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Important Instructions (D-Styles)

1. 21 Crankcase Oil Pressure Adjustment 22 Adjustment of Mechanical Unloader Controls 22 Startup Checklist a We Thal ie ee eee oe 24 4 ROUTINE MAINTENANCE PAGE 25 5 ROUTINE SERVICE AND REPAIR PAGE 26 te taka en Pe cat aa aap oe Ay ERA 26 Cylinder and Heade cay eee a ee aR Ce ee le ey Bee tas 29 Piston Rings and Piston Ring 29 Piston 29 Piston Rod Packing 30 wae te Sells ol 30 Wrist Pin Bushing 31 Connecting Rod 6 31 Roller Bears ere er ee ee a a ee eR ee area aig ee a to 31 OilP mp Inspectio
2. PAGE 12 cc eet cantata 12 FOUN ATION ee BR 12 PUDING ete eee RO eras thon aca 12 Mapa 13 Driver Installation 15 Lubrication 3 2025 24 ee ee 15 Cooling Water Yin ese EA ade 16 VUNG ate dates ihn tant gee ci mt gute E T 16 Shutdown Alarm Devices 17 Purging and Draining of Distance 17 ots as Skat anata th Sele te 18 Cylinder Lubricators Lubricated Models 19 3 START UP OF YOUR CORKEN 5 PAGE 21 Inspection After Extended Storage 21 Flywheel and V belt
3. amp SIGHT GLASS FOR RESERVOIR OIL LEVEL BLOWOUT DISK SIGHT DOME MANUAL PRIMING PLUNGER FLOW ADJUSTING NUT LOCK NUT FIGURE 1 8B Figure 1 8B illustrates the different parts of the lubricator The lubricant is supplied to the lubri cator pump through a 1 8 NPT connection on the plastic sight dome Note the Corken cylin der lubricator is not sump fed A blowout disk prevents the lubricator discharge pipe from being over pressured See Section 2 12 for operation of the lubricator Two stage units are equipped with a filter and divider block to split the lubricant flow between the injection quills installed on each stage Both the compressor and the lubricator may be operated in either direction Gas Compressors 11 2 INSTALLING YOUR CORKEN COMPRESSOR 2 1 LOCATION Corken compressors are designed manufactured for outdoor duty For applications in which the compressor will be subjected to extreme conditions for extended periods such as hot boiler rooms corrosive environments arctic or desert conditions etc consult Corken Check local safety regulations and building codes to assure installation will meet local safety standards Corken recommends that machines compressing toxic or flammable gases be placed outdoors If such units are placed indoors make sure the area is well ventilated and vent the distance piece to the outdoors Compressors with only one packing set and n
4. VALVE O RINGS a UNLOADER PISTON b HOLDDOWN SCREW COVER PLATE O RING ACTUATOR SPRING NOTE SMALL END SUCTION SPEC 4 SUCTION SPEC 3 DISCHARGE ALL SPECS GBD OF SPRING 2 72 VALVE ASSEMBLY TOWARD 7 VAWE SS e a 1 i HEAD HEAD NOTES a Older units may have a metal gasket instead of the O Ring b If the unloader is disassembled or is new seals are required 1 Replace the seals proper orientation see detail 2 Apply Loctite 290 to the screw threads when assembling the unloader piston FIGURE 5 1C The metal valve gasket should always be replaced when the valve is reinstalled Make sure suction and discharge valves are in the right slots as shown in the illustrations Reinstall cages spacers unloader parts and then tighten the valve hold down screw to 40 ft Ib to ensure the valve gasket is properly seated Replace O rings sealing the valve cover and valve cap if they show any signs of wear or damage Reinstall valve caps sealed by flat metal gaskets with new gaskets Refer to Appendix D for torque values 28 Gas Compressors Spec suction valves have an adjusting screw to set the liquid relief pressure To adjust tighten the adjusting screw until it bottoms then back off one and a half turns on the size 491 only 5 2 CYLINDERS AND HEAD Cylinders and heads very seldom require replace ment if the compressor is properly mainta
5. 2 IN THE LAST DIGIT OF THE MODEL NO 691 692 BASIC MODEL 691 4 TWO STAGE DUCTILE IRON 191 391 591 ALL EXCEPT T STYLE INLET PRESSURE ABOVE ATMOSPHERIC A ALL EXCEPT T STYLE ATMOSPHERIC INLET OR VACUUM SERVICE B PACKING ALL T STYLE STANDARD PACKING ARRANGEMENT FOR T STYLE G ARRANGEMENT ALL T STYLE PACKING ARRANGED FOR PURGING OF DISTANGE PIECE H 91 ONLY SPLASH LUBRICATED CRANKCASE J 91 491 EXTENDED CRANKSHAFT E ALL EXCEPT 91 STANDARD PRESSURE LUBRICATED CRANKCASE M CRANKCASE ALL EXCEPT 91 STANDARD CRANKCASE WITH CRANKCASE HEATER M STYLE ALL EXCEPT 91 STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR L LUBRICATOR ALL EXCEPT 91 STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR LUBRICATOR AND CRANKCASE HEATER ALL LIQUID RELIEF SUCTION VALVES ALL STANDARD SUCTION AND DISCHARGE VALVES ALL EXCEPT 91 LOADLESS START THROUGH SUCTION VALVE UNLOADERS AND HYDRAULIC UNLOADER BRASS VENTS TO ATMOSPHERE ALL CONSTANT SPEED UNLOADING THROUGH SUCTION VALVE UNLOADERS AND PILOT VALVE BRASS VENTS TO ATMOSPHERE ALL EXCEPT 91 COMBINATION CONTROL INCLUDES LOADLESS STARTING VALVES AND CONSTANT SPEED UNLOADING ALL SUCTION VALVE UNLOADERS 391 491 SERIES SPEC 3 VALVES AS NOTED ABOVE WITH MC1002 rm CORROSION RESISTANT COATING rm 391 491 SERIES SPEC 4 VALVES AS NOTED ABOVE WITH 1002 CORROSION RESISTANT COATING 391 491 SERIES SPEC 9 VALVES AS NOTED ABOVE WITH MC1002 CORROSION RESISTANT COATING ALL EXCEPT 391 491 SPEC 4 VALVES AS NOTED ABOVE W
6. 100 INSTRUCTIONS GAS COMPRESSORS Solutions beyond products CORKEN 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 A S I 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 WARNING Install use and maintain this equipment according to Corken s instructions and all applicable federal state local laws and codes Periodic inspection 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 W 36th Street Oklahoma City Oklahoma 73112 Parts subject to wear or abuse such as mechanical seals blades p
7. LT Low oil pressure indicator lamp Controlled via LOP High temperature indicator lamp Controlled via Curcuit Functions 1 Allows start stop control with loadless starting 2 Allows constant speed unloading 3 Provides shutdown for high discharge temperature high discharge pressure or low suction pressure and low oil pressure and indication of cause of shutdown Other shutdown controls may be easily added FIGURE 2 8A 10 to 30 second time delay is required to activate a 3 way solenoid valve during startup to affect loadless starting Corken s 3371 low oil pressure switch is equipped with a time delay that may be used for this purpose If a different brand of LOP switch is used which does not have a time delay a time delay can be added to the control panel To activate the solenoid when discharge pressure exceeds a certain point constant speed unloading a pressure switch should be wired into the system as shown in Figure 2 8A The pressure switch is designated PS2 in the schematic For more Spec 9 unloading systems see Section 1 7 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 meet local code requirements Shutdown alarm devices typically used on Corken compressors are Low Oil Pressure Switch shuts down the unit if crankcase oil pressu
8. SUCTION UNLOADER LINE HYDRAULIC UNLOADER RECEIVER CRANKSHAFT UNLOADED SUCTION VALVE UNLOADER SUCTION UNLOADER LINE HYDRAULIC UNLOADER RECEIVER CRANKSHAFT LOADED SPECIFICATION 7 FIGURE 1 7A SPECIFICATION 7 Use only for air or non contaminating non hazardous gases Specification 7 unloader system allows the compressor to start under no load see Figure 1 7A When the compressor is not running the suction valves are held open by the pressure in the unloader line from the receiver As the compressor starts 8 Gas Compressors running the crankcase oil pressure rises and closes the hydraulic unloader this vents the unloader line and the suction valves may begin normal operation When the compressor stops the hydraulic unloader opens again unloading the suction valves CONSTANT SPEED UNLOADING FOR AIR OR NON CONTAMINATING OR NON HAZARDOUS GAS SUCTION VALVE UNLOADER SUCTION VALVE UNLOADER LINE PILOT VALVE RECEIVER CRANKSHAFT UNLOADED SUCTION VALVE UNLOADER UNLOADER LINE PILOT VALVE RECEIVER CRANKSHAFT LOADED SPECIFICATION 8 FIGURE 1 7B SPECIFICATION 8 Use only for air or non contaminating non hazardous gases The discharge pressure range is set by adjusting the unloader pilot valve see Figure 1 7B When the compressor is running and the pressure reaches the maximum setting the unloader pilot valve opens the line to
9. Three types of mountings are typically used The inside mounting Figure 7 2A drives the compressor directly off the PTO shaft The PTO 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 7 2B Always use an even number of U joints OUTSIDE TRANSPORT MOUNTING FIGURE 7 2C TOP TRANSPORT MOUNTING FIGURE 7 2D Depending on the truck design the compressor may be outside or top mounted as shown in Figures 7 2C and D 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 Gas Compressors 39 APPENDIX MODELS INVOLVED DESCRIPTION bet FEATURE EXAMPLE AIR a COOLING 391 591 691 691 4 WATER COOLED HEAD ALL ANSI DIN FLANGE INLET AND OUTLET CONNECTION STYLE ALL SINGLE DISTANCE PIECE D DISTANCE 4 ALL DOUBLE DISTANCE PIECE T PIECE DESIGN SINGLE STAGE DUCTILE IRON 91 291 NOTE MODELS ARE AVAILABLE WITH DIN IRON 491 492 HEAD CYLINDER MODEL NO WILL BE DESIGNATED BY 491 3
10. tight If the shaft is too tight add more shims but make sure not to over shim Appendix E lists the proper crankshaft end play When the shaft can be rotated freely by hand and no end play is present the rest of the compressor may be reassembled If the crankshaft roller bearings are too tight or too loose premature bearing failure will result Reinstall the flywheel on the crankshaft and check the runout as shown in Appendix LOCATE OIL FILTER ADAPTER AS SHOWN PIN OIL SUCTION PIN PUMP COVER MUST FALL IN GROOVED AREA OIL PUMP ASSEMBLY OIL FILTER OIL FILTER ADAPTER NOTE FOR COMPRESSORS WITHOUT OIL FILTER ASSEMBLIES USE OPTIONAL PUMP COVER ASSEMBLY INSTRUCTIONS ARE THE SAME AS ABOVE CS 32 Gas Compressors ALIGN SLOT PUMP SHAFT ADAPTER WITH PIN CRANKSHAFT ALIGN TANG OIL PUMP ASSSEMBLY WITH SLOT PUMP SHAFT ADAPTER 0 5 7 OIL PUMP INSPECTION Damage to the oil pump may result if the compressor operates for a prolonged period with dirty or contaminated crankcase oil To check the oil pump unbolt the pump cover and remove the oil pump spring guide spring and oil pump shaft as shown Figure 5 7A 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
