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Corken Compressor parts and maintenance manual

1. Four way Inlet Suction valve Discharge control valve pressure unloaders pressure 1 NPT gauge optional gauge drain valve ca 314 NPT ene 1 fe opening OE II VE Liquid 1 O TT relief valve ob uill MEY trap tank Ch GIL y f L Ps A VI C H dp be H OC E AS a H Electric Megna E Ta SIS LD A a motor driver 7 W Y Lo AD _ L I YN 10 16 ETE d 4 Se 2 ele J L 1 ses T TT DIE E ia 30 13 16 I JS i a SE A 78 26 E Je l stia PI n q 18 3 16 o aa la py 6620 A ES d gH F i 17 118 NS SOS ZA E 1 H E om Inna war Dago 43 50 a NS SY a T A LS SEX TI f mi ya 7 62 el ipe tap fl Ei FAL Crank q i CA m fh o o ida il 8 il eraan id il Use four ES Crankcase Low oil Adjustable 1 2 oe ei 159 22m 24 58 heater pressure switch slide base Nay 12 7 i i optional tional OS LS eg 5 SE E e 30 48 x 12 64 3 17 100 33 12 70 38 10 106 68 Inches Centimeters Dimensions apply to 107A mounting only 41 Appendix D Outline Dimensions Model 491 with 107 or 107A Mounting model 107A shown below Mi f i Il dl Tu Dei i TT DL kb el
2. Connecting Rod Assembly Bill of Materials Part No Description 1384 X Crosshead assembly 1498 Retainer ring 1496 Wrist pin 1495 Xab Wrist pin bushing 1492b Bolt 1490 X Connecting rod assembly 1490b Connecting rod 1491b Connecting rod bearing oS NJS n N 1493b Nut a Must be rebored after replacing 0 8754 0 8751 dia b Included with connecting rod assembly Torque connecting rod nut to 30 ft Ibs Never attempt to separate the piston rod and crosshead When repair becomes necessary the entire crosshead assembly must be replaced CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 70 Appendix H 490 491 and F491 Flywheel Assembly Details Assembly Number Flywheel Assembly Bill of Materials Assembly Name 2549 X Front Side Flywheel assembly Flywheel 16 O D 3 groove 2549 Hub with three blots and lockwashers H SF 1 375 71 Appendix H 490 491 and F491 Crankcase Assembly Details 19 GN d Gg SN d 72 Part No Description Appendix H 490 491 and F491 Crankcase Assembly Details Crankcase Assembly Bill of Materials Description 3855 Oil seal Oil pump spring 7001 037NC075A Hex head bolt 3 8 16 x 3 4 Spring guide 7001 031NC075A He
3. Outline Dimensions Inches Centimeters Model L M N O P 1 1 4 1 4 2 11 16 7 3 4 29 691 107 107A 3 2 0 63 6 8 19 6 73 0 Dimensions apply to 107A mounting only 43 Appendix D Outline Dimensions Model 91 691 with 109 or 109A Mounting model 109A shown below Inlet pressure gauge 4 A1 M m m a Outlet pressure gauge Liquid ie level fk ERO control ne Ad d Gilet switch SC H L 109A only 21 109 only Outlet 1 2 NPT AT Drain KC 8 valve ji 1 4 NPT 4 1 4 Belt guard NPT inlet Outline Dimensions Inches Centimeters Model A B Cc D D1 E H 91 109 109A 1 3 16 3 7 12 30 5 13 5 16 33 8 31 1 2 80 0 1 1 2 3 8 31 3 16 79 2 291 109 109A 5 12 7 12 30 5 15 3 4 40 0 39 1 2 100 3 1 1 2 3 8 30 7 8 78 4 491 109 109A 5 3 4 14 6 15 38 1 18 45 7 45 1 2 115 6 1 1 2 3 8 33 3 4 85 7 691 109 109A 8 1 4 30 0 17 43 2 19 1 4 48 8 49 1 2 125 7 1 1 2 3 8 Outline Dimensions Inches Centimeters 43 3 16 109 6 Model K L N P R S 91 109 109A 28 3 16 71 6 3 4 NPT 2 5 16 5 9 3 7 6 1 1 4 3 2 3 5 8 9 2 9 1 2 24 1 291 109
4. LA Beltguard p H A Crankcase 4 GH Lan oil drain ie d E 7 3 4 ft 19 68 o Crankcase 5 3 4 oil drain 14 61 La 15 5 1 4 38 10 18 13 34 45 72 Dimensions apply to 107A mounting only Inlet pressure guage Discharge pressure guage Four way control valve 1 1 4 NPT mmm High discharge a 3 4 NPT opening for relief valve kK temperature switch CE optional Electric motor driver O SS Inches Centimeters S peg p A de d Low oil _ 4 9 7 16 Crankcase heater Pressure switch Use four 1 2 r Gu k optional optional anchor bolts o 48 45 1 2 ie 115 57 42 Appendix D Outline Dimensions Model 691 with 107 or 107A Mounting model 107A shown below 1 1 4 in NPT four wa Inlet pressure gauge Outlet pressure gauge y Vent valve control valve pp a Relief valve opening 107 only ir EE Ba 3 4 NPT Kon le Liquid ile eh Trap BEA NCA H guard Drain valve 1 4 P 3 K i ii Adjustable driver J it Zi slide base TT N Q 1 2 anchor bolts D B L Cc G Inches Centimeters Outline Dimensions Inches Centimeters Model 691 107 107A
5. 2 5 Driver Installation Flywheels Corken vertical compressors may be driven by either electric motors or combustion engines gasoline diesel natural gas etc Corken compressors are usually V belt driven but they are also suitable for direct drive applications as well Direct drive applications require an extended crankshaft to allow the attachment of a rigid metal coupling NOTE Flexible couplings are not suitable for reciprocating compressors Never operate a reciprocating compressor without a flywheel Drivers should be selected so the compressor operates between 350 to 825 RPM The unit must not be operated without the flywheel or severe torsional imbalances will result that could cause vibration and high horsepower requirement The flywheel should never be replaced by another pulley unless it has a higher wk2 value than the flywheel A humid climate can cause problems particularly in explosion proof motors The normal breathing of the motor and alternating between being warm when running and being cool when stopped can cause moist air to be drawn into the motor This moist air will condense and may eventually add enough water inside the motor to cause it to fail To prevent this make a practice of running the motor at least once a week on a bright dry day for an hour or so without the V belts In this period of time the motor will heat up and vaporize the condensed moisture driving it from the motor No motor manu
6. Minimum Maximum 0 020 0 51 mm 0 044 1 12 mm de si Piston Rod a The distance from the bottom of the head to the top of the piston CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 52 Appendix F 91 and F91 Packing Assembly Details Packing Assembly Bill of Materials Part No Description 2242 Cylinder 2 235_4 O ring for cylinder 5000 137 Retainer ring 1012 Washer 1628 Packing spring 1714 Packing box washer 1453 1 Male packing ring 14546 Packing ring 1452 1 Female packing ring 2240 Crosshead guides 1387 Adjusting screw 2526 Crankcase gasket 1452 1X1 Packing set a sch a sch CO ajaj sch sch 1 aj ai Assembly Assembly Number Name 1132 X2 Crosshead piston rod assembly 1452 1X1 Packing set with 1452 1 1453 1 1454 8 1626 1714 1452 2X1 Packing set alloy 50 with 1452 1 1453 1 1454 2 8 1626 1714 O ring Code A Buna N B Neoprene9c a _ denotes O ring code See O ring chart above for details b The quantity of 1454 packing rings required will vary due to tolerances Use cone 4005 for installation of packing Registered trademarks of the DuPont company Optional equipment CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs Piston Rod 12 53 Appendix F
7. 1284 Crankshaft orifice 2590 Pipe plug 1 8 NPT fl Seal 2135 Drive pin 4225 Filter 2933 Link pin 2798 Pump cover pin included w 4222 X 3786 Crankshaft SIN S A SLV N gt z 3503 Flywheel key 3580 Bearing cone 3786 X1 Crankshaft assembly 7001 031NC075A Bolt 5 16 18 x 3 4 hex head 2122 Inspection cover 2123 Gasket inspection cover 2 210A O ring 3225 X1 Oil bayonet assembly w O ring 2126 Breather ball 3579 Bearing cup 3589 Bearing adjustment shim 005 2589 1 Bearing adjustment shim 007 2589 2 Bearing adjustment shim 020 3539 Bearing cover 3526 Oil seal 1280 Filter screw 1281 Gasket filter 2 116A O ring 1276 Washer 1275 Oil filter screen 3443 Pipe plug 1 2 NPT steel 3221 Crankcase 7001 037NC100A Bolt 3 8 16 x 1 hex head Gr 5 3875 Access cover 7003 025NC037E Screw 1 4 20 x 3 8 3874 Gasket access cover 1515 X Closure cap assembly 7001 025NC050A Bolt 1 4 20 x 1 2 hex head 1515 Closure cap 1516 Closure body 2 118A O ring 1290 Relief valve adjusting screw 3220 2X Assembly Number Name Assembly Bearing carrier assembly 3852 x2 Flywheel assembly D891 only 38524 Flywheel 21 2
8. C1050 steel Nitrotec Crosshead Gray iron ASTM A48 Class 30 Piston rings Teflon glass and moly filled Alloy 50 Piston ring expanders 302 stainless steel Head gasket O ring Buna N Teflon Viton Neoprene Adapter plate Packing cartridge Connecting rod Ductile iron ASTM A536 Packing rings Teflon glass and moly filled Alloy 50 Crankshaft Ductile iron ASTM A536 Connecting rod bearing Bimetal D 2 Babbit Wrist pin C1018 Steel Wrist pin bushing Bronze SAE 660 Main bearing Tapered roller Inspection plate Aluminum O rings Buna N Teflon Viton Neoprene Retainer rings Steel Miscellaneous gaskets 1 Teflon Viton and Neoprene are registered trademarks of the DuPont company Coroprene 33 Appendix C Compressor Selection Compressor Mounting Selections Interconnecting piping Inlet pressure gauge Outlet pressure gauge OMO Non lube LZ full port 4 way valve Relief valve port 3 o NEMA 7 E liquid level gt switch 1 2 NPT M Enclosed steel 40 mesh LL l beltguard Optional driver suction Sech Liquid trap al Drain valve Steel baseplate AQ Ec Adjustable driver slide base Inlet pres
9. INSIDE OF BEARING CARRIER OIL PASSAGE HOLE To check the oil pump unbolt the pump cover and remove the oil pump spring guide spring and oil pump shaft adapter as shown in figure 5 8A Inspect the gears in the oil pump for corrosion or pitting and replace if necessary Check the oil pump shaft bushing in the bearing carrier If the bushing is corroded pitted or worn the oil pump shaft bushing should be replaced Before reassembling the oil pump mechanism replace the O rings in the oil pump cover and on the oil pump adapter shaft see figure 5 8A Rotate the drive pin in the crankshaft to a vertical position for easiest reassembly Insert the shaft adapter so it engages the drive pin Next insert the spring spring guide and oil pump assembly The tang on the oil pump must align with the slot in the shaft adapter Install the pump cover so the pin on the case is in the opening on the oil pump assembly as shown in figure 5 8A When you are sure the pin is properly aligned install the cover bolts finger tight Rotate the crankshaft by hand to ensure smooth operation Then rotate it in opposite directions listening for a click which indicates proper alignment of the oil pump s pins and slots Finally tighten the bolts in an alternating sequence See section 3 3 for directions on oil pressure adjustment 23 LOCATE OIL FILTER ADAPTER AS SHOWN ALIGN SLOT PUMP SHAFT ADAPTER WITH PIN CRANKSH
10. NPT 1 1 4 NPT 2 NPT Outlet 3 4 NPT 3 4 NPT 1 1 4 NPT 1 1 2 NPT Base Model Inlet 3 4 ANSI 3 4 ANSI 1 1 4 ANSI 2 ANSI Model Number Base XXXXXXXXXX Outlet 3 4 ANSI 3 4 ANSI 1 1 4 ANSI 2 ANSI Packing Arrangement Pressurized inlet Standard A Splash lubricated Standard N A N A N A Extended crankshaft Extra cost Extra cost Extra cost N A E Crankcase Style a Pressure lubricated N A Standard Standard Standard Standard with heater N A Extra cost Extra cost Extra cost MH Liquid relief suction Standard Valves Standard valves No extra cost A PTFE Standard F Piston Rings and Packing Alloy 50 Extra Cost Aluminum Standard B Gasket Material Copper No extra cost Cc Lead iron No extra cost D O rings Buna N Standard A Neoprene No extra cost B Viton Extra cost D Teflon Extra cost E Intercooler None N A for single stage compressor N 14 flywheel used with extended crankshaft No charge WA i Flywheel Heavy duty Extra cost Extra cost Extra cost Extra cost H No flywheel No extra cost N Standard 14 Standard S Protective Coating No coating Standard N s Nitrotec Standard N Piston Rod Coating Chrome oxide Extra cost Cc 1 Teflon Neoprene and Viton are regis
11. 109A 28 1 2 72 4 3 4 NPT 2 11 16 6 8 3 1 1 4 3 2 3 7 8 9 9 9 1 2 24 1 491 109 109A 30 1 8 76 5 1 1 4 NPT 4 10 2 1 1 4 3 2 4 10 2 10 1 2 26 7 691 109 109A 39 1 8 99 3 1 1 2 NPT 6 3 8 16 1 1 1 4 3 2 4 1 8 10 4 21 7 16 54 4 44 Appendix D Outline Dimensions Model D891 Bare with Flywheel Suction 5 1 2 5 1 2 valve unloaders 13 9 13 9 optional ld dea E A oo oo m Inlet a H 2 Weld ad p Cl fh Outlet flange al ZI pressure TG gauge A Inlet oun pressure E Outlet T H flange 1 4 NPT drain E gt A 43 1 4
12. 2805 Pump shaft bushing 2850 Pump shaft adapter a Optional equipment Crankcase capacity 3 quarts 2 8 liters CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 73 691 and F691 Head and Valve Assembly Details Appendix 19 Valve Holddown Assemblies Discharge All Specs Valve Assemblies SZ _ 9 N Suction Valve Discharge Valve Suction Valve All Specs Spec 4 Spec 3 690 Head Assembly 691 Head Assembly F691 Head Assembly 74 Part No Description Appendix I 691 and F691 Head and Valve Assembly Details Head and Valve Bill of Materials Assembly No Assembly Name 1743 Head 690 3458 Head 691 4299 F691 head 2144 2 2144 2S Flange suction 2 NPT Flange 2 weld 2144 1 5 2144 1 5S Flange discharge 1 1 2 NPT Flange 1 1 2 Weld 2 2319 O ring 17445 1744 10 Head gasket 690 Head gasket grafoil 2 2612 O ring for head 691 7001 043 NC150A Bolt 7 16 14 x 1 1 2 hex head 2136 Center head bolt 1625 1625 1 1625 20 Center head bolt gasket aluminum Center head bolt gasket copper Center head bolt gasket iron lead 7005 043 NC125A Bolt 7 16 14 x 1 1 4 ferry head 7006 043A Reg lockwasher 7 16 7005 050 NC150A Bolt 1 2 13 x 1 1 2 ferry hea
13. 91 and F91 Connecting Rod Assembly Details S DD Connecting Rod Assembly Bill of Materials Part No Description 1132 X2 Crosshead assembly 1498 Retainer ring 2505 Wrist pin 1846 xa b Wrist pin bushing 15995 Bolt 1889 1X Connecting rod assembly 1889 15 Connecting rod 13675 Connecting rod bearing 2011 Dipper 1600b c Nut 2 3 4 5 6 ra 8 9 o a Must be rebored after replacing 0 8754 0 8751 dia b Included with connecting rod assembly Torque connecting rod nut to 28 ft Ibs Never attempt to separate the piston rod and crosshead When repair becomes necessary the entire crosshead assembly must be replaced CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 54 Appendix F 91 and F91 Flywheel Assembly Details E Sch EQ Up Flywheel Assembly Bill of Materials Assembly Assembly Number Name 3271 X2 Flywheel assembly Flywheel 14 O D 2 groove 3271 Hub with three blots and lockwashers 4 H SF 1 125 Front Side 55 Appendix F 91 and F91 Crankcase Assembly Details Appendix F 91 and F91 Crankcase Assembly Details Crankcase Assembly Bill of Materials Ref Part No No Description 1 3259 Oil seal 1483 Roll pin 1 8 x 1 7001 037NC075A Hex head 3 8 16 x 3 4 Gr 5 5 3260 Bearing carrier 2796
14. compressors the valve type will be spec 3 Valve Holddown Assemblies Depending on your model of compressor the valve holddown assembly has all or a combination of the following A Valve cap Valve cap O ring Holddown screw Valve cover plate Valve cover plate bolts Valve cover plate O ring Valve spacer model 491 only Valve cage oO oO N m FeO N Valve assembly 10 Valve gasket Valve Assemblies Depending on your valve specification the valve assembly has all or a combination of the following A Gasket Adjusting screw Relief ball spring Relief ball Valve seat Valve plate Spacers Washer O e NOA A o Valve spring 4 o Suction valve post 11 Valve bumper 12 Valve gasket See valve holddown and valve assembly part details in the appendix for a complete list of part numbers and descriptions Valve Inspection and or Replacement for Models 91 and 291 Compressors Before removing and inspecting the valves begin by depressurizing and purging if necessary the unit 17 Disassembly 1 2 Unscrew the valve cap and remove O ring Withthespecial wrenchsupplied with yourcompressor at time of purchase remove the holddown screw After the holddown screw has been removed the valve assembly and valve gasket can be lifted out Carefully inspect for dirt or broken damaged parts Inspect valves for breakage corrosion debris and scratches on the valve disc or plate
15. 1 Neoprene Packing cartridge connecting rod All Ductile iron ASTM A536 None Packing rings All Teflon glass and moly filled Alloy 50 Crankshaft All Ductile iron ASTM A536 None Con rod bearing All Bimetal D 2 Babbit None Wrist pin All C1018 steel None Wrist pin busing All Bronze SAE 660 None Main bearing All Tapered roller None Inspection plate All Aluminum None O rings All Buna N PTFE Viton Neoprene Retainer rings All Steel None Misc gaskets All Coroprene 1 Teflon Viton and Neoprene are registered trademarks of the DuPont company None 29 Appendix B Vertical Single Acting Specifications Bolt Torque Values Piston Valve Valve Lock Piston Cap Cap Bearing Bearing X Head Head Nut Screw Torque Torque Carrier Cover Torque Torque w Gaskets w O Rings ftelb ftelb ftelb inelb ftelb ftelb 38 38 45 50 40 25 30 30 45 50 40 25 26 35 45 40 25 40 40 60 40 25 1 Preliminary tightening snug all head bolts in the sequence shown Final torqueing torque all head bolts in the sequence shown to the listed value 2 Retorque to the listed value after 2 5 hours running time O BOLT FROM TOP 5 BOLT FROM BOTTOM MODEL 91 Sol MODEL 690 MODEL 691 30 Appendix
