D 691 Compressor Instruction Manual
Contents
1. FIVE VALVE MANIFOLD PIPING SYSTEM FIGURE 2 3B All piping must be in accordance with the laws and For Ammonia The American National Standards codes governing the service In the United States Institute Inc K61 1 1989 Storage and Handling of the following codes apply Anhydrous Ammonia For LP Gas The National Fire Protection Association Copies of these are available from NFPA 60 Pamphlet No 58 Standard for the Storage and Baterymarch Street Boston Mass 02110 and ANSI Handling of Liquefied Petroleum Gases 1430 Broadway New York N Y 10018 Install use and maintain this equipment according to Corken instructions and all applicable federal state and local laws and previously mentioned codes Liquid Transfer Vapor Recovery Compressors 11 C OPERATION OF VALVES SERVICE TO PERFORM VALVE POSITION 4 WAY A 1 Unload Tank Car into Position Open Storage Tank One 2 Recover Vapors from Tank Position Close Car into Storage Tank Two POSITION 1 POSITION 2 THREE VALVE MANIFOLD PIPING SYSTEM FIGURE 2 3C 2 4 LIQUID TRAPS OUTLET Compressors are designed to pressurize gas not to pump liquids The entry of even a small amount of liquid into the compressor will result in serious damage to the compressor VACUUM BREAKER VALVE ANAM O NAA VA AN I HP I rer A era a aay E On liquefied gas applications a liquid trap m2. POSSIBLE CAUSES 4 8 14 16 17 18 19 20 1 7 9 10 11 12 13 28 21 22 23 24 25 26 27 28 WHAT TO DO Valves broken stuck or leaking Piston ring worn Inlet strainer clogged Leaks in piping Inlet or ambient temperature too high Compression ratio too high Loose flywheel or belt Worn piston rod packing Worn wrist pin or wrist pin bushing Worn connecting rod bearing Unbalanced load Inadequate compressor base Improper foundation or mounting Loose valve piston or packing Dirty cooling fins 4 way control valve not lubricated Leaking gas blowing oil from crankcase Bad oil seal No oil in crankcase Oil pump malfunction Low voltage Motor wired wrong Wire size too small for length or run Wrong power characteristics Wrong size of heaters in starter Compressor overloading Motor shorted out Bad motor bearing 1 2 3 4 5 6 7 8 Inspect and clean or repair Inspect and replace as necessary Clean or replace screen as necessary Inspect and repair Consult factory Check application and consult factory Tighten Replace Replace Replace Inspect valve or consult factory Strengthen replace or grout Tighten mounting or rebuild foundation Tighten or replace as necessary Clean weekly Inspect and lubricate Tighten packing Replace Add oil See oil pressure adjustm ent Check line voltage with motor nameplate Consult power company Check wiring diagram Replace with correct
3. FEATURE ALL ANSI DIN FLANGE INLET AND OUTLET HEAD CONNECTION STYLE SINGLE STAGE DUCTILE IRON NOTE MODELS ARE AVAILABLE NOTE MODELS ARE AVAILABLE WITH DIN IRON HEAD CYLINDER MODEL NO WILL BE DESIGNATED BY A 2 THE LAST DIGIT OF THE MODEL NO 91 291 491 492 491 3 BASIC MODEL 691 692 ALL INLET PRESSURE ABOVE ATMOSPHERIC PACKING ADJUSTMENT 91 ONLY 91 491 ALL EXCEPT 91 ALL EXCEPT 91 ALL EXCEPT 91 ALL EXCEPT 91 SPLASH LUBRICATED CRANKCASE EXTENDED CRANKSHAFT STANDARD PRESSURE LUBRICATED CRANKCASE STANDARD CRANKCASE WITH CRANKCASE HEATER STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR UBRICATOR NDARD CRANKCASE WITH EXTERNAL COMPRESSOR UBRICATOR AND CRANKCASE HEATER CRANKCASE STYLE ALL ALL ALL ALL EXCEPT 391 491 ALL EXCEPT 391 491 LIQUID RELIEF SUCTION VALVES STANDARD SUCTION AND DISCHARGE VALVES SUCTION VALVE UNLOADERS SPEC 4 VALVES AS NOTED ABOVE WITH PEEK VALVE PLATES SPEC 9 VALVES AS NOTED ABOVE WITH PEEK VALVE PLATES VALVES 91 491 SERIES 691 ALL PTFE PISTON RING AND PACKING MATERIAL PTFE PISTON RING AND ALLOY 50 PACKING MATERIAL SAME AS F WITH THE ADDITION OF K RING SPACERS PISTON RING AND PACKING MATERIAL ALL ALL ALL ALUMINUM GASKET MATERIAL COPPER GASKET MATERIAL IRON LEAD GASKET MATERIAL GASKET MATERIAL ALL ALL ALL BUNA N NEOPRENE VITON O RING MATERIAL ALL SINGLE STAGE COMPRESSORS NOT APPLICABLE SINGLE
4. aauvununa varenr rn nrk nr nrk nen 18 Startup Checklist oca rita Gude Heat Uae a Pace 4 GREG URAL MAE GE ak Be gd acid J 19 4 ROUTINE MAINTENANCE CHART aaaam mama mr rv rn rn nn ee ee eee 20 5 ROUTINE SERVICE AND REPAIR PROCEDURES aan nur cece ee eee eee eee eee 21 VaIVGS oeee tt caae SS 21 Cylinder and Head 1 eee 22 Piston Rings and Piston Ring Expanders 00 te ee 22 PISIONS Aer TN NGT 22 Piston Rod Packing Adjustment esaa saasa aka a a RNE A o 24 Bearing Replacement aaauuan unna ENSIA AA eee 25 Wrist Pin Bushing Replacement sssssssisiser kiirt rakk eee 25 Connecting Rod BearingS o ooorr eee 25 Roller BEAnngs saauetee dess pa ands be Eta ANGRE tere bek ka abre Essen ae s t 25 Oil Pump Inspection avvvavv vaar r nn eee 26 Servicing the Four Way Valve 0 0 0 00 narrer nn nen 28 6 EXTENDED STORAGE PROCEDURES cccoco erre rn eee PAGE 29 APPENDIX A Model Number and Mounting Identification Code 0 0000 rn nn naken 30 B Material Specifications oooo oomomomorr eee 31 C Mechanical Specifications oooooocooooommrrr eee 32 D Bolt Torque ValueS sic wade Pete Bee ge saa AAA AA AAA A EA 33 E Clearance and Dimensions 0 000 cette 34 F LPG Liquid Transfer Compressor Performance Charts 0 0000 ce eee ete 35 PROPANG ss eet bara tn hb Malad oP dh Cea ae ed As 35 NBU IE Ss 302 Ader cn ae ct ed et eevee in ae ation bee eons 36 AMMO
5. Low OIL LEVEL BAYONET OIL PRESSURE GAUGE OIL PRESSURE ADJUSTING SCREW FLYWHEEL INSTALLATION FIGURE 3 3A 3 4 STARTUP CHECK LIST Please verify all of the items on this list before starting your compressor Failure to do so may result in a costly or dangerous mistake Before Starting the Compressor 1 10 11 12 13 14 15 16 17 18 19 Become familiar with the function of all piping associated with the compressor Know each line s use Verify that actual operating conditions will match the anticipated conditions Ensure that line pressures are within cylinder pressure ratings Clean out all piping Check all mounting shims cylinder and piping supports to ensure that no undue twisting forces exist on the compressor Verify that strainer elements are in place and clean Verify that cylinder bore and valve areas are clean Check V belt tension and alignment Check drive alignment on direct drive units Rotate unit by hand Check flywheel for wobble or play Check crankcase oil level Drain all liquid traps separators etc Verify proper electrical supply to motor and panel Check that all gauges are at zero level reading Test piping system for leaks Purge unit of air before pressurizing with gas Carefully check for any loose connections or bolts Remove all stray objects rags tools etc from vicinity of unit Verify that all valves are open or clos
6. connecting rod lubricant passage with a long drill Bore the wrist pin bushing I D as indicated in Appendix E Overboring the bushing can lead to premature failure of the wrist pin bushing Inspect the oil passage for debris Clean thoroughly before proceeding Press the wrist pin back into the crosshead and wrist pin and reinstall retainer rings NOTE The fit between the wrist pin and bushing is tighter than on ordinary lubricated air compressors and combustion engines 5 6 2 CONNECTING ROD BEARINGS Connecting rod bearings are easily replaced after removing the semicircular inserts Make sure the indentations in the connecting rod bearing and connecting rod line up when installing the new bearings Before reinstalling the crosshead connecting rod assembly make sure the crankshaft throw and bearing surface are clean and lubricated Tighten the connecting rod bolts to the torques listed in Appendix D 5 6 3 ROLLER BEARINGS To inspect the roller bearings remove the flywheel from the crankshaft and then remove the bearing carrier and crankshaft from the crankcase If corrosion or pitting is present the roller bearing should be replaced When replacing roller bearings always replace the entire bearing not just the cup or the cone To replace the bearings press the cups out of the crankcase and bearing carrier and press the cones off the crankshaft Press the new bearings into position and reassemble the crankshaft and bearing ca
