Ariel JGM Manuale utente

ARIEL

Heavy Duty

Balanced Opposed

Compressors

TECHNICAL MANUAL

For Models:

JGM, JGN, JGP and JGQ;

and JGI Vertical Non-Balanced

ARIEL CORPORATION

35 BLACKJACK ROAD, MOUNT VERNON, OHIO 43050

TELEPHONE: 740-397-0311 FAX: 740-397-3856

VISIT OUR WEB SITE: www.arielcorp.com REV: 1/99

THIS PAGE LEFT INTENTIONALLY BLANK

WHEN THIS SYMBOL APPEARS ON THE COMPRESSOR OR CON-

TROL PANEL, THIS TECHNICAL MANUAL IS TO BE CONSULTED

FOR SPECIFIC INFORMATION BEFORE PROCEEDING. IF MORE

INFORMATION IS NEEDED CONTACT YOUR PACKAGER AND/OR

ARIEL CORPORATION.

CAUTION

GAS COMPRESSOR UNITS ARE COMPLICATED AND DANGEROUS PIECES OF

EQUIPMENT, IF YOU ARE NOT FULLY TRAINED AND FAMILIAR WITH THEIR

OPERATION.

BEFORE STARTING THIS UNIT:

FAMILIARIZE YOURSELF WITH THE UNIT.

READ AND STUDY START-UP AND SHUT-DOWN INFORMATION FOR BOTH

PACKAGE AND COMPRESSOR CAREFULLY!

A GAS/AIR MIXTURE UNDER PRESSURE CAN EXPLODE! YOU CAN BE SEVERELY

INJURED OR KILLED. MAKE SURE THE COMPRESSOR IS SUFFICIENTLY PURGED

OF ANY EXPLOSIVE MIXTURE BEFORE LOADING.

AFTER COMPLETING THE ABOVE, BEGIN PROPER STARTING PROCEDURE.

CAUTION

DO NOT ATTEMPT TO START-UP UNIT WITHOUT REFERRING TO THIS

MANUAL SECTION 1 -“START UP”. IT IS ALSO ESSENTIAL TO REFER

TO THE PACKAGER’S OPERATING MANUAL.

CAUTION

THIS MANUAL EDITION IS BASED ON THE CURRENT DESIGN AND

BUILD PRACTICES. THIS MANUAL MAY NOT BE APPLICABLE TO

EQUIPMENT BUILT PRIOR TO THE DATE ON FRONT COVER AND IS

SUBJECT TO CHANGE WITHOUT NOTICE. CONTACT ARIEL WITH ANY

QUESTIONS. REFER TO LAST PAGE OF THIS MANUAL FOR CONTACT

INFORMATION.

THIS PAGE LEFT INTENTIONALLY BLANK

FOR MODELS: JGI, JGM, JGN, JGP AND JGQ TABLE OFCONTENTS

9/08 i

TABLE OFCONTENTS

Design Specifications & Data ........................................................... 1-1

General ...................................................................................................................1-1

Specifications .........................................................................................................1-3

Opposed Throw - Reciprocating Weight Balancing ................................................ 1-5

Product Information and Safety Plates ...................................................................1-6

Important Safety & Data Information ................................................................. 1-7

Clearances ........................................................................................................... 1-10

Piston Ring and Packing Ring Side Clearance, Inches (mm) .........................1-11

Fastener Tightening Torque .................................................................................1-15

Tightening Torque Procedures ........................................................................ 1-19

Ariel Bolting .......................................................................................................... 1-21

Zone 1 Environment ............................................................................................. 1-21

Installation ........................................................................................... 2-1

The Skid or Package .........................................................................................2-1

Lifting the Compressor ......................................................................................2-1

Setting the Compressor ....................................................................................2-2

Leveling Limits for Compressors ....................................................................... 2-3

Aligning Main Bearing Bores .............................................................................2-3

Alignment - to Driver .........................................................................................2-6

Electrical Grounding ........................................................................................2-11

Pneumatically Actuated Unloaders & Clearance Devices ............................... 2-11

Vents and Drains ............................................................................................. 2-11

BICERA Type Crankcase Over-Pressure Relief Valves .................................2-12

Start Up ............................................................................................... 3-1

General ...................................................................................................................3-1

Start Up Check List .................................................................................................3-1

