Ariel JGJ Series Technical Manual Download | Manualshive

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AND

JGJ

S

ECTION

5 - M

AINTENANCE

PAGE 5 - 18

Piston and Rod - Removal

1.

Remove the crosshead guide side covers and the cylinder head. The cylinder

head is to be loosened first to the Caution! instructions above.

2.

Move the crosshead to its inner dead center position. Back off, but do not

remove, the crosshead nut set screws. Loosen the crosshead nut with the spe-

cial slugging wrench, (see Figure 7-1: on page 7-3). Use the open-end wrench

for hex nuts and the peg wrench for round nuts.

3.

Remove the cylinder head. In the case of tandem cylinders where the outboard

cylinder bore is smaller than the inboard bore, it is necessary to remove the out-

board cylinder. Support such cylinders during removal and installation, as to not

put excessive weight on the piston and rod assembly which might cause bend-

ing.

4.

Use the Piston Nut Spanner and Ratchet Extension Support to screw the piston

and rod assembly out of the crosshead. Refer to Figure 5-11: on page 5-19. The

two dowels on the Piston Nut Spanner fit the holes in the piston nut. Turn the

crosshead nut off the piston rod.

5.

As the piston leaves the cylinder, be careful in handling the piston rings. Despite

their toughness in service, rings are fragile with regard to removal. Always han-

dle them with clean tools and hands protecting the rings from nicks, marring,

and bending. Move the piston out of the cylinder until a fraction of the first ring

clears the cylinder. Encircle the ring by hand (use a band for larger sizes) until it

is clear and remove it. Use this same procedure to remove the succeeding rings

and wear band.

6.

Slide the piston rod out of the head end. The threaded crosshead end of the rod

is 1/8 inches (3 mm) smaller in diameter than the inside diameter of the packing.

Using extreme care, slowly slide the piston rod through the packing to avoid

damaging the rod threads or the packing rings.

CAUTION

TO PREVENT PERSONAL INJURY, ENSURE THAT COMPRESSOR
CRANKSHAFT CANNOT BE TURNED BY THE DRIVER OR COMPRES-
SOR CYLINDER GAS PRESSURE DURING MAINTENANCE: -- ON
ENGINE-DRIVEN COMPRESSORS, REMOVE THE CENTER COUPLING
OR LOCK THE FLYWHEEL. -- ON ELECTRIC MOTOR-DRIVEN COM-
PRESSORS, IF IT IS INCONVIENIENT TO DETACH THE DRIVER FROM
THE COMPRESSOR, THE DRIVER SWITCH GEAR MUST BE LOCKED
OUT DURING MAINTENANCE.

BEFORE PERFORMING ANY MAINTENANCE, COMPLETELY VENT
SYSTEM. BEFORE REMOVING A CYLINDER HEAD, BACK OFF ALL
CAPSCREWS 1/8" (3 mm). MAKE SURE THE HEAD IS LOOSE AND THE
CYLINDER IS COMPLETELY VENTED.

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Summary of Contents for JGJ Series

Page 1: ...osed Compressors TECHNICAL MANUAL For Models JGW JGR and JGJ ARIEL CORPORATION 35 BLACKJACK ROAD MOUNT VERNON OHIO 43050 TELEPHONE 740 397 0311 FAX 740 397 3856 VISIT OUR WEB SITE www arielcorp com EMAIL info arielcorp com REV 1 01 ...

Page 2: ...E THE COMPRESSOR IS SUFFICIENTLY PURGED OF ANY EXPLOSIVE MIXTURE BEFORE LOADING AFTER COMPLETING THE ABOVE BEGIN PROPER STARTING PROCEDURE CAUTION DO NOT ATTEMPT TO START UP UNIT WITHOUT REFER RING TO THIS MANUAL SECTION 3 START UP IT IS ALSO ESSENTIAL TO REFER TO THE PACKAGER S OPERATING MANUAL CAUTION THIS MANUAL EDITION IS BASED ON THE CURRENT DESIGN BUILD AND PRACTICES THIS MANUAL MAY NOT BE A...

Page 3: ...tion Setting 1 23 Installation 2 1 General 2 1 Procedure For Setting and Aligning 2 1 Setting 2 2 Alignment 2 2 Vents and Drains 2 3 Start Up 3 1 General 3 1 Start Up Check List 3 2 Maximum Allowable Working Pressure 3 6 Relief Valve Settings 3 7 Filling Sump Priming a Main Oil Lube Oil System Before Starting 3 8 Filling The Sump 3 8 Priming Main Lube Oil System 3 8 Force Feed Lubricator Adjustmen...

Page 4: ...Balance Valves on Subsequent Start up 4 21 Frame Lubricating System Description 4 21 Lube Oil Strainer Filter Filter Installation Instructions 4 24 Lube Oil Strainer 4 24 Lube Oil Filter 4 24 Filter Element Installation Instructions 4 24 Lube Oil Pump Lube Oil Pressure 4 25 Description Adjustment 4 25 Lube Oil Pressure 4 25 Low Oil Pressure Shutdown 4 25 Maintenance 5 1 General Introduction 5 1 Co...

Page 5: ...25 Types of Piston Rod Packing Rings 5 27 Type P Pressure Breaker 5 27 Type BTR Single Acting Seal Set 5 28 Type BD Double Acting Seal Set 5 29 Type 3RWS Oil Wiper Set 5 30 Type AL Double Acting Seal Set 5 31 Typical Arrangement of Piston Rod Packing Rings 5 31 Piston Rod Packing Ring Material 5 32 Valves 5 32 Valves Removal 5 32 Valves Maintenance 5 33 Valves Reassembly 5 33 Bolt Tightening for V...

Page 6: ...Ariel Tools 7 1 Ariel Furnished Tools 7 1 Ariel Optional Tools 7 1 Minimum Hand Tools Required 7 2 Terms Abbreviations and Conversion to SI Metric 7 3 Area 7 3 Flow Gas 7 3 Flow Liquid 7 4 Force 7 4 Heat 7 4 Length 7 4 Mass 7 4 Moment or Torque 7 4 Power 7 4 Pressure or Stress 7 4 Speed 7 5 Temperature 7 5 Time 7 5 Viscosity 7 5 Volume 7 5 Other Abbreviations 7 5 Gas Analysis Common Abbreviations ...

Page 7: ...l prior to operating the compressor This manual is designed to provide information on installation start up operation and main tenance of a JGW JGR or JGJ compressor If you have any questions please contact your packager If they are unable to provide resolution they will refer your concerns to Ariel Cor poration If you prefer you may always contact Ariel directly This manual provides design specif...

Page 8: ...60 35 10 250 260 35 10 250 260 35 10 250 260 35 Maximum Width in m 103 2 62 103 2 62 103 2 62 103 2 62 Maximum Length in m 41 1 04 77 1 96 41 1 04 77 1 96 Approximate Weight with Cylinders lb kg 4000 1814 7000 3175 4200 1905 8200 3720 Oil Pump Capacity GPM L s 8 0 50 14 0 88 8 0 50 14 0 88 Oil Heat Rejection BTU hr J s 7000 2065 12 000 3540 8000 2360 14 000 4130 Sump Capacity US gallons L 6 23 15 ...

Page 9: ... 260 35 10 250 260 35 10 250 260 35 Maximum Width in m 103 2 62 103 2 62 103 2 62 Maximum Length in m 41 1 04 77 1 96 113 2 87 Approximate Weight with Cylinders lb kg 4200 1905 8200 3720 12 000 5445 Oil Pump Capacity GPM L s 8 0 50 14 0 88 20 1 26 Oil Heat Rejection BTU hr J s 10 000 2940 16 000 4700 21 000 6170 Sump Capacity US gallons L 6 23 15 57 24 91 Piston Rod Diameter in mm 1 500 38 10 1 50...

