (see Chapter 1 - Technical Data). Data).

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JOB No. 012 SUCTION VALVE UNLOADER ACTUATORS - REMOVE & REFIT LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

To Remove 1)

Disconnect the control air pipe from the actuator and cap open ends.

2)

Remove the end fittings from the actuators and store carefully.

3)

Slacken locknut and screw actuator out of top cover. Place the actuator onto a clean work surface.

To Inspect 1) Remove the diaphragm chamber cover and disassemble the unit for examination of the condition of the diaphragm, spring, bush, spindle and seal ring. 2)

Check that the small vent hole in the side of the lower half case is clear (if this becomes blocked then the diaphragm cannot deflect properly due to pressure buildup).

3)

If there is deterioration of any part, it is recommended that the complete actuator is replaced. Under normal circumstances actuators given given long and trouble free service.

To Refit 1)

Ensure that the suction valve is fitted correctly and that its securing cover is fully tightened down squarely. It is essential that the correct gap is present between the actuator and the valve, otherwise the suction valve may not open or close fully.

2)

Carefully screw the actuator (with its locknut screwed back) until the spindle just contacts the valve unloader. The unloader is spring loaded so take care to just contact it and NOT depress NOT depress it.

3)

Screw back the actuator about 1.5mm and pinch tighten the locknut.

4)

Insert a hard wood dowel/rod through the control air connection hole in the top of the actuator casing until it just touches the top of the diaphragm.

5)

With the dowel/rod in position, mark mark it accurately in line with the actuator cover plate top.

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JOB No. 012 - SUCTION VALVE UNLOADER UNLOADER ACTUATORS - REMOVE & REFIT (Cont) 6)

Using the dowel/rod depress the actuator (against the action of the spindle return spring) until it just contacts the unloader, but do not depress it.

7)

While holding the dowel/rod dowel/rod in position, mark mark it accurately again in line with the actuator cover plate top. Then release the dowel/rod (it will rise under the action of the actuator spindle return spring).

8)

Remove the dowel/rod dowel/rod and measure the distance distance between the marks. If it is NOT between 1.4mm and 1.6mm then adjust the actuator position, by screwing it in or, out of the cover plate, as required.

9)

When the gap is set correctly, tighten the locknut to the correct torque.

10)

When all the actuators on the compressor are correctly set, fit the end fittings to the actuators; reconnect the control air pipework to the actuators and to the associated vent vale and test the compressor for correct operation.

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JOB No. 013 PISTON RODS - REMOVE & REFIT LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

To Remove 1)

Remove the cylinder top cover as described in Job No.003. No.003.

2)

Remove the piston as described in Method 1, 1, Job No.004 or No.004 or if the piston rod is to be removed with the piston attached skip this step. Before slackening the crosshead locknut mark on the crosshead two fine centre-punch dots (about 70 to 75mm apart). One on the piston rods taper portion and the other on the crosshead. Then, set a pair of dividers to the length between the dots and record this figure.

3)

Remove the securing pin from the crosshead.

4)

Unscrew the piston rod from the crosshead crosshead - the loosened locknut should be held by a spanner to be unscrewed off the rod end simultaneously, and removed as the rod is withdrawn.

5)

Using suitable lifting equipment, carefully withdraw the piston and rod assembly from the cylinder If the packing gland is to be reused, great care must be taken as the threaded portion of the rod is lifted through the gland rings to prevent damage.

To Refit Prior to refitting the piston rod, examine the rod with a gauge and if found to be worn (evenly or tapered) or scored then renew as necessary. 1)

Fit the piston piston rod, using a piston rod thread guard cap, to pass through the packing gland and scraper gland until it just enters the guide top.

2)

Remove the cap and fit the crosshead locknut at the crosshead as the rod enters the guide. When refitting the rod, ensure that the centre-punch dots coincide at the correct distance apart and check the alignment of the cruciform slot at the bottom of the rod to the securing pin hole in the crosshead, before tightening the locknut on the crosshead.

3)

Ensure that the securing securing pin pin can pass through the piston rod foot (slot in line) and tighten the locknut to the crosshead.

4)

Refit the piston as described in Job No.004 (if No.004 (if necessary).

5)

Check the piston bumping clearances as described in Job No.005. No.005.

6)

Turn the compressor over a couple of times to ensure satisfactory operation.

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JOB No. 014 OIL FILTER - REMOVE & REFIT LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

To Remove 1)

To open the filter body undo the bottom bolt bolt (using (using a clean bucket to catch spilled oil), the filter body and element draw off vertically downwards.

2)

Discard the old element and clean out the body.

3)

When replacing the assembly assembly (with a new filter pack) care should be taken that the seal ring gasket at the top and an d the washer at the bottom are in their correct positions. A new seal ring gasket is supplied as part of the filter element spare.

4)

There is is a spring spring fitted internally onto the bolt - this is installed to hold the filter element up against the top t op cover and so form the seal; it also provides the automatic safety filter bypass (for use should the element become heavily fouled).

5)

Before assembly of the filter body to its cover, fill the body with clean compressor lubricating oil.

JOB No. 015 OIL PRESSURE RELIEF VALVE - ADJUSTMENT LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

To Adjust 1)

Remove the valve cap.

2)

Slacken the locknut locknut on the adjusting screw and adjust to obtain the required oil pressure (screw IN to IN to raise the pressure, screw OUT to OUT to decrease the pressure).

3)

Tighten the locknut and refit the cap.

