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    Hamworthy Main Air Compressor

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    2K views64 pages

    Hamworthy Main Air Compressor

    Uploaded by

    june
    Hamworthy Main Air Compressor

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    Service: Main Air Compressor Type: 2SF4 Serial No: CO 44795-29/30 DEN ~ DieCompREst oe, TSR = Aue Comp. HAMWORTHY Pumps & Compressors 2SF4F Mk.II Two-stage Air Compressor Part No. 50102417 Publication No. PCH 1204 HAMWORTHY PUMPS & COMPRESSORS LIMITED Fleets Corner, Poole, Dorset. BH17 7LA. England. Telephone; 0202 665566. Telex; 41348 (HAMPAC G). Fax; 0202 665444. Offices in London Stockport and Troon (Scotland). Offices or associate companies in Allentown (P.A.), Bombay, Cape Town, Oslo, Osaka, Rio de Janeiro, Rotterdam, Singapore, St. Catherines (Ontario), Sydney, and agents throughout the world, Standard Performance Range Specification Recommended Maximum Wear Clearances General DETAILED Crankase and Cylinder Block Moving Parts . Crankshaft Connecting Rods Piston Cylinder Head Relief Valves Suction andDeiiveryValves |. Lubrication System ‘i i G20 4G x Oil Pump f eee ea OilFitter : a a Water Cooling System Water Circulating Pump Water Jacket Bursting Disc First Stage Cooler Second Stage Cooler : High Water Temperature Switch WaterJacketInletandOutletThermometers = sss Water Shut-off Valve cielgce 7 009 Air Pressure Safety Valve ‘i PressureGauges . Delivery Line Non Return Valve : AutomaticOrainTrap pees ‘Automatic Unioader - Plunger Operated AirGovernor 5 eS Solenoid Operated Unioader/Cooler DrainValves§ =. | | | High Air Temperature Switch jl : Air elivery Thermometer Low Lubricating Oil Pressure Switch Heat Exchanger and Jacket Water Circulating Pump Heat Exchanger Water Circulating Pump Thermostatic By-Pass Valve Radiator with Jacket Watar Circulating Pump Automatic Controls INSTALLATION DATA COOLINGWATER QUANTITY : FECOMMENDED COOLING PIPEWORK DIMENSIONS COOLING WATER TEMPERATURE RECOMMENDED LUBRICANTS ‘Compressor Crankcase Lubricant CoolingWaterPumplubricants + Motor Lubricants : Cooling Water Pressure Compressor Weight and Dimensions INSTALLATION PROCEDURE General Location Suggested Marine installation Procedure ‘Ships Compressor Mounting CONTENTS SECTION 1 — TECHNICAL DATA Page WwW wv 73 SECTION 2 — DESCRIPTION 2 12/2 2/2 2/2 2/2 12/2 12/2 2/2 2/2 12/3 bo 128 2/8 12/8 12/8 12/8 12/8 12/8 2/8 2/8 12/6 12/8 12/6 22/7 2/7 5 12/8 poe 2/8 cee 2/8 Bolt 2/9 ee 12/9 : to. 62/9 2/3 2/9 2/3 2/3 29 SECTION 3 — INSTALLATION 31 3/1 3/1 3/2 Do. 13/2 toe 18/2 3/2 3/2 13/4 13/4 13/4 3/4 ‘Suggested industrial installation Procedure Foundations Aligament of Sets with Pin Type Butter Coupling Alignment of identical Half Couplings Electrical installation MainAirLine : Automatic Unioader {WhenFitted) —. Pressure Switch and Solenoid Valve Connections: ‘Automatic Drain Trap (When Fitted) Non-return Valve (When Fitted) Poly-V Belt Drive Recommendations for Cooling Water" : CoolingWater Temperature. oe Cooling Water Pressure Cooling Water Quantity Water Pipe Size and Layout PRINCIPLE OF OPERATION Compressor ee ao Automatic Valves en 5 Non-return Valve , : Automatic OrainTrap(Whenfitted) | |) ‘Automatic Unioader (When Fitted) AirGovernor. ee Water Shut-off Valve Poot Automatic Controls ene cee OPERATING PROCEDURE Checks Sefore Initial Run Commissioning Procedure Starting (Manual Control Only) Starting the Compressor on Automatic Control Aspe otis aria Covet OilLevel Te 7 Oil Pressure : : . CoolingWeterSystem | |! 7 : Air Pressure Safety Valves ROUTINE MAINTENANCE General ; a0 Adtomatic Valves a0 c Suction Valves Delivery Valves : Aur Filter/Silencer Topping Up Crankcase Suma with Lubricating Oi! Oil Fier and Crankcase Sump ‘Arr Coolers (General) Compressor Not in Use OVERHAUL OR REPAIR OF COMPRESSOR, General Compressor Oismantiing Procedure Removal of Second Stage Cylinder Head Removal of First Stage Cylinder Head First Stage Cooler Remove and Refit Second Stage Cooler Remove and Refit : Removal of Piston and Connect ng Rod First Stage Cylinder “Wet” Liner Fiywheel/Crankshaft Assembly Cleaning ana Inspection Installation of Flywheel and Crankshaft Assembly First Stage Cylinder “Wet” Liner Installation of Piston and Connecting Rod Installation of First Stage Cylinder Head -3/6 3/6 23/7 13/8 13/8 : 15 3/8 ae +: 3/8 ae) fo. l 1379 : 13/3 23/8 :3/9 13/3 13/8 13/8 . 23/8 sos 3710 SECTION 4 — OPERATION ss et AAA neva 24/2 4/2 14/2 14/2 473 24/3 2 ale ee ney : 14/5 toll lars eee?) ee.) ; 14/8 14/6 ‘SECTION 5 — MAINTENANCE 5/4 15/4 5/4 5/6 5/8 5/6 5/6 5/7 13/7 5/8 5/8 5/8 “5/9 15/9 “5/9 5/8 5/9 3/10 5/10 5/10 8/1 5th 5/11 8/11 5/12 Installation of Second Stage Cylinder Head Sub-Assemblies and Ancillary Equioment General : Lubricating Oil Pump Removal and Dismantling of Pump ‘Assembly and installation of Pump il Pressure Relief Vaive Water Pump (if Fitted) Removal and Dismantiing of Pump Assembly and Installation of Pump Automatic Drain Trap ‘Automatic Delivery Line Unloader - Plunger Operated. Removal and Dismantling Procedure Assembly and Installation of Unioader Inspection or Removal of Big End Shell Bearings Removal of Connecting Rod Big End Bearing Shells : Inealaion end Assembly of Connecting Rod Big End Bearings Automatic Valves 5 Delivery Line Non-Return Vaive : Removal and Inspection of Delivery Valve Asgembly and instalation of Delivery Valve Spare Parts Ordering Procedure , Air Pressure Safety Valve RECOMMENDED MAXIMUM WEA CLEARANCES. COOLINGWATER QUANTITY RECOMMENDED COOLING WATER PIPEWORK DIMENSIONS RECOMMENDED LUBRICANTS MAINTENANCE SCHEDULE FAULTFINDING CHART USTOF PARTS, Arrangement of 2SF4 Compressor Automatic Valve A Oil System and Flow Diagram” Principle of Flexible Rotor Water Pump Air Pressure Safety Valve Non-ReturnValve Automatic Unioader~ Plunger Ooerated Automatic Drain Trap, AirGovernor Water Shut-off Valve. General Arrangement of 2SF4 Compressor Suggested Installation on Fabricated Mountings Anti-vibration Pads for Marine Installation Foundation Template a : ae Alignment ofCouplings-PinType ao Alignment of Couplings - Identical inal ype Alignment of Belt Orwve AirFlowSchematicDiagram 5. ss Principle of Automatic DrainTrap |. oa Typical Compressor Installation with Automatic Contra! ‘Automatic Vaives ace nea Flexible Rotor Water Pump : : Automatic Drain Trap ee Automatic Delivery Line Unloader Delivery Line Non-Return Valve Air Pressure Safety Valve Air Governor Woter Shut-off Valve Sectional Arrangement 2SF4 Compressor Drawing No. 04614 Sheets 1. 2. 8/12 5/13 5/13. 25 8/18 2. 8/18 5/14 B/14 5/14 B/14 5/18 8/17 8/17 8/17 + 8/18 oes 8718 ols 8/18 + 8/18 oll 8719 5 5/19, 5/19 5/19 8/20 8/20 TABLES Page 1/3 23/1 13/1 13/2 18/1 5/2 5/21 ILLUSTRATIONS, v6 273 124 22/8 127 12/7 278 2/8 2/8 22/8 23/3 3/8 23/6 13/8 3/7 23/8 3/10 “4/1 4/2 4/3 :8/8 5/15 5/18 5/17 5/18 5/20 5/30 5/32 WARNING 1. Health & Safety Act Compliance. Before working on this equipment personnel should be made aware of, ‘and ensure compliance with, the Health and Safety Regulations appropriate to this class of work. PLEASE NOTE 2. Before iting, installing and operating the unit. the instructions detailed below, and also the accompanying ‘manual, must be read. 3. Ensure that all equipment used for lifting the unit is adequate for the weight. The weight is normally stencilled on the unit and/or stamped on the machine nameplate 4. The handling points are indicated on the unit and these must be used. The hooks of slings must not be fitted directly to lifting eyebolts or lugs, shackles must be used. 5. Before running the unit for the first time, the installation must be thoroughly checked and the procedure detailed in Section 3 of the manual, under the heading “Checks Before initial Run”, referred to. 6. The unit must not be run unless all protective guards supplied with the equipment are in position. 7. Before proceeding with maintenance on the unit, or making adjustments to its connections and fittings, it must be stopped and isolated electrically and mechanically and visible warning notices displayed. Some units are on automatic standby duty, or isolators are remote from the unit. and extra care is then necessary to be sure that isolation is complete. 8. Before commencing repair or overhaul a preliminary check of available spares must be made, e.g. replace- ‘ment set of O-rings, joints or joiming material 9. On compressors when work is to be proceeded with on'water and/or air passages, the unit must be vented of all pressurised air and drained of cooling water. 10. Pumps handle various liquids, sometimes not those for which the pump was initially supplied. Know the properties of the liquids that have been pumped, and actions necessary to make handling safe and in the event of an emergency. 