Page 10: ... instructions See Page 4 24 IMPORTANT SAFETY INFOR MATION PLATES See Page 1 5 Information plate Model Frame serial number Stroke Maximum and minimum speed Maximum rod load Ariel ship ping date Normal lube oil pressure Low oil pressure shutdown and Maximum lube oil temperature ARIEL LOGO NAME PLATE AND ADDRESS Top Cover Direction of Rotation plate located at the drive end ...

Page 11: ...L INJURY AND 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 PACKAGER S INFORMATION FOR ANY SPECIFIC RECOMMENDATIONS WEAR HEARING PROTECTION WHEN UNIT IS RUNNING CAUTION HOT GAS TEMPERATURES ESPECIALLY THE CYLINDER DISCHARGE AREAS 190 F 88 C OIL AND HIGH ...

Page 12: ...s NOTE THE FORCE FEED LUBRICATOR BOX CONTAINS APPROXIMATELY 1 3 GAL LONS 1 L OF LUBRICANT FIGURE 1 4 FORCE FEED LUBRICATOR PUMP TYPICAL FIGURE 1 5 FORCE FEED LUBRICATOR DATA PLATES Data Plate Distribution Block Part Number Force Feed Lubricator Data Plate for Twin Pumps Indicator Cycle Time Force Feed Lubricator Data Plate for Single Pump Indicator Cycle Time Normal Seconds cycle Break In Seconds ...

Page 13: ...IGURE 1 6 IDENTIFICATION PLATES TYPICAL Serial Number MAWP Part Number Work Order Number Hydrostatic Test Pressure Test Date and Tester s Personal Stamp are stamped on the end of each cylinder Discharge Valve Pocket Identifica tion plate Suction Valve Pocket Identifica tion Plate Unloader Identification Plate Customer Work Order Number Hydrotest Pressure and Tester s Personal Stamp are stamped nea...

Page 14: ...ions per Minute Crank End Head End Piston End Clearance Inches Cylinder Serial Number Minimum Volumetric Clearance Percentage Unloader Serial Number UNLOADER IDENTIFICATION PLATE Thread Lead Threads Per Inch Travel Inches Cubic Inches Per Inch Volume Nominal Unloader Bore Diameter Inches Nominal Cylinder Bore Diameter Inches Maximum Allowable Working Pressure Max imum Relief Valve Set ting PSIG Po...

Page 15: ...tile Iron to Guide JGJ JGR Feeler Gaugea a Crosshead guide to crosshead clearance at the top is to be checked by inserting a standard 0 5 inch 13 mm wide feeler stock from one side edge of the crosshead across to the opposite side This is to be done at both ends The bottom clearance is to be checked with 0 0015 inch 0 038 mm feeler stock at the 4 corners If the feeler can be inserted more than 0 5...

Page 16: ...92 to 7 98 0 006 to 0 010 0 15 to 0 25 0 004 to 0 008 0 10 to 0 20 3 8 9 53 0 375 to 0 377 9 53 to 9 58 0 008 to 0 012 0 20 to 0 30 0 004 to 0 008 0 10 to 0 20 3 4 19 05 0 750 to 0 752 19 05 to 19 10 0 016 to 0 022 0 41 to 0 56 0 006 to 0 010 0 15 to 0 25 TABLE 1 5 RIDER RING SIDE CLEARANCE INCHES mm ACTUAL GROOVE WIDTH CLEARANCE 1 000 0 012 to 0 018 0 30 to 0 46 2 000 0 024 to 0 030 0 61 to 0 76 ...

Page 17: ... 46 0 066 to 0 090 1 68 to 2 29 0 270 6 86 6 152 0 013 to 0 018 0 33 to 0 46 0 072 to 0 112 1 83 to 2 84 0 336 8 53 6 375 162 0 014 to 0 019 0 36 to 0 48 0 077 to 0 117 1 96 to 2 97 0 351 8 92 7 178 0 015 to 0 020 0 38 to 0 51 0 084 to 0 124 2 13 to 3 15 0 372 9 45 7 125 181 0 015 to 0 021 0 38 to 0 53 0 085 to 0 125 2 16 to 3 18 0 375 9 53 7 375 187 0 015 to 0 020 0 38 to 0 51 0 089 to 0 129 2 26...

Page 18: ... 113 2 11 to 2 87 0 339 8 61 7 375 187 0 090 to 0 096 2 29 to 2 44 0 097 to 0 127 2 46 to 3 23 0 381 9 68 7 5 191 0 090 to 0 096 2 29 to 2 44 0 088 to 0 118 2 24 to 3 00 0 354 8 99 8 203 0 090 to 0 096 2 29 to 2 44 0 106 to 0 136 2 69 to 3 45 0 408 10 36 8 375 213 0 090 to 0 096 2 29 to 2 44 0 112 to 0 142 2 84 to 3 61 0 426 10 82 8 5 216 0 090 to 0 096 2 29 to 2 44 0 114 to 0 144 2 90 to 3 66 0 4...

Page 19: ...23 to 0 031 6 0 079 to 0 087 0 072 to 0 112 0 336 0 192 0 025 to 0 033 6 375 0 079 to 0 087 0 077 to 0 117 0 351 0 204 0 025 to 0 033 7 0 085 to 0 093 0 084 to 0 124 0 372 0 224 0 028 to 0 036 7 375 0 085 to 0 093 0 089 to 0 129 0 387 0 236 0 028 to 0 036 8 0 090 to 0 099 0 096 to 0 136 0 408 0 256 0 030 to 0 038 8 375 0 090 to 0 099 0 101 to 0 141 0 423 0 268 0 030 to 0 038 9 25 0 094 to 0 103 0 ...

Page 20: ...6 6 78 4 47 0 58 to 0 79 152 6 2 01 to 2 21 1 83 to 2 84 8 53 4 88 0 64 to 0 84 162 6 375 2 01 to 2 21 1 96 to 2 97 8 92 5 18 0 64 to 0 84 178 7 2 16 to 2 36 2 13 to 3 15 9 45 5 69 0 71 to 0 91 187 7 375 2 16 to 2 36 2 26 to 3 28 9 83 5 99 0 71 to 0 91 203 8 2 29 to 2 51 2 44 to 3 45 10 36 6 48 0 76 to 0 97 213 8 375 2 29 to 2 51 2 57 to 3 58 10 74 6 81 0 76 to 0 97 235 9 25 2 39 to 2 62 2 82 to 3...

Page 21: ... FASTENER TIGHTENING VALUES FASTENER NOMINAL SIZE INCH TPI TYPE TORQUE LB X FT N m Main Bearing Cap Cap Screw 5 8 11 12 Point Grade 8 97 132 Connecting Rod Cap Detuner Donut Cap Screw 5 8 18 12 Point Grade 8 123 167 Connecting Rod Cap Detuner Donut Cap Screw 3 4 16 12 Point Grade 8 216 293 Crosshead Pin Thru Bolt Lock Nut 7 16 20 Hex Prevailing 39 53 Spacer Bar Cap Screw 3 4 16 12 Point Grade 8 16...