7. containers where both the liquid and vapor phases are present There is a piping connection between the vapor sectons of the storage tank and the tank being unloaded and there is a similar connection between the liquid secitons of the two tanks If the connections are opened the liquid will seek its own level and then flow will stop however by creating a pressure in the tank being unloaded which is high enough to overcome pipe friction and any static elevation difference between the tanks all the liquid will be forced into the storage tank quickly see Figure 1 10 The Gas Compressor accomplishes this by withdrawing vapors from the storage tank compressing them and then discharging into the tank to be unloaded This procedure slightly decreases the storage tank pressure and increases the pressure in the other tank thereby causing the liquid to flow COMPRESSOR INCREASES PRESSURE IN TANK CAR BY ADDING VAPOR PRESSURE DIFFERENCE BETWEEN TANKS CAUSES LIQUID TO FLOW OUT OF THE TANK CAR INTO THE STORAGE TANK Four Way Valve Position 1 LIQUID LINE The process of compressing the gas also increases the temperature which aids in increasing the pressure in the tank being unloaded CORKEN GAS COMPRESSOR CRANKCASE CAPACITY 2 QTS LIT PAT NO 3 805 827 READ INSTRUCTIONS BEFORE OPERATING IF NO INSTRUCTION BOOK WAS RECEIVED WRITE THE FACTORY MODEL SERIAL NO CORKEN ING OKLAHOMA CITY OK MADE IN U S A 1 TYPICA
8. place Install the piston head and tighten the socket head bolts in an alternating sequence Reinstall the head see Section 5 5 and follow standard startup procedure Note New compressors may have self locking nuts without roll pins Liquid Transfer Vapor Recovery Compressors 23 CASTELLATED RISTON MUT PISTON RING EXPANDER PISTON x PISTON CLEARANCE WA APP E ZN Na N N A gt E kN BODD VEN PISTON PLATFORM CYLINDER PISTON ROO PISTON CROSS SECTION SIZES 91 THROUGH 491 FIGURE 5 4A 5 5 PISTON ROD PACKING ADJ USTMENT Piston rod packing should be adjusted or replaced whenever leakage becomes noticeable Typically it is a good idea to replace piston rod packing and piston rings at the same time Instructions for packing replacement are included with each set of packing Inspection of the rod packing is generally not productive since packing that cannot be adjusted to an acceptable leakage rate should be replaced To adjust the packing remove the compressor nameplate tighten the packing adjusting nut s 1 4 turn with the wrench supplied then run the compressor a few minutes to reseat the packing If the leakage is still unacceptable tighten the adjusting nut as necessary using 1 4 turns at a time Do not overtighten If the adjusting nut is tightened until the packing spring is solid the packing should be replaced If packing will not seal carefully inspect piston rods for
9. possible scoring Replace if needed Reattach the compressor nameplate after adjustments or repairs are made 24 Liquid Transfer Vapor Recovery Compressors CASTELLATED PISTON NUT PISTON RING EXPANDER PISTON x PISTON ROLL PISTON PISTON CLEARANCE HEAD PIN BOLT SEE APP E RNE RF SIR A NE ER T PISTON CROSS SECTION SIZE 691 FIGURE 5 4B NOTE FILL CRANKCASE WITH OIL THROUGH THIS OPENING TIGHTEN Y TURN PACKING ADJUSTING NUTS FIGURE 5 5A 5 6 BEARING REPLACEMENT To replace the crankcase roller bearings wrist pin bushing and connecting rod bearings begin by removing the head cylinder piston crosshead guide and crosshead Drain the crankcase and remove the inspection plates Loosen and remove the connecting rod bolts in order to remove the crosshead connecting rod assembly 5 6 1 WRIST PIN BUSHING REPLACEMENT To replace the wrist pin bushing remove the retainer rings that position the wrist pin in the crosshead Press out the wrist pin so the crosshead and connecting rod may be separated Inspect the wrist pin for wear and damage and replace if necessary Press out the old wrist pin bushing and press a new bushing into the connecting rod DO NOT MACHINE THE O D OR I D OF THE BUSHING BEFORE PRESSING INTO CONNECTING ROD Make sure the lubrication hole in the bushing matches the oil passage in the connecting rod If the holes do not align drill out the bushing through the
10. prevent the entry of liquid into the compressor The inlet of the compressor should be protected from liquid entry by a liquid trap see Section 2 4 It is of equal importance to protect the discharge of the compressor from liquid This may be done by installing a check valve on the discharge and designing the piping so liquid cannot gravity drain back into the compressor Make sure to install a check valve on vapor lines discharging to the liquid space of the tank VAPOR TO TRUCK A APOR LINE TO TRUCK OF TRAILER LOADING H ATC EF VALVE VAPOR LINE TO VAPOR SECTION OF STORAGE a VAPOR LINE TO LIQUID PHASE FOR VAPOR RECOVERY 4 WAY VALVE NOTE PROVIDE ADEQUATE SUPPORT FOR PIPING DO NOT USE COMPRESSOR 5 TO SUPPORT PIPING ER VAPOR LINE TO TANK CAR OR TRANSPORT BURY OR INSULATE IN COLD CLIMATE AREAS SERVICE TO PERFORM VALVE POSITION Unload Tank Car into Position Storage Tank One D A t OPERATION OF VALVES Recover Vapors from Tank Position Car into Storage Tank Two Unload Transport or Truck Position into Storage Tank One Recover Vapors from Transport Position or Truck into Storage Tank Two Load Truck or Field Tank Position from Storage Tank Two POSITION 2 Load Truck or Field Tank Position from Tank Car One Equalize Between Tank Car and Storage Tank Without using Vapor Pump Equalize Between Truck or Field Tank and Storage Tank Without Using Vapor Pump
11. size Voltage phase and frequency must coincide with motor nameplate Consult with power company Check and replace according to manufacturer s instructions Reduce speed See driver installation Lubricate according to manufacturer s instructions APPENDIX G 38 Liquid Transfer Vapor Recovery Compressors CORKEN COMPRESSOR LOG SHEET ELECTRIC DRIVEN UNITS Compressor Model Serial RPM Package Motor BHP Frame RPM F L Amps Manuf Installation Date Start up Date Customer Location A Field Contact Telephone ft Make and Grade of Oil Pressure Switch Settings Suction Pressure Discharge Pressure Date Time Readings Suction Pressure Discharge Pressure Check List Oil Level Change Oil Flywheel Bolts Mounting Bolts Motor Amperage Additional Notes Outside Temperature Hour Meter Suction Temperature Discharge Temperature Strainers Valve Positions Belt Tension Gauges Zero Position Drain Liquid Trap Checked By APPENDIX H Liquid Transfer Vapor Recovery Compressors 39 Solutions beyond products CORKEN P O Box 12338 Oklahoma City OK 73157 3805 N W 36th St Oklahoma City OK 73112 Phone 405 946 5576 Fax 405 948 7343 E mail corken corken com Web address www corken com Printed in U S A September 1999
12. 0 044 0 012 0 027 Clearance Conrod bearing to 0 0005 0 0019 crankshaft journal 0 0025 0 0035 Clearance Wrist pin to wrist pin 0 0009 0 0020 bushing max Cylinder Bore Diameter max 4 011 4 515 Cylinder Finish RMS 16 32 16 32 Piston ring radial thickness min 0 082 0 082 Clearance Oil pump adapter shaft 0 0050 0 0050 to bushing max Crankshaft end play cold 0 000 0 002 0 002 0 003 Flywheel runout at O D max 0 020 0 020 Clearance Crosshead to crosshead 0 012 0 013 guide bore max Crosshead guide bore finish 32 RMS limited number of small pits and scratches are acceptable Dimensions for honing are included with new bushings which must be installed then honed Clearance should be set with machine cold APPENDIX E 34 Liquid Transfer Vapor Recovery Compressors PROPANE COMPRESSOR SELECTION TABLE DRIVER HORSEPOWER LIQUID LIQUID TRANSFER TRANSFER AND WITHOUT RESIDUAL RESIDUAL DRIVER SEAVE VAPOR VAPOR PIPING SIZE CAPACITY DISPLACEMENT COMPRESSOR SIZE P D 2 RECOVERY RECOVERY 3 SERVICE GPM 1 CFM RPM 1750 RPM 1460 RPM 100 F 80 F 100 F 80 F LIQUID 400 A3 0 A3 6 505 A3 8 B 4 6 590 B 4 6 B5 6 695 B 5 4 B 6 6 345 A3 0 A3 6 795 B6 2 B7 4 390 A3 4 B 4 0 435 A3 8 B 4 6 490 B 4 4 B5 2 535 B 4 8 B 5 8 580 B 5 2 B6 2 625 B 5 6 B 6 6 695 B 6 2 B7 4 735 B 6 6 B8 0 345 A3 0 A3 6 780 B7 0 B 8 6 370 A3 2 A3 8 390 A 3
13. 1 amp 01 01 01 amp ala ala ao een Q 101 Q 0 N AF NNN SSS UNLOADING LARGE TANK CARS MULTIPLE VESSELS BARGES OR TERMINALS AKARARARAPRHIKARRRRRLSIOVOVVOVVJVIOVLVV WW WA WW WW WAY WW WW OW NN Consult factory for compressors for higher flows NOTES 1 The capacities shown are based on 70 but will vary depending upon piping fittings used product being transferred and temperatures The factory can supply a detailed computer analysis if required 2 Driver sheaves 91 2 belts 290 291 490 491 3 belts 690 691 4 belts 3 The piping sizes shown are considered minimum If the length exceeds 100 ft use the next larger size APPENDIX F3 Liquid Transfer Vapor Recovery Compressors 37 COMPRESSOR TROUBLESHOOTING In most cases problems with your Corken Gas Compressor can be solved quite simply This chart possible causes If you are having a problem which is not listed or if you cannot find the source of the lists some of the more frequent problems that occur problem consult the factory with reciprocating compressors along with a list of PROBLEM POSSIBLE CAUSE Low capacity Overheating Knocks rattles and noise Oil in cylinder Abnormal piston ring wear Product leaking through crankcase breather Product leakage Oil leakage around compressor base No oil pressure Excessive vibration Motor overheating or starter tripping out