16. 5 2 B 7 4 B 4 0 B 4 6 B 5 2 B 5 8 B 6 2 OO OO YA aja YN UY Ol aa aa wd aja Y O O 1 1 2 1 1 2 290 291 625 290 291 695 290 291 735 490 491 345 290 291 780 490 491 370 B 5 6 B 6 2 B 6 6 A3 0 B 7 0 A 3 2 B 6 6 B 7 4 B 8 0 A3 6 B 8 6 A 3 8 al j i J i 1 1 1 2 i 4 A 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 Unloading two or more tank cars at one time or large transport with excess flow valves of adequate capacity 490 491 390 490 491 415 490 491 490 491 490 491 470 490 491 A3 4 A3 6 A 3 8 B 4 0 B 4 2 B 4 4 B 4 0 B 4 4 B 4 6 B 4 8 B 5 0 B 5 2 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 490 491 490 491 490 491 490 491 490 491 490 491 B 4 6 B 4 8 B 5 0 B 5 2 B 5 4 B 5 6 B 5 6 B 5 8 B 6 0 B 6 2 B 6 4 B 6 6 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 2 490 491 490 491 690 691 490 491 690 691 490 491 B 5 8 B 6 0 B 4 4 B 6 2 B 4 6 B 6 6 B 7 0 B 5 2 B 7 4 B 5 6 B 8 0 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 690 691 690 691 690 691 690 691 B 4 8 B 5 0 B 5 2 B 5 4 B 5 8 B 6 0 B 6 2 B 6 4 1 1 2 1 1 2 1 1 2 1 1 2 Unloading large tank cars multiple vessels barges or terminals 690 691 690 691 690 691 690 691 690 691 690 691 690 691 690 691 690 691 690 691 690 691 690 691 B 5 6 B 5 8 B 6 0 B 6 2 B 6 4 B 6 6 A7 0 B 7 4 ATA 1 1 2
17. Breather ball 1279 X O ring part of bearing cap assembly 1279 X Breather cap assembly with O ring ref no 6 2725 Bearing carrier gasket 9 1807 Roll pin 1 8 x 5 8 14 2289 Flywheel key 15 2290 Oil ring retainer washer 16 2554 Crankcase 18 2729 Inspection plate gasket 2 2 Bearing adjustment shim 0 005 Bearing adjustment shim 0 007 Bearing adjustment shim 0 020 23 2720 Bearing cap Assembly Assembly Number Name 2476 X Crankshaft assembly with 2476 2290 and 2719 2476 SX Extended crankshaft assembly with 2719 2 and 2290 optional 3260 X Bearing carrier assembly with 3260 2718 3259 1279 X 2 111 1483 2796 and 1807 3271 X24 Flywheel assembly 14 2 groove with H SF 1 125 and 3271 a Not shown not part of the crankcase assembly Crankcase capacity 0 9 quarts 0 8 liters CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 57 Appendix G 291 and F291 Head and Valve Assembly Details 291 Head Assembly Valve Holddown Assemblies Suction Discharge Spec 4 All Specs Suction Valve Spec 3 Valve Assemblies Details Suction Valve Discharge Valve Spec 4 All Specs 58 Appendix G 291 and F291 Head and Valve Assembly Details Head and Valve Bill of Materials Description 2912 Head model 291 2912 X1 Head assy for model 291 spec 3 2912 X2 Head assy for model 291 spec 4 4300 Hea
18. No Description 3923 Cylinder cap 3924 Cylinder head 4 1 2 2 246 P O ring 7001 050 NC150A Bolt 1 2 13 x 1 1 2 hex head Gr 5 Torque to 65 ftelbs 2714 1 Valve cap 2 031_P O ring 2715 Holddown screw 1764 Valve cover plate 2 235_P O ring 3570 1 Valve cage 3732 X Suction valve assembly 6 3733 X Discharge valve assembly 6 21148 Valve gasket 7001 043 NC150A Bolt 7 16 14 x 1 1 2 hex head Torque to 37 ftelbs 3827 Valve seat 6 3828 Stud 3830 Valve plate outer 3831 Valve plate inner 3829 Spring 3826 Valve bumper 6 3805 X1 Valve repair kit 1st stage O ring Code A Buna N B Neoprene 4 a Included with valve assembly b _ denotes O ring code See O ring chart above for details Included with valve repair kit d Registered trademarks of the DuPont company CAUTION Always relieve pressure in the unit before attempting any repairs 82 Appendix J D891 Piston Assembly Details Piston Assembly Number 3925 X1 Bill of Materials Piston Diameter 4 5 11 43 cm Part No Description 7002 025 TP100A Screw orlo gr 8 Torque to 8 ftelbs 3927 Piston cap 2902 Shim washer thick 3902 1 Shim washer thin 3604 Lock nut Torque to 150 ftelbs 3730 Thrust washer 3925 Piston
19. P Drain valve o 1 NPT di L di R Crankcase JL r Adjustable dri Use ight 3 4 3 oil drain S I E ee basa anchor bolts U W E F G V e Y Outline Dimensions Inches Centimeters Model B Cc D D891 109B 2 5 3 4 16 5 1 14 6 40 6 Outline Dimensions Inches Centimeters Model l J N O D891 109B 77 9 16 66 3 16 39 1 8 27 1 8 39 13 16 197 1 168 1 99 4 68 9 101 1 Outline Dimensions Inches Centimeters Model T U V W X D891 109B 7 3 8 18 28 3 8 24 3 4 65 1 2 18 7 45 7 72 1 62 8 166 3 48 Appendix E Troubleshooting Inmostcases problems with your Corken gas compressor can be solved quite simply This chart lists some of the more frequent problems that occur with reciprocating Problem compressors along with a list of possible causes If you are having a problem which is not listed or if you cannot find the source of the problem consult the factory Possible Cause Low capacity 1 2 3 4 16 Overheating 1 2 3 5 6 11 15 Knocks rattles and noise 7 9 10 11 14 Oil in cylinder Abnormal piston ring wear 5 6 11 14 15 Product leaking through crankcase breather Product leakage Oil leakage around compressor base No oil pressure Excessive vibration 1 7 9 10 11 12 13 28 Motor overheating or starter tripping ou
20. Refer to the drawing for item description Q SEAL O RING 4 zE BOTTOM ROTOR WASHER BODY O RING INCLUDED IN REPAIR KIT BOTTOM CAP Figure 5 9A Figure 5 9B 24 Figure 5 9C Remove the body O ring stem O ring cap O ring and top rotor washer and discard Remove the rotor and four seals as a unit from the body IMPORTANT Because of the close tolerance care must be taken to remove the rotor on its axis to prevent damage to the rotor and body Rotating the handle with a lifting action will help remove the rotor as shown in figure 5 9D Figure 5 9D Discard the four seals Inspect the rotor for wear and damage Remove the bottom rotor washer and discard Inspect the body for wear and damage Assembly Refer to figure 5 9B Have the repair kit laid out ie 2 Place the new bottom rotor washer into the body Assemble the four seals and O rings onto the appropriate surfaces of the rotor Assemble the rotor and seal assembly into the body IMPORTANT Because of the close tolerance care must be taken to press the rotor on its axis to prevent damage to the rotor and body A ring compressor is helpful Be sure that the rotor is bottomed in the body Rotate the rotor so that the position marks on the end of the rotor shaft are the same as recorded before disassembly Assemble the new top rotor washer and cap O ring onto the shoulder of the rotor Assemble the new stem O ring and th
21. Suction valve bumper 2441 Discharge valve bumper 2439 Discharge valve seat 2533 1 Adjusting screw 1411 Relief ball spring 1410 Relief ball 2532 1 Suction valve seat 2534 1 Suction valve post 2447 Suction valve bumper 7001 043NC125A Bolt 7 16 14 x 1 1 4 hex head B Neoprene 9 a Optional equipment b denotes O ring code See O ring chart above for details Not included in Head Assembly d Prior to SIN FZ44188 e SIN FZ44188 and later f Place spacers back to back as shown 9 Registered trademarks of the DuPont company CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 67 Appendix H 490 491 and F491 Piston Assembly Details Piston Assembly Number 1985 X Bill of Materials Piston Diameter 4 10 16 cm Part No Description 7002 0250C125A Screw socket head 7207 025A Lock Washer 1985 Head iron 1776 Ring expander 1773 Piston ring 1482 Locknut 1483 Lock pin 1986 Piston platform 1528 Shim washer thick 1528 1 Shim washer thin 1527 Thrust washer 2 lt Piston Clearance Cold Minimum Maximum 0 000 0 00 mm 0 024 0 61 mm Piston Rod at 0 020 0 51 mm 0 044 1 12 mm a The distance from the bottom of the head to the top of the piston b For 491 compressor with flat gasket For 491 compres
22. W 36th Street Oklahoma City Oklahoma 73112 Parts subject to wear or abuse such as mechanical seals blades piston rings valves and packing and other parts showing signs of abuse are not covered by this limited warranty Also equipment parts and accessories not manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser must look to the original manufacturer s warranty if any This limited warranty is void if the Corken product has been altered or repaired without the consent of Corken ALL IMPLIED WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY NEGATED TO THE EXTENT PERMITTED BY LAW AND SHALL IN NO EVENT EXTEND BEYOND THE EXPRESSED WARRANTY PERIOD CORKEN DISCLAIMS ANY LIABILITY FOR CONSEQUENTIAL DAMAGES DUE TO BREACH OF ANY WRITTEN OR IMPLIED WARRANTY ON CORKEN PRODUCTS Transfer of toxic dangerous flammable or explosive substances using Corken products is at the user s risk Such substances should be handled by experienced trained personnel in compliance with governmental and industrial safety standards Contacting The Factory For your convenience the model number and serial number are given on the compressor nameplate Space is provided below for you to keep a written record of this information Always include the model number and serial number when ordering parts Model No Serial No Date Pur
23. WASHER SHIMS PISTON ROD Figure 5 4A Piston Cross Section Model Sizes 91 Through 491 CASTELLATED PISTON NUT PISTON RING EXPANDER PISTON RING y PISTON PISTON CLEARANCE HEAD SEE APP B ROLL PIN PISTON BOLT DRA NN S pt e MA UZ ES PISTON PLATFORM PISTONROD CYLINDER SHIMS Figure 5 4B Piston Cross Section Model 691 12 Install the piston head and tighten the socket head bolts in an alternating sequence 13 Reinstallthe head seesection 5 2 and follow standard startup procedure Note Some compressors may have self locking nuts without roll pins 5 9 Piston Rod Packing Adjustment Piston rod packing should be adjusted or replaced whenever leakage becomes noticeable Typically it is a good idea to replace piston rod packing and piston rings at the same time For instructions on adjusting and replacing the piston rod packing see section 5 6 NOTE Inspection of the rod packing is generally not productive since packing that cannot be adjusted to an acceptable leakage rate should be replaced NOTE FILL CRANKCASE WITH OIL THROUGH THIS OPENING TIGHTEN TURN Figure 5 5A Packing Adjusting Nuts 5 6 Cylinder and Packing Replacement Cylinders very seldom require replacement if the compressor is properly maintained The primary cause of damage to cylinders is corrosion and the entry of solid debris or liquid into the compression
24. appendix in the back of this IOM manual Use instructions below that apply to the MODEL and SERIAL NUMBER of your compressor Be careful to arrange packing sets in the proper order Cleanliness Sealing a reciprocating piston rod is a very difficult task Keep all parts tools and your hands clean during installation Your new packing needs every chance it can get so keep it clean Workmanship Your Corken compressor is a precision piece of equipment with very close tolerances Treat it as such Never beat on it to get parts in or out Model 91 Compressor Refer to Appendix F for packing assembly details Disassembly of Packing 1 Depressurize and open the compressor 20 2 Remove head piston cylinder inspection plate and crosshead guide 3 Loosen adjusting screw and remove retainer ring washers packing spring and old packing from crosshead guide Assembly of Packing 1 Clean then lightly oil packing area inside the crosshead guide 2 Slightly thread in the adjusting screw into the crosshead guide 3 Install packing rings including male and female packing rings one at a time as shown in Appendix F Push in each one completely before adding the next ring The quantity of packing rings required will vary due to tolerances a good rule of thumb is to put in as many as are removed 4 Insert thin packing box washer packing spring and thicker washer into the top of the crosshead guide 5 Tighten ad
25. assembly 1284 Crankshaft orifice 2590 Pipe plug 1 8 NPT fl Seal 2135 Drive pin 4225 Filter 2933 Link pin 2798 Pump cover pin included w 4222 X 3786 Crankshaft 3503 Flywheel key 3580 Bearing cone 3786 X1 Crankshaft assembly 7001 031NC075A Bolt 5 16 18 x 3 4 hex head 2122 Inspection cover 2123 Gasket inspection cover 2 210A O ring 3225 X1 Oil bayonet assembly w O ring 2126 Breather ball 3579 Bearing cup 3589 Bearing adjustment shim 005 2589 1 Bearing adjustment shim 007 2589 2 Bearing adjustment shim 020 3539 Bearing cover 3526 Oil seal 1280 Filter screw 1281 Gasket filter 2 116A O ring 1276 Washer 1275 Oil filter screen 3443 Pipe plug 1 2 NPT steel 3221 Crankcase 7001 037NC100A Bolt 3 8 16 x 1 hex head Gr 5 3875 Access cover 7003 025NC037E Screw 1 4 20 x 3 8 3874 Gasket access cover 1515 X Closure cap assembly 7001 025NC050A Bolt 1 4 20 x 1 2 hex head 1515 Closure cap 1516 Closure body 2 118A O ring 1290 Relief valve adjusting screw 2 011A O ring 1291 Adjusting screw locknut 1292 Relief valve spring 1293 Relief valve ball 4222 X Oil filter adapter assembl
26. belt guard Pressure gauges are mounted on the compressor 107A Mounting includes All items on the 107 replacing the mechanical float in the liquid trap with a NEMA 7 liquid level switch 107B Mounting includes All items on the 107 replacing the liquid trap with a larger ASME code liquid trap with 2 NEMA 7 liquid level switches set for alarm and shutdown 107TR Mounting includes All items on the 107 set up to be used as a transport unit Note that the compressor must have the optional 14 flywheel and extended crankshaft to use this mounting 2 109 Mounting includes Steel baseplate mechanical liquid trap interconnecting piping adjustable driver slide base V belt drive and enclosed steel belt guard Pressure gauges are mounted on the compressor 109A Mounting includes All items on the 109 replacing the mechanical float in the liquid trap with a NEMA7 liquid level switch 109B Mounting includes All items on the 109 replacing the liquid trap with a larger ASME code liquid trap with 2 NEMA 7 liquid level switches set for alarm and shutdown 109TR Mounting includes All items on the 109 set up to be used as a transport unit Note the compressor must have the optional 14 flywheel and extended crankshaft to use this mounting 2 3 2 Not suitable for 691 3 Discharge relief valves are required but not included in these mountings 27 Appendix B Vertical Single Acting Specifications Models 91 691 Equ
27. cap 1739 Piston rings PTFE 1739 2 Piston rings Alloy 1739 3 Piston rings PEEK 1740 Expander ring 3603 Shim washer thick 3603 1 Shim washer thin Piston Rod a Loctite tube 620 3812 Piston Clearance Cold Top Min Top Max Bottom Min P Bottom Max 0 084 2 13 mm 0 104 2 64 mm 0 010 0 25 mm 0 020 0 50 mm a The distance from the bottom of the head to the top of the piston b The distance from the bottom of the piston to the top of the crosshead guide CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 83 Appendix J D891 Crosshead Guide Assembly Details Part No Description 3922 Cylinder 1054 Drain valve lubricated models 1071 Nipple 1 4 x close 2 246 _4 O ring for cylinder 3442 Pipe plug 1 4 NPT 7001 050NC175A Bolt 1 2 13 x 1 3 4 hex head gr 5 3793 2S Flange inlet outlet 2 231_4 O ring for flange 3253 Roll pin 2405 1 Crosshead guide 1064 Elbow 1 4 NPT 3974 Tag 1761 Gasket crankcase 1760 Gasket inspection cover 1721 Inspection cover i Aj ap sch sch sch NO NO 7012 010NC025B O ring Code A Buna N B Neoprene gt Bolt 10 24 x 1 4 Phillip hd a _ denotes O ring code See O ring chart above for details Regi
28. minimum of 18 inches 45 cm clearance between the compressor and the nearest wall is advised to make it accessible from all sides and to provide unrestricted air flow for adequate cooling NOISE Corken vertical compressors sizes model 91 through 891 should not exceed an 85 DBA noise level when properly installed 2 2 Foundation Proper foundations are essential for a smooth running compression system Corken recommends the compressor be attached to a concrete slab at least 8 in thick with a 2 in skirt around the circumference of the baseplate The baseplate should be securely anchored into the foundation by 1 2 in diameter J bolts 12 in long Four bolts should be used for models 91 291 and 491 Six bolts should be used for model 691 The total mass of the foundation should be approximately twice the weight of the compressor system compressor baseplate motor etc After leveling and bolting down baseplate the volume beneath the channel iron baseplate must be grouted to prevent flexing of the top portion of the baseplate and the J bolt that extends beyond the foundation The grout also improves the dampening capabilities of the foundation by creating a solid interface between the compressor and foundation On some of the longer baseplates such as with the 691 107 a3 in hole can be cut in the baseplate for filling the middle section of the baseplate with grout See ED410 Compressor Foundation Design 2 3 Pip