Page 22: ...107 lb x in 12 7 16 14 172 lb x in 19 1 2 13 22 30 9 16 12 32 43 5 8 11 44 60 3 4 10 79 105 7 8 9 130 170 1 8 190 260 Distribution Block Tie Rod Nut 1 4 28 Hex 68 lb x in 7 7 Distribution Block Divider Valve Screw 1 4 28 Socket Head 109 lb x in 12 Grade 5 Hex Cap Screw All Hex Grade 5 Hand Wrench Tight a When studs are specified for cylinder applications tighten stud nuts to the same values as cap...

Page 23: ...FOR MODELS JGW JGR AND JGJ SECTION 1 DESIGN SPECIFICATIONS DATA 1 01 PAGE 1 17 FIGURE 1 8 DOG POINT STUDS STUD ...

Page 24: ... only 5 16 24 12 Point Steel Grade 8 26 35 3 8 24 45 61 7 16 20 62 83 5 16 24 12 Point Steel Grade 5 18 24 3 8 24 32 43 7 16 20 50 68 5 16 24 12 Point Grade B8M Stainless Steel 120 lb x in 13 6 3 8 24 192 lb x in 21 7 7 16 20 24 33 Center Stud Drake Lock Nut 1 4 28 Bottom Half 103 lb x in 11 6 Top Half 66 lb x in 7 5 5 16 24 Bottom Half 168 lb x in 18 9 Top Half 96 lb x in 10 8 3 8 24 Bottom Half ...

Page 25: ...nd used by qualified person nel to achieve the required fastener tightening torque for all critical parts except for the crosshead balance lock nut which may be tightened using the tried and true slugging procedure 2 Always check to determine over what range the torque wrench is accurate since most torque wrenches are not accurate over their entire range FIGURE 1 9 SPIRALOCK THREADED VALVE ASSEMBL...

Page 26: ...orque wrench is put back to its lowest setting the spring will relax and retain its accuracy 7 Do not use a torque wrench to break fasteners loose as it may overload the torque wrench and or cause loss of calibration 8 For applications requiring the use of a boxed end or crowsfoot adapter with a torque wrench to reach not readily accessible fasteners the torque wrench setting will not be the actua...

Page 27: ...he identification of bolts used in an Ariel compres sor Connecting rod valve cap and suction discharge nozzle Ariel supplied specialized compan ion flange bolting is modified to prevent fatigue and cannot be replaced with standard bolts If attempting to replace other bolting with standard bolts and there is any question contact your packager or Ariel Ariel supplied replacement bolting is recommend...

Page 28: ...CATIONS DATA PAGE 1 22 1 01 FIGURE 1 13 BOLT IDENTIFICATION Hex Socket Head Grade 8 Hex head Grade 8 Hex head Grade 9 Hex head Grade 5 12 Point Grade 8 12 Point Grade B7M NACE 12 Point Interim Grade 5 12 Point Grade 5 12 Point Stainless Steel Grade B8M ...

Page 29: ...eutectic alloy device is selected to melt at 228 F 109 C to vent control pressure and to provide a shutdown signal Upon melting the fuse rod must be replaced To ensure proper operation of the detector replace the fuse rod every five years Electrical Instrumentation Setting Set within 10 of normal operating temperature to a maximum of 220 F 104 C alarm and 230 F 110 C shutdown ...

Page 30: ...FOR MODELS JGW JGR AND JGJ SECTION 1 DESIGN SPECIFICATIONS DATA PAGE 1 24 1 01 NOTES ...

Page 31: ...es vertical support but also prevents horizontal movement perpendicular to the piston rod 3 Each crosshead guide will deflect an amount relative to the weight of the cylin der mounted on that throw This amount of deflection which does not include the weight of the pulsation bottles or piping is shown in the Ariel Application Data Book Shims equaling the deflection value as listed on the cylinder o...

Page 32: ...ured To these measurements add the amount of deflection due to the cylinder weight as listed on the appropriate compressor cylinder outline drawing Raise the cylinder and shim between the guide and guide support before tightening the crosshead guide mounting bolts Consult Packager s information for mounting bolt tightening torque values This work must be performed prior to the addition of bottles ...

Page 33: ...necessary to install screens over the vents and drains to ensure that they do not become blocked This can be essential if the compres sor is shutdown for a long period of time Some other points are 1 A vent should be provided to safely relieve pressure from the system 2 Adequate vents and drains are to be provided for the distance pieces primary packing vents and crankcase Primary vents and drains...

Page 34: ...FOR MODELS JGW JGR AND JGJ SECTION 2 INSTALLATION PAGE 2 4 1 01 NOTES ...

Page 35: ...N BEFORE STARTING A NEW COMPRESSOR OR AFTER RE LOCATING OR RE APPLYING A COMPRESSOR OR AFTER MAJOR OVERHAUL BE SURE TO COMPLETE AND CHECK OFF ALL THE ITEMS ON THE START UP CHECK LIST ON PAGES 3 2 THROUGH 3 4 THIS LIST IS DESIGNED TO ENSURE MAXIMUM SAFETY IN STARTING AND OPERATING THE COMPRESSOR CAUTION FOR SAFE OPERATION DO NOT ATTEMPT TO START UP THE UNIT WITHOUT BEING COMPLETELY KNOWLEDGABLE ON ...

Page 36: ...ons for the compressor model such as rod load maximum and minimum speed discharge temperature been checked ______ ______ 3 Have the design operating conditions been determined ______ ______ Pressure PSIG kPa Suction __________ Discharge_________ Temperature F C Suction _______ Discharge_______ Maximum RPM__________ Minimum RPM___________ 4 Soft Foot Check Have the compressor feet and crosshead gui...

Page 37: ...er Compressor inlet oil temperature is 190 F 88 C max _____ ______ 23 Is the crankcase oil temperature shutdown installed set and working _____ ______ 24 If oil is cooled is there a temperature control valve _____ ______ 25 Is the crankcase breather element clean _____ ______ 26 Is the force feed lubricator box filled with oil _____ ______ 27 Is the force feed lubrication system primed _____ _____...

Page 38: ... 45 Has the Packager s representative done the required review of the Packager s Start Up and Operating Instructions for the unit with the unit operator ______ ______ Check List After Starting YES NO 1 Did the oil pressure come up immediately ______ ______ 2 Are the oil filter and force feed pump pressure gauges working ______ ______ 3 Oil filter diff pressure 10 psi 69 kPa unless otherwise specif...

Page 39: ...anty Notification and Installation List Data form been completed and mailed or faxed to Ariel ______ ______ 16 Has a copy of this completed Start up Checklist been mailed to Ariel at Ariel Corporation 35 Blackjack Road Mount Vernon OH 43050 USA Attention Administrative Assistant Sales or faxed to Ariel at 740 397 3856 Attention Administrative Assistant Sales ______ ______ ...

Page 40: ...he manufacturer has designed the equipment or any part to which the term is referred when handling the specified fluid at the maximum specified temperature API SPEC 11P paragraph 2 5 1 1 defines Maximum Allowable Working Pressure for Compressor Cylinders as follows The maximum allowable working pressure of the cylinder shall exceed the rated discharge pressure by at least 10 percent or 25 psig1 wh...

Page 41: ...argin Pressure Above System psig kPa Discharge Pressure 14 7 to 150 101 to 1034 15 PSI 100 kPa 151 to 2500 1035 to 17 237 10 2501 to 3500 17 238 to 24 132 8 3501 to 5000 24 133 to 34 474 6 NOTE For rated discharge pressures above 5000 psig 34 474 kPa the relief valve setting shall be agreed upon between the purchaser and the vendor CAUTION WHEN A BYPASS IS FURNISHED A RELIEF VALVE MUST BE INSTALLE...

