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Installation, Operation

& Maintenance Manual

Plain & T-Style Double-Acting Gas Compressors

Models HG601, HG602, THG601 & THG602 Series

ORIGINAL INSTRUCTIONS

IJ100F

Warning: (1) Periodic inspection and maintenance of Corken products is essential. (2) Inspection, maintenance and installation of

Corken products must be made only by experienced, trained and qualified personnel. (3) Maintenance, use and installation of Corken

products must comply with Corken instructions, applicable laws and safety standards. (4) Transfer of toxic, dangerous, flammable or

explosive substances using Corken products is at user’s risk and equipment should be operated only by qualified personnel according

to applicable laws and safety standards.

Model HG601EE

(Plain style)

Model THG602BE

(T-style)

Solutions beyond products...

Содержание HG601 Series

Страница 1: ...ducts must be made only by experienced trained and qualified personnel 3 Maintenance use and installation of Corken products must comply with Corken instructions applicable laws and safety standards 4...

Страница 2: ...nties including any implied warranty of merchantability or fitness for a particular purpose are expressly negated to the extent permitted by law and shall in no event extend beyond the expressed warra...

Страница 3: ...Lubrication Lubed models only 15 3 7 Variable Clearance Heads VCH 16 3 8 Startup Check List 16 Chapter 4 Routine Maintenance Chart 17 Chapter 5 Routine Service and Repair Procedures 17 5 1 Compressor...

Страница 4: ...zed gas in the compression chamber from the crankcase While piston rings seal the piston tightly enough for it to do compression work they do not provide enough sealing to isolate the compression cham...

Страница 5: ...ner oil wiper ring set Inner packing set Heavy duty crankcase A rugged internally ribbed design incorporating heavy duty main bearings and four bolt connecting rods Variable clearance head Allows chan...

Страница 6: ...SUPPORT PIPING WITH THE COMPRESSOR The compressor must not support any significant piping weight therefore the piping must be fully supported The use of flexible connections to the compressor is highl...

Страница 7: ...ce In the United States the following codes apply For LP Gas The National Fire Protection Association Pamphlet No 58 Standard for the Storage and Handling of Liquefied Petroleum Gases For Ammonia The...

Страница 8: ...ide the motor can condense and if enough water accumulates the motor will fail To prevent this two method can be followed Make a practice of running the motor at least once a week on a bright dry day...

Страница 9: ...e unable to protect the components from wear Viscosity Index Viscosity Index VI is a measure of how much the oil s viscosity changes as its temperature changes A low viscosity index is an indication t...

Страница 10: ...e 2 Viscosity ISO 3 Viscosity Index3 Pour Point 3 40 to 100 F 4 to 38 C Mobil DTE 10 Excel 100 C 100 127 27 F 33 C Mobil Rarus 427 C 100 100 16 F 9 C Phillips 66 Gas Compressor Oil C 100 102 20 F 29 C...

Страница 11: ...3suchtests adetermination can be made for a recommended oil change interval for a particular compressor in its specific environmental situation and operating conditions Regular oil analysis can help i...

Страница 12: ...o select the set pressure on a relief valve located on compressor piping discharge is for it to be between 10 20 above the highest discharge pressure the compressor can produce but less than the maxim...

Страница 13: ...lywheel and V belt Alignment Before working on the drive assembly be sure that the electric power is disconnected When mounting new belts always make sure the driver and compressor are close enough to...

Страница 14: ...gauge If the gauge fails to indicate pressure within 30 seconds stop the machine and loosen the oil filter Restart the compressor and run until oil comes out and tighten the filter The oil pressure s...

Страница 15: ...end of the crankcase see lubricator assembly details in Appendix D Since lubricators supplied with Corken compressors are made by a number of different manufacturers refer to the manufacturer s instr...

Страница 16: ...ipated conditions 3 Ensure that line pressures are within cylinder pressure ratings 4 Clean out all piping 5 Check all mounting shims cylinder and piping supports to ensure that no undue twisting forc...

Страница 17: ...part details appendix in the back of this Installation Operation Maintenance IOM manual for a complete list of part numbers and descriptions 5 1 Compressor Valves Test the compressor valves by closin...

