Ariel JGI Technical Manual Download Page 119 | Manualshive

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background image

F

OR

M

ODELS

: JGI, JGM, JGN, JGP

AND

JGQ

S

ECTION

5 - M

AINTENANCE

PAGE 5-3

Compressor Components

Positioning a Throw for Maintenance

Compressor maintenance often requires manually turning the crankshaft to locate a particu-
lar throw in one of two positions: the inner dead center or the outer dead center. During nor-
mal operation, the crossheads slide back and forth in the crosshead guides. In the inner
dead center position, the crossheads slide in toward the crankcase as far as possible. In the
outer dead center position, the crossheads slide out away from the crank case as far as pos-
sible (see figures below). Some procedures, such as setting piston clearances, require a dial
indicator with magnetic base to locate the precise inner or outer dead center.

F

IGURE

5-1 C

OMPRESSOR

C

OMPONENTS

- T

YPICAL

JGM:N:P:Q

Compressor
Piston

Crankshaft

Connecting
Rod

Crosshead

Crosshead/Balance Nut

Eye Bolt

Lube Oil Filter

Piston Integral
w/Piston Rod

Compressor
Cylinder

Breather

FF Oil Distribution Block

Crosshead
Guide Cover

Valve Cap

VVCP

Compressor
Piston

Rod

Packing

Piston Rod

Rod

Packing

Connecting
Rod

Eye Bolt

Crosshead/

Balance Nut

VVCP

Valve Cap

Valve Cap

Valve
Cap

Compressor
Cylinder

Compressor Frame
w/Integral Crosshead
Guides

FF Oil Flow Monitoring Device

Eccentric
Chain Drive
Adjustment

Lube Oil

Pressure
Gauges

FF Blowout Disc

FF Lube Filter

FF Lubricator Box

Lube Oil
Pump

Lube Oil

Strarainer

Rod

Packing

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Summary of Contents for JGI

Page 1: ...ompressors TECHNICAL MANUAL For Models JGM JGN JGP and JGQ and JGI Vertical Non Balanced ARIEL CORPORATION 35 BLACKJACK ROAD MOUNT VERNON OHIO 43050 TELEPHONE 740 397 0311 FAX 740 397 3856 VISIT OUR W...

Page 2: ...THIS PAGE LEFT INTENTIONALLY BLANK...

Page 3: ...RESSOR CAREFULLY A GAS AIR MIXTURE UNDER PRESSURE CAN EXPLODE YOU CAN BE SEVERELY INJURED OR KILLED MAKE SURE THE COMPRESSOR IS SUFFICIENTLY PURGED OF ANY EXPLOSIVE MIXTURE BEFORE LOADING AFTER COMPLE...

Page 4: ...THIS PAGE LEFT INTENTIONALLY BLANK...

Page 5: ...its for Compressors 2 3 Aligning Main Bearing Bores 2 3 Alignment to Driver 2 6 Electrical Grounding 2 11 Pneumatically Actuated Unloaders Clearance Devices 2 11 Vents and Drains 2 11 BICERA Type Cran...

Page 6: ...s 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 1...

Page 7: ...s 4 44 Proflo PF1 Operation Notes 4 45 Proflo Normally Open and Normally Closed Definition 4 46 Proflo PF1 Using Pulse Output and Alarm Circuit at Same Time 4 47 Proflo PF1 Using PLC to Calculate Oil...

Page 8: ...gs Removal and Installation w Crankshaft Removed 5 20 Main Bearings Removal and Installation w Crankshaft In Place 5 21 Crankshaft Installation 5 22 Chain Drive System 5 23 Description 5 23 Chain Adju...

Page 9: ...Restoration Guidelines 5 46 Ethylene Glycol Contamination 5 47 Technical Assistance 6 1 Recommended Maintenance Intervals 6 1 Daily 6 1 Monthly in addition to Daily Requirements 6 2 Every 6 Months or...

Page 10: ...FOR MODELS JGI JGM JGN JGP AND JGQ TABLE OF CONTENTS vi 9 08...

Page 11: ...ion and main tenance of a JGI JGM JGN JGP or JGQ compressor If you have any questions please contact your Packager If they are unable to provide resolution they will refer your concerns to Ariel Corpo...

Page 12: ...ELS JGI JGM JGN JGP AND JGQ SECTION 1 DESIGN SPECIFICATIONS DATA PAGE 1 2 9 08 Engine Motor Drive End Throw 2 Throw 1 Frame Data Information Plate Auxiliary End JGM 2 JGN 2 JGP 2 JGQ 2 Oil Filter Brea...

Page 13: ...ed may be less resulting in a lower piston speed rating To 467 2 37 To 875 4 45 To 875 4 45 To 900 4 57 To 900 4 57 Number of Throws 1 1 2 1 2 Horsepower to hp kW 55 41 84 63 168 125 85 63 170 127 Hei...

Page 14: ...be less resulting in a lower piston speed rat ing To 875 4 45 To 875 4 45 To 900 4 57 To 900 4 57 Number of Throws 1 2 1 2 Horsepower to hp kW 126 94 252 188 140 104 280 209 Height Bottom to Crankshaf...