29. not available 2798 2848 X Pump cover pin with 2848 X Pump cover includes pin 4225 Filter a Optional equipment Crankcase capacity 1 5 quarts 1 4 liters Oil filter assembly with 4222 4225 2798 3289 standard on all models starting January 1 1993 CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 65 Appendix H 490 491 and F491 Head and Valve Assembly Details O y 5 D o SZ LA Fb Zb K o 0 MEX Da SY Pa ac o lt D a N KI 2 E Di E Di N Q lt E 2 E S 38 8 SS OO 3 0 lt x oa CO nn ye 2 L o 2 T gt EI E gt i GQ 3 O gt co 5a oo nn BO 5 D gt E gt D gt 5 Di 2 N E E st 5 Kei N Y bd N lt x T 5 xo 3 S 3 vt T lt CH Sg E o Q lt LL o o wv 66 Part No Description No Valve Assembly Appendix H 490 491 and F491 Head and Valve Assembly Details Compressor Head and Valve Bill of Materials Assembly Name 29140 Head ductile iron 491 37129 Head ductile iron 491 4297 4297 1 Head ANSI flanged F491 Head flanged Din spec only F492 14810 Head gasket 490 and 491 2 253b 0 8 O ring 491 3442 Pipe plug 1 4 NPT 1479 Center head bolt 1480 10 14800 Center head bolt gasket copper Center head bolt gasket steel 7005 043NC12
30. numbers specify pressure containing abilities of the compressor cylinder and head For many applications factors other than the pres sure rating will limit the maximum allowable discharge pressure to lower values These factors include horsepower temperature and rod load 28 Appendix B Vertical Single Acting Specifications Models 91 691 Material Specifications Part Model Standard Material Optional Material Head Cylinder All Ductile iron ASTM A536 None Crosshead guide crankcase flywheel bearing carrier All Gray iron ASTM A48 Class 30 None Flange 691 Ductile iron ASTM A536 Steel weld flange Valve seat amp bumper 91 291 17 4 PH stainless steel 491 Ductile iron ASTM A536 691 17 4 PH stainless steel None Valve plate 91 291 410 stainless steel 491 17 7 PH stainless steel 691 410 stainless steel None Valve spring 91 291 691 17 7 PH stainless steel 491 Inconel None Valve gaskets All Soft aluminum Iron lead Copper Piston All Gray iron ASTM A48 Class 30 None Piston rod All C1050 steel Nitrotec coated Chrome oxide Crosshead All Gray iron ASTM 48 Class 30 None Piston rings All PTFE glass and moly filled Alloy 50 Ring expanders All 302 stainless steel None Head gasket All O ring Buna N Teflon Viton
31. of solid debris or liquid into the compression chamber Improper storage can also result in corrosion damage to the head for proper storage instructions see chapter 6 Many compressor repair operations require removal of the head While the compressor is disassembled special care should be taken to avoid damage or corrosion to the head If the compressor is to be left open for more than a few hours bare metal surfaces should be coated with rust preventative When reassembling the compressor make sure the bolts are retightened as shown in Appendix B 5 3 Piston Rings and Piston Ring Expanders Figure 5 3A Piston Removal Piston ring life will vary considerably from application to application Ring life will improve dramatically at lower speeds and temperatures 1 To replace the piston rings depressurize the compressor and purge if necessary 2 Remove the head to gain access to the compressor cylinder 3 Loosen the piston head bolts Remove the piston as shown in figure 5 3A by pinching two loose bolts together 4 Piston rings and expanders may then be easily removed and replaced Corken recommends replacing expanders whenever rings are replaced To determine if rings should be replaced measure the radial thickness and compare it to the chart in Appendix B 5 4 Pistons 1 10 11 PISTON HEAD To replace the pistons depressurize the compressor and purge if necessary Remove the compressor cylinde
32. on washer and insert retainer ring 6 Tighten adjusting screw until plastic locking device engages the first thread in the packing box cartridge 7 Oil piston rod and replace cartridge O ring 8 Install packing installation cone part number 4005 over the threaded end of the piston rod 9 Carefully slip the packing cartridge over the piston rod otherwise you may damage the lips of the packing rings 10 Remove packing installation cone 11 Install and tighten cartridge holddown screw with special wrench 12 Install cylinder O ring cylinder pistons and head Model 691 Compressor Refer to Appendix for packing assembly details Disassembly of Packing 1 Depressurize and open the compressor 2 Remove head pistons and cylinder 3 Remove cartridge holddown screw with special wrench supplied with the compressor and packing box cartridge 4 Loosen adjusting screw and remove retainer ring washers packing spring and old packing from packing box cartridge Assembly of Packing 1 Clean then lightly oil packing area inside packing box cartridge 2 Thread in adjusting screw until locking device is engaged into first thread of the packing cartridge 3 Install packing rings including male and female packing rings one at a time as shown in Appendix Push in each one completely before adding the next ring 4 Insert a packing washer packing spring and another packing washer 5 Push down on w
33. operating pressures Consult factory for additional recommendations for your specific application Change oil every 2 200 hours of operation or every 6 months whichever occurs first If the oil is unusually dirty change it as often as needed to maintain a clean oil condition Change replacement filter 4225 with every oil change Liquid traps should be drained prior to startup 16 Chapter 5 Routine Service and Repair Procedures CAUTION Always relieve pressure in the unit before attempting any repairs After repair the unit should be pressure tested and checked for leaks at all joints and gasket surfaces If routine maintenance is performed as listed in chapter 4 repair service on your Corken gas compressor is generally limited to replacing valves or piston rings When it comes time to order replacement parts be sure to consult the part details appendix in the back of this Installation Operation amp Maintenance IOM manual for a complete list of part numbers and descriptions 5 1 Valves Test the compressor valves by closing the inlet piping valves while the unit is running however do not allow the machine to operate in this way very long If the inlet pressure gauge does not drop to zero almost immediately one or more of the valves is probably either damaged or dirty It is possible of course that the pressure gauge itself is faulty Inspect valves for breakage corrosion and scratches on the valve dis
34. pre Agua E i Le N ta NPT d drain d L valve d A akne d H CORKEN Cor EN 4 DI y a DD zi 8 d Crankcase d oil drain 3 5 16 FARI y f 8 36 Ol 9 p i B 13 16 LI L 5 1 4 9 71 Li 13 34 Fine 3 65 CL vam 12 30 48 3 81 15 38 10 Dimensions apply to 107A mounting only Discharge Inlet pressure gauge pressure INIL gauge SC es ffe ENS f 3 4 NPT Liquid Cl CH 7 opening for 31 3 16 trap tank A N YAS SE 79 17 Four way SODI Pa valve 24 NPT SE ot Electric motor driver 18 3 16 46 20 Ea A a 16 9 16 KIN 42 07 Lh ZLI si VOSGI Z Z Gi Co ES f d Re la m am 200 7 62 i IL Li 22 316 VAT SEH Wes four S _ 9 Adjustable dri Se 56 36 18 911716 24 53 ee 1 2 gt 13 5 16 33 81 anchor bolts 31 1 2 80 01 Inches Centimeters 34 86 36 40 Appendix D Outline Dimensions Model 291 with 107 or 107A Mounting model 107A shown below
35. 1 1 2 1 1 2 D891 D891 OO FRRHRHRAIPHRRRHRAWBWWWIWWWWWWIWDBWWWWWIWNWWWW D WWINMNYNN NIN PD h 1 The capacities shown are based on 70 F but will vary depending upon piping fittings used product being transferred and temperature The factory can supply a detailed computer analysis if required 2 Driver sheaves 91 2 belts 290 291 490 491 3 belts 690 691 4 belts 3 The piping sizes shown are considered minimum If the length exceeds 100 ft use the next larger size NOTE Please consult factory for compressors with higher flows 37 Appendix D Outline Dimensions Models 91 691 and F91 F691 Bare with Flywheel Outline Dimensions Inches Centimeters Model c D E F G K 1 13 16 3 11 16 13 32 5 8 6 1 4 3 7 8 25 5 16 22 11 16 4 6 9 4 1 03 1 59 15 9 9 8 64 3 57 6 3 3 8 3 11 16 13 32 5 8 9 13 16 12 25 13 16 23 3 8 8 6 9 4 1 11 1 59 24 9 30 4 65 2 59 4 4 1 8 4 11 16 1 2 11 16 10 11 16 13 29 11 16 26 3 16 10 5 11 9 1 27 1 75 27 2 33 1 75 4 66 5 4 3 4 5 3 8 9 16 1 14 14 3 8 39 1 8 35 1 8 12 1 13 7 1 5 2 5 35 6 35 6 99 4 89 2 91 F91 291 F291 491 F491 691 F691 PD Flywheel Pitch Diameter Model L1 M1 A belt Groove B belt Groove 91 F91 3 4 300 Ib 4 1 4 13 2 2 13 6 ANSI 10 8 d 3
36. 109 9 Crankcase heater optional 4 it 35 5 8 90 4 Tani I 24 15 32 Y A hp 62 1 1 fi o O zax T o A 53 8 H Pd O e d A 8 1 4 1 8 Ko o 20 9 E Yy F Y y LUI lt gt 5 5 8 4 3 4 5 1 2 1 14 3 12 0 13 9 2 5 da TILA Sec Li 13 1 4 Hole Diameter i i 33 6 10 1 4 i 26 0 Inches Centimeters 45 Appendix D Outline Dimensions Model D891 with 103 Mounting optional H 5 1 2 5 1 2 13 92 13 92 EEES I O 820 0 0 gt Inlet yT Jn Y i am i fq DE Outlet 2 Weld flange eig ea do ola Pala EA pressure gauge PEC e tea i dt E DI TOK Oo 00 o H Lee onoo Inlet AS OE Outlet TO W pressure guage fc DE 2 Weld flange o ol ia DA TOTO To i E Crankcase heater Electric motor Beltguard bil K ae TC P optional driver E 1 mi IRE A E 49 1 4 T MMMM gt 125 0 po m A Il imam ell A Mal la 41 5 8 O 10578 1 gg ap B tin i Sept Lp AAA E Crank LIN oildrain 20 118 go z 66 36 fl pal J EL We 4 Ji a 1 LD ll Low oil pressure am JL o l 6 4 Pa j Adjustable driver ota optional lide b 1 91 17 78 Li 15 24 10 21 la slide base i 45 72 7 24 3 9 16 e 10 36 17 7
37. 3 5 34 5 291 F291 3 4 300 Ib 4 1 4 15 2 15 6 ANSI 10 8 d 38 6 39 6 13 21 13 61 33 5 34 5 491 F491 1 1 4 1 1 4 300 Ib 5 5 8 15 2 15 6 NPT ANSI 14 3 38 6 39 6 13 21 13 61 33 5 34 5 691 F691 22 6 15 16 3 13 16 19 1 8 17 6 9 7 48 5 1 Optional flywheel 91 291 491 691 only 2 Optional flanges 1 1 4 1 1 2 NPT 1 1 4 1 1 2 or 2 Weld F91 F291 F491 F691 only 38 Appendix D Outline Dimensions Models 91 691 with 103 Mounting Intake pressure Discharge pressure Belt guard Adjustable base A Use 4 1 2 anchor bolts D 291 103 491 103 691 103 Outline Dimensions Inches Centimeters Model H J K L 28 11 16 26 3 8 4 15 16 7 75 72 9 67 0 12 5 19 7 28 22 32 26 6 16 4 15 16 7 3 4 72 9 67 0 12 5 19 7 33 11 16 30 3 16 5 3 4 10 85 6 76 7 14 6 25 4 43 1 8 39 1 8 8 25 9 25 109 5 99 4 21 0 23 5 91 103 291 103 491 103 691 103 39 Appendix D Outline Dimensions Models 91 with 107 or 107A Mounting model 107A shown below o fa AM D Zara A O Liquid N e level switch r L ES Y Ke je
38. 3A On 107 mountings the fexible con nectors should be located near the four way valve Care must be taken if a restrictive device such as a valve pressure regulator or back check valve is to be installed in the compressor s suction line The suction line volume between the restrictive device and the compressor suction nozzle must be at least ten times the swept cylinder volume 107 style compressors are usually connected using a five valve figure 2 3B or three valve manifold figure 2 3C The five valve manifold allows the storage tank to be both loaded and unloaded The three valve manifold only allows the storage tank to be loaded Adequate sizing of the liquid and vapor lines is essential to limit the pressure drop in the system to a reasonable level 20 psi or less The line size helps determine the plant capacity almost as much as the size of the compressor and liquid line sizes are a bigger factor than vapor lines If the pressure gauges on the head indicate more than a 15 to 20 psi 2 07 to 2 40 bars differential between the inlet and outlet pressures the line sizes are too small or there is some fitting or excess flow valve creating too much restriction The less restriction in the piping the better the flow Appendix C shows recommended pipe sizes for typical LPG NH3 compressor installation VAPOR LINE TO TRUCK OR TRAILER LOADING A tank car unloading riser should have two liquid hoses connected to the car li
39. 4 6 3 4 1 1 4 bulk 590 B 4 6 B 5 6 1 1 1 4 plants 695 B 5 4 B 6 6 1 1 1 2 290 291 345 A 3 0 A 3 6 1 1 1 2 91 795 B 6 2 B7 4 1 1 1 2 290 291 390 A3 4 B 4 0 1 1 1 2 290 291 435 A 3 8 B 4 6 1 1 1 2 1 1 1 1 290 291 490 B 4 4 B 5 2 Unloading 290 291 535 B 4 8 B 5 8 single tank 290 291 580 B 5 2 B 6 2 car or 290 291 625 B 5 6 B 6 6 transport 290 291 695 B 6 2 B7 4 290 291 735 B 6 6 B 8 0 490 491 345 A3 0 A3 6 290 291 780 B7 0 B 8 6 490 491 370 A 3 2 A 3 8 490 491 390 A3 4 B 4 0 490 491 415 A3 6 B 4 4 490 491 A 3 8 B 4 6 490 491 B 4 0 B 4 8 490 491 470 B 4 2 B 5 0 1 1 4 Unloading 490 491 B 4 4 B 5 2 1 1 4 two or 490 491 B 4 6 B 5 6 1 1 4 more tank 490 491 B 4 8 B 5 8 1 1 4 cars at 490 491 B 5 0 B 6 0 1 1 4 one time 490 491 B 5 2 B 6 2 1 1 4 or large 490 491 B 5 4 B 6 4 1 1 4 transport 490 491 B 5 6 B 6 6 1 1 2 with excess 490 491 B 5 8 B 7 0 1 1 2 flow valves 490 491 B 6 0 1 1 2 of adequate 690 691 B 4 4 B 5 2 1 1 2 capacity 490 491 B 6 2 B 7 4 1 1 2 690 691 B 4 6 B 5 6 1 1 2 490 491 B 6 6 B 8 0 1 1 2 690 691 B 4 8 B 5 8 1 1 2 490 491 B 6 8 B 8 0 1 1 2 490 491 B 7 0 B 8 6 1 1 2 690 691 B 5 0 B 6 0 1 1 2 690 691 B 5 2 1 1 2 490 491 B 7 4 1 1 2 690 691 B 5 4 A 6 4 1 1 2 690 691 B 5 6 B 6 8 1 1 2 Unloading 690 691 B 5 8 B 7 0 1 1 2 large 690 691 B 6 0 1 1 2 tank cars 690 691 B 6 2 multiple 690 691 B 6 4 A 7 4 vessels 690 691 B 6 6 barges or 690 691 B 6 8 terminals 690
40. 499 1501 1503 2590 Extended crankshaft assembly with 1284 2 1286 1499 S 1501 1503 2590 1508 X1 Oil bayonet assembly with 1508 X 2 112A Closure cap assembly including 2 218A 2 Spec 3 4 8 9 only Flywheel assembly with 2549 3217 not part of crankcase assembly not shown Bearing carrier assembly with 1290 1291 1292 1293 1500 1508 X1 1513 1515 X 1629 2 2590 2804 2848 X 2849 X 2850 2851 2852 2961 X 2 011A 2 112A 2 228A 2847 1X 3271 X Bearing cover assembly with 2847 1 3855 Flywheel assembly with 3271 3217 not part of crankcase assembly not shown 1276 Filter screen washer 1275 Oil filter screen 3289 Pipe plug 1661 Plug 3 8 NPT 1290 Relief valve adjusting screw 1291 Adjusting screw locknut 2 011A O ring relief valve adjusting screw 1292 Relief valve spring 1293 Relief valve ball 1502 Bearing cup 2961 X Air release valve assembly with 2961 2962 2963 1513 Bearing carrier gasket 2804 Bearing carrier gasket 2 218A O ring closure body 2 Spec 3 4 8 9 only 1515 X Closure cap assembly 7001 025NC050A Hex head bolt 1 4 20 x 1 2 1302 Oil pressure gauge 2 228A O ring pump cover 4222 X Oil filter assembly external 1629 1 16 NPT pipe plug flush seal 7001 037NC100A Hex head bolt 3 8 16 x 1
41. 5 B 5 4 B 6 6 1 1 1 2 290 291 345 A3 0 A3 6 1 1 1 2 91 795 B 6 2 B7 4 1 1 1 2 290 291 390 A 3 4 B 4 0 1 1 1 2 290 291 435 A 3 8 B 4 6 1 1 1 2 1 1 1 1 aja a a w zoo N I Sa ka 290 291 490 B 4 4 B 5 2 2 Unloading 290 291 535 B 4 8 B 5 8 single tank 290 291 580 B 5 2 B 6 2 car or 290 291 625 B 5 6 B 6 6 1 1 4 transport 290 291 695 B 6 2 B7 4 1 1 4 290 291 735 B 6 6 B 8 0 1 1 4 490 491 345 A3 0 A3 6 1 1 4 290 291 780 B 7 0 B 8 6 1 1 4 490 491 370 A3 2 A 3 8 1 1 4 490 491 390 A 3 4 B4 0 1 1 4 490 491 415 A 3 6 B 4 4 1 1 4 490 491 A 3 8 B 4 6 1 1 4 490 491 B 4 0 B 4 8 1 1 4 490 491 470 B 4 2 B 5 0 1 1 4 Unloading 490 491 B 4 4 B 5 2 1 1 4 two or 490 491 B 4 6 B 5 6 1 1 4 more tank 490 491 B 4 8 B 5 8 1 1 4 cars at 490 491 B 5 0 B 6 0 1 1 4 one time 490 491 B 5 2 B 6 2 1 1 4 or large 490 491 B 5 4 B 6 4 1 1 4 transport 490 491 B 5 6 B 6 6 1 1 2 with excess 490 491 B 5 8 B 7 0 1 1 2 flow valves 490 491 B 6 0 1 1 2 of adequate 690 691 B 4 4 B 5 2 1 1 2 capacity 490 491 B 6 2 B 7 4 1 1 2 690 691 B 4 6 B 5 6 1 1 2 490 491 B 6 6 B 8 0 1 1 2 690 691 B 4 8 B 5 8 1 1 2 690 691 B 5 0 B 6 0 1 1 2 690 691 B 5 2 B 6 2 1 1 2 690 691 B 5 4 B 6 4 1 1 2 690 691 B 5 6 1 1 2 690 691 B 5 8 1 1 2 690 691 B 6 0 A 7 0 1 1 2 690 691 B 6 2 B 7 4 Unloading 690 691 B 6 4 ATA large 690 691 B 6 6 tank cars 690 691 B 6 8 multiple 690 691 B 7 0 vessels 690 691 B 7 4 barges or 690 691 B 8 0 te
42. 50 F 45 70 F 35 50 F Texaco Regal R amp O Oil 65 100 F 45 70 F 35 50 F Sun SunVis 900 Oil 65 100 F 45 70 F 35 50 F Figure 2 6A Oil Selection Chart Compressor Model 91 Approximate Quarts 0 9 Capacity 291 491 691 Figure 2 6B Oil Capacity Chart 2 7 Relief Valves An appropriate relief valve must be installed at the compressor discharge On Corken 107 style mounted units a relief valve should be fitted in the piping between the compressor discharge and the four way valve see figure 1 3A Relief valves should be made of a material compatible with the gas being compressed Local codes and regulations should be checked for specific relief valve requirements Also relief valves may be required at other points in the compressor s system piping 2 8 Truck Mounted Compressors Corken compressors are may be mounted on trucks to perform liquid transfer operations as described in section 1 1 The compressor should be mounted so the inspection plate is accessible for packing adjustment The compressor must be protected against liquid as explained in section 2 4 and a relief valve must be installed in the discharge piping before the first downstream shutoff valve 12 Three types of mountings are typically used The inside mounting figure 2 8A drives the compressor directly off the PTO shaft The P