14. 3 60 1699 Max Pressure psia bars 350 24 14 280 19 31 350 24 14 280 19 31 350 24 14 Max Motor Size HP 15 15 15 35 35 Max Outlet Temperature F C 350 177 350 177 350 177 350 177 350 177 These numbers specify pressure containing abilities of the compressor cylinder and head For many applications factors other than the pressure rating will limit the maximum allowable discharge pressure to lower values These factors include horsepower temperature and rod load 32 Liquid Transfer Vapor Recovery Compressors APPENDIX C BOLT TORQUE VALUES BEARING BEARING CRANK i PISTON PISTON VALVE VALVE CARRIER COVER CASE LOCK SCREW CAP CAP FT LB FT LB INSPEC NUT TORQUE TORQUE TORQUE PLATE TORQUE IN LB W GASKETS W O RINGS FT LB FT LB FT LB FT LB 1 Preliminary tightening snug all headbolts in the sequence shown Final torqueing torque all headbolts in the sequence shown to the listed value 2 Retorque to the listed value after 2 5 hours running time BOLT FROM O TOP 3 BOLT FROM BOTTOM MODEL 690 MODEL 691 APPENDIX D Liquid Transfer Vapor Recovery Compressors 33 CLEARANCES AND DIMENSIONS ALL DIMENSIONS ARE IN INCHES 491 691 M Crankcase Clearance X Piston 0 000 0 020 0 000 0 015 Fig 5 4A amp 5 4B 0 024
15. 4 B4 0 415 A3 6 B 4 4 435 A3 8 B 4 6 445 B 4 0 B 4 8 470 B 4 2 B5 0 490 B 4 4 B5 2 3 1 5 5 5 3 7 2 3 3 5 5 5 5 7 2 7 2 7 2 10 72 7 2 TY 7 2 7 2 7 2 10 515 B 4 6 B 5 6 10 10 10 10 10 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 20 20 20 20 20 25 1 1 1 1 1 1 1 SMALL BULK PLANTS UNLOADING SINGLE TANK CARS OR TRANSPORT UNLOADING TWO OR MORE TANK CARS AT ONE TIME OR LARGE TRANSPORT 535 B 4 8 B 5 8 560 B 5 0 B6 0 580 B 5 2 B 6 2 605 B 5 4 B 6 4 FLOW VALVES OF ADEQUATE CAPACITY 650 B 5 8 B7 0 670 B 6 0 400 B 4 4 B5 2 695 B6 2 B7 4 420 B 4 6 B5 6 740 B 8 0 440 B 5 8 455 B6 0 475 B 6 2 495 510 530 550 565 585 605 620 640 675 730 785 820 UNLOADING LARGE TANK CARS MUTIPLE VESSELS BARGES OR TERMINALS 4 5 6 7 7 8 8 9 10 11 12 13 14 15 15 16 16 17 18 19 20 21 22 23 24 25 26 27 WITH EXCESS 28 625 B 5 6 B 6 6 29 30 30 31 31 32 32 34 35 36 38 39 41 42 43 45 46 47 48 54 58 60 BPHHPHHHSPIPHP HPP HPAL WWW w0A Y YO Y WAY Y YOU Y WWA Y WOW WW NNNNNRDNID D Consult factory for compressors for higher flows NOTES 1 The capacities shown are based on 70 F but will vary depending upon piping fittings used product being transferred and temperatures The factory can supply a detailed computer analysis if req
16. 8 CLASS 30 NONE PISTON RINGS ALL PTFE GLASS AND MOLY FILLED NONE PISTON RING EXPANDERS ALL 302 STAINLESS STEEL NONE HEAD GASKET 91 291 491 691 O RING BUNA N 91 290 291 491 691 PTFE VITON NEOPRENE ADAPTER PLATE PACKING CARTRIDGE CONNECTING ROD ALL DUCTILE IRON ASTM A536 NONE PACKING RINGS ALL PTFE GLASS AND MOLY FILLED NONE CRANKSHAFT ALL DUCTILE IRON ASTM A536 NONE CONNECTING ROD BEARING ALL BIMETAL D 2 BABBIT NONE WRIST PIN ALL C1018 STEEL ROCKWELL 62C NONE WRIST PIN BUSHING ALL BRONZE SAE 660 NONE MAIN BEARING ALL TAPERED ROLLER NONE INSPECTION PLATE ALL ALUMINUM NONE O RINGS ALL BUNA N PTFE VITON NEOPRENE RETAINER RINGS ALL STEEL NONE MISCELLANEOUS GASKETS ALL COROPRENE VITON AND NEOPRENE ARE REGISTERED TRADEMARKS OF DUPONT APPENDIX B NONE Liquid Transfer Vapor Recovery Compressors 31 MECHANICAL SPECIFICATIONS Specifications SINGLE STAGE 291 490 491 690 691 Cylinder Bore Inches cm First Stage 3 7 62 4 5 11 43 4 5 11 43 Stroke Inches cm 25 6 35 4 10 16 4 10 16 Piston Displacement CFM Lit Min Min at 300 RPM Max at 825 RPM 6 170 16 453 13 368 36 1019 13 368 36 1019 22 623 60 1699 22 62
17. ASSEMBLY GASKET NOTE a OLDER UNITS MAY HAVE A METAL GASKET INSTEAD OF O RING COMPRESSOR SIZE 491 FIGURE 5 1B The metal valve gasket should always be replaced when the valve is reinstalled Make sure suction and discharge valves are in the right slots as shown in the illustrations Reinstall cages and spacers then tighten the valve hoiddown screw to the value listed in Appendix D to ensure the valve gasket is properly seated O rings sealing the valve cover and valve cap should be replaced if they show any signs of wear or damage Valve caps sealed by flat metal gaskets should be reinstalled with new gaskets Refer to Appendix D for torque values 22 Liquid Transfer Vapor Recovery Compressors SUCTION SPEC 3 DISCHARGE VALVE CAP O RING a HOLDDOWN VALVE ASSEMBLY I GASKET HEAD NOTE fa OLDER UNITS MAY HAVE METAL GASKET INSTEAD OF THE O RING COMPRESSOR SIZE 691 FIGURE 5 1C Some Spec 3 suction valves have an adjusting screw to set the liquid relief pressure To adjust tighten the adjusting screw until it bottoms then back one turn on the size 491 91 291 691 s are pre set 5 2 CYLINDERS AND HEAD Cylinders and heads very seldom require replacement if the compressor is properly maintained The primary cause of damage to cylinders and heads are corrosion and the entry of solid debris or liquid into the compression chamber Improper storage can also result in corrosion damag
18. GAUGE 107 STYLE COMPRESSOR MOUNTING FIGURE 1 3A 1 3 COMPRESSOR CONSTRUCTION FEATURES The Corken liquid transfer vapor recovery compressor is a vertical single stage single acting reciprocating compressor designed to handle flammable gases like LPG and toxic gases such as ammonia Corken compressors can handle these potentially dangerous gases because the LPG NH3 is confined in the compression chamber and isolated from the crankcase and the atmosphere A typical liquid transfer vapor recovery compressor package is shown in Figure 1 3A Corken gas compressors are mounted on oil lubricated crankcases that remain at atmospheric pressure Crankshafts are supported by heavy duty roller bearings and the connecting rods ride the crankshaft on journal bearings With the exception of CRANKSHAFT PRESSURE LUBRICATION SYSTEM FIGURE 1 3B the small Size 91 compressor all compressor crankcases are lubricated by an automotive type oil pressure system An automatically reversible gear type oil pump circulates oil through passages in the crankshaft and connection rod to lubricate the journal bearings and wrist pins see Figure 1 3B Sturdy iron crossheads transmit reciprocating motion to the piston Corken s automatically reversible oil pump design allows the machine to function smoothly in either direction of rotation Corken compressors use iron pistons that are locked to the piston rod The standard piston ring material is
19. IE101F IMPORTANT INSTRUCTIONS LIQUID TRANSFER VAPOR RECOVERY COMPRESSORS Solutions beyond products CORKEN 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 such as NFPA Pamphlet 58 for LP Gas and ANSI K61 1 1972 for Anhydrous Ammonia 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 WARNING Install use and maintain this equipment according to Corken Inc instructions and all applicable federal state local laws and codes and NFPA Pamphlet 58 for LP Gas or ANSI K61 1 1989 for Anhydrous Ammonia Periodic inspection and maintenance is essential CORKEN ONE YEAR LIMITED WARRANTY Corken Inc warrants that its products will be free from defects in material and workmanship for a period of 12 months following date of purchase from Corken Corken products which fail within the warranty period due to defects in material or workmanship will be repaired or replaced at Corken s option when returned freight prepaid to Corken Inc 3805 N W 36th Street Oklahoma City O
20. L NAMEPLATE Also Serves as the Packing Adjusting Screw Cover FIGURE 1 1B VAPOR LINES COMPRESSOR REDUCES PRESSURE IN STORAGE TANK BY REMOVING VAPOR 4 WAY VALVE OPERATION INLET FROM STORAGE TANK INLET TO COMPRESSOR DISCHARGE TO TANK CAR LIQUID TRANSFER BY VAPOR DIFFERENTIAL PRESSURE FIGURE 1 1C Liquid Transfer Vapor Recovery Compressors 5 LIQUID HEEL VAPOR LINES REMOVING VAPOR FROM TANK CAUSES LIQUID HEEL TO BOIL INTO VAPOR Four Way Valve Position 2 Pe Saa m m e o h DE EE ee e LIQUID LINE IS VALVED CLOSED DURING VAPOR RECOVERY VAPOR IS BUBBLED THROUGH LIQUID TO HELP COOL AND RECONDENSE IT 4 WAY VALVE OPERATION DISCHARGE TO t STORAGE TANK INLET FROM TANK CAR RESIDUAL VAPOR RECOVERY FIGURE 1 2A 1 2 RESIDUAL VAPOR RECOVERY The Principle of Residual Vapor Recovery is just the opposite of Liquid Transfer After the liquid has been transferred the Four Way Control Valve or alternate valve manifolding is reversed so that the vapors are drawn from the tank just unloaded and discharged into the receiving tank Always discharge the recovered vapors into the liquid section of the receiving tank This will allow the hot compressed vapors to condense preventing an undesirable increase in tank pressure See Figure 1 2A Residual Vapor Recovery is an essential part of the value of a Compressor There is an economical limit to the amount of vapors that should be reco
