Heavy Duty Balanced Opposed Compressors - Ariel Corporation
Heavy Duty Balanced Opposed Compressors - Ariel Corporation Heavy Duty Balanced Opposed Compressors - Ariel Corporation
Section 3 - Maintenance For Models: JGH:E:K:T Independent Oil Supply When given gas and pressure conditions prevent adequate frame lube oil to cylinders and packings, a separate force feed lube oil supply is required. An elevated tank supplies pressurized oil to the lubricator. To prevent compressor frame oil contamination by force feed oil, the force feed lubricator overflow drains away from the compressor frame and into an appropriate drain system. Independent force feed lube systems normally require oil with a viscosity below 5000 SUS (1100 cSt) at the lubricator pump inlet. Possible measures to ensure a force feed pump filled with oil during the suction stroke: change pipe and fitting size from tank to force feed pump, heat the oil, and pressurize the supply tank. A recommended 5 micron nominal in-line oil filter or fine screen filters oil between the supply tank and force feed lubricator pumps. 7 8 1. Oil Supply Tank 2. Oil Filter 3. System Inlet 1/4-inch NPT (Female) Customer Connection 4. Sintered Bronze Filter 5. Force Feed Lubricator Pump 6. Rupture Disk 7. Pressure Gauge 8. Divider Valves/Distribution Block 9. Fluid Flow Monitor No-Flow Timer Shutdown Switch 9 FIGURE 3-13 Force Feed Lubrication System: Independent Oil Supply Force Feed Lubrication Conditions Cylinder Lubrication Paper Test NOTE: System must provide positive pressure to force feed lubricator pump. To appropriate drain 1/4-inch NPT (female) customer connection. Do not drain to crankcase. CAUTION: To prevent personal injury, verify driver or compressor cylinder gas pressure cannot turn compressor crankshaft during maintenance: on engine-driven compressors, either remove the center coupling or lock the flywheel; on electric motor-driven compressors, either detach the driver from the compressor or lock out the driver switch gear. CAUTION: Before any maintenance or component removal, relieve all pressure from compressor cylinders. See Packager’s instructions to completely vent the system. After maintenance, purge the entire system with gas prior to operation to avoid a potentially explosive air/gas mixture. 1. Remove head end head and position piston for the desired cylinder at inner dead center. 2. Using light pressure, wipe the cylinder bore with two layers of regular unwaxed cigarette paper together. Begin at the top and wipe downward about 20° along the bore circumference. The paper against the bore surface should be stained (wetted with oil), but the second paper should not be soaked through. 3. Repeat the test at both sides of the bore at about 90° from the top, using two clean papers for PAGE 3-24 3/11 4 1 6 2 3 5
For Models: JGH:E:K:T Section 3 - Maintenance each side. Paper against the bore surface not stained through may indicate under-lubrication; both papers stained through may indicate over-lubrication. In either case, Ariel normally recommends changing lubrication rate accordingly and repeating all paper tests until passed. 4. Repeat this procedure for all cylinders. If the test indicates a lubrication rate reduction or increase for a cylinder, change in 5% increments by adjusting cycle time at the force feed lube pump (see “Force Feed Lubricator Adjustment” on page 3-15). Repeat oil film testing, for affected cylinders, after 24 hours of operation. NOTE: The paper test indicates only oil film quantity. Aftermarket devices exist that measure flow. Neither method indicates viscosity quality. Oils diluted with water, hydrocarbons, or other constituents may ostensibly produce an adequate film or flow, but dilution may reduce load-carrying capability below requirements. Under/Over Lube Under lubrication causes extremely rapid breakdown of piston and packing ring materials. Black, gummy deposits in the distance piece, packing case, cylinder, and valves indicate under lubrication. When symptoms indicate under lubrication: • Verify proper operation of force feed lubricator pumps. • Confirm distribution block cycle time matches the lube sheet or force feed lubricator data plate. • Verify all tubing and fitting tightness; check for leakage. Check fittings inside cylinder gas passages. • Pressure test or replace divider valves to ensure they do not bypass. Over lubrication can result in excessive oil carryover into the gas stream, and increased valve and gas passage deposits. Valve plate breakage and packing failure may also indicate over-lubrication. Lubricator Cycle Time Lubricant flow rates (measured in seconds per cycle) are generally so low that all required flow to a lube point may consist of a drip at a loosened supply fitting. Ariel calculates break-in and normal lube rates (cycle times) stamped on the force feed lubricator data plate to match gas and operating conditions supplied with the compressor order. The lube sheets in the Ariel Parts Book state gas conditions and list the base rate multiplier at each lube point. If gas conditions were not supplied with the compressor order, the data plate/lube sheet rates apply to clean, dry, 0.65 specific gravity, sweet gas at frame rated speed and discharge pressures. Changes in operating conditions (such as gas properties or pressures, temperatures, flow requirements, or cylinder re-configuration) require lubrication rate re-calculation and possibly force feed lubrication system alteration. Consult your Packager and/or Ariel. To set proper force feed lubricator pump flow rate, read the cycle time on the Proflo electronic lubricator fluid-flow monitor/no-flow timer switch located at the distribution block or in the control panel. For a digital no-flow timer switch (DNFT), time the cycle from flash to flash; for a magnetic cycle indicator assembly, time the cycle from initial indicator pin movement at the fully retracted position to the time when the pin returns to the fully retracted position and just begins initial movement out again. Adjust the lubricator pump to provide the required cycle time. NOTE: Do not set the force feed lubrication pump stroke too low. Pump output can become inconsistent when set too low. Break-in Rate Set the break-in cycle time about half the normal cycle time (67% max.) to increase lube rate. Maintain this break-in rate for 200 hours of operation for new equipment, or when replacing packing and/or piston rings. Contact Ariel if existing pump is incapable of minimum flow rate required. 3/11 PAGE 3-25
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Section 3 - Maintenance For Models: JGH:E:K:T<br />
Independent Oil Supply<br />
When given gas and pressure<br />
conditions prevent adequate<br />
frame lube oil to cylinders and<br />
packings, a separate force<br />
feed lube oil supply is<br />
required. An elevated tank<br />
supplies pressurized oil to the<br />
lubricator. To prevent<br />
compressor frame oil<br />
contamination by force feed<br />
oil, the force feed lubricator<br />
overflow drains away from the<br />
compressor frame and into an<br />
appropriate drain system.<br />
Independent force feed lube<br />
systems normally require oil<br />
with a viscosity below 5000<br />
SUS (1100 cSt) at the<br />
lubricator pump inlet. Possible<br />
measures to ensure a force<br />
feed pump filled with oil during<br />
the suction stroke: change<br />
pipe and fitting size from tank<br />
to force feed pump, heat the<br />
oil, and pressurize the supply<br />
tank. A recommended 5<br />
micron nominal in-line oil filter<br />
or fine screen filters oil<br />
between the supply tank and<br />
force feed lubricator pumps.<br />
7<br />
8<br />
1. Oil Supply Tank<br />
2. Oil Filter<br />
3. System Inlet 1/4-inch NPT<br />
(Female) Customer Connection<br />
4. Sintered Bronze Filter<br />
5. Force Feed Lubricator Pump<br />
6. Rupture Disk<br />
7. Pressure Gauge<br />
8. Divider Valves/Distribution Block<br />
9. Fluid Flow Monitor No-Flow<br />
Timer Shutdown Switch<br />
9<br />
FIGURE 3-13 Force Feed Lubrication<br />
System: Independent Oil Supply<br />
Force Feed Lubrication Conditions<br />
Cylinder Lubrication Paper Test<br />
NOTE: System<br />
must provide<br />
positive pressure<br />
to force feed<br />
lubricator pump.<br />
To appropriate drain 1/4-inch NPT<br />
(female) customer connection.<br />
Do not drain to crankcase.<br />
CAUTION: To prevent personal injury, verify driver or compressor cylinder gas pressure<br />
cannot turn compressor crankshaft during maintenance: on engine-driven compressors,<br />
either remove the center coupling or lock the flywheel; on electric motor-driven compressors,<br />
either detach the driver from the compressor or lock out the driver switch gear.<br />
CAUTION: Before any maintenance or component removal, relieve all pressure from<br />
compressor cylinders. See Packager’s instructions to completely vent the system. After<br />
maintenance, purge the entire system with gas prior to operation to avoid a potentially<br />
explosive air/gas mixture.<br />
1. Remove head end head and position piston for the desired cylinder at inner dead center.<br />
2. Using light pressure, wipe the cylinder bore with two layers of regular unwaxed cigarette paper<br />
together. Begin at the top and wipe downward about 20° along the bore circumference. The<br />
paper against the bore surface should be stained (wetted with oil), but the second paper should<br />
not be soaked through.<br />
3. Repeat the test at both sides of the bore at about 90° from the top, using two clean papers for<br />
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1<br />
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