Page 15: ...reciprocating components must be exchanged to the opposite throw except the connecting rod assemblies Check the Balancing Record sheet and recalculate reciprocating weight differential with the connec...

Page 16: ...ATED SPEED CONSULT ARIEL TECHNICAL MANUAL BEFORE OPERATING UNIT OR PERFORMING MAINTENANCE A 14766 ARIEL LOGO NAME PLATE AND ADDRESS Aluminum Top Cover Direction of Rotation Plate Located At The Drive...

Page 17: ...ND PROPERTY DAMAGE WILL RESULT IF SUCTION AND DISCHARGE VALVES ARE NOT INSTALLED IN THEIR PROPER LOCATION CAUTION NOISE GENERATED BY RECIPROCATING MACHINERY CAN BE A SOURCE FOR HEARING INJURY SEE PACK...

Page 18: ...ouched without proper insulated protective clothing If servicing the compressor allow these surfaces to cool or warm to safe temperatures or wear protective clothing before proceeding When applied to...

Page 19: ...stamped on the end of each cylinder Customer work order number and hydrotest pressure stamped near VVCP plates on top of VVCP body Variable Volume Clearance Pocket Serial Number Base Volume in cubic...

Page 20: ...Pin to Connecting Rod Bearing Jack 1 Connecting Rod Thrust Side JGM N P Q Connecting Rod Thrust Side JGI Connecting Rod Bushing to Crosshead Pin Crosshead Bushing to Crosshead Pin JGN Q Crosshead Bron...

Page 21: ...IDE CLEARANCE INCHES mm 3 16 4 76 0 187 to 0 189 4 75 to 4 80 0 007 to 0 012 0 18 to 0 30 1 4 6 35 0 250 to 0 252 6 35 to 6 40 0 008 to 0 013 0 20 to 0 33 3 8 9 53 0 375 to 0 377 9 53 to 9 58 0 008 to...

Page 22: ...o 1 42 0 224 5 69 3 875 98 0 010 to 0 014 0 25 to 0 36 0 047 to 0 057 0 19 to 1 45 0 228 5 79 4 125 105 0 010 to 0 014 0 25 to 0 36 0 049 to 0 060 1 24 to 1 52 0 240 6 10 4 375 111 0 011 to 0 015 0 28...

Page 23: ...44 0 068 to 0 084 1 73 to 2 13 0 336 8 53 5 75 146 0 090 to 0 096 2 29 to 2 44 0 071 to 0 087 1 80 to 2 21 0 348 8 84 6 125 156 0 090 to 0 096 2 29 to 2 44 0 069 to 0 099 1 75 to 2 51 0 396 10 06 6 5...

Page 24: ...0 324 8 23 6 125 156 0 013 to 0 019 0 33 to 0 48 0 073 to 0 093 1 85 to 2 36 0 372 9 45 6 5 165 0 014 to 0 020 0 36 to 0 51 0 077 to 0 097 1 96 to 2 46 0 388 9 86 7 125 181 0 015 to 0 021 0 38 to 0 5...

Page 25: ...d 3 5 8JG CE 3 375 86 3 625 92 which use piston rider rings Piston rider rings are optional for other JG Cylinders except for 1 3 4JG FS HE which uses conventional rings and wear band PISTON TO BORE C...

Page 26: ...1 2 13 12 Point Grade 8 48 65 Crosshead Guide to Support Cap Screw 5 8 11 Hex Grade 8 or 9 90 120 Eccentric Vernier Cap Cap Screw 5 16 18 Hex Grade 8 Hand wrench Tight Idler Sprocket Through Bolt Loc...

Page 27: ...68 lb in 7 7 Distribution Block Divider Valve Screw 1 4 28 Socket Head 75 lb in 8 5 Force Feed Lubricator 1 14 Hex Jam Nut 75 100 Grade 5 Hex Cap Screw All Hex Grade 5 Hand wrench Tight a Tighten loo...

Page 28: ...arts SPL3 4 144 lb in 16 3 8 24 21 28 7 16 20 30 41 5 16 24 12 Point Steel Grade 5 Material Parts SPL5 18 24 3 8 24 32 43 7 16 20 50 68 5 16 24 12 Point Stainless Steel Grade B8M Material Parts SPL6 1...

Page 29: ...ening torque for all critical parts The exception is the crosshead balance lock nut which may be tightened using the Ariel tried and true slugging method 2 Always check to determine over what range th...

Page 30: ...roper required torque value and slowly apply a steady force until the click is felt 8 Always reset the torque wrench to its lowest setting when the job is complete If the torque wrench is left in a hi...

Page 31: ...upplied speciality companion flange bolting is designed to resist fatigue and cannot be replaced with standard cap screws If attempting to replace other bolting with standard cap screws and there is a...

Page 32: ...FOR MODELS JGI JGM JGN JGP AND JGQ SECTION 1 DESIGN SPECIFICATIONS DATA PAGE 1 22 9 08 NOTES...