11. COMPRESSOR WITHOUT A FLYWHEEL Select drivers so that the compressor operates between 350 to 825 RPM Do not operate the unit without the flywheel 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 as well as alternating between being warm when running and cool when stopped can draw moist air 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 manufacturer will guarantee explosion proof or totally enclosed TEFC motors 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 compressors Detergent oils tend to keep wear particles and debris suspended in the oil whereas non detergent oils let them settle to the bottom of the crankcase When non detergent oils are a
12. Corken offers the most versatile line of small gas compressors in the world NOTE To confirm the options provided with your machine check the model number on your compressor s nameplate against the chart in Appendix A CORKEN GAS COMPRESSOR CRANKCASE CAPACITY 2 LIT NO 3 805 827 READ INSTRUCTIONS BEFORE OPERATING IF NO INSTRUCTION BOOK WAS RECEIVED WRITE THE FACTORY MODEL SERIAL NO CORKEN INC OKLAHOMA CITY MADE IN U S A 4 1 2 RUNNING GEAR Corken gas compressors are mounted on sturdy oil lubricated crankcases Crankshafts are supported by heavy duty roller bearings The connecting rods ride the crankshaft on journal bearings With the exception of the small Size 91 compressor all compressor crankcases are pressure lubricated An automatically reversible gear type oil pump circulates oil through passages drilled in the crankshaft and connecting rod to lubricate journal bearings and wrist pins see Figure 1 2A 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 A replaceable 10 micron spin on oil filter ensures long life PRESSURE LUBRICATION SYSTEM OILPUMP WRIST PIN BUSHING JOURNAL BEARING CRANKSHAFT FIGURE 1 2A Gas Compressors 5 COMPARISON DIFFERENT COMPRESSOR SEALING SYSTEMS 2 ENS LA ADJUSTING N
13. Purchased 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 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 CONTENTS 1 HOW YOUR CORKEN COMPRESSOR 6 PAGE 4 Why Corken Compressors are 4 Running Gear ai ere eee Sa ee di eee gs Se 5 Piston Rod Packing Distance 6 Pistons Pist n RINGS vs iaaa dk eo eer ete oe eee we eee ete re ee ee 7 Oe E 7 COONING 7 Suction 222 25 7 2 2 tec a a ei ee ee 10 2 INSTALLING YOUR CORKEN 5
14. for use where the compressor is kept under fairly close observation by the operator This trap is provided with the 109 and 107 compressor packages See bottom of Appendix A for details on standard Corken compressor packages Gas Compressors 13 AUTOMATIC LIQUID TRAP LIQUID LEVEL FLOAT SWITCH BAFFLE INLET DRAIN VALVE FIGURE 2 4B For continuous duty operation applications such as those found in the chemical industry an automatic trap should be used see Figure 2 4B The automatic trap replaces the mechanical 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 sophisticated 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 activates a dump valve not included with trap or sounds an alarm A drain valve is included to manually drain the trap This trap also contains a mist pad a mesh of 14 Gas Compressors ASME AUTOMATIC TRAP RELIEF VALVE Li MIST PAD HIGH LIQUID LEVEL SHUTDOWN SWITCH LIQUID LEVEL ALARM SWITC
15. mechanism replace the O rings the oil pump cover in the oil pump adapter shaft see Figure 5 7A 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 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 7A 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 direction 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 PUMP SHAFT ADAPTER SPRING SPRING GUIDE OIL PUMP ASSEMBLY FIGURE 5 7A 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 Drain the crankcase oil and refill with rust inhibiting oil 2 Operate for a few minutes while fogging oil into the compressor suction 3 Relieve V belt tension 4 Plug all openings to prevent entry of insects and moisture The cyl
16. strainer clogged Leaks in piping Inlet or ambient temperature too high Compression ratio too high Loose flywheel or belt Worn piston rod packing Worn wrist pin or wrist pin bushing Worn connecting rod bearing Unbalanced load Oil in distance piece Inadequate compressor base Improper foundation or mounting Loose valve piston or packing Dirty cooling fins 4 way control valve not lubricated Leaking gas blowing oil from crankcase Bad oil seal No oil in crankcase Oil pump malfunction Low voltage Motor wired wrong Wire size too small for length of run Wrong power characteristics Wrong size of heaters in starter Compressor overloading Motor shorted out Bad motor bearing 1 2 3 4 5 6 7 8 TWO STAGE COMPRESSOR TROUBLE SHOOTING Two stage compressors can have problems that never occur with single stage machines Interstage pressure is an important indicator of the condition of a two stage compressor Interstage pressure is too high 1 Second stage valves may be broken or leaking 2 Second stage piston rings may be worn Inspect and clean or repair Inspect and replace as necessary Clean or replace screen as necessary Inspect and repair Consult factory Check application and consult factory Tighten Replace Replace Replace Inspect valve or consult factory Tighten packing nut drain weekly Strengthen replace or grout Tighten mounting or rebuild foundation Tighten or replace as necessary Clean we
17. the suction valve unloader is pressurized and the suction valves are held open The compressor is not running unloaded As the pressure in the receiver drops to the preset minimum the pilot valve closes the line to the suction valve unloader is vented and the suction valves return to normal operation See Sec 3 4 for adjustment information SPECIFICATION 7 8 advantages of Specification 7 and Specification 8 unloading systems may be combined as shown in Figure 1 7C A control valve allows the pilot valve to be isolated from the system when start stop control with a pressure switch is preferred See Sec 3 4 for adjustment information DUAL CONTROL UNLOADING FOR AIR NON CONTAMINATING OR NON HAZARDOUS GAS HEAD UNLOADER A CONTROL VALVE OPEN CONSTANT SPEED PILOT OPERATION CLOSED AUTOMATIGOADLESS PILOT START START STOP PERA TION VALVE CONNECT TO THE RECEIVER AND AUTOMATICPRESSURESWITCH HYDRAULIC WITH 3 8 O D MINIMUM TUBING UNLOADER SPECIFICATION 7 8 FIGURE 1 7C Gas Compressors 9 3 WAY SOLENOID CONNECT TO COMPRESSOR DISCHARGE LINE MUST GO DOWNSTREAM OF ANY BACK CHECK VALVE OR TO EXTERNAL GAS SOURCE PRESSURE MUST BE AT LEAST 40 PSI GREATER THAN COMPRESSOR INLET PRESSURE VENT TO SUCTION lt OR ATMOSPHERE SUCTION VALVE COMPRESSOR UNLOADED 3 WAY SOLENOID VENT TO SUCTION x OR ATMOSPHERE A CONNECT TO COMPRESSOR DISCHARGE LINE MUST GO DOWN
18. 5 7 62 7 62 10 16 Piston Displacement CFM lit min 4 113 8 0 226 8 0 226 17 2 487 9 8 277 29 2 827 23 2 657 2 8 81 4 0 113 11 4 323 11 4 323 26 2 742 Minimum at 400 RPM 6 170 6 170 17 481 8 226 Maximum at 825 8 226 16 453 16 453 36 1019 20 566 60 1699 48 359 5 8 166 8 226 22 623 22 623 54 1529 Max Allowable Rod Loads 3600 3600 3600 4000 4000 5500 5500 3600 3600 4000 4000 5500 LBS Kg 1632 96 1632 96 1632 96 1814 40 1814 40 2494 80 2494 80 1632 96 1632 96 1814 40 1814 40 2494 80 Minimum Inlet Pressure psia Bars Maximum Pressure psia Bars Maximum Motor Size Hp 7 5 15 15 15 15 35 35 15 15 15 35 Maximum Outlet Temp F 350 177 350 177 350 177 350 177 350 177 350 177 350 177 350 177 350 177 350 177 350 177 350 177 These numbers specify pressure containing abilities of the compressor cylinder and head For many applications factors other than the pressure rating will limit the maximum allowable discharge pressure to lower values These factors include horsepower temperature and rod load 42 Gas Compressors APPENDIX D PISTON SCREW TORQUE IN LB VALVE UNLOADER CAP TORQUE W GASKETS FT LB VALVE UNLOADER CAP TORQUE W O RINGS FT LB 50 50 35 ST1 191 50 ST1 35 ST2 100 100 S
19. APTER BEFORE GOING TO START UP CHECKLIST 3 1 INSPECTION AFTER EXTENDED STORAGE If your compressor has been out of service for a long time verify that the cylinder bore and valve areas are free of rust and other debris see the maintenance section of this 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 the crankcase with the appropriate lubricant Squirt oil on the cross heads and rotate the crank by hand to ensure that all bearing surfaces are coated with oil Rotate the unit manually to ensure that the running gear functions properly Replace the nameplate and proceed with start up 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 FLYWHEEL INSTALLATION FIGURE 3 2A TYPICALLY 1 4 TO 3 8 6 4 MM TO 9 5 MM FIGURE 3 2B Normal rotation is counterclockwise facing the flywheel This is important for two stage units with intercoolers Improper belt tension and sheave alignment can cause vibrations excessive belt wear and premature bearing failures Before operating your compressor check the alignmen
20. CYLINDER ONLY C PROTECTIVE ALL 0 COATING N COATING ALL COATING ON ALL NECESSARY WETTED PARTS WwW ALL CHROME OXIDE PISTON ROD COATING PISTON ROD ALL NITROTEC PISTON ROD COATING STANDARD N COATING ALL SPECIAL PISTON ROD COATING CONSULT FACTORY Z 40 Gas Compressors HEAD CYLINDER APPENDIX B STANDARD 590 690 690 4 MATERIAL GRAY IRON ASTM 48 CLASS 30 OPTIONAL MATERIAL 91 191 291 391 491 691 DUCTILE IRON ASTM A536 492 692 DUCTILE IRON DIN 1693 666 40 3 DISTANCE PIECE CROSSHEAD GUIDE CRANKCASE FLYWHEEL BEARING CARRIER ALL GRAY IRON ASTM 48 CLASS 30 FLANGE 590 691 DUCTILE IRON ASTM A536 590 690 691 690 4 STEEL WELDING VALVE SEAT AND BUMPER VALVE PLATE 91 191 291 17 7 PH STAINLESS STEEL 391 491 490 3 DUCTILE IRON ASTM A536 590 691 91 191 291 STAINLESS STEEL 410 STAINLESS STEEL 91 191 291 391 491 490 3 17 7 PH STAINLESS STEEL 590 691 STAINLESS STEEL 590 691 VALVE SPRING VALVE GASKETS 91 191 291 590 691 17 7 PH STAINLESS STEEL 391 491 490 3 ALL INCONEL SOFT ALUMINUM COPPER IRON LEAD PISTON 91 191 291 391 491 590 691 590 691 GRAY IRON ASTM 48 CLASS 30 PISTON ROD ALL C1050 STEEL NITROTEC ROCKWELL 60C ALL D amp T STYLE MODELS CHROM OXIDE COATING CROSSHEAD ALL GRAY IRON ASTM A48 CLASS 30 PISTON RINGS ALL