4)

Normally adjustment is not necessary after initial initial setting by the manufacturer. If a fault should occur and adjustment has no noticeable effect, the trouble could be a particle of foreign matter trapped under the valve. Dismantling, cleaning and re-assembly is then required (first noting the valve adjusting screw setting).

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JOB No. 016 LUBRICATING OIL PUMP AND DRIVE - INSPECT & OVERHAUL LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

To Overhaul 1) Disconnect all pipes connected to the oil pump. 2)

Remove the cap screws securing the oil pump to bearing housing and carefully withdraw the pump, together togeth er with the filter body attached, its drive coupling can then be inspected.

3)

Wear on the coupling coupling is expected to be negligible but ifif excessive wear is present investigate the cause, remove, and fit a new drive coupling.

4)

When refitting the oil pump renew the gasket if the old one has deteriorated.

5)

Prime the suction side of the pump with oil.

6)

Refit the pipework to the oil pump.

JOB No. 017 INTERCOOLER - INSPECT & OVERHAUL LIST OF CONSUMABLES Description Industrial cleaning fluid (White Spirit) & lint free cloth

Qty As required

To Inspect 1)

The cooler MUST MUST be removed completely in order for a complete examination to be performed. Internal and external inspection, to check for fouling or damage, is annual. This period will, however, vary depending on site conditions (being extended with good clean water circulating).

To Overhaul 1) It is not expected that the inside (i.e., tube internals) will foul. Any untoward accumulation of soft deposits at the tube entrance may be removed by blowing backwards with compressed air, the cooler being off the compressor for this purpose. 2)

If hard carbonaceous deposits have accumulated, specialist attention may be required.

3)

Should the cooling water side become fouled then use a proprietary procedure as recommended by local water treatment specialists - this to be compatible with the materials of construction (see Chapter 1 - Technical Data). Data).

4)

When refitting (after cleaning) all joints must be in good condition.

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Lists of Tools

5.3.1 Commercially Available Tools List The following is the recommended list of tools required to perform maintenance tasks on this compressor: Tool Standard tool box tools including: A range of open-jaw, o pen-jaw, ring, and socket type spanners A set of hexagonal section Allen keys (Metric) Torque wrench Circlip pliers Eyebolts Fitters tools Long-nosed pliers

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Supplementary Information Information Various job locations

Tightening range 0 to 1200 Nm For removal and refitting crosshead gudgeon pin retaining circlips. M24 x 3.0 male thread x 65mm long for cylinder top cover lifting, M12 x 1.75 (for piston rod lifting). Feeler (thickness) gauges, standard sizes Thin ended, for removal of circlip from suction valve unloader

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Issue: Issue:

1


Date:

May 2002


Page:

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5.3.2 Specialist Service Tools List The following specialised service tools are designed to aid compressor maintenance work and are available f rom Belliss & Morcom. Tool No MB021-09 MB072-02 MB072-03 MB073-03 PSB038-006 PSB038-008 PSB038-009 PSB038-010 PSB038-011 PSB038-012 PSB038-013 PSB038-014 PSB038-015 PSB038-021

Description Hexagon nut (M16) Collared steel eyebolt (M16) Collared steel eyebolt (M20) Eyebolt adaptor (M20) Bearing nut 'C' spanner Valve cage extractor bridge Delivery valve cage extractor assembly Socket spanner - piston rod Short extension bar 3/4" drive Drive adaptor 3rd stage valve cage extractor assembly 3rd stage delivery valve extractor stud 3rd stage delivery valve extractor nut 2nd stage (T bar) - delivery valve extractor

Specialist service tools (which can be manufactured locally) or purchased direct from Gardner Denver Belliss & Morcom, Morcom, can be used to aid compressor maintenance work. Tool Valve extractor Valve extractor Valve holding clamp Valve supporting details Piston rod gland wear checking tool Tool for assembling piston rod packing gland Piston rod clamp Piston rod thread guard cap

©


Drg No DD594 DD622 DD816 DD600 DD938

Supplementary Information Information nd rd (2 & 3 Stage) (1st Stage) Use of clamp DD816

DD579 DD615

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5.4


Issue: Issue:

1


Date:

May 2002


Page:

90 of 145

Waste Products There are very few waste products associated with air compressors: old lubricating oil and oil filter elements and condensate mainly. On closed loop systems, coolant may also be considered.

5.4.1 Oil - After Oil Changes When handling and disposing of sump oil after an oil change several important points need to be followed: a.

Avoid contact with the skin and wash off any contamination immediately.

b.

Dispose of old oil and filter elements in accordance with local regulations.

For further details contact your local oil company representative, or local government department dealing with factory wastes. . 5.4.2 Coolant Coolant from closed loop systems i.e. wate r with anti-freeze added, should be disposed of in a safe manner. For further advice contact the local Water Authority.

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CHAPTER 6 SPARE PARTS

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COMPRESSOR TYPE WH40H3N CHAPTER 6 - SPARE PARTS

6

Issue: Issue: 1 Date:

May 2002

Page: 92 of 145

SPARE PARTS This document provides information regarding the recommended spare parts policy for this equipment. Information regarding recommended consumables and special tool requirements are provided in Chapter 5. 5. Items not identified as a spare can be found within the Illustrated parts list for the compressor. These items, under normal operating conditions, will last for the designed lifetime of the equipment. Fasteners used on this equipment, such as screws, nuts, washers, bolts and clips etc; have not been included within the Spare Lists. For details regarding the fastener refer to the Illustrated Parts List for this equipment.

WARNING! Always use the specified fastener. On no account should a lower specification fastener be used.