Warranty Notification - Installation List Data and Start Up Check Lists for

JG:A:M:N:P:Q:R:J:H:E:K:T:C:D Reciprocating Compressors ........................... 3-2

Maximum Allowable Working Pressure ................................................................ 3-10

Relief Valve Settings ............................................................................................ 3-11

Filling Sump & Priming a Main Oil Lube Oil System - Before Starting ................. 3-11

Filling The Sump ............................................................................................. 3-11

Priming - Main Lube Oil System ...................................................................... 3-12

Compressor Prelube ............................................................................................. 3-12

Force Feed Lubricator Adjustment ....................................................................... 3-12

Compressor Re-Application .................................................................................. 3-12

Lubrication ......................................................................................... 4-1

General ...................................................................................................................4-1

Lubrication Functions .............................................................................................4-1

FOR MODELS: JGI, JGM, JGN, JGP AND JGQ TABLE OFCONTENTS

ii 9/08

Lubricant Characteristics ........................................................................................4-2

Viscosity ............................................................................................................4-2

Viscosity Index ...................................................................................................4-3

Pour Point ..........................................................................................................4-3

Flash Point .........................................................................................................4-3

Lubricant Base Stock ..............................................................................................4-3

Petroleum-Based Lubricants (also referred to as mineral oils) ..........................4-3

Synthetic Lubricants ..........................................................................................4-4

Lubricant Formulations ...........................................................................................4-5

Compounded Cylinder Oils ................................................................................4-5

R&O Oil .............................................................................................................4-5

Engine Oil ..........................................................................................................4-5

Used Engine Oil .................................................................................................4-6

Gear Oil .............................................................................................................4-6

FRAME OIL SYSTEM .............................................................................................4-7

COMPONENTS .................................................................................................4-7

Oil Strainer .........................................................................................................4-7

Oil Pump ............................................................................................................4-7

Oil Cooler ...........................................................................................................4-7

Oil Temperature Control Valve ..........................................................................4-8

Oil Filtration .......................................................................................................4-8

Compressor Prelube Pump ...............................................................................4-9

Oil Heaters .........................................................................................................4-9

Lube Oil Analysis Sampling Point ....................................................................4-10

Cold Starting ....................................................................................................4-11

Dry Sump .........................................................................................................4-12

FRAME OIL OPERATING CONDITIONS .............................................................4-13

Compressor Frame Lubricant ..........................................................................4-13

Oil Viscosity .....................................................................................................4-14

Oil Pressure .....................................................................................................4-14

Oil Temperature ...............................................................................................4-14

Oil Maintenance ...............................................................................................4-15

Oil Sampling ....................................................................................................4-15

Oil System Cleanliness .........................................................................................4-15

Cylinder and Packing Lubrication .........................................................................4-17

Independent Force Feed Lubricator Systems .................................................4-17

Common Oil Supply .........................................................................................4-17

Independent Oil Supply ...................................................................................4-18

Force Feed Lubrication System Components .......................................................4-18

Gas Inlet Debris Screens to Maintain Lube Performance ...............................4-18

Injection Oil Inlet Filter .....................................................................................4-19

Oil Dilution .......................................................................................................4-19

Cylinder Oil Lubrication Examples ...................................................................4-19

Under/Over Lube .............................................................................................4-19

Inadequate Lubrication Symptoms ..................................................................4-20

Lubrication Quantity - Paper Test Method .......................................................4-20

Lubricator Cycle Time ......................................................................................4-20

Cycle Time Indication ......................................................................................4-21

Force Feed Lubrication System Monitoring: ....................................................4-21

FOR MODELS: JGI, JGM, JGN, JGP AND JGQ TABLE OFCONTENTS

9/08 iii

Minimum Requirements .................................................................................. 4-21

Devices ........................................................................................................... 4-21

Choosing a Lube System Monitor ...................................................................4-22

Break-in Rate .................................................................................................. 4-25

Liquids in Gas ................................................................................................. 4-25

Lube Type & Rate Recommendations ............................................................4-26

RATE CALCULATION NOTES ....................................................................... 4-28

Water-Cooled Packing .......................................................................................... 4-30

Coolant System Requirements ....................................................................... 4-31

Force Feed Lubrication System - Description ...................................................... 4-31