Page 42: ...e pump should run at pressure for a minimum of fifteen seconds before starting the unit All electric motor driven compressors and all unattended start compressors with any type driver must have a separate motor driven prelube pump to ensure oil flow prior to start up The prelube pump flow rate should be 50 of the flow rate of the com pressor frame lube oil pump A start permissive for these applica...

Page 43: ...ps in equal increments until the break in cycle time is properly set The pumps should be stroking at approximately the same rate 3 After break in the pumps should be readjusted using the same technique until the prescribed cycle time is set At this rate the pumps should be operating with a stroke at least 20 of maximum Pump stroke below 20 of maximum results in unreliable pump output If necessary ...

Page 44: ...FOR MODELS JGW JGR AND JGJ SECTION 3 START UP PAGE 3 10 1 01 NOTES ...

Page 45: ...ompressor and deserves special attention in the package design Oil Cooler All compressors must have an oil cooler Maximum allowable oil temperature into the com pressor frame is 190 F 88 C The packager is responsible for sizing a proper oil cooler Operating conditions which must be taken into account are the cooling medium cooling medium temperature cooling medium flow rate lube oil temperature an...

Page 46: ... based oils and synthetic fluids Lubricant additives are used to improve the viscosity index inhibit oxidation depress the lubricant pour point inhibit rust formation improve detergency provide anti wear protec tion provide extreme pressure protection improve lubricity decrease effects of gas dilu tion increase wetability and resist washing of the lubricant due to water wet or saturated gas or dil...

Page 47: ...resistance better lubricity better film strength natural detergency lower volatility and results in decreased operating temperatures These attributes can help to decrease cylinder feed rate requirements Justification for the use of synthetic lubricants is based on energy savings reduced lubricant usage increased compo nent life decreased equipment downtime and reduced maintenance labor Some synthe...

Page 48: ... low lube oil pressure shutdown set at 35 psig 2 4 barg is required for protection of the compressor The maximum viscosity of the lube oil for cold ambient temperature starting is 15 000 SUS 3300 cSt typically 40 F 4 C for SAE 30 weight ISO 100 grade oil or 55 F 13 C for SAE 40 weight ISO 150 grade oil The minimum lube oil operating temperature is 150 F 66 C This is the minimum tempera ture requir...

Page 49: ...inder and packing lubrication the resulting force feed lube systems are installed as shown in Figure 4 7 on page 4 17 Independent Oil Supply When process gas composition and cylinder operating conditions require an independent cylinder oil supply the resulting separate force feed lube systems require an oil supply as shown in Figure 4 8 on page 4 19 Lubricator oil is supplied under pressure from a...

Page 50: ...cigarette paper tests be repeated until passed Repeat for all cylinders If a reduction or increase of the lubrication rate is indicated for a cylinder change in 5 increments by adjusting cycle time at the force feed lube pump as discussed in Force Feed Lubricator Adjustment on page 3 9 Repeat oil film testing for the cylinders affected after 24 hours of operation NOTE THE CIGARETTE PAPER TEST ONLY...

Page 51: ...iltered i e 20 micron nominal Oil viscosity must be monitored and tested as follows for serviceability Oil should be changed at regular maintenance intervals 6 months or 4 000 hours when oil filter differential pressure exceeds 10 psi 0 7 Bar for spin on filters or when oil sample results indicate the need A more frequent oil change interval may be required if operating in an extremely dirty envir...

Page 52: ...or Synthetic Diester Polyglycol 2 x Base Rate Contact Lubricant Supplier Natural Gas Water Satu rated and Carbon Dioxide 2 to 10 SAE 40 50 wt ISO 150 220 1 25 x Base Rate or Various Synthetics Base Rate SAE 50 60 wt ISO 220 320 or SAE 40 wt ISO 150 w Compounding 1 5 x Base Rate or Var Synthetics 1 25 x Base Rate Cylinder Oil ISO 460 680 w Compounding 2 x Base Rate or Synthetic PAG 1 5 x Base Rate ...

Page 53: ...tact Lubricant Supplier Nitrogen Bone Dry Contact Ariel SAE 40 wt ISO 150 Base Rate or Various Synthetics Base Rate SAE 40 50 wt ISO 150 220 Base Rate or Various Synthetics Base Rate SAE 50 wt ISO 220 Base Rate or Various Synthetics Base Rate SAE 60 wt ISO 320 Base Rate or Various Synthetics Base Rate Cylinder Oil ISO 460 680 Base Rate or Various Synthetics Base Rate Propanec Refrigerant SAE 40 wt...

Page 54: ...INTS BREAK IN LUBE RATE SHOULD BE TWICE THE RECOMMENDED DAILY RATE 150 MINIMUM I E THE BREAK IN CYCLE TIME SHOULD BE APPROXIMATELY ONE HALF THE NORMAL CYCLE TIME 67 MAXIMUM TO INCREASE LUBE RATE BREAK IN RATE SHOULD BE MAINTAINED FOR 200 HOURS OF OPERATION THE RECOMMENDED LUBE RATES FOR BREAK IN OR NORMAL OPERA TION IN CYCLES PER SECOND AS STAMPED ON THE LUBRICATOR BOX INFORMATION PLATE ARE CALCUL...

Page 55: ...he disc Venting the system through the blow out disc causes the no flow shutdown switch to close The oil then travels to the distribution block It is here that the lubricating oil is apportioned to provide the exact amounts to the cylinders and packings The pistons in the intermediate sections of the distribution block move back and forth in a continuous cycle forcing lubricant successively throug...

Page 56: ...ge 1 15 for blow out fitting cap tightening torque Do not over tighten cap or blow out pressure can be reduced ARIEL P N COLOR THICKNESS ARIEL P N RATED PSI RATED MPa INCHES mm Lincoln A 0080 3250 22 4 A 0124 Purple 0 0225 0 57 Lubriquip A 3531 3700 26 A 3536 Yellow 0 010 0 28 Lubriquip A 3532 4600 32 A 3537 Red 0 012 0 30 Lubriquip A 3533 5500 38 A 3538 Orange 0 014 0 36 Lubriquip A 3534 6400 44 ...

Page 57: ...ICATION AND VENTING 1 01 PAGE 4 13 Divider Valves NOTE REFER TO PARTS BOOK FOR THE FRAME BEING SERVICED FOR ASSEM BLY DRAWINGS PARTS LIST AND REPAIR KITS THAT ARE AVAILABLE FOR DIVIDER VALVES FIGURE 4 3 DIVIDER VALVE DISTRIBUTION BLOCK TYPICAL ...

Page 58: ...intermediate blocks in the baseplate There must be a minimum of three working valves on each valve and base plate assembly Standard Electronic Lubricator Digital No Flow Timer Switch DNFT The DNFT is a microprocessor based switch used to sense no flow or slow flow conditions in the compressor cylinder lubrication system to facilitate alarm and or shutdown The DNFT also contains an amber light emit...

Page 59: ... BACKWARDS 1 Screw three tie rods into inlet block until ends are flush with surface of block 2 Slide inlet gasket onto tie rods 3 Alternately slide an intermediate block and an intermediate gasket plate onto the tie rods until the last intermediate block is in place 4 Discard remaining intermediate gasket plate 5 Slide end gasket plate and end block onto tie rods 6 Lay baseplate assembly on flat ...

Page 60: ...n 2 and through outlet 3 Piston 3 shift directs lubricant through connecting passage to the left side of piston 1 See Figure 4 5 illustration 4 Lubricant flow against left side of piston 1 begins the second half cycle which shifts pistons from left to right dispensing lubricant through outlets 4 5 and 6 of the divider valve If pistons refuse to move check for air lock in one or more valve ports by...