6.1

Ordering Spares and Spares to be Held in Stock Stock IMPORTANT - When - When ordering spare parts please quote the following details:     

Compressor Serial Number Compressor Type Description of Part required. Part Number (if available) Quantity required

We recommend that users of our compressors should hold in stock a complete set of spares. The spares stock should be maintained at the original level, replacements being ordered in good time to ensure availability when required. Parts must be kept in good order with appropriate preservation precautions to meet the climatic conditions. The quantities given within the lists are the recommended minimum holding. For spare parts associated with the control console, drive system etc; reference should be made to the spares information and recommendations provided with these items.

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6.2


May 2002

Page: 93 of 145

Spares List COMPRESSOR SPARE PARTS Item

Qty

Part No.

1

1st Stage Top Cover Gasket

1

PSB008-108 PSB008-108

2

2nd Stage Top Cover Gasket

1

PSB008-135 PSB008-135

3

3rd Stage Top Cover Gasket

1

PSB008-044 PSB008-044

4

3rd Stage Top Cover 'O' Ring

1

PSB006-008 PSB006-008

5

Crankcase Door Gasket

2

PSB008-027

6

Main Guide Door Gasket

3

PSB008-006

7

1st Stage Valve 'O' Ring

8

2-70-310-04 2-70-310-04

8

1st Stage Valve Cover 'O' Ring

8

2-70-310-05 2-70-310-05

9

2nd Stage Valve Cage 'O' Ring

8

MB133-48

10

2nd Stage Valve Cover 'O' Ring

8

MB133-49

11

3rd Stage Suction Valve 'O' Ring

4

MB133-56

12

3rd Stage Delivery Valve 'O' Ring

4

MB133-55

13

Actuator Diaphragm

14

1st Stage Piston Rod Pkg Wrg Parts

1 Set

QAP13-64-C32616A QAP13-64-C32616A

15

2nd Stage Piston Rod Pkg Wrg Parts

1 Set

QAP13-64-C32616B QAP13-64-C32616B

16

3rd Stage Piston Rod Pkg Wrg Parts

1 Set

PSB032-061 PSB032-061

17

Piston Rod Scraper Wearing Parts

3 Sets

PSB032-004

18

1st Stage Piston Rings

2

2-28-660-03

19

1st Stage Rider Ring

1

2-28-660-04

20

2nd Stage Piston Rings

3

PSB022-027

21

2nd Stage Rider Ring

1

PSB022-028

22

3rd Stage Piston Rings

5

PSB022-054

23

3rd Stage Rider Ring

1

PSB022-055

24

Piston Rod Piston Nut

3

PSB002-010

25

Oil Suction Strainer

1

PSB025-005

26

Oil Delivery Filter Element C/W 'O' Ring

1

PSB025-010

Oil Filter Element 'O' Ring

1

PSB025-006

Air Inlet Filter Element

1

NSBP-859-004 NSBP-859-004

26A 27

©

Description


12

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PSB028-003





May 2002

Page: 94 of 145

VALVE SPARE PARTS Item

Description

Qty

Part No.

28

1st Stage Valve Plate

8

QAP13-70-8754A QAP13-70-8754A

29

2nd Stage Valve Plate

8

PSB027-014 PSB027-014

30

3rd Stage Valve Plate

8

PSB027-006 PSB027-006

31

1st Stage Valve Damper Plate

4

PSB027-074 PSB027-074

32

2nd Stage Valve Damper Plate

4

PSB027-015 PSB027-015

33

3rd Stage Valve Damper Plate

4

PSB027-007 PSB027-007

34

1st Stage Suction Valve Spring

48

PSB027-011 PSB027-011

35

1st Stage Delivery Valve Spring

48

PSB029-100 PSB029-100

36

2nd Stage Suction Valve Spring

32

PSB027-018 PSB027-018

37

2nd Stage Delivery Valve Spring

32

PSB029-006 PSB029-006

38

3rd Stage Suction Valve Closing Spring

16

PSB027-010 PSB027-010

39

3rd Stage Suction Valve Damping Spring

16

PSB027-011 PSB027-011

40

3rd Stage Delivery Valve Closing Spring

16

PSB029-006 PSB029-006

41

3rd Stage Delivery Valve Damping Spring

16

PSB027-010 PSB027-010

42

1st / 2nd Stage Unloader Circlip

8

PSB027-024 PSB027-024

43

3rd Stage Unloader Circlip Circl ip

4

PSB027-125

VALVE ASSEMBLIES Item

©

Description Description

Qty

Part No.

44

1st Stage suction valv e complete

6

PSB027-181 PSB027-181

45

1st Stage delivery valv e complete

6

PSB029-110 PSB029-110

46

2nd Stage suction valv e complete

6

2-70-553-01 2-70-553-01

47

2nd Stage delivery valv e complete

6

PSB029-085 PSB029-085

48

3rd Stage suction valv e complete

4

2-70-517-01 2-70-517-01

49

3rd Stage delivery valv e complete

4

2-70-518-01 2-70-518-01


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6.3


May 2002

Page: 95 of 145

Illustrated Parts List - Main Component Location View View

Main Component Location View Key Fig 1 Crankcase Assembly Fig 3 Crankshaft Assembly Fig 5 Bearing End Cover Assembly Fig 7 Second Stage Piston Rod Assembly