43. 5A Bolt 7 16 14 x 1 1 4 ferry head 490 amp 491 prior to serial FZ44188 7005 043NC150A Bolt 7 16 14 x 1 1 2 ferry head 491 serial FZ44188 and later 1477 Valve screw nut 1478 1478 18 1478 2 Gasket steel Gasket copper Gasket iron 1476 Valve holddown screw 1475 Valve cover plate 2 143b O ring for cover plate 2438 X Suction valve assembly see ref no 7 17 18 19 20 21 2 22 23 24 2438 X19 Same as 2438 X but with copper gaskets 2438 X24 Same as 2438 X but with iron lead gaskets 2439 X Discharge valve assembly see ref no 7 17 18 20 21 2 22 26 25 2439 X18 Same as 2439 X but with copper gaskets 2439 X24 Same as 2439 X but with iron lead gaskets 2532 1X Suction valve assembly spec 3 with aluminum 2532 1X1 Same as 2532 1X but with copper 2532 1X2 Same as 2532 1X but with iron lead Head Assembly No Model Valve Specifcanon 2914 X2 1409f Valve spacer 2914 X4 2448 Cage 1418 1418 18 1418 24 Valve gasket aluminum Valve gasket copper Valve gasket iron 2446 Bolt 2438 Suction valve seat 2442 Valve plate 2445 Spacer two per valve 3355 Washer 1407 Valve spring 3712 X19 3712 X29 3 3 4297 X1 4297 X2 4297 1X1 4297 1X2 O ring Code A Buna N 2440
44. 5V 5 groove 39184 Flywheel hub type J2 1 8 bore D891 only 17629 Flywheel 19 1 2 AB 4 groove 3221 X19 Crankcase assembly M3 4 8 9 without lubrication 3221 X29 Crankcase assembly M7 78 without lubrication 3221 X39 2 011A O ring 1291 Adjusting screw locknut 1292 Relief valve spring 1293 Relief valve ball 4222 XE Oil filter adapter assembly w pin 2 228A O ring 2849 1X Oil pump assembly 2851 Spring guide 2852 Oil pump spring 3219 Pump shaft adapter 2 112A O ring 2805 XD Pump shaft bushing 1629 Pipe plug 1 16 NPT fl seal 1736 Bearing cup 1302 Oil pressure gauge 1044 Bushing 1 8 x 1 4 NPT 3220 2 Bearing carrier 3221 X48 a Not shown b Must be rebored and honed after replacing 0 876 0 875 diameter Caution To avoid damage during assembly refer to installation Instruction Manual 1E400 Crankcase assembly L3 4 8 9 without lubrication Crankcase assembly L7 78 without lubrication CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 89 Solutions beyond products CORKEN IBEX CORKEN INC e A Unit of IDEX Corporation 3805 N W 36th St Oklahoma City OK 73112 U S A Phone 405 946 5576 e 800 631 4929 Fax 405 948 7343 Visit our website at http www corken com or e
45. 691 B 7 0 690 691 B 7 4 690 691 B 8 0 690 691 B 8 6 690 691 TB 9 0 D891 5V 7 1 D891 5V 9 75 1 The capacities shown are based on 70 F but will vary depending upon piping fittings used product being transferred and temperature The factory can supply a detailed computer analysis if required 2 Driver sheaves 91 2 belts 290 291 490 491 3 belts 690 691 4 belts 3 The piping sizes shown are considered minimum If the length exceeds 100 ft use the next larger size NOTE Please consult factory for compressors with higher flows 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 1 1 4 aaa a aja Om YN Y VI U1 oooh ain dI WW Ww aa Oo Oo a aja VI VI VI VI VI WI Y Y YN ain aww wo aa a VI aja Om YN Y aja Y Y 0 N VIN G W Ww aa a a a aja Y VI VI VI Oto Y A YN VIN ow Ww wo O O fi4sASs Ass Ap AA AS SA AV 0 DI DI Go GO ua Y Y 13 LI JAY Y WO Y WAY Y Ca Ca u GO WN NN NN NIN NM PY 35 Appendix C Compressor Selection Propane Compressor Selection Table Driver Horsepower Liquid Liquid Transfer Transfer amp Without Residual Residual Driver Sheave Size Vapor Vapor Displacement Compressor Pitch Diameter inches Recovery Recovery Piping Size Service cfm RPM 1 750 RPM 1 450 RPM 100 F 80 F 100 F 80 F Vapor Liquid 400 A 3 0 A 3 6 3 3 3 3 4 1 1 4 Small 505 A 3 8 B 4 6 3 4 1 1 4 bulk 590 B 4 6 B 5 6 1 1 1 4 plants 69
46. 8 60 96 9 05 25 40 da 91 40 142 24 Suction valve unloaders 46 Appendix D Outline Dimensions Model D891 with 107B Mounting Optional unloader solenoid valve Pressure gauge Liquid trap High liquid level shutdown Belt guard switch 1 2 NPT High liquid level alarm switch 1 2 NPT Crankcase oil drain D SC Gd Four way valve O 2 300 ANSI flange Optional suction y valve unloaders Optional di high discharge mm mam Px temperature switch ET d dl BG La za ST E L K 9 Seil TO SE mel yh Opening for optional f I aj relief valve 1 1 2 NPT wa n o ain Electric motor driver o l O 9 i ul SS Drain valve P al 1 NPT eh RW ET R VII NES Poo L 28 D SE s L ol fi jii mi A D fi LU Optional low oil pressure switch Optional Adjustable EM crankcase driver slide W heater base x Use eight 3 4 y anchor bolt
47. AFT ALIGN TANG OIL PUMP ASSEMBLY WITH SLOT PUMP SHAFT ADAPTER O TANG PIN PUMP COVER MUST FALL IN GROOVED AREA OIL PUMP ASSEMBLY OIL FILTER PUMP SHAFT ADAPTER SPRING Lr i A SPRING GUIDE Tie OIL FILTER ADAPTER NOTE FOR COMPRESSORS WITHOUT OIL FILTER ASSEMBLIES SAL FUME ASSEMBEY USE OPTIONAL PUMP COVER ASSEMBLY INSTRUCTIONS ARE THE SAME AS ABOVE Figure 5 8A 5 9 Servicing the Four Way Valve 1 Remove the hex nut indicator plate and handle from the rotor shaft Unlike older units new Corken compressors mounted in 2 the 107 arrangement are being supplied with anon lube four way valve No maintenance is normally required on this valve If you have reason to disassemble the valve please follow the instructions below see figures 5 9A Remove the four hex head bolts and the cap from the body The cap should be rotated until free do not pry Inspect cap for wear and damage see figure 5 90 and 5 9B Q HEX NUT INDICATOR LE PLATE CAUTION Always Relieve Pressure In The Unit HANDLE Before Attempting Any Repairs G BOLT a Before Disassembly 1 Record the position marks on the end of the rotor shaft o d TOP CAP 2 Record the positions of the handle stops on the cap BODY O RING NOTE A small amount of silicone grease applied CAP O RING CT to each part before assembly facilitates assembly STEM O RING ET if allowed TOP ROTOR WASHER A Disassembly
48. B Vertical Single Acting Specifications Clearances and Dimensions 491 691 M crankcase Clearance X piston figure 5 4A amp 5 4B 0 000 0 020 0 024 0 044 0 000 0 015 0 012 0 027 Clearance connecting rod bearing to crankshaft journal 0 0005 0 0025 0 0019 0 0035 Clearance wrist pin to wrist pin bushing max 0 0009 0 0020 Cylinder bore diameter max 4 011 4 515 Cylinder finish RMS 16 32 16 32 Piston ring radial thickness min 0 082 0 082 Clearance oil pump adapter shaft to bushing max 0 0050 0 0050 Crankshaft end play cold 0 000 0 002 0 002 0 003 Flywheel runout at O D max 0 020 0 020 Clearance crosshead to crosshead guide bore max 0 012 0 013 Crosshead guide bore finish 32 RMS limited number of small pits and scratches are acceptable Dimensions for honing are included with new bushings which must be installed then honed Clearance should be set with machine cold 31 Appendix B Vertical Single Acting Specifications Model D891 Equipment Type amp Options Applications Double acting vertical reciprocating piston type vapor compressor Bulk transfer Double packed rod Truck tank railcar barge unloading LTVR and scavenger applications Slip on weld connections Emergency evacuation Features and Benefits Self lubricating piston rings No
49. IE101G Installation Operation amp Maintenance Manual Liquid Transfer Vapor Recovery Compressors Warning 1 Periodic inspection and maintenance of Corken products is essential 2 Inspection maintenance and installation of Corken products must be made only by experienced trained and qualified personnel 3 Maintenance use and installation of Corken products must comply with Corken instructions applicable laws and safety standards such as NFPA Pamphlet 58 for LP Gas and ANSI K61 1 1972 for Anhydrous Ammonia 4 Transfer of toxic dangerous flammable or explosive substances using Corken products is at user s risk and equipment should be operated only by qualified personnel according to applicable laws and safety standards Solutions beyond products CORKEN Warning Install use and maintain this equipment according to Corken Inc instructions and all applicable federal state local laws and codes and NFPA Pamphlet 58 for LP Gas or ANSI K61 1 1989 for Anhydrous Ammonia Periodic inspec tion and maintenance is essential Corken One Year Limited Warranty Corken Inc warrants that its products will be free from defects in material and workmanship for a period of 12 months following date of purchase from Corken Corken products which fail within the warranty period due to defects in material or workmanship will be repaired or replaced at Corken s option when returned freight prepaid to Corken Inc 3805 N
50. In many cases valves may simply be cleaned and reinstalled If the valves show any damage they should be repaired or replaced Replacement is usually preferable although repair parts are available If valve plates are replaced seats should also be lapped until they are perfectly smooth If more than 005 in must be removed to achieve a smooth surface the valve should be discarded If plates are replaced without relapping the seat rapid wear and leakage may occur Assembly 1 Insert metal valve gasket into the suction and or discharge opening of the head The metal valve gasket should always be replaced when the valve is reinstalled Insert cleaned or new valve assembly Make sure the suction and discharge valves are in the proper suction and discharge opening in the head NOTE The spec 3 suction valves for a model 91 and 291 compressor are pre set so no adjustments to liquid relief pressure are necessary Replace the holddown screw and tighten to the value listed in Appendix B to ensure the valve gasket is properly seated NOTE Gaskets and O rings are not normally reusable Replace the O ring or gasket and valve cap and tighten to the value listed in Appendix B O rings sealing the valve caps should be replaced Check bolts and valve holddown screws after first week of operation Re torque if necessary See Appendix B for torque values Valve Inspection and or Replacement for Models 491 691 and 891 Compressors Bef
51. LD CLIMATE AREAS OPERATION OF VALVES POSITION 1 POSITION 2 SERVICE TO PERFORM RELIEF VALVE 4 WAY VALVE fe ES e VALVE POSITION 4 WAY Unload Tank Car into Storage Tank Position One Position Two Recover Vapors from Tank Car into Storage Tank Position One Unload Transport or Truck into Storage Tank Position Two Recover Vapors from Transport or Truck into Storage Tank Load Truck or Field Tank from Storage Tank Position Two Load Truck or Field Tank from Tank Car Position Equalize Between Tank Car and Storage Tank Without using Vapor Pump Equalize Between Truck or Field Tank and Storage Tank Without Using Vapor Pump Figure 2 3B Five Valve Manifold Piping System 9 OPERATION OF VALVES POSITION 1 POSITION 2 SERVICE TO PERFORM VALVE POSITION 4 WAY A B Cc 1 Unload Tank Car into Position Close Storage Tank One 2 Recover Vapors from Tank Position Close Open Car into Storage Tank Two Figure 2 3C Three Valve Manifold Piping System large enough to do a good job and these should be replaced by a suitable size valve The liquid discharge should be connected to the tank truck pump inlet line rather than the often oversized filler valve connection in the tank head It is of extreme importance to prevent the entry of liquid into the compressor The inlet of the compressor sho
52. Pont company Piston Rod CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 61 Appendix G 291 and F291 Connecting Rod Assembly Details Connecting Rod Assembly Bill of Materials Part No Description 1132 X28 Crosshead assembly 1498 Retainer ring 2505 Wrist pin 1846 X3b Wrist pin bushing 15999 Bolt 1889 X Connecting rod assembly 18899 Connecting rod 13675 Connecting rod bearing 2 3 4 5 6 T 8 9 16005 c Nut a Must be rebored after replacing 0 8754 0 8751 dia b Included with connecting rod assembly Torque connecting rod nut to 28 ft Ibs Never attempt to separate the piston rod and crosshead When repair becomes necessary the entire crosshead assembly must be replaced CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 62 Appendix G 291 and F291 Flywheel Assembly Details Back Side Assembly Number Flywheel Assembly Bill of Materials Assembly Name 2549 X1 Front Side Flywheel assembly Flywheel 16 O D 3 groove 2549 Hub with three blots and lockwashers H SF 1 250 63 Appendix G 291 and F291 Crankcase Assembly Details Appendix G 291 and F291 Crankcase Assembly Details Crankcase Ass
53. TO must be selected to drive the compressor between 400 and 800 RPM An extended compressor crankshaft is required so the U joint yoke may connect to the compressor without removing the flywheel Do not operate the compressor without a flywheel Use a U joint with a splined joint and make sure the connections are parallel and in line The U joint angle should be less than 15 degrees see figure 2 8B Always use an even number of U joints Depending on the truck design the compressor may be outside or top mounted as shown in figures 2 8C and 2 8D to be V belt driven Power is transmitted through a U joint drive shaft jackshaft with two pillow block bearings V belt sheave and V belts An idle pulley may be used under the truck frame 2 9 Shutdown Alarm Devices For many applications shutdown alarm switches will provide worthwhile protection that may prevent serious damage to your compressor system All electronic devices should be selected to meet local code requirements Shutdown alarm devices typically used on Corken compressors are Low Oil Pressure Switch shuts down the unit if crankcase oil pressure falls below 12 psi due to oil pump failure or low oil level in crankcase High Temperature Switch shuts down the unit if the normal discharge temperature is exceeded This is strongly recommended for all applications Typically the set point is about 30 F 1 C above the normal discharge temperature Low Suction High Discha
54. VE E Shan NON LUBE ANZIO FOUR WAY IN AE VALVE OIL PRESSURE GAUGE LIQUID TRAP DRAIN VALVE STRAINER Figure 1 3A 107 Style Compressor Mounting Crankshafts are supported by heavy duty roller bearings and the connecting rods ride the crankshaft on journal bearings With the exception of the small size model 91 compressor allcompressor crankcases are lubricated by an automotive type oil pressure system An automatically reversible gear type oil pump circulates oil through passages in the crankshaft and connection rod to lubricate the journal bearings and wrist pins see figure 1 3B Sturdy iron crossheads transmit reciprocating motion to the piston Corken s automatically reversible oil pump design allows the machine to function smoothly in either direction of rotation Corken compressors use iron pistons that are locked to the piston rod The standard piston ring material is a glass filled PTFE polymer specially formulated for non lubricated services Piston ring expanders are placed behind the rings to ensure that the piston rings seal tightly against the cylinder wall Piston rod packing is used to seal the gas in the compression chamber and prevent crankcase oil from entering the compressor cylinder The packing consists of several PTFE V rings sandwiched between a male and female packing ring and held in place by a spring see figure 1 3C The typical Corken compressor valve consists of a seat bumper
55. asher and insert retainer ring 6 Oil piston rod and replace cartridge O ring 7 Install packing installation cone part number 3905 over the threaded end of the piston rod 8 Carefully slip the packing cartridge over the piston rod otherwise you may damage the lips of the packing rings 9 Install and tighten cartridge holddown screw with special wrench 10 Replace cylinder O ring cylinder pistons and head Model D891 Compressor Refer to Appendix J for packing assembly details Disassembly of Packing 1 Depressurize and open the compressor 2 Remove the cylinder cap heads pistons and cylinder 3 To remove the packing barrels pry upward under each one and lift entire barrel cartridge assembly up from piston rod 4 Remove the four socket head screws that hold the packing cartridge to the barrel Assembly of Packing 1 Replace packing as required The segmented packing and cups are in the barrel The V ring packing is in the cartridge Note the arrangement of the particular packing set for the model machine you have 2 Reattach the cartridges to the barrels using the four socket head screws 3 Install cartridge barrel assemblies noting the alignment of the barrels as they sit on the crosshead guide The valve scallops on the barrels must align properly with the valves of the cylinder 4 Replace cylinder pistons heads and cap See piston assembly details for proper clearance values 5 Rotate unit by ha