11. Before commencing work on a pump, close the suction and discharge valves in the system pipelines and remove the casing drain plug to ensure that the pump interior is at atmospheric pressure. WARNING: THIS EQUIPMENT CONTAINS ASBESTOS. BREATHING ASBESTOS DUST IS DANGEROUS TO HEALTH. FOLLOW SAFETY INSTRUCTIONS. GASKET JOINTING MATERIAL USED IN THIS EQUIPMENT MAY INCLUDE ASBESTOS. REMOVE AFTER SOAKING WITH OIL OR WATER, PREFERABLY ASSISTED BY USE OF HAND TOOLS. POWER TOOLS SHOULD NOT BE USED UNLESS SUITABLE DUST EXTRACTION IS PROVIDED OR RESPIRATORY PROTECTIVE EQUIPMENT IS WORN. PLACE WASTE MATERIALS IN HEAVY GAUGE PLASTIC SACKS AND DISPOSE OF AS ADVISED BY THE LOCAL WASTE DISPOSAL AUTHORITY. ‘Standard Performance Range Free Air Delivered Pressure Speed Specification Number of Stages Number of Cylinders Suction Valves Delivery Valves First Stage Cooler Second Stage Cooler Air Pressure Safety Valve Relif Valves (Water) Relief Vaives (Oil) Fusible Plug Crankshaft Main Bearings Thrust Washers Connecting Rod Connecting Rod Big End Bearing Connecting Rod Small End Bearing Pistons il Pump Oil Fiter Air Filter/Silencer ‘Water Pump *Unloader “when Fitted Piston Ring Gap 2sF4 First Stage Second Stage 2sF42 First Stage Second Stage Piston Ring Clearance First Stage In Groove Second Stage Crankshaft End Float Cylinder Head Clearance Sump Capacity Torque Settings Valve Cage Setscrew (Item 161) Valve Cage Capscrew item 236 and 166) Connecting Rod Balt Nut (Item 3) Cylinder Head Nuts 1st Stage tItem 77) Cylinder Head Nuts 2nd Stage litem 186) Cylinder Head Nuts 2nd Stage (Item 189) SECTION 1 — TECHNICAL DATA 2sr4 2SF42 22 to 73 mi/h, 38 to 109 m3/h 14 10 42 bar 14 10 30 bar 585 to 1750 rev./min. 885 to 1750 rev./min. Two Two (Low Lift low inertia plate type (One per stage 3 Copper 'U' tubes 2 Copper ‘U' tubes, One per stage. Set 10% above stage working pressure, Bursting disc. Relieves at 2.1 bar (2.8 bar special order) Integral with oi! pump. Relieves at 2.8 bar Fusing Temperature 121°C Single Crank, Two Bearing Shaft with Integral Balance Weights Two. Steel backed. White metal ined. Incorporated in Main Bearings. One. Forged Steel/S.6. Iron. One. Steel backed. White metal lined shells. (One Lead Bronze Bearing Bush Steeple Type. Aluminium. with Integral Buffer Piston, Rotary Gear Type Cartridge Tecalemit RT.40.70. Full Flow Type Fitted to First Stage Air Inlet Rotary Self-priming Air Operated (early machines) Solenoid Operated (later machines) Unloading on First and Second Stage Coolers 0.304 to 0.406 mm 0.229 t0 0.304 mm. 0.356 t0 0.508 mm. 0.229 t0 0.304 mm. 0.083 t0 0.139 mm, 0.0125 to 0.083 mm 0.808 to 0.762 mm 0.308 to 1.270 mm. 1st Stage 0.762 to 1.524 mm. 2nd Stage 7 Litres Minimum 12.5 Litres Maximum 5.83 Kgf m. 5.53 Katm 8.3 Kgfm 4.2 Kgfim 83 Kgfm 4.2 Kgf.m, mw Maximum Compressor Weight Bare Compressor 398 Ka, Baseplated Set 898 Ka. Hydrostatic Test Pressures ~ Cooler Tubes 2sFa First Stage 10.8 bar Second Stage 84 bar 2sFa2 First Stage 10.5 bar Second Stage 62 bar 2 RECOMMENDED MAXIMUM WEAR CLEARANCES — 2SF42F amo RECOMENDED EE ALL MEnsions eCOMMENDED Scrone RENEWAL eae Sceenanee serone id wn] max, sree [Pato 087 eis 7 sore wees TRosTaGe | RSTON vas 2B zone a2 SALE SUBGEDH a On oats aa - use : az siGENo vounway | oate wm aeaning 7 = wane vounnat | mts oe zeaning : = Baron vetsraceé |i NS in 2ND STAGE 1.108 ang worn om 1ST STAGE COMPRESSION 7 - EMSe. onoovemonr] «O° }oOvES COMPRESSION 7 340 RING WOTH Se an : | ou asosrace [ COON = 388 ance : Srovts | anewiere Te causa iN GROOVE WIDTH 0.208 _ zie Geenewon ceancsuart| omexsion | ose END FLOAT WHEN, 10.762 Mew All recommendations are supplied for guidance only, The criteria to be used for replacement should be loss of performance or material damage. The above figures, may however be of some advantage for planned maintenance procedures. 1a Air Pressure Safety Valve - 2nd Stage Oil and Air Pressure Gauges Air Pressure Safety Valve - 1st Stage Low Lubricating Oil Pressure Switch * Automatic Delivery Line Unioader Water Circulating Pump 2SF4 Air Compressor s Hand Drain Valves H* Automatic Orain Valves J k L M. Automatic Orain Block Oil Pump Air Inlet Filter and Silencer High Water Temperature Switch Alternative systems SECTION 2 — DESCRIPTION GENERAL {A pictorial illustration of the type 2SF4 compressor is shown opposite. The compressor is a medium pressure two stage. single crank, single acting, water cooled machine. It has been designed primarily as a compact and cobust marine unit suitable for starting, control air dutias and general service air. However. its attributes make the compressor equally suitable for many industrial applications. The dasign is in accordance with the best modern practice, the outstanding features being compactness and ease of maintenance. The valves are particularly accessible, ‘A combined filter and silencer on the air intake protects the machine from atmospheric impurities and also reduces the ambient noise level Each compressor is supplied complete with all the necessary fittings, These include first stage cooler, second stage cooler, air and water pressure safety/relief valves. drain cocks and pressure gauges. The air pressure gauges are mounted on an instrument bracket together with an oil pressure gauge. This instrument bracket is fitted at 2 convenient height on the non-drive end of the machine. Lubrication is automatic, all bearing surfaces being force fed by an integral gear pump, driven from the crankshaft. The system is fitted with 2 full flow type oil filter and spring loaded relief vaive. The lower cylinder walls are lubricated by oil mist. A supply of cooling water is required. Closed circuit or constant flow systems are used dependent upon machine specification. Where a constant flow system is to be-used water inlet and outlet connactions to the machine must be sized to obtain the water flow requirements detailed in Section 3. A water circulating pump, drivan from the compressor crankshaft, can be supplied. A water jacket safety valve is fitted to the compressor as a protection against excessive pressure developing in the event of an internal leakage, Baseplated units complete with electric motors. or other typas of prime mover, can be supplied as required. Automatic control systems, unloading equipment, drain traps, non-return valves and moisture separators can also be supplied on request. an DETAILED Crankcase and Cylinder Block The crankcase and cylinder block are combined in one casting. Two main bearings are fitted: the drive end bearing is fitted in a bearing housing bolted to the crankcase and the non drive end bearing is fitted directly in the crankcase. A large inspection door is provided on one side of the crankcase permitting access to all working parts, A lubricating oil dipstick and filler is located at the non drive end of the crankcase and above the oil pump on the same side is fitted a crankcase breather. ‘The cylinder block is fitted with @ first stage centrifugally cast liner. The liner is a light drive fit in the cylinder block. sealed at the bottom by two O-ring seals and at the top by the first stage cylinder head to crankcase joint. The cylinder head retains the liner in position. Moving Parts ‘These comprise the crankshaft, connecting rod and piston. Crankshaft. The crankshaft incorporates integrally cast balance weights and is drilled at the non drive end for the oil ‘pump coupling collar drive pins. The crankshaft drive end is provided with a keyway and is drillec and tapped for attach- ment of the flywheel Connecting Red. The connacting rod is fitted with thin wall, steel backed, white metal lined big end bearing shells and a lead bronze small end bearing bush. Piston. The aluminium alloy piston is of the steeple type which incorporates both stages. The first stage section is fitted with two compression rings and two slotted oil control rings and the second stage section with four compression tings. A fully floating gudgeon pin is retained in the piston by internal circlips. Cylinder Heads and Air Pressure Safety Valves The first stage cylinder head incorporates the integrally cast second stage cylinder. the first and second stage suction chambers, the first stage delivery chamber and a transfer passage for air passing from the first stage cooler tothe second stage suction chamber. It is located concentrically with the first stage cylinder liner by means of a spigot on the liner and is retained by studs. spring washers and nuts. The second stage cylinder head incorporates the cast delivery chamber, two passages from the delivery chamber to the second stage cooler. and the final discharge chamber. The final discharge chamber is fitted with the second stage safety valve, a condensate drain valve, a fusible plug. and a tapping for the final air delivery, NOTE: The lifting eye-bolts fitted in the cylinder head are suitable to lift the compressor complete with flywheel and ‘MUST NOT be used to lift a unit complete with baseplate and motor. ‘A combined suction ait flter/silencer is fitted on the side of the cylinder head and connected to the suction chamber, An air pressure safety valve. fitted in a tapping in the air transfer passage, is set to crack at 10% above first stage normal working pressure.Also mounted on the side of the cylinder head is the water jacket bursting disc ang its mounting flange. This disc will burst should the water jacket pressure rise due to an internal air leak and thus alleviate eny further danger. Should the final air temperature rise above a predetermined scale 50 unload the machine F any reason the fusible plug will meltto release air and ‘Suction and Delivery Valves ‘The suction and delivery valves open and remain open by differential fluid pressure and are closed by spring plates when. the fluid pressure ceases. One suction and one delivery valve is provided for each stage and are located in their respective cylinder heads, Each valve makes metal to metal contact with its seat and is retained in the cylinder head by a valve cage. The cage is, secured to the cylinder head by screws and an O-ring is used to seal each valve. Automatic Valve Seat Buffer Plate Centre Bolt Valve Plate Cushion Plate Spring Plates Guide Washer Locating Pin - seat Slotted Nut 1a, Self Locking Nut (Alternative) Washer Spitt Pin Lubrication System A schematic flow diagram of the compressors lubrication system is illustrated. The main bearings and big end bearings are pressure fed with oll from a rotary gear type pump located in the crankcase. The pump is directly driven from the nan drive end of the crankshaft by means of drive pins and @ coupling collar. Oil is drawn from the crankcase reservoir through @ ful flow oil filter into the oil pump. The oil is then fed through drilled Passages in the crankshaft to the main, big-end and small-end bearings. The oil pump