Page 61: ... Shutdown Switch To Other Cylinders and Packings Sintered Bronze Filter Blow Out Disc Compressor Frame Oil Gallery Force Feed Lubricator Pump Drain to Crankcase Single Ball Check Valve Double Ball Check Valve Bottom Cylinder Injection Point Packing Injection Point Single Ball Check Valve Divider Valves Distribution Block Pressure Gauge Top Cylinder Injection Point To Check Valve To Lube Point ...

Page 62: ...ew locknut Turn the plunger stroke adjustment screw to the full up position Tighten the adjusting screw lock nut Proper feed rate may be set after the machine is started Running Conditions When the machine is running make sure that the oil level in the lubricator reservoir is at least one half way up the sight level but does not exceed two thirds See your packager s specific data to determine the ...

Page 63: ...witch errors or blown rupture discs A force feed balance valve is shown in Figure 4 9 FIGURE 4 8 FORCE FEED LUBRICATION SYSTEM INDEPENDENT OIL SUPPLY Oil Supply Tank NOTE The system must be designed to provide posi tive pressure to the force feed lubricator pump Oil Filter Sintered Bronze Filter ForceFeed Lubricator Pump Blow out Disc To Appropriate Drain 1 4 Inch NPT Female Customer Connection Do...

Page 64: ...intain at approximately same pressure on each pressure gauge in the injection lines of the pump system affected A system should be set and main tained within 500 psi 3400 kPa total or less The closer the individual line pressures are maintained the more reliable the system will become Once the balance valves have been set they should be checked 4 to 6 hours later to ensure the pressures have not c...

Page 65: ...ced if it is not balanced on start up If a balance valve s was installed but is not required leave or set the spring adjustment at zero If back pressure on an unused balance valve is high enough it may eventually begin to leak oil In this case replace the balance valve internal assembly with a plug assembly Ariel Part Number A 10330 DO NOT RUN UNIT WITH LEAKY BALANCE VALVES A valve seal repair kit...

Page 66: ...connecting rod bearings Holes drilled through the length of the connecting rods deliver oil to the connecting rod bush ing Oil travels from the bushings thru holes drilled in the middle of the crosshead pin to the hol low crosshead pins and from there to the crosshead bushing Drilled passages from the oil gallery deliver oil at full system pressure thru the tubing to lubri cate the top and bottom ...

Page 67: ...mostatic Control Valve Oil Tubing From Frame Gallery to Top and Bot tom of Guide to Lubri cate Crosshead Lube Oil Inlet to Cast In Oil Gallery Oil flows to the Crankshaft Main Bearings and thru Drilled Holes in the Crankshaft to Connecting Rod Bearings From there thru Drilled Holes in the Connect ing Rods to the Crosshead Pins and Bearings Lube Oil Cooler Customer Lines Filter Inlet Customer Lines...

Page 68: ...10 PSI 70 kPa across the filter at normal operating temperatures or at six month intervals Filter Element Installation Instructions 1 Clean filter base surface and be certain old gasket is removed 2 Fill filter with clean oil using the same grade oil as in the crankcase 3 Apply clean lube oil to the filter gasket 4 After the filter gasket contacts the base tighten one turn 5 After starting the uni...

Page 69: ...R EXCEEDS 600 RPM FOR THE JGW AND JGR AND 900 RPM FOR JGJ IF OIL PRESSURE DROPS BELOW 50 PSI 350 kPa THE CAUSE MUST BE FOUND AND CORRECTED Low Oil Pressure Shutdown The low oil pressure shutdown is normally mounted by the packager and is supplied to cus tomer specifications Ariel provides an oil pressure pickup fitting on the oil gallery located after the cooler and filter The electric or pneumati...

Page 70: ...UNNING THIS WILL CAUSE OIL FOAMING AND UNNECESSARY NO FLOW SHUTDOWNS IN THE FORCE FEED LUBRICATION SYSTEM 3 SINCE THE FORCE FEED LUBRICATION SYSTEM IS CONSTANTLY USING OIL FROM THE CRANKCASE A WORKING CRANKCASE OIL LEVEL CON TROLLER IS NECESSARY THIS MUST BE DESIGNED TO ALLOW OIL TO FLOW INTO THE CRANKCASE FROM AN OVERHEAD TANK AT ALL AMBI ENT TEMPERATURE CONDITIONS ...

Page 71: ...DISTANCE PIECE VENTING Eye Bolt Packing Secondary Vent Packing Lubrication From Distribution Block Crosshead Guide Vented Space Aluminum Gasket Piston Rod Oil Oil and Gas Gas Tube This Drain Off of Skid or Out of the Building Primary Vent Tube Off of Skid or Out of the Building Primary Vent O Ring Seal Drain ...

Page 72: ...TING PAGE 4 28 1 01 FIGURE 4 13 PACKING LUBRICATION AND VENTING Primary Vent Drain Packing Lubrication O Ring Seal Lubricating Oil Gas and Oil Gas Purge Gas Optional Secondary Vent Optional Purge Gas Connection Section A A Section A A Piston Rod Seal Gasket ...

Page 73: ...or from dust except when actually working on the unit Any com ponents that have been removed should be protected from falling objects that might mar or chip running surfaces Whenever the machine is dismantled gaskets at non pressure positions are to be carefully inspected before reuse Damaged gaskets must be replaced Gaskets at pressure locations should be replaced Always apply an anti seize lubri...

Page 74: ...ARE HEAVY CARE MUST BE TAKEN WHEN HANDLING TO CAUTION TO PREVENT PERSONAL INJURY ENSURE THAT COM PRESSOR CRANKSHAFT CANNOT BE TURNED BY THE DRIVER OR COMPRESSOR CYLINDER GAS PRESSURE DURING MAINTENANCE ON ENGINE DRIVEN COMPRES SORS REMOVE THE CENTER COUPLING OR LOCK THE FLYWHEEL ON ELECTRIC MOTOR DRIVEN COMPRES SORS IF IT IS INCONVIENIENT TO DETACH THE DRIVER FROM THE COMPRESSOR THE DRIVER SWITCH ...

Page 75: ...reciable wear of the babbitt would expose the bronze underneath Such exposure indicates the need for bearing replacement There are notches in the rod and rod cap for the bearing tabs in order to position and main tain the position of the bearing halves NOTE CRANK PIN BEARINGS AND MAIN BEARINGS ARE NO LONGER FUNCTION ALLY INTERCHANGEABLE CRANK PIN CONNECTING ROD BEARINGS HAVE A NARROWER GROOVE DO N...

Page 76: ...UMBERED BY THROW BEGINNING WITH NUM BER ONE AT THE DRIVE END ALWAYS INSTALL RODS WITH THE NUM BERS UP BE SURE TO PROTECT CRANK PIN AT ALL TIMES 2 Fit the connecting rod to the crank pin and turn to the highest position Replace the cap the half bearing shell properly located in the notch and the bolts Snug up all bolts Do not tighten bolts to full torque at this point 3 Reconnect the rod and the cr...

Page 77: ...kets apply an anti seize lubricant to both sides to aid in their easy removal at a later date Replace the top cover and crosshead guide cover Tighten all capscrews Crosshead Removal FIGURE 5 2 CROSSHEAD TYPICAL CAUTION BEFORE REMOVING THE CYLINDER HEAD BACK OFF ALL CAPSCREWS TO 1 8 INCHES 3 mm MAKE SURE THAT THE HEAD IS LOOSE AND THE CYLINDER IS VENTED SEE IMPORTANT SAFETY INFORMATION PLATES ON UN...

