Corken 491 Liquid Transfer Compressors Instruction Manual
Liquid Transfer-Vapor Recovery Compressors are vertical single-stage, single-acting reciprocating compressors designed to handle flammable gases like LPG and toxic gases such as ammonia. Corken compressors confine the LPG/NH3 in the compression chamber and isolate it from the crankcase and the atmosphere. These packages also include a four-way control valve. The principle of residual vapor recovery allows for the economical recovery of vapors.
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IMPORTANT
INSTRUCTIONS
LIQUID TRANSFER-VAPOR
RECOVERY COMPRESSORS
IE101F
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, Oklahoma 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 not 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 4
Liquid Transfer by Vapor Differential Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Residual Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compressor Construction Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. INSTALLING YOUR CORKEN COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 9
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Liquid Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Driver Installation / Flywheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Crankcase Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Truck Mounted Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Shutdown/Alarm Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. STARTING UP YOUR CORKEN COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 17
Inspection After Extended Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flywheel and V-belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankcase Oil Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. ROUTINE MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5. ROUTINE SERVICE AND REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cylinder and Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston Rings and Piston Ring Expanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston Rod Packing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wrist Pin Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Roller Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Servicing the Four-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6. EXTENDED STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 29
APPENDIX
A. Model Number and Mounting Identification Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B. Material Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
C. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
D. Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
E. Clearance and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F. LPG Liquid Transfer Compressor Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
N-Butane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
G. Compressor Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
H. Compressor Log Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CHAPTER ONE
INTRODUCTION
CONSTRUCTION DETAILS - MODEL 491
FIGURE 1.1A
1.1 LIQUID TRANSFER BY
VAPOR DIFFERENTIAL PRESSURE
Corken LPG/NH
3 compressors are designed to transfer liquefied gases such as butane/propane mixtures (liquefied petroleum gas or LPG) and
Anhydrous Ammonia (NH
3
) from one tank to another. Liquefied gases such as LPG & NH
3 are stored in closed containers where both the liquid and vapor phases are present.
4 Liquid Transfer-Vapor Recovery Compressors
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 1.1C). 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.
The process of compressing the gas also increases the temperature, which aids in increasing the pressure in the tank being unloaded.
TYPICAL NAMEPLATE
(Also Serves as the Packing Adjusting Screw Cover)
FIGURE 1.1B
LIQUID TRANSFER BY VAPOR DIFFERENTIAL PRESSURE
FIGURE 1.1C
Liquid Transfer-Vapor Recovery Compressors 5
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.
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.
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 recovered, 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
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.
6 Liquid Transfer-Vapor Recovery Compressors
107-STYLE COMPRESSOR MOUNTING
FIGURE 1.3A
PRESSURE LUBRICATION SYSTEM
FIGURE 1.3B
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/NH
3 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.
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 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
Corken compressors use iron pistons that are locked to the piston rod. The standard piston ring material is 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
COMPRESSOR SEALING SYSTEM
FIGURE 1.3C
SUCTION AND DISCHARGE VALVES
FIGURE 1.3D
Piston rod packing is used to seal the gas in the compression chamber and prevent crankcase oil from entering the compressor cylinder. The packing consists of several PTFE V-rings sandwiched between a male and female packing ring and held in place by a spring (see Figure 1.3C).
The typical Corken compressor valve consists of a seat, bumper, spring and valve disk as shown in
Figure 1.3D. Special heat-treated alloys are utilized to prolong life of the valve in punishing nonlubricated services. The valve opens whenever the 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. Check local safety regulations and building codes to assure installation will meet local safety standards.
2” MIN.
ALL SIDES
8” MIN.
Corken compressors handling toxic or flammable gases such as LPG/NH
3 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.
HEX NUT
WASHER
NOTE:
LOCATE “J” BOLTS PER
COMPRESSOR OUTLINE
DIMENSION DRAWINGS.
COMPRESSOR
BASEPLATE
GROUT BENEATH
BASE
CONCRETE FOUNDATION
WITH REINFORCEMENTS
SHOULD BE USED ON
ALL MODELS
1/2” “J” BOLTS
12” LONG
NOISE. Corken vertical compressors sizes 91 through 691 will not exceed an 85 DBA noise level when properly installed.
RECOMMENDED FOUNDATION DETAILS FOR
CORKEN COMPRESSORS 91 - 691
FIGURE 2.2A
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.
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 2.3A).
On some of the longer baseplates, such as the 691
107, a 3-inch hole can be cut in the baseplate for filling the middle section of the channel iron base with grout.
Liquid Transfer-Vapor Recovery Compressors 9
valve creating too much restriction. The less restriction in the piping, the better the flow. Appendix
F shows recommended pipe sizes for typical
LPG/NH
3 compressor installation.
A tank car unloading riser should have two liquid hoses connected to the car liquid valves. If only one liquid hose is used the transfer rate will be slower, and there is a good possibility that the car’s excess flow valve may close.
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/NH
3 liquid transfer systems should be designed to limit pressure drops to 20 PSI (1.3 Bar). Appendix F shows recommended pipe sizes for each compressor for typical LPG/NH
3 installations.
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.
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.
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.
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
It is of extreme importance to 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.