21. H DRAIN FIGURE 2 4C 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 If the switch is installed with the conduit connection in the top position it will normally be closed as shown in Figure 2 4D If the conduit is in the bottom position the switch with normally be open 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 WIRING DIAGRAM LEVEL SWITCH 2462 5 PROTECTIVE THYRECTOR 110VAC CORKEN 3848 OR G E V150 LA1 220VAC CORKEN 3849 OR G E V300 LA2 FIGURE 2 4D If your compressor is equipped with a liquid trap of other than Corken manufacture make sure it is of a size adequate to thoroughly remove any liquid entrained in the suction stream 2 5 DRIVER INSTALLATION FLYWHEELS Corken vertical compressors may be driven either by electric motors or combustion engine gasoline diesel natural gas etc Corken compressors are usually V belt driven but they are 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
22. IGURE 5 5A Synthetic lubricants are generally not necessary Please consult the factory if you are considering the use of a synthetic oil 2 7 COOLING WATER Certain Corken compressor models may be equipped with water cooling features where air cooling is not sufficient Appendix A summarizes water cooling options available on Corken compressors Although the top packing set of the 590 690 690 4 and 691 Standard and D style may be water cooled these units are designed to run completely air cooled so water cooling the packing is not required Usually a two way solenoid valve is used to shut off cooling water flow when the compressor is operating see Section 2 8 for typical wiring Increasing cooling water flow rates will improve cooling up to a certain point For most watercooled Corken compressors flow rates of 1 to 2 GPM are most practical but you may increase the flow rate if it significantly improves cooling The best water flow rate and path will vary from application to application Normally the water discharge temperature should be 120 130 F 49 54 C to ensure optimum ring and valve life Lower water temperatures may be used only if the gas has no condensables 2 8 WIRING Wiring of electric motor drivers and compressor controls and instrumentation should only be done by trained electricians Figure 2 8A shows a general wiring schematic for typical shutdown and control devices such as low oil pr
23. IMETER Minimum Maximum 91 191 291 491 b 020 51 1044 1 12 A91 091 A191 D191 A291 0291 WA391 WD391 0491 b 491 3 b 0391 0491 3 FD151 025 64 049 1 24 T690 4 WT690 4 WT690 WT590 T590 T691 190 390 490 491 a A190 D190 A390 D390 A490 D490 D491 D490 3 1491 490 3 WT391 T491 b T491 3 T191 T291 T91 590 690 W690 691 A590 WA590 A690 WA690 D590 WD490 D690 DD690 4 WD690 WD690 4 D691 D691 4 NOTES a For 491 Compressors with flat gasket b For 491 Compressor with O rings CAUTION ALWAYS RELIEVE PRESSURE IN THE UNITS BEFORE ATTEMPTING ANY REPAIRS Gas Compressors 45 APPENDIX PURGING AND DRAINING OF DISTANCE PIECE AND PISTON ROD PACKING ORIENTATION MODEL CONDITIONS DISTANCE PIECE OPENING 1 4 INCH NPT V RINGS POINT SERVICE UPPER LOWER D91A D191A D290A D291A D390A WD391A D490A D490 3A D491A D590A WD590A D690A D691A D690 4A WD690A WD590 4A Inlet pressure Above 15 psia 1 General gas transfer Plugged to allow the Pipe to drain or vent distance piece pressure with a shut off valve to reach its own level Distance piece must be drained weekly to 2 Highly toxic gases Pressurized via an prevent an accumulation external gas source to a of oil or condensate pressure below suction pressure and above atmospheric pressure Or vented to atmospheri
24. ITH PEEK VALVE PLATES ALL EXCEPT 391 491 SPEC 9 VALVES AS NOTED ABOVE WITH PEEK VALVE PLATES gJ 91 491 SERIES PTFE PISTON RING AND PACKING MATERIAL mi 591 691 SERIES PTFE PISTON RING AND ALLOY 50 PACKING MATERIAL JJ SAME AS F WITH ADDITION OF K RING SPACERS PISTON RING ALLOY 50 PISTON RINGS AND PACKING MATERIAL AND PACKING SAME AS G WITH THE ADDITION OF K RING SPACERS MATERIAL PEEK PISTON RING AND ALLOY 50 PACKING MATERIAL SAME AS H WITH THE ADDITION OF K RING SPACERS SPECIAL PISTON RING AND PACKING MATERIAL Z LUMINUM GASKET MATERIAL B COPPER GASKET MATERIAL C GASKET m IRON LEAD GASKET MATERIAL D MATERIAL UNA N EOPRENE B O RING D MATERIAL Z ALL AIR COOLED TWO STAGE R COOLED IRON RATED FOR 625 PSI A COMPRESSORS EXCEPT 591 ALL AIR COOLED TWO STAGE R COOLED COPPER RATED FOR 625 PSI B COMPRESSORS EXCEPT 591 ALL TWO STAGE WATER COOLED BRASS RATED FOR 150 PSI C ALL TWO STAGE WATER COOLED STAINLESS STEEL RATED FOR 200 PSI D ALL TWO STAGE EXCEPT 591 HEAVY DUTY AIR COOLED COPPER RATED FOR 500 PSI E ALL TWO STAGE NPT FLANGES ONLY NO INTERCOOLER F INTERCOOLER ALL TWO STAGE COOLING LOOP COPPER G ALL TWO STAGE COOLING LOOP STAINLESS STEEL H ALL SINGLE STAGE A SINGLE STAGE COMPRESSOR NO INTERCOOLER N ALL TWO STAGE SPECIAL INTERCOOLER 2 191 491 SERIES 14 FLYWHEEL USED IN CONJUNCTION WITH EXTENDED E CRANKSHAFT 91 491 SERIES HEAVY DUTY FLYWHEEL H FLYWHEEL gt ALL NO FLYWHEEL SUPPLIED N ALL STANDARD FLYWHEEL 5 ALL COATED
25. K CAR BY ADDING VAPOR COMPRESSOR REDUCES PRESSURE IN STORAGE TANK BY REMOVING VAPOR PRESSURE DIFFERENCE BETWEEN 4 VALVE OPERATION TANKS CAUSES LIQUID TO FLOW LIQUID LINE INLET FROM OUT OF THE TANK CAR INTO storace TANK THE STORAGE TANK DISCHARGE FROM OMPRESJOR NS aoe DISCHARGE TO FIGURE 7 1B TANK CAR POSITION 2 LIQUID HEEL VAPOR LINES VAPOR IS BUBBLED THROUGH LIQUID TO HELP COOL AND RECONDENSE IT et ne ene REMOVING VAPOR FROM TANK 4 WAY VALVE OPERATION CAUSES LIQUID HEEL TO LIQUID LINE IS VALVED CLOSED DISCHARGE TO BOIL INTO VAPOR DURING VAPOR RECOVERY 1 STORAGE TANK 4 DISCHARGE FROM COMPRESSOR T INLET FROM FIGURE 7 1C TANK CAR Gas Compressors 35 107 Style compressors are usually connected using three valve manifold only allows the storage tank to a five valve Figure 7 1D or three valve manifold be loaded Adequate sizing of the liquid and vapor Figure 7 1E The five valve manifold allows the lines is essential to limit the pressure drop the storage tank to be both loaded and unloaded The system to a reasonable level 20 psi or less FIVE VALVE MANIFOLD PIPING SYSTEM VAPOR LINE TO TRUCK OR TRAILER LOADING VAPOR LINE TO VAPOR SECTION OF STORAGE HYDROSTATIC RELIEF VALVE VAPOR LINE TO LIQUID PHASE RS RELIEF VALVE FOR VAPOR RECOVERY 2167 1 4 WAY VALVE NOTE PROVIDE ADEQUATE SUPPORT FOR PIPING DO N
26. LEARANCE HEAD ROLL PISTON BOLT PISTON RING PISTON ROD CYLINDER SHIMS FIGURE 5 4B PISTON PLATFORM Before installing the new piston measure the thickness of the existing shims For Models 90 through 491 the shims are placed between the thrust washer and piston platform For sizes 590 through 691 the shims are placed between the platform and piston head see Figure 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 the illustration If this measurement does not fall within the tolerances shown in Appendix E 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 D Now install a new roll pin to lock the castellated piston nut in place Install the piston head and tighten the socket head bolts in an alternating sequence Reinstall the head see Section 5 5 and follow standard start up procedure 5 5 PISTON ROD PACKING ADJUSTMENT Piston rod packing should be replaced whenever leakage approaches an unacceptable level Acceptable leakage should be determined by the customers according to safety and environmental regulations for their area Typically it is a good idea to replace piston rod packing
27. OT USE COMPRESSOR TO SUPPORT PIPING VAPOR LINE TO TANK CAR OR TRANSPORT BURY OR INSULATE IN COLD CLIMATE AREAS OPERATION OF VALVES SERVICE TO PERFORM VALVE POSITION 4 WAY B C Unload Tank Car into Position Open Close Storage Tank One Recover Vapors from Tank Position Open Open Car into Storage Tank Two Unload Transport or Truck Position Close Close into Storage Tank One Recover Vapors from Transport Position Close Open or Truck into Storage Tank Two Load Truck or Field Tank Position Close Close POSITION 1 POSITION 2 from Storage Tank Two Load Truck or Field Tank Position Open Close from Tank Car One Equalize Between Tank Car Open Close and Storage Tank Without using Vapor Pump Equalize Between Truck or Field Tank and Storage Tank Without Using Vapor Pump FIGURE 7 1D 36 Gas Compressors THREE VALVE MANIFOLD PIPING SYSTEM VAPOR LINE TO VAPOR SECTION OF STORAGE VAPOR LINE TO LIQUID PHASE FOR VAPOR RECOVERY HYDROSTATIC RELIEF VALVE s BACK CHECK VALVE SEEE VANE b 1 210 4 4 WAY VALVE ve fo oS 72 20 4 NOTE PROVIDE ADEQUATE SUPPORT FOR PIPING DO NOT USE COMPRESSOR TO SUPPORT PIPING Se VAPOR LINE TO TANK CAR OR TRANSPORT BURY OR INSULATE IN COLD CLIMATE AREA A OPERATION OF VALVES SERVICE TO
28. PERFORM VALVE POSITION 4 WAY A B 1 Unload Tank Car into Position Open Open Storage Tank One 2 Recover Vapors from Tank Position Close Open Car into Storage Tank Two POSITION 1 POSITION 2 FIGURE 7 1D Gas Compressors 37 PLANT CAPACITY GPM LT MIN PIPE SIZE INCHES VAPOR PIPING LIQUID PIPING Up to 40 1 3 4 1 3 4 Up to 50 1 1 1 1 2 Up to 80 1 1 4 2 Up to 90 1 1 4 2 1 2 Up to 20 1 1 2 3 755 Up to 350 1325 2 4 FIGURE 7 1F Figure 7 1F shows recommended pipe sizes for liquid and vapor piping For line lengths over 100 ft 30 meters the next larger pipe size should be used Line size helps determine plant capacity almost as much as the size of the compressor does 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 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 A tank car unloading riser should have two liquid hoses connected to the car liquid 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 compr