56. be vaporized before it can be recovered so do not expect the pressure to drop immediately Actually more vapor will be recovered during the first few minutes while this liquid is being vaporized than that during the same period of time later in the operation Remember that more than half of the economically recoverable product is usually recovered during the first hour of operation on properly sized equipment 1 3 Compressor Construction Features The Corken liquid transfer vapor recovery compressor is a vertical single stage single acting reciprocating compressor designed to handle flammable gases like LPG and toxic gases such as ammonia Corken compressors can handle these potentially dangerous gases because the LPG NH is confined in the compression chamber and isolated from the crankcase and the atmosphere A typical liquid transfer vapor recovery compressor package is shown in figure 1 3A Corken gas compressors are mounted on oil lubricated crankcases that remain at atmospheric pressure mp mm mp ma P eS vam mg ee sc LIQUID LINE IS VALVED CLOSED DURING VAPOR RECOVERY VAPOR IS BUBBLED THROUGH LIQUID TO HELP COOL AND RECONDENSE IT 4 WAY VALVE OPERATION DISCHARGE TO tT STORAGE TANK lt DISCHARGE FROM COMPRESSOR Le INLET FROM TANK CAR RELIEF VALVE AN APPROPRIATE RELIEF VALVE MUST BE INSTALLED BEFORE STARTING THE COMPRESSOR INLET PRESSURE GAUGE OUTLET PRESSURE GAUGE BREAKER VAL
57. c and debris In many cases valves may simply be cleaned and reinstalled If the valves show any damage they should be repaired or replaced Replacement is usually preferable although individual parts are available If valve discs are replaced seats should also be lapped until they are perfectly smooth If more than 005 in must be removed to achieve a smooth surface the valve should be discarded If discs are replaced without relapping the seat rapid wear and leakage may occur Each suction and or discharge valve assembly is easily removed as a unit for inspection If any part of the valve assembly is broken the valve assembly should be replaced See valve assembly parts details in the appendices for a complete list of part numbers and descriptions If a valve is leaking due to dirt or any other foreign material that keeps the valve plate and seat from sealing the valve may be cleaned and reused New gaskets and or O rings should be used to assure a good seal The valve holddown assemblies and valve assemblies on the following pages show the various specifications used on models 91 291 491 691 and 891 compressors Since more than one suction valve arrangement is available for each model of compressor it is necessary to know your complete model number so you can identify the valve type specification number see example listed below Model number EECH Valve type spec 3 In most cases for liquid transfer and or vapor recovery
58. chamber Improper storage can also result in corrosion damage to cylinder for proper storage instructions see chapter 6 If the cylinder does become damaged or corroded use a hone to smooth the cylinder bore and then polish it to the value shown in Appendix B If more than 005 in must be removed to smooth the bore replace the cylinder Cylinder liners and oversized rings are not available OVERBORING THE CYLINDER WILL RESULT IN GREATLY REDUCED RING LIFE Many compressor repair operations require removal of the cylinder While the compressor is disassembled special care should be taken to avoid damage or corrosion to the cylinder If the compressor is to be left open for more than a few hours bare metal surfaces should be coated with rust preventative When reassembling the compressor make sure the bolts are retightened as shown in Appendix B Packing Replacement Instructions Caution Bleed all pressure from the compressor and piping and purge if necessary before starting to install new piston rod packing After repair the unit should be pressure tested and checked for leaks at all joints and gasket surfaces When the compressor is being used with toxic dangerous flammable or explosive gases this pressure and leak testing should be done with air or a dry inert gas such as nitrogen For simplicity heads pistons and inspection plates are not shown For specific construction details and actual part numbers consult the
59. chased Date Installed Purchased From Installed By IMPORTANT NOTE TO CUSTOMERS CORKEN INC does not recommend ordering parts from general descriptions in this manual To minimize the possibility of receiving incorrect parts for your machine Corken strongly recommends you order parts according to part numbers in the Corken Service Manual and or Installation Operation amp Maintenance IOM Manual If you do not have the appropriate service manual pages call or write Corken with model number and serial number from the nameplate on your compressor TABLE OF CONTENTS CHAPTER 1 INTRODUCTION ooo PAGE 4 1 1 Liquid Transfer by Vapor Differential Pressure 5 1 2 Residual Vapor Recovery is A A Be te 5 1 3 Compressor Construction Features 6 CHAPTER 2 INSTALLING YOUR CORKEN COMPRESSOR 000 c eee eee eee eee eee PAGE 8 sch Location irradia e eee hoe Woh ea dated wR we wae A add pons E aOR ARS mega epee Bed 8 222 Foundation erar scr dr e ERR SAREE RS EE 8 2 3 PPNO WEE 8 2A LIQUIA RT EE 10 2 5 Driver Installation Flywheels LL 12 2 6 Grankcase Lubricationi ipse ees E EELER REEL na 12 Sat Relief ValVeS ei odors arie aa CER a di aa ra aa 12 2 8 Truck Mounted Compressors geita arranha Ea a DE E ee a ERE 12 2 9 Shutdown Alarm Devices 13 CHAPTER 3 STARTING UP YOUR CORKEN COMPRESSOR cece seen eee een eee PAGE 14 3 1 Inspection After Extended Storage 00 cee eee 14 3 2 Flywheel and V belt AlignMen
60. d 2714 2714 1 Valve cap Valve cap grooved for O ring 2 0314 2716 2716 1 2716 20 O ring for valve cap Gasket aluminum for valve cap Gasket copper for valve cap Gasket iron for valve cap 2715 Holddown screw 7001 043 NC137A Bolt 7 16 14 x 1 3 8 hex head 1764 Valve cover plate 2 2353 O ring cover plate 2797 Valve cage 2114 2114 10 2114 20 Valve gasket aluminum Valve gasket copper Valve gasket iron 5000 77 Retainer ring 3977 Suction valve relief housing spec 3 1411 Spring 1410 Relief ball 3948 Valve seat spec 3 2534 1 Suction valve post spec 3 3872 Inner valve plate 3871 Outer valve plate 3929 Inner valve spring 3928 Outer valve spring 3949 Valve bumper spec 3 3857 Valve bumper 3920 Valve stud 3856 Valve seat 3948 X Suction valve assembly spec 3 includes valve gasket 3948 X1 Same as above but with copper gasket 3948 X2 Same as above but with iron lead gasket 3856 X Suction valve assembly includes valve gasket 3856 X1 Same as above but with copper gasket 2255 X2 Same as above but with iron lead gasket 3857 X Discharge valve assembly includes valve gasket 3857 X1 Same as above but with copper gasket 3857 X2 Same as above but with iron lead gas
61. d after replacing 0 8754 0 8751 dia b Included with connecting rod assembly Torque connecting rod nut to 40 ft Ibs d Must be rebored after replacing 1 1256 1 252 dia 6 7 Note Never attempt to separate the piston rod and crosshead When repair alignment becomes necessary the entire crosshead assembly must be replaced marks CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 78 Appendix I 691 and F691 Flywheel Assembly Details Back Side Flywheel Assembly Bill of Materials Assembly Assembly Number Name 1762 X1 Flywheel assembly Flywheel 19 5 O D 4 groove 1762 Hub with three blots and lockwashers 4 H E 2 125 Front Side 79 Appendix I 691 and F691 Crankcase Assembly Details Inside of Bearing Carrier Oil Passage Hole Important Line up hole in gasket with oil passage hole Pump Cover Oil Filter Adapter D o 42 di oi WM rA 60 o o 61 Pumpside of adapter shown for Includes all parts shown proper orientation of cover and except 52 and 53 location of pump cover pin 80 Part No Crankcase Assembly Bill of Materials Description Part No Appendix I 691 and F691 Crankcase Assembly Details Description 1737 Bearing cone 3289 Pipe plug 1 4 NPT fl seal 3638 Spacer 2131 Bearing carrier gasket 3635 Drive sprocket 2961 X Air release valve
62. d model F291 ANSI flange 7001 037 NC100A Bolt 3 8 16 x 1 Gr 5 hex head 2731 Center headbolt 2732 Gasket for center headbolt 2 235 P O ring S 2 113 gt O ring 3 3483 1X Suction valve assy spec 3 3483 1X14 Same as above but with copper gaskets 3483 1X22 Same as above but with iron lead gaskets Suction valve assy spec 4 Same as above but with copper gaskets Same as above but with iron lead gaskets Discharge valve assy all specs Same as above but with copper gaskets Same as above but with iron lead gaskets Valve gasket aluminum Valve gasket copper Valve gasket iron lead 14 5000 77 Retainer ring spec 3 15 3977 Suction valve relief housing 16 1411 Spring spec 3 17 1410 Ball spec 3 19 3972 Suction valve plate spec 3 24 4009 Suction spring spec 4 O ri Cod a Optional Tng Voce b _ denotes O ring code See O ring chart to the left for details A Buna N Registered trademarks of the DuPont company B Neoprene CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 59 Appendix G 291 and F291 Piston Assembly Details Piston Assembly Number 1983 X Bill of Materials Piston Diameter 3 7 62 cm Part No Description 7002 0100C100A Screw socket head 7207 010A Lock washer 1983 Head iron 1775 Ring expander 1772 Piston ring 2 lt 1482 Locknut 1483 Lock pin 1984 Piston platform 1528 S
63. del sii a A A A a 49 F Model 91 and F91 Parts Details 50 57 G Model 291 and F291 Parts Details 58 65 H Model 490 491 and F491 Parts Details 66 73 I Model 691 and F691 Parts Details 74 81 J Model D891 Parts Details 82 89 Chapter 1 Introduction Threaded and ANSI flanges _ e E Compressors are available in either threaded NPT ANSI or DIN flanged connections High efficiency valves Corken valves offer quiet operation and high durability in oil free gas applications Specially designed suction valves which tolerate small amounts of condensate are used in liquid transfer vapor recovery compressors O ring head gaskets Easy to install O ring head gaskets providing highly reliable seals A Ductile iron construction All cylinders and heads are ductile iron for maximum thermal shock endurance Self lubricating PTFE piston rings Corken provides a variety of state of the art piston ring designs to provide the most cost effective operation of compressors for non lube service The step cut design provides higher efficiencies during the entire life of the piston ring Positively locked pistons Simple piston design allows end clearance to be precisely set to provide maximum efficiency and long life Self lubricating piston rod seals Seals constructed of PTFE incorporating special fillers to ensure no oil carry over and maximize leakage control Spring loaded seal design self adjusts to comp
64. e body O ring into their grooves in the rotor and body 10 Place the cap over the rotor shaft Rotate the rotor so the position of the handle stops on the cap is the same as recorded before disassembly Assemble the four hex head bolts through the cap and into the body Be sure that the body O ring is in the proper position and tighten the hex head bolts Reassemble the handle indicator plate and hex nut Be sure that the handle is assembled so that the stop on the handle mates with the stops on the cap Chapter 6 Extended Storage Procedures Following a few simple procedures will greatly minimize the risk of the unit becoming corroded and damaged Corken recommends the following precautions to protect the compressor during storage 1 2 Drain the crankcase oil and refill with rust inhibiting oil Operate for a few minutes while fogging oil into the compressor suction Relieve V belt tension Plug all openings to prevent entry of insects and moisture The cylinders may also be protected by the use of a vapor phase inhibitor silica gel or dry nitrogen gas If the silica gel is used hang a tag on the unit indicating that it must be removed before start up Store in a dry area off the ground if possible Rotate the flywheel every two weeks if possible 25 Appendix A Vertical Single Acting Model Number Identification Code Base Model 91 291 491 691 Inlet 3 4 NPT 3 4
65. e crankshaft and bearing carrier to the crankcase When reinstalling the bearing carrier make sure the oil pump shaft slot is aligned with the pin in the crankshaft Make sure to install the bearing carrier gasket so the oil passage hole is not blocked see figure 5 6 3A 3 In order to check the crankshaft endplay the oil pump must first be removed see section 5 8 4 Press the end of crankshaft towards the crankcase if a clicking noise or motion is detected the crankshaft has too much endplay See Appendix B 5 To reduce endplay remove the bearing cover and remove a thin shim Recheck the endplay after replacing the bearing cover 6 When there is no detectable endplay the shaft must still be able to rotate freely If the crankshaft sticks or becomes abnormally warm then the crankshaft bearings are too tight If the crankshaft is too tight add more shims but make sure not to over shim Appendix B lists the proper crankshaft endplay When the crankshaft can be rotated freely by hand with proper endplay the rest of the compressor may be reassembled If the crankshaft roller bearings are too tight or too loose premature bearing failure will result 7 Reinstall the flywheel on the crankshaft and check the run out as shown in Appendix B 5 8 Oil Pump Inspection If the compressor operates for a prolonged period with dirty or contaminated crankcase oil damage to the oil pump may result 10 SHIM BEARING COVER
66. ect the oil passage for debris and clean thoroughly before proceeding Press the wrist pin back into the crosshead and wrist pin and reinstall retainer rings NOTE The fit between the wrist pin and bushing is tighter than ordinary lubricated air compressors and combustion engines 5 7 2 Replacing Connecting Rod Bearings Connecting rod bearings are easily replaced by removing the semicircular bearings Make sure the indentations in the connecting rod bearing and connecting rod line up when installing the new bearings MAKE SURE THE ARROW AND OR ALIGNMENT NOTCH ON CONNECTING ROD AND CAP ARE ALIGNED Before reinstalling the crosshead connecting rod assembly make sure the crankshaft throw and bearing surface are clean and lubricated Tighten the connecting rod bolts to the torques listed in Appendix B 5 7 3 Replacing Crankcase Roller Bearings To inspect the roller bearings remove the flywheel from the crankshaft and then remove the bearing carrier and crankshaft from the crankcase If corrosion or pitting is present the roller bearings should be replaced When replacing roller bearings always replace the entire bearing not just the cup or the cone 1 To replace the bearings press the cups out of the crankcase and bearing carrier and press the cones off the crankshaft 22 ALIGN PIN WITH SLOT OIL PASSAGE HOLE Figure 5 6 3A Bearing Carrier Replacement 2 Press the new bearings into position and reassemble th
67. embly Bill of Materials Part No Assembly Description Number 1278 Assembly Name Oil seal 1279 X 7001 037NC075A Breather cap assembly with 1279 2 111A Bolt 3 8 16 x 3 4 hex head 1341 X1 2957 Bearing cover 1273 1273 1 1273 2 Crankshaft assembly with 1284 2 1286 1341 1501 2590 2719 Bearing adjustment shim 0 005 Bearing adjustment shim 0 007 1342 X19 Extended crankshaft assembly with 1284 2 1286 1342 1501 2590 2719 Bearing adjustment shim 0 020 1368 X1 1500 Oil bayonet assembly with 1368 X 2 112A Bearing cup 1368 X 1419 2X1 Oil bayonet Hydraulic unloader assembly up to 200 psi Spec 7 78 only Crankcase inspection plate gasket 1419 2x24 Crankcase inspection plate O ring Crankcase Hydraulic unloader assembly 200 psi amp above Spec 7 78 only Closure cap assembly including 2 218A 2 Spec 3 4 8 9 only Breather cap O ring breather cap Breather ball Flywheel assembly 16 O D 3 groove with 2549 and 3218 not part of crankcase assembly not shown Lock pin 1 8 x 1 Flywheel key Bearing cone Crankshaft assembly with 1284 2 Bearing carrier assembly with 1285 1290 1291 1292 1293 1515 X 2718 2805 2806 2 2848 X 2849 X 2850 2851 2852 2956 2961 X 2011 A 2 112A 2 228A 1286 1341 1501 2590 2719 Bearing cover as
68. ency must coincide with motor nameplate Consult with power company Wrong size of heaters in starter Check and replace according to manufacturer s instructions Compressor overloading Motor shorted out Reduce speed See driver installation Bad motor bearing Lubricate according to manufacturer s instructions 49 Appendix F 91 and F91 Head and Valve Assembly Details 91 Head Assembly Valve Holddown Assemblies 5 DEJO GOW CCO O Suction Discharge Spec 4 All Specs Valve Assemblies Suction Valve Suction Valve Discharge Valve Spec 3 Spec 4 All Specs 50 Appendix F 91 and F91 Head and Valve Assembly Details Head and Valve Bill of Materials 2374 2374 X8 2374 X1 4302 2 235_ a 2714 1 Description Head model 91 Head assy for model 91 spec 3 Head assy for model 91 spec 4 Head model F91 ANSI flange 7001 037 NC100A Bolt 3 8 16 x 1 Gr 5 hex head O ring Valve cap 2 031_ O ring 2715 Holddown screw 3483 1X 3483 1X1D 3483 1X25 3483 X 3483 X1D 3483 X2b 3485 X 3485 X1D 3485 X2b 12 5000 77 Suction valve assy spec 3 Same as above but with copper gaskets Same as above but with iron lead gaskets Suction valve assy spec 4 Same as above but with copper gaskets Same as above but with iron lead gaskets Discharge valve assy all specs Same as above but with copper gaskets Same as above but with iron lead gask