10 Liquid Transfer-Vapor Recovery Compressors
SERVICE TO PERFORM
1. Unload Tank Car into
Storage Tank
2. Recover Vapors from Tank
Car into Storage Tank
3. Unload Transport or Truck into Storage Tank
4. Recover Vapors from Transport or Truck into Storage Tank
5. Load Truck or Field Tank from Storage Tank
6. Load Truck or Field Tank from Tank Car
7. Equalize Between Tank Car and Storage Tank Without using Vapor Pump
8. Equalize Between Truck or
Field Tank and Storage Tank
Without Using Vapor Pump
VALVE POSITION
4-WAY A B C D E
Position Open Open Close Close Close
One
Position Close Open Open Close Close
Two
Position Open Close Close Close Open
One
Position Close Close Open Close Open
Two
Position Open Close Close Close Open
Two
Position Close Open Close Open Close
One
--Open Open Close Open Open
--Open Close Close Open Close
FIVE-VALVE MANIFOLD PIPING SYSTEM
FIGURE 2.3B
All piping must be in accordance with the laws and codes governing the service. In the United States, the following codes apply:
For Ammonia – The American National Standards
Institute, Inc., K61.1-1989, Storage and Handling of
Anhydrous Ammonia.
For LP Gas – The National Fire Protection Association
Pamphlet No. 58, Standard for the Storage and
Handling of Liquefied Petroleum Gases.
Copies of these are available from NFPA, 60
Baterymarch Street, Boston, Mass, 02110 and ANSI,
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
SERVICE TO PERFORM
1. Unload Tank Car into
Storage Tank
2. Recover Vapors from Tank
Car into Storage Tank
4-WAY
VALVE POSITION
A B C
Position Open Open Close
One
Position Close Open Open
Two
THREE-VALVE MANIFOLD PIPING SYSTEM
FIGURE 2.3C
2.4 LIQUID TRAPS
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.
On liquefied gas applications a liquid trap must 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 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 compressor packages).
MECHANICAL TRAP
FIGURE 2.4A
12 Liquid Transfer-Vapor Recovery Compressors
AUTOMATIC LIQUID TRAP
FIGURE 2.4B
ASME AUTOMATIC TRAP
FIGURE 2.4C
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 compressor. 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.
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
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.
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 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.
NOTE: The level switch MUST be removed from the trap before 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.
2.6. 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.
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.
Synthetic lubricants are generally not necessary.
Please consult the Factory if you are considering the use of synthetic oil.
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
2 value than the flywheel.
14 Liquid Transfer-Vapor Recovery Compressors
Ambient Temperature
At Compressor SAE Viscosity
Below 0°F (-18°C) 5W, 5W-30
0° to 32°F (-18° to 0°C) 10W, 5W-30, 10W-40
32°F to 80°F (0° to 27°C) 20, 5W-30, 10W-40
Above 80°F (27°C) 30, 5W-30, 10W-40
OIL SELECTION CHART
FIGURE 2.6A
INSIDE TRANSPORT MOUNTING
FIGURE 2.8A
Compressor Approximate Capacity
Model Quarts Liters
91
290, 291
490, 491
690, 691
0.9
1.5
3.0
7.0
0.8
1.4
2.8
6.6
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.
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.
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 crankshaft is required so the U-joint yoke may connect to the compressor
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 point 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.
OUTSIDE TRANSPORT MOUNTING
FIGURE 2.8C
TOP TRANSPORT MOUNTING
FIGURE 2.8D
16 Liquid Transfer-Vapor Recovery Compressors
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.
when installation is complete. Always check the
flywheel runout before startup and readjust if it exceeds the value listed in Appendix E.
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).
Bushing
Size
SF
E
J
Diameter
In. (cm)
4.625 (11.7)
6.0 (15.2)
7.25 (18.4)
Bolt Torque
Ft.-lb. (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.
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 functions 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
FLYWHEEL INSTALLATION
FIGURE 3.2A
Liquid Transfer-Vapor Recovery Compressors 17
3.3 CRANKCASE OIL PRESSURE
ADJUSTMENT
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). It 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.
FLYWHEEL INSTALLATION
FIGURE 3.3A
18 Liquid Transfer-Vapor Recovery Compressors
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. Become familiar with the function of all piping associated with the compressor. Know each line’s use!
1. Verify and note proper oil pressure. Shut down and correct any problem immediately.
2. Verify that actual operating conditions will match the anticipated conditions.
2. Observe noise and vibration levels. Correct immediately if excessive.
3. Verify proper compressor speed.
3. Ensure that line pressures are within cylinder pressure ratings.
4. Examine entire system for gas, oil or water levels.
4. Clean out all piping.
After Starting Compressor
5. Note rotation direction.
5. Check all mounting shims, cylinder and piping supports to ensure that no undue twisting forces exist on the compressor.