Fig 2 Fig 4 Fig 6

Connecting Rod Assembly Main Guide Assembly Flywheel End Cover Assembly

Fig 8

Third Stage Piston Rod Assembly

Fig 9 Crosshead Assembly Fig 11 Piston Rod Scraper Assembly

Fig 10 Oil Pump and Cooler Assembly Fig 12 Crosshead Assembly

Fig 13 First Stage Piston Rod Assembly Fig 15 First Stage Top Cover Assembly

Fig 14 First Stage Cylinder Assembly Fig 16 Distance Piece Assembly

Fig 17 First Stage Piston Assembly Fig 19 First Stage Suction Valve Assembly

Fig 18 First Stage Packing Box Assembly Fig 20 First Stage Delivery Valve Assembly

Fig 21 Second Stage Cylinder Assembly Fig 23 Distance Piece Assembly

Fig 22 Second Stage Top Cover Assembly Fig 24 Second Stage Piston Assembly

Fig 25 Second Stage Packing Box Assembly

Fig 26 Second Stage Suction Valve Assembly

Fig 27 Second Stage Delivery Valve Assembly Fig 29 Third Stage Top Cover Assembly

Fig 28 Third Stage Cylinder Assembly Fig 30 Distance Piece Assembly

Fig 31 Third Stage Piston Assembly Fig 33 Third Stage Suction Valve Assembly

Fig 32 Third stage Packing Box Fig 34 Thir d Stage Delivery Valve Assembly

Fig 35 First Stage Interstage Pipework Assembly Fig 37 Cooling Water Assembly

Fig 36 Second Stage Intercooler Assembly Fig 38 Pressure Gauge Assembly

Fig 39 Unloader Assembly

Fig 40 Ancillaries

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May 2002

Page: 96 of 145

Fig 1 Crankcase Assembly (2-03-288) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

©

Part No. 2-03-288-01 MB013-27 MB118-08 PSB024-001 MB006-05 MB011-05 MB050-03 MB038-10 PSB004-010 PSB008-006 PSB008-026 PSB008-027 PSB009-002 PSB009-007 MB130-01 MB118-11 MB006-07


Description Crankcase Bolt M24 x 150 long Plug, 1/2" BSP Breather Setscrew M10 x 20 long Setscrew M20 x 45 long Capscrew-socket M16 x 35 long Spring washer M16 Locking plate Gasket-Crankcase guide Gasket-Big end cover Gasket-Crankcase door Door-Main guide Door-Crankcase Window nut 1 1/4" BSP Plug 3/4" BSP Setscrew M10 x 25 long

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Qty. 1 4 1 1 44 36 6 6 2 3 1 2 3 2 1 1 2





May 2002

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Fig 2 Connecting Rod Assembly (2-76-426) Item 1 2 3

©

Part No. 2-05-090 NSBP-220-025 PSB014-004


Description Connecting rod assembly Split pin Bottom end shell

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Qty. 1 2 1





May 2002

Page: 98 of 145

Fig 3 Crankshaft Assembly (2-06-383) Item 1 2 3 4 5 6 7

©

Part No. 2-06-310-02 2-06-312-02 2-06-383-01 PSB002-008 PSB004-003 PSB014-006 PSB003-010


Description Driving dog Motor key Crankshaft Locknut Washer Washe r Roller bearing Distance piece

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Qty. 1 1 1 2 2 3 1





May 2002

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Fig 4 Main Guide Assembly (2-07-280) Item 1 2

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Part No. 2-07-280-01 PSB006-001


Description Main guide 'O' ring

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Qty. 1 1





May 2002

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Fig 5 Bearing End Cover Assembly (2-25-121) Item 1 2 3

©

Part No. 2-25-121-01 MB046-18 PSB008-023


Description Bearing housing Capscrew M8 x 50 long Gasket - oil pump

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Qty. 1 8 1





May 2002

Page: 101 of 145

Fig 6 Flywheel End Cover Assembly (2-25-123) Item

Part No.

Description

Qty.

1 2 3 4

2-25-123-01 PSB008-028 PSB015-003 PSB007-006

Flywheel end cover Gasket Clamping ring Oil seal

1 1 1 1

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May 2002

Page: 102 of 145

Fig 7 Second Stage Piston Rod Assembly (2-30-144) Item 1 2 3

Part No. PSB002-009 PSB002-010 2-30-144-01

Description Nut Nut 1 5/8" BSF Piston Rod

Qty. 1 1 1

Fig 8 Third Stage Piston Rod Assembly (2-30-202) Item 1 2 3 4

©

Part No. 2-121-001-09 2-30-202-01 NSBP-220-042 PSB002-009


Description Castle nut 1 5/8" BSF Piston rod Split pin Nut

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Qty. 1 1 1 1





May 2002

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Fig 9 Crosshead Assembly (2-31-066) Item 1 2 3 4 5

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Part No. 2-31-045-02 2-31-066-01 MB137-09 PSB001-002 PSB004-001


Description Gudgeon pin Crosshead Circlip Securing pin Locking plate

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Qty. 1 1 2 1 1





May 2002

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Fig 10 Oil Pump and Cooler Assembly (2-34-562)

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May 2002

Page: 105 of 145

Fig 10 Oil Pump and Cooler Assembly (2-34-562) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

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Part No. 2-34-562-01 PSB026-099 PSB026-149 PSB017-011 PSB025-005 PSB025-009 PSB013-033 PSB008-009 2-34-459-02 MB021-06 PSB026-296-04 PSB026-277-04 PSB026-150 MB121-01 2-34-459-05 2-34-562-03 2-34-562-04 2-34-459-03 MB040-63 MB004-03 MB006-03


Description Oil manifold block Oil hose assembly Flexible pipe Oil pump Strainer Filter Relief valve Gasket Stud M10 Nut M10 Union-straight 3/4" BSP Nipple 3/4" BSP Stud adaptor Plug 1/8" BSP Oil cooler Hose-inlet Hose-outlet Bracket Washer M27 Setscrew M6 x 12 long Setscrew M10 x 16 long