21. NS viskes ska i ee eee aba acetals ag aie EW Eee ge wide 37 G Compressor Trouble Shooting 000 ccc eee eee 38 H Compressor Log Sheet 39 CHAPTER ONE INTRODUCTION VALVE SCREW NUT VALVE HOLDDOWN SCREW VALVE COVER PLATE GASKET CYLINDER HEA VALVE COVER PLATE SUCTION VALVE ASSEMBLY VALVE GASKET CYLINDER PISTON RINGS AND EXPANDERS ROD ASSEMBLY WAIST PIN WRIST PIN BUSHING CROSSHEAD GUIDE CONNECTING AOD CRANKCASE GASKET OIL LEVEL BAYONET bolt Le pz Say mis mil prest E OIL Hid N PRESSURE a RS E gre AN SCREW SK a MM CRANKCASE INSPECTION PLATE OIL RELIEF VALVE PISTON ASSEMBLY CYLINDER PACKING CARTRIDGE ASSEMBLY NAMEPLATE PACKING SET PACKING ADJUSTING CYLINDER GASKET SCHEW COVER PACKING ADJUSTING SCREW BEARING CROSSHEAD PISTON FA ADJUSTMENT SHIMS OIL DRAIN BREATHER VALVE ASSEMBLY CRANKSHAFT OIL PRESSURE PLUG CONNECTING GAUGE ROD BEARINGS CONSTRUCTION DETAILS MODEL 491 FIGURE 1 1A 1 1 LIQUID TRANSFER BY VAPOR DIFFERENTIAL PRESSURE Corken LPG NH3 compressors are designed to transfer liquefied gases such as butane propane 4 Liquid Transfer Vapor Recovery Compressors mixtures liquefied petroleum gas or LPG and Anhydrous Ammonia NH3 from one tank to another Liquefied gases such as LPG amp NH are stored in closed
22. R AS SHOWN ALIGN SLOT PUMP SHAFT ADAPTER WITH PIN CRANKSHAFT ALIGN TANG OIL PUMP ASSEMBLY WITH SLOT PUMP SHAFT ADAPTER GAUGE PIN PUMP COVER MUST FALL IN GAGOVED AREA OIL PUMP ASSEMBLY PUMP SHAFT BUSHING OIL FILTER je pe SPRING SPRING GUIDE OIL FILTER ADAPTER NOTE FOR COMPRESSORS WITHOUT OIL FILTER ASSEMBLIES CICIRUMP ASSEMBLY USE OPTIONAL PUMP COVER ASSEMBLY INSTRUCTIONS ARE THE SAME AS ABOVE FIGURE 5 7A Liquid Transfer Vapor Recovery Compressors 27 5 8 SERVICING THE FOUR WAY VALVE Unlike older units new Corken compressors mounted in the 107 arrangement are being supplied with a non lube four way valve No maintenance is normally required on this valve If you have reason to disassemble the valve please follow the instructions below CAUTION Always Relieve Pressure In The Unit Before Attempting Any Repairs BEFORE DISASSEMBLY 1 Record the position marks on the end of the rotor shaft 2 Record the positions of the handle stops on the cap NOTE Asmall amount of silicone grease applied to each part before assembly facilitates assembly if allowed HEX NUT hh INDICATOR S L PLATE HANDLE BOLT 4 TOP CAP BODY O RING CAP O RING 63 STEM O RING ac TOP ROTOR WASHER SEAL O RING 4 mozo BG DO BOTTOM ROTOR WASHER BODY O RING INCLUDED IN REPAIR KIT 28 Liquid Transfer Vapor Recovery Comp
23. STAGE COMPRESSOR NO INTERCOOLER INTERCOOLER 191 491 SERIES ONLY 91 491 SERIES ONLY ALL ALL 14 FLYWHEEL USED IN CONJUNCTION WITH EXTENDED CRANKSHAFT HEAVY DUTY FLYWHEEL NO FLYWHEEL SUPPLIED STANDARD FLYWHEEL FLYWHEEL ALL NO COATING PROTECTIVE COATING ALL NITROTEC PISTON ROD COATING STANDARD VITON AND NEOPRENE ARE REGISTERED TRADEMARKS OF DUPONT APPENDIX A 30 Liquid Transfer Vapor Recovery Compressors PISTON ROD COATING L6p N EXAMPLE 438 WAN T1300N MATERIAL SPECIFICATIONS STANDARD OPTIONAL PART SIZE MATERIAL MATERIAL HEAD CYLINDER 91 291 491 691 DUCTILE IRON ASTM A536 NONE CROSSHEAD GUIDE CRANKCASE FLYWHEEL BEARING CARRIER FLANGE ALL 691 GRAY IRON ASTM A48 CLASS 30 DUCTILE IRON ASTM A536 690 691 NONE STEEL WELDING VALVE SEAT AND BUMPER 91 291 17 4 PH STAINLESS STEEL 491 DUCTILE IRON ASTM A536 691 GRAY IRON ASTM A48 CLASS 30 NONE VALVE PLATE 91 291 410 STAINLESS STEEL 491 17 7 PH STAINLESS STEEL 691 STEEL ROCKWELL 50C VALVE SPRING 91 291 691 17 7 PH STAINLESS STEEL 491 INCONEL NONE VALVE GASKETS ALL SOFT ALUMINUM IRON LEAD PISTON ALL GRAY IRON ASTM A48 CLASS 30 NONE PISTON ROD C1050 STEEL ALL HARD CHROMIUM PLATED ROCKWELL 60C NONE CROSSHEAD ALL GRAY IRON ASTM A4
24. THE END OF THE ROTOR SHAFT ARE THE SAME AS 7 Assemble the four hex head bolts through the cap RECORDED BEFORE DISASSEMBLY and into the body Be sure that the body o ring is in the proper position and tighten the hex head bolts 4 Assemble the new top rotor washer and cap O ring onto the shoulder of the rotor 8 Reassemble the handle indicator plate and hex nut Be sure that the handle is assembled so that 5 Assemble the new stem o ring and the body o ring the stop on the handle mates with the stops on into their grooves in the rotor and body the cap CHAPTER 6 EXTENDED STORAGE PROCEDURES Following a few simple procedures will greatly 4 Plug all openings to prevent entry of insects and minimize the risk of the unit becoming corroded and moisture The cylinders may also be protected damaged Corken recommends the following by the use of a vapor phase inhibitor silica gel precautions to protect the compressor during storage or dry nitrogen gas If the silica gel is used hang a tag on the unit indicating that it must be 1 Drain the crankcase oil and refill with rust removed before a start up inhibiting oil 5 Store in a dry area off the ground if possible 2 Operate for a few minutes while fogging oil into the compressor suction 6 Rotate the flywheel every two weeks if possible 3 Relieve V belt tension Liquid Transfer Vapor Recovery Compressors 29 MODEL NUMBER AND MOUNTING IDENTIFICATION CODE MODELS INVOLVED DESCRIPTION
25. a glass filled PTFE polymer specially formulated for nonlubricated services Piston ring expanders are placed behind the rings to ensure that the piston rings seal tightly against the cylinder wall Liquid Transfer Vapor Recovery Compressors 7 LIQUID RELIEF VALVE HOUSING LIQUID RELIEF VALVE SPRING LIQUID RELIEF VALVE SPRING CROSSHEAD GUIDE SUCTION COMPRESSOR SEALING SYSTEM SUCTION AND DISCHARGE VALVES FIGURE 1 3C FIGURE 1 3D Piston rod packing is used to seal the gas in the The typical Corken compressor valve consists of a compression chamber and prevent crankcase oil seat bumper spring and valve disk as shown in from entering the compressor cylinder The packing Figure 1 3D Special heat treated alloys are utilized consists of several PTFE V rings sandwiched to prolong life of the valve in punishing non between a male and female packing ring and held in lubricated services The valve opens whenever the place by a spring see Figure 1 3C pressure on the seat side exceeds the pressure on the spring side The discharge valve is an inverted version of the suction valve 8 Liquid Transfer Vapor Recovery Compressors CHAPTER TWO INSTALLING YOUR CORKEN COMPRESSOR 2 1 LOCATION Corken compressors are designed and manufactured for outdoor duty For applications where the compressor will be subjected to extreme conditions for extended periods such as corrosive environments arctic conditions etc consult Corken Che
26. ankshaft is required so the U joint yoke may connect to the compressor INSIDE TRANSPORT MOUNTING FIGURE 2 8A COMPRESSOR FLYWHEEL EXTENDED CRANKSHAFT U JOINT DRIVE FOR COMPRESSOR FIGURE 2 8B without removing the flywheel Do not operate the compressor without a flywheel Use a U joint with a splined joint and make sure the connections are parallel and in line The U joint angle should be less than 15 degrees see Figure 2 8B Always use an even number of U joints Liquid Transfer Vapor Recovery Compressors 15 Depending on the truck design the compressor may be outside or top mounted as shown in Figures 2 8C and 2 8D to be V belt driven Power is transmitted through a U joint drive shaft jackshaft with two pillow block bearings V belt sheave and V belts An idle pulley may be used under the truck frame 2 9 SHUTDOWN ALARM DEVICES For many applications shutdown alarm switches will provide worthwhile protection that may prevent serious damage to your compressor system All electronic devices should be selected to meet local code requirements Shutdown alarm devices typically used on Corken compressors are Low Oil Pressure Switch shuts down the unit if crankcase oil pressure falls below 12 psi due to oil pump failure or low oil level in crankcase High Temperature Switch shuts down unit if the normal discharge temperature is exceeded and is strongly recommended for all applications Typically the set poin