6. Check start-up voltage drop, running amperage and voltage at motor junction box (not at the starter).
6. Verify that strainer elements are in place and clean.
7. Test each shutdown device and record set points.
7. Verify that cylinder bore and valve areas are clean.
8. Test all relief valves.
8. Check V-belt tension and alignment. Check drive alignment on direct drive units.
9. Check and record all temperatures, pressures and volumes after 30 minutes and 1 hour.
9. Rotate unit by hand. Check flywheel for wobble or play.
10. After 1 hour running time, tighten all head bolts, valve holddown bolts, and baseplate bolts.
10. Check crankcase oil level.
11. Drain all liquid traps, separators, etc.
12. Verify proper electrical supply to motor and panel.
13. Check that all gauges are at zero level reading.
14. Test piping system for leaks.
15. Purge unit of air before pressurizing with gas.
16. Carefully check for any loose connections or bolts.
17. Remove all stray objects (rags, tools, etc.) from vicinity of unit.
18. Verify that all valves are open or closed as required.
19. Double-check all of the above.
Liquid Transfer-Vapor Recovery Compressors 19
CHAPTER 4
ROUTINE MAINTENANCE CHART
ITEM TO CHECK
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 Contact Points
Piston Rings
Daily
X
X
X
X***
Weekly Monthly Six Months Yearly
X***
X
X
X
**
X
X
X
**
X
X
*
X
X
* 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. It is possible of course, that 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.
COMPRESSOR SIZES 91, 290, 291
FIGURE 5.1A
Liquid Transfer-Vapor Recovery Compressors 21
COMPRESSOR SIZE 491
FIGURE 5.1B
COMPRESSOR SIZE 691
FIGURE 5.1C
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.
*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).
22 Liquid Transfer-Vapor Recovery Compressors
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 damage 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.
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.
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.
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).
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, measure the radial thickness and compare it to the chart in
Appendix E.
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 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
PISTON CROSS SECTION
SIZES 91 THROUGH 491
FIGURE 5.4A
5.5 PISTON ROD PACKING
ADJUSTMENT
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 possible scoring. Replace if needed.
Reattach the compressor nameplate after adjustments or repairs are made.
PISTON CROSS SECTION
SIZE 691
FIGURE 5.4B
PACKING ADJUSTING NUTS
FIGURE 5.5A
24 Liquid Transfer-Vapor Recovery Compressors
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.
5.6.3 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.
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.
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 carrier 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).
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 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.
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.
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.
Reinstall the flywheel on the crankshaft and check the run out as shown in Appendix E.
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.
Liquid Transfer-Vapor Recovery Compressors 25
BEARING CARRIER REPLACEMENT
FIGURE 5.6.3A
5.7 OIL PUMP INSPECTION
If the compressor operates for a prolonged 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.
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.
Before reassembling the oil pump mechanism, replace the 0-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
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.
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.
CAUTION: Always Relieve Pressure In The Unit
Before Attempting Any Repairs.
BEFORE DISASSEMBLY:
Inspect cap for wear and damage.
1. Record the position marks on the end of the rotor shaft.
3. Remove the body O-ring, stem O-ring,, cap Oring, and top rotor washer and discard.
4. Remove the rotor and four seals as a unit from the body. IMPORTANT: Because of the close
2. Record the positions of the handle stops on the cap.
NOTE: A small amount of silicone grease applied to each part before assembly facilitates assembly if allowed.
28 Liquid Transfer-Vapor Recovery Compressors 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 0-rings onto the appropriate surfaces of the rotor.
3. Assemble the rotor and seal assembly into the body.
IMPORTANT: Because of the close tolerance, care must be taken to press the rotor on its axis to prevent damage to the rotor and body. A ring compressor is helpful. Be sure that the rotor is bottomed in the body.
6. Place the cap over the rotor shaft.
ROTATE THE ROTOR SO THAT THE
POSITION OF THE HANDLE STOPS ON
THE CAP ARE THE SAME AS
RECORDED BEFORE DISASSEMBLY.
ROTATE THE ROTOR SO THAT THE
POSITION MARKS ON THE END OF
THE ROTOR SHAFT ARE THE SAME AS
RECORDED BEFORE DISASSEMBLY.
7. Assemble the four hex head bolts through the cap 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 Oring, onto the shoulder of the rotor.
5. Assemble the new stem o-ring and the body o-ring into their grooves in the rotor and body.
8. Reassemble the handle, indicator plate and hex nut. Be sure that the handle is assembled so that the stop on the handle mates with the stops on the cap.
CHAPTER 6
EXTENDED STORAGE PROCEDURES
Following a few simple procedures will greatly minimize the risk of the unit becoming corroded and damaged. Corken recommends the following precautions to protect the compressor during storage:
1. Drain the crankcase oil and refill with rust inhibiting oil.
4. Plug all openings to prevent entry of insects and moisture. (The cylinders may also be protected by the use of a vapor phase inhibitor, silica gel, or dry nitrogen gas. If the silica gel is used, hang a tag on the unit indicating that it must be removed before a start-up.)