69. ensate for normal wear Nitride coated piston rods Impregnated nitride coating provides superior corrosion and wear resistance Nameplate Serves as packing adjusting screw cover see figure 1 1A Cast iron crossheads Durable cast iron crossheads provide superior resistance to corrosion and galling Pressure lubricated crankcase with filter Self reversing oil pump ensures proper lubrication regardless of directional rotation to main and connecting rod bearings Standard 10 micron filter ensures long lasting bearing life not available on Model 91 Construction Details Model F291 Compressor CORKEN GAS COMPRESSOR CRANKCASE CAPACITY 2 QTS LIT PAT NO 3 805 827 READ INSTRUCTIONS BEFORE OPERATING IF NO INSTRUCTION BOOK WAS RECEIVED WRITE THE FACTORY MODEL SERIAL NO CORKEN INC OKLAHOMA CITY OK MADE IN U S A 1996 Figure 1 1A Typical Nameplate Also Serves as the Packing Adjusting Screw Cover 1 1 Liquid Transfer By Vapor Differential Pressure Corken LPG NH3 compressors are designed to transfer liquefied gases such as butane propane mixtures liquefied petroleum gas or LPG and Anhydrous Ammonia NH3 from one tank to another Liquefied gases such as LPG amp NH3 are stored in closed containers where both the liquid and vapor phases are present There is a piping connection between the vapor sections of the storage tank and the tank being unloaded and there is a similar connection bet
70. ets Valve gasket aluminum Valve gasket copper Valve gasket iron lead Retainer ring spec 3 13 3977 Suction valve relief housing 14 1411 Spring spec 3 15 1410 Ball spec 3 16 3483 1 Suction valve seat spec 3 3972 Suction valve plate spec 3 17 18 4009 Suction spring spec 3 19 3484 Suction valve bumper spec 3 20 3483 Suction valve seat spec 4 21 3972 Suction valve plate spec 4 4009 Suction spring spec 4 22 23 3484 Suction valve bumper spec 4 2 3486 Discharge valve bumper 2 2 3973 Discharge valve plate 2 3485 Discharge valve seat O ring Code A Buna N B Neoprene9d 4 i 5 4008 Discharge spring 6 i T a Not shown b Optional denotes O ring code See O ring chart to the left for details d Registered trademarks of the DuPont company CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 51 Appendix F 91 and F91 Piston Assembly Details Piston Assembly Number 1983 X Bill of Materials Piston Diameter 3 7 62 cm Part No Description 7002 0100C100A Screw socket head 7207 010A Lock washer 1983 Head iron 1775 Ring expander 1772 Piston ring 2 lt 1482 Locknut 1483 Lock pin 1984 Piston platform 1528 Shim washer thick 1528 1 Shim washer thin 1527 Thrust washer l vlv a a Piston Clearance Cold
71. facturer will guarantee their explosion proof or totally enclosed TEFC motor against damage from moisture For installation with engine drivers thoroughly review instructions from the engine manufacturer to assure the unit is properly installed 2 6 Crankcase Lubrication Non detergent oil is recommended for Corken vertical compressors Detergent oils tend to keep wear particles and debris suspended in the oil whereas non detergent oils let them settle in the bottom of the crankcase When non detergent oils are not available detergent oils may usually be successfully substituted although compressors handling ammonia amine or imine gases are notable exceptions These gases react with the detergent and cause the crankcase oil to become corrosive and contaminated figures 2 6A and 2 6B show recommended oil viscosities and crankcase capacities Synthetic lubricants are generally not necessary Please consult your lubricate supplier if you are considering the use of synthetic oil Acceptable Crankcase Oil Products for Corken Compressors Constant Weight Non Detergent R amp O Inhibited ISO SAE Ambient Temp Oil product Exxon TERESSTIC 65 100 F 45 70 F 35 50 F 20 20 a Mobil RARUS 427 Reciprocating Compressor Oil DTE Oil Heavy Medium Dectol R amp O Oil Conoco Dectol R amp O Oil 30 65 100 F 45 100 F 35 50 F 35
72. him washer thick 1528 1 Shim washer thin 1527 Thrust washer vlv gt gt A Piston Clearance Cold Minimum Maximum 0 020 0 51 mm 0 044 1 12 mm oe Piston Rod a The distance from the bottom of the head to the top of the piston CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 60 Appendix G 291 and F291 Packing Assembly Details Packing Assembly Bill of Materials Part No Description 2913 1 Cylinder 2 235_4 O ring for cylinder 5000 137 Retainer ring 1012 Washer 1628 Packing spring 1714 Packing box washer 1453 1 Male packing ring 14546 Packing 1452 1 Female packing ring 4398 Cartridge holddown screw 4394 Packing box cartridge 1387 Adjusting screw 2 135_4 O ring POPP DI PM P TPO PO PO DP packing cartridge 4393 Crosshead guide 2702 Crankcase gasket 1452 1X1 Packing set 1192 Locking device Assembly Assembly Number Name 1132 X2 Crosshead assembly 1452 1X1 Packing set with 1452 1 1453 1 1454 8 1628 1714 O ring Code A Buna N B Neoprene a denotes O ring code See O ring chart above for details b The quantity of 1454 packing rings required will vary due to tolerances Use Cone 4005 for installation of packing Registered trademarks of the Du
73. ing Proper piping design and installation is as important as the foundation is to smooth operation of the compressor Improper piping installation will result in undesirable transmission of compressor vibration to the piping HEX NUT ALL SIDES BASEPLATE GROUT BENEATH BASE CONCRETE FOUNDATION WITH REINFORCEMENTS SHOULD BE USED ON ALL MODELS Vere ora Oo G e Hots e i S Gs E o d o 8 MIN an a ae 1 2 J BOLTS oe Se 12 LONG lat 2 NOTE LOCATE J BOLTS PER COMPRESSOR OUTLINE DIMENSION DRAWINGS Figure 2 2A Recommended Foundation Details for Corken Compressors 91 691 DO NOT SUPPORT PIPING WITH THE COMPRESSOR Unsupported piping is the most frequent cause of vibration of the pipe The best method to minimize transmission of vibration from the compressor to the piping is to use flexible connectors see figure 2 3A Pipe must be adequately sized to prevent excessive pressure drop between the suction source and the compressor as well as between the compressor and the final discharge point In most cases piping should be at least the same diameter as the suction nozzle on the compressor Typically LPG NH3 liquid transfer systems should be designed to limit pressure drops to 20 psi 1 3 bar Appendix C shows recommended pipe sizes for each compressor for typical LPG NHz installations FLEXIBLE CONNECTORS RIGID PIPING RIGID PIPING SUPPORT Figure 2
74. ing rod 35424 Connecting rod bearing 172780 Nut a Included with connecting rod assembly b Torque connecting rod nut to 40 ft Ibs Must be rebored after replacing 1 1256 1 252 dia Never attempt to separate the piston rod and crosshead When repair becomes necessary the entire crosshead assembly must be replaced CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 86 Appendix J D891 Flywheel Assembly Details Back Side Flywheel Assembly Bill of Materials Assembly Assembly Number Name 3852 X Flywheel assembly Flywheel 21 2 O D 5 groove 3852 Hub with three blots and lockwashers H E 2 125 Front Side 87 Appendix J D891 Crankcase Assembly Details Inside of Bearing Carrier Oil Passage Hole Important Line up hole in gasket with oil passage hole Pump Cover Oil Filter Adapter D o 42 di oi WM rA 60 o o 61 Pumpside of adapter shown for Includes all parts shown proper orientation of cover and except 52 and 53 location of pump cover pin 88 Appendix J D891 Crankcase Assembly Details Crankcase Assembly Bill of Materials F a Part No Description Part No Description 1737 Bearing cone 3289 Pipe plug 1 4 NPT fl seal 3638 Spacer 2131 Bearing carrier gasket 3635 Drive sprocket 2961 X Air release valve assembly
75. ipment Type amp Options Applications Single acting vertical reciprocating piston type vapor compressor Bulk transfer Single packed rod Vapor recovery NPT or 300 ANSI connections Tank evacuation Gas scavenging Features and Benefits Self lubricating piston rings Non lubricated operation to minimize oil in gas NPT or 300 ANSI connections Versatility for your application Multiple mounting configurations Versatility for your application High efficiency valves Quiet reliable operation Reversible oil pump Allows operation in either direction Simplified top down design Routine maintenance is minimally invasive Specifications Model Number Specification 291 491 Bore of cylinder inches mm 3 0 76 2 3 0 76 2 4 0 101 6 4 5 114 3 Stroke inches mm 2 5 63 5 2 5 63 5 3 0 76 2 4 0 101 6 Piston displacement cfm m3 hr minimum 400 RPM 4 0 6 8 8 0 13 6 17 2 29 2 29 2 49 6 maximum 825 RPM 8 3 14 1 16 5 28 0 35 5 60 3 60 2 102 3 Maximum working pressure psig bar g 335 23 1 Maximum brake horsepower kW 7 5 5 6 15 11 15 11 35 26 1 Maximum rod load Ib kg 3 600 1 632 9 3 600 1 632 9 4 000 1 814 4 7 000 3 175 1 Maximum outlet temperature F C 350 177 Bare unit weight Ib kg 115 52 2 160 72 6 260 117 9 625 283 5 Maximum flow propane gpm m3 hr 50 11 4 101 22 9 215 48 8 361 82 0 1 These
76. justing screw until plastic locking device engages the first thread in the crosshead guide 6 Oil piston rod and install the packing installation cone part number 4005 over the threaded end of the piston rod 7 Carefully slip the crosshead guide over the piston rod otherwise you may damage the lips of the packing rings 8 Remove packing installation cone 9 Install the crosshead guide O ring cylinder piston and head Model 291 Compressor serial no SS55685 and later Model 491 Compressor serial no XC30633 and later Refer to Appendix G or H for packing assembly details Disassembly of Packing 1 Depressurize and open the compressor 2 Remove head pistons and cylinder 3 Remove cartridge holddown screw with special wrench supplied with the compressor and packing box cartridge 4 Loosen adjusting screw and remove retainer ring washers packing spring and old packing from packing box cartridge Assembly of Packing 1 Clean and then lightly oil packing area inside packing box cartridge 2 Slightly thread in adjusting screw 3 Install packing rings including male and female packing rings one at a time as shown in Appendix G or H Push in each one completely before adding the next ring The quantity of packing rings required will vary due to tolerances a good rule of thumb is to put in as many as are removed 4 Insert thin packing box washer packing spring and thicker washer 5 Push down
77. ket 3146 X1 Valve repair kit suction amp discharge Head Assembly Number Models Valve Specification 1743 X 690 3 3458 X 691 3 a For O ring material coding see page A500 b Not included in head assembly Optional d SIN NQ51455 and later Earlier models use gasket 2177 15 Appendix I 691 and F691 Piston Assembly Details Piston Assembly Number 1987 X Bill of Materials Piston Diameter 4 5 11 43 cm Part No Description 7002 0250C125A Screw socket head 7207 025A Lock washer 1987 Head iron 1740 Ring expander 1739 Piston ring 1482 Locknut 1483 Lock pin 1735 Shim washer thick 1735 1 Shim washer thin 1988 Piston platform Piston Clearance Cold Minimum Maximum 0 000 0 00 mm 0 012 0 30 mm 0 015 0 38 mm 0 027 0 68 mm Piston Rod E eng SE a The distance from the bottom of the head to the top of the piston CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 76 Appendix I 691 and F691 Packing Assembly Details Packing Assembly Bill of Materials Part No Description 3457 Cylinder 2 247 4 O ring for cylinder 1749 Cartridge holddown screw 5000 175 Retainer ring 1731 Packing spring 1728 Packing washer 1724 Male packing ring 1725 Packing ring 1723 Female packing ring 2407 Packing box cartridge 2 2332 O ring packing cartridge 1748 Cartridge
78. lest is a mechanical float trap see figure 2 4A As the liquid enters the trap the gas velocity is greatly reduced which allows the entrained liquid to drop out If the liquid level rises above the inlet the float will plug the compressor suction The compressor creates a vacuum in the inlet piping and continues to operate until the operator manually shuts it down The trap must be drained and the vacuum breaker valve opened before restarting the compressor to allow the float to drop back This type of trap is only appropriate for use where the operator keeps the compressor under fairly close observation This trap is provided with the 109 and 107 compressor packages see Appendix C for details on standard Corken compressor packages When the compressor will not be under more or less constant observation an automatic trap is recommended OUTLET L VACUUM BREAKER VALVE S NIE NI H H p f f Ei ALZA H BALL FLOAT 4 y y g d p R p Kg INLET L DRAIN VALVE Figure 2 4A Mechanical Trap 10 see figure 2 4B The automatic trap replaces the float with electrical float switches If the liquid level should rise too high the level switch will open and disconnect the power to the motor starter stopping the compressor This design ensures the machine will be protected even when it is not under close observation and is standard in the 109A and 107A mounting configurations Corken s most sophistica
79. mail us at info corken idexcorp com Printed in the U S A November 2006
80. n lubricated operation to minimize oil in gas Multiple materials and configurations Versatility for your application Multiple mounting configurations Versatility for your application High efficiency valves Quiet reliable operation Reversible oil pump Allows operation in either direction Simplified top down design Routine maintenance is minimally invasive Features and Benefits Bore of cylinder inches mm 4 5 113 Stroke inches mm 4 0 101 6 Piston displacement cfm m3 hr minimum 400 RPM 56 6 96 2 maximum 825 RPM 113 2 192 0 Maximum working pressure psig bar g 465 32 1 Maximum brake horsepower kW 45 34 Maximum rod load Ib kg 7 000 3 175 2 Maximum outlet temperature F C 350 177 Bare unit weight lb kg 855 387 8 Maximum flow propane gpm m3 hr 694 157 6 32 Appendix B Vertical Single Acting Specifications Model D891 Material Specifications Part Standard Material Optional Material Head cylinder Ductile iron ASTM A536 Distance piece Crosshead guide Crankcase flywheel Bearing carrier Gray iron ASTM A48 Class 30 Flange ASTM A86 carbon steel Valve seat bumper 17 7 PH stainless steel Valve plate 410 stainless steel Valve spring 17 7 PH stainless steel Valve gaskets Soft aluminum Copper iron lead Piston Ductile iron ASTM A536 Piston rod
81. nd to ensure proper assembly 5 7 Bearing Replacement for Crankcase and Connecting Rod 1 To replace the crankcase roller bearings wrist pin bushing and connecting rod bearings begin by removing the head cylinder piston crosshead guide and crosshead assembly Drain the crankcase and remove the inspection plate s Before disassembly choose and mark one connecting rod and the corresponding connecting rod cap DO NOT MIX CONNECTING RODS AND CAPS Loosen and remove the connecting rod bolts in order to remove the crosshead and connecting rod assembly 5 7 1 Wrist Pin Bushing Replacement 1 Toreplace the wrist pin bushing remove the retainer rings that position the wrist pin in the crosshead Press out the wrist pin so the crosshead and connecting rod may be separated Inspect the wrist pin for wear and damage and replace if necessary Press out the old wrist pin bushing and press a new bushing into the connecting rod DO NOT MACHINE THE OD OR LD OF THE BUSHING BEFORE PRESSING INTO CONNECTING ROD Make sure the lubrication hole in the bushing matches the oil passage in the connecting rod If the holes do not align drill out the bushing through the connecting rod lubricant passage with a long drill Bore the wrist pin bushing LD as indicated on the respective connecting rod assembly details These pages are located in the appendices Over boring the bushing can lead to premature failure of the wrist pin bushing Insp
82. ng to turn the screw and tighten it after making any adjustment OIL LEVEL BAYONET FULL LOW OIL PRESSURE GAUGE OIL PRESSURE ADJUSTING SCREW Figure 3 3A Oil Pressure Adjustment 3 4 Startup Check List Please verify all of the items on this list before starting your compressor Failure to do so may result in a costly or dangerous mistake Before Starting the Compressor 1 Become familiar with the function of all piping associated with the compressor Know each line s use 2 Verify that actual operating conditions will match the anticipated conditions 3 Ensure that line pressures are within cylinder pressure ratings 4 Clean out all piping 5 Check all mounting shims cylinder and piping supports to ensure that no undue twisting forces exist on the compressor Verify that strainer elements are in place and clean Verify that cylinder bore and valve areas are clean Check V belt tension and alignment Check drive alignment on direct drive units Rotate unit by hand Check flywheel for wobble or play 10 11 12 13 14 15 16 17 Check crankcase oil level Drain all liquid traps separators etc Verify proper electrical supply to motor and panel Check that all gauges are at zero level reading Test piping system for leaks Purge unit of air before pressurizing with gas Carefully check for any loose connections or bolts Remove all stray objects rags tools etc from vicinit