27. ck local safety regulations and building codes to assure installation will meet local safety standards Corken compressors handling toxic or flammable gases such as LPG NH should be located outdoors A minimum of 18 inches 45 cm clearance between the compressor and the nearest wall is advised to make it accessible from all sides and to provide unrestricted air flow for adequate cooling NOISE Corken vertical compressors sizes 91 through 691 will not exceed an 85 DBA noise level when properly installed 2 2 FOUNDATION Proper foundations are essential for a smooth running compression system Corken recommends the compressor be attached to a concrete slab at least 8 thick with a 2 skirt around the circumference of the baseplate The baseplate should be securely anchored into the foundation by 1 2 diameter J bolts 12 long The total mass of the foundation should be approximately twice the weight of the compressor system compressor baseplate motor etc After leveling and bolting down baseplate the volume beneath the channel iron baseplate must be grouted to prevent flexing of the top portion of the baseplate and the J bolt that extends beyond the foundation The grout also improves the dampening capabilities of the foundation by creating a solid interface between the compressor and foundation On some of the longer baseplates such as the 691 107 a 3 inch hole can be cut in the baseplate for filling the m
28. e the radial thickness and compare it to the chart in Appendix E PISTON REMOVAL FIGURE 5 3A 5 4 PISTONS To replace the pistons Depressurize the compressor and purge if necessary Remove the compressor cylinder and head see Section 5 2 Remove the piston head by loosening and removing the socket head bolts holding the piston head to the piston platform see Figure 5 3A Next remove the roll pin with a pair of needle nose pliers The castellated nut may now be removed and the piston platform lifted off the end of the piston rod Check the thrust washer and shims for damage and replace if necessary Before installing the new piston measure the thickness of the existing shims For Models 91 through 491 the shims are placed between the thrust washer and piston platform For model 691 the shims are placed between the platform and piston head see Figure 5 4A and 5 4B Reinstall the piston platform with the same thickness of shims as before BUT DO NOT REINSTALL THE ROLL PIN Replace the cylinder and install the piston heads with new piston rings and expanders Now measure dimension X shown in the illustration If this measurement does not fall within the tolerances shown in Appendix E remove the piston adjust the shims as necessary and remeasure the X dimension When the piston is properly shimmed tighten the castellated nut as shown in Appendix D Now install a new roll pin to lock the castellated piston nut in
29. e to the head and cylinder for proper storage instructions see Section 5 8 If the cylinder does become damaged or corroded use a hone to smooth the cylinder bore and then polish it to the value shown in Appendix E If more than 005 must be removed to smooth the bore replace the cylinder Cylinder liners and oversized rings are not available Overboring the cylinder will result in greatly reduced ring life Many compressor repair operations require removal of the head and cylinder While the compressor is disassembled special care should be taken to avoid damage or corrosion to the head and cylinder If the compressor is to be left open for more than a few hours bare metal surfaces should be coated with rust preventative When reassembling the compressor make sure the bolts are retightened as shown in Appendix D 5 3 PISTON RINGS AND PISTON RING EXPANDERS Piston ring life will vary considerably from application to application Ring life will improve dramatically at lower speeds and temperatures To replace the piston rings Depressurize the compressor and purge if necessary Remove the head to gain access to the compressor cylinder Loosen the piston head bolts Remove the piston as shown in Figure 5 3A by pinching two loose bolts together Piston rings and expanders may then be easily removed and replaced Corken recommends replacing expanders whenever rings are replaced To determine if rings should be replaced measur
30. ed as required Double check all of the above After Starting Compressor 1 10 Liquid Transfer Vapor Recovery Compressors Verify and note proper oil pressure Shut down and correct any problem immediately Observe noise and vibration levels Correct immediately if excessive Verify proper compressor speed Examine entire system for gas oil or water levels Note rotation direction Check start up voltage drop running amperage and voltage at motor junction box not at the starter Test each shutdown device and record set points Test all relief valves Check and record all temperatures pressures and volumes after 30 minutes and 1 hour After 1 hour running time tighten all head bolts valve holddown bolts and baseplate bolts 19 CHAPTER 4 ROUTINE MAINTENANCE CHART ITEM TO CHECK Monthly Six Months Crankcase Oil Pressure Compressor Discharge Pressure Overall Visual Check Crankcase Oil Level Drain Liquid from Accumulation Points Drain Distance Piece Clean Cooling Surfaces on Compressor and Intercooler Lubricator Supply Tank Level Check Belts for Correct Tension Inspect and Clean Filter Felts on Control Pilot Valve Spec 78 8 Inspect and Clean Filter Felts on Crankcase Hydraulic Unloader Valve Spec 7 78 Inspect Valve Assemblies Lubricate Motor Bearings in Accordance with Manufacturers Recommendations Inspect Motor Starter Contac
31. ed the transfer rate will be slower and there is a good possibility that the car s excess flow valve may close Since the heat of compression plays an important part in rapid liquid transfer the vapor line from the compressor to the tank car or other unloading container should be buried or insulated to prevent the loss of heat and the compressor should be located as near as possible to the tank being emptied In extremely cold climates if the line from the storage tank to the compressor is over 15 feet 4 6 meters long it should be insulated to lessen the possibility of vapors condensing as they flow to the compressor The vapor recovery discharge line is better not insulated Placing the compressor as close as possible to the tank being unloaded will minimize heat loss from the discharge line for the best liquid transfer rate Unloading stationary tanks with a compressor is quite practical Delivery trucks and other large containers can be filled rapidly if the vapor system of the tank to be filled will permit fast vapor withdrawal and if the liquid piping system is large enough Many older trucks and some new ones are not originally equipped with vapor excess flow valves large enough to do a good job and these should be replaced by a suitable size valve The liquid discharge should be connected to the tank truck pump inlet line rather than the often oversized filler valve connection in the tank head It is of extreme importance to
32. elow 0 F 18 C 0 to 32 F 18 to 0 C 32 F to 80 F 0 to 27 C Above 80 F 27 C OIL SELECTION CHART FIGURE 2 6A Compressor Approximate Model Quarts 91 0 9 290 291 1 5 490 491 3 0 690 691 7 0 Capacity Liters 0 8 1 4 OIL CAPACITY CHART FIGURE 2 8A 2 7 RELIEF VALVES An appropriate relief valve must be installed at the compressor discharge On 107 style mounted units a relief valve should be fitted in the piping between the compressor discharge and the four way valve see Figure 1 3A Relief valves should be made of a material compatible with the gas being compressed Local codes and regulations should be checked for specific relief valve requirements Also relief valves may be required at other points in the compressor s system piping 2 8 TRUCK MOUNTED COMPRESSORS Corken compressors are frequently mounted on trucks to perform liquid transfer operations as described in Section 1 1 The compressor should be mounted so the inspection plate is accessible for packing adjustment The compressor must be protected against liquid as explained in Section 2 4 and a relief valve must be installed in the discharge piping before the first downstream shutoff valve Three types of mountings are typically used The inside mounting Figure 2 8A drives the compressor directly off the PTO shaft The PTO must be selected to drive the compressor between 400 and 800 RPM An extended compressor cr