incorporates an oll pressure reliat valve (see Data page for setting) The cylinder walls are lubricated by oil mist 218 ll System and Flow Diagram A 8 c 0. E F Full Flow Oil Filter il Pump Oil Pressure Gauge Pressure Feed to Small End Bearing Pressure Feed to Main and Big End Bearings Inset ~ Oi! Mist Lubrication to Small End Bearing prior to October 1980 216 Oil Pump. The oil pump comprises a body and cover which tagether house the driving and driven gear impellers ‘The impeller shafts run in bearing bushes in the pump body. ol Fitter ‘The oil filter is located at tha non drive end of the machine and is ofthe full low type. The filter consists of a bonded paper element attached to the filter caver by means of a stud, washer and aut, The filter cover is attachad to the crankcase by satscrews. NOTE: The operating oil pressure may vary from the figure quoted on the Data page dependent upon oil temperature and viscosity. ‘The compressor cooling water inlet is situated at the non drive end of the compressor cylinder black at the bottom. The cooling water outlet is at the opposite end of the machine at the top of the second stage cylinder head NOTE: When the comprassor is fitted with a water circulating pump it is mounted on the oil pump at the non drive end of the machine. The water inlet to the machine is then at the pump suction flange and the delivery flange of the ‘pump is connected to tha cylinder head by a copper pipe. The cooling water circulates around the first stage cylinder liner and cooler tubes and into the first stage cylinder head ‘where it cools the valve pockets, second stage cylinder and associated cooler tubes. The water then passes into the second stage cylinder head cooling the valve pockets and completes the circuit by passing through the cylinder head outlet flange, Water Circulating Pump (When specified) The water circulating pump is a flexible rotor, positive displacement type pump. It comprises a body and end cover which house a rotor and a cam to operate the impeller flexible blades. The rotor is mountad on a shaft which is carried in two. ball bearings fitted in a separate bearing housing bolted to the body. Sealing of the pump is achieved by means of a mechanical seal fitted to the pump shaft Principle of Water Pump Water Jacket Bursting Disc ‘The first stage cylinder head is provided with a water jacket bursting disc to protect the machine in the unlikely event of {an internal air leak, ist Stage Cooler The first stage cooler consists of three U-shaped tubes secured to the first stage cylinder head by compression fitings ‘and suspended into the cylinder block water jacket. ‘Second Stage Cooler The cooler for the second stage is similar to that of the first stage: comprising two U-shaped tubes which are secured to the second stage cylinder head by compression fittings. The tubes in this case are suspended into the first stage cylinder head water jacket. 208 High Water Temperature Switch (When specified) The high water temperature switch, when required. 1s fitted into a tapping in the side of the second stage cylinder head Should the water temperature rise above a predetermined level the switch will stop the compressor by means of the automatic controller Water Jacket Inlet and Outlet Thermometers (When specified) When required water inlet and outlet temperature thermometers are screwed into tappings in the compressor crankcase and second stage cylinder head adjacent to the inlet and outlet connections. Water Shut-off Valve (When specified) ‘The water shut-off valve is fitted to the compressor water jacket inlet tapping. Its pneumatically operated by air taken from a tapping in the first stage cooler, via an adjustable air flow control valve. which restricts the ai flow from the diaphragm chamber to provide slow closing of the valve. The vaive consists of a valve body. vaive assembly and valve over. tis spring loaded in the shut position and is operated by a diaohragm, housed in an adapter flange and top cover, assembly, through @ push rod. Water Shut-off Valve Top Cover Diaphragm Adapter Flange Assembly Pushrod Globe Valve Body Valve Cover Compression Spring Valve Assembly rommoo@> Air Pressure Safety Valves ‘An air safety valve is fitted into a tapping to each of the first and second stage cylinder heads. Each valve comprises abody cap and seat which together house a plunger and spring. The spring pressure is set by means of the adjuster so that the valve will lift at 10% above its associated stage operating pressure. Pressure Gauges The first and second stage air pressure gauges together with the oll pressure gauge sre mounted on 2 support anglé secured to the first stage cylinder head. When larger {102 mm.) diameter gauges ara specified they are mountec on a board secured to the cylinder head ‘The first stage gauge 1s connected by copper pipe to the transfer passage in the first stage cylinder head and the second stage gauge similarly to the second stage cylinder head. Gauge cocks are incorporated in the connecting pipe lines to the air gauges to contral gauge pointer vibration 26 Air Pressure Safety Valve A. Spring Sleave 8 Spring © Spindle Non Return Valve ©. Spring Seat €. Setting Collar AL Valve Cage Valve 8. Valve Housing G. Valve Seat C. Delivery Valve Delivery Line Non-Return Valve (When specified) The function of the non-return valve is to prevent the reverse flow of air from the raceiver back to the compressor. ‘This 1s particularly important when a delivery line unloader 1s fitted, A practical feature of the design is that the delivery valve can be removed for routine service or replacement without disturbing the pipeling connections. The umt consists of a valve housing and a valve cage which togetner house a low inertia type delivery valve. The delivery valve 18 similar to those fitted in the compressor and reference should be made to the compressor automatic valves illustration. Automatic Drain Trap A. Orain Cap 8. Silencer © Cap D Body E. Adapter Automatic rain Trap The automatic drain trap discharges condensate from the compressor coolers and comorises a body. cap and drain cap which together house @ disc and screen. Shims are fitted between the cap and body and the screen is retained by the drain cap, All components are of stainless steel The drain traps are normally mounted on a connecting block at the non drive end of the machine, 27 Automatic Unioader — Plunger Operated (When specified) The unloader comprises a top body. a lower body and a diaphragm cover which together house the first and second stage valves. valve seats and plungers. The vaives are spring loaded onto their seats which also act as valve guides, ‘The unloader is mounted on the non drive end of the cylinder block and the exhaust air escapes to atmosphere through inlet filter silencer without causing excessive noise ‘Automatic Unioader — Plunger Operated Top Plug ‘Second Stage Spring Second Stage Ball Valve Exhaust Connection Second Stage Plunger First Stage Ball Valve Diaphragm Air Governor Connection Diaphragm Backing Disc First Stage Plunger First Stage Inlet Connection First Stage Spring Second Stage Inlet Connection bP Zerneronmoomy Air Governor (When specified) The air governor contrals the operation of the main air delivery line unloader and is fitted to the air receiver: itis connected to the unloader by a pipe. The governor consists of a body. a spring loaded valve and spindle and an upper and lower seat. Adjusting collars are provided for setting the cut-out pressure and shims for adjusting the cut-in pressure, Ar from the receiver passes through a mesh filter Solencid Operated Cooler Drain Valves /Unioader (When specified) Solenoid operated cooler drain valves drain the condensate from the coolers whilst operating on @ pressure switch controlled START-STOP cycle. The valves being of ‘normally open’ construction, vent the coolers and pressure spaces lof the compressor whilst its stationary and provide an unloaded state for cestarting. Air Governor A. Spindle 8 Adjuster ©. Collar D. Upper Seat E F 6. H Shims Body Lower Seat Adapter 218 When the compressor is started adjustable timed contacts energise and de-energise the solenoid operated drain valves to bring the compressor on load and to drain condensate from the coolers, The frequency of the condensate drainage and the drain period are independently adjustable, High Air Temperature Switch (When specified) The high air temperature switch. when required, is fitted into the second stage delivery valve cage, Should the compressed air temperature rise above a predetermined level the switchwill stop the compressor by means of the automatic controller. Air Delivery Thermometer (When specified) When itis required to monitor the temperature of the air delivered by the compressor a thermometer is fitted in the final air delivery outlet flange, Low Lubricating Oil Pressure Switch (When specified) The low lubricating oil pressure switch is mounted on the non drive end of the cylinder block and is connected into the oil pressure gauge pipe. The switch is set to stop the compressor. through the automatic controller, should the lubricating oll pressure drop below a predetermined level Heat Exchanger and Jacket Water Circulating Pump (When specified) When specified a heat exchanger is fitted for cooling the compressor jacket water system: the compressor system is then ‘closed circuit’ with a water make-up tank incorporated The heat exchanger is mounted longitudinally on the compressor and motor baseplate with the jacket water inlet and outlet flanges adjacent to the compressor water pump. Heat exchanger water connactions are located eithar end of the unit. Thermometers are fitted at these two flanges when specified, Heat Exchanger Water Circulating Pump (When specified) A separate water pump, belt driven from