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Qty. 1 1 1 1 1 1 1 2 2 2 1 2 2 3 1 1 1 1 4 4 2





May 2002

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Fig 11 Piston Rod Scraper Assembly (2-63-047) Item 1 2 3 4 5 6 7

©

Part No. MB006-05 MB007-03 PSB008-015 PSB008-016 PSB032-001 PSB032-002 PSB032-003


Description Setscrew M10 x 20 long Setscrew M12 x 25 long Gasket Gasket Scraper box Oil shedder Support plate

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Qty. 6 4 1 1 1 1 1





May 2002

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Fig 12 Crosshead Assembly (2-31-067) Item 1 2 3 4 5

©

Part No. 2-31-045-02 2-31-052-04 2-31-067-01 MB137-09 PSB004-001


Description Gudgeon pin Securing pin Crosshead Circlip Locking plate

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Qty. 1 1 1 2 1





May 2002

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Fig 13 First Stage Piston Rod Assembly (2-30-252) Item 1 2 3

©

Part No. 2-30-252-01 PSB002-009 PSB002-010


Description Piston rod Crosshead nut Nut 1 5/8” BSF

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Qty. 1 1 1





May 2002

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Fig 14 First Stage Cylinder Assembly (2-01-908)

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May 2002

Page: 110 of 145

Fig 14 First Stage Cylinder Assembly (2-01-908) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

©

Part No. 2-01-908-01 MB021-11 MB021-13 MB029-10 MB118-04 MB120-01 MB011-10 MB013-08 MB013-10 MB035-11 MB086-27 MB088-09 MB088-22 PSB008-108 PSB008-109 PSB026-143 PSB026-279-05 PSB026-279-07 MB118-08 MB023-10 MB040-16


Description Cylinder Nut M20 Nut M24 Self locking, nut M24 Plug 1/4” BSP Ball valve 1/4” BSP Bolt M20 x 60 long Setscrew M24 x 65 long Setscrew M24 x 70 long Washer M24 Stud M20 x 280 long Stud M24 x 99 long Stud M24 x 290 long Gasket-top cover Gasket-suction and delivery Drain cock 1/2” BSP Plug, csk 1 1/4” BSP Plug, csk 2" BSP Plug, 1/2” BSP Dome nut M24 Washer M24

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Qty. 1 1 17 4 3 1 12 24 12 12 1 4 19 1 2 1 6 8 1 2 2





May 2002

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Fig 15 First Stage Top Cover Assembly (2-04-467) Item 1 2 3 4

©

Part No. 2-04-467-01 MB011-10 PSB026-280-06 PSB026-279-07


Description Top cover Bolt M20 x 60 long Plug 1 1/4” BSP Plug 2" BSP

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Qty. 1 12 1 1





May 2002

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Fig 16 Distance Piece Assembly (2-07-414) Item 1 2 3 4 5 6

©

Part No. 2-07-414-01 2-07-414-02 MB004-01 MB013-11 MB031-13 MB118-04


Description Cylinder distance piece Aperture cover Setscrew M6 x 8 long Bolt M24 x 75 long Washer M24 Plug 1/4" BSP

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Qty. 1 2 16 12 12 1





May 2002

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Fig 17 First Stage Piston Assembly (2-28-660) Item 1 2 3 4 5 6

©

Part No. 2-28-660-01 2-28-660-02 2-28-660-03 2-28-660-04 PSB003-008 PSB003-009


Description Piston-top half Piston-bottom half Piston ring Bearing ring Washer-top Washe r-top Washer-reinforcing Washer-reinf orcing

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Qty. 1 1 2 1 1 1





May 2002

Page: 114 of 145

Fig 18 First Stage Packing Box Assembly (2-64-285) Item 1

©

Part No. 2-64-285


Description Packing Box

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Qty. 1





May 2002

Page: 115 of 145

Fig 19 First Stage Suction Valve Assembly (2-70-489) Item 1 2 3 4 5 6

©

Part No. 2-70-489-01 2-70-310-04 2-70-310-05 2-70-479-03 PSB027-181 PSB028-041


Description Valve cover ‘O’ ring ‘O’ ring Valve cage Suction valve Actuator

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Qty. 1 1 1 1 1 1





May 2002

Page: 116 of 145

Fig 20 First Stage Delivery Valve Assembly (2-70-490) Item 1 2 3 4 5

©

Part No. 2-70-310-04 2-70-310-05 2-70-490-01 2-70-480-03 PSB029-110


Description 'O' ring 'O' ring Valve cover Valve cage Delivery valve

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Qty. 1 1 1 1 1





May 2002

Page: 117 of 145

Fig 21 Second Stage Cylinder Assembly (2-01-531)

©


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May 2002

Page: 118 of 145

Fig 21 Second Stage Cylinder Assembly (2-01-531) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

©

Part No. 2-01-531-01 MB009-11 MB011-05 MB013-06 MB021-11 MB023-09 MB029-09 MB035-11 MB040-15 MB086-08 MB086-22 MB118-04 MB118-07 MB120-01 PSB008-103 PSB008-135 PSB026-279-07 PSB026-280-06 PSB026-143


Description Cylinder Bolt M16 x 60 long Setscrew M20 x 45 long Setscrew M24 x 60 long Nut M20 Dome nut M20 Philidas nut M20 Washer M24 Washer M21 Stud M20 x 85 long Stud M20 x 200 long Plug 1/4" BSP Plug 1/2" BSP Ball valve 1/4" BSP Gasket-suction and delivery Gasket-top cover Plug 2" BSP Plug 1 1/4" BSP Drain cock 1/2" BSP