Page 33: ...r lifting lugs install the lugs 4 with the proper Grade 8 cap screws and tighten to the torque value given in the Technical Manual Section 1 or the tool box torque chart the ER 63 chart is also availa...

Page 34: ...is relatively close so that the equipment movement will be minimal and within the bolting foot push pads or grout box allowance 4 Grout as required and allow grout to set With the compressor cylinder...

Page 35: ...s up to and including JGU Z 2 throw frames to be sure main bearing bores are in proper alignment except for the JGI which uses only soft foot 3 On JGU Z B V KBB V 4 throw and 6 throw frames the top pl...

Page 36: ...d and after the ini tial rough coupling alignment On KBB V 6 or other model compressors shipped disassembled the initial check can be carried out prior to the guide cylinder assemblies being installed...

Page 37: ...ess inspection outlined above 10 To check soft foot the compressor frame hold down bolting is to be properly installed and tightened Loosen each hold down bolt individually while checking the frame fo...

Page 38: ...r classes of cylinders bosses and tapped holes are provided on all K T C D Z U B V class cylinders See Ariel cylinder outline drawings for dimen sional details These supports must be adjusted and set...

Page 39: ...lose to zero as possible on the coupling hub faces and rim diameters at nor mal operating temperature Do not exceed 0 005 inches 0 13 mm on the face and rim diameter Except for coupling hubs with outs...

Page 40: ...20 6 0 005 0 13 350 9 125 23 2 0 005 0 13 375 10 063 25 6 0 005 0 13 425 11 000 27 9 0 005 0 13 450 11 875 30 2 0 005 0 13 500 13 438 34 1 0 005 0 13 550 15 000 38 1 0 005 0 13 600 16 750 42 6 0 005...

Page 41: ...he face and rim TIR at the coupling after all components are heat soaked When properly aligned the forces on the connected equipment will be at a minimum This will result in a smooth running unit and...

Page 42: ...lcu lated for the compressor Refer to the driver manufacturer s thermal growth prediction for the driver differential tempera ture increase to normal operat ing temperature When larger compressors are...

Page 43: ...ase reference this document for system design and evaluation The docu ment may be found at support vendor literature reciprocating compressors ACI on the Ariel web site www arielcorp com Vents and Dra...

Page 44: ...storage The BICERA valves are boxed and shipped sepa rately The BICERA valves are to be installed on the compressor crosshead guides just prior to startup A valve may be placed on any throw by replaci...

Page 45: ...TANCE PIECE VENTING Eye Bolt Packing Secondary Vent Packing Lubrication From Distribution Block Crosshead Guide Vented Space Metallic Gasket Piston Rod Oil Oil and Gas Gas Tube This Drain Off of Skid...

Page 46: ...GI JGM JGN JGP AND JGQ SECTION 2 INSTALLATION PAGE 2 14 9 08 Primary Vent Drain Packing Lubrication O Ring Seal Lubricating Oil Gas and Oil Gas Purge Gas Optional Secondary Vent Optional Purge Gas Con...

Page 47: ...e latest available Start Up Check List refer to ER 10 4 01 at www arielcorp com CAUTION BEFORE STARTING A NEW COMPRESSOR OR AFTER RELOCATING OR REAPPLYING A COMPRESSOR OR AFTER MAJOR OVERHAUL BE SURE...

Page 48: ...Purchase Rental Lease Unit Compressor Frame Frame Model ___________________________ Frame Serial _________________________________ Frame Lubricant Make and Grade ______________________________________...

Page 49: ...___________ Coupling Manufacturer ___________________________________ Coupling Model ___________________ Compressor Cylinders and Operating Conditions Cylinder Stage Throw Serial Bore Dia Inlet Temp I...

Page 50: ...ending or diverting blending preferred _____________ Commissioning Agent __________________ Distributor ___________ 9 Check compressor crankcase oil level controller for proper installation operation...

Page 51: ..._______ _________ NOTE Pre lube compressor before turning crank shaft Commissioning Agent __________________ Distributor ___________ 20 Measure crosshead clearances with cylinders mounted To check top...

Page 52: ..._________ 3 Verify correct inlet screen orientation in process piping Commissioning Agent __________________ Distributor ___________ 4 Check and verify vents and drains of the primary and sec ondary p...

Page 53: ...___________________ ________________________________________ ________________________________________ ________________________________________ Commissioning Agent __________________ Distributor ______...

Page 54: ...oil pressure shutdown and bearing temperature shut downs Record initial pressure at operating speed ______________________ Commissioning Agent __________________ Distributor ___________ 2 Check and v...

Page 55: ...ck verify and record tank levels that indicate the amount of liquids removed from the gas __________________________ Commissioning Agent __________________ Distributor ___________ 12 Check and verify...

Page 56: ...tle or head end cylinder supports adjust when components are heat soaked to ensure no excessive forces exist to cause detrimental cylinder deflec tion Commissioning Agent __________________ Distributo...

Page 57: ...sible types of equipment failure mal operation and the protection of piping systems Relief valves shall be set to operate at not more than the max imum allowable working pressure but not less than the...