a pulley behind the compressor flywheel, s fitted to order to circulate the heat exchanger cooling water. The cooling water inlet is then an the pump inlet flange and a pipe connects pump to heat ‘exchanger. Outlet from the heat exchanger is unchanged. ‘Thermostatic By-Pass Valve (When specified) To facilitate rapid heating of the compressor cooling water, when a closed circuit system is in use. a thermostatic water by-pass vaive is fitted to the compressor jacket water outiet connection on the second stage cylinder head. The valve comprises a cast iron body housing a removable bronze element. When cold the valve circulates the jacket water around the cylinder head by-oassing the main system, As the tamperature Of the cooling water rises the bronze element in the vaive lifts to close the by-pass port and allow the circulating water to pass to the main cooling water system, Radiator with Jacket Water Circulating Pump (When specified) The fan cooled radiator when fitted is mounted on a bracket attached to the compressor crankcase above the flywheel The fan is belt driven from a pulley behind the compressor flywheel with both fan and drive belt adequately guarded. An integral header tank situated above the radiator is connacted by flexible pipe to the compressor water outlet connact- ‘on, The cooled water outlet connection at the base of the radiator connects via pipework to the pump suction flange. ‘Automatic Controls (When fitted) Various methods of controls are available, depending on system requirements, for one, two or three compressors Visual alarm facilities with automatic compressor lockout and manual reset are also available. 29 SECTION 3 — INSTALLATION INSTALLATION DATA COOLING WATER QUANTITY REQUIRED APPROXIMATE COMPRESSOR * COOLING WATER PRESSURE DROP SPEED QUANTITY ACROSS COMPRESSOR rov./min. L/min. bar 585 33 08 875 49 08 1178 86 07 1780 98. a |» NOTE COMPRESSOR SPEEDS SHOWN ARE TYPICAL SPEEDS OBTAINED WHEN USING AN ELECTRIC MOTOR AS PRIME MOVER. J RECOMMENDED COOLING WATER PIPEWORK DIMENSIONS NOMINAL PIPE DIAMETER MAXIMUM RECOMMENDED WATER FLOW mm. L/min, 10.5 12 140 22 18.0 36 22.0 54 27.0 a2 36.0 138 418 196 54.0 330 72.0 585 84.0 800 COOLING WATER TEMPERATURE The maximum recommended cooling water temperature into the compressor is 38°C. If temperatures in excess of this, figure are being considered our TECHNICAL DEPARTMENT must be consulted and it may be possible ta make spacial recommendations an RECOMMENDED LUBRICANTS Compressor Crankcase Lubricant ‘Supplier Oil Type ‘Supplier Oll Type. Agip FORM 64 Gulk Compressor O11 63 Ampol Darola Oil 20 Mobil OTE Oil Heavy/Medium Antar & Ocean Turbine T 68 Rarus 425 Misola H 68 Petrofina Soleo AC 43 BP. Energol OF 68 Soleo SAE 20/20W Caltex Regal Oil PCR & 0. Eolen AC 34 Castrol Aircol PD 68 Shell Taipa Oil 20 Perfecto T 68 Corena Oil H 68 Chevron Delo Special Oil 20 Turbo Oil T 78 Refrigeration Oil 18 LF Texaco Alcaid Oil Ouckhams Deenol 20 Regal Oil R & 0 68 Esso Zerice $ 100 Compressor Oil VOL 46 Golden Fleece Circol 46 Wisura Ventura 42 (Australia) Circo! 68 Hydroma 42 oid 29x Cooling Water Pump Lubricants Shell Alvania Grease 3, Esso Beacon 3, or equivalent grease, Motor Lubricants ‘See Manufacturer's recommendations. Engine Lubricants See Manufacturer's recommendations. Cooling Water Pressure The maximum permissible water inlet pressures to the compressor are quoted on the Data page. It is essential that the correct quantity of water is supplied when the machine is cunning and itis preferred that this flow is shut off when the compressor is stopped. Compressor Weight and Dimensions The maximum weight of the compressor and the complete baseplated set, the overall dimensions. and the minimurt clearances for removal of parts are shown on the General Arrangement Drawings. For complete dimensional data on any particular installation, reference should always be made to the General Arrange ment Orawings suppliad with the equipment. 32 Goneral Arrangement of 2SF4 Compressor A. Lifting Eye Bolt Bare Compressor Baceplated Set - maximum 898 ke. 8. Lifting Lug Baseplated Set Maximum Weight: C. Clearance Required for Dismantling Compressor «Bare Compressor 395 kg caution: THE HOOKS OF SLINGS MUST NOT BE FITTED DIRECTLY TO LIFTING EYE BOLTS OR LUGS. ‘SHACKLES MUST ALWAYS BE USED. 3/3 ‘The standard DIRECTION OF ROTATION for the compressor is clockwise, looking on the non-drive end of the machine. Non-standard direction of rotation can also be supplied on request. Reference must be made to the general arrangement Grawing supplied with each compressor. A direction of rotation arrow is fitted to the compressor at the non-drive end of the cylinder block. NOTE: The litting positions to be employed for installation and removal of the compressor or the complete baseplated set are indicated on the general arrangement drawing, together with the maximum liting weights. INSTALLATION PROCEDURE Goneral The circulation of cooling water through the compressor must be positive and some form of visual flow indicator should bbe provided in the circuit, Recommendations for cooling water systems are detailed in this section and flowrate require- ments are also supplied, lis recommended that an automatic plate type non-return valve is fitted in the air delivery line, as near to the compressor as possible, If automatic unloading equipment is fitted to the compressor. this type of valve is essential {tis of utmost importance that sufficient space is provided around the machine to allow personnel access. andto facilitate removal and installation of components during normal maintenance routines. t is advisable to leave ample headroom above the unit for crane joists or lifting tackle. Minimum required clearance dimensions for component removal are shown in the general arrangement drawing supplied with the compressor and also included in this Section. Check the rotation of the prime mover before coupling up to the machine. The direction of rotation must be as shown in the general arrangement drawing of the machine being installed. and by the direction arrow on the compressor. ‘The compressor must nat be run in the wrong direction or damage may result. NOTE: Before running the compressor for the first time the installation must be thoroughly checked and the procedure indicated in Section 4 for initial start up consulted. Location In order thet the maximum efficiency can be obtained from an air compressor. careful consideration must be given 10 its location. It is important to ensure that the maximum amount of air can be drawn into the cylinders and that the air intake be as cool and dry as possible. Each machine is fitted with a combined silencer and filter on the air intake, but its still important that the initial air intake be clean ‘Suggested Marine Installation Procedure Compressor sets must, where possible, be installed at engine room floor level. Where engine room flats are utilised they are to be of strong cantilever construction adequately tied at the outboard end. Plate thickness for seatings should, generally be not less than 18 mm., with adequate stiffening ribs provided adjacent to the baseplate holding down bolts. Under deck stiffening must extend from main frame to main frame where possible, to prevent vibration above any single frame. ‘Ships Compressor Mounting ‘A compressor is @ reciprocating machine and consequently the seating should be of adequate strength to prevent vibration. If the compressor is mounted on a “lat, it is recommended that flexible pipe connections are used. 3/4 SS eee Neale eee ercdcoee 0 e\ ‘Suggested Installation on Fabricated Mountings Ribs as Close as Possible to Each Holding Down Bolt Deep Stiffening Ris. NOTE: Underdeck stiffening ribs should. it possible, extend from main beam to main beam to prevent oscillation about any single beam. Main Athwart Beam, Deep Frame Seiow. Tee Sections Framework Built on Top of Flat. Stffening as for Above. a> mmoo 35 ° Anti-vibration Pads for Marine Installation 5 Baseplate ‘Anti vibration bush Heaw stee! washers Anti vibration pads Steel chock moog 1 | ULD ‘Suggested Industrial Installation Procedure The provision of a good foundation is an essential requirement to the satisfactory working of any machine. Concrete is the most satisfactory medium for foundations which must be sufficiently substantial to absorb any vibration. and to form 2 rigid support for the baseplate. Whenever possible the foundations of the machine should not join the foundations of 8 building, otherwise vibration may be transmitted, Foundations Generally speaking the size of the concrete block should be approximately 300 mm. longer and wider than the base of the machine. The depth can only be determined after excavation of the site. but its important that the concrete is carrie down until a solid base is reached. The machine and prime mover are correctly aligned on their baseplates before shipment, The alignment, however, may bé disturbed during transit or by incorrect levelling of the baseplate on its foundations. Adjust wedges to level the set using the machined under surfaces at the sides of the baseplate for this purpose. Remove the coupling bolts and connect up the pipework. Pipes should line up naturally; under no circumstances should they ba forced into position. The pipes should also be supported independently. Consideration of the last two points will ensui that no external strains are applied to the unit, Now check the alignment as described in the accompanying illustratiog| whichever is applicable. 