29. PTFE GLASS AND MOLY FILLED OR ALLOY 50 ALL SPECIAL ORDER MATERIALS AVAILABLE PISTON RING EXPANDERS ALL 302 STAINLESS STEEL NONE HEAD GASKET 590 CELLULOSE FIBER 590 GRAFOIL 91 191 290 291 391 491 691 491 691 O RING BUNA N 91 191 290 291 391 491 691 PTFE VITON NEOPRENE ADAPTER PLATE PACKING CARTRIDGE CONNECTING ROD ALL DUCTILE IRON ASTM A536 PACKING RINGS ALL PTFE BRASS AND MOLY FILLED OR ALLOY 50 SPECIAL ORDER MATERIALS AVAILABLE CRANKSHAFT ALL DUCTILE IRON ASTM A536 CONNECTING ROD BEARING ALL BIMETAL D 2 BABBIT WRIST PIN ALL C1018 STEEL ROCKWELL 62C WRIST PIN BUSHING ALL BRONZE SAE 660 MAIN BEARING ALL TAPERED ROLLER INSPECTION PLATE ALL ALUMINUM O RINGS ALL BUNA N PTFE VITON NEOPRENE RETAINER RINGS ALL STEEL MISCELLANEOUS GASKETS ALL COROPRENE VITON AND NEOPRENE ARE REGISTERED TRADEMARKS OF DUPONT Gas Compressors 41 APPENDIX Specifications Single Stage Two Stage 690 4 D690 4 WwD690 4 Cylinder Bore Inches cm First Stage 3 3 3 45 2 5 3 45 45 6 7 62 7 62 7 62 11 43 6 35 7 62 11 43 11 43 15 25 1 25 1 75 2 5 2 5 3 25 Second Stage 3 18 445 6 35 6 35 8 26 Stroke Inches cm 2 5 2 5 2 5 4 2 5 2 5 3 3 4 6 35 6 35 6 35 10 16 6 35 6 3
30. R GROUT BENEATH BASE CONCRETE FOUNDATION WITH REINFORCEMENTS SHOULD BE USED ON ALLMODELS gt 008 ae g eo Hotta amp 434 qo 1 2 J BOLTS 12 LONG NOTE LOCATE J BOLTS PER COMPRESSOR OUTLINE DIMENSION DRAWINGS FIGURE 2 2A DO NOT SUPPORT PIPING WITH THE COMPRESSOR Unsupported piping is the most frequent cause of pipe vibration Transmission of vibration from the compressor to the piping is minimized by using 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 If a restriction device such as a valve pressure regulator or back check valve is to be installed in the compressor s suction line the volume between the restrictive device and the compressor nozzle must be at least ten times the swept cylinder volume FLEXIBLE CONNECTORS RIGID PIPING RIGID PIPING SUPPORT SUPPORT FIGURE 2 3A Piping must be installed to prevent condensate from draining into the compressor This is especially important on applications where gas is being handled at or near its saturation point On oil field gas compressors heavy ends such as pentane hexane heptane etc may accumulate beneath the piston over a
31. RESSURE ADJUSTING SCREW FIGURE 3 3A TUBING INSTALLATION FOR LOADLESS STARTING SYSTEM SPEC 7 SUCTION VALVE UNLOADERS TUBE TO RECEIVER HYDRAULIC UNLOADER MOUNTED ON CRANKCASE ACTUATED BY OIL PRESSURE FIGURE 3 4A 22 Gas Compressors To assure critical lubrication of crossheads and crosshead guide during the initial start up period e Remove inspection plate from crosshead guide Fill crankcase with lubricating oil through the inspection plate opening Check crankcase oil level at the oil bayonet Re install the inspection plate and gasket Follow any other pre start up procedures that may be necessary in your application e Start compressor observing the crankcase oil pressure gauge If oil pressure gauge does not register 20 30 PSIG after 30 seconds stop the unit Refer to Trouble Shooting Guide in Important Instruction Book Consult the Factory if condition cannot be corrected Double check the crankcase oil level 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 Remove the pressure gauge Restart the compressor and run it until oil comes out of the pressure gauge opening Re install the gauge The oil pressure should be about 20 psi 2 4 Bars minimum for normal service If the discharge pressure is above 200 psi 14 8 Bars or if the compressor is equipped with a hydrauli
32. STON ASSEMBLIES ONLY ONE ON SIZE 91 PACKING SET UPPER OILDEFLECT OR RING INSPECTION PLATE MODEL AND SERIALNUMBER PACKING SET LOWER CROSSHEAD AND PISTON ROD ASSEMBLY WRIST PIN CONNECTING ROD OILLEVELBAYONET OILPRESSURE ADJUSTMENT SCREW EXCEPT SIZE 91 MAIN BEARING OILPUMP EXCEPT SIZE 91 OILPRESSURE GAUGE EXCEPT SIZE 91 HEAD DISCHARGE VALVE ASSEMBLY OUTLET CYLINDER INTERCOOLER 2 STAGE ONLY DISTANCE PIECE CROSSHEAD GUIDE FLYWHEEL CRANKCASE FIGURE 1 2A 1 1 WHY CORKEN COMPRESSORS ARE SPECIAL Corken industrial gas compressors are unique among compressors their size Unlike ordinary lubricated gas compressors Corken compressors completely isolate the pressurized gas in the 4 Gas Compressors compression chamber from the crankcase While piston rings seal the piston tightly enough for it to do compression work they do not provide enough sealing to isolate the compression chamber from the crankcase To further seat the compression chamber a crosshead piston rod design with seals around the piston rod is required see Figure 1 1A By utilizing specialized piston rod sealing systems Corken compressors can compress pressurized flammable and toxic gases It is also used to compress harmless gases where oil free compression or elevated suction pressures are required With numerous design options available
33. STREAM OF ANY BACK CHECK VALVE OR TO EXTERNAL GAS SOURCE PRESSURE MUST BE AT LEAST 40 PSI GREATER THAN COMPRESSOR INLET PRESSURE SUCTION VALVE UNLOADER SUCTION VALVE COMPRESSOR LOADED SPECIFICATION 9 FIGURE 1 7D SPECIFICATION 9 When the gas being compressed cannot be vented to the atmosphere electronic controls should be used as shown in Figure 1 7D An optional three way solenoid valve allows gas from the unloader to be vented back to the compressor suction instead of to atmosphere A time delay may be used to achieve loadless start a pressure switch to achieve constant speed unloading See Section 2 8 for typical wiring of Specification 9 unloader controls 1 8 CYLINDER LUBRICATORS For gas compression applications where some oil contamination is acceptable a cylinder lubricator will typically quadruple piston ring and valve life The cylinder lubricator is a high pressure oil pump which injects lubricant from an external reservoir into the suction of each stage The lubricator is mounted on the crankcase and driven by either a small V belt 10 Gas Compressors connected to a sheave mounted behind the flywheel see Figure 1 8A or by an internal sprocket and chain FIGURE 1 8A EXTERNAL LUBRICATOR DISCONNECT HERE DURING PRIMING O DISCHARGE LINE TO Oy 7 DIVIDER BLOCK WY FILTER V s C A Fa k M OIL SUPPLY LINE FROM EXTERNAL TANK RESERVOIR FILL lt
34. T1 35 ST1 100 491 391 691 591 1 For D91 see size 91 for T491 see 490 etc 2 Preliminary tightening snug all headbolts in the sequence shown First torqueing torque all headbolts in the sequence shown to the listed value 3 Retorque to the listed value after 2 5 hours running time OUT OUT MODEL 291 OUT MODEL 391 MODEL W391 Gas Compressors 43 APPENDIX D OUT OUT MODELS 491 491 3 O BOLT FROM TOP 47 BOLT FROM BOTTOM OUT MODELS 690 W690 W690 4 MODEL 691 44 Gas Compressors All Dimensions in Inches APPENDIX E CLEARANCES AND DIMENSIONS Clearance Conrod bearing to crankshaft journal Clearance Wrist Pin to Wrist Pin Bushing max Cylinder Borer Diameter max Cylinder Finish RMS Piston Ring Radial Thickness min Clearance Oil Pump Adapter Shaft to Bushing max Crankshaft End Play Cold Flywheel Runout at 0 D max Clearance Crosshead to Crosshead Guide Bore max 011 011 011 011 012 012 012 Crosshead Guide Bore Finish max 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 PISTON CLEARANCE X COLD See Figures 5 4A and 5 4B PISTON CLEARANCE COLD MODEL X INCHES MILL
35. UT r 5 A e RE 22 V RING N Ni maw PACKING SSW E Sow DEFLECTOR 2 2 f Z 2 f 5 3N SPRING 2 2 Wa RY G fa STANDARD 2 STYLE 4 A 2 5 1 9 S 5 22 2 oes 20 2 FIGURE 1 3A 1 3 PISTON ROD PACKING DISTANCE PIECES Piston rod packing seals gas into the compression chamber and prevents seepage of oil out of the crankcase into the compressor cylinder The packing consists of several PTFE V rings sandwiched between a male and female ring see Figure 1 3A The packing rings are spring loaded to allow a small amount of float to alleviate cyclic stresses reduce wear and assure a positive seal Corken manufactures compressors with one two or three packing sets Standard style units contain one packing set For completely oil free compression two packing sets are used see Figure 1 3A oil free 6 Gas Compressors compressors are designated by the prefix D Oil that seeps past the first packing set is prevented from reaching the second by an oil deflector ring Three packing sets and two distance pieces are available on special machines for compressing highly corrosive gases Units with three packing sets are designated by the prefix T The construction of the D and T st
36. X Delivery per stroke Sizes 590 to 691 Compressor RPM X 0151 X Delivery per stroke One Drop 0 0024 cubic inches Ideal lubrication rates depend on the application As long as the proper cylinder lubricant is chosen over lubrication usually is not a problem To adjust the flow rate loosen the lock nut on the manual priming plunger stem Turn the flow adjusting nut counterclockwise up to increase the flow rate and clockwise down to decrease the flow rate Retighten the lock nut after adjusting the flow To ensure best lubricator performance 1 Use only clean oil 2 Keep lubricator reservoir full of oil 3 Make sure connections stay tight 4 Make sure oil tubing is firmly supported to prevent vibration 5 Make sure lubricator drive system components stay aligned 6 Make sure all mounting bolts stay tight NO FLOW SHUTDOWNS On unattended compressor installations it is good practice to install a no flow shutdown switch to stop the compressor if the cylinder lubrication system fails NOTE No flow switches need a 3 to 4 drops per minute flow rate to indicate a flowing condition EXTERNAL LUBRICATOR DISCONNECT HERE DURING PRIMING DISCHARGE LINE TO DIVIDER BLOCK SIGHT GLASS FOR RESERVOIR OIL LEVEL BLOWOUT DISK SIGHT DOME MANUAL PRIMING PLUNGER FLOW ADJUSTING NUT LOCK NUT FIGURE 2 12B 20 Gas Compressors 3 STARTING UP YOUR CORKEN COMPRESSOR NOTE READ ENTIRE CH