Page 58: ...plates Reference Section 1 for data plate location and legend illustra tion Indicators on the distributor blocks show the rate at which a block is cycling To adjust loosen locknut and turn the feed r...

Page 59: ...some applications the lubricants must be different Lubrication Functions Lubrication performs at least six functions in a compressor 1 Reduce friction A lubricant decreases the resistance to movement...

Page 60: ...n base stock types Oil viscosity will increase when the oil begins to oxidize or when it is contaminated with oil or another liquid with higher viscosity Oil viscosity will decrease when it is contami...

Page 61: ...create a combustible mixture in air If exposed to flame the mixture will flash into flame and then extinguish itself This is important in high temperature applications when the oil may come in contac...

Page 62: ...ferred to as PAO Diester and PAG NOTE Most synthetic lubricants with the proper viscosity are acceptable for use in the compressor frame Check with your lubricant supplier or Ariel before using ANY lu...

Page 63: ...in steam cylinders and or compressor cylinders These lubricants enhance oil film strength to counter the effects of water wet gases sol vents etc present in the gas Additives can be animal or vegetabl...

Page 64: ...viscosity is the most important aspect of com pressor lubrication Although engine oil is generally not the best choice for compressor lubri cation operational aspects such as previous experience inven...

Page 65: ...e pump is direct coupled to the crankshaft by a chain and sprocket and is designed to provide adequate oil flow to the bearings when the compressor is operating at one half of maximum rated speed The...

Page 66: ...to mix with the hot oil from the bypass In the diverting mode the oil is diverted to the cooler when the oil from the compres sor is hot enough to open the valve The diverting mode monitors the tempe...

Page 67: ...Specification Tables for frame oil pump flow rates or see the Electronic Databook in the Ariel Perfor mance Program The purpose is to be sure there is oil flow to all bearings and bushings and the cl...

Page 68: ...of dirt or debris that can collect around the dispensing point A needle valve should be used to better control the flow of the pressurized oil TABLE 4 4 HEAT REQUIRED TO MAINTAIN MINIMUM FRAME TEMPERA...

Page 69: ...le A6 Filter Vent return Connection to the Oil Sump when applica ble on some models A7 Oil tubing connections from Frame Gallery Tube to top and bottom of the Crosshead Guides to lubricate Crossheads...

Page 70: ...a dry sump dry crankcase and separate oil reservoir See the table for lim its which are based on the angle where the crankshaft connecting rods will contact the oil level causing foaming The limits a...

Page 71: ...d Bushings A5 Pressure Regulating Valve Return Connection to Crank case when applicable on some models A6 Filter Vent Return Connection to the Crankcase when appli cable on some models A7 Oil Tubing C...

Page 72: ...SO 150 grade oil at about 25 F 4 C Oil Pressure Normal pressure on the discharge side of the lube oil filter is factory set for 60 psig 4 1 barg for compressors that were tested mechanically complete...

Page 73: ...irt 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 clea...

Page 74: ...l 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 o...

Page 75: ...nk Common Oil Supply 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...

Page 76: ...does not drain into the crankcase The lubricator box over flow tubing must be disconnected from the compressor frame and directed to an appropriate drain system Independent force feed lube systems re...

Page 77: ...l lubrication dilution saturation by the process gas stream is influenced by the following factors 1 Process gas composition Specific Gravity SG usually the higher the SG the greater the oil dilution...

Page 78: ...n circumferential motion through about 20 The paper next to the bore should be stained wetted with oil but the second paper should not be soaked through Repeat the test at both sides of the bore at ab...

Page 79: ...ion 5 Or if a digital no flow timer switch DNFT is provided time the cycle from flash to flash or for a magnetic cycle indicator assembly time the cycle from initial movement of the indicator pin at t...

Page 80: ...frared Port YES NO NO NO PLC Creates Shutdown NO YES NO NO Remote Mounting YES NO NO NO Area Classification CSA CSA CSA CE EX ATEX CSA CE CSA 203633 Class I Div 2 Groups ABCD T4A 044787 Class I Groups...

Page 81: ...roduce a switch change of state or a pulse every time the pin changes position This device must be combined with a PLC or some other counter timer device to produce the shutdown Some devices on the ma...

Page 82: ...e a display of the timer timing so the operator can see a change and show that something is happening Average Cycle Time Cycle time will vary a few seconds from cycle to cycle It is sometimes helpful...

Page 83: ...le of the minimum flow rate required Liquids in Gas The use of higher viscosity lubricants or specially compounded lubricants can compensate somewhat for the presence of liquids in the gas stream FIGU...

Page 84: ...Rate SAE 40 50 wt ISO 150 220 1 25 x Base Rate or Various Synthetics 1 x Base Rate SAE 50 wt ISO 220 w Compounding 1 5 x Base Rate or Various Synthetics 1 25 x Base Rate Cylinder Oil ISO 320 460 w Com...

Page 85: ...50 wt ISO 150 220 w Compounding 2 x Base Rate or Various Synthetics 1 5 x Base Rate SAE 50 wt ISO 220 w Compounding 2 5 x Base Rate or Various Synthetics 2 x Base Rate SAE 60 wt ISO 320 w Compounding...