83. o that they are taut but not extremely tight Consult your V belt supplier for specific tension recommendations Belts that are too tight may cause premature bearing failure Refer to figure 3 2B 3 3 Crankcase Oil Pressure Adjustment Corken compressor models 291 through 891 are equipped with an automatically reversible gear type oil pump if your compressor is the splash lubricated Model 91 proceed to section 3 4 It is essential to ensure the pumping system is primed and the oil pressure is properly adjusted in order to assure smooth operation Before starting your compressor check and fill the crankcase with the proper quantity of lubricating oil When the compressor is first started observe the crankcase oil pressure gauge If the gauge fails to indicate pressure within 30 seconds stop the machine 14 Remove the pressure gauge Restart the compressor and run it until oil comes out of the pressure gauge opening Reinstall the gauge The oil pressure should be about 20 psi 1 4 bars minimum for normal service If the discharge pressure is above 200 psi 14 8 bars the oil pressure must be maintained at a minimum of 25 psi 1 7 bars A spring loaded relief valve mounted on the bearing housing opposite the flywheel regulates the oil pressure As shown in figure 3 3A turn the adjusting screw clockwise to increase the oil pressure and counterclockwise to lower it Be sure to loosen the adjusting screw locknut before tryi
84. one or more spring s and one or more valve s discs or plates as shown in figure 1 3D Special heat treated alloys are utilized to prolong life of the valve in punishing non lubricated services The valve opens whenever the pressure on the seat side exceeds the pressure on the spring side WRIST PIN AND BUSHING CONNECTING ROD JOURNAL BEARING CRANKSHAFT Figure 1 3B Pressure Lubrication System Not Available on Model 91 PACKING MALE PACKING RING r Li CS E V RING Gi FEMALE PACKING hs SA PACKING a E PISTON ROD CROSSHEAD GUIDE Figure 1 3C Compressor Sealing System LIQUID RELIEF VALVE HOUSING KE LIQUID RELIEF VALVE SPRING BUMPER S LIQUID RELIEF I VALVE SPRING SPRING DIRECTION SEAT WASHER EZ GAS FLOW SF WASHER CA SPACERS SPRING BUMPER SUCTION Figure 1 3D Suction and Discharge Valves Chapter 2 Installing Your Corken Compressor 2 1 Location NOTE Compressor must be installed in a well ventilated area Corken compressors are designed and manufactured for outdoor duty For applications where the compressor will be subjected to extreme conditions for extended periods such as corrosive environments arctic conditions etc consult Corken Check local safety regulations and building codes to assure installation will meet local safety standards Corken compressors handling toxic or flammable gases such as LPG NH3 should be located outdoors A
85. ore removing and inspecting the valves begin by depressurizing and purging if necessary the unit Disassembly 1 2 Unscrew the valve cap nut and remove the gasket from the coverplate Remove the valve cover plate O ring and holddown screw by removing each of the four bolts NOTE 4 Since the holddown screw has been secured with an impact wrench at the factory you will probably need to wait to remove the holddown screw until after the cover plate has been removed At this point in time the holddown screw can be easily removed from the cover plate The holddown screw on model 691 and 891 is most easily removed with the special wrench supplied with your compressor at time of purchasing After the cover plate and O ring have been removed the valve spacer model 491 only valve cage valve assembly and valve gasket can be lifted out Inspect valves for breakage corrosion debris and scratches on the valve plate In many cases valves may simply be cleaned and reinstalled If the valves show any damage they should be repaired or replaced Replacement is usually preferable although repair parts are available If valve plates are replaced seats should also be lapped until they are perfectly smooth If more than 005 in must be removed to achieve a smooth surface the valve should be discarded If plates are replaced without relapping the seat rapid wear and leakage may occur Assembly 1 Insert metal valve gaske
86. plate 5000 350 Retainer ring 2405 Crosshead guide 1722 Adjusting screw 1761 Crankcase gasket 1725 2X Packing set 1192 Locking device for adj screw 2893 Locking device cartrige holddown screw N N N SA N N N N B N ND ND N Assembly Assembly Number Name 1717 X1 Crosshead assembly P style 1725 2X Packing set with 1723 1724 1725 4 1728 1731 2405 X Crosshead guide assembly with 1748 2 2405 5000 350 2 3544 X4 Crosshead assembly M style O ring Code A Buna N Piston Rod B Neoprene8b a _ denotes O ring code See O ring chart above for details b Registered trademarks of the DuPont company CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs TI 1 Registered trademarks of the DuPont company Appendix I 691 and F691 Connecting Rod Assembly Details 5 Connecting Rod Assembly Bill of Materials Part Number Spec K P Spec M Only Only Description 1717 X1 3544 X4 Crosshead assy 1498 3590 Retainer ring 1718 3540 Wrist pin 5 1495 xab 3541 Xb d Wrist pin bushing 1726b 17265 Bolt 1720 X 3785 X1 Conn rod assy 17205 37855 Connecting rod 17195 3542 Conn rod bearing 17275 17275 Nut a Must be rebore
87. quid valves If only one liquid hose is used the transfer rate will be slower and there is a good possibility that the car s excess flow valve may close Since the heat of compression plays an important part in rapid liquid transfer the vapor line from the compressor to the tank car or other unloading container should be buried or insulated to prevent the loss of heat and the compressor should be located as near as possible to the tank being emptied In extremely cold climates if the line from the storage tank to the compressor is over 15 feet 4 6 meters long it should be insulated to lessen the possibility of vapors condensing as they flow to the compressor The vapor recovery discharge line is better not insulated Placing the compressor as close as possible to the tank being unloaded will minimize heat loss from the discharge line for the best liquid transfer rate Unloading stationary tanks with a compressor is quite practical Delivery trucks and other large containers can be filled rapidly if the vapor system of the tank to be filled will permit fast vapor withdrawal and if the liquid piping system is large enough Many older trucks and some new ones are not originally equipped with vapor excess flow valves HYDROSTATIC RELIEF VALVE VAPOR LINE TO VAPOR SECTION OF STORAGE NOTE PROVIDE ADEQUATE SUPPORT FOR PIPING DO NOT USE COMPRESSOR TO SUPPORT PIPING sg VAPOR LINE TO TANK CAR OR TRANSPORT BURY OR INSULATE IN CO
88. r and head see section 5 2 Remove the piston head by loosening and removing the socket head bolts holding the piston head to the piston platform see figure 5 3A Next remove the roll pin with a pair of needle nose pliers The castellated nut may then be removed and the piston platform lifted off the end of the piston rod Check the thrust washer and shims for damage and replace if necessary Before installing the new piston measure the thickness of the existing shims For Models 91 through 491 the shims are placed between the thrust washer and piston platform For model 691 the shims are placed between the platform and piston head see figures 5 4A and 5 4B Reinstall the piston platform with the same thickness of shims as before BUT DO NOT REINSTALL THE ROLL PIN Replace the cylinder and install the piston heads with new piston rings and expanders Now measure dimension X shown in the illustration If this measurement does not fall within the tolerances shown in Appendix B remove the piston adjust the shims as necessary and remeasure the X dimension When the piston is properly shimmed tighten the castellated nut as shown in Appendix B Now install a new roll pin to lock the castellated piston nut in place CASTELLATED PISTON NUT PISTON RING EXPANDER PISTON x ROLL f PISTON PISTON CLEARANCE SEE APP B SS N AR gt PISTON PLATFORM THRUST CYLINDER
89. rew 1 4 20 x 1 socket head 1725 X Packing set 3810 X1 Packing set 2 036_44 Cup O ring a _ denotes O ring code See O ring chart for details b Slinger ring is loose within the packing cartridge until fitted on the piston rod Must be put in from the bottom of the cartridge Insert item 17 into the groove in the bottom of the barrel d Starting with S N NN51397 e Packing cup O ring not included in packing set f Registered trademarks of the DuPont company Identification of Packing Specification Example Model Number D891 K M4FBA Packing Spec Segmented packing align pin with hole 3810 SPEC J amp K Radial Cut without pin Tangent Cut with pin ring Te Crankcase Back up Segmented packing align pin with hole 3814 SPEC J amp K norman ee a l N Tangent Cut Tangent Cut with pin ring without pin To Crankcase Back up IMPORTANT Identify and line up the rings before installing Be sure they face the way shown here and that the pin and hole are aligned when assembled 85 Appendix J D891 Connecting Rod Assembly Details Connecting Rod Assembly Bill of Materials Part No Description 3544 X3 Crosshead assembly 3590 Retainer ring 3540 Wrist pin 3541 Xa b Wrist pin bushing 17265 Bolt 3785 X8 Connecting rod assembly 37854 Connect
90. rge Pressure Switch shuts down the unit if inlet or outlet pressures are not within preset limits Vibration Switch shuts down the unit if vibration becomes excessive Recommended for units mounted on portable skids Figure 2 8A Inside Transport Mounting COMPRESSOR FLYWHEEL 15 MAXIMUM SLIP JOINT YOKES PARALLEL EXTENDED CRANKSHAFT SHAFTS PARALLEL Figure 2 8B U joint Drive for Compressor Il Figure 2 8D Top Transport Mounting Chapter 3 Starting Up Your Corken Compressor NOTE Before initial startup of the compressor be sure the principal of using a compressor for liquid transfer by vapor differential pressure is understood see section 1 1 Read this entire chapter then proceed with the startup checklist 3 1 Inspection After Extended Storage If your compressor has been out of service for a long period of time you should verify that the cylinder bore and valve areas are free of rust and other debris see chapter 5 of this IOM manual for valve and or cylinder head removal instructions Drain the oil from the crankcase and remove the nameplate and crankcase inspection plate Inspect the running gear for signs of rust and clean or replace parts as necessary Replace the crankcase inspection plate and fill crankcase with the appropriate lubrican
91. rminals 690 691 B 8 6 690 691 TB 9 0 D891 5V 7 1 D891 5V 9 75 aja Om 40 000 Y aja VI WWW k OD OO a OO FPRRHRHRHRAPRRHRAWBWWWIWWWWHWWIWDWWWWWIWNWWWW D WWINM MY NNN NIN h 1 The capacities shown are based on 70 F but will vary depending upon piping fittings used product being transferred and temperature The factory can supply a detailed computer analysis if required 2 Driver sheaves 91 2 belts 290 291 490 491 3 belts 690 691 4 belts 3 The piping sizes shown are considered minimum If the length exceeds 100 ft use the next larger size NOTE Please consult factory for compressors with higher flows 36 Appendix C Compressor Selection Ammonia Compressor Selection Table Service Displacement cfm Compressor Driver Sheave Size Pitch Diameter inches Driver Horsepower Liquid Transfer amp Residual Vapor Recovery Liquid Transfer Without Residual Vapor Recovery Piping Size RPM 1 750 RPM 1 450 RPM 100 F 80 F 100 F 80 F Vapor Liquid Small bulk plants 400 505 590 695 290 291 345 A 3 0 A3 8 B 4 6 B 5 4 A3 0 A3 6 B 4 6 B 5 6 B 6 6 A3 6 3 3 3 4 1 1 4 3 4 1 1 4 1 1 1 4 1 1 2 1 1 2 Unloading single tank car or transport 91 795 290 291 390 290 291 435 290 291 490 290 291 535 290 291 580 B 6 2 A3 4 A3 8 B 4 4 B 4 8 B
92. s Z A1 Outline Dimensions Inches Centimeters Model B C E F G 1 9 16 4 0 D891 107B 3 11 16 9 4 3 4 7 13 16 19 9 9 3 Outline Dimensions Inches Centimeters 3 21 32 Model K L O 8 3 4 22 2 D891 107B Outline 79 7 16 201 8 68 1 16 172 9 Dimensions Inches Centimeters Model D891 107B V 9 1 16 23 0 X Y 30 13 16 45 78 3 114 3 47 Appendix D Outline Dimensions Model D891 with 109B Mounting H Relief valve 2 NPT pipe away H Optional suction NE valve unloaders CH d E Outlet pressure gauge Optional Inlet r Z __high discharge 2 300 Ib R F temperature switch Weld neck flange 4 i a Outlet 3 A d D IE X 2 flange NED gt DE WA High liquid level AL DI E 10 TI ati NPT Te Ss l D J Belt d Q E Low oil Electric motor guard I Inlet A pressure switch driver High liquid level E pressure A j as 1 2 NPT N
93. sembly with 2957 and 1278 Crankshaft orifice 2 Air release valve assembly with 2961 2962 2963 Bearing cone Pump shaft drive pin Flywheel assembly 14 O D 2 groove with 3218 and 3271 not part of crankcase assembly not shown Pipe plug 1 8 NPT flush seal Filter screen screw 2 116A Filter screen screw gasket O ring filter screen 1276 Filter screen washer 1275 Oil filter screen 3289 Pipe plug 1 4 NPT flush seal 1661 Pipe plug 3 8 NPT 1290 Relief valve adjusting screw 1291 Adjusting screw locknut 2 011A O ring relieve valve adjustment screw 1292 Relief valve spring 1293 Relief valve ball 2718 Bearing cup 2961 X Air release valve assembly with 2961 2962 2963 1285 Bearing carrier gasket 2956 Bearing carrier 2 218A O ring closure body 2 required Spec 3 4 8 9 only 1515 X Closure cap assembly including 2 218A 2 Spec 3 4 8 9 only 7001 025NC050A Bolt 1 4 20 x 1 2 hex head 1302 Oil pressure gauge 2 228A O ring pump cover 4222 X Oil filter assembly 1629 Pipe plug 1 16 NPT flush seal 7001 037NC100A Bolt 3 8 16 x 1 hex head 2805 Pump shaft bushing 2850 Pump shaft adapter 2852 Oil pump spring 2851 Spring guide 2849 X Oil pump assembly individual pump parts
94. sor with head O rings CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 68 Appendix H 490 491 and F491 Packing Assembly Details Packing Assembly Bill of Materials Part No Description 37138 Cylinder 491 w O ring 2 243 gt O ring for cylinder 5000 137 Retainer ring 1012 Washer 1628 Packing spring 1714 Packing box washer 1453 1 Male packing ring 14540 Packing ring 1452 1 Female packing ring 2801 Cartridge holddown screw 2799 Packing box cartridge 1387 Adjusting screw 2 139 P O ring N N JO N N N N N N packing cartridge 27654 Crosshead guide 1489 Crankcase gasket 1452 1X1 Packing set 1192 Locking device Assembly Assembly Number Name 1384 X Crosshead assembly 1452 1X1 Packing set with 1452 1 1453 1 1454 8 1628 1714 O ring Code A Buna N B Neoprene9e a SIN FZ44188 and later Piston Rod b _ denotes O ring code See O ring chart above for details The quantity of 1454 packing rings required will vary due to tolerances Use Cone 4005 for packing installation d SIN XC30633 and later e Registered trademarks of the DuPont company CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 69 Appendix H 490 491 and F491 Connecting Rod Assembly Details
95. stered trademarks of the DuPont company a o CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs NOTE Packing barrel installation 1 Use packing installation cone 905 on the piston rod 2 Insert small barrel first use finger holes to align slinger ring on to the rod Slip the packing barrel into place 3 Align pin with slot in large packing barrel 4 Slip large packing barrel in place 84 Appendix J D891 Packing Assembly Details 197 13 2 eS xX Js Js 14 boa HE Packing Direction 14 ZN Fe oa aN Di an installing packing NOTE Use installation Cone 3905 over piston rod when CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs O ring Code A Buna N B Neoprene b Packing Assembly Bill of Materials Part No Description 3926 Packing barrel 4 1 2 3885 Cartridge 17925 Oil slinger ring 5000 175 Snap ring 3906 Crush gasket 3817 Packing cup Not included in 3810 X1 packing set 3810 Segmented packing radial tangent pair 3814 Segmented packing tangent tangent pair 3811 Back up ring 1728 Washer 1731 Spring 1724 Male packing ring 1725 Packing ring 1723 Female packing ring 2 238_4 O ring 2 231_2 O ring 7002 0250C100A Sc