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Qty. 1 16 12 12 14 2 2 12 2 2 16 2 1 1 2 1 6 1 1





May 2002

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Fig 22 Second Stage Top Cover Assembly (2-04-274) Item 1 2 3 4

©

Part No. 2-04-274-01 MB021-11 MB086-04 PSB026-280-06


Description Top cover Nut M20 Stud M20 x 65 long Plug 1 1/4" BSP

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Qty. 1 12 12 1





May 2002

Page: 120 of 145


©

Part No. 2-07-281-01 MB004-01 MB013-11 MB031-13 PSB009-006 MB118-04


Description Distance piece Setscrew M6 x 8 long Bolt M24 x 75 long Washer M24 Cover Plug 1/4" BSP

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Qty. 1 8 12 12 2 1





May 2002

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Fig 24 Second Stage Piston Assembly (2-28-481) Item 1 2 3 4 5 6

©

Part No. 2-28-481-01 2-28-481-02 PSB003-008 PSB003-009 2-28-481-04 2-28-481-03


Description Piston-top Piston-bottom Washer-top Washe r-top Washer-reinforcing Washer-reinf orcing Piston ring Bearing ring

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Qty. 1 1 1 1 2 1





May 2002

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Fig 25 Second Stage Packing Box Assembly (2-64-286) Item 1

©

Part No. 2-64-286



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Qty. 1





May 2002

Page: 123 of 145

Fig 26 Second Stage Suction Valve Assembly (2-70-503) Item 1 2 3 4 5 6 7 8

©

Part No. PSB027-001 PSB028-001 2-70-126-02 2-70-126-01 PSB003-006 MB133-48 MB133-49 2-70-503-01


Description Suction valve Actuator Cover Cage Distance piece 'O' ring 'O' ring Locating peg

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Qty. 1 1 1 1 1 1 1 1





May 2002

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Fig 27 Second Stage Delivery Valve Assembly (2-70-504) Item 1 2 3 4 5 6

©

Part No. PSB029-066 2-70-127-02 2-70-129-02 MB133-48 MB133-49 2-70-504-01


Description Delivery valve Cover Cage 'O' ring 'O' ring Rod

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Qty. 1 1 1 1 1 1





May 2002

Page: 125 of 145

Fig 28 Third Stage Cylinder Assembly (2-01-481)

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May 2002

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Fig 28 Third Stage Cylinder Assembly (2-01-481) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

©

Part No. 2-01-481-01 MB013-04 MB013-08 MB021-11 MB021-13 MB029-09 MB031-13 MB086-06 MB086-09 MB088-15 MB118-07 MB118-03 PSB026-072 PSB026-280-06 PSB008-044 PSB026-279-07 2-01-481-04 PSB026-143


Description Cylinder Setscrew M24 x 55 long Setscrew M24 x 65 long Nut M20 Nut M24 Philidas nut M20 Washer M24 Stud M20 x 75 long Stud M20 x 90 long Stud M24 x 129 long Plug 1/2" BSP Plug 1/4" BSP Adaptor Plug 1 1/4" BSP Gasket Plug 2" BSP Gasket Drain cock 1/2" BSP

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Qty. 1 16 12 64 8 4 12 64 4 8 1 4 2 1 1 8 2 1





May 2002

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Fig 29 Third Stage Top Cover Assembly (2-04-305) Item 1 2 3 4

©

Part No. 2-04-305-01 PSB026-279-07 PSB006-008 PSB026-279-05


Description Top cover Plug 2" BSP 'O' ring Plug 1 1/4" BSP

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Qty. 1 2 1 1





May 2002

Page: 128 of 145


©

Part No. 2-07-281-01 MB004-01 MB013-11 MB031-13 PSB009-006 MB118-04


Description Distance piece Setscrew M6 x 8 long Bolt M24 x 75 long Washer M24 Cover Plug 1/4" BSP

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Qty. 1 8 12 12 2 1





May 2002

Page: 129 of 145

Fig 31 Third Stage Piston Assembly (2-28-523) Item 1 2 3

©

Part No. 2-28-430-01 PSB022-054 PSB022-055


Description Piston Piston ring Rider ring

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Qty. 1 5 1





May 2002

Page: 130 of 145

Fig 32 Third stage Packing Box (PSB032-060) Item 1

©

Part No. PSB032-060



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Qty. 1





May 2002

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Fig 33 Third Stage Suction Valve Assembly (2-70-236) Item 1 2 3 4 5

©

Part No. 2-70-150-02 2-70-150-03 MB133-56 PSB027-113 PSB028-038


Description Cage Cover 'O' ring Suction valve Actuator

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Qty. 1 1 1 1 1





May 2002

Page: 132 of 145

Fig 34 Third Stage Delivery Valve Assembly (2-70-237) Item 1 2 3 4

©

Part No. 2-70-151-03 2-70-151-02 MB133-55 PSB029-058


Description Cover Cage 'O' ring Delivery valve

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Qty. 1 1 1 1





May 2002

Page: 133 of 145

Fig 35 First Stage Interstage Pipework Assembly 2-71-780

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May 2002

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Fig 35 First Stage Interstage Pipework Assembly (2-71-780) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

©

Part No. 2-79-039-01 2-71-780-01 2-71-413-05 MB011-07 PSB008-029 PSB026-281-04 PSB026-281-07 2-74-032-01 2-71-413-06 MB082-13 MB031-07 PSB008-137 MB009-03 MB118-01 MB118-03 2-136-001 2-71-802 MB011-20 MB021-11 MB086-09 Y24664