Page 78: ...age 1 9 Wear on the pin can be determined by a visual inspection Replace the pin if necessary If the bushings need to be replaced hacksaw or file to within 1 32 inches 1 mm of their thickness They can be easily drifted out A press will be needed to install new bushings The bushing can be installed in the crosshead by cooling the bushing in a dry ice and alcohol solution The bushing needs to be lef...

Page 79: ... 3 Reinstall the crosshead nut on the piston rod Be sure to have setscrew cup points on the crosshead side of the nut Screw the piston rod assembly into the crosshead using the Piston Nut Torquing Adaptor Make sure all threads are well lubricated with clean fresh oil to ensure smooth installation NOTE PISTON END CLEARANCE MUST NOW BE SET OR SERIOUS DAMAGE COULD OCCUR REFER TO Table 1 3 on page 1 9...

Page 80: ...o damage the sharp corners on each end of the top of the crank case These corners form the junction between the end covers top cover and base thus they must be kept sharp and unmarred to prevent oil leaks 4 Detach the connecting rods See Connecting Rod Removal on page 5 2 Move the rods to their full outer position 5 Remove the capscrews on the chain adjustment cap Turn the cap to loosen the chain ...

Page 81: ...Appropriately sized nylon slings should be used dur ing this operation to avoid marring of the running surface of the crankshaft Great care must be taken during this operation since the shaft could bind and become damaged NOTE THE LOWER HALF BEARING SHELLS SOMETIMES HAVE A TENDENCY TO STICK TO THE SHAFT JOURNALS BECAUSE OF THE CLOSE FITTING OILY SURFACES OF THE TWO PARTS THEREFORE WHEN THE SHAFT H...

Page 82: ...ation Put a rod at least 1 2 inches 13 mm in diameter through the slinger Special care should be exercised when handling the slinger not only to keep its surfaces unmarred but to avoid being cut by the outer sharp edge After the slinger is suspended heat it with a small torch When it has attained a yellow glow approximately 400 F 240 C it can be slipped over the drive end of the crankshaft Hold th...

Page 83: ...r two pieces of clean wood rotating it slightly to make sure it is square until it has cooled enough to shrink on the crankshaft DO NOT TOUCH HOT SURFACES WITHOUT PROPER INSULATION TO PREVENT INJURY Main Bearings Removal and Installation Bearings must be replaced if they show signs of wear or scoring Wear will be indicated by the bronze showing through the babbitted surface If replacement bearings...

Page 84: ...ent to the bearing cap Push down on the crank set indicator to zero pry up observe and record reading This is best done before the connecting rods are installed by pulling a clean lifting strap around the adjacent pin and pulling up on the crankshaft with a crane or bar on the strap 5 Reattach the connecting rods See Connecting Rod Installation on page 5 4 packing diaphragms and unloaders head end...

Page 85: ...king rollers or ruining the pump and lubri cator bearings when the chain goes through its tightest position 2 Remove the two capscrews and eight plugs from the eccentric adjustment cap Rotate the cap 6 degrees clockwise facing cap from outside to line up two new capscrew holes If this makes the chain too tight try turning the cap around in a counterclockwise direction for a different hole lineup 3...

Page 86: ...age 5 15 2 Remove the frame top cover Remove the dust plugs and the two capscrews that hold the eccentric adjustment cap to the end cover Rotate the eccentric cap to loosen the chain for removal After dropping the chain off the idler sprocket the entire assembly can be removed from the end cover 3 Remove the locknut capscrew sprocket and Stat O Seal washer Discard these items since they must be re...

Page 87: ...for 2 throw units or a square 3 16 x 1 inches 4 8 x 25 mm long for 4 and 6 throw units after first checking to make sure the key will fit into the new sprocket If the key is too thick it can be pol ished with an emery cloth on a flat surface until it can easily slide into the notch If may also be a little high and require filing of the top edge 7 Install a new sprocket to the original measurement ...

Page 88: ...remove any burrs raised by the cup point of the set screw Install a new O ring 6 Install a new No 204 Woodruff Key after first checking to make sure the key will fit into the new sprocket If it is too thick it can be polished with an emery cloth on a flat surface until it can easily slide into the notch It may also be a little high and require filing of the top edge 7 After the new key has been in...

Page 89: ... SPROCKET TYPICAL Oil O Ring Before Assembly Drain Plug Drain to Crankcase or to an Appropriate Drain System Sight Glass Sintered Bronze Filter 1 4 Inch Tubing Connection for a Priming Pump Priming Stem Pump Outlet to Distribution Block Locknut Lubricator Oil Fill Connection Sprocket No 204 Woodruff Key Setscrew Sprocket Face to Face Thickness ...

Page 90: ...reful in handling the piston rings Despite their toughness in service rings are fragile with regard to removal Always han dle them with clean tools and hands protecting the rings from nicks marring and bending Move the piston out of the cylinder until a fraction of the first ring clears the cylinder Encircle the ring by hand use a band for larger sizes until it is clear and remove it Use this same...

Page 91: ...lamping Fixture shown in Figure 5 12 on page 5 20 will be useful for the piston and rod disassembly and reassembly operations This fixture may be purchased from Ariel FIGURE 5 11 PISTON AND ROD REMOVAL AND INSTALLATION Ratchet Extension Support Tool B 1240 Set Screw Crosshead Nut Crosshead Piston Nut Spanner A 0424 or Turning Tool A 1678 ...

Page 92: ... that has been formed 2 Remove piston nut using piston nut spanner see Figure 7 1 on page 7 3 NOTE A SMALL AMOUNT OF GAS PRESSURE CAN BUILD UP WITHIN THE PISTON DURING OPERATION THIS WILL VENT WHEN THE PISTON NUT IS LOOS ENED 3 After the piston nut has been removed the piston and collar will slip off the end of the rod Reassembly 1 Clean all piston and rod assembly parts thoroughly Be sure piston ...

Page 93: ...ell lubricated with clean fresh oil to ensure proper assem bly Position the crankshaft in the inner dead center position Remove a crank end discharge valve Determine the required piston crank end clearance as shown on the cylinder identification plate Refer to Table 1 3 on page 1 9 Insert a feeler gage equal to the required crank end clearance thru the discharge valve pocket Use the tools illustra...

Page 94: ...oward the drive end of the frame will be recorded as a negative reading Copy Table 5 3 to record readings Bar over crankshaft by hand and record readings at mid stroke and with piston at the head end Compare readings to Table 5 4 If a vertical reading is greater than the maximum acceptable reading the following proce dure is used to determine acceptability With the piston at the head end use feele...

Page 95: ...pped seal joint piston rings and very small cylinders which use two piece rings Seal joint rings are available for double acting cylinders Refer to Figure 5 13 Seal joint piston rings are directional and must be installed properly To utilize the seal joint rings in double acting cylinders in place of angle cut rings contact Ariel for new part numbers TABLE 5 5 FEELER THICKNESS TO CORRECT FOR PISTO...

Page 96: ... is important Wear band pro jection can be checked by measuring piston to cylinder bore clearance at the bottom of the bore This can be done without removing the piston from the cylinder Replace the wear band before it has worn enough to allow the piston to touch the cylinder bore Piston Rings Installation 1 Place the rings over the grooves in the piston Compress the Teflon one piece rings by hand...