37. alve cover plate before the valves can be removed COMPRESSOR SIZES 391 491 491 3 SUCTION SPEC 4 SUCTION SUCTION DISCHARGE SPEC 7 78 8 9 SPEC 3 ALL SPECS VALVE CAP UNLOADER GASKET O RING a UNLOADER PISTON b HOLDDOWN SCREW COVER PLATE O RING SPACER CAGE c bli ACTUATOR 25 SPRING NOTE SMALL END VALVE ASSEMBLY 20 OOF SPRING gt TOWARD GASKET VALVE HEAD NOTES Older units may have metai gasket instead of the O Ring b If the unloader is disassembled or new seals are required 1 Replace the seals in proper orientation see detail 2 Apply Loctite 290 to the screw threads when assembling the unloader piston 4 2 SUCTION VALVE DISCHARGE VALVE c Grooved end down FIGURE 5 1B Inspect valves for breakage corrosion scratches on the valve disk and debris In many cases valves may simply be cleaned and reinstalled If valves show any damage they should be repaired or replaced Replacement is usually preferable although repair parts are available If valve disks are replaced seats should also be lapped until they are perfectly smooth If more than 005 must be removed to achieve a smooth surface the valve should be discarded If disks are replaced without relapping the seat rapid wear and leakage will occur Gas Compressors 27 COMPRESSOR SIZES 590 691 691 4 SUCTION SPEC 7 78 8 9 UNLOADER
38. and piston rings at the same time 30 Gas Compressors PACKING ADJUSTING NUTS NOTE FILL CRANKCASE WITH OIL THROUGH TIGHTEN TURN THIS OPENING FIGURE 5 5A Instructions for packing replacement are included with each set of packing Inspection of the rod packing is generally not productive since packing that cannot be adjusted to an acceptable leakage rate should be replaced To adjust the packing remove the compressor nameplate tighten the packing adjusting nut s 1 4 turn with the wrench supplied then run the compressor a few minutes to reseat the packing If the leakage is still unacceptable tighten the adjusting nut as necessary 1 4 turn at a time do not over tighten If the adjusting nut can be tightened until the packing spring is solid the packing should be replaced If packing will not seal carefully inspect piston rods for possible scoring Replace if needed Reattach the compressor after adjustments or repairs are made nameplate 5 6 BEARING REPLACEMENT To replace the crankcase roller bearings wrist pin bushing and connecting rod bearings begin by removing the head cylinder piston crosshead guide and crosshead Drain the crankcase and remove the inspection plates Loosen and remove the connecting rod bolts in order to remove the crosshead connecting rod assembly 5 6 1 WRIST PIN BUSHING REPLACEMENT To replace the wrist pin bushing remove the retainer rings that position the wrist pin in
39. c pressure at a suitable location or to a low pressure flare D191B D390B WD391B D590B WD590B Inlet pressure limited vacuum to 25 psia or distance piece pressure greater than Inlet pressure General gas transfer Pressurized via an or evacuation external gas source to a pressure above interstage pressure Or tubed to second stage inlet D91B 0191 D290B D291B D390E WD391E D490B D491B D590E WD590E D690B D691B WD690B Inlet pressure 3 psia to 25 psia General gas transfer Pressurized via an Pipe to drain or vent or evacuation external gas source to a with a shut off valve pressure above discharge Distance piece must be pressure Or tubed to drained weekly to compressor discharge prevent an accumulation of oil or condensate D91D D191D D290D D291D D390D WD391D D490D D491D D590D WD590D D690D D691D WD690D Inlet pressure 15 psia to 50 psia T91G T191 291G T391 491G A A A 7 Lea lt lt LL ke Vy 42222 SS SSS SNS N 5 N 7 0 55 2 A 46 Gas Compressors Oxygen transfer None Distance None piece milled open General gas transfer all distance piece Openings are plugged to allow d pieces to reach their own pressure level Optional con
40. c unloader Specification 7 or 78 see Figure 3 4A the oil pressure must be maintained at a minimum of 25 psi 2 7 Bars The oil pressure is regulated by a spring loaded relief valve mounted on the bearing housing opposite the flywheel As shown in Figure 3 3A turn the adjusting screw clockwise to increase the oil pressure counterclockwise to lower it Be sure to loosen the adjusting screw lock nut before trying it after any adjustment 3 4 ADJUSTMENT OF MECHANICAL UNLOADER CONTROLS NOTE If your compressor is not equipped with mechanical unloader control valve unloader Spec 7 78 and 9 see Appendix A to determine if this applies to your machine proceed to Section 3 5 See Section 1 7 for explanation of how suction valve unloaders work TUBING INSTALLATION FOR CONSTANT SPEED UNLOADING SYSTEM SPEC 8 PILOT VALVE DIFFERENTIAL LOCKNUT OIFFERENTIAL ADJUSTING SCREW PRESSURE LOCKNUT PRESSURE ADJUSTING SCREW WING NUT VALVE UNLOADERS CONNECT TO RECEIVER WITH 3 8 O D MINIMUM TUBING FIGURE 3 4B CONSTANT SPEED Red Spring 30 70 psi VALVE UNLOADER SPEC 8 Lt Yellow Spring 71 150 psi Lt Green Spring 151 500 psi The unloading pressure is adjustable and is regu lated by the pressure adjusting screw turn clock wise to increase and counterclockwise to decrease Tighten lock nut after adjusting The differential difference between unloading and loading pressure is modified by using the differential a
41. crankcase or Repl ioht fi tight onl lubricator sump Typically a 5 to 10 gallon tank 5 signi domme fingertignt ony mounted above the lubricator as shown Figure 7 Connect tubing between top of sight dome AARONO KS well and external supply tank The best type of lubricant will vary from application to 8 Remove discharge tubing from filter application depending on the gas and the compressor discharge temperature Corken recommends that 9 Prime by manually pumping plunger in front of users consult a reputable supplier of industrial sight dome until air bubbles are purged and oil lubricants for selection of the cylinder lubricant is clear Before starting up the compressor the cylinder 10 Reconnect discharge tubing to filter lubrication system must be primed to prevent the system from air locking Procedures for priming 11 Operate compressor manually to check the lubricator stroke alignment and operation 1 Cheek inet all tubing 8 Mae kinke 12 Precautions taken at this time will eliminate the Replacement tubing should be clean and the ends free of burrs 2 Fill reservoir with oil possibility of malfunction and prevent damage to your lubricator or equipment Gas Compressors 19 FLOW ADJUSTMENT The lubricator may be adjusted to provide a delivery of 0 to 3 4 drops per stroke of the lubricator plunger The lubrication rate may be approximated as follows Sizes 190 to 491 Compressor RPM X 0063
42. d voltage at motor junction box not at the starter Verify proper lube rate lubed units only Test each shut down device and record set points Test all relief valves and unloaders dump valves Check and record all temperatures pressures and volumes after 30 minutes and 1 hour After 1 hour of running time tighten all head bolts valve hold down bolts and baseplate bolts 4 ROUTINE MAINTENANCE CHART ITEM TO CHECK Monthly Six Months X Crankcase oil pressure Compressor discharge pressure Overall visual check Crankcase oil level Drain moisture from accumulation points Drain distance piece Clean cooling surfaces on compressor and intercooler Lubricator supply tank level Check belts for correct tension Inspect and clean filter felts on control pilot Valve Spec 78 8 Inspect and clean filter felts on crankcase hydraulic unloader Valve Spec 7 78 Inspect valve assemblies Lubricate motor bearings in accordance with manufacturer s recommendations Inspect motor starter contact points Inspect piston rings Piston ring life varies greatly depending on application gas and operating pressures Consult factory for additional recommendations for your specific applications Change oil and filter every 1000 hours of operation or every 3 months whichever occurs first If the oil is unusually dirty or contaminated by th
43. djusting screw Increase by turning clockwise decrease by turning counterclockwise After changing tighten lock nut The pilot valve is fitted with different springs for different pressure ranges COMBINATION CONTROL VALVE UNLOADER SPEC 78 Operation of the combination control system is maintained by the control valve shown in Figure 3 4C When the valve is closed the unit will operate as a loadless start unit as described above If the valve is open operation will be constant speed set the pilot valve as described above to a lower cut out pressure than your pressure switch TUBING INSTALLATION FOR COMBINATION CHECK VALVE PILOT VALVE HYDRAULIC UNLOADER lf an SUCTION VALVE UNLOADERS AoA A A CONTROL VALVE OPEN CONSTANT SPEED PILOT OPERATION CLOSED AUTOMATIC LOADLESS START START STOP OPERATION CONNECT TO THE RECEIVER AND AUTOMATIC PRESSURE SWITCH WITH 3 8 O D MINIMUM TUBING FIGURE 3 4C Gas Compressors 23 3 5 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 10 11 12 13 14 15 16 24 Become familiar with the function of all piping associated with the compressor Know each line s use Verify that actual operating conditions will match anticipated conditions Ensure that line pressures are withi
44. e might be utilized If you design a special purge system for your compressor remember that the higher pressure and the packing spring must be on the open end of the V to ensure good sealing HIGHLY CORROSIVE GASES The compressor should be blocked from the system via valves on the suction and discharge piping then purged with dry inert gas before being shut down Experience has proven this significantly lowers corrosion damage to the machine 2 11 RELIEF VALVES Any line leading to or from the compressor that can be blocked by a valve or other restrictive device must be equipped with a relief valve The relief valve should be able to relieve a volume of gas higher than the piston displacement of the compressor Relief valves should be made of materials compatible with the gas being compressed For compressors handling toxic or flammable gases the relief valves should be piped to an area where it is safe to release gas AFTERCOOLER 2220 5 9 5 y CYLINDER LUBRICANT Fn SUPPLY TANK COMPRESSOR SUCTION SCRUBBER CONTROL PANEL CYLINDER LUBRICATOR PUMP FIGURE 2 10A 2 12 CYLINDER LUBRICATOR 3 If oil is visible in sight dome go to Step 7 Lubricated Models Only 4 Remove sight dome The lubricator on lubricated Corken compressors 5 Fill pump must be supplied with oil from an external supply tank NOT from the compressor