36 Machine in Position Ready for Grouting Baseplate Stee! Wedges Anchor Pi Foundation Bolt Space Beneath Baseplate and Holes, Fill in with Grouting Foundation Bolt Nut and Washer mmooep ‘Sets with Pin Type Buffer Coupling With the compressor set positioned on the stool. ratse the unit approximately 25 mm. with the aid of jacking screws in the baseplate or steel wedges inserted between the baseplate and the stool. Fit the baseplate holding down bolts but do not tighten them at this stage. Mount a clock gauge with a magnetic base on the compressor flywheel and, with the ‘gauge set at zero on the motor half coupling, adjust the jacking screws or wedges so that by tightening or loosening the holding down bolts the baseplate alignment is within 0.08 mm. as indicated on the clock gauge. This should be done at four points on the coupling, the points being 90° apart.'and by turning the flywheel and coupling together as one unit, Check that the coupling and flywheel faces are parallel with a taper gauge. When correct alignmentis achieved, with a pair of inside calipers measure the gap between the underside of the baseplate and the stool at each holding down bolt 2osition. Make a solid steel chock, slightly oversize. for each position and file them to make each one a light tap fit between the Deseplate and the stool. As each chock is fitted the alignment should be checked on the clock gauge, Fully tighten all holding down bolts and re-check for correct alignment. NOTE 1. Thause of an approvedresin filler in place of steel chocks is acceptable provided thet the respective manufacturers installation procedures are fully adopted. NOTE 2. if the coupling alignment detailed above cannot be achieved, the best reading possible should be obtained before fitting the chocks. The motor dowels should then ba ramoved, the motor moved to suit the compressor position, {and the motor dowels refitted. Alignment of Sets with Pin Type Buffer Coupling Motor Shaft Dial indicator Flywheel Coupling Bolt Compressor Crankshatt Coupling Gap mmoom> 37 Identical Half Couplings Check the alignment at the coupling by placing a straight edge across the coupling flanges. This should be done at four Points on the coupling, the points being 90° apart. The distance between the faces of the coupling halves should also be checked at four points with a thickness gauge. They should be spaced far enough apart so that the axial clearance between the compressor and prime mover couplings is in excess of their respective end floats. Allowance should also be made for wear in the thrust bearings. A clk — } 4 i wehec D E F Identical Half Couplings A. Straight Edge ©. 0,081 mm. Maximum E. Angular Misalignment 8. Normal Coupling Gap ©. Offset Misalignment F. Perfect Alignment Electrical Installation Each installation is to be wired in accordance with the relevant wiring diagram and recognised standards of practice. Earth continuity must be provided for all exposed metalwork of electrical apparatus, cable sheaths and armour. cable Glands, conduit, ducts. trunking ete. Flexible conductors must be provided to earth resiliently mounted equipment, Ensure that overload relays are set to the correct current rating of the motor(s) they are protecting. Main Air Line An efficient compressor plant is dependent upon a well de signed air pipework system. Condensate is generated in the sir system by the compression/cooling cycle. This condensate is removed at various stages of the compression process. The amount of moisture which may eventually pass into the pneumatic plant cen be reduced by correct drainage of the air supply pipework. A typical compressor installation incorporating automatic controls is shown in the illustration, \Vertical runs of pipework directly upward from the compressors should be avoided, and horizontal runs should descend ‘away from the compressor with a slope of approximately 1 in 12. This will prevent condensate running back to the machines and to pipeline ralief valves. ‘Automatic Unloader (When Fitted) The automatic unloader is fitted to the air inlet/ilter mounting bracket. Pilot air must be piped away from the air receiver to the unloader via a solenoid vaive or other control device. Pressure Switch and Solenoid Vaive Connections To avoid erratic operation of these control devices. it is preferable that they are attached to the receivers by separate Pipework. tit is imperative that these connections are taken from the common balance pipe. then it must be ensured ‘that this pipe hes a capacity in excess of 500 cm®. This will prevent a sudden pressure drop affecting the control devices when air is passed to a compressor unicader. 3/8 ‘Automatic Drain Trap (When Fitted) The trap should be fitted with the disc vertical (ie. with the cap on the horizontal cantreine) If itis arranged in a vertical line it must discharge downwards, The piping, particularly at low pressure, to and from the trao should be the maximum size with the minimum of benas and fittings, which woula cause “estrictions, ts permissible to nave up to 300 mm. of piping on the drain trap outlats. Ira longer pioeline is required, the automatic drain trap should be moved 10 the end of the desired pipe. An isolating valve should then be fitted Defore the trao to allow trap maintenance Non-Return Valve (When Fitted) ‘The non-return valve cust be fitted as close as possible to the delivery side of the compressor. It may be installed in horizontal or vertical pipelines and orientated in any position in the pipeline. Care must be taken to ensure that the vaive does not act as a condensate trap. especially for condensate from a compressor other than the comoressor on wnich itis intended to act as a non-return valve. The valve must be installed in accordance with the direction of flow arrow cast lon the side of the valve housing. e. from the compressor to the receiver or system. A non-return vaive must be fitted wher unloaders are used to prevent the air receiver discharging on comoressor shutdown, Poly V Belt Drive When assembling the drive, the prime mover must be moved toward the compressor to allow the belt to be fitted. The pulleys and their grooves must be clean and free of rust and mounted as near to the shaft suport bearings as possible The drive and driven shafts must be parailel and the pulleys incorrect alignment, The alignment can oe checked by placing 2 straight eage across the face of both pulleys ansuring that the near and far points on the face of each pulley toucnes the straignt edge, To tension ine belt: 1. Ensure that the ibs are a snug fit in the pulley grooves and tighten the bett sufficiently to prevent it sagging at the centre of the span 2. Mark two lines on the back of the belt 305 mm. apart, 3. Tension the belt whilst siowly rotating the drive until the distance between the lines 1s increased 0 308.4 mm 4. Ensure that the belt is protected by a well venulated guard NOTE: Check the belt tension frequently during the first days running and adjust, if necessary, as detailed above. Insufficient tension will cause the belt to slip and excessive tension will overload the belt and the clutch bearings. Recommendations for Cooling Water Cooling Water Temperature. The maximum recommended cooling water temperature into the compressor 1s 38°C IW temperatures in excess of this are being considered, our TECHNICAL DEPARTMENT must be consulted and it may be possible to make special recommendations Cooling Water Pressure. The maximum allowable water inlet pressure to the comaressor 's quoted on the Data page Cooling Water Quantity. The minimum quantity of cooling water required and the pressure drop across the compressor is shown in the tables on Page 3/1 The maximum temperature rise allowable for the cooling water for each compressor naturally varies but a good average maximum is 8°C. A temperature rise greater than this normally indicates insufficient turbulence through the compressor vlinder block. and resultant hot spots may occur in the machine The fitting of a water pump to a compressor cooling systam is strongly recommandad as t ansures that the correct quantity of water is supplied when the macnine 's running, particularly if several units are supplied from a common suction main and are discharging into a common main 39 THe OFFSET-correct by moving ANGLED-shafts not parallel) ANGLED-shafts not in same either pulley along the shaft correct by setting shafts plane) correct by resetting until aligned. parallel. Ensure no deflect- shafts in the same pla fon is taking place in supporting framework or shafts CORRECT Belt Tension Alignment of Belt Drive It is not recommended to have cooling water flow through the compressor whilst the machine is stationary. Should water pumps not be required, Hamworthy Engineering Limited can supply water shut-off valves. fitted to the ‘machines, to be actuated automatically Water Pipe Size and Layout In order to avoid excessive friction loss through piping, it must always be kept as short as possible. The table on Page 3/1 ives @ guide to the pipe size required. It hhouid be noted that the compressor connections must not be used to establish the final pipe size to be used. as the compressor has a wide range of duties. Minor reductions in pipe fittings size are acceptable local to the compressor. provided they are kept to a minimum, Should the system pipework losses be high. a larger size pipe than that obtained from the table, should be used. The size of the pipework to be employed should be determined by the friction losses allowable in the system, The use of a compressor's own water pump is recommended. as itis sized to give the correct cooling water quantity. Even with a pressure cooling system it helps to ensure that the unit is not starved by other units. When more than one. compressor is drewing off a single suction pipe it must be ensured that one unit cannot starve the system of water. therefore it is important that the common suction pipe has a greater cross-sectional area than the total cross-sectional ‘area of the pipes to the individual compressors. If individual water pumps are fitted to the compressors in such a system, then each individual circuit must include @ non-return valve, as shown, to prevent internal water re-circulation. Non-return valves and any other valves used in the system must have low losses. If the compressor is in an inverted loop of pipework, an air vent must be fitted to avoid the formation of ait pockets. 