Page 86: ...s Synthetics 1 x Base Rate SAE 60 wt ISO 320 1 x Base Rate or Various Synthetics 1 x Base Rate Cylinder Oil ISO 460 680 1 x Base Rate or Various Synthetics 1 x Base Rate Propanec Refrigerant SAE 40 wt...

Page 87: ...ating conditions and lubricant Special Lubricant Certification Special lubricant formulations are available from lubricant suppliers for specific applications Suppliers who will certify suitability of...

Page 88: ...ston rod packing friction increases with the higher pressures and piston speed Cooled packing cases are required for cylin ders in accordance with Figure 4 8 FIGURE 4 9 WATER COOLED PACKING CASE TYPIC...

Page 89: ...he piston rod packings Oil is supplied to the 150 micron sintered bronze filter on the suction side of the force feed lubricator pump directly from the pressure side of the frame lube oil system or fr...

Page 90: ...WITH A PROPERLY RATED RUPTURE DISK INSTALLED IN THE TUBING LINE BETWEEN THE FORCE FEED LUBRICATOR PUMP AND THE NO FLOW SHUTDOWN THE DISK COLOR SHOULD SHOW AT THE FITTING BLOW OUT HOLE THE FORCE FEED...

Page 91: ...stream from a force feed pump for a pump circuit rated 5500 psig 380 barg or greater orange pink and blue disks that is circuits with any cylinders greater than 3600 psig MAWP 248 barg should be 1 4 i...

Page 92: ...all lube ports Valve blocks containing metering pistons discharge a predetermined amount of lubricant with each cycle Valve blocks can be single or twin and can be externally singled or cross ported...

Page 93: ...nlet through in terconnecting passages flows against the right end of the section 1 piston Lubricant flow shifts section 1 piston from right to left dispensing lubricant to Outlet 1 see il lustrations...

Page 94: ...t Section End Section Section No 1 Section No 2 Section No 3 O Ring Inlet Section End Section Section No 1 Section No 2 Section No 3 O Ring Inlet Section End Section Section No 1 Section No 2 Section...

Page 95: ...Section No 3 O Ring Inlet Section End Section Section No 1 Section No 2 Section No 3 O Ring Inlet Section End Section Section No 1 Section No 2 Section No 3 O Ring Inlet Section End Section Section No...

Page 96: ...T Divider Valve Individual testing of each outlet ensures both sides of the piston will build adequate pres sure All divider valves stamped with an S on the front are to have both outlets on the base...

Page 97: ...e feed lube system by allowing accurate monitoring of the cycle time and system performance This information may be used to opti mize force feed lube and reduce operating costs The Proflo PF1 fluid fl...

Page 98: ...white wires can be con nected to a dry contact proximity switch This allows remote mounting of the monitor box housing in a convenient location on the compressor frame or in the control panel Ariel r...

Page 99: ...ay be increased in a directly proportional relationship At 50 rated speed the lube cycle time is doubled see lube sheets provided in the Ariel Parts Manual for table of speeds vs cycle timing 3 Push t...

Page 100: ...system computers are available at most electronic or discount stores or on the Internet For more details on this product and other Proflo PF1 accessories see the Ariel web at www arielcorp com and or...

Page 101: ...eS2 model number L91 batteries be used to reduce maintenance costs This is a true Lithium battery where other brands might not be While not recommended replacement alkaline batteries can still be used...

Page 102: ...emaining new bat tery power percentage The monitor will automatically search for the battery voltage at the next 30 minute read write interval and update to the new battery power percentage at that ti...

Page 103: ...l Proflo PF1 fault The Proflo PF1 processor tried and failed three resets The most likely cause is failure to write to the EEPROM NOTE THE MOST LIKELY CAUSE OF RESET ERRORS IS MOISTURE ON THE PRO FLO...

Page 104: ...tput connec tion on both the pulse and alarm outputs Proflo Normally Open and Normally Closed Definition There has been some confusion among PLC programmers and electrical people over the def inition...

Page 105: ...o out puts the isolation must take place on the equipment that is reading the contacts If the PLC input card is not isolated between channels both the alarm and pulse outputs will act as the alarm con...

Page 106: ...3 cubic inches x 2 are for each block moving in 1 full cycle 0 0346 is the conversion from in3 to pints US liquid pints in3 Divide pints by 8 gallons US liquid Multiply gallons US liquid X 3 78541 lit...

Page 107: ...any arc welding including repair welding as follows Disconnect all connections to the flow monitor including ground and remove the batteries Or completely remove the flow monitor from the compressor...

Page 108: ...ws Remove DNFT housing to a safe atmosphere 3 Use 3 8 inch ratchet wrench to remove the pipe plug 4 Remove battery from the DNFT and disconnect from the polarized connector 5 Connect the new battery A...

Page 109: ...ed it can be filled and primed through a 1 8 inch plug on the discharge end of the lubricator pump 3 Prime the force feed lubrication system just prior to starting the compressor using a proper primin...