Страница 18: ...valves may simply be cleaned and reinstalled If the valves show any damage they should be repaired or replaced Replacement is usually preferable although repair parts are available If valve plates are...

Страница 19: ...ed Corken recommends replacing expanders whenever rings are replaced To determine if rings should be replaced measure the radial thickness and compare it to the chart in Appendix B 5 4 Pistons While r...

Страница 20: ...to smooth the cylinder bore and then polish it to the value shown in Appendix B If more than 005 of an inch must be removed to smooth the bore replace the cylinder Cylinder liners and oversized rings...

Страница 21: ...the packing cartridge cap to the adapter It is not normally necessary to remove the adapter from the crankcase in order to disassemble or reassemble the packing c Partially insert the bolts in the pu...

Страница 22: ...re is needed to keep from losing them or having them become dislodged during assembly d Install a purge packing cup with O ring and biased packing set tangent tangent with springs toward crankcase sTT...

Страница 23: ...Pull outward to remove the packing cartridge assembly from the adapter and over the piston rod a 2 3 4 and 3 1 4 Cylinders Using a pair of flat bladed screwdrivers or similar tools engage the annular...

Страница 24: ...mbly Place the oil wiper ring cup and oil wiper ring set onto the purge packing cup A full inner packing set is now positioned on the end plate of the tool See figure 5 6C c Orient the packing cartrid...

Страница 25: ...plate Nut Slotted clamp Purge packing cup and inner packing set Packing assembly tool 4794 X Step 2 Figure 5 6D Packing assembly Cup spacer Socket head screw Packing cartridge adapter Packing cartrid...

Страница 26: ...ause most packing cartridge bodies can only be installed in one position i Install the packing cartridge cap in the adapter Be sure the mark previously made on the packing cartridge cap is oriented up...

Страница 27: ...rankshaft throw and bearing surface are clean and lubricated Tighten the connecting rod nuts to the torque value listed in Appendix B 5 7 3 Replacing Crankcase Roller Bearings To inspect the roller be...

Страница 28: ...ring cup and bearing cover Slowly lower the opposite end of the crankshaft to the bottom of the bearing carrier opening 6 Before installing the bearing carrier make sure the slot at the end of the oil...

Страница 29: ...proper alignment of the oil pump s pins and slots 5 9 Disposal Disposal of compressor or components once deemed non usable by the factory and end user should be done in accordance with all applicable...

Страница 30: ...Standard head PTFE steel 3582 X2A 3 1 4 Adjustable head Buna N steel 3582 X2D 3 1 4 Adjustable head Viton 1 steel 3582 X2E 3 1 4 Adjustable head PTFE steel 3582 X2B 3 1 4 Adjustable head Neoprene 1 s...

Страница 31: ...all areas accessible to personnel which contain concentrations of process gases capable of displacing breathing air shall be kept at acceptable levels per all local regulations codes 6 End user to tak...

Страница 32: ...a hoist forklift or sling to the lifting eye s on the crankcase of the compressor End user must ensure the lifting apparatus has a load capacity at least as large as the weight of the compressor bein...

Страница 33: ...33...

Страница 34: ...l NA NA NA NA NA 4BL1 Low inlet pressure valves and blank valves with PEEK plates NA Optional NA NA NA NA 4PBL1 Unloaders Optional NA NA Optional Optional NA 9 Unloaders with PEEK plates NA Optional O...

Страница 35: ...ves with blank valves Optional NA NA NA NA NA 4BL1 Low inlet pressure valves and blank valves with PEEK plates NA Optional NA NA NA NA 4PBL1 Unloaders Optional NA NA Optional Optional NA 9 Unloaders w...

Страница 36: ...age with PEEK plates Optional Optional NA Optional Optional 4PFL1 Standard valves with blank valves in 2nd stage NA NA Optional NA NA 4S Standard and blank valves in 2nd stage with PEEK plates Optiona...

Страница 37: ...ous page Piston Ring and Packing Material PTFE piston and Alloy 50 packing material Standard F Gasket Material Steel Standard D O ring Material Buna N Standard A Neoprene 2 No charge option B Viton 2...