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
ALL
ALL
91 ONLY
91-491
ALL EXCEPT 91
ALL EXCEPT 91
ALL EXCEPT 91
ALL EXCEPT 91
ALL
ALL
ALL
ALL EXCEPT 391-491
ALL EXCEPT 391-491
91-491 SERIES
691
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL SINGLE STAGE
COMPRESSORS
191-491 SERIES ONLY
91-491 SERIES ONLY
ALL
ALL
ALL
ALL
DESCRIPTION
ANSI/DIN FLANGE INLET AND OUTLET
SPLASH LUBRICATED CRANKCASE
EXTENDED CRANKSHAFT
STANDARD PRESSURE LUBRICATED CRANKCASE
STANDARD CRANKCASE WITH CRANKCASE HEATER
STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR
LUBRICATOR
STANDARD CRANKCASE WITH EXTERNAL COMPRESSOR
LUBRICATOR AND CRANKCASE HEATER
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
PTFE PISTON RING AND PACKING MATERIAL
PTFE PISTON RING AND ALLOY 50 PACKING MATERIAL
SAME AS F WITH THE ADDITION OF K-RING SPACERS
ALUMINUM GASKET MATERIAL
COPPER GASKET MATERIAL
IRON-LEAD GASKET MATERIAL
BUNA-N
NEOPRENE*
VITON*
NOT APPLICABLE - SINGLE STAGE COMPRESSOR
(NO INTERCOOLER)
14" FLYWHEEL USED IN CONJUNCTION WITH EXTENDED
CRANKSHAFT
HEAVY DUTY FLYWHEEL
NO FLYWHEEL SUPPLIED
STANDARD FLYWHEEL
NO COATING
NITROTEC PISTON ROD COATING (STANDARD)
CODE
F
J
E
M
MH
L
LH
3
4
9
4P
9P
F
FK
B
C
D
A
B
D
N
E
H
N
S
N
N
FEATURE
HEAD
CONNECTION
STYLE
SINGLE-STAGE, DUCTILE IRON NOTE: MODELS ARE AVAILABLE 91, 291
NOTE: MODELS ARE AVAILABLE WITH DIN IRON HEAD/CYLINDER 491/492
MODEL NO. WILL BE DESIGNATED BY A "2" THE LAST DIGIT OF 491-3
THE MODEL NO.
INLET PRESSURE ABOVE ATMOSPHERIC A
BASIC
MODEL
691/692
PACKING
ADJUSTMENT
CRANKCASE
STYLE
VALVES
PISTON RING
AND PACKING
MATERIAL
GASKET
MATERIAL
O-RING
MATERIAL
INTERCOOLER
FLYWHEEL
PROTECTIVE
COATING
PISTON ROD
COATING
*VITON AND NEOPRENE ARE REGISTERED TRADEMARKS OF DUPONT.
EXAMPLE
APPENDIX A
30 Liquid Transfer-Vapor Recovery Compressors
MATERIAL SPECIFICATIONS
PART
STANDARD
SIZE MATERIAL
HEAD, CYLINDER
CROSSHEAD GUIDE
CRANKCASE, FLYWHEEL
BEARING CARRIER
FLANGE
91, 291, 491, 691
ALL
691
VALVE SEAT AND BUMPER 91,291
491
691
VALVE PLATE 91,291
491
691
VALVE SPRING 91,291,691
491
VALVE GASKETS
PISTON
ALL
ALL
DUCTILE IRON ASTM A536
GRAY IRON ASTM A48, CLASS 30
DUCTILE IRON ASTM A536
17-4 PH STAINLESS STEEL
DUCTILE IRON ASTM A536
GRAY IRON ASTM A48, CLASS 30
410 STAINLESS STEEL
17-7 PH STAINLESS STEEL
STEEL, ROCKWELL 50C
17-7 PH STAINLESS STEEL
INCONEL
SOFT ALUMINUM
GRAY IRON ASTM A48, CLASS 30
PISTON ROD
CROSSHEAD
PISTON RINGS
ALL
ALL
ALL
C1050 STEEL,
HARD CHROMIUM PLATED
ROCKWELL 60C
GRAY IRON ASTM A48, CLASS 30
PTFE, GLASS- AND MOLY-FILLED
PISTON RING EXPANDERS ALL
HEAD GASKET 91, 291, 491, 691
302 STAINLESS STEEL
O-RING (BUNA-N)
ADAPTER PLATE,
PACKING CARTRIDGE,
CONNECTING ROD
PACKING RINGS
CRANKSHAFT
CONNECTING ROD
BEARING
WRIST PIN
ALL
ALL
ALL
ALL
WRIST-PIN BUSHING
MAIN BEARING
INSPECTION PLATE
ALL
ALL
ALL
ALL
O-RINGS
RETAINER RINGS
ALL
ALL
MISCELLANEOUS GASKETS ALL
DUCTILE IRON ASTM A536
PTFE, GLASS- AND MOLY-FILLED
DUCTILE IRON ASTM A536
BIMETAL D-2 BABBIT
C1018 STEEL, ROCKWELL 62C
BRONZE SAE 660
TAPERED ROLLER
ALUMINUM
BUNA-N
STEEL
COROPRENE
*VITON AND NEOPRENE ARE REGISTERED TRADEMARKS OF DUPONT.