Page 110: ...s possible 2 Multiple pumps with manifolding are used to ensure that 150 of the normal lubrication rate can be provided during break in 3 Pumps are not allowed to operate below 20 of full stroke the p...

Page 111: ...tart up the compressor and bring up to normal operating pressure After the operating pressures have stabilized with all balance valves backed off zero spring load note the highest gauge pressure reach...

Page 112: ...on the filter inlet and outlet Normal pressure drop through a clean filter is 2 to 6 PSID 0 15 to 0 4 bard at normal operating temperature From the filter oil travels through a pressure regulator to...

Page 113: ...ks and retighten the filter if neces sary 6 Do not run the compressor with a damaged filter canister It can fracture or leak 7 Replace the filter only with an Ariel approved non bypass type filter Oil...

Page 114: ...ver and tighten hold down nuts to 70 80 lb ft 95 110 N m torque 8 Install the flowing vent line and orifice and tighten the fittings 9 Install and tighten the filter vessel drain plug Fill the vessel...

Page 115: ...g into the compressor when crankshaft speed equals or exceeds minimum normal operating speed If oil pressure into the compressor while running at minimum operating speed and normal operating temperatu...

Page 116: ...4 barg is desirable NOTE 1 THE COMPRESSOR MUST HAVE A WORKING LOW OIL PRESSURE SHUT DOWN WHEN SHUTDOWN AS RESULT OF LOW OIL PRESSURE DO NOT ATTEMPT TO RE START UNTIL FAULT IS FOUND AND CORRECTED 2 DO...

Page 117: ...en access covers have been removed keep the frame covered to protect the interior from dust except when actually working on it Any components that have been removed should be protected from falling ob...

Page 118: ...RS REMOVE THE CENTER COUPLING OR LOCK THE FLYWHEEL ON ELECTRIC MOTOR DRIVEN COMPRESSORS IF IT IS INCONVENIENT TO DETACH THE DRIVER FROM THE COMPRESSOR THE DRIVER SWITCH GEAR MUST BE LOCKED OUT DURING...

Page 119: ...low Some procedures such as setting piston clearances require a dial indicator with magnetic base to locate the precise inner or outer dead center FIGURE 5 1 COMPRESSOR COMPONENTS TYPICAL JGM N P Q Co...

Page 120: ...ing wear by checking actual jack and side clearances against the clearance limits given in Table 1 3 on page 1 10 and the last bearing clearance check values if available High copper content in the oi...

Page 121: ...cting rod do not pry on rod cap tight toward dial indicator Release pres sure on pry bar Hold rod in place with minimum pressure to keep it from moving Set dial indicator to zero Then pry on the conne...

Page 122: ...ell installation If clearance readings are not within tolerance after installing new bearings con tact your packager or Ariel before proceeding Connecting Rod Removal 1 Remove the top cover from the c...

Page 123: ...haft pin If bearing shells do not come loose rotate slide them out of the connecting rod and or cap 9 Turn the crankshaft throw to near the inner dead center position and remove the rod through the cr...

Page 124: ...5 6 ROD BUSHING INSTALLATION Bushing Oil Hole Bushing Exterior Annular Groove Bushing Oil Passage Connecting Rod Position the connecting rod on the press table so that the chamfered edge of the rod bu...

Page 125: ...crank pin up near to the highest position while supporting the rod Oil the crankshaft crank pin bearing surfaces with new clean lubricating oil same type as is used in the frame before installing the...

Page 126: ...any doubt about their condition install new gaskets Before installing a gasket apply an antiseize lubricant to both sides or to the metal seating surfaces This will help to hold the gasket in place d...

Page 127: ...put excessive weight on the piston and rod assembly which might cause bending 4 Turn the crankshaft to position the crosshead to near its inner dead center posi tion and back off but do not remove the...

Page 128: ...y cooling the bushings in a 95 percent alcohol with dry ice solu tion The bushings need to be left in the solution long enough to reach the same temperature as the solution about 110 F 80 C Position t...

Page 129: ...SEE THE REQUIRED PISTON CRANK END CLEARANCE AS SHOWN ON THE CYLINDER IDENTIFICATION PLATE REFER TO TABLE 1 3 ON PAGE 1 10 6 Position the crankshaft to the exact inner dead center position of the thro...

Page 130: ...page 5 31 and Table 1 3 on page 1 10 for crosshead clearances and checking procedure If clearances are out of limits contact your packager or Ariel 18 Replace the crosshead guide side covers and gaske...

Page 131: ...mpressor frame and thrust the crankshaft tight toward the dial indicator Release pressure on the pry bar Hold crankshaft in place with minimum pressure to keep it from moving Set the dial indicator to...

Page 132: ...If clearances are out of limits contact your packager or Ariel Record values on a copy of the form on Page 5 48 FIGURE 5 11 MEASURING CRANKSHAFT THRUST CLEARANCE Dial Indicator Magnetic Stand Placemen...