Страница 38: ...dard valves w blank valves in 2nd stage w PEEK plates Optional 4PS Low inlet pressure valves with blank valves in 2nd stage with PEEK plates Optional Optional NA NA NA 4PSL1 Unloaders with PEEK plates...

Страница 39: ...1st stage Optional 4F Standard valves with blank valves in 2nd stage Optional 4S Unloaders Optional NA 9 Unloaders with blank valves in both stages Optional NA 9B Unloaders with blank valves in 1st s...

Страница 40: ...andard NA 4 Standard valves with PEEK plates NA Standard NA Standard 4P Suction valve unloaders Optional NA Optional NA 9 Suction valve unloaders with PEEK plates NA Optional NA Optional 9P Piston Rin...

Страница 41: ...Data Stroke inches mm 3 0 76 2 Maximum gas rod load lb kg 7 500 3 401 9 Maximum motor size hp kg 75 55 9 Maximum discharge temp F C 1 350 6 177 Minimum temp F C 1 20 28 9 RPM range 400 1 200 THG HG600...

Страница 42: ...7 870 394 6 845 383 3 845 383 3 THG model 1 170 530 7 1 010 458 1 990 449 1 970 440 0 945 428 7 945 428 7 Two stage Horizontal Compressors Two Cylinder Models HG602AB THG602AB HG602AC THG602AC HG602AD...

Страница 43: ...1EE 429 HG601FF 383 THG601FF 429 HG602AB 449 THG602AB 494 HG602AC 444 THG602AC 490 Horizontal Compressor Model Machine Mass kg Horizontal Compressor Model Machine Mass kg HG602AD 440 THG602AD 485 HG60...

Страница 44: ...25 4 5 Steel 6 8 Aluminum A356 T6 Ductile iron A536 Grade 65 45 12 single stage only Piston rod All 1045 Steel Nitrotec 1 Crosshead All Gray iron ASTM A48 Class 30 Connecting rod and packing cartridge...

Страница 45: ...ylinder to adapter 1 65 65 65 65 65 65 Valve cover plate bolt 35 35 40 40 40 40 Valve holddown screw2 40 40 40 40 40 40 Piston nut torque 150 150 150 150 150 150 Piston screw torque 100 50 100 100 100...

Страница 46: ...93 2 36 0 093 2 36 0 098 2 49 T Style Bottom minimum clearance Y 0 005 0 13 0 005 0 13 0 005 0 13 0 005 0 13 0 005 0 13 0 005 0 13 Bottom maximum clearance Y 0 015 0 38 0 015 0 38 0 015 0 38 0 015 0 3...

Страница 47: ...863 9 2 slip on 6 22 94 582 7 5 94 150 9 30 25 768 4 33 06 839 7 2 slip on 8 23 63 600 2 7 25 184 2 32 13 816 1 34 69 881 1 3 slip on a 1 5 Class 1500 RF flange not supplied NOTE 1 Standard flywheel...

Страница 48: ...25 184 2 32 13 816 1 34 69 881 1 3 slip on a 1 5 Class 1500 RF flange not supplied NOTE 1 Standard flywheel not shown 5 5V 21 2 2 Jacking screw provided for cylinder support 8 and 6 cylinders only In...

Страница 49: ...1 062 2 2 slip on 6 30 75 781 1 5 94 150 9 38 07 967 0 40 88 1 038 4 2 slip on 8 31 50 800 1 7 25 184 2 40 07 1 017 8 42 88 1 089 0 3 slip on a 1 5 Class 1500 RF flange not supplied NOTE 1 Standard fl...

Страница 50: ...slip on 8 31 50 800 1 7 25 184 2 40 07 1 017 8 42 88 1 089 0 3 slip on a 1 5 Class 1500 RF flange not supplied NOTE 1 Standard flywheel not shown 5 5V 21 2 2 Jacking screw provided for cylinder suppor...

Страница 51: ...pressure in the unit before attempting any repairs Cylinder Bill of Materials Ref No Part No Description Qty per Cylinder 1 2 232_a O ring 2 2 3888 Cylinder 1 3 3899 1 Adjustable head 1 4 2 225_ a f...