OPTIONAL
SIZE
690,691
MATERIAL
NONE
NONE
STEEL WELDING
NONE
NONE
ALL
NONE
IRON-LEAD
NONE
NONE
NONE
NONE
NONE
91,290,291, 491, 691 PTFE, VITON, NEOPRENE*
ALL
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
PTFE, VITON, NEOPRENE*
NONE
NONE
APPENDIX B
Liquid Transfer-Vapor Recovery Compressors 31
MECHANICAL SPECIFICATIONS
Specifications
Cylinder Bore, Inches (cm)
First Stage
Stroke,
Inches (cm)
Piston Displacement
CFM (Lit/Min)
Min. at 300 RPM
Max. at 825 RPM
*Max. Pressure psia (bars)
Max. Motor Size HP
Max. Outlet
Temperature °F (°C)
91
3
(7.62)
2.5
(6.35)
290
3
(7.62)
2.5
(6.35)
291
3
(7.62)
2.5
(6.35)
SINGLE STAGE
490
4
(10.16)
3
(7.62)
491
4
(10.16)
3
(7.62)
690
4.5
(11.43)
4
(10.16)
691
4.5
(11.43)
4
(10.16)
3 (85) 6 (170) 6 (170) 13 (368) 13 (368) 22 (623) 22 (623)
8 (226) 16 (453) 16 (453) 36 (1019) 36 (1019) 60 (1699) 60 (1699)
350
(24.14)
7.5
280
(19.31)
15
350
(24.14)
15
280
(19.31)
15
350
(24.14)
15
280
(19.31)
35
350
(24.14)
35
350
(177)
350
(177)
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.
APPENDIX C
32 Liquid Transfer-Vapor Recovery Compressors
BOLT TORQUE VALUES
SIZE CONN. BEARING BEARING CRANKX-HEAD CYL.
ROD CARRIER COVER CASE GUIDE TO
BOLT FT-LB FT-LB INSPEC FT-LB
VALVE
HEAD PLATE
VALVE
COVER HOLD-
DOWN
FT-LB PLATE
FT-LB
(1,2) BOLT
FT-LB FT-LB
SCREW
2
FT-LB
PISTON
LOCK
NUT
TORQUE
FT-LB
91 28 38 38 15 30 20 -40 45
291
491
691
28
30
40
30
26
40
30
35
40
13
8
9
25
33
40
20
33
30
--
35
37
40
40
40
45
45
60
PISTON
SCREW
TORQUE
VALVE
CAP
TORQUE
VALVE
CAP
TORQUE
IN-LB (W/ GASKETS) (W/ O-RINGS)
FT-LB FT-LB
50
50
100
100
40
40
40
40
25
25
25
25
(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.
APPENDIX D
Liquid Transfer-Vapor Recovery Compressors 33
CLEARANCES AND DIMENSIONS
ALL DIMENSIONS ARE IN INCHES.
**Clearance: "X" Piston
Fig. 5.4A & 5.4B
Clearance: Conrod bearing to crankshaft journal
Clearance: Wrist pin to wrist pin bushing* (max)
Cylinder Bore Diameter (max)
Cylinder Finish (RMS)
Piston ring radial thickness (min)
Clearance: Oil pump adapter shaft to bushing* (max)
Crankshaft end play (cold)
91
0.020
0.044
0.0005
0.0025
0.0009
3.009
16-32
0.082
0.0050
291
0.020
0.044
0.0005
0.0025
0.0009
3.009
16-32
0.082
0.0050
491
0.000/0.020
0.000/0.015
0.024/0.044
0.012/0.027
0.0005
0.0025
0.0009
4.011
16-32
0.082
0.0050
691
(M Crankcase)
0.0019
0.0035
0.0020
4.515
16-32
0.082
0.0050
Flywheel runout at O.D. (max)
Clearance: Crosshead to crosshead guide bore (max)
Crosshead guide bore finish
0.000
0.002
0.020
0.011
0.000
0.002
0.020
0.011
0.000
0.002
0.020
0.012
0.002
0.003
0.020
0.013
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
SERVICE
CAPACITY DISPLACEMENT COMPRESSOR
GPM (1) CFM
DRIVER SEAVE
SIZE P.D.* (2)
DRIVER HORSEPOWER
LIQUID LIQUID
TRANSFER
AND
TRANSFER
WITHOUT
RESIDUAL
VAPOR
RECOVERY
RESIDUAL
RECOVERY
MODEL RPM 1750 RPM 1460 RPM 100ËšF 80ËšF 100ËšF
VAPOR
80ËšF
PIPING SIZE
VAPOR
(3)
LIQUID
SMALL
BULK
PLANTS
UNLOADING
SINGLE TANK
CARS OR
TRANSPORT
UNLOADING
TWO OR MORE
TANK CARS AT
ONE TIME,
OR LARGE
TRANSPORT
WITH EXCESS
FLOW VALVES
OF ADEQUATE
CAPACITY
UNLOADING
LARGE TANK
CARS, MUTIPLE
VESSELS,
BARGES OR
TERMINALS
136
141
147
152
158
163
163
168
95
101
106
108
114
119
125
130
171
179
178
186
193
200
208
215
223
230
237
245
252
260
275
297
319
334
61
66
71
79
45
44
50
56
84
84
89
89
23
29
34
40
39
29
30
30
31
25
26
27
28
21
22
23
24
17
18
19
20
31
32
32
34
35
36
38
39
41
42
43
45
46
47
48
54
58
60
11
12
13
14
8
8
9
10
15
15
16
16
6
7
4
5
7
491
491
491
491
491
491
691
491
491
491