3/10 SECTION 4 — OPERATION PRINCIPLE OF OPERATION Compressor ‘The type 25F4 ma positive displacement. two stage. single acting. piston type compressor. On the downward suction stroke of the first stage piston. air is drawn through the comoined ait inlet silencer/titer through the first stage suction valve and into the cylinder. [As the piston commences the uoward compression stroke, the suction valve spring plates close, sealing the valve. and airis compressed in the cylinder to the required first stage air pressure, At ths point ne first stage air delivery valve opens and the compressed air passes to the first stage cooler. Passing through the cooler. air 1s directed through a transfer passage where condensate is collected and drained off. through the second stage suction vaive into the second or final stage cylinder. The second stage suction and comoression strokes are identical to those of the first stage [After passing through the second stage suction vaive the valve plates close, the air is compressed until fluid prassuce equalises. opening the delivery valve and allowing air to pass into the second stage cylinder head. Passing through the sécond stage cooler tubes the cooled air collects in the final discharge chamber and out to an ai receiver or system, ep Aine 7 | \ cv Ait Flow Schematic Diagram A. At Flow G. Second Stage Cylinder 8. Suction Filter H. First Stage Air Cooler C. Suction Valve I. Second Stage Air Cooler D. Delivery Valve J. Non-return Valve E. First Stage Cylinder L. Oil and Water Separator F. Cooling Water M. Condensate Extraction Automatic Valves ‘The automatic valves open and ramain open by differential prassure, and are cloged by soring plates when this differential Pressure ceases, The first stage suction valve wall only open when the first stage cylinder pressure is below atmospheric pressure and the discharge vaive of this stage will only open when the pressure in the cylinder is in excess of that in the first to second stage air connecting pipework. Similarly the second stage suction vaive will only open when tne air pressure in that cylinder is less than that in the interstage connecting pipawork. The second stage delivery will open anlywhen the cylinder Dressure is in excess of final system or air receiver pressure. The pressure difference necessary for the opening of the valves, also for the airflow through the valves, .s caused by the movement of the compressor pistons. At the moment when the valves open, this pressure difference has to overcome the Inertia of the valve olates. the soring load. and friction losses. In order to synchronise the cycie of vaive movement with piston stroke, the correct spring load is of paramount »mport ‘ance. When flow ceases. the spring load acting on the valve plate closes the valve without delay. an Non Return Valve The operation of the non return valve assembly is similar to a compressor discharge automatic valve, Automatic Drain Trap (When Fitted) ‘The thermodynamic drain traps automatically remove the condensate which builds up in the first and second stage cooler air passages due to the cooling df the compressed air. The thermodynamic drain trap works on the principle that in a moving fluid, the total pressure is the same at all points. This total pressure is the sum of the dynamic and static pressures at any one point. ‘The tlow of condensate through the trap varies the static and dynamic pressure acting on the disc, with the result that it discharges any condensate present, ‘A complete cycle of the automatic drain trap is illustrated, Principle of Automatic Drain Trap 1. The disc A is raised from the seat rings C by incoming pressure allowing instant discharge of air and condensate through outlet 8, 2. The high velocity of following air creates a low pressure area under the disc which draws it towards the seat. and at the same time builds up pressure in chamber D. 3. Pressure in chamber D, acting on the {ull top area of the disc, forces it down against the incoming pressure until it seats on the inner ring C. thus closing the inlet. At the same time the disc also seats on the outer ring C, trapping pressure in chamber D. 4, The pressure in chamber D will be reduced after a period of time due to very small leakage across the outer ring C. and the disc will be raised from the seat and the cycle repeated, ‘Automatic Unloader (When Fitted) The unloader operates by venting the first and second stage coolers to atmosphere. Each stage then delivers air at nominal pressure so that the majority of work done is to overcome friction losses through valves and air passages. The machine is therefore running “off load” and is not delivering air to the discharge air receiver or system. When the compressor is on load. the unlosder valves are held on their seats by the air pressure of the appropriate stage. The springs only provide a light load sufficient to reseat the vaives when no air loads are applied. ‘These valves are lifted when air is supplied (by some appropriate means, e.g. three-way solenoid valve) to the plunger guide cover thus forcing down the plunger. Air is vented from the first stage seat and second stage discharge chamber to the suction filter/silencer dssembly, Air Governor ith tn comaressor running at pressure in the a reeiver bulls up uti the load on the lower seat re ofthe va txceess preset spring load ne governor andihevatvelits end sestson ne upper seallowing ine eceve si pressure (psc rough teat tute aot ley in none hen two presse ie acer es Below the predatermmned ating, the governor spring "eres nevenve on ine lower seat andthe a actuating he auto rate delivery ine unioser ir vented to atmaepner alow he compressor to some om ose 42 Water Shut-off Valve c : tapping inthe frst stage cooler is greater than the valve soning Jen the compressor‘ running, a pressure from he tapping in th Westie wal tia antuaea fs cpoptoog st us too we I ts. voce ecpaly OM ts set Ths dtzeg wit plow Sreough the valve into the compressor. When the compressor stoos and the ar pressure drops. the spring closes thevalve nd shuts off the cooling water supply. When the compressor starts up again, the cycle is repeated Automatic Controls Compressor automatic controlle's are available for use with one, two or the with suitable starters to control the sequence of compressor(s) operation compressors. They are usedin conjunction ‘Typical Compressor Installation with Solenoid Operated Drains A Air Receiver K. Sclenoid Operated Orain/Unieading 8. Air Recewer Obtiet Valves ©. Isolating Vaives L.No. 1 Compressor D. No. 2 Compressor M. Oil/Water Separator (Below Machine E. Compressor Discharge Level) F Tundish N. Air Line 1 in 12 Slope Away from G. Hand Drain Valves Compressors H. Hand/Auto Drain Valve ©. To Pressure Switenes J. Non-return Valve P. Pressure Switches 43 ‘Automatic controls also include solencid operated unloader/cooler drain valves and can incorporste also feult protection alarm systems when required. Two modes of opération are available, ‘HAND’ and "AUTOMATIC", With the starter selector switch in the HAND’ position the compressor is started by means of the ‘START button, The unloader/cooler drain vaives being of normally open construction, vent the coolers and pressure spaces of the compressor while itis stationary and provide unloaded starting. When the ‘START’ button is pressed a time delay relay comes into operation and after approximately two seconds adjustable up to five seconds} of the compressor running unloaded the solenoid valves close bringing the compressor on load. After approximately 5 mins, running (adjustable between 1 and 10 mins.) the solenoid valves open to drain condensate, from the inter and after coolers. This cycle is repeated until the compressor is stopped by means of the selector switch being turned to the ‘OFF position. With the selector switch in the ‘AUTO’ position starting and stopping of the compressor is controlled by a pressure switch fitted to the receiver. The operation of the solenoid valves is as previously described for ‘HAND’ operation The selector switch is turned to the ‘OFF’ position to close down the compressor. For full details of any particular panel re nce should be made to the instructions supplied with the unit. OPERATING PROCEDUFE CAUTION 1. DO NOT ATTEMPT TO START THE COMPRESSOR UNTIL THIS MANUAL HAS BEEN FULLY READ AND UNDERSTOOD. 2. NO ADJUSTMENTS TO THE COMPRESSOR, ITS CONNECTIONS OR FITTINGS MUST Ba CARRIED OUT WHILST MACHINE IS RUNNING. 3. THE COMPRESSOR SHOULD NEVER BE RUN UNLESS ALL PROTECTIVE GUARDS ON THI MACHINE AND PRIME MOVER ARE FITTED. 4, HEALTH & SAFETY ACT COMPLIANCE. BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF, AND ENSURE COMPLIANCE WITH, THE HEALTH AND SAFETR REGULATIONS APPROPRIATE TO THIS CLASS OF WORK. Checks Before Initial Run Before starting the compressor for the first time or after maintenance the following checks must be made, 1. Check that all pipework installation is complete and all relevent pipework has been hydrotested, 2. If work has been carried out on the prime mover (or if there is any doubt about direction of rotation of prime move re-check the direction of rotation with the drive disconnected 3. If the machine has been lying idle for some considerable time, or if crankcase and/or prime mover have been move re-chack alignment ab indicated in Section 3. ‘Commissioning Procedure 1. Check oil level in the sump. Fill or top up as required to the maximum level marked on the dipstick. Use only recomat ended lubricants. See Section 3. 