Страница 52: ...3665 3665 Adjusting screw nut 1 13 7001 050NC150A 7001 050NC150A 7001 050NC150A Bolt hex head 1 2 13 x 1 1 2 16 14 3527 3763 5293 Head 1 15 3442 3442 3442 Pipe plug 1 4 4 16 3698 3698 3698 Nameplate...

Страница 53: ...3663 3683 Adjusting cup 1 9 2 250_ a 2 262_ a O ring 1 10 3637 3682 Adjusting cap 1 11 2 127_ a 2 127_ a O ring 1 12 3665 3665 Adjusting screw nut 1 13 7001 050NC150A 7001 050NC150A Bolt hex head 1 2...

Страница 54: ...01 043NC150A 16 2 Valve cover plate 3894 4 2205 4 1764 4 3 O ring 2 224_ b 4 2 143_ b 4 2 235_ b 4 4 Suction valve assembly 3900 X steel 2 4029 X2 steel 2 3807 X steel 2 5 Discharge valve assembly 390...

Страница 55: ...y 3857 5X2 steel 2 3857 2X2 steel 4 3709 X2 steel 4 6 Valve gasket 2114a 4 2114a 4 3691 a 4 7 Valve cap 2714 1d 4 2714 1d 4 2714 1d 4 8 O ring 2 031_ b 4 2 031_ b 4 2 031_ b 4 9 Holddown screw 2715 4...

Страница 56: ...r 3939 4 3826 4 3857 4 8 Spring buttona 9 Spring inner a 3924 4 3829 4 3929 4 3829 1 Inconel optional Spring outer a 3928 4 10 Repair kit 3804 X1 4 3124 X suction 2 3805 X1 4 3146 X1 4 3125 X discharg...

Страница 57: ...3709 X aluminum 4 3709 X aluminum 4 3857 5X2 steel 4 3857 3X2 steel 4 3709 X2 steel 4 3709 X2 steel 4 3 Valve seat 3856 4 3856 4 3834 2 3834 2 4 Stud c 3920 4 3920 4 3828 2 3828 2 5 Valve plate inner...

Страница 58: ...1 NOTE See Appendix B for piston clearance specifications 1 2 3 4 6 2 7 8 9 10 Piston rod see connecting rod assembly for more information 7 11 8 Piston Size NOTE See Appendix B for piston clearance s...

Страница 59: ...b 3812 1 3812 1 3812 1 Ref No Description Cylinder Diameter 5 6 8 Part No Qty Part No Qty Part No Qty 1 Piston assembly iron 5301 X1 3530 X1 1 3674 X1 1 Piston assembly aluminum 5301 1X1 1 3530 1X1 1...

Страница 60: ...c Direction of oil wiper ring set is important See packing assembly page for details d _ denotes material code See material code chart for details e Registered trademark of the DuPont company f Apply...

Страница 61: ...g location b Direction of packing is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assembly page for details d _ denotes material code See...

Страница 62: ...etails c Direction of oil wiper ring set is important See packing assembly page for details d _ denotes material code See material code chart for details e Registered trademark of the DuPont company f...

Страница 63: ...4 1 a See detail for O ring location b Direction of packing is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assembly page for details d _...

Страница 64: ...mbly page for details d _ denotes material code See material code chart for details e Registered trademark of the DuPont company f Apply a small amount of Loctite 272 to the circumference of the threa...

Страница 65: ...is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assembly page for details d _ denotes material code See material code chart for details e...

Страница 66: ...cking assembly page for details d _ denotes material code See material code chart for details e Registered trademark of the DuPont company f Apply a small amount of Loctite 272 to the circumference of...

Страница 67: ...b Direction of packing is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assembly page for details d _ denotes material code See material co...

Страница 68: ...ded Cup Spacer not included Backup Ring with 6 springs Crankcase Side Cylinder Side 1 Standard Specification Oil wiper ring set Radial Radial 2 Purge Specification Oil wiper ring set Radial Radial Par...

Страница 69: ...ng not included Crankcase Side Cylinder Side Packing Cup not included Backup Ring not included Align pin with hole on backside Tangent Cut with pin Tangent Cut without pin Crankcase Side Cylinder Side...

Страница 70: ...ing set 1 a See detail for O ring location b Direction of packing is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assembly page for detail...