96. sure gauge Interconnecting piping Outlet pressure gauge Enclosed Steel Optional Belt guard Driver Steel Baseplate Adjustable driver slide base Standard 107 Items Steel baseplate V Belt drive Adjustable driver slide base Enclosed steel belt guard Inlet and outlet pressure gauges 40 Micron strainer Non lube 4 way valve Interconnecting piping Liquid trap as specified below 107 Mounting Mechanical liquid trap with ball float 107A Mounting Automatic liquid trap with one NEMA 7 liquid level switch 107B Mounting Automatic liquid trap with two NEMA 7 liquid level switches Standard 109 Items Steel baseplate V Belt drive Adjustable driver slide base Enclosed steel belt guard Inlet and outlet pressure gauges Interconnecting piping Liquid trap as specified below 109 Mounting Mechanical liquid trap with ball float 109A Mounting Automatic liquid trap with one NEMA 7 liquid level switch 109B Mounting Automatic liquid trap with two NEMA 7 liquid level switches 34 Appendix C Compressor Selection Butane Compressor Selection Table Driver Horsepower Liquid Liquid Transfer Transfer amp Without Residual Residual Driver Sheave Size Vapor Vapor Displacement Compressor Pitch Diameter inches Recovery Recovery Piping Size Service cfm RPM 1 750 RPM 1 450 RPM 100 F 80 F 100 F 80 F Vapor Liquid 400 A 3 0 A 3 6 3 4 1 1 4 Small 505 A 3 8 B
97. t Possible Causes 21 22 23 24 25 26 27 28 What To Do Valves broken stuck or leaking Inspect and clean or repair Piston ring worn Inspect and replace as necessary Inlet strainer clogged Clean or replace screen as necessary Leaks in piping Inspect and repair Inlet or ambient temperature too high Consult factory Compression ratio too high Check application and consult factory Loose flywheel or belt Tighten LE Di 3 4 5 6 T 8 Worn piston rod packing Replace Worn wrist pin or wrist pin bushing Replace Worn connecting rod bearing Replace Unbalanced load Inspect valve or consult factory Inadequate compressor base Strengthen replace or grout Improper foundation or mounting Tighten mounting or rebuild foundation Loose valve piston or packing Tighten or replace as necessary Dirty cooling fins Clean weekly 4 way control valve not lubricated Inspect and lubricate Leaking gas blowing oil from crankcase Tighten packing Bad oil seal Replace No oil in crankcase Add oil Oil pump malfunction See oil pressure adjustment Low voltage Check line voltage with motor nameplate Consult power company Motor wired wrong Check wiring diagram Wire size too small for length or run Replace with correct size Wrong power characteristics Voltage phase and frequ
98. t Squirt oil on the crossheads and rotate the crankshaft by hand to ensure that all bearing surfaces are coated with oil Rotate unit manually to ensure running gear functions properly Replace nameplate and proceed with startup 3 2 Flywheel and V belt Alignment Before working on the drive assembly be sure that the electric power is disconnected When mounting new belts always make sure the driver and compressor are close enough together to avoid forcing Improper belt tension and sheave alignment can cause vibration excessive belt wear and premature bearing failures Before operating your compressor check alignment of the V grooves of the compressor flywheel and driver sheave Visual inspection often will indicate if the belts are properly aligned but use of a square is the best method The flywheel is mounted on the shaft via a split tapered bushing and three bolts These bolts should be tightened in an even and progressive manner until torqued as specified below There must be a gap between the bushing flange and the flywheel when installation is complete Always check the flywheel runout before startup and readjust if it exceeds the value listed in Appendix B Diameter In cm Bushing Size SF E J Bolt Torque Ft Ib kg meter 30 4 1 60 8 3 135 18 7 4 625 11 7 6 0 15 2 7 25 18 4 TYPICALLY 1 4 TO 3 8 6 4 MM TO 9 5 MM Figure 3 2B Belt Tension Tighten the belts s
99. t sere rrera pers A dE ee bee Pe wa ae hae EME NEEN ae a 14 3 3 Crankcase Oil Pressure Adjustment LL 14 3 4 Startup Checklist sue rer teed dr Oka aoa a ele AA peas Skene eae ai Be ee a 15 CHAPTER 4 ROUTINE MAINTENANCE CHART 0000s eee eee eee PAGE 16 CHAPTER 5 ROUTINE SERVICE AND REPAIR PROCEDURES o PAGE 17 DA Vales ei E E r E BEE Eer 17 A AA E eR EEN 19 5 3 Piston Rings and Piston Ring Expanders tees 19 5 4 PISTONS uso ca A AA e A A ala 19 5 5 Piston Rod Packing Adjustment oococooconoooo ee eee 20 5 6 Cylinder and Packing Replacement 0 0 0 ete eee 20 5 7 Bearing Replacement for Crankcase and Connecting Rod 22 5 71 Wrist Pin Bushing Replacement 02 00 eee 22 5 7 2 Replacing Connecting Rod BearingS 0 00 tees 22 5 7 3 Replacing Roller Bearings 0 0 teens 22 5 8 Oil PUMP ASPEGHON it I air Mave E a Wig a Ag ache oka agate n 23 5 9 Servicing the Four Way Valve eee 24 CHAPTER 6 EXTENDED STORAGE PROCEDURES Lera PAGE 25 APPENDICES A Model Number and Mounting Identification Code 26 27 B Operating and Material Specifications Bolt Torque Values Clearance and Dimensions 28 33 C Compressor Selection Mounting Selections iii ia ER eee eee a 34 K NT 35 Propane cua aaa ee Para aes Mewes we NGO ER Ratan e ey ee ees 36 nl TEE 37 D Outline DIMENSIONS 222 56 oia ir Eeer dee he ee Sheed bel Ee a eke et cree eRe Pee a 38 48 Es Tee e
100. t into the suction and or discharge opening of the head The metal valve gasket should always be replaced when the valve is reinstalled Insert cleaned or new valve assembly Make sure the suction and discharge valves are in the proper suction and discharge opening in the head Insert the valve cage and valve spacer NOTE spacer applies to model 491 compressor only Replace the O ring and valve cover plate Torque bolts to the value listed in Appendix B CAUTION Be sure the holddown screw has been removed Insert the holddown screw and tighten to the value listed in Appendix B to ensure the valve gasket is properly seated NOTE Gaskets and O rings are not normally reusable Replace the O ring or gasket and valve cap nut and tighten to the value listed in Appendix B O rings sealing the valve cap should be replaced if they show signs of wear or damage Valve caps sealed by flat metals gaskets should be reinstalled with new gaskets NOTE Spec 3 suction valves have an adjusting screw to set the liquid relief pressure To set the liquid relief pressure tighten the adjusting screw until it bottoms then back out 3 4 turn Check bolts and valve holddown screws after first week of operation Re torque if necessary See Appendix B for torque values 18 5 2 Heads A compressor head very seldom requires replacement if the compressor is properly maintained The primary cause of damage to a head is corrosion and the entry
101. ted trap provides the most thorough liquid separation see figure 2 4C This trap is larger and is ASME code stamped It contains two level switches one for alarm and one for shutdown In some cases the alarm switch is used to activate a dump valve not included with trap or sound an alarm for the trap to be manually drained by the operator This trap also contains a mist pad A mist pad is a mesh of interwoven wire to disentrain fine liquid mists The ASME code trap is standard in the 109B and 107B mounting configurations A typical wiring diagram for the liquid level switch is shown in figure 2 4D NOTE The level switch MUST be removed from the trap before grounding any welding devices to the trap or associated piping Failure to do so will damage the switch contacts LIQUID LEVEL FLOAT SWITCH DRAIN VALVE Figure 2 4B Automatic Liquid Trap If your compressor is equipped with a liquid trap of other than Corken manufacture make sure it is of adequate size to thoroughly remove any liquid entrained in the suction stream Typical Float Switch Wiring Diagram 1 Common black 2 Normally closed blue 3 Normally open red L1 OLR 2 d 3 o ed STOP 1 Es EE DEEN Figure 2 4D Typical Float Switch Wiring Diagram RELIEF VALVE Ld MIST PAD HIGH LIQUID LEVEL SHUTDOWN SWITCH LIQUID LEVEL ALARM SWITCH DRAIN Figure 2 4C ASME Automatic Liquid Trap 11
102. tered trademarks of the DuPont company See Appendix C for mounting options 26 Appendix A Vertical Single Acting Model Number Identification Code Base Model Number D891 Model Number Inlet Connection 2 Weld Base XX X X X X X X XX Outlet Connection 2 Weld Ship Weight Ib 900 Packing n Arrangement Packing arranged for padding of distance piece Standard J Crankcase Pressure lubricated Standard M Style Standard with heater Extra cost MH Standard suction and discharge valves Standard Valves Suction valve unloaders Extra cost Piston Ring and Packing Teflon Standard F Material Gasket Material Aluminum Standard B O ring Buna N Standard A Material Neoprene 1 No charge B Intercooler N A for single stage compressor Standard N Flywheel No flywheel provided No charge Standard flywheel Standard S Protective None Standard N Coating Fiston Rod Nitrotec Standard N Coating 1 Teflon and Neoprene are registered trademarks of the DuPont company Mounting Selections 103 Mounting includes Steel baseplate adjustable driver slide base V belt drive and enclosed steel belt guard Pressure gauges are mounted on the compressor 3 107 Mounting includes Steel baseplate mechanical liquid trap non lube 4 way valve interconnecting piping strainer adjustable driver slide base V belt drive and enclosed steel
103. uld be protected from liquid entry by a liquid trap see section 2 4 It is of equal importance to protect the discharge of the compressor from liquid This may be done by installing a check valve on the discharge and designing the piping so liquid cannot gravity drain back into the compressor Make sure to install a check valve on vapor lines discharging to the liquid space of the tank All piping must be in accordance with the laws and codes governing the service In the United States the following codes apply For LP Gas The National Fire Protection Association Pamphlet No 58 Standard for the Storage and Handling of Liquefied Petroleum Gases For Ammonia The American National Standards Institute Inc K61 1 1989 Storage and Handling of Anhydrous Ammonia Copies of these are available from NFPA 60 Baterymarch Street Boston Mass 02110 and ANSI 1430 Broadway New York N Y 10018 Install use and maintain this equipment according to Corken instructions and all applicable federal state and local laws and previously mentioned codes 2 4 Liquid Traps Compressors are designed to pressurize gas not to pump liquids The entry of even a small amount of liquid into the compressor will result in serious damage to the compressor On liquefied gas applications a liquid trap must be used to prevent the entry of liquid into the compressor Corken offers three types of liquid traps for removal of entrained liquids The simp
104. venting an undesirable increase in tank pressure see figure 1 2A Residual vapor recovery is an essential part of the value of a compressor There is an economical limit to the amount of vapors that should be recovered however When the cost of operation equals the price of the product being recovered the operation should be stopped For most cases in LP Gas and Anhydrous Ammonia services this point is reached in the summer when the compressor inlet pressure is 40 to 50 psig 3 8 to 4 5 VAPOR LINES COMPRESSOR REDUCES PRESSURE IN STORAGE TANK BY REMOVING VAPOR 4 WAY VALVE OPERATION INLET FROM STORAGE TANK DISCHARGE FROM INLET TO 4 COMPRESSOR COMPRESSOR Figure 1 1B Liquid transfer by vapor differential pressure LIQUID HEEL VAPOR LINES REMOVING VAPOR FROM TANK CAUSES LIQUID HEEL TO BOIL INTO VAPOR Four Way Valve Position 2 Figure 1 2A Residual Vapor Recovery bars A good rule of thumb is not to operate beyond the point at which the inlet pressure is one fourth the discharge pressure Some liquids are so expensive that further recovery may be profitable but care should be taken that the ratio of absolute discharge pressure to absolute inlet pressure never exceeds 7 to 1 Further excavation of very high value products would require a Corken two stage gas compressor Invariably there is some liquid remaining in the tank after the liquid transfer operation This liquid heel must
105. ween the liquid sections of the two tanks If the connections are opened the liquid will seek its own level and then flow will stop however by creating a pressure in the tank being unloaded which is high enough to overcome pipe friction and any static elevation difference between the tanks all the liquid will be forced into the storage tank see figure 1 1B The gas compressor accomplishes COMPRESSOR INCREASES PRESSURE IN TANK CAR BY ADDING VAPOR PRESSURE DIFFERENCE BETWEEN TANKS CAUSES LIQUID TO FLOW OUT OF THE TANK CAR INTO THE STORAGE TANK Four Way Valve Position 1 LIQUID LINE this by withdrawing vapors from the storage tank compressing them and then discharging into the tank to be unloaded This procedure slightly decreases the storage tank pressure and increases the pressure in the other tank thereby causing the liquid to flow The process of compressing the gas also increases the temperature which aids in increasing the pressure in the tank being unloaded 1 2 Residual Vapor Recovery The principle of residual vapor recovery is just the opposite of liquid transfer After the liquid has been transferred the four way control valve or alternate valve manifolding is reversed so that the vapors are drawn from the tank just unloaded and discharged into the receiving tank Always discharge the recovered vapors into the liquid section of the receiving tank This will allow the hot compressed vapors to condense pre
106. x head bolt 5 16 18 x 3 4 2847 1 Bearing cover 1504 1504 1 1504 2 Bearing adjustment shim 0 005 Bearing adjustment shim 0 007 Bearing adjustment shim 0 020 1500 Bearing cup 1508 X Oil bayonet 1511 Crankcase inspection plate gasket 2853 Crankcase inspection plate 2 112A O ring oil bayonet amp pump shaft 2803 Crankcase Oil pump assembly individual pump parts not available Assembly Number Pump cover pin with 2848 X Pump cover includes pin Assembly Name 1279 X Breather cap assembly with 1279 2 111A 1419 2X1 Hydraulic unloader assembly up to 200 psi Spec 7 78 only 1279 Breather cap 2 111A O ring breather cap 2796 Breather ball 1483 Lock pin 1663 Flywheel key 1501 Bearing cone 1499 X Crankshaft assembly with 1284 2 1286 1499 1501 1503 2590 1499 SX Extended crankshaft assembly with 1284 2 1286 1499 S 1501 1503 2590 1284 Crankcase orifice 2 1503 Bearing cone 1286 Pump shaft drive pin 1459 2590 Crankshaft plug depends on design Pipe plug depends on design 1280 Filter screw 1281 Filter screen screw gasket 2 116A O ring filter screen 1419 2X29 Hydraulic unloader assembly 200 psi and above Spec 7 78 only 1499 X 1499 SX Crankshaft assembly with 1284 2 1286 1
107. y w pin 2 228A O ring 2849 1X Oil pump assembly 2851 Spring guide 2852 Oil pump spring 3219 Pump shaft adapter 2 112A O ring 2805 XD Pump shaft bushing 1629 Pipe plug 1 16 NPT fl seal 1736 Bearing cup 1302 Oil pressure gauge 1044 Bushing 1 8 x 1 4 NPT 3220 2 Bearing carrier Assembly Number 3220 2X Bearing carrier assembly Assembly Name 3852 Xa Flywheel assembly D891 only 3852a Flywheel 21 2 5V 5 groove 3918a Flywheel hub type J2 1 8 bore D891 only 1762a Flywheel 19 1 2 AB 4 groove 3221 X1a Crankcase assembly M3 4 8 9 without lubrication 3221 X2a Crankcase assembly M7 78 without lubrication 3221 X3a 3221 X4a a Not shown Crankcase assembly L3 4 8 9 without lubrication Crankcase assembly L7 78 without lubrication b Must be rebored and honed after replacing 0 876 0 875 diameter Caution To avoid damage during assembly refer to installation Instruction Manual 1E400 CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs 81 Appendix J D891 Head and Valve Assembly Details 891 Head Valve Hold down Assembly Suction or Discharge Valve Assemblies 21 Suction Discharge Valve Valve Compressor Head and Valve Bill of Materials Part
108. y of unit 18 19 Verify that all valves are open or closed as required Double check all of the above After Starting Compressor 1 Verify and note proper oil pressure Shut down and correct any problem immediately 2 Observe noise and vibration levels Correct immediately if excessive 3 Verify proper compressor speed 4 Examine entire system for gas oil or water levels 5 Note rotation direction 6 Check start up voltage drop running amperage and voltage at motor junction box not at the starter 7 Test each shutdown device and record set points 8 Test all relief valves 9 Check and record all temperatures pressures and volumes after 30 minutes and 1 hour 10 After 1 hour running time tighten all head bolts valve holddown bolts and baseplate bolts See Appendix B for torque values 15 Chapter 4 Routine Maintenance Chart Item to Check Monthly Six Months Crankcase oil pressure Compressor discharge pressure Overall visual check Crankcase oil level Drain liquid from accumulation points Clean cooling surfaces on compressor Lubricator supply tank level if any Check belts for correct tension Inspect valve assemblies Lubricate motor bearings in accordance with manufacturers recommendations Inspect motor starter contact points Piston rings Piston ring life varies greatly depending on application gas and

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