Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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FOR MODELS: JGZ AND JGU SECTION 4 LUBRICATION Oil Sampling Oil samples should be collected on a regular basis and analyzed to verify suitability of oil for continued service. Consistent oil analysis can identify when to change the oil on the basis of need rather than on a scheduled interval. Depending on the service, the length of time between oil changes can be significantly extended through oil analysis. Oil analysis should include: • Viscosity testing should be performed at 100°F (40°C) and 212°F (100°C). This is to be sure that the oil has not mixed with cylinder oils or process gas. • Particle counting to the latest version of ISO 4406. • Spectroscopy to determine wear metals, contaminants, and additives. • FTIR (Fourier Transform Infrared Spectroscopy) to check for oxidation, water or coolant contamination, and additive depletion. This is more important if a separate lube oil is used for the force feed system. Oil System Cleanliness The compressor frame oil piping system and components are to be free of foreign matter including, but not limited to dirt, sand, rust, mill scale, metal chips, weld spatter, grease and paint. It is recommended that a commercial pipe cleaning service be used to clean the oil piping system. If that is not practical, proper cleaning procedures using cleaners, acids, and/or mechanical cleaning are to be used to meet the cleanliness requirements. Cleaning by-products are to be properly disposed; a disposal service is recommended. It is also recommended that all oilpiping systems be flushed using an electric or pneumatic driven pump and filtered clean production oil. All compressor frame cavities are thoroughly cleaned prior to assembly and compressors are test run with a filtered closed loop lube system at the <strong>Ariel</strong> factory. NOTE: ARIEL RECOMMENDS THAT THE LUBE OIL PIPING DOWNSTREAM OF THE INSTALLED OIL FILTER NOT BE DISTURBED AS CONTAMINANTS THAT ENTER THAT PIPING OR OPEN PORTS WILL BE FLUSHED INTO THE BEAR- INGS CAUSING CATASTROPHIC DAMAGE. IF THE PIPING MUST BE REMOVED OR ALTERED, GREAT CARE MUST BE TAKEN TO COVER THE INLETS TO THE OIL GALLERY, THE ENDS OF THE PIPING, AND THE FILTER OUTLET SO THAT NO CONTAMINANTS MAY ENTER. BEFORE REINSTALLA- TION, CHEMICAL AND MECHANICAL CLEANING IS REQUIRED. THE PIPE MUST THEN BE FLUSHED IN ACCORDANCE WITH ARIEL’S STATED CLEANLI- NESS REQUIREMENTS. For all compressors that are installed with an electric or pneumatic powered pre-lube pump, which have less than 50 feet (15 m) of oil piping are to be flushed as follows, prior to starting the compressor. The cooler oil passages are to be included in the flushing loop. Oil systems for compressors without an electric or pneumatic powered pre-lube pump, which have less than 50 feet (15 m) of oil piping, must be clean and while oil flushing is desirable for these systems, it is not a requirement. Prior to assembling the lube oil piping remove scale, weld slag, rust and any other matter that could contaminate the lube oil. Confirm: • The entire lube oil system is complete and closed. • The crankcase is filled to the correct level with the appropriate oil. 7/09 PAGE 4 - 15
FOR MODELS: JGZ AND JGU SECTION 4 LUBRICATION • The proper lube oil filters are installed correctly. • The oil pressure transducer or gauge, oil filter differential-pressure transducers or gauges, and oil temperature RTD or indicator are operational & values are viewable. Start the pre-lube pump, record the oil pressure, oil filter differential-pressure and oil temperature. Minimum measured oil pressure should be 30 psig (2.1 bar g ) for effective flushing. Do not exceed 90 psig (6.2 bar g ). A continuous hour of pre-lube flushing time must be achieved with an oil filter differential-pressure increase less than 10% of the measured oil pressure into the filter. Record the oil pressure, oil filter differential pressure and oil temperature at 15 minute intervals. If the oil temperature increase is greater than 10°F (5.5°C) during an hour of flush time, it is not a valid test of system cleanliness, due to oil viscosity change. If the differential pressure or temperature increases exceed the limits in the paragraph above, after an hour of pre-lube flushing, continue the flushing operation. Whenever the lube oil filter differential pressure exceeds the change filter limits, stop the pre-lube pump and change the oil filter. Re-set time and continue the flushing operation until a continuous hour of flushing time is achieved within the differential pressure and temperature increase limits to ensure system cleanliness. For all compressors with an oil piping system greater than 50 feet (15 m), cleaning and flushing must result in a cleanliness level to ISO-4406, Grade 13/10/9, and/or NAS- 1638, Class 5 (see table), prior to starting the compressor. See ISO-4406 "International Standard - Hydraulic fluid power - Fluids - Method for coding level of contamination by solid particles" and/or NAS-1638 "National Aerospace Standard, Aerospace Industries Association of America, Inc. - Cleanliness Requirements for Parts Used in Hydraulic Systems" for complete information. Utilize a competent oil laboratory for testing. Cylinder and Packing Lubrication Common Oil Supply TABLE 4-4 OIL FLUSHING CLEANLINESS ISO-4406 GRADE 13/10/9; 1 mL Oil Sample Requirements Particle Size µm No. Particles Allowed /13 Greater than 4 40 to 80 /10 Greater than 6 5 to 10 /9 Greater than 14 2.5 to 5 NAS-1638 GRADE 5; 100mL Oil Sample Particle Size Range µm Maximum Number Particles 5 to 15 8,000 15 to 25 1,424 25 to 50 253 50 to 100 45 over 100 8 When process gas composition and cylinder operating conditions allow compressor frame lubricating oil to be used for cylinder and packing lubrication, the resulting force feed lube systems are installed as shown in Figure 4-5. PAGE 4 - 16 7/09
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Heavy Duty Balanced Opposed Compressors - Ariel Corporation

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