45. e process gas change it as often as needed to maintain a clean oil condition Gas Compressors 25 COMPRESSOR SIZES 91 191 291 SUCTION SPEC 7 78 8 9 SUCTION SPEC 3 4 DISCHARGE ALL SPECS UNLOADER 7 VANE CAP O RINGS a UNLOADER PISTON b CORKEN WRENCH HOLDDOWN SCREW SZ ACTUATOR i 1 SPRING dD lt D w VALVE ASSEMBLY 2 O 2 GASKET Oo 1 HEAD HEAD HEAD NOTES a Older units may have a metal gasket instead of the O Ring b If the unloader is disassembled or new seals are required 1 Replace the seals in proper orientation see detail 2 Apply Loctite 290 to the screw threads when assembling the unloader piston FIGURE 5 1A 5 1 VALVES CAUTION Always relieve pressure in the unit before attempting any repairs Low capacity overheating noise and vibration are all indications of possible valve failure Because valve problems can manifest themselves in so many different forms valve inspection is frequently the best first step in troubleshooting poor performance 26 Gas Compressors To remove and inspect valves begin by depressurizing and purging if necessary the unit Next remove the valve cap or unloader assembly and then remove the valve holddown screw see Figure 5 1 Athrough 5 1 C with the special wrench supplied with the compressor Valves in sizes 91 through 291 may then be removed Sizes 391 through 691 require removal of the v
46. e severity of the problem The compressor must not support any significant piping weight The piping must properly supported The use of flexible connections at the compressor is highly recommended Rigid unsupported piping combined with a poor foundation will result in severe vibration problems Corken baseplates come with anchor bolt mounting holes Use all mounting holes when installing baseplates If you have any questions about the compressor foundation for your installation please feel free to contact Corken APPENDIX H Do not suspend baseplate with spacers shims allowing Support entire length of base to slab Some shims may be support only at the anchor bolts required on an unlevel slab Lead anchors will not hold If anchors must be used Permanent anchor bolts imbedded in concrete slab is a very permanently they should be the type with good installation method Grouting the baseplate to the a steel stud and sleeve slab is highly recommended Anchors or lags with a shallow mounting will pull loose Be If the existing floor is too weak to support compressor sure the existing floor is solid Special consideration mounting cut out existing floor and mount a separate foun should be given to units on suspended floors dation directly on the ground Gas Compressors 49 APPENDIX 7 8 YES Rubber mounts pads are generally not recommended NOTE A special rigid baseplate is required on this mount
47. ekly Inspect and lubricate Tighten packing Replace Add oil See oil pressure adjustment Check line voltage with motor nameplate Consult power company Check wiring diagram Replace with correct size Voltage phase and frequency must coincide with motor nameplate Consult with power company Check and replace according to manufacturer s instructions Reduce speed See driver installation Lubricate according to manufacturer s instructions Interstage pressure is too low 1 First stage valves may be broken or leaking 2 First stage piston rings may be worn Another cause of high interstage pressure is a low compression ratio Two stage machines should not be used in applications where the compression ratio is below 5 To use two stage compressors in this kind of situation results in rapid ring wear machine imbalance and excessive horsepower If you think you have a problem in this area consult the factory Gas Compressors 47 APPENDIX H Corken Vertical Compressors are similar in many ways to the small vertical lubricated compressors that have been used for years However Corken Oil Free Compressors are by design much taller than most other compressor types This also means that the vertical center of gravity is considerably higher These factors amplify the magnitude of any vibration present and must be considered when selecting a mounting location for your compressor Corken recommends that all installatio
48. essor to the tank car or other unloading container should be buried or insulated to prevent the loss of heat 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 also 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 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 38 Gas Compressors trucks and some new ones are not originally equipped with vapor excess flow valves large enough to do a good job 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 oilen 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 should 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 discha
49. essure switches pressure switches high temperature switches water control solenoid etc The wiring diagram also shows how to wire 3 way solenoid valve controls on compressors with Spec 9 unloader systems 16 Gas Compressors He SC MOMENTARY START 2 SWITCH gt 15 ee 33371 X LOW OIL PRESSURE SWITCH 5 Starter coil and two contacts SC 5 CR Control relay and two contacts and CR gt HT High temperature switch Additional two line devices may be placed in series with HT These devices cause complete shutdown with no automatic restart PS Pressure switch Additional two line control devices may be placed in series with PS4 These devices can both stop and start the unit A pressure switch for start stop control would be placed here PS Pressure switch to affect constant speed unloading via the 9 three way solenoid valve and the Spec 9 suction valve unloaders Other two line control devices can be placed in series with 5 Example Machine is required to unload on either low inlet pressure or high discharge pressure 9 Three way solenoid valve used to control suction valve unloaders When energized unit is unloaded 3371 X Corken low oil pressure switch with built in 30 second time delay NEMA7 ULL listed LOP LOP Low oil pressure switch in 3371 X WS Two way solenoid to control coolant flow to compressor and or heat exchange
50. heel from the crankshaft then remove the bearing carrier and crankshaft from the crankcase If corrosion or pitting is present replace the roller bearing When replacing roller bearings always replace the entire bearing not just the cup or the cone To replace the bearings press the cups out of the crankcase and bearing carrier and press the cones off the crankshaft Press the new bearings into position and reassemble the crankshaft and bearing carrier to the crankcase When reinstalling the BEARING CARRIER REPLACEMENT ALIGN PIN WITH SLOT BEARING CARRIER OIL PASSAGE HOLE FIGURE 5 6 3A I SHIM BEARING COVER INSIDE OF BEARING CARRIER OIL PASSAGE HOLE Gas Compressors 31 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 To check the crankshaft end play first remove the oil pump see Section 5 7 Press the end of shaft towards the crankcase if a clicking noise or motion is detected the crankshaft has too much end play To reduce end play remove the bearing cover and remove a thin shim Recheck the end play after replacing the bearing cover When there is no detectable end play the shaft must still be able to rotate freely If the shaft sticks binds or becomes abnormally warm the crankshaft bearings are too
51. inders may also be protected with a vapor phase inhibitor silica gel or dry nitrogen gas If silica gel is used hang a tag on the unit indicating that it must be removed before a start up Store in a dry area off the ground if possible Rotate the flywheel every two weeks if possible Gas Compressors 33 7 INSTALLATION LIQUEFIED GAS TRANSFER COMPRESSORS 7 1 STATIONARY COMPRESSORS Corken supplies its single stage compressors in the 107 Style mounting for the transfer of liquefied gases Figure 7 1A The compressor suction and discharge are connected through a four way valve When the four way valve is in position one Figure 7 1B the compressor can be used to create a differential pressure between the vapor spaces of two tanks of liquid This induces a liquid flow through a separate liquid line to unload one tank into the other In position two Figure 7 1C vapor can be evacuated from one tank to the other note that the liquid line should be shut off in position 2 The vapor is discharged to the storage tank in the liquid phase to recondense the vapor to liquid See Corken publication CP226 Guide to Corken Liquefied Gas Transfer Equipment for more information 107 STYLE COMPRESSOR MOUNTING RELIEF VALVE AN APPROPRIATE RELIEF VALVE MUST BE INSTALLED BEFORE STARTING THE COMPRESSOR FIGURE 7 1A 34 Gas Compressors POSITION 1 COMPRESSOR INCREASES VAPOR LINES PRESSURE IN TAN
52. ined The primary causes of damage to cylinders and heads are corrosion and the entry of solid debris or liquid into the compression chamber Improper storage can also result in corrosion damage to the head and cylinder for proper storage instructions see Section 5 8 If the cylinder does become damaged or corroded use a hone to smooth the cylinder bore then polish it to the value shown in Appendix E If more than 005 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 head and cylinder While the compressor is disassembled take special care to avoid damage or corrosion to the head and cylinder If the compressor will be left open for more than a few hours coat bare metal surfaces with rust preventative When reassembling the compressor make sure the bolts are retightened as shown in Appendix D 5 3 PISTON RINGS AND PISTON RING EXPANDERS Piston ring life will vary considerably from application to application Ring life will improve dramatically at lower speeds and temperatures or lubricated service To replace the piston rings Depressurize the compressor and purge if necessary Remove the head to gain access to the compressor cylinder Loosen the piston head bolts Remove the piston as FIGURE 5 3A shown in Figure 5 3A by pinching two l