Force Feed Lubricator Adjustment .................................................................. 4-32

Blow-Out Fittings, Rupture Disks and Tubing .................................................4-32

Divider Valves ................................................................................................. 4-34

Description ......................................................................................................4-34

Divider Valve Block Assembly Instructions ...........................................................4-35

Operation - (see Figure 4-13 and Figure 4-14) ............................................... 4-35

Pressure Testing For Divider Valve By-Passing ............................................. 4-38

Electronic Lubricator Fluid-Flow Monitor/No-Flow Timer Switch - Proflo PF1 ...... 4-39

Proflo PF1 Monitor wiring identification and instructions for electronic indication: 4-40

Proflo PF1 Button Operation: .......................................................................... 4-41

Downloading Proflo PF1 Data: ........................................................................ 4-41

Proflo PF1 Setup Alarm Time and Mode: ....................................................... 4-42

Proflo PF1 Battery Replacement: .................................................................... 4-43

Proflo PF1 Display Errors: ............................................................................... 4-44

Proflo PF1 Operation Notes: ........................................................................... 4-45

Proflo Normally Open and Normally Closed Definition: .................................. 4-46

Proflo PF1 - Using Pulse Output and Alarm Circuit at Same Time: ................ 4-47

Proflo PF1 - Using PLC to Calculate Oil Consumption: ..................................4-48

Proflo PF1 Accessories Available: .................................................................. 4-49

Protection of Electronics & the Compressor When Arc Welding .......................... 4-49

Electronic-Lubricator Digital No-Flow Timer Switch (DNFT) ................................4-49

Replacing the (Field-Replaceable) Battery in the DNFT: ................................4-50

Oil Head at Lube Points ........................................................................................4-51

Force Feed Lubrication System and Running Conditions .................................... 4-51

Force Feed Lubrication System ...................................................................... 4-51

Running Conditions ......................................................................................... 4-52

System Design Considerations and Operating Parameters ............................ 4-52

Force Feed Balance Valves .................................................................................4-52

Setting and Maintaining Balance Valves ......................................................... 4-52

Checking/Adjusting Balance Valves on Subsequent Start-up ......................... 4-53

Frame Lubricating System - Description .............................................................. 4-54

Lube Oil Strainer, Filter & Filter Installation Instructions .......................................4-54

Lube Oil Strainer ............................................................................................. 4-54

Lube Oil Filter .................................................................................................. 4-55

Oil Filter Installation for Spin-On Type Filters .................................................4-55

Oil Filter Element Installation for Cartridge Type Filters ..................................4-55

Lube Oil Pump & Lube Oil Pressure ..................................................................... 4-57

Description & Adjustment ................................................................................ 4-57

Lube Oil Pressure Regulating Valve ............................................................... 4-57

FOR MODELS: JGI, JGM, JGN, JGP AND JGQ TABLE OFCONTENTS

iv 9/08

Low Oil Pressure Shutdown ..................................................................................4-58

Maintenance ....................................................................................... 5-1

General Introduction ...............................................................................................5-1

Compressor Components ..................................................................................5-3

Positioning a Throw for Maintenance ......................................................................5-3

Connecting Rod ......................................................................................................5-4

Connecting Rod (Crank Pin) Bearing ................................................................5-4

Connecting Rod - Removal ...............................................................................5-6

Connecting Rod Bushing Replacement .............................................................5-7

Connecting Rod - Installation ............................................................................5-8

Crosshead............................................................................................................. 5-11

Crosshead - Removal ......................................................................................5-11

Crosshead - Installation ...................................................................................5-13

Crankshaft .............................................................................................................5-14

Main Bearings - Checking Clearances ............................................................5-14

Crankshaft - Removal ......................................................................................5-17

Oil Slinger - Removal .......................................................................................5-18

Oil Slinger - Installation ....................................................................................5-18

Chain Sprocket - Removal ...............................................................................5-18

Chain Sprocket - Installation ............................................................................5-19

Fan Shaft Assembly Procedure .......................................................................5-19

Main Bearings - Removal and Installation w/Crankshaft Removed .................5-20

Main Bearings - Removal and Installation w/Crankshaft In Place ...................5-21

Crankshaft - Installation ........................................................................................5-22

Chain Drive System ..............................................................................................5-23