Страница 71: ...of packing is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assembly page for details d _ denotes material code See material code chart for...

Страница 72: ...4 27 4273 1X2 Packing set 1 a See detail for O ring location b Direction of packing is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assemb...

Страница 73: ...ee detail for O ring location b Direction of packing is important See packing assembly page for details c Direction of oil wiper ring set is important See packing assembly page for details d _ denotes...

Страница 74: ...egmented Packing Set Tangent Tangent with springs toward cylinder TTs Part number 3816 Part number 4273 Middle Packing Details Backup Ring not included Packing Cup not included Align pin with hole on...

Страница 75: ...ncluded Purge Packing Spacer not included Crankcase Side Cylinder Side Packing Cup not included Breaker Ring Crankcase Side Cylinder Side 1 Pad Specification Segmented Packing Set Tangent Tangent 2 Pa...

Страница 76: ...t 4 3 3542 Connecting rod bearing pair 1 4 1726 Connecting rod bolt 4 5 3541 a Wrist pin bushing 1 6 3590 Wrist pin retainer ring 2 7 3544 X1 Crosshead assembly HG600 1 3544 X11 Crosshead assembly THG...

Страница 77: ...043NC150A a Bolt hex head 1 2 13 x 1 1 2 8 8 8 8 8 8 8 8 6 7001 050NC250A b Bolt hex head 7 16 14 x 2 1 2 3 3 3 3 9 7 3812 Loctite 620 tube 1 1 1 1 1 1 1 1 a Use Loctite retaining compound 620 and tor...

Страница 78: ...ather cap and ball details 31 34 34 32 32 35 29 33 33 Note Oil transfer tubing mounts inside the crankcase 4 3 2 5 Cross section of bearing carrier shows lubrication tubing used to lubricate the cross...

Страница 79: ...1435 Tee 1 8 P x 1 4 T x 1 4 T brass 2 34 1399 Male elbow 1 8 P x 1 4 T brass 2 35 3643 Pipe plug 1 NPT steel 1 Crankcase Assembly Bill of Materials Ref No Part No Description Qty 1 3538 Crankcase 1 3...

Страница 80: ...s Ref No Part No Description Qty 14 2 112A O ring 1 15 3219 Pump shaft adapter 1 16 2852 Oil pump spring 1 17 2851 Spring guide 1 18 2849 1X a Oil pump assembly 1 19 2 228A O ring 1 20 4222 Oil filter...

Страница 81: ...C100A Bolt hex head 3 8 16 x 1 4 16 3526 Oil seal 1 a Caution To avoid damage during assembly refer to Important Instructions IE400 Crankcase Assembly Bill of Materials Ref No Part No Description Qty...

Страница 82: ...k check valve 2 26 3668 Xc Divider valve assembly single cylinder 1 27 7201 037A Washer 3 8 4 a Except 2 3 4 cylinder b 2 3 4 cylinder only c Single cylinder units only d Optional Crankcase Assembly B...

Страница 83: ...e plug 1 8 NPT flush 1 a Must be installed in the center hole on the backside of the oil filter adapter See reference 29 on page 80 for details on the backside of the oil filter adapter part 4222 Ref...

Страница 84: ...2 2 2 2 2 2 Back Side Front Side Flywheel Bill of Materials Ref No Part No Description Qty 1 3852 Flywheel 21 2 O D 5 V grooves 1 2 H J 2 125 Hub with three bolts and lockwashers 1 Assembly Number Ass...

Страница 85: ...8 14 Oil leakage around compressor base 16 17 No oil pressure 18 19 Excessive vibration 1 7 9 10 11 12 13 25 27 Motor overheating or starter tripping out 20 21 22 23 24 25 26 27 Ref No Possible Causes...

Страница 86: ...ristics Voltage phase and frequency must coincide with motor nameplate Consult with power company 24 Wrong size of heaters in starter Check and replace according to manufacturer s instructions 25 Comp...

Страница 87: ......

Страница 88: ...h 2020 CORKEN INC A Unit of IDEX Corporation 9201 North I 35 Service Road Oklahoma City OK 73131 Phone 405 946 5576 Fax 405 948 7343 Website www corken com E mail cocsalesdept idexcorp com Solutions b...

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