33. fittings used product being transferred and temperatures The factory can supply a detailed computer analysis if required 2 Driver sheaves 91 2 belts 290 291 490 491 3 belts 690 691 4 belts 3 The piping sizes shown are considered minimum If the length exceeds 100 ft use the next larger size APPENDIX F2 36 Liquid Transfer Vapor Recovery Compressors AMMONIA COMPRESSOR SELECTION TABLE DRIVER HORSEPOWER LIQUID LIQUID TRANSFER TRANSFER AND WITHOUT RESIDUAL RESIDUAL DRIVER SEAVE VAPOR VAPOR PIPING SIZE CAPACITY DISPLACEMENT COMPRESSOR SIZE P D 2 RECOVERY RECOVERY 3 SERVICE GPM 1 CFM 1750 RPM 1460 RPM 100 F 80 F 100 F 80 F VAPOR LIQUID A3 0 A3 6 SMALL A 3 8 B 4 6 BULK B 4 6 B 5 6 PLANTS B 5 4 B 6 6 A 3 0 A 3 6 B 6 2 B 7 4 A 3 4 B 4 0 A 3 8 B 4 6 B 4 4 B 5 2 UNLOADING B 4 8 B 5 8 SINGLE TANK B 5 2 B 6 2 CARS OR B 5 6 B 6 6 TRANSPORT B 6 2 B 7 4 B 6 6 B 8 0 A 3 0 A 3 6 B 7 0 B 8 6 A 3 2 A 3 8 A 3 4 B 4 0 A 3 6 B 4 4 A 3 8 B 4 6 B 4 0 B 4 8 B 4 2 B 5 0 UNLOADING B 4 4 B 5 2 TWO OR B 4 6 B 5 6 MORE TANK B 4 8 B 5 8 CARS AT B 5 0 B 6 0 ONE TIME B 5 2 B 6 2 OR LARGE B 5 4 B 6 4 TRANSPORT B 5 6 B 6 6 WITH EXCESS B 5 8 B 7 0 FLOW B 6 0 VALVES OF B 4 4 B 5 2 ADEQUATE B 6 2 B 7 4 CAPACITY B 4 6 B 5 6 B 6 6 B 8 0 B 5 8 B 6 0 B 6 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 aja O71 O AY Q 01 amp O71 01 OF1 C O aja 110 OG O
34. hat the pressure gauge itself is faulty To remove and inspect valves begin by depressurizing and purging if necessary the unit Next remove the valve cap and then remove the valve holddown screw see Figure 5 1A through 5 1C with the special wrench supplied with the compressor Valves in sizes 91 through 291 may then be removed Sizes 491 through 691 require removal of the valve cover plate before the valves can be removed Inspect valves for breakage corrosion and scratches on the valve disc and debris In many cases 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 discs are replaced seats should also be lapped until they are perfectly smooth If more than 005 must be removed to achieve a smooth surface the valve should be discarded If discs are replaced without relapsing the seat rapid wear and leakage may occur SUCTION SPEC 3 VALVE CAP O RING a HOLODOWN SCREW 6 VALVE ASSEMBLY O DISCHARGE ET 2 NOTE a OLDER UNITS MAY HAVE A METAL GASKET INSTEAD OF THE O AING COMPRESSOR SIZES 91 290 291 FIGURE 5 1A Liquid Transfer Vapor Recovery Compressors 21 SUCTION DISCHARGE SPEC 3 VALVE CAP in GASKET cT D HOLDDOWN SCREW COVER b CAGE GROOYED END IEF DOWN ADJUSTING EW RELIEF SPAING RELIEF BALL VALVE
35. iddle section of the channel iron base with grout HEX NUT COMPRESSOR 2 MIN BASEPLATE ALL SIDES WASHER GROUT BENEATH BASE CONCRETE FOUNDATION WITH REINFORCEMENTS SHOULD BE USED ON ALL MODELS 1 2 J BOLTS 12 LONG NOTE LOCATE J BOLTS PER COMPRESSOR OUTLINE DIMENSION DRAWINGS RECOMMENDED FOUNDATION DETAILS FOR CORKEN COMPRESSORS 91 691 FIGURE 2 2A 2 3 PIPING Proper piping design and installation is as important as the foundation is to smooth operation of the compressor Improper piping installation will result in undesirable transmission of compressor vibration to the piping DO NOT SUPPORT PIPING WITH THE COMPRESSOR Unsupported piping is the most frequent cause of vibration of the pipe The best method to minimize transmission of vibration from the compressor to the piping is to use flexible connectors see Figure 2 34 Liquid Transfer Vapor Recovery Compressors 9 FLEXIBLE CONNECTORS RIGID PIPING SUPPORT FIGURE 2 3A Pipe must be adequately sized to prevent excessive pressure drop between the suction source and the compressor as well as between the compressor and the final discharge point In most cases piping should be at least the same diameter as the suction nozzle on the compressor Typically LPG NHs liquid transfer systems should be designed to limit pressure drops to 20 PSI 1 3 Bar Appendix F shows recommended pipe sizes for each c
36. iquid Transfer Vapor Recovery Compressors 17 3 3 CRANKCASE OIL PRESSURE ADJ USTMENT Corken compressor models 291 through 691 are equipped with an automatically reversible gear type oil pump if your compressor is the splash lubricated Model 91 proceed to Section 3 4 lt is essential to ensure the pumping system is primed and the oil pressure is properly adjusted in order to assure smooth operation Before starting your compressor check and fill crankcase with the proper quantity of lubricating oil see Figure 5 5A for proper filling location When the compressor is first started observe the crankcase oil pressure gauge If the gauge fails to indicate pressure within 30 seconds stop the machine Remove the pressure gauge Restart the compressor and run it until oil comes out of the pressure gauge opening Reinstall the gauge The oil pressure should be about 20 psi 2 4 Bars minimum for normal service If the discharge pressure is above 200 psi 14 8 Bars the oil pressure must be maintained at a minimum of 25 psi 2 7 Bars A spring loaded relief valve mounted on the bearing housing opposite the flywheel regulates the oil pressure As shown in Figure 3 3A turn the adjusting screw clockwise to increase the oil pressure and counterclockwise to lower it Be sure to loosen the adjusting screw locknut before trying to turn the screw and tighten it after making any adjustment 18 Liquid Transfer Vapor Recovery Compressors FULL
37. klahoma 73112 Parts subject to wear or abuse such as mechanical seals blades piston rings valves and packing and other parts showing signs of abuse are not covered by this limited warranty Also equipment parts and accessories not manufactured by Corken but furnished with Corken products are not covered by this limited warranty and purchaser must look to the original manufacturer s warranty if any This limited warranty is void if the Corken product has been altered or repaired without the consent of Corken All implied warranties including any implied warranty of merchantability or expressed warranty period CORKEN DISCLAIMS ANY LIABILITY FOR CONSEQUENTIAL DAMAGES DUE TO BREACH OF ANY WRITTEN OR IMPLIED WARRANTY ON CORKEN PRODUCTS Transfer of toxic dangerous flammable or explosive substances using Corken products is at the user s risk Such substances should be handled by experienced trained personnel in compliance with governmental and industrial safety standards CONTACTING THE FACTORY For your convenience the valve size and serial code are given on the valve nameplate This serial code tells the month and year your valve was built Space is provided below for you to keep a written record of this information Always include the valve size and serial code when ordering parts Model No Serial No Date Purchased Date Installed Purchased From Installed By IMPORTANT NOTE TO CUSTOMERS CORKEN INC does no
38. ns properly Replace nameplate and proceed with startup 3 2 FLYWHEEL 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 together to avoid forcing Improper belt tension and sheave alignment can cause vibration excessive belt wear and premature bearing failures Before operating your compressor check alignment of the V grooves of the compressor and driver sheaves visual inspection often will indicate if the belts are properly aligned but use of a square is the best method The flywheel is mounted on the shaft via a split tapered bushing and three bolts These bolts should be tightened in an even and progressive manner until torqued as specified below There must be a gap between the bushing flange and the sheave when installation is complete Always check the flywheel runout before startup and readjust if it exceeds the value listed in Appendix E Diameter In cm Bushing Size SF 4 625 11 7 E 6 0 15 2 J 7 25 18 4 Bolt Torque Ft Ib kg meter 30 4 1 60 8 3 135 18 7 Tighten the belts so that they are taut but not extremely tight Consult your V belt supplier for specific tension recommendations Belts that are too tight may cause premature bearing failure TYPICALLY 1 4 TO 3 8 6 4 MM TO 9 5 MM FLYWHEEL INSTALLATION FIGURE 3 2A L
39. ompressor for typical LPG NH installations Care must be taken if a restrictive device such as a valve pressure regulator or back check valve is to be installed in the compressor s suction line The suction line volume between the restrictive device and the compressor suction nozzle must be at least ten times the swept cylinder volume 107 style compressors are usually connected using a five valve Figure 2 3B or three valve manifold Figure 2 3C The five valve manifold allows the storage tank to be both loaded and unloaded The three valve manifold only allows the storage tank to be loaded Adequate sizing of the liquid and vapor lines is essential to limit the pressure drop in the system to a reasonable level 20 psi or less The line size helps determine the plant capacity almost as much as the size of the compressor and liquid line sizes are a bigger factor than vapor lines If the pressure gauges on the head indicate more than a 15 to 20 psi 2 07 to 2 40 Bars differential between the inlet and outlet pressures the line sizes are too small or there is some fitting or excess flow 10 Liquid Transfer Vapor Recovery Compressors valve creating too much restriction The less restriction in the piping the better the flow Appendix F shows recommended pipe sizes for typical LPG NH3 compressor installation A tank car unloading riser should have two liquid hoses connected to the car liquid valves If only one liquid hose is us