Description .......................................................................................................5-23

Chain Adjustment ............................................................................................5-24

Chain and Sprocket Replacement ...................................................................5-24

Chain Idler Sprocket Replacement - (Eccentric Adjustment Cap) ...................5-25

Lube Oil Pump Chain Sprocket Replacement .................................................5-25

Force Feed Lubricator Chain Sprocket Replacement .....................................5-26

Piston and Rod .....................................................................................................5-27

Piston and Rod - Removal ...............................................................................5-27

Piston and Rod Disassembly ...........................................................................5-28

Piston and Rod Reassembly ...........................................................................5-29

Piston and Rod - Installation ............................................................................5-30

Piston Rod Run Out ..............................................................................................5-31

Piston Rings ..........................................................................................................5-32

Determining Ring Wear: ..................................................................................5-32

Removal: .........................................................................................................5-32

Piston Rings - Installation ................................................................................5-32

Wear Bands ..........................................................................................................5-32

Determining Wear Band Wear: ........................................................................5-33

Wear Band - Installation ..................................................................................5-33

Piston Rod Pressure Packing - Removal ..............................................................5-33

Piston Rod Packing - Reassembly ........................................................................5-34

Types of Piston Rod Packing Rings ......................................................................5-35

FOR MODELS: JGI, JGM, JGN, JGP AND JGQ TABLE OFCONTENTS

9/08 v

Type "P" Pressure Breaker ............................................................................. 5-35

Type "BTR" Single Acting Seal Set ................................................................. 5-36

Type “AL” Double Acting Seal Set .................................................................. 5-36

Type "BD" Double Acting Seal Set .................................................................. 5-36

Type "3RWS" Oil Wiper Set ............................................................................ 5-37

Typical Arrangement of Piston Rod Packing Rings ..............................................5-37

Piston Rod Packing Ring Material ........................................................................ 5-37

Water-Cooled Piston Rod Packing ....................................................................... 5-38

Reassembly .................................................................................................... 5-38

Testing ............................................................................................................ 5-38

Valves ................................................................................................................... 5-39

Valves - Removal ............................................................................................ 5-39

Valves - Maintenance ...................................................................................... 5-40

Valves - Reassembly ...................................................................................... 5-41

Bolt Tightening for Valve Caps ............................................................................. 5-42

VVCP - Head-End Variable Volume Clearance Pocket ........................................ 5-43

VVCP - Removal ............................................................................................. 5-44

VVCP - Disassembly ....................................................................................... 5-44

VVCP - Maintenance ....................................................................................... 5-45

VVCP - Adjustment ......................................................................................... 5-45

Compressor Cylinder Re-Boring & Bore Restoration Guidelines .........................5-46

Ethylene Glycol Contamination ............................................................................ 5-47

Technical Assistance ........................................................................ 6-1

Recommended Maintenance Intervals ...................................................................6-1

Daily ..................................................................................................................6-1

Monthly (in addition to Daily Requirements) .....................................................6-2

Every 6 Months or 4000 Hours (plus Daily/Monthly) .........................................6-3

Yearly or 8000 Hours (plus Daily/Monthly/6 Months) ........................................6-3

Every 2 Years or 16,000 Hours (plus Daily/Monthly/6 Months/Yearly) ............. 6-4

Every 4 Years or 32,000 Hours (plus Daily/Monthly/6 Months/1 & 2 Years) ..... 6-4

Every 6 Years or 48,000 hours (plus Daily/Monthly/6 Months/1, 2 & 4 Years) .6-5

Trouble Shooting .................................................................................................... 6-5

Appendices ......................................................................................... 7-1

Ariel Tools ...............................................................................................................7-1

Ariel Furnished Tools ........................................................................................7-1

Ariel Tools - Purchased Separately From Authorized Dealer ...........................7-3

Minimum Hand & Commercial Tools Required ......................................................7-3

Gas Analysis Common Abbreviations ....................................................................7-7

Technical and Service Schools on Ariel Compressors ........................................... 7-7

Ariel Customer Technical Bulletins .........................................................................7-8

Vendor Literature ....................................................................................................7-8

Ariel Contact Information ........................................................................................ 7-8

FOR MODELS: JGI, JGM, JGN, JGP AND JGQ TABLE OFCONTENTS

vi 9/08

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