Description Vessel-1 st stage Separator Bottom cover Setscrew M20 x 50 long Gasket Plug 1/2” BSP Plug 1 1/4" BSP Relief valve Deflector dish Stud M12 x 95 long Washer M12 Gasket-relief valve Setscrew M16 x 35 long Plug 1/8" BSP Plug 1/4" BSP Temperature gauge Intercooler Assembly Bolt M20 x 90 long Nut M20 Stud M20 x 90 long Philidas nut M12

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Qty. 1 1 1 12 1 3 1 1 1 1 1 1 4 1 1 1 1 12 24 12 1





May 2002

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Fig 36 Second Stage Intercooler Assembly (2-71-781)

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May 2002

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Fig 36 Second Stage Intercooler Assembly (2-71-781) Item 1 2 3 4 5 6 7 8 9 10 11 12 13

©

Part No. 2-79-037-02 2-71-781-01 PSB026-281-04 PSB026-281-06 PSB026-281-02 2-74-033-01 PSB026-281-07 2-136-001 2-72-572-07 MB009-03 2-71-803 MB011-22 MB021-11


Description Vessel-2nd stage Separator Plug 1/2“ BSP Plug 1“ BSP Plug 1/4“ BSP Relief valve Plug 1 1/4“ BSP Temperature gauge Gasket Setscrew-M16 x 35 long Intercooler assembly Bolt M20 x 100 long Nut M20

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Qty. 1 1 3 1 1 1 1 1 1 4 1 24 24





May 2002

Page: 137 of 145

Fig 37 Cooling Water Assembly (2-45-2515)

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May 2002

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Fig 37 Cooling Water Assembly (2-45-2515) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

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Part No. 2-45-2515-01 2-45-2515-02 PSB026-277-06 PSB026-142 PSB026-297-06 2-45-2190-01 PSB026-269-29 2-45-2190-02 PSB026-292-04 PSB026-269-17 MB120-03 2-45-2515-03 2-45-1678-06 PSB026-272-07 PSB026-278-13 2-45-2515-04 PSB026-299-04 2-45-2515-05 2-45-2515-06 PSB026-289-06 2-45-2515 –07 PSB026-361 2-45-2515-08 2-45-2515-09 PSB026-277-04 PSB026-105 PSB026-223 PSB026-213 PSB026-269-10 PSB026-150 2-45-2515-11 15655/12 15656/12 2-45-2515-10


Description Inlet manifold Outlet manifold Nipple 1 1/4” BSP Stud adaptor 1 1/4” BSP Union 1 1/4” BSP Hose Bush 2” x 1 1/4” BSP Hose Tee-pitcher-1 1/4” BSP Bush 1 1/4” x 1/2” BSP Ball valve 1/2” BSP Hose Globe valve 1 1/4” BSP Elbow F 1 1/4” BSP Nipple 1 1/2” x 1 1/4” Flow indicator 1 1/2” BSP Union elbow M&F 1 1/4” BSP Hose Hose Tee 1 1/4” x 3/4” x 1 1/4” BSP Hose Cone adaptor 3/4” BSP Hose Hose Nipple-hex 3/4” BSP Nipple 3/4” BSP Ball valve 3/4” BSP Strainer Bush 3/4” x 1/2” BSP Stud adaptor Hose Tubing nut Tubing sleeve Hose

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Fig 37 Cooling Water Assembly (2-45-2515)

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Fig 37 Cooling Water Assembly - (2-45-2515) Cont. Item 35 36 37 38 39 40 41 42 43 44

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Part No. PSB012-038 PSB026-277-03 2-45-1600-07 2-45-2515-12 MB021-06 2-45-2515-13 PSB026-279-05 PSB026-299-02 MB009-08 MB031-09


Description Flow indicator 1/2” BSP Nipple-hex-1/2” BSP Bracket U-bolt M10 Nut M10 Gasket 3” ANSI Plug 1 1/4” BSP Elbow-union M&F-3/4” BSP Setscrew M16 x 50 long Washer M16

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Fig 38 Pressure Gauge Assembly (2-46-1250) Item 1 2 3 4 5 6 7 8 9 10 11 12 13

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Part No. 2-46-1265 2-46-1250-06 MB101-03 MB111-03 MB106-04 MB108-06 MB120-01 MB142-01 PSB012-011 MB128-01 MB129-03 PSB026-347-02 PSB026-110


Description Gauge panel Adaptor Tube Tee Stud coupling Stud elbow Ball valve, 1/4" BSP M&F Cock, 1/4" BSP Pressure temperature switch Pipe clip Self tapping screw, No 6 x 1/2” long Nipple 1/4" BSP Leather washer

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Fig 39 Unloader Assembly (2-68-642)

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Fig 39 Unloader Assembly (2-68-642)

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Fig 39 Unloader Assembly (2-68-642) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

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Part No. MB101-03 MB108-05 MB108-06 MB110-04 MB111-03 MB128-01 MB128-02 11911/3 PSB012-012 PSB012-063 PSB026-277-03 PSB026-349-02 PSB026-350-03 PSB026-269-05 MB124-08 PSB012-064 44110/13 MB031-04 PSB026-347-02 MB021-04 2-68-642-02 2-68-642-01 PSB026-286-19 MB096-03 MB106-05 2-68-642-03