Page 97: ...tching edges will be square 9 The metal gasket on the end cup can be pried loose with a sharp awl Be careful not to scratch the sides of the gasket groove 10 Before reassembly be certain all parts are perfectly clean Piston Rod Packing Reassembly 1 Be sure to refer to the pressure packing assembly in your parts book Ariel sup plies four parts books with each unit Please contact your distributor if...

Page 98: ...y with the oil supply point on top Using the rod packing bolts pull the packing into place 10 Reinstall the packing diaphragm and wiper packing 11 Reinstall the piston and rod Follow the steps under Piston and Rod Installa tion on page 5 21 12 After the crosshead nut has been tightened tighten the rod packing bolts evenly to the recommended torque in Table 1 11 on page 1 15 This procedure will ens...

Page 99: ...r the ring is 0 030 to 0 036 inches 0 76 to 0 91 mm for PEEK material and 0 015 to 0 021 inches 0 38 to 0 53 mm for bronze and cast iron materials This ring breaks down or slows the gas flow without sealing it completely This end gap should be maintained by adjusting the ring gap or replacing the ring See Figure 5 14 FIGURE 5 14 TYPE P PRESSURE BREAKER Radial Cut Material PEEK Letters toward press...

Page 100: ...ntially step cut ring and is also made of Teflon The first two rings are doweled so the cuts are staggered from one ring to the other The third ring is called a back up ring and is radially cut The bore in this ring is larger than the rod diameter This allows the radial joints to be tight together forming a gas seal No dowel is necessary for this ring See Figure 5 15 FIGURE 5 15 TYPE BTR SINGLE AC...

Page 101: ...es 1 98 to 2 77 mm for Teflon material and 0 156 to 0 187 inches 3 96 to 4 75 mm for bronze Polyimide and PEEK materials The set is double acting in that it will seal in either direction It is used in cylinders operating near atmospheric pressure to prevent air from entering the cylinder Install with the match mark letters facing the pressure See Figure 5 16 FIGURE 5 16 TYPE BD DOUBLE ACTING Align...

Page 102: ...ed to provide a staggered arrangement Their purpose is to keep crankcase oil out of the packing and cylinder Assemble with the blank face towards the oil crankcase and the slotted side towards the pressure packing See Figure 5 17 FIGURE 5 17 TYPE 3RWS WIPER SET Crankcase Side Radial Cut This side toward pressure cylinder Material Cast Iron ...

Page 103: ... designed for gas purge applications See Figure 5 18 Typical Arrangement of Piston Rod Packing Rings Ariel supplies JGW JGR and JGJ packings in two pressure ranges The general arrange ment of the oil supply seal ring and vent locations is shown below The oil wiper rings and a seal ring set are carried on a separate diaphragm in the crosshead guide when a two compartment distance piece is supplied ...

Page 104: ... the valve cap bolts A pair of prybars or screwdrivers one on each side of the cap will help pry it loose With the retainer still in place screw a valve tool over the valve center bolt See Figure 7 1 on page 7 3 Now the valve and retainer can be pulled out together For cylin der class 2R FS HE and 2RJ FS HE tandem cylinders the suction and dis charge piping and cylinder head must be removed to gai...

Page 105: ...n either case care must be taken to keep this gasket from falling into the gas passage 2 The retainer keeper is a plastic thumb screw in a threaded hole in the bottom valve retainers This should be screwed through just far enough to provide fric tion so that bottom retainers will not fall out while the cap is being installed 3 Using the Valve Tool illustrated in Figure 7 1 on page 7 3 the valve an...

Page 106: ...rush of the gasket which could cause a leak and could also cause bolt failure This step tightening procedure is also recommended for all valve caps Install the valve assembly and high clearance spacer when applicable with the flat gas kets and valve retainer in the valve pocket See Valves Reassembly on page 5 33 For FIGURE 5 19 TYPICAL VALVE ASSEMBLIES Cylinder Bore Typical Suction Valve Valve Cap...

Page 107: ...en each bolt until snug using a criss cross pattern Next tighten each bolt to 25 of full torque moving across from bolt to bolt in a criss cross pattern See Figure 5 20 1 2 3 4 5 Repeat this step for 50 75 and 100 of full torque Proper tightening and torquing is important for all valve caps but is especially important for high pressure valve cap assemblies High pressure applications have caution p...

Page 108: ...Unsnap the thread protector bellows from the slot in the hand wheel With the locking handle locked remove locknut and hand wheel A hammer or puller may be required to break hand wheel to stem tapered fit Loosen locking handle and unscrew to remove handle Remove socket head screws at inside of bolt flange and separate the halves of the VVCP Unscrew the VVCP stem and piston assembly to remove FIGURE...

Page 109: ...snug using a criss cross pattern Next tighten each cap screw to 25 of full torque moving from cap screw to cap screw in a criss cross pattern Repeat this step for 50 75 and 100 of full torque See Table 1 11 on page 1 15 for tightening torque value Reconnect VVCP packing vent When installing a new VVCP check total piston end clear ance and re set crank end head end feeler clearances with VVCP compl...

Page 110: ...at stem is free to turn Turn the stem by use of the hand wheel on the outboard end of the shaft Turn hand wheel clockwise to load counterclockwise to unload Re tighten the stem locking handle to 150 lbs ft 203 Nm torque FIGURE 5 21 CYLINDER WITH VVCP TYPICAL Compressor Cylinder Compressor Piston Rod Assembly VVCP Assembly VVCP Packing VVCP Packing Vent Grease Fitting Stem Piston Hand Wheel Thread ...

Page 111: ...en in Figure 1 11 on page 1 15 Using fin gers make sure that all rings move freely radially in their grooves Side loaded WAT and AL rings will be snug but should still move using fingers Testing 100 verification of function is required for all internal passages The passages are to be checked by blowing compressed air thru the connection taps on the flange and verifying that air is exiting at the p...

Page 112: ...nt leak must be found and repaired If sampling indicates ethylene glycol contamination greater than 5 or if the compressor has seized due to contamination the unit must be disassembled cleaned with 100 butoxyeth anol flushed with kerosene or fuel oil and repaired as required All surfaces that come in contact with crankcase oil must be cleaned with butoxyethanol including all passages and piping an...

Page 113: ... on page 5 39 using water instead of oil for testing Thoroughly dry packing case with warm air such as with a hair dryer Handle cleaned parts with new or clean rubber or new white cotton gloves Before installing the piston rod into the unit wipe the piston rod with denatured alcohol Be careful not to leave any fingerprints on the rod before it contacts the packing case rings Make sure the piston r...

Page 114: ...FOR MODELS JGW JGR AND JGJ SECTION 5 MAINTENANCE PAGE 5 42 1 01 NOTES ...

Page 115: ...ted A log book should be kept with each unit Every maintenance item can be recorded with exacting detail in order that records will be available for tracking maintenance cost per unit and for trouble shooting Operator logs should be reviewed by qualified personnel to determine trends in compressor performance and or maintenance Daily 1 Check frame oil pressure It should be 50 60 PSIG 350 420 kPa w...

Page 116: ...es it A less frequent oil change interval may be allowed if the oil is replenished on a regular basis due to force feed lubricator usage 4 Clean the sintered element in the small oil filter supplied on the force feed lubri cation system This filter should also be cleaned every time the main oil filter is changed 5 Clean strainer when oil is changed 6 Open frame when oil is changed and visually ins...

Page 117: ...nches 0 03 mm or tapered more than 0 002 inches 0 05 mm replace the rod 7 Rebuild cylinder packing cases 8 Inspect for frame twist or bending by checking shimming of compressor feet 9 Realign if necessary to hold coupling alignment within 0 005 inches 0 13 mm TIR 10 Check and re calibrate all temperature and pressure gauges 11 Check and record compressor rod run out 12 Grease VVCP stem threads at ...