491
491
491
491
491
491
691
491
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
91
291
291
291
291
291
291
291
291
491
491
491
91
91
91
91
291
560
580
605
625
650
670
400
695
390
415
435
445
470
490
515
535
420
740
440
455
475
495
510
530
550
565
585
605
620
640
675
730
785
820
795
390
435
490
535
580
625
695
735
345
780
370
400
505
590
695
345
A 3.6
B 4.6
B 5.6
B 6.6
A 3.6
B 7.4
B 4.0
B 4.6
B 5.2
B 5.8
B 6.2
B 6.6
B 7.4
B 8.0
A 3.6
B 8.6
A 3.8
B 4.0
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 7.0
B 5.2
B 7.4
B 5.6
B 8.0
B 5.8
B 6.0
B 6.2
B 6.4
B 6.8
B 7.0
A 7.0
B 7.4
A 7.4
B 8.0
A 8.2
B 8.6
B 9.4
15
15
15
15
10
15
15
15
15
15
15
15
10
10
10
10
7h
7h
7h
7h
7h
10
7h
3
3
5
5
5
5
7h
7h
7h
10
7h
5
5
3
5
3
15
15
15
15
15
15
20
20
20
20
20
25
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 4.4
B 6.2
A 3.4
A 3.6
A 3.8
B 4.0
B 4.2
B 4.4
B 4.6
B 4.8
B 4.6
B 6.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 6.8
B 7.0
B 7.4
B 8.0
B 8.6
TB9.0
A 3.0
A 3.8
B 4.6
B 5.4
A 3.0
B 6.2
A 3.4
A 3.8
B 4.4
B 4.8
B 5.2
B 5.6
B 6.2
B 6.6
A 3.0
B 7.0
A 3.2
10
15
10
15
15
15
10
15
15
15
10
10
15
15
7h
7h
7h
7h
7h
7h
10
10
7h
3
3
5
5
5
7h
7h
10
5
10
7h
5
5
3
5
3
15
15
15
15
15
15
15
20
20
20
25
25
15
15
15
15
15
15
15
15
10
10
10
15
7h
10
10
10
15
15
15
15
15
15
7h
5
5
5
5
7h
7h
7h
10
7h
10
7h
5
5
5
5
3
20
20
20
20
20
20
20
20
25
25
25
30 A 10.6
Consult factory for compressors for higher flows.
NOTES: (1) The capacities shown are based on 70ËšF, 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.
2
2
2
2
1h
1h
1h
2
2h
2h
2h
2h
1q
1q
1q
1q
1q
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
1
1
1q
1q
1q
1q
1q
1q
1
1
1
1
1q
1q
1q
1h
1h
1h
1h
1h
1q
1q
1q
1q
1q
1q
1q
1q
1h
1h
1h
1h
1h
1h
2
2
2
2
1h
1h
1h
2
2
2
2
2 t t
1
1
1
15
15
15
15
15
15
15
15
20
20
20
20
10
15
10
10
15
15
10
15
10
15
10
10
10
15
7h
7h
7h
7h
7h
7h
7h
10
7h
3
3
5
5
5
5
7h
7h
5
10
5
5
5
3
5
3
APPENDIX F
Liquid Transfer-Vapor Recovery Compressors 35
N-BUTANE COMPRESSOR SELECTION TABLE
SERVICE
CAPACITY DISPLACEMENT COMPRESSOR
GPM (1) CFM
DRIVER SEAVE
SIZE P.D.* (2)
DRIVER HORSEPOWER
LIQUID LIQUID
TRANSFER
AND
TRANSFER
WITHOUT
RESIDUAL
VAPOR
RECOVERY
RESIDUAL
RECOVERY
MODEL RPM 1750 RPM 1460 RPM 100ËšF 80ËšF 100ËšF
VAPOR
80ËšF
PIPING SIZE
VAPOR
(3)
LIQUID
SMALL
BULK
PLANTS
UNLOADING
SINGLE TANK
CARS OR
TRANSPORT
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
91
94
97
94
77
81
84
87
56
60
63
65
68
71
75
100
98
107
103
110
113
107
111
119
116
120
124
129
133
137
142
145
150
158
184
184
193
36
39
42
47
27
26
30
33
50
50
53
53
13
17
20
24
23
28
29
30
30
24
25
26
27
17
18
19
20
21
22
23
33
34
34
35
31
31
32
32
36
36
38
39
41
42
43
45
46
47
48
54
58
60
11
12
13
14
8
8
9
10
15
15
16
16
4
5
6
7
7
491
491
491
491
491
491
491
691
491
491
491
491
491
491
491
491
691
491
691
491
491
691
691
491
691
691
691
691
691
691
691
691
691
691
691
691
691
91
291
291
291
291
291
291
291
291
491
291
491
91
91
91
91
291
535
560
580
605
625
650
670
400
390
415
435
445
470
490
515
695
420
740
440
760
780
455
475
825
495
510
530
550
565
585
605
620
640
675
730
785
820
795
390
435
490
535
580
625
695
735
345
780
370
400
505
590
695
345
A 3.6
B 4.6
B 5.6
B 6.6
A 3.6
B 7.4
B 4.0
B 4.6
B 5.2
B 5.8
B 6.2
B 6.6
B 7.4
B 8.0
A 3.6
B 8.6
A 3.8
B 4.0
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 7.0
B 5.2
B 7.4
B 5.6
B 8.0
B 5.8
B 8.0
B 8.6
B 6.0
B 6.2
B 8.6
B 6.4
B 6.8
B 7.0
A 7.0
B 7.4
A 7.4
B 8.0
A 8.2
B 8.6
B 9.4
A 10.6
Consult factory for compressors for higher flows.
