Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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FOR MODELS: JGZ AND JGU SECTION 5 - MAINTENANCE can make a seal that takes some time to vent. If gas is trapped behind the piston, the VVCP can be adjusted when the cylinder is pressurized, but difficult to turn when cylinder is vented. This problem is corrected by disassembling the VVCP and cleaning. To adjust volume, loosen stem locking handle (or locknut), so that stem is free to turn. Turn stem by use of adjusting handle on outboard end of shaft (or wrench flats). Turn clockwise to load; counterclockwise to unload the compressor cylinder. See the VVCP instruction plate on the equipment for the dimensional positions for fully closed (load) and fully open (unload). Reference Section 1 for an illustration. Re-tighten stem locking handle (or locknut) to hold stem in place. Compressor Cylinder Re-Boring and Bore Reconditioning Guidelines Cylinder Re-Boring If the cylinder bore surface is blemished, gouged, or more than 0.001 inches per inch of cylinder bore diameter (0.001 mm/mm) out of round or tapered, or if it affects efficiency or causes rapid ring wear, replace the cylinder body or restore the bore to the guidelines below. 1. A cylinder requires counterbores to allow ring over-travel, else future wear makes piston removal very difficult. Ariel compressor cylinders ship with counterbores 0.050 inches (1.27 mm) larger than the nominal cylinder bore. The maximum over-bore on an Ariel cylinder bore diameter is 0.044 inches (1.12 mm) larger than nominal, provided the new main bore is concentric with both counterbores, leaving 0.003 inches (0.08 mm) minimum steps to the counterbores. 2. Cylinder bore diameters more than 0.020 inches (0.51 mm) larger than nominal may require a special oversize wear band and/or sealing rings, depending on pressures and gas conditions. This applies more to light gases, such as Hydrogen. Ariel offers no oversize wear bands or piston rings. See Ariel Technical Manual, Section 1 for maximum ring end gaps. 3. In a given cylinder class, a qualified machine shop can re-machine a smaller bore cylinder to the larger bore diameter and counterbores. It requires a new piston, piston rings, wear band (if applicable), cylinder data tag, and hydro-testing. Re-boring may expose internal casting shrinkage, which renders the cylinder body unusable. CAUTION: Any counterbore re-machining to restore the bore of a smaller bore cylinder of a given class requires a qualified facility to hydro-test the cylinder body. Test at 1.5 times the cylinder data plate MAWP rating before returning the cylinder to service. 4. Cylinder design is based on wall thickness at the counterbores of the larger cylinder bore for any given cylinder class. Therefore, the larger bore cylinder counterbores of a cylinder class cannot be machined larger. In this case, either replace or recondition the cylinder. Reconditioning may include aftermarket application of metal spray. Ariel does not provide this service. See "Cylinder Bore Reconditioning by Thermal Spraying" below for additional information. 5. Cylinder re-boring removes the nitrided layer (if applicable) that extends bore service life. The user should determine the cylinder bore hardness required for the application. To 7/09 PAGE 5 - 63
FOR MODELS: JGZ AND JGU SECTION 5 - MAINTENANCE maintain OEM hardness level, harden re-machined iron bore surfaces after finish machining by nitriding or other process that does not cause bore distortion detrimental to compressor operation. Consider resulting bore hardness when metal spraying. Contact Ariel for assistance on cylinder bore hardness requirements. 6. Qualified suppliers must perform cylinder re-boring and bore restoration. Consider resulting bore diameters, geometry, surface hardness and finish - contact Ariel for applicable dimensions and tolerances to help determine inspection limits and ensure a mechanically sound product. Cylinder Bore Reconditioning by Thermal Spraying The four primary thermal spray processes to build up metal surfaces are listed below in order from least strength and most porosity to most strength and least porosity: 1. Powder feed through an oxygen/fuel gas flame (flame powder). 2. Wire feed through an oxygen/fuel gas flame (flame wire). 3. Two consumable wires that form an arc (wire arc). 4. Powder feed into a plasma, an inert gas passed through a DC arc (plasma). Solid or powder feedstock Electric or gas heat source melts material Molten particles are accelerated Particles impact substrate and flatten FIGURE 5-51 THERMAL SPRAYING Oxide Inclusions Cleaned and roughened substrate Finished Coating Below are questions to consider before hiring a subcontractor to perform this work. For more information, call Ariel Technical Services. 1. Thermal spray process used. Some equipment can be used only in larger bores. 2. Shop experience in thermal spraying inside diameters. 3. Consistent 90° spray angle to the surface. 4. Substrate preparation. a. Contaminate removal. b. Grit quality and cleanliness, if grit blasted. c. Areas masked from the spray pattern, if machine anchored spray. 5. Strength of bond coat for process used, if applicable (use strongest). 6. Top coat wear qualities, corrosion resistance, and machinablility to a good finish. Re-bore cylinder to OEM dimensions. Ariel designates cylinder bore sizes with a whole number or a whole number and fraction in inches. The whole number and fraction converted PAGE 5 - 64 7/09
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Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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