40. re grounding any welding devices to the trap or associated piping Failure to do so will damage the switch contacts If your compressor is equipped with a liquid trap of other than Corken manufacture make sure it is of adequate size to thoroughly remove any liquid entrained in the suction stream 2 5 DRIVER INSTALLATION FLYWHEELS Corken vertical compressors may be driven by either electric motors or combustion engines gasoline diesel natural gas etc Corken compressors are usually V belt driven but they are also suitable for direct drive applications as well Direct drive applications require an extended crankshaft to allow the attachment of a rigid metal coupling Note flexible couplings are not suitable for reciprocating compressors Never operate a reciprocating compressor without a flywheel Drivers should be selected so the compressor operates between 350 to 825 RPM The unit must not be operated without the flywheel or severe torsional imbalances will result that could cause vibration and high horsepower requirement The flywheel should never be replaced by another pulley unless it has a higher wk value than the flywheel 14 Liquid Transfer Vapor Recovery Compressors A humid climate can cause problems particularly in explosion proof motors The normal breathing of the motor and alternating between being warm when running and being cool when stopped can cause moist air to be drawn into the motor This moist air
41. ressors DISASSEMBLY Refer to the drawing for item description 1 Remove the hex nut indicator plate and handle from the rotor shaft 2 Remove the four hex head bolts and the cap from the body Cap should be rotated until free do not pry Inspect cap for wear and damage 3 Remove the body O ring stem O ring cap O ring and top rotor washer and discard 4 Remove the rotor and four seals as a unit from the body IMPORTANT Because of the close tolerance care must be taken to remove the rotor on its axis to prevent damage to the rotor and body Rotating the handle with a lifting action will help remove the rotor 5 Discard the four seals Inspect the rotor for wear and damage 6 Remove the bottom rotor washer and discard Inspect the body for wear and damage REASSEMBLY Refer to drawing Have Repair Kit laid out 1 Place the new bottom rotor washer into the body 2 Assemble the four seals and O rings onto the appropriate surfaces of the rotor 3 Assemble the rotor and seal assembly into the body IMPORTANT Because of the close tolerance 6 Place the cap over the rotor shaft care must be taken to press the rotor on its axis to prevent damage to the rotor and body A ring ROTATE THE ROTOR SO THAT THE compressor is helpful Be sure that the rotor is POSITION OF THE HANDLE STOPS ON Pote Ma oou THE CAP ARE THE SAME AS ROTATE THE ROTOR SO THAT THE RECORDED BEFORE DISASSEMBLY POSITION MARKS ON
42. rolonged period with dirty or contaminated crankcase oil damage to the oil pump may result To check the oil pump unbolt the pump cover and remove the oil pump spring guide spring and oil pump shaft adapter as shown in Figure 5 7A Inspect the gears in the oil pump for corrosion or pitting and replace if necessary Check the oil pump shaft bushing in the bearing carrier If the bushing is corroded pitted or worn the oil pump shaft bushing should be replaced Before reassembling the oil pump mechanism replace the O rings in the oil pump cover and on the oil pump adapter shaft see Figure 5 7A Rotate the drive pin in the crankshaft to a vertical position for easiest reassembly Insert the shaft adapter so it engages the drive pin Next insert the spring spring 26 Liquid Transfer Vapor Recovery Compressors guide and oil pump assembly The tang on the oil pump must align with the slot in the shaft adapter Install the pump cover so the pin on the case is in the opening on the oil pump assembly as shown in Figure 5 7A When you are sure the pin is properly aligned install the cover bolts finger tight Rotate the crankshaft by hand to ensure smooth operation Then rotate it in opposite directions listening for a click which indicates proper alignment of the oil pump s pins and slots Finally tighten the bolts in an alternating sequence See Section 3 3 for directions on oil pressure adjustment LOGATE OIL FILTER ADAPTE
43. rrier to the crankcase When reinstalling the bearing carrier make sure the oil pump shaft slot is aligned with the pin in the crankshaft Make sure to install the bearing carrier gasket so the oil passage hole is not blocked see Figure 5 6 3A In order to check the crankshaft end play the oil pump must first be removed see Section 5 7 Press the end of shaft towards the crankcase if a clicking noise or motion is detected the crankshaft has too much end play To reduce end play remove the bearing cover and remove a thin shim Recheck the end play after replacing the bearing cover When there is no detectable end play the shaft must still be able to rotate freely If the shaft sticks or becomes abnormally warm then the crankshaft bearings are too tight If the shaft is too tight add more shims but make sure not to overshim Appendix E lists the proper crankshaft end play When the shaft can be rotated freely by hand and no end play is present the rest of the compressor may be reassembled If the crankshaft roller bearings are too tight or too loose premature bearing failure will result Reinstall the flywheel on the crankshaft and check the run out as shown in Appendix E Liquid Transfer Vapor Recovery Compressors 25 ALIGN PIN WITH SLOT SHIM BEARING COVER INSIDE OF BEARING CARRIER OIL PASSAGE HOLE BEARING CARRIER REPLACEMENT FIGURE 5 6 3A 5 7 OIL PUMP INSPECTION If the compressor operates for a p
44. sor This design ensures the machine will be protected even when it is not under close observation and is standard in the 109A and 107A mounting configurations q RELIEF VALVE MIST PAD HIGH LIQUID LEVEL 7 SHUTDOWN SWITCH LIQUID LEVEL ALARM SWITCH DAAIN ASME AUTOMATIC TRAP FIGURE 2 4C Corken s most sophisticated trap provides the most thorough liquid separation see Figure 2 4C This trap is larger and is ASME code stamped It contains two level switches one for alarm and one for shutdown In some cases the alarm switch is used to activate a dump valve not included with trap or sound an alarm for the trap to be manually drained by the operator This trap also contains a mist pad A mist pad is a mesh of interwoven wire to disentrain fine liquid mists The ASME code trap is standard in the 109B and 107B mounting configurations Liquid Transfer Vapor Recovery Compressors 13 L2 L1 ee OLR STOP l M 1 2 I I 1 1 3 1 CONDUIT CONNECTION MUST BE FACING DOWN it COMMON BLACK 2 NORMALLY CLOSED BLUE 3 NORMALLY OPEN RED FIGURE 2 4D A typical wiring diagram for the liquid level switch is shown in Figure 2 4D If the switch is installed with the conduit connection in the top position it will be normally closed as shown in Figure 2 4D If the conduit is in the bottom position the switch will be normally open NOTE The level switch MUST be removed from the trap befo
45. t Points Piston Rings Piston ring life varies greatly depending on application gas and operating pressures Consult factory for additional recommendations for your specific applications Change oil every 2200 hours of operation or every 6 months whichever occurs first If the oil is unusually dirty change it as often as needed to maintain a clean oil condition Change replacement filter 4225 with every oil change Liquid traps should be drained prior to startup 20 Liquid Transfer Vapor Recovery Compressors CHAPTER 5 ROUTINE SERVICE AND REPAIR PROCEDURES CAUTION Always relieve pressure in the unit before attempting any repairs After repair the unit should be pressure tested and checked for leaks at all joints and gasket surfaces If routine maintenance is performed as outlined in Chapter 4 repair service on your Corken Gas Compressor is generally limited to replacing valves or piston rings When it comes time to order replacement parts be sure to consult your Corken Service Manual Section E for the correct part number and include the Compressor Model and Serial Number 5 1 VALVES Test the Compressor valves by closing the inlet piping valves while the unit is running do not allow the machine to operate in this way very long however If the inlet pressure gauge does not drop to zero almost immediately one or more of the valves is probably either damaged or dirty lt is possible of course t