NOTES: (1) The capacities shown are based on 70ËšF, 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.
2
2
2
2
1h
1h
1h
2
2h
2h
2h
2h
1q
1q
1q
1h
1h
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
1
1
1q
1q
1q
1q
1q
1q
1
1
1
1
1q
1q
1q
1q
1h
1h
1h
1h
1q
1q
1q
1q
1q
1q
1q
1h
1h
1h
1h
1h
1h
1h
1h
1h
1h
2
2
2
2
1h
1h
1h
2
2
2
2
2 t t
1
1
1
10
10
10
10
10
10
10
10
15
15
15
15
5
5
5
5
7h
7h
10
7h
10
10
7h
7h
7h
7h
7h
7h
7h
7h
5
5
5
10
10
10
10
5
5
3
3
3
3
5
2
5
5
5
5
3
3
3
5
2
10
10
10
10
10
10
10
10
15
15
15
15
5
5
5
5
7h
7h
10
7h
10
10
7h
7h
7h
7h
7h
7h
7h
7h
5
5
5
10
10
10
10
5
5
3
3
3
3
5
2
5
5
5
5
3
3
3
5
2
5
5
7h
7h
7h
7h
7h
7h
7h
10
10
7h
10
10
5
5
5
10
10
15
10
10
10
10
10
10
10
10
10
10
15
15
15
15
15
15
15
5
5
3
5
3
3
5
2
5
5
7h
5
3
3
3
5
2
5
5
7h
7h
7h
7h
7h
7h
7h
10
10
7h
10
10
5
5
5
10
10
15
10
10
10
10
10
10
10
10
10
10
15
15
15
15
15
15
15
5
5
3
5
3
3
5
2
5
5
7h
5
3
3
3
5
2
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 4.4
A 3.4
A 3.6
A 3.8
B 4.0
B 4.2
B 4.4
B 4.6
B 6.2
B 4.6
B 6.6
B 4.8
B 6.8
B 7.0
B 5.0
B 5.2
B 7.4
B 5.4
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 6.8
B 7.0
B 7.4
B 8.0
B 8.6
TB9.0
A 3.0
A 3.8
B 4.6
B 5.4
A 3.0
B 6.2
A 3.4
A 3.8
B 4.4
B 4.8
B 5.2
B 5.6
B 6.2
B 6.6
A 3.0
B 7.0
A 3.2
APPENDIX F2
36 Liquid Transfer-Vapor Recovery Compressors
AMMONIA COMPRESSOR SELECTION TABLE
SERVICE
CAPACITY DISPLACEMENT COMPRESSOR
GPM (1) CFM
DRIVER SEAVE
SIZE P.D.* (2)
DRIVER HORSEPOWER
LIQUID LIQUID
TRANSFER
AND
TRANSFER
WITHOUT
RESIDUAL
VAPOR
RECOVERY
RESIDUAL
RECOVERY
MODEL RPM 1750 RPM 1460 RPM 100ËšF 80ËšF 100ËšF
VAPOR
80ËšF
PIPING SIZE
VAPOR
(3)
LIQUID
SMALL
BULK
PLANTS
UNLOADING
SINGLE TANK
CARS OR
TRANSPORT
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
138
142
148
153
160
165
165
170
96
102
107
110
115
120
126
131
173
181
180
188
195
203
211
218
226
233
240
248
255
264
278
301
323
334
46
45
50
56
62
67
72
80
85
85
90
90
23
29
34
40
43
4
5
6
7
7
8
8
9
10
11
12
13
14
15
15
16
16
29
30
30
31
25
26
27
28
21
22
23
24
17
18
19
20
31
32
32
34
35
36
38
39
41
42
43
45
46
47
48
54
58
60
91
91
91
91
291
91
291
291
291
291
291
29/1
291
291
491
491
491
491
491
491
491
491
491
491
491
491
491
491
491
491
491
691
491
691
491
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
691
400
505
590
695
345
795
390
435
490
535
580
625
695
735
345
780
370
390
415
435
445
470
490
515
535
560
580
605
625
650
670
400
695
420
740
440
455
475
495
510
530
550
565
585
605
620
640
675
730
785
820
A 3.0
A 3.8
B 4.6
B 5.4
A 3.0
B 6.2
A 3.4
A 3.8
B 4.4
B 4.8
B 5.2
B 5.6
B 6.2
B 6.6
A 3.0
B 7.0
A 3.2
A 3.4
A 3.6
A 3.8
B 4.0
B 4.2
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 4.4
B 6.2
B 4.6
B 6.6
B 4.8
B 5.0
B 5.2
B 5.4
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 6.8
B 7.0
B 7.4
B 8.0
B 8.6
TB9.0
A 3.6
B 4.6
B 5.6
B 6.6
A 3.6
B 7.4
B 4.0
B 4.6
B 5.2
B 5.8
B 6.2
B 6.6
B 7.4
B 8.0
A 3.6
B 8.6
A 3.8
B 4.0
B 4.4
B 4.6
B 4.8
B 5.0
B 5.2
B 5.6
B 5.8
B 6.0
B 6.2
B 6.4
B 6.6
B 7.0
B 5.2
B 7.4
B 5.6
B 8.0
B 5.8
B 6.0
B 6.2
B 6.4
B 6.8
B 7.0
A 7.0
B 7.4
A 7.4
B 8.0
A 8.2
B 8.6
B 9.4
A 10.6
5
5
5
5
3
7h
5
5
5
7h
7h
10
10
15
15
15
15
15
15
15
15
10
15
15
15
10
10
10
10
7h
7h
7h
10
15
15
15
20
20
20
20
20
20
20
20
20
25
25
25
25
30
30
1h
1h
1h
2
2
2
2
2
2h
2h
2h
2h
1q
1q
1q
1h
1h
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
5
5
5
5
7h
7h
7h
7h
7h
5
3
3
5
5
3
5
3
15
15
15
15
10
10
15
15
15
15
15
15
10
10
10
10
7h
7h
7h
7h
7h
10
15
15
15
15
20
20
20
20
20