Page 133: ...lide crankshaft out through carrier hole to remove it FIGURE 5 13 BEARING CAP PULLER Crankshaft 13 33 cm Long Steel Bar 1 2 13 UNC Puller Hole 10 250 mm Long 1 2 13 UNC Threaded Rod Drill an 5 8 15 mm...

Page 134: ...crankshaft in the horizonal position Put a rod of at least 1 2 inches 13 mm in diam eter through the slinger Special care should be exercised when handling the slinger not only to keep its surfaces un...

Page 135: ...to the stud threads on one end only 2 Work quickly before Loctite begins to harden and thread the stud end with the Loctite into the fan shaft until fully seated hand tight in the bottom of the hole...

Page 136: ...INGERNAIL The bearing shells must be absolutely clean Be sure that bearing shell part numbers on both halves match The old bearings halves are easily slid out tab end first Be sure both the main beari...

Page 137: ...pacer or oth erwise lockout 2 Remove the top cover 3 Remove the cap screws from main journal bearing cap 1 Pull the cap straight up to prevent damage to the dowel fit If the cap is tight use a Bearing...

Page 138: ...e metal seating surfaces This will help to hold the gasket in place during assembly and aid in easy of removal Tighten cover bolts hand wrench tight 15 Replace coupling spacer to packager s recommenda...

Page 139: ...Main Bearings Checking Clearances on Page 5 14 Record readings on a copy of the form on Page 5 48 6 Replace connecting rods bearings and re attach the connecting rods refer to Connecting Rod Installat...

Page 140: ...d be replaced if the elongation exceeds 0 084 inches 2 13 mm over a 10 pitch length The section of chain to be measured should be stretched tight in place in the compressor and measured with vernier c...

Page 141: ...stment on page 5 24 Lube Oil Pump Chain Sprocket Replacement 1 FIGURE 5 19 LUBE OIL PUMP AND SPROCKET Sprocket No 204 Woodruff Key Set Screws Adapter Pump Gaskets Remove the cap screws from the drive...

Page 142: ...ighten the set screw when the sprocket is properly aligned 10 Re install and adjust the chain according to the instructions in Chain Adjust ment on page 5 24 11 Re install all piping tubing to the pum...

Page 143: ...steps 1 through 5 at Crosshead Removal on page 5 11 2 With the cylinder head unloader removed and the cross head balance nut loos ened use the piston turning piston nut torquing tool Ariel furnished...

Page 144: ...ts onto piston nut using 2 5 16 18 x 1 1 4 long Cap Screws Compressor Piston Piston Nut Key Wrench Two Required for each Tight ening of Set Screws Clamp the piston and rod assembly in the special Clam...

Page 145: ...E ACROSS A 3 4 IN 20 mm WIDE BAND FOR MANUFACTURING PURPOSES THIS IS THE HEAD END OF THE PISTON 8 Apply a thin coat of Never Seez regular grade to the piston nut threads and piston mating face Install...

Page 146: ...it to enter the cylinder without damage Use the same procedure for succeeding rings and wear band if applicable 3 Be sure that the crosshead balance nut seating surfaces are flat and free of burrs Dre...

Page 147: ...a negative reading Copy Table 5 1 to record readings Bar over crankshaft by hand and record readings at mid stroke and with piston at the head end TABLE 5 1 PISTON ROD RUN OUT Compare readings to Tabl...

Page 148: ...ons See Table 1 7 on page 1 12 or Table 1 9 on page 1 14 for new end gap dimensions Removal See paragraph 3 at Piston and Rod on page 5 27 for piston ring removal Piston Rings Installation 1 Place the...

Page 149: ...e the small nuts from the studs These studs hold the entire packing case together so it can be removed as an assembly 5 Screw two short 3 8 16 UNC cap screws into the two tapped holes provided in the...

Page 150: ...ng set on the rod shine a light from behind the ring if any light is observed between the ring and the rod the ring set is not acceptable 6 Make sure that each rod ring and cup is properly positioned...

Page 151: ...TIL NO TURNING OF THE FASTENERS IS OBSERVED THE TORQUE ON THESE FASTENERS SHOULD BE RE CHECKED AT THE NEXT SERVICE INTERVAL 15 Retighten the small tie stud nuts Re install the tubing connections for t...

Page 152: ...rm a wedge that overcomes rod friction and forces the set to have con stant contact against both groove faces during either direction of rod travel The installed total end gap is 1 8 to 5 32 inches 3...

Page 153: ...is supplied NOTE REFER TO THE PACKING ASSEMBLY IN THE ARIEL PARTS BOOK SEE FIG URE 2 4 ON PAGE 2 13 FOR PACKING TUBING AND DISTANCE PIECE VENT ING AND FIGURE 2 5 ON PAGE 2 14 FOR PACKING LUBRICATION A...

Page 154: ...Parts Book and Figure 5 28 on Page 5 38 The studs are offset so the cups will only fit one way Make sure the tie studs are completely screwed into the end cup Put the proper ring in the groove and fac...

Page 155: ...sassembled inspected repaired re assem bled and re tested Packing cases may be bolted into place in a cylinder head to aid sealing using proper bolting and tightening torques Valves Valves Removal 1 S...