Description Tube Elbow-stud, M Elbow-stud, M Tee-stud, M Tee 6mm equal Pipe clip Pipe clip Screw, pan head Poppet valve Blow down valve Nipple 1/2” BSP hex Union 1/4” M&F Bush 3/8” x 1/4” BSP Bush 1/2” x 1/4” Adaptor-M Diffuser Stud M6 x 110 long Washer M6 Nipple 1/4” BSP Nut M6 Solenoid valve Poppet valve, 3/2 Tee-1/2” BSP Coupling-straight Coupling-stud-M Coil plugs

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Fig 40 Ancillaries (2-150-055) Item 1 2 3 4 5 6 7 8

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Part No. 2-87-012-01 NSBP-859-004 2-76-419 2-61-209 2-61-210 2-49-128 2-76-427 2-76-429


Description Filter silencer Air filter element Chocking bracket assembly Index plates Silica gel bags Spanners and tools Crankcase plugging kit Drain trap fittings

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APPENDICES

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SAFE WORKING LIMITS Gardner Denver Belliss & Morcom Ltd Chequers Bridge, Gloucester, GL1 4LL, England

EQUIPMENT MODEL MODEL No…………………………………………………..…… No…………………………………………………..…… VH40H3N

MAXIMUM MAXIMUM COMPRESSOR SPEED:………………………….………..……… 750 RPM 1st STAGE MAXIMUM MAXIMUM WORKING PRESSURE:……………………..……..… 3.5 BAR G 2nd STAGE MAXIMUM WORKING PRESSURE:……………………...……… 14.0 BAR G 3rd STAGE MAXIMUM WORKING PRESSURE:……………………………….47.8 BAR G

MAXIMUM TEMPERATURES: TEMPERATURE S:

3rd Stage Delivery Pipe………….… 175 °C 3rd Stage Separator Pipe………..… 65 °C

MAXIMUM MAXIMUM AMBIENT TEMPERATURE:……….……………… TEMPERATURE:……….…………………………….… …………….… 45 °C COOLING WATER WAT ER PRESSURE:

Maximum…………….…………….. 7.0 BAR G Maximum…………….…………….. Minimum…………………………… Minimum…………………………… 3.0 BAR G

COOLING WATER WAT ER TEMPERATURE: Maximum…………...……………… 36 °C Minimum………..…………………. 16°C COOLING WATER MINIMUM MINIMUM:: FLOWS

OIL PRESSURE:

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1ST STAGE COOLER/CYLINDERS COOLER/CYLINDERS 10.0 m3/hr 2ND STAGE COOLER……………. 8.0 m3/hr AFTERCOOLER………………….. 9.0 m3/hr Start-up Maximum………………… 8.0 BAR G Normal Operation Maximum…….. 4.8 BAR G Shut Down Down Minimum……………… Minimum……………… 1.8 BAR G

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WARRANTY REQUEST CLAIM FORM

Gardner Denver Belliss & Morcom Ltd Chequers Bridge, Gloucester, GL1 4LL, England

QUALITY MANUAL

CLAIM DATE:

SECTION 1 - Request For Authorisation Authorisation To Proceed With Work

Y Number and Category Number

Y __ __ __ __ __ / __

Customer:

Agent:

Site:

Site Address:

Contact: Fax / Tel No: Serial No: Machine Type:

Date Despatched:

Date of Commissioning:

Warranty End Date:

Hours Run:

Customer Order No:

Problem / Defect:

This form is to be completed and faxed to Belliss & Morcom Service Department PRIOR to PRIOR to commencement of work. Fax No: +44 (0) 1452 338317. All 338317. All parts are to be returned to Belliss & Morcom by the most economical means of transport unless otherwise requested. Should failed parts not be returned within 60 days of the date of this claim, Belliss & Morcom shall reserve the right to charge for parts replaced. Authorisation to Proceed: Yes

No

Signed:

Date:

SECTION 2 - Warranty Claim Details Action Required / Taken: Detail Below

Date of Issue This Sheet - JUNE 2001

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Completion Date:

Document No. CM4F2

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Rev. 6

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WARRANTY REQUEST CLAIM FORM

Gardner Denver Belliss & Morcom Ltd Chequers Bridge, Gloucester, GL1 4LL, England

QUALITY MANUAL

VOLUME 4

Continuation

Parts Used Part Description:

Part No. (If Known)

Continue on a separate sheet if necessary. Details of Labour (sub contract or direct)

For Gardner Denver Belliss & Morcom Internal Morcom Internal Use Only Warranty Claim Categories

Estimated Value of Warranty Claim

A-

Warranty Warr anty claim for a f ailure of GDB&M product where reasons reasons for failure cannot be allocated to others.

Value of Parts

£_________

B-

Warranty Warr anty claim charged to external suppliers.

Value of Labour

£_________

C-

Warranty Warr anty claim charged to manufactur ing, i.e. rework caused by original manufacturing defect or failure.

Total

£_________

D-

Goodwill expenditure particularl y after warranty expiry date.

E-

Warranty Warr anty claim due to design defect or problem.

F-

Warranty Warra nty claim due to incorrect or failure of service work.

G-

Warranty Warr anty claim due to incorrect contract specification or failure to Authorised _________________ include a feature or requirement specified by the customer.

H-

Special reason please state.

Signed ____________________

Dated _____________________ X-

Warranty Warr anty claim that cannot be attribut ed or deferred to any of the above, therefore remains "uncategorised".

Date of Issue This Sheet - JUNE 2001

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Document No. CM4F2

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Rev. 6

Page 2 of 2


COMPRESSOR LOG SHEET Gardner Denver Belliss & Morcom Ltd Chequers Bridge, Gloucester, GL1 4LL, England

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WH40H3N (set-04)

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