20
25
25
15
15
15
15
15
15
15
15
15
20
20
25
10
15
10
10
10
15
10
15
10
15
10
10
10
10
5
7h
7h
7h
7h
7h
7h
10
5
5
5
5
7h
7h
5
7h
5
5
3
3
5
5
3
5
3
10
15
15
15
15
15
15
15
15
15
20
20
10
15
10
10
10
10
10
10
10
10
7h
7h
7h
7h
10
10
5
7h
7h
7h
7h
7h
5
5
3
5
5
7h
5
7h
5
5
3
3
5
5
3
3
3
1
1
1
1q
1q
1q
1q
1q
1q
1
1
1
1q
1q
1q
1h
1h
1h
1h
1h
1q
1q
1q
1q
1q
1q
1q
1q
1h
1h
1h
1h
1h
1h t t
1
1
1
2
2
2
2
1h
1h
1h
2
2
2
2
2
Consult factory for compressors for higher flows.
NOTES: (1) The capacities shown are based on 70ËšF, 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 lists some of the more frequent problems that occur with reciprocating compressors along with a list of possible causes. If you are having a problem which is not listed, or if you cannot find the source of the problem, consult the factory.
PROBLEM POSSIBLE CAUSE
Low capacity
Overheating
Knocks, rattles and noise
Oil in cylinder
1, 2, 3, 4, 16
1, 2, 3, 5, 6, 11, 15
1, 7, 9, 10, 11, 14
8, 14
Abnormal piston-ring wear 1, 3, 5, 6, 11, 14, 15
Product leaking through crankcase breather 8, 14
Product leakage
Oil leakage around compressor base
4, 8, 14, 16
17, 18
No oil pressure
Excessive vibration
Motor overheating or starter tripping out
19, 20
1, 7, 9, 10, 11, 12, 13, 28
21, 22, 23, 24, 25, 26, 27, 28
REF.
POSSIBLE CAUSES WHAT TO DO
1.
Valves broken, stuck or leaking
2.
Piston ring worn
3.
Inlet strainer clogged
4.
Leaks in piping
5.
Inlet or ambient temperature too high
6.
Compression ratio too high
7.
Loose flywheel or belt
8.
Worn piston-rod packing
9.
Worn wrist pin or wrist-pin bushing
10.
Worn connecting-rod bearing
11.
Unbalanced load
12.
Inadequate compressor base
13.
Improper foundation or mounting
14.
Loose valve, piston or packing
15.
Dirty cooling fins
16.
4-way control valve not lubricated
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
17.
Leaking gas blowing oil from crankcase Tighten packing
18.
Bad oil seal Replace
19.
No oil in crankcase
20.
Oil-pump malfunction
Add oil
See oil-pressure adjustment
21.
Low voltage
22.
Motor wired wrong
23.
Wire size too small for length or run
24.
Wrong power characteristics
Check line voltage with motor nameplate. Consult power company
Check wiring diagram
Replace with correct size
Voltage, phase and frequency must coincide with motor nameplate. Consult with power company.
25.
Wrong size of heaters in starter
26.
Compressor overloading
27.
Motor shorted out
28.
Bad motor bearing
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 #
RPM
Motor BHP
Installation Date
, Frame
Customer
Location
Field Contact
Make and Grade of Oil
Pressure-Switch Settings:
Suction Pressure
, RPM
Serial #
Package #
, F.L. Amps
Start-up Date
Telephone #
Discharge Pressure
, Manuf.
Date
Readings:
Check List:
Time
Suction Pressure
Discharge Pressure
Outside Temperature Hour Meter
Suction Temperature
Discharge Temperature
Oil Level
Change Oil
Flywheel Bolts
Mounting Bolts
Motor Amperage
Strainers
Valve Positions
Belt Tension
Gauges (Zero Position)
Drain Liquid Trap
Additional Notes:
Checked By:
APPENDIX H
Liquid Transfer-Vapor Recovery Compressors 39
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 [email protected]
Web address www.corken.com
Printed in U.S.A.
September 1999
advertisement
Key Features
- Vertical single-stage, single-acting reciprocating compressor
- Handles flammable and toxic gases
- LPG/NH3 confined in the compression chamber
- Four-way control valve
- Residual vapor recovery