Page 118: ...ur poses for which it was not intended Recording of the interstage pressures and temperatures on multistage units 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 If it rises the problem is normally in the higher pressure cylinder While it would be i...

Page 119: ...en 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 higher stage Obstruction bind or valve closed in discharge line High Discharge Temperature Excessive ratio across cylinder due to leaking inlet valves or rings on next higher stage Fouled intercooler piping ...

Page 120: ...FOR MODELS JGW JGR AND JGJ SECTION 6 TECHNICAL ASSISTANCE PAGE 6 6 1 01 NOTES ...

Page 121: ...ing Tool for 9 16 socket A 1678 provided with small tandem cylinders only Torque Chart D 2159 Ariel provides these tools with every compressor Please contact your Distributor if you do not have these tools These tools are specifically designed for use on Ariel units Clean all tools before use Ensure that the tool and the part being removed or installed are fully engaged during the process If a too...

Page 122: ...rive Speed Wrench 1 2 Female x 3 4 Male Adaptors 1 2 Square Drive Universal Joint 3 8 Square Drive Torque Wrenches 10 LB IN to 250 LB IN 1 2 Square Drive Torque Wrenches 15 LB FT to 250 LB FT 3 4 Square Drive Torque Wrench to 1590 LB FT 5 16 3 8 7 16 1 2 9 16 3 4 5 8 and 15 16 12 Point Sockets for a 1 2 Square Drive Ratchet Wrench 1 2 Hex Key and 1 4 Hex Key Allen Sockets for a Square Drive Ratche...

Page 123: ... F x 0 310 normal meter3 second at 1 01325 bar 0 C or mn 3 s SCFM or standard cubic feet per minute at 14 696 psia 60 F x 1 607 normal meter3 hour at 1 01325 bar 0 C or mn 3 h FIGURE 7 1 ARIEL TOOLS 1 US units of measure can appear abbreviated in upper or lower case 2 Maintain upper and lower case letters in SI Metric as shown Valve Tool A 0135 A 0409 A 0626 Piston Nut Spanner A 0424 Ratchet Exten...

Page 124: ... or or inches x 25 4000 millimeters or mm ft or feet x 0 304800 meter or m Mass lb or pound mass 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 Power1 HP or Horsepower x 0 745700 kilowatt or kW Pressure2 or Stress psi x 6894 757 Pascal or Pa Pa x 0 000145 psi psi x 6 894757 kiloPascal o...

Page 125: ... per second or m s RPM or r min or revolutions per minute x 60 revolutions per second or rev s Temperature F or degrees Fahrenheit F 32 1 8 degrees Celsius or C Time sec second or s min or minute x 60 second or s hr or h or hour x 3600 second or s Viscosity SSU SUS or Saybolt Universal seconds x 0 22 180 SSU mm2 s centistoke or cSt for a range of 33 thru 200 000 SUS Volume gal or gallons US liquid...

Page 126: ... Minimum N A Not Applicable NO Number NPT National Pipe Thread PEEK Poly Ether Ether Ketone plastic material Percent PIST Piston P N Part Number SAE Society of Automotive Engineers SG Specific Gravity SI International System as applied to the modern metric system S N or S N Serial Number TFE Teflon THD Thread TIR Total Indicator Reading TPI Threads Per Inch TRAV Travel UNC Unified Inch National Co...

Page 127: ... C4H10 IC5 Iso Pentane 2 Methyl Butane C5H12 NC5 N Pentane C5H12 NEOC5 Neopentane C5H12 NC6 Hexane C6H14 NC7 Heptane C7H16 NC8 Octane C8H18 NC9 Nonane C9H20 NC10 N Decane C10H22 NC11 N Undecane Hendecane C11H24 NC12 N Dodecane C12H26 C2 Ethylene Ethene C2H4 C3 Propane Propylene C3H6 BENZ Benzene C6H6 TOL Toluene C7H8 EBNZ Ethylbenzene C8H10 CO Carbon Monoxide CO CO2 Carbon Dioxide CO2 H2S Hydrogen...

Page 128: ...technical information including changes corrections and or additions to the Technical Manual for Packagers and End Users Be sure to refer to this material before operating or servicing the equipment A complete listing of these Bulletins is available at the Ariel Website and copies may be obtained from the Packager or from Ariel TABLE 7 2 USEFUL SI METRIC MULTIPLE AND SUBMULTIPLE FACTORS MULTIPLICA...

Page 129: ...3602 For all calls to Spare Parts Group day or night Spare Parts Fax 740 393 5054 The after hours system works as follows 1 Dial number 2 Calls are answered by voice mail 3 Leave message caller s name telephone number serial number of equipment in question frame cylinder unloader and brief description of emergency 4 The call will be immediately forwarded to a responsible individual who will return...

Page 130: ...FOR MODELS JGW JGR AND JGJ SECTION 7 APPENDICES PAGE 7 10 1 01 NOTES ...

Page 131: ...X1 32 0 0000 0 00 2 B 0419 GSKT RET 12 1 4 X 8 1 8X1 32 0 0000 0 00 1 A 0661 LO FILTER ELEMENT SPIN ON 0 0000 0 00 4 A 0124 BLOW OUT DISC 3250 PSIG PURPLE 0 0000 0 00 1 A 3689 CHECK VALVE 1 8M X 1 8F PPT SS 0 0000 0 00 Sub Total 0 00 Start Up Grand Total 0 00 Page 1 of 4 Ariel Recommended Spares 9 15 2010 https www arielcorp com members reports cust recspr recspr_strup1 asp ordnum 45671 ...

Page 132: ...SEAT SS 0 0000 0 00 1 A 8723 K FILTER KIT LUBRICATOR 150 MIC 0 0000 0 00 1 A 9477 FF LUBR PUMP 1 4 PREMIER 0 0000 0 00 2 A 0661 LO FILTER ELEMENT SPIN ON 0 0000 0 00 4 A 0124 BLOW OUT DISC 3250 PSIG PURPLE 0 0000 0 00 1 A 0080 BLOW OUT ASSY SPECIFY DISC 0 0000 0 00 3 A 3689 CHECK VALVE 1 8M X 1 8F PPT SS 0 0000 0 00 Sub Total 0 00 Consumables Grand Total 0 00 Page 2 of 4 Ariel Recommended Spares 9...

Page 133: ...G H S MAIN R W J ACF 0 0000 0 00 2 A 12036 SEAL DUST OIL 1 625 SHAFT DIA 0 0000 0 00 6 B 0301 BUSHING BZ XHD R J ACF 0 0000 0 00 1 A 0419 12 PT 7 16 20 X 7 LG 0 0000 0 00 2 FN0467FA SELF LOCK NUT FLEXLOC 7 16 20 0 0000 0 00 1 B 0332 CROSSHEAD PIN JGR W J 0 0000 0 00 2 A 3763 CHK VLV 1 8MX1 8F SS PPT 14PSI 0 0000 0 00 1 A 0077 SIGHT GLASS 1 NPT 0 0000 0 00 1 A 5641 SIGHT GLASS 3 4 NPT 0 0000 0 00 1...

Page 134: ...Printed Wed Sep 15 17 42 17 EDT 2010 2010 ARIEL CORPORATION Page 4 of 4 Ariel Recommended Spares 9 15 2010 https www arielcorp com members reports cust recspr recspr_strup1 asp ordnum 45671 ...

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