2. Prime lubricating oll pump. Fill ol! pump suction through connection item 97) and suction pipe {item 120) 3, Remove one valve ata tiie from each cylinder and pour ina small quantity of il. This will ensure adequate lubricatit Of the cylinder on initial start up. 4, Re-fit valves and check all valve cages have been tightened to recommended torque settings. (See Date. Section 5, Check manual cooler drain valves. These should be open. One is situated on the first stage cylinder head at the dra fend of the machine and the other, at right-angles to it, on the second stage cylinder head. 416 6 Check gauge cocks. These should be partially open and are immediately below their respective pressure gauges. This precaution will ensure gauges are not damaged by any sudden increase in pressure on start up. 7 Check stop valves and visual flow indicator (when fitted) on cooling water pipelines. Valves should be open and the indicator register a flow. NOTE: If the cooling water lines form an inverted loop. ensure thet the compressor water spaces are vented of all ai. 8 Check that the machine is frag to rotate by barring the crankshaft through at least one complete revolution. 9 Ifa water circulating pump is fitted. check that bearing greasers if any) are filled with grease and ensure bearings are lubricated, 10 Carry out inital start up cteck of prime mover as recommended by the manufacturer ‘Starting (Manual Control Only) 1 Start prime mover. If it is a variable speed unit run up to full speed slowiy 2, Check oil pressure. Under nc: circumstances must this be allowed to fall below 0.7 bar. Should there be a sudden drop of oll pressure. stop the nachine immediately and refer to the fault finding chart for probable cause and remedy. 3. Close first stage and second stage cooler drains in that order, and compressor will commence to operate, 4. Adjust pressure gauge cocks to prevent vibration of the pointers, * 5. If automatic drains are not fiited to the compressor. ensure that the cooler drain valves are just sufficiently open to allow the moistura deposited in the coolers to pass. Without attention to this point an emulsion of ail and water will form on the suction and discharge valves with detrimental results 6. Alter compressor has been running on load for some time adjust cooling water flow to that recommended in Installation Data, Section 3 ‘Starting the Compressor on Automatic Control 1 When power supply is introcucad to the control panel after it has been isolated (for any reason) the manual re-set ‘button for jock out alarms (if fitted) must normally be pressed. For full details of any exceptions to this. rafer to the Instruction manual supplied with the controller. 2 Set control pane! switch to automatic control. in the Auto stop/start mode the machine will start automatically iV air demand is required. On auto-continuous control the start button of the compressor must be pressed for initial start-up, 3 Continue as from point 2 in 2revious paragraph (Manual Control Stopping the Compressor (Marval Control Only) 1. Unload the machine by oper ing the first and second stage cooler drain valves. 2 Purge the compressor coole’s of condensate by running the machine for two minutes off-load. 3. Stop compressor, leaving hand drains open. 4. If compressor is to be stoppad for any length of time it 1s preferable to isolate the cooling water supoly Oit Level The oil level inthe crankcase sum must be checked daily. Oo not attamptto carry out this ope 's tuning, For a list of recommended lubricants rafer to installation Data, Section 3. Occasionally aase the drain plug, situated near the base of he crankcase atthe free end of the machine. Run off anywoter which may have gathered peneat the oil. This water accumulates from moisture in the air and varies greatly with working conditions, 408 Oil Pressure ‘The oil pressure valve must be set to relieve at the pressure indicated in Date, Section 1. when the oil is hot To alter the system pressure the oil:pressure relief valve situated in the crankcase must be adjusted. For details see Section 5 (Auxiliary Equipment) Cooling Water System A cylinder cooling water jacket safety relief vaive is fitted to the comprassor and will operate in the event of an air leakage lor excessive pressure in the water spaces. The valve is provided with a handle and should be lifted periodically to ensure that itis free on its seat CAUTION: IN COLD CLIMATES WHERE THE COOLING WATER IS LIABLE TO FREEZE IF THE COMPRESSOR IS NOT IN USE, DRAIN WATER SPACES BY REMOVAL OF DRAIN PLUGS IMMEDIATELY AFTER SHUTDOWN. ENSURE THAT WATER COLLECTING ON THE COOLER DRAIN VALVES DOES NOT FREEZE THUS PREVENTING THEM FROM FUNCTIONING. ‘Air Pressure Safety Valves The air safety valves fitted to each stage are set during assembly to blow at 10% above working pressure. They are of the non-freeze, pop action type and will immediately reseat as soon as excess pressure is relieved. If these valves operate for nay unknown reason, stop the compressor and refer to the fault finding chart for probable fault and remedy. SECTION 5 — MAINTENANCE MAINTENANCE SCHEDULE Commissioning Period Normal Operational Service Obes. | Gwks. ]3mths.|émths.[ tyr. | 2yrs. | dyre. Operation 10 hrs. | SO hrs. | or or or or or or or 180 hrs.| 280 hrs.| 500 hrs,|1.000 hrs{2,000 hrs44,000 hrs. Check ol level in crankcase x x Check oll and air pressures and gauge cock settings x x Clean air inter titer | x x Clean and inspect automatic vaives x x fe water jacker ralief valve x Ra Clean. inspect and raset ai reli valves x Check operating pressures and | tamperaturas of all automatic protection devices (if fitted) x x Check automatic sequence of compressor in all ‘modes (if applicable) x x Drain and inspect crankcase. Refill with new oi! x x Clean and inspect delivery line non-return valve x x Glean and inspect all Valves, vaive seats and O-ring seals. Replace as necessary x Ficnaw fusible slug x | Fit new oll filter alement x Check condition of I holding down ots an adjust as necessary x Check compressor/ornme | mover alignment ang adjust as necessary a water spaces | : Strip and measure moving parts for wear x FAULT FINDING CHART FAULT PROBABLE CAUSE REMEDIAL ACTION + 2nd stage relief valve Stop valve in compressor line Open stop valve. blowing. close: Reservoir system full ‘Stop compressor. Relief vaive faulty Inspect valve. Incorrect pressure switch Check setting setting. 1st stage 2nd stage suction or delivery Clean and inspect valves, blowing. valve damaged or dirty renew any broken parts, Relief vaive faulty. Inspect valve. Overheating of compressor. Cooling water tlow incorrect. Check cooling water flow. Blockage of coolers. Clean and inspect coolers. Overheating of 1st stage, 1st stage valves damaged or Clean and inspect each valve. airy. Overheating of 2nd stage. 2nd stage valves damaged or Clean and inspect each valve. int. Compressor will not operate Valves damaged or dirty Clean and inspect vaives and at full pressure or is (reduced capacity indicates renew all broken parts operating at reduced capacity. Frequency of valve maintenance excessive. trouble with 1st stage valves) Leaking piston rings Ensure that rings are free in grooves. Renew worn or distorted rings. Excessive cylinder wear. ‘On machines fitted’ with liners, remove and renew liners, pistons and rings as necessary. Speed low. Check compressor speed and adjust. Blocked suction filter Clean filter. Unloader fauity Check operation of unioader system, (Overheating, Keep vaives, piston rings and cooling water system in good working order. Blocked suction, Inspect and clean suction filter. 5/2 FAULT FINDING CHART (Cont’d.) FAULT PROBABLE CAUSE REMEDIAL ACTION Excessive oll carryover Ensure that oil control piston from ist stage piston rings of 1st stage piston are not worn or slack in their grooves and that the oll holes in the grooves are not blocked. Renew parts as necessary. Excessive moisture in Check the joints between passages. cylinder block and 1st and 2nd stage heads are tight, and use cooler drain cocks a8, detailed in “Starting Up’ instructions, Dirt drawn into compressor. Perform “Routine Maintenance’ (on air filter. Overheating at air delivery. Cooling system not function- Check flow indicator (if fitted). ing properly. Open stop valves, clear blockage or prime pump. | Overheating in crankcase, Prolonged running with See previous fault, | previous fault \ | Knock’ in motion work. Slack connecting rod or m Adjust or renew the bearing bearings. concerned. LW oil pressure. Inlet strainer choked Remove and clean by washing in petrol. Allow it to drain, then dry before replacing it Insufficient oil in crankcase. Check oil level. top up with corract grade of oil. if necess- ary (see Recommended Lubricants) Pipe broken in oil system. Replace pipe, Oil pump requires overhaul Overhaul pump. (See Section 4) Bearing clearance excessive. Renew bearing(s) Air delivery line Damaged seats Dismantie, clean. and lap in non-return valve leaking, valve faces and valve to valve housing seat. | ee | Ie aaceeininichtesenteeniael 53 ROUTINE MAINTENANCE WARNING 1. MAINTENANCE MUST NOT BE CARRIED OUT ON THE COMPRESSOR WHILST IT IS IN ‘MOTION. 2. STOP THE COMPRESSOR AND ISOLATE THE AIR, WATER AND ELECTRICAL SYSTEMS. DISPLAY WARNING NOTICES ON THE MACHINE AND CONTROL PANEL. 3. WHEN WORKS TO BE CARRIED OUT ON WATER AND/OR AIR PASSAGES THE COMPRESSOR MUST BE VENTED OF mLL PRESSURISED AIR AND DRAINED OF COOLING WATER. 