46. t is about 30 F 1 C above the normal discharge temperature Low Suction High Discharge Pressure Switch shuts down unit if inlet or outlet pressures are not within preset limits Vibration Switch shuts down unit if vibration becomes excessive Recommended for units mounted on portable skids 16 Liquid Transfer Vapor Recovery Compressors OUTSIDE TRANSPORT MOUNTING FIGURE 2 8C TOP TRANSPORT MOUNTING FIGURE 2 8D CHAPTER 3 STARTUP UP YOUR CORKEN COMPRESSOR NOTE Before initial startup of the compressor be sure the principal of using a compressor for liquid transfer by vapor differential pressure is understood see Section 1 1 Read this entire chapter then proceed with the startup checklist 3 1 INSPECTION AFTER EXTENDED STORAGE If your compressor has been out of service for a long period of time you should verify that the cylinder bore and valve areas are free of rust and other debris see the maintenance section of this manual for valve and or cylinder head removal instructions Drain the oil from the crankcase and remove the nameplate and crankcase inspection plate Inspect the running gear for signs of rust and clean or replace parts as necessary Replace the crankcase inspection plate and fill crankcase with the appropriate lubricant Squirt oil on the X heads and rotate the crank by hand to ensure that all bearing surfaces are coated with oil Rotate unit manually to ensure running gear functio
47. t recommend ordering parts from general descriptions in this manual To minimize the possibility of receiving incorrect parts for your machine Corken strongly recommends you order parts according to part numbers in the Corken Service Manual If you do not have the appropriate service manual pages call or write Corken with model number and serial number from the nameplate on your compressor TABLE OF CONTENTS 1 INTRODUCTION cs veke ke A eee eee Gee ee Cee ee PAGE 4 Liquid Transfer by Vapor Differential Pressure aaauuuunuva varaner nne 4 Residual Vapor Recovery aaaaan av nr trink es 6 Compressor Construction Features s 0000 tee 7 2 INSTALLING YOUR CORKEN COMPRESSOR ama maa arr rv nr nn vnr eee mr PAGE 9 LOCION cierra e e il a AEE 9 FOUND AIN ciar kes dr BGGGGe sekret 9 PIP oa KAMAL Eee NAKKE BARE Fedme AEE Pale 9 Liquid TrapS s 2 2 vada svaie k od Sock it ra eae deta 12 Driver Installation Flywheels 0 000 et eee 14 Crankcase Lubrication 2 0 0 ce ee eee 14 Relief Valves sities a ek GE hee A ae ee RE eten Das ONG meme Nes 15 Truck Mounted Compressors 0 suasana cee eee eee 15 Shutdown Alarm Devices o o ooooo rn nn eee 16 3 STARTING UP YOUR CORKEN COMPRESSOR oooococcc eee eee eee PAGE 17 Inspection After Extended Storage ooooocccoo rn nn knr rann eee ee 17 Flywheel and V belt Alignment 00000 nrk ann rn anne 17 Crankcase Oil Pressure Adjustment
48. uired 2 Driver sheaves 91 2 belts 290 291 490 491 3 belts 690 691 4 belts 3 The piping sizes shown are considered minimum If the length exceeds 100 ft use the next larger size APPENDIX F Liquid Transfer Vapor Recovery Compressors 35 N BUTANE COMPRESSOR SELECTION TABLE DRIVER HORSEPOWER LIQUID LIQUID TRANSFER TRANSFER AND WITHOUT RESIDUAL RESIDUAL DRIVER SEAVE VAPOR VAPOR PIPING SIZE CAPACITY DISPLACEMENT COMPRESSOR SIZE P D 2 RECOVERY RECOVERY SERVICE GPM 1 CFM RPM 1750 RPM 1460 RPM 100 F 80 F 100 F 80 F 400 A3 0 A3 6 SMALL 505 A3 8 B 4 6 BULK 590 B 4 6 B 5 6 PLANTS 695 B 5 4 B 6 6 345 A3 6 795 B7 4 390 i B 4 0 435 E B 4 6 490 i B 5 2 UNLOADING 535 B5 8 SINGLE TANK 580 5 B6 2 CARS OR TRANSPORT 3 3 3 5 2 5 2 3 3 3 5 5 5 5 5 TV 5 5 5 5 5 5 Y a a O1 O1 OT LE OL L N OUT CO SNE NN 10 Wo N oon na 1 E jasa a ar aia Y nEn NEEE aja A YA ao a ot a a YO O aio amp WH WP 0 N O1W DD UNLOADING TWO OR MORE TANK CARS AT ONE TIME OR LARGE TRANSPORT WITH EXCESS FLOW VALVES OF ADEQUATE CAPACITY UNLOADING LARGE TANK CARS MULTIPLE VESSELS BARGES OR TERMINALS BHHHHHSSPHPHPHPHPHA LWWWW WW oa WW WOW WAY HOW WW WAY HO WHO WW 0 NNNNNRNDNID D Consult factory for compressors for higher flows NOTES 1 The capacities shown are based on 70 F but will vary depending upon piping
49. ust be used to prevent the entry of liquid into the compressor Corken offers three types of liquid traps for removal of entrained liquids The simplest is a float trap see Figure 2 4A As the liquid enters the trap the gas velocity is greatly reduced which allows the entrained liquid to drop out If the liquid level rises above the inlet the float will plug the compressor suction The compressor creates a vacuum in the inlet piping and continues to operate until the operator manually shuts it down The trap must be drained and the vacuum breaker valve opened INLET before restarting the compressor to allow the float to drop back This type of trap is only appropriate for use where the operator keeps the compressor under fairly close observation This trap is provided with the 109 and 107 compressor packages see bottom of Appendix A for details on standard Corken M eree f compressor packages i pe MECHANICAL TRAP FIGURE 2 4A rn RA LE L DRAIN VALVE 12 Liquid Transfer Vapor Recovery Compressors LIQUID LEVEL FLOAT SWITCH INLET DRAIN VALVE AUTOMATIC LIQUID TRAP FIGURE 2 4B When the compressor will not be under more or less constant observation an automatic trap is recommended see Figure 2 4B The automatic trap replaces the float with electrical float switches If the liquid level should rise too high the level switch will open and disconnect the power to the motor starter stopping the compres
50. vered however When the cost of operation equals the price of the product being recovered the operation should be stopped For most cases in LP Gas and Anhydrous Ammonia services this point is reached in the summer when the compressor inlet pressure is 40 to 50 psig 3 8 to 4 5 Bars A good rule of 6 Liquid Transfer Vapor Recovery Compressors thumb is not to operate beyond the point at which the inlet pressure is one fourth the discharge pressure Some liquids are so expensive that further recovery may be profitable but care should be taken that the ratio of absolute discharge pressure to absolute inlet pressure never exceeds 7 to 1 Further excavation of very high value products would require a Corken Two Stage Gas Compressor Invariably there is some liquid remaining in the tank after the liquid transfer operation This liquid heel must be vaporized before it can be recovered so do not expect the pressure to drop immediately Actually more vapor will be recovered during the first few minutes while this liquid is being vaporized than that during the same period of time later in the operation Remember that more than half of the economically recoverable product is usually recovered during the first hour of operation on properly sized equipment RELIEF VALVE AN APPROPRIATE RELIEF VALVE MUST BE INSTALLED BEFORE STARTING THE COMPRESSOR INLET OUTLET PRESSURE GAUGE PRESSURE GAUGE VACUUM BREAKER VALVE OIL PRESSURE
51. will condense and may eventually add enough water inside the motor to cause it to fail To prevent this make a practice of running the motor at least once a week on a bright dry day for an hour or so without the V belts In this period of time the motor will heat up and vaporize the condensed moisture driving it from the motor No motor manufacturer will guarantee his explosion proof or totally enclosed TEFC motor against damage from moisture For installation with engine drivers thoroughly review instructions from the engine manufacturer to assure the unit is properly installed 2 6 CRANKCASE LUBRICATION Non detergent oil is recommended for Corken vertical compressors Detergent oils tend to keep wear particles and debris suspended in the oil whereas non detergent oils let them settle in the bottom of the crankcase When non detergent oils are not available detergent oils may usually be successfully substituted although compressors handling ammonia amine or imine gases are notable exceptions These gases react with the detergent and cause the crankcase oil to become corrosive and contaminated Figures 2 6A and 2 6B show recommended oil viscosities and crankcase capacities Synthetic lubricants are generally not necessary Please consult the Factory if you are considering the use of synthetic oil Ambient Temperature At Compressor SAE Viscosity 5W 5W 30 10W 5W 30 10W 40 20 5W 30 10W 40 30 5W 30 10W 40 B
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