Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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FOR MODELS: JGZ AND JGU TABLE OF CONTENTS Maximum Allowable Working Pressure ................................................................3-12 Relief Valve Settings .............................................................................................3-13 Filling Sump & Priming a Main Oil Lube Oil System - Before Starting ..................3-14 Filling The Sump ..............................................................................................3-14 Priming - Main Lube Oil System ......................................................................3-14 Compressor Prelube .............................................................................................3-14 Force Feed Lubricator Adjustment ........................................................................3-14 Compressor Re-Application ..................................................................................3-15 Lubrication ............................................................................................ 4-1 General ...................................................................................................................4-1 Lubrication Functions ..............................................................................................4-1 Lubricant Characteristics ........................................................................................4-2 Viscosity ............................................................................................................4-2 Viscosity Index ...................................................................................................4-2 Pour Point ..........................................................................................................4-3 Flash Point .........................................................................................................4-3 Lubricant Base Stock ..............................................................................................4-3 Petroleum-Based Lubricants (also referred to as mineral oils) ..........................4-3 Synthetic Lubricants ..........................................................................................4-4 Lubricant Formulations ...........................................................................................4-5 Compounded Cylinder Oils ................................................................................4-5 R&O Oil .............................................................................................................4-5 Engine Oil ..........................................................................................................4-5 Used Engine Oil .................................................................................................4-6 Gear Oil .............................................................................................................4-6 Frame Oil System Components ..............................................................................4-7 Oil Strainer .........................................................................................................4-7 Oil Pump ............................................................................................................4-7 Oil Cooler ...........................................................................................................4-7 Oil Temperature Control Valve ..........................................................................4-8 Oil Filtration .......................................................................................................4-8 Compressor Prelube Pump ...............................................................................4-9 Oil Heaters .........................................................................................................4-9 Lube Oil Analysis Sampling Point ....................................................................4-10 Cold Starting ....................................................................................................4-11 Dry Sump .........................................................................................................4-12 Frame Oil Operating Conditions ...........................................................................4-13 Compressor Frame Lubricant ..........................................................................4-13 Oil Viscosity .....................................................................................................4-14 Oil Pressure .....................................................................................................4-14 Oil Temperature ...............................................................................................4-14 Oil Maintenance ...............................................................................................4-14 Oil Sampling ....................................................................................................4-15 Oil System Cleanliness .........................................................................................4-15 Cylinder and Packing Lubrication .........................................................................4-16 Common Oil Supply .........................................................................................4-16 Independent Oil Supply ...................................................................................4-17 ii 7/09
FOR MODELS: JGZ AND JGU TABLE OF CONTENTS Gas Inlet Debris Screens to Maintain Lube Performance ............................... 4-18 Injection Oil Inlet Filter ..................................................................................... 4-18 Oil Dilution ....................................................................................................... 4-18 Cylinder Oil Lubrication Examples .................................................................. 4-18 Under/Over Lube ............................................................................................. 4-19 Inadequate Lubrication Symptoms .................................................................. 4-19 Lubrication Quantity - Paper Test Method ...................................................... 4-19 Lubricator Cycle Time ..................................................................................... 4-19 Cycle Time Indication ...................................................................................... 4-20 Force Feed Lubrication System Monitoring: ................................................... 4-20 Minimum Requirements .................................................................................. 4-20 Devices ........................................................................................................... 4-20 Choosing a Lube System Monitor ................................................................... 4-20 Break-in Rate .................................................................................................. 4-24 Liquids in Gas ................................................................................................. 4-24 Lube Type & Rate Recommendations ............................................................ 4-24 RATE CALCULATION NOTES ....................................................................... 4-26 Water-Cooled Packing .......................................................................................... 4-28 Coolant System Requirements ....................................................................... 4-29 Force Feed Lubrication System - Description ...................................................... 4-29 Force Feed Lubricator Adjustment .................................................................. 4-30 Blow-Out Fittings, Rupture Disks and Tubing ................................................. 4-31 Divider Valves ................................................................................................. 4-32 Description ...................................................................................................... 4-32 Divider Valve Block Assembly Instructions ........................................................... 4-33 Operation - (see Figure 4-3: and Figure 4-4:) ................................................. 4-33 Pressure Testing For Divider Valve By-Passing ............................................. 4-36 Electronic Lubricator Fluid-Flow Monitor/No-Flow Timer Switch - Proflo PF1 ...... 4-37 Proflo PF1 Monitor wiring identification & instructions - electronic indication: 4-38 Proflo PF1 Button Operation: .......................................................................... 4-39 Downloading Proflo PF1 Data: ........................................................................ 4-39 Proflo PF1 Setup Alarm Time and Mode: ....................................................... 4-40 Proflo PF1 Battery Replacement: .................................................................... 4-41 Proflo PF1 Display Errors: ............................................................................... 4-42 Proflo PF1 Operation Notes: ........................................................................... 4-43 Proflo Normally Open and Normally Closed Definition: .................................. 4-44 Proflo PF1 - Using Pulse Output and Alarm Circuit at Same Time: ................ 4-45 Proflo PF1 - Using PLC to Calculate Oil Consumption: .................................. 4-46 Proflo PF1 Accessories Available: .................................................................. 4-47 Protection of Electronics & the Compressor When Arc Welding .......................... 4-47 Electronic-Lubricator Digital No-Flow Timer Switch (DNFT) ................................ 4-47 Replacing the (Field-Replaceable) Battery in the DNFT: ................................ 4-48 Oil Head at Lube Points ........................................................................................ 4-49 Force Feed Lubrication System and Running Conditions .................................... 4-49 Force Feed Lubrication System ...................................................................... 4-49 Running Conditions ......................................................................................... 4-50 System Design Considerations and Operating Parameters ............................ 4-50 Force Feed Balance Valves ................................................................................. 4-50 Setting and Maintaining Balance Valves ......................................................... 4-50 7/09 iii
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Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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