4. HEALTH & SAFETY ACT COMPLIANCE. BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF, AND ENSURE COMPLIANCE WITH, THE HEALTH AND SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK. General Route maintenance of the gompressor should be carried out atthe inten listed inthe Maintenance Schedule Page 5/11. Procedures to be adopted for routine maintenance are detailed under the appropriate heading, in this section, Before re-assembly of dismantled components. all parts must be thoroughly cleaned with kerosene or gasolene and all arts examined for wear. corrosion, cracks. distortion. or any other damage and be renewed as necessary. Reference should be made to the weer tolerances given in Data. Section 1. If dimensions of the appropriate wearing items are close to or in excess of those recommended it may be appropriate to replace them at this time. All joints, gaskets. and O-ring seals should be examined for serviceability and renewed as thought necessary, When re-assembling compressor components ensure that all flat faced joints. solid copper rings and O-rings are refitted. In any operation conderning the latter great care must be taken to ensure that they are not damaged, f they are damaged in any way during assembly they must be renewed. Solid copper rings. if in good condition. can be re-used provided they are annealed otcasianally by heating and quenching, It is very important when replacing joints (especially cylinder head joint) that the correct thickness and type of jointing '$ used to maintain the correét assembly clearances, ‘Automatic Valves When servicing a suction or gelivery valve, withdraw. clean. if'spect and refit valves one ata time. This will ensure that ail valves and valve cages are relitted in their correct valve pockets. failure to ensure this may result in the development of @ hazardous situation. ‘Suction Valves (See Mlustrations) 1. Remove set screws (161) or capscrews (166) securing the valve cage (131) or (132) 2. Withdraw the valve cage taking care not to damage the O-ring seal (164) 3. Screw valve extractor to0! to the protruding end of valve cenyye bolt and withdraw the valve assembly (157 or 159 from its seating. NOTE: On certain valves a self locking nut is used to retain the assembly in place of a slotted nut and split pin. 4. Take out the split pin, if fitted, and unscrew slotted or self-locking nut from the valve bolt. ‘each valve component to facilitate correct re-assembly, Reference should always be made to the illustration of the valve being assembled to ensure that the components af ‘operation of the valves 5. Withdraw the washers ti plates from the centre bolt. At the same time note the method and order of removal 0 { rebuilt in their correct order. This is essential for correct 6. Clean all components thoroughly. Remove grease and carbon deposits with a soft brush using a hot water and sod solution. Care must be taken during the cleaning operation as any surface scratch may cause leakage and ultimately 2 breakage. 7. Each component should be inspected end any items which appear defective, worn. or damaged should be renewed 54 The valve plate and valve seat can be lightly “lapped” by means of 2 fine carborundum paste. Before clean all components and ensure that all traces of grinding paste have been removed assembly NOTE: The preferred method of carrying out this operation is to lightly “lap” the valve plate and valve seat to @ surface plate. It should be ensured that, when this operation is complete, the surfeces are “flat” when in an unstressed condition. 8. Assemble valve components in reverse order to their removal. fit the nut and tighten to the torque setting shown in Data, Section 1. If nut is not of the self-locking type fit 2 new split pin, 9. Check that the valve can function correctly and that plate movement exists. Extreme care must be taken to ensure that the valve plate is not scraped or damaged during this operation. 10. The vaive assembly should be lightly “lapped” to its seating in the vaive pocket with @ fine carborundum paste. Clean valve assembly and valve seat thoroughly and ensure all traces of grinding peste are removed. 11, Replace valve assembly (17) or (189) in cylinder head. 12. Place valve cage (131) oF (132) in position, taking care not to damage the O-ring seal. Fit retaining capscrews (166) or setscrews (161) and tighten them uniformly to the recommended torque settings (see Data, Saction 1) Delivery Valves (See Illustrations) 1. Remove capscrews (166) or (236) retaining the valve cage (221) or (131). 2. Remove valve cage taking care not to damage O-ring seal (164) or (167). For delivery valve maintenance proceed as detailed in preceding paragraphs 3 to 11 (Suction Valves), 4. Place valve cage (131) oF (221) in position taking care not to damage the O-ring seal |164) or (167). Fit retaining ‘capscrews (168) or (236) and tighten them uniformly to the recommended torque settings (see Data, Section 1). NOTE: For ease of maintenance it is recommended thet all capscrews are lightly coated with heet-resistant anti-seize ‘compound. Air Filter/Silencor To clean and lubricate the air filter ment (177) 1. Remove the round headed serew at air intake end and withdraw the element. 2, Wash the element in a suitable solvent and allow to drain 3, Immerse the element in lubricating oil and again allow to drain 4, Refit element into silences and secure with screw. Topping Up Crankease Sump with Lubricating Oil 1. Stop machine and allow oil level to settle. 2. Drain any water accumulation in the crankcase sumo. 3. Check oil level and fill to maximum mark indicated on dip-stick. Ol Fit and Crankease Sump To drain and clean crankcase sump, replace oil filter and refill sump with clean new oil 1. Remove érain plug (55) and washer (56) located at the base of the crankcase below the crankcase door, and drain the oil from the sump whilst the machine is warm having been run for some time. 2. Remove crankcase door (11) and joints (24) and clean out any residue in the sump. 3. To change the oil filter disconnect the union nut (118) from the filter inlet connection. Remove screws (122) and spring washers (123) and withdraw the oll filter cover {107}. joint (121) and filter element (108) BIR 4, Remove nut (113), spring washer (112) and withdraw elament and spacer (110) from filter cover. 5. Clean filter cover and spacer. Fit spacer (110) and new element (108) to filter cover and secure with spring washer and nut. Check that joint (121) is serviceable and refit joint and element assembly to crankeast (123) and screws (122). secure with spring washers 7. Fill oil pump suction (through connection item 97) with lubricating oi 8. Fill the oil pump suction pipe (120) with lubricating oll, reconnect suction pipe and tighten compression fittings (97 and 118). 8. Position joint washer (56) on drain plug (56) and re-fit to crankcase. 10. Check crankcase door joint '24) and re-fit door (11). Secure with spring washers (25) and setscrews (23) 11, Refill sump with oll to the maximum mark indicated on dip-stick. Air Coolers (General) Both first and second stage coolers are ‘U' shaped tubular type and are housed in their respective cylinder heads. itis important that the cooler elements are cleaned both inside and out at regular intervals, the frequency being dependent Upon the condition of the cooling water being used. Failure to maintain the coolers in @ reasonably clean condition can result in excessive temperatures in the compressor air passages. Carbonisation of the air passages will occur with resultant damage to valves, coolers ete. Scale on the outside of the cooler tubes and in the watér jackets can be removed by @ strong solution of hot soda or 3 proprietary de-scaler. The internal surfaces of the coolers can be cleaned with a flexible wire brush. See paragraph ‘Ovarhaul or Repair of Compressor’ (Section 5). Defective tubes must be renewed: if care is taken when drilling out faulty tubes it is possible to expand replacements into the same tubeplates. The ends of the tubes to be expanded must be annealed by heating and quenching. After replacement of any tubes. the tube banks with covers. must be hydraulically tested to twice the stage working pressure of the compressor. ‘Compressor Not in Use ‘The running and standby compressor should be alternated weekly. if any compressor is not being regularly operated it should be rotated weekly by “barring” the thywheel round by at least one revolution. OVERHAUL OR REPAIR OF COMPRESSOR WARNING 1. DO NOT ATTEMPT TO CARRY OUT REPAIR OR OVERHAUL OF COMPRESSOR UNTIL THIS. MANUAL HAS BEEN STUDIED. 2. BEFORE COMMENCING ANY OVERHAUL OR REPAIR WORK A PRELIMINARY CHECK OF AVAILABLE SPARES SHOULD BE CARRIED OUT, 0.g. REPLACEMENT SET OF JOINTS OR JOINTING MATERIAL. 3, ENSURE THAT THE PRIME MOVER HAS BEEN ISOLATED AND CANNOT BE STARTED INADVERTENTLY. 4, THE COMPRESSOR AIR DELIVERY LINE SHOULD BE ISOLATED AND ALL AIR PASSAGES VENTED. 5, COOLING WATER INLET AND RETURN LINES SHOULD BE ISOLATED AND THE COMPRESSOR WATER SPACES DRAINED. 6. WHEN USING LIFTING EQUIPMENT TO DISMANTLE THE COMPRESSOR. ENSURE THAT IT 1S ADEQUATE FOR THE LOADS INCURRED. THE CORRECT LIFTING POSITIONS AS INDICATED IN THIS HANDBOOK (SECTION 3) SHOULD BE ADHERED TO AT ALL TIMES. 57 General The compressor should be regularly overhauled in accordance with the maintenance schedule which will be found at the beginning of this Section, The following sub assemblies, or components can be removed from the compressor without completely dismantling the machine, Automatic Valve Assemblies Water Purp Assembly (if fitted) Oil Pump Assembly Unloader Assembly (if fitted) Silencer/Filter Assembly il Filter Assembty Valve Assembly Water Jacket Relief Valve Assembly Auxiliary Indication and Protection Devices Big End Bearings SSearxeasen= The dismantling and re-assembly procedure for all the above assemblies are detailed later in this section under the heading Ancillary Equipment ‘When carrying out repair, overhaul or inspection of the following items of equipment. it will be necessary to proc:

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