53. ing Installing mounts at the compressor s center of gravity is effective on smaller units models 90 490 If skid mounting do not mount the compressor assembly Do not mount the compressor assembly across beams on shallow beams or angle iron without center support 11 YES 12 YES Mount the baseplate so that the beam or channel provides The compressor must not support any significant piping support along the entire length of the baseplate NOTE weight The piping must be properly supported The use of Crossbeams should be full depth of main beams The flexible connections at the compressor is highly recom baseplate is normally welded to the skid directly over the mended Rigid unsupported piping combined with a poor vertical web of the support beam foundation will result in severe vibration problems 50 Gas Compressors Solutions beyond products CORKEN 3805 N W 36th St Oklahoma City OK 73112 Phone 405 946 5576 Fax 405 948 7343 E mail corken corken com Web address www corken com Printed in U S A June 2011
54. iston 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 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 Before you contact the factory note the Model Number and Serial Number of your pump The Serial Number directs us to a file containing all information on material specifications and test data applying to your specific pump When ordering parts the Corken Service Manual should be consulted for the proper Part Numbers ALWAYS INCLUDE THE MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS The Model and Serial Numbers are shown on the nameplate of the unit Record this information for future reference Model No Serial No Date
55. n 2 he lee OY Jb ss ele de aes Phage 32 6 EXTENDED STORAGE PROCEDURES PAGE 33 7 INSTALLATION OF LIQUID GAS TRANSFER COMPRESSORS PAGE 34 95 2 eee ee eee ee EE ee ee Oe ae eee 34 Truck Mounted Compressors 38 APPENDIX A Model Number and Mounting Identification 40 B Material Specifications wed a eel ae ede tease Sg eee ae 41 Mechanical Specifications 42 Dz Bot TOrqQue Vales a ich ct i ee i 43 Clearance and 45 F Purging Drawing and Rod 46 Compressor Trouble 0 47 Compressor 48 HOW YOUR CORKEN COMPRESSOR WORKS CROSS SECTION OF A TYPICAL CORKEN OIL FREE VERTICAL COMPRESSOR UNLOADER ASSEMBLY OPTIONAL SUCTION VALVE ASSEMBLY PI
56. n be provided with a concrete pad or sturdy structural steel mounting base Most Corken units do fine with the baseplate mounted directly to a solid reinforced concrete slab Special attention should be given to the large vertical compressors models 590 690 791 and 891 These units require very firm foundations due to their vertical height The HG 600 series is a horizontal balanced opposed unit but we suggest that the same foundation guidelines be followed Generally speaking the larger the foundation the less likely you are to have vibration or shaking problems 48 Gas Compressors Permanent anchor bolts or J bolts embedded in the foundation will usually provide excellent stability Grouting the baseplate into your foundation and checking the mounting bolts for tightness at frequent intervals is highly recommended As a rule of thumb when preparing the foundation the mounting slab should be a minimum of 8 inches thick with the overall length and width 4 inches longer and wider on each side of the baseplate The following illustrations show some basic guidelines to follow The mounting variations shown are guidelines only properly engineered foundation should be installed before putting your new compressors into service A special baseplate is required on some of the illustrations IMPORTANT Any proposed isolation mounting arrangement must be properly engineered Failure to do so will most likely increase th
57. n cylinder pressure ratings Clean out all piping Check that distance piece vents are tubed or plugged as desired 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 Check crankcase oil level and all other fluid levels lubricator radiator oil reservoirs etc 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 with air before pressurizing with gas Gas Compressors 17 18 19 20 Carefully check for any loose connections or bolts Remove all stray objects rags tools etc from vicinity of unit Verify that all valves are open or closed as required Double check all of the above AFTER STARTING THE COMPRESSOR 1 10 Verify and note proper oil pressure Shut down and correct any problem immediately Observe noise and vibration levels Correct immediately if excessive Verify proper compressor speed Examine entire system for gas oil or water leaks Note rotation direction Check start up voltage drop running amperage an
58. nect any of the d piece Openings to an atmospheric vent at an appropriate location or low pressure flare Lowered piece purge should be an inert gas at a pressure slightly greater than compressor suction pressure The top d piece pressure is maintained by a needle valve or regulator at a pressure lower than the compressor suction pressure 4 LL 2 ol WO GAS IN 25595 NEEDLE VALVEOR TO DRAIN REGULATOR APPENDIX COMPRESSOR TROUBLE SHOOTING GENERAL In most cases problems with your Corken Gas Compressor can be solved quite simply This chart lists some of the more frequent problems that occur with reciprocating 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 PROBLEM Low capacity Overheating Knocks rattles and noise Oil in cylinder Abnormal piston ring wear Product leaking through crankcase breather Product leakage Oil leakage around compressor base No oil pressure Excessive vibration Motor overheating or starter tripping out POSSIBLE CAUSE 1 2 3 4 17 1 2 3 5 6 11 16 1 7 9 10 11 15 8 12 15 1 3 5 6 11 15 16 8 15 4 8 15 17 18 19 20 21 1 7 9 10 11 13 14 29 22 23 24 25 26 27 28 29 REF POSSIBLE CAUSES Valves broken stuck or leaking Piston ring worn Inlet
59. o distance piece are not suitable for indoor use with flammable or toxic gases 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 thick with a 2 skirt around the circumference of the baseplate The baseplate should be securely anchored into the foundation by 1 2 J bolts 12 long 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 grout the volume beneath the channel iron baseplate to prevent flexing of the top portion of 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 the 691 107 cut a 3 inch hole in the baseplate to fill the middle section of the channel iron base with grout See additional foundation design aids in Appendix H 2 3 PIPING Proper piping design and installation is as important as the foundation to smooth operation of the compressor Improper piping installation will result in undesirable transmission of compressor vibration to the piping 12 Gas Compressors RECOMMENDED FOUNDATION DETAILS FOR CORKEN COMPRESSORS 91 691 HEX NUT COMPRESSOR BASEPLATE 2 MIN ALLSIDES WASHE
60. oose bolts together 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 E Rings should be replaced if they are near the minimum listed in Appendix E 5 4 PISTONS To replace the pistons Depressurize the compressor and purge if necessary Remove the compressor cylinder 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 needle nose pliers The castellated nut may now 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 Note On model 151 Stage 2 use compressor wrench to remove piston from rod No piston nut roll pin or bolts are required Apply loctite to piston rod threads prior to re assembly PISTON CROSS SECTION SIZES 91 THROUGH 491 CASTELLATED PISTON NUT PISTON RING EXPANDER PISTON RING ROLL PISTON PISTON CLEARANCE ZAIN Y 2 a PISTON HEAD PISTON CYLINDER WASHER PLATFORM SHIMS PISTON ROD FIGURE 5 4A Gas Compressors 29 PISTON CROSS SECTION SIZES 91 THROUGH 691 CASTELLATED PISTON NUT PISTON RING EXPANDER x PISTON PISTON C
61. period of time For this reason lubricated compressors are equipped with a drain cock to allow draining of the volume beneath the piston before start up 2 4 LIQUID TRAPS Compressors are designed to pressurize gas not to pump liquids Since liquids are not compressible the entry of even a small amount of liquid into the compressor can result in a highly undesirable phenomenon called liquid slugging When the compressor attempts to compress compressible fluid high impact stresses are created that will result in serious damage to the compressor Where the presence of entrained liquids in the suction gas is a possibility a liquid trap must be used to prevent the entry of liquid into the compressor MECHANICAL TRAP VACUUM BREAKER VALVE BALL FLOAT INLET DRAIN VALVE FIGURE 2 3A Corken offers three types of liquid traps for removal of entrained liquids The simplest is a mechanical float trap see Figure 2 4A As the liquid enters the trap the gas velocity is greatly reduced allowing 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 manually shut down by the operator Before restarting the compressor drain the trap and open the vacuum breaker valve to allow the float to drop back to the bottom of its holder This type of trap is only appropriate
62. r cooled Water cooled heads and cylinders are available for some applications requiring additional cooling Two stage compressors may be supplied with either air cooled or water cooled intercoolers See Sec 2 7 for more information about water cooled units 1 7 SUCTION VALVE UNLOADERS OPTIONAL Some Corken compressors are equipped with suction valve unloaders Check your model number against Appendix A to determine the valve unloader arrangement for your machine If the valve unloader number for your machine is 3 or 4 proceed to section 1 8 your machine has no unloaders The suction valve unloader is a small piston and cylinder assembly installed over the suction valve see Figure 1 1A The small piston is connected to a rod that extends into the suction valve assembly The unloader piston is depressed when gas pressurized to 40 psi or more above suction pressure is injected into the unloader cylinder In the depressed position the piston pushes the rod against the suction valve disk to hold the suction valve in an open position In this position no compression will occur even though the pistons are still moving up and down The unloaders are controlled by devices which control the flow of gas into and out of the unloader cylinder The different types of unloader controls may be summarized as follows Gas Compressors 7 LOADLESS STARTING FOR AIR OR NON CONTAMINATING OR NON HAZARDOUS GAS SUCTION VALVE UNLOADER
63. re falls below 12 psi due to oil pump failure or few oil level in crankcase High Temperature Switch shuts down unit if the normal discharge temperature is exceeded Strongly recommended for all applications Typically the set point is about 30 F 17 C above the normal discharge temperature Low Suction High Discharge Pressure shuts down unit if inlet or outlet pressures are not within preset limits Vibration Switch shuts down unit if vibration becomes excessive Recommended for units mounted on portable skids See Section 2 8 for typical wiring instructions 2 10 PURGING AND DRAINING OF DISTANCE PIECES D AND T STYLE COMPRESSORS ONLY The key to leakage control and oil free operation of Corken compressors is the distance piece Distance pieces are equipped with tapped holes to purge vent and drain see Figure 2 10A Proper connections to and from these tapped holes are essential for optimum compressor performance TYPICAL CONNECTION POINTS FOR DISTANCE PIECE VENT OR PURGE LINES NS P 55550 Ser 63 6 DISTANCE PIECE DRAIN FLYWHEEL SIDE FIGURE 2 10A Since some oil will pass the bottom packing set regular draining of the distance piece is essential to maintain oil free operation See Figure 2 10A Corken recommends draining the distance piece once a week for units in continuous duty operation In
64. rea flare or treatment facility depending on the gas and on local regulations PURGE amp BUFFER For applications with vacuum inlet pressures and or low operating pressure 200 psig or less buffering offers advantages over purge only systems For buffered systems the distance piece is pressurized ABOVE discharge pressure with a clean dry inert gas usually dry air or nitrogen The top packing set is inverted to point up For B amp E Style packing arrangements disconnect and plug lines running to the discharge of the compressor first or second stage Otherwise the purge gas will tend to leak into the compression chamber Purging buffering be accomplished by venting the distance piece to a safe release area A backpressure valve may be used to maintain proper distance piece pressure VENT Only compressors used for flammable but non toxic non corrosive gases or for indoor applications require the distance piece to be vented to an appropriate release area flare or treatment facility DOUBLE DISTANCE PIECE COMPRESSORS For highly corrosive gases such as chlorine VCM hydrogen sulfide etc Corken recommends the use of a double distance piece compressor Where purge gas is not available use the G Style packing arrangement see Appendix F If purge gas is available use the H Style arrangement 18 Gas Compressors For some applications purging systems other than the typical ones recommended her
65. rge 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 L P 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 1972 Safety Requirements for the Storage and Handling of Anhydrous Ammonia Copies of these are available from NFPA 60 Batterymarch Street Boston Mass 21100 and ANSI 1430 Broadway New York N Y 10018 Install use and maintain this equipment according to Corken instructions and all applicable federal state local laws and previously mentioned codes 7 2 TRUCK MOUNTED COMPRESSORS Corken compressors are frequently mounted on trucks to perform liquid transfer operations as described in Section 7 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 7 1 and a relief valve must be installed in the discharge piping before the first downstream shutoff valve INSIDE TRANSPORT MOUNTING z 22 FIGURE 7 2 U JOINT DRIVE FOR COMPRESSOR COMPRESSOR FLYWHEEL EXTENDED CRANKSHAFT FIGURE 7 2B
66. stalling a drain cock to the distance piece drain will help simplify draining of the distance piece Compressors with Style B or E packing arrangements see Appendix A and F will have the vent connection tubed to the discharge of the compressor s first stage Style B or second stage Style E Compressors with A Style packing arrangements are shipped with all connections plugged Compressors with D Style packing arrangements have large openings in the distance piece so the unit s distance piece is continuously vented and drained used on oxygen applications only Gas Compressors 17 Corrosive gases should be prevented from entering the crankcase since even minute amounts of leakage into the crankcase can_ seriously contaminate the crankcase oil To prevent this contamination the distance piece may be purged buffered or both purged and buffered by a dry clean non corrosive gas like air or nitrogent PURGING Purging without buffering can only be performed units with A Style packing arrangements Purge gas at a pressure fewer than the suction pressure fed into the distance piece through the purge connection and discharged from the vent Moisture and condensate can be removed from the distance piece with the purge gas by placing the vent connection at the bottom of the distance piece Leakage into the distance piece is quickly diluted by the purge gas and swept away The purge gas should be vented to a safe release a
67. t of the V grooves of the compressor and drive sheaves visual inspection with often 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 sheave when installation is complete Always check the flywheel runout before start up and readjust if it exceeds the value listed in Appendix E Bushing Diameter Bolt Torque Size In cm ft lb kg meter SF 4 625 11 7 30 4 1 E 6 0 15 2 60 8 3 J 7 25 18 4 135 18 7 Tighten the belts so 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 Gas Compressors 21 3 3 CRANKCASE OIL PRESSURE ADJUSTMENT Corken compressor Models 190 through 691 are equipped with an automatically reversible geartype oft pump If your compressor is the splash lubricated Model 91 proceed to Section 3 4 Ensure that the pumping system is primed and the oil pressure properly adjusted to assure smooth operation Before starting your compressor check and fill the compressor crankcase with the proper quantity of lubricating oil OIL PRESSURE ADJUSTMENT OIL LEVEL BAYONET FULL LOW OIL PRESSURE GAUGE OIL P
68. 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 O D OR 1 0 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 1 0 as indicated in Appendix Overboring the bushing can lead to premature failure of the wrist pin bushing Inspect the oil passage for debris clean thoroughly before proceeding Press the wrist pin back into the crosshead and reinstall retainer rings NOTE The fit between the wrist pin and bushing is tighter than on ordinary lubricated air compressors or combustion engines 5 6 2 CONNECTING ROD BEARINGS Connecting rod bearings are easily replaced after removing the semicircular inserts Make sure the indentations in the connecting rod bearing and connecting rod line up when installing the new bearings 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 D 5 6 3 ROLLER BEARINGS To inspect the roller bearings remove the flyw
69. vailable detergent oils usually may be substituted successfully 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 amp B show recommended oil viscosities and crankcase capacities ACCEPTABLE CRANKCASE OIL PRODUCTS FOR CORKEN COMPRESSORS CONSTANT WEIGHT NON DETERGENT R amp O INHIBITED OIL PRODUCT ISO SAE AMBIENT TEMP Exxon TERESSTIC 95 30 95 20 95 20 65 100 F 45 70 F 35 50 F Mobil RARUS 427 Reciprocating Compressor Oil 65 100 F 45 100 F 35 50 F DTEOil Heavy Medium Dectol R amp OOil Conoco Dectol R amp OOil 35 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 45 70 F 35 50 F FIGURE 2 6A Compressor Model Includes Standard D Styles Quarts Capacity Liters 91 0 9 0 8 290 291 191 1 5 1 4 390 W391 490 490 3 491 3 0 2 8 590 690 690 4 691 7 0 6 6 FIGURE 2 6B Gas Compressors 15 NEW OR REBUILT UNITS SHOULD BE FILLED WITH OILTHROUGH THE OPENING BEHIND THE COMPRESSOR NAMEPLATE THIS PROVIDES EXCELLENT LUBRICATION FOR THE CROSSHEADS INITIAL STARTUP SEE F
70. yle units ensures that no part of the rod which travels into the crankcase enters the cylinder The distance pieces may be vented or purged with an inert gas The orientation of the packing varies with the application See Sec 2 10 and Appendix F for more details GAS FLOWS DOWN FROM CYLINDER PISTON RING GROOVE GAS PRESSURE FORCES RING AGAINST WALL CYLINDER WALL PISTON RING EXPANDER PISTON RING FIGURE 1 4A 1 4 PISTON PISTON RINGS 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 service Piston ring expanders are placed behind the rings to ensure that piston rings seal tightly against the cylinder wall see Figure 1 4A LIQUID RELIEF m VALVEHOUSING _ LIQUID RELIEF 5 VALVE SPRING LIQUID ice E VALVE BALL 0 SEAT_ A XQ SPRING WASHER SPACER DIRECTION OF GAS FLOW SPRING WASHER 227 BUMPER FIGURE 1 5A 1 5 VALVES The typical Corken compressor valve consists of a seat bumper spring and valve disk as shown in Figure 1 5A Special heat treated alloys prolong the 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 The discharge valve is an inverted version of the suction valve 1 6 COOLING Most Corken compressor models are ai

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