Page 156: ...ustable rod are the best tools to see the gasket clearly On cylinders with horizontal valves the gasket may fall into the gas passage A small magnet on a flexible extension rod will help fish it out T...

Page 157: ...s charge pockets The valve pock ets have identification plates All valves are installed with the valve fastener s positioned away from the cylinder bore If a valve is not marked for suction or dischar...

Page 158: ...ended torque in Table 1 12 on page 1 16 See Bolt Tightening for Valve Caps on page 5 42 If the assembly is correct the dis tance from the underside of the cap to the valve boss surface on the cylinder...

Page 159: ...rface on the cylinder will be uniform 1 8 inches 3 mm Proper tightening and torquing is important for all valve caps but is especially important for high pressure valve cap assemblies High pressure ap...

Page 160: ...s have a locking nut in lieu of a locking handle A hammer or puller may be required to break adjusting handle to stem tapered fit Loosen the locking handle or locknut and unscrew to remove Remove hea...

Page 161: ...full torque Refer to Section 1 for tightening torque value Reconnect VVCP packing vent Re install and tighten locking handle or locknut install bel lows adjusting handle and Nylon insert locknut if a...

Page 162: ...er and counterbores New piston piston rings wear band if applicable re stamping cylinder data tag and hydro testing are required Re boring can expose internal casting shrinkage which would render the...

Page 163: ...ssor Bearings should be continuously flushed for 1 2 hour while barring over crankshaft All surfaces that come in contact with crankcase oil are to be flushed which includes spraying all interior surf...

Page 164: ...IN mm THROW NUMBER 1 2 3 4 5 6 MAIN BEARINGS CONN ROD BEARINGS If measured clearances exceed the tolerances in Table 1 3 on page 1 10 after installing new bearings contact your packager or Ariel befo...

Page 165: ...ntered with exacting detail in order that records will be available for tracking maintenance costs per unit and for trouble shooting Operator logs should be reviewed by qualified personnel to determin...

Page 166: ...5 Check and correct any gas leaks 6 Check and correct any oil leaks 7 Check operating pressure and temperatures If not normal determine cause of abnormality and correct It is recommended that a daily...

Page 167: ...when oil is changed and visually inspect for foreign material Disas sembly is not recommended unless a reason for it is found 7 Check fluid level in torsional vibration damper if applicable Take fluid...

Page 168: ...e and pressure gauges 9 Check and record compressor rod run out 10 Grease VVCP stem threads at grease fitting with 2 to 3 pumps of multi purpose grease using a standard hand pump grease gun 11 Clean c...

Page 169: ...is valuable because any variation when operating at a given load point indicates trouble in one of the stages Normally if the interstage pressure drops the trouble is in the lower pressure cylin der...

Page 170: ...roken or leaking valves causing high temperature Excessive temperature due to high pressure ratio across cylinders Relief Valve Popping Faulty relief valve Leaking suction valves or rings on next high...

Page 171: ...8 with every JGI M N P Q compressor It contains the tools shown in the figure below These tools are specifically designed for use on Ariel compres sors Clean all tools before use and verify full tool...

Page 172: ...s Short Arm 10 provided 10 3 32 in Allen Wrenches Short Arm 10 provided 11 Valve Puller Tool 5 16 x 1 2 in UNF A 0135 12 Valve Puller Tool 1 4 x 3 8 in UNF A 0409 13 Piston Turning Piston Nut Torquing...

Page 173: ...Chisel Set including a 60 Center Punch 3 8 in Square Drive Wrench Set including 1 12 Point Socket Set w Breaker Bar Ratchet Speed Wrench Extensions 2 Universal Joint Impact Type Ball 3 Adapter to 1 2...

Page 174: ...t Wrench approximately 100 ounce or 6 lb 3 kg for JGC D frames and 56 ounce or 3 5 lb 1 5 kg for smaller frames Long Blade Feeler Gage Pack in Assorted Thickness Pry Bar 3 feet 1 m Long Hexagon Allen...

Page 175: ...mass or lbm x 0 453592 kilogram or kg Moment or Torque Lb x Ft or pound foot force x 1 35583 Newton meter or N m Lb x In or pound inch force x 0 112985 Newton meter or N m Power Horsepower based on 55...

Page 176: ...USEFUL SI METRIC MULTIPLE AND SUBMULTIPLE FACTORS FACTOR PREFIX SI SYMBOL Maintain Case 1 000 000 106 mega M 1 000 103 kilo k 100 102 hecto not recommended h 10 101 deka not recommended da 0 1 10 1 d...

Page 177: ...ing on location Contact Ariel for details COMMON ABBREVIATION COMPONENT NAME SYNONYM CHEMICAL FORMULA C1 Methane CH4 C2 Ethane C2H6 C3 Propane C3H8 IC4 Iso Butane 2 Methyl Propane C4H10 NC4 N Butane C...

Page 178: ...ndor Literature When available vendor literature on purchased parts used in Ariel Compressors is provided on the Ariel Website www arielcorp com or copies may